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

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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

OPERATING CONTROLS

Operator Station Controls (D110, D120, D130)

ABrake Pedal B Park Brake Lock Lev er C Throttle/Choke Lever D Service Reminder/Hourmeter EKey Switch F Cruise Control Lever (D120 and D 130) G Attachm e nt Eng ag em ent Lever H Rev erse Implement Option (RIO) Switch I Forward Travel Pedal J Rev erse Travel Pedal K Deflector Shield L Fuel Level Window M Att ac hm e nt Lift Lever

MX49390

Operating Controls - 19

OPERATING CONTROLS

Operator Station Controls (D140, D160, D170)

ABrake Pedal B Park Brake Lock Lever C Throttle/Choke Lever D Service Reminder/Hourmeter EKey Switch F Cruise Control Lever G Reverse Implement Option (RIO) Switch H Attach ment Engagement Switch I Forward Travel Pedal J Reverse Travel Pedal K Deflector Shield L Fuel Level Window M Attachment Lift Lever

MX49389

Operating Controls - 20

OPERATING

Operating

Daily Operating Checklist

❏ Test saf ety systems.

❏ Check tire pressure.

IMPORTANT: Avoid damage! Usin g stale, contaminated or improper fuel can result in engine and fuel system damage. Repairs caused by stale, contaminated or improper fuel are not covered by warranty.

❏ Chec k fu el le vel. (See SER V IC E MISCE LLA NE OUS se ct ion, Us ing

Proper Fuel and Stabilizer)

4. Release seat adjustment lever to lock in position.

Lumbar Seat Adjustment (D160, D170)

• Turn lumbar seat adjustment dials (B) on either side of seat to adjust firmness of seat.

Adjusting Cutting Height

Cutting height can be adjusted from approximately 25 - 100 mm (1 - 4 in.) in 6.4 mm (1/4 in.) increments. When mower deck is in transport position, cuttin g he ight is app roxim a tely 100 mm (4 in.) .

Detents allow the adjustment lever to be positioned at each indicated mower s etting, as wel l as the mid-point between each s etting.

Mower Setting Approximate Cutti ng H eig ht

1 25 mm (1 in.)

❏ Check engine oil level.

❏ Remove grass and debris from engine compartment and muffler

area, and on top of mower deck, before and after operating machine.

❏ Clea n air intake screen.

❏ Check area below machine for leaks.

Avoid Damage to Plastic and Painted Surfaces

• Do not wipe pl astic parts unless rinsed first. Using a dry cloth may cause scratches.

• Insect repellent spray may damage plastic and painted surfaces. Do not spray insect repel lent near machine.

• Be careful not to spill fuel on machine. Fuel may damage surface. Wipe up spille d fu el im m ed ia t el y.

• Prolonged exposu re to sunlight w ill damage hood s urfaces.

Adjusting Seat

1. Sit in seat.

– 38 mm (1 1/2 in.) 2 50 mm (2 in.) – 65 mm (2 1/2 in.) 3 75 mm (3 in.) – 90 mm (3 1/2 in.) 4 (Transport) 100 mm (4 in.)

1. Put attachment lift lever into the slot adjacent to desired cutting height.

2. Adjust mower deck wheels.

Transporting or Getting On and Off Machine

• Pull attachment lift lever all the way back to transport position or 100 mm (4 in.) cutting height.

Checking and Adjusting Mower Deck Level

c CAUTION: Avoid injury! Rotating blades are dangerous.

Before adjusting or servicing mower:

• Disconnect spark plug wire(s) or battery negative (-) cable to prevent engine from starting accidently.

• Always wear gloves when handling mower blades or working near bl ades.

NOTE: Mower deck wheels should not contact the ground when leveling the mower deck.

Method One

1. Make sure machine is on a flat, level surface.

2. Park machine safely. (See Parking Safely in the SAFETY section.)

3. Check that tires are inflated to correct tire pressure. Tire pressure is marked on the side of the tire.

MX46483

2. Lift up on seat adjustment lever (A) on right side of seat.

3. Lean forward and slide seat forward or rearward to desired position. Do not lean back on top of seat to push rearward.

Operating - 21

OPERATING

M17687a

Picture Note: 107 cm (42 in.) mower deck shown

4. Place three short 51 mm (2 in.) blocks of wood under the edges (A) of the mower deck.

5. Lower mower deck to the 65 mm (2.5 in.) cutting height position.

6. Check that the mower deck is level and lightly touching each of the three wooden blocks.

MX51678

Picture Note: 107 cm (42 in.) mower deck shown

• If the front of the mower deck is not lightly touching the front block, adjust the front draft arm by turning the nut (C).

7. Raise the cutting height to the next highe st position and remove the three wooden blocks.

8. Turn the nut (C) on the front draft arm counterclockwise 1-2 full turns so that the front of the deck is 3-6 mm (1/8-1/4 in.) lower than the rear. This adjustment prevents “double cutting,” which wastes horsepower and causes brown gras s tip s.

MX16561

• If the rear of the mower deck is not touching the rear blocks, or is sitting heavily on the blocks, adjust the rear lift links by turning the leveling nut (B) on each lift link. The blocks should be able to easily slide in and out beneath the mo wer deck when the mower deck is correctly adjusted.

Method Two

NOTE: An optional mower deck leveling gauge (AM130907) is available from your John Deere dealer. It allows for precision mower deck leveling by measuring mower deck level at the blade tips.

1. Make sure machine is on a flat, level surface.

2. Park machine safely. (See Parking Safely in the SAFETY section.)

3. Inflate tires to the correct pressure.

4. Move mower lift handle to preferred cutting height.

5. Measu re mower deck level (side-to-side).

MX4871

Picture Note: A convenient leveling gauge (A) (AM130907) is available from your dealer.

a.Position mower blades as follows and me asure from each outside blade tip (B) to the level surface.

Operating - 22

OPERATING

b.Turn left b l ad e (C) a s s ho w n. H o ld drive belt and turn ri ght b la de (D ) as shown. Take measurement for both blades.

The difference between blade measurements must not be more than 3 mm (1/8 in.).

c.Adjust mower deck le vel, if necessary, by turning rear nuts (E) clockwise to raise the side of the mow er deck, or counterclockwise to lower the mower deck.

6. Measure mower level (front-to-rear).

MX4896

MX16561

MX51678

Picture Note: 107 cm (42 in.) mower deck shown

c.Adjust mower deck level, if necessary, by turning the nut (G) counterc lockw i se to lower the fro nt of deck or cl ockwis e to rais e front of deck.

Adjusting Mower Deck Wheels

IMPORTANT: Avoid damage! The mower deck can be damaged if mower wheels are adjusted wrong:

• Wheels must not ride on ground supporting mower weight.

• Check wheel adjustment each time cutting height is changed.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Inflate tires to the correct pressure.

3. Lower mower dec k to the desired mowing position.

NOTE: Bottom of wheels should be approximately 3-13 mm (1/8-1/2 in.) from the ground.

MX4896a

a.Turn right blade (F) so blade tip points straight forward. b.Measure from blade t ip to the surface. Take measurement for both

blades. The front blade tip must be 3–6 mm (1/8 -1/4 in.) lower than rear blade

tip.

Operating - 23

MX10509a

4. Check each mower wheel position. Remove nut (A) and bolt (B), and move mower wheel to proper hole.

A- 38 mm (1.5-In.) B- 51 mm (2-In.) C- 64 mm (2.5-In.) D- 76 mm (3-In.) and above

OPERATING

3. Unlock the park brake.

4. Try to start engine. Result: Engine must not start. If engine starts, there is a problem with

your safety interlock circuit.

Testing Park Brake

1. Park machine safely. (See Parking Safely in the SAFETY Section.)

2. Lock the park brake.

3. Put transmission in park. Engage bypass ro d located at rear of machine.

4. Try to push machine manually.

MIF

Result: Park brake must prevent machine from moving. If machine moves, parking brake needs to be adjusted.

Testing Attachment Engagement Switch or Lever

5. Install bolts and nuts to lock wheels in position. Tighten nuts to 34 N•m (25 lb-ft).

Testin g Safety Systems

c CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death. Do not run an engine in an enclosed area, such as a garage, even

with doors or windows open ed. Move the machine to an outsid e area before r unn ing the engi ne .

The safety systems installed on your machine should be checked before each machine use. Be su re you have read the machine operator manu al and are completely familiar with the operation of the machine before performing these safety system checks.

Use the following checkout procedures to check for normal operation of machine.

If there is a malfunction during one of these procedures, do not operate machine. See your authorized dealer for service.

Perform these tests in a clear open area. Keep bystanders a way.

Testin g Park Brake Switch

1. Park machine safely . (See Parking Safely in the SAFETY Section.)

2. Sit on seat.

c CAUTION: Avoid injury! The mower blades should stop in

approximately five seconds when the mower or PTO 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 your machine.

1. Park machine safely. (See Parking Safely in the SAFETY Section.)

2. Sit on seat.

3. Lock the park brake.

4. Engage mower:

• On models with electric attachment engagement switch, pull switch up.

• On models wi th mechanical attachment en gagement le ver, pu sh lever forward.

5. Try to start engine. Result: Engine must not start. If engine starts, there is a problem with

your safety interlock circuit.

Te sting Seat Switch

1. Park machine safely. (See Parking Safely in the SAFETY Section.)

2. First test:

a.Start engi ne. b.Move throttle lever up to maximum engine speed. c.Unlock park brake. d.Engage mower . e.Raise up off seat. Do not get off machine.

Result: Engine and mower blades should stop. If engine and mower blades do not stop, there is a problem with your safety interlock circuit.

3. Second test:

a.Lock pa r k brake. b.Disengage mower. c. St a rt engi ne. d.Unlock park brake.

Operating - 24

OPERATING

e.Rais e up off seat. D o no t get off machine.

Result: Engine should stop . If engine does not stop, there is a problem with your safety interlock circuit.

4. Third test: a.Di se ng ag e mow e r. b.Start en gine. c.Lock park brake. d.Rais e up off seat. D o no t get off machine.

Result: Engine should continue to run. If engine stops, there is a problem with your safety interlock circuit.

Testi ng Reverse Implement Option (RIO)

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Start engine.

3. Engage attachment engagement switch or lever to start attachment.

c CAUTION: Avoid injury! Rotating blades are dangerous.

Children or bystanders may be injured by runover and rotating blades.

Before backing up, carefully check the area around the machine.

4. Look behind the vehicle to be sure there are no bystanders.

5. Begin reverse travel by depressing reverse pedal for hydrostatic

transmissio n or mov in g auto ma tic sh ift lever to R (reverse) posi tio n for automatic transmission and depressing pedal.

Result: Attachment and engine should stop operation. If attachment or engine continues to operate as machine begins travel in reverse, do not continu e to operate ma c hine.

Using the Park Brake

Using the Hourmeter and Service Reminder

• The hou rmeter (A) shows the number of hours the engine has run. The service reminder will indicate that a g eneral lubrication (B) or mow er/ engine (C) service interval has been reached. When service is required, the service “SVC” arrows (D) will periodically flash for two hours. Follow the service timetable on the maintenance schedule located under the seat. For specific service procedures, see the Servi ce section of this manual.

• Hourmeter cannot be reset.

• The hourmeter display will always be on.

• The decimal point will flash while the hourmeter is accumulating time.

MX49388

Using Key Switch and Headlights

c CAUTION: Avoid injury! Children or bystanders may

attempt to move or operate an unattended machine. Always lock the park brake and remove the key before leaving the

machine unattended.

Locking park brake:

1. Push and hold brake pedal down.

2. Pull park brake lever up to lock park brake.

3. Release brake pedal. Pedal should stay down and park brake lever

should stay locked.

Unlocking pa rk brake:

1. Push and hold brake pedal down.

2. Push park brake lever down to unlock park brake.

3. Release brake p edal.

Operating - 25

M94336a

A- STOP Position B- Headlights On Position C- Run Position D- Start Position

Engine Off

NOTE: Headlights will drain the battery rapidly if key switch is left in headlights on position (B) with the engine off.

• To turn headlights on, turn key switch to headlights on position (B).

• To turn headlights off, turn key switch to STOP position (A).

Engine On

• T o turn headlights on, start engine, then turn key switch from run position (C) to headlights on position (B).

OPERATING

• To turn headlights off, turn key switch from headlights on position (B) to

run position (C).

Starting the Engine

IMPORTANT: Avoid damage! Hydrostatic transmission might be damaged if the bypass rod is not pushed back to operating position before attempting to start the engine. Do not start or operate the machine with the bypass rod in the pulled-out position.

1. Make sure bypass rod is pushed in.

c CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death. Do not run an engine in an enclosed area, such as a garage, even

with doors or windows open ed. Move the machine to an outsid e area before r unn ing the engi ne .

2. Sit in seat.

3. Make sure mower is disengaged. (See Engaging and Disengaging

Mower in the OPERATING s ection.)

4. Lock the park brake.

5. For automatic models, put transmission in park.

6. Check starting conditions:

• Repeat procedure if necessary.

IMPORTANT: Avoid damage! Unnecessary engine idling may cause engine damage. Excessive idling can cause engine overheating, carbon build-up, and poor performance.

9. Let engine run at high idle for a couple of minutes to warm-up before operating machine.

Idling the Engine

IMPORTANT: Avoid damage! Unnecessary engine idl ing may cause engine or transmission

damage. Excessive idling can cause engine overheating, carbon build-up, and poor performance.

Idling or low throttle operation while mowing, climbing hills, or towing could result in transmission overheating. always operate at full throttle on ce the engine is warm.

Do not operate machine with hood open. Hood must be closed for proper engine cooling and exhaust.

• Engine is air cooled and needs a large volume of air to keep cool. K eep air intake screen on top of engine clean.

• Keep hood closed when engine is idling.

Stopping the Engine

IMPORTANT: Avoid damage! Do not stop the engine by moving choke control to the choke position. Backfire, fire or engine damage can occur. Follow recommended procedure for stopping engine.

MX49386

• If engine is co ld: Mo v e thr ot tl e/ ch ok e le v e r (A ) up to the cho k e po si tion .

• If engine is warm: Move throttle/choke lever (A) to the half-speed position.

IMPO R TANT : A v o i d da ma ge ! Sta rter ma y be da m a ge d if sta rt e r is operated for more th an 20 seconds at a time:

• Wait two minutes before trying again if engine does not start.

7. Turn key to start position for no more than five seconds.

8. Release key to run position when engine starts, and gradually move

choke lever down to the off position.

• If engine does not start, wait 10 seconds.

• Turn key to start position again for no longer than 5 seconds.

1. Let engine run at high throttle without load for a few seconds.

2. Turn key to STOP position. Engine will stop and headlights will turn off.

3. Remove key.

4. Lock the park brake.

Using Travel Controls on Automatic Transmission

c CAUTION: Avoid injury! Children or bystanders may be

injured by runover and rotating blades. Before traveling forward or rearward:

• Careful ly check the area around the machine.

• Disengage the mower before backing up.

IMPORTANT: Avoid damage! Stop machine movement before shifting between reverse and forward to prevent transmission damage.

Operating - 26

OPERATING

T ravel Forward

1. Completely remove foot from travel pedal (A).

2. Push brake pedal (B) all the way down to stop machine.

3. Move transmission shift lever to forward (C).

4. Release brake p edal.

5. Slowly apply foot to travel pedal.

T ravel in Reverse

1. Completely remove foot from travel pedal (A).

NOTE: Any operating attachment and the engine will stop as the transm is si o n shift lever is moved to R (reve rse) wi th attachmen t engaged.

2. It may be required to push brake pedal to stop machine when on a

slope.

3. Move transmission shift lever to reverse (D).

4. Look behind the machi ne to be sure there are no bystan ders nearby.

5. Release brake p edal.

6. Slowly apply foot to trvael pedal.

Emergency Stopping

Push brake pedal all the way down to stop machine.

MX51677

Using Travel Controls on Hydrostatic Tran sm ission

c CAUTION: Avoid injury! Children or bystanders may be

injured by runover and rotating blades. Before traveling forward or rearward:

• Carefully check the area around the machine.

• Disengage the mower before backing up.

Travel Forward

• Push down the forward travel pedal (A).

Travel in Reverse

NOTE: Any operating attachment and the engine will stop as the reverse motion pedal is pressed with attachment engaged.

1. Disengage attachment:

• On models with mechanical attachment engagement lever (B), pull lever back to the off position.

• On models with electric attachment engagement switch, push switch in loca tion (C) (not sh own above) down to the off position.

2. Look behind the machine to be sure there are no bystanders nearby.

3. Touch the r everse travel pedal (D) with front of foot and slide foot over pedal f rom front to rear.

Emergency Stopping

• Push brake pedal all the way down to stop machine.

MX46484

Using The Reverse Implement Option (RIO)

c CAUTION: Avoid injury! Children or bystanders may be

injured by runover and rotating blades. Before traveling forward or rearward:

• Careful ly check the area around the machine.

• Disengage the mower before backing up.

NOTE: Backing up while the mower is engaged is strongly discouraged. The Reverse Implement Option should be used only when operating another attachment or when the operator deems it necess ary to repositi on the machine with the mowe r engaged.

1. Stop forward travel.

2. Look behind the machine to be sure there are no bystanders.

Operating - 27

OPERATING

• On models with electric attachment engagement switch: Pull switch up.

• On models with mechanical attachment engagement lever: Push lever forward.

NOTE: The mower and engine will stop as the reverse foot pedal is pressed for hydrostatic transmission or when the automatic shift lever is moved to the R (reverse) position for automatic transmission with mower engaged.

5. Disengage mower blades before moving in revers e or stopping engine.

• Machines with mechanical attachment engagement lever: Pull lever

back.

• Machines with electric attachment engagement switch : Push switch down.

MX46484

3. Push and hold in the reverse implement switch (A) while depressing

reverse pedal slightly for hydrostatic transmission or moving the automatic shift lever to the R (reverse) position for automatic transmission.

NOTE: If the engine and mower stop while repositioning the machine, return the attachment engagement lever/switch to the off position. Start engine and engage mower. Begin again with Step 2.

4. Release the reverse impleme nt switch and reposition the machine as

the machine begins to move rearward.

5. Resume forward travel. The mower should continue operating.

6. Repeat procedure to position the machine again.

Using Cruise Control (D120, D130, D140, D160, D170)

c CAUTION: Avoid injury! Do not use cruise control when

going down hills. Machine speed will increase. Operate machine in a large, open ar e a t o lea rn how t he cr u ise co ntr ol wor k s.

Use cruise control when you want to maintain travel speed without having to hold the forward travel pedal down. Cruise control operates only for forward travel.

Engage Cruise Control

1. Push forward pedal down until you reach desired travel speed.

2. Pull cruise control lever up and release forward pedal to lock the cruise

control.

Disengage Cruise Control

• Depress brake pedal, tap on forward pedal or push cruise control lever

down to the off position.

Engaging and Disengaging Mower

NOTE: Put attachment lift lever in transport position to transport machine or when parking machine.

1. Start engine and run at half speed for a couple of minutes to warm up.

2. Lower mower deck to desired cutting height position.

NOTE: Throttle lever should be at full throttle position before engaging mower to avoid stalling engine.

3. Push throttle lever up to the full throttle position.

4. Engage mower.

Using Wash Por t to Clea n Mower Deck

NOTE: Follow this procedure after each use to prevent buildup and remove corrosive lawn chemic als.

1. Park machine safely. (See Parking Safely in the Safety section).

MX38397

2. Attach quick-coupler to garden hose.

3. Attach garden hose with quick-coupler to wash port (A) on the mower deck.

4. Turn on water.

5. Start engine.

6. Run at full throttle.

7. Engage mower blades.

8. Flush water under deck for approximately one mi nute.

9. Disengage mower blades.

10. Stop engine.

11. Turn off water and remove garden hose and quick-coupler from wash port.

12. Remove quick-coupler from garden hose and store for future use.

Operating - 28

OPERATING

Unplugging Mower, Bagger, or Material Collection System

c CAUTION: Avoid injury! Do not attempt to unplug

attachment with machine running.

• Rotating blades are dangerous. Shut off the engine and remove the key before getting off the seat to inspect the machine and attachment.

• Thrown objects can cause serious injury. Make sure all machine parts are stopped before raising hopper top or removing chutes.

Checking For Plugging While Driving

If grass builds up in front of mower discharge chute, check for plugged chute or problems with blower assembly (if equipped).

If there is a trail of clippings behind mower or clippings blow to the side, check for plugged chute, full collector bags, or problems with blower assembly.

Removing Debris From Inspection Points:

c CAUTION: Avoid injury! Do not use hands or feet to clear

plugged mower deck or blower assembly. Stored energy can cause blades to rotate.

1. Park machine safely. Wait for all moving parts to stop before getting off

to inspect machine.

2. Open ho pp er cove r. Che ck ch ute ou t le t .

3. Remove chut e fr om mow er deck or blower as se m bl y. Check chut e inl et.

4. Check under mower deck for debris.

Moving Machine by Hand

c CAUTION: Avoid injury! When the bypass valve is open, the

machine will have unrestricted motion.

• Do not open the bypass valve when the machine is stopped on an incline to prevent it from going downhill out of control.

IMPORTANT: Avoid damage! Transmission damage m ay occur i f the machine is towed or moved incorrectly:

• Move machine by hand only.

• Do not use another vehi cle to move machine.

• Do not tow machine.

1. Unlock the park brake.

2. Put automatic transmission in P (park).

MX16558

3. On automatic and hyd rostatic Models: Pull out on by pass rod (A).

4. Push machine to desired location.

5. Push bypass rod back in.

6. Lock the park brake.

Transporting Machine on Trailer

NOTE: Trailer capacity must exceed combined machine weight and attachmen t weight. (See Spe cif ica tions section in ope rato r ’s manual.)

Be sure the trailer has all necessary lights and signs required by law.

c CAUTION: Avoid injury! Use extra care when loading or

unloading the machine onto a trailer or truck.

• Park trailer on a level surfa ce .

• Use of a trailer with sides is recommended.

• Keep wheels away from drop-offs and edges.

• Back slowly and in a straight line.

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

• Do not secure machine using optional bumper as this can

dislodge during transport.

IMPORTANT: Avoid damage! Transporting a machine on a trailer or on a truck bed at high speeds can result in hood or engine cover raising and possibly coming off machine if not secured.

• Position machine on trailer so hood or engine cover opens from rear of trailer to prevent wind from blowing hood or cover open.

• Secure hood or engine cover with existing machine locks or latches.

• Secure hood or engine cover with tie down straps if no locks or latches exist.

1. Park trailer on a level surface.

2. Raise mower deck, if installed, before drivi ng machine onto trailer.

Operating - 29

OPERATING

3. Drive machine onto heavy-duty trailer. Position machine on trailer so

hood or engine cover will not raise in wind while being transported.

4. Lower mower deck completely.

5. Lock park brake.

6. Turn off machine and remove key.

MX49387

7. Secure front of machine at both sides of the axle at points (A) to trailer

with heavy-duty straps, chains, or cables. Straps must be directed down and outwar d fro m machine.

MX51679

Picture Note: D105 shown.

9. For automatic transmission machines, secure rear of machine at both sides of the axle at points (C) to trailer with heavy-duty straps, chains, or cables. Straps must be directed down and outward from machine.

10. Secure ho od to prevent from lif tin g whi le dr iv in g.

IMPORTANT: Avoid damage! Do not secure machine using transmission housing.

MX43712

8. For hydrostatic transmissions, secure rear of machine at both sides of

the axle at points (B) to trailer with heavy-duty straps, chains, or cables. Strap s must be directed down and outward from machine.

Using Weigh t s

c CAUTION: Avoid injury! The machine may become unstable

when ope r ating on sl ope s and/or wit h some attach ments. Use weights to improve stability when operating on slopes or

using attachments. Remove weights when not required.

IMPORTANT: Avoid damage! Never use liquid in tires or wheel weights as ballast. Transmission damage can occur.

When rea r ballast is needed, use only the approved rear weight bracket and attaching weights.

NOTE: See your authorized dealer for recommended weights.

• Install fr ont wei gh t s f or adde d st ab il ity and st eeri ng con tro l wh en yo u us e equipment such as the rear-mounted grass bagger.

• Install rear weights when using the snow blade or snowblower.

• Remove weights when not required.

Using Ti re C hai ns

IMPO RTANT: Avoid damage! Do not use chains with mower deck or tiller.

Tire chains are recommended for use with most front attachments. Remove tire chains before installing mower deck.

See your attachment Operator’ s Manual for tire chain recommendation. See yo ur authorized dealer for the chains.

Operating - 30

SERVICE INTERVALS

Using Accessories

Using the Power Port (If Equipped)

• Adjust cutting height to remove only 1/3 of the grass at a time.

• Do not mow wet grass.

• Mow grass often. Short grass clippings w ill decay quickly.

• Mow with engine at full throttle.

• Adjust travel spee d to match mowing conditions:

• Travel at slow speed when you mow thick, tall grass, make sharp turns or trim around objects.

• Travel at moderat e sp eed when you mow thi n gr as s.

• Use a different mowing pattern each time you mow. Overlap mowing paths 50 - 100 mm (2 - 4 in.).

MX46479

• Drive over ridges and through shallow ditches straight-on, not at an angle.

c CAUTION: Avoid injury! Safe operation requires your full

attention. Do not wear radio or music headphones while operating machine.

An electric power port (A) can be used for accessories. See your author ized deal er.

Using CargO Mount System™

The front and rear CargO Mount System™ brackets (B) can be used for easy attachment of selected optional equipment.

Use John Deere approved optional equipment only. See your Authorized Service Center for approved optional equipment.

Choosing Mower Blades

Three types of mower blades are available for use with D series mowers.

• 3-N- 1 blades. These are general purpose blades that are best suited for

side-di s charge op er at io n, but ca n be use d wi th a ba gg er attachm e nt, or with a mulch cover installed. They are not designed for optimal perfor ma nc e whe n ba gg ing or mulch in g.

• Bagg er blades. These blades ar e designed fo r optimal performance

when used wi th ba gg er attachme nts .

• Mulching blades. These blades are designed for optimal performance

when used with a mulch cover installed.

Mowing Tips

The following recommendations will produce the best lawn cut quality and appearance:

• Keep mower blades sharp. Dull blades will tear grass; tips of grass will

then turn brown.

• Cutting grass too sh ort may kill grass and let weeds grow easily. The

suggested finished cut height range is 44 - 70 mm (1.75 - 2.75 in.).

MIF

• Mow around the outside twice, then mow inside in straight passes. Best cut is achieved when mowing in a straight line.

• When mowing or mulch ing near pavement, overlap the pavement by 50 mm (2 in.) to allow clippings to dispense over grass.

• A thick layer of mul che d l ea v es c an pr ev e nt su nlig ht f rom g et tin g t o gr a ss and smother it. Taller grass heights allo w mulched leaves to dispense easier in lawn. Mulch leaves several times if needed.

• Use a thatc he r in la te spr ing or sum mer t o pul l up de ad gr a ss an d aer at e ground.

• For Mulching Mower: Shorter cut heights w ill provide better cut quality, but may leave noticeable clippings. Higher cut heights will reduce clippings, but cut quality may decline.

Service Intervals

Servicing Your Machine

IMPORTANT: Avoid damage! Operating in extreme conditions may require more frequent service intervals:

• Engine components may become dirty or plugged when operating in extreme heat, dust or other severe conditions.

• Engine oil can degrade if machine is operated constantly at slow or low engine speeds or for frequent short periods of time.

Please use the following timetables to perform routine maintenance on your mac hine.

Park the vehicle safely. See Park Safely in the SAFETY Section.

Service Intervals - 31

SERVICE LUBRICATION

Service Intervals

After First 8 Hours

• Change en gi ne oil.

• On 107 cm (42 in.) deck: Check and adjust mower dec k belt tension.

• On 107 cm (42 in.) deck: Check and adjust mower deck spindle brakes.

• Lubricate mower spindles

• Lubricate mower pivot points.

• Lubricate front axle pivot.

• Lubricate front axle wheel spindles and bushings.

Every 25 Hours

• Lubricate mower spindles.

• Lubricate mower pivot points.

• Lubricate front axle pivot.

• Lubricate front axle wheel spindles and bushings.

Every 50 Hours

• Change engine oil and replace filter. (Service more frequently under

dusty co ndition s.)

• Clean/replace air filter precleaner. (Service more frequently under dusty

conditions.)

• Replace air filter element. (Service more frequently under dusty

conditions.)

• Clean/replace emis sion filter (if equipped).

• Clean engine cooling fins.

• Replace fuel filt er.

• Replace spark plug(s).

• Clean battery terminals.

• Shar pen/replace mower blades.

• Check/replace mower drive belt.

• Clean mower deck.

• Check/ leve l mow e r deck .

• On 107 cm (42 in.) deck: Check/adjust mower deck belt tension.

• On 107 cm (42 in.) deck: Check/adjust mower deck spindle brakes.

Every 200 Hours

• Check/adjust valve clearance. See your John Deere dealer for this

service.

The fol lowing greases are preferred:

• John Deere Multi-Purpose SD Polyurea Grease

• John Deer e Multi-Purpose HD Lithiu m Complex Grease If not using any of the preferred greases, be sure to use a general all-

purpose grease with an NLGI grade No.2 rating. Wet or high speed conditions may require use of a special-use grease.

Contact your Servicing dealer for information.

Lubricating Front Axle

MX16565

Wheel Sp indles and Bushings

NOTE: The D170 model does not require lubrication at the hub grease fitting (B).

• Lubricate front wheel spindle grease fitting (A) and wheel hub grease fitting (B), one on each side, with one or two shots of general all-purpose grease.

Front Axle Pivot

• Lubricate front axle center pivot grease fitting (C) with one or two shots of general all-purpose grease.

Lubricating Pivot Points

107 cm (42 in.) Mower Deck:

Service Lubrication

Grease

IMPORTANT: Avoid damage! Use recommended John Deere greases to avoid component failure and premat ure wear.

The recommended John D eere greases are effective within an average air temperature range of - 29 to 135 degree s C (-20 to 275 degrees F).

If operating outside that temperature range, contact your Servicing dealer for a special-use grease.

Service Lubr ication - 32

MX25899

A- Blade Brake Pivots B- Deck Idler Pivot C- Spindle Grease Fitting (2)

• Lubricate the blade brake pivots (A) and deck idler pivot (B) w ith a general all-purpose spray lubricant.

SERVICE ENGINE

• Lubricate the two spindle grease fittings (C) with one or two shots of

general all-purpose grease.

122 cm (48 in.) and 137 cm (54 in.) Mower Decks:

SAE 15W-40

SAE 10W-40

SAE 10W-30

SAE 5W-30

MX25900

Picture Note: 122 cm (48 in.) mower deck used for illustration. A- Deck Idler Pivot B- Spindle Gre ase Fitting (3)

• Lubric ate the deck idler pivot ( A) with a general all-purpose spray

lubricant.

• Lubricate the three spindle grease fittings (B) with one or two shots of

general all-purpose grease.

Service Engine

Engine Warranty Maintenance Statement

Mainte na nc e, r ep ai r, or replac ement of the em is s io n con t ro l devi ce s an d systems on this engine, which are being done at the customer’s expense, may b e performed by any non-road en gine repair establishment or indiv idual. Warr anty repairs must be perfo rmed by an authorized John Deere de al er.

Avoid Fumes

c CAUTION: Avoid injury! Engine exhaust fumes contain

carbon monoxide and can cause serious illness or death. Do not run an engine in an enclosed area, such as a garage, even

with doors or windows open ed. Move the machine to an outsid e area before r unn ing the engi ne .

10050122

60 80

20 30

-20 0 20 40

-40

The fol lowing John Deere oils are preferred:

• TURF-GARD™

• PLUS- 4™

• PLUS-50™ II

Other oils may be used if above John Deere oils are not available, provided they meet the following specification:

• API Service Classification SJ or higher

-20-30

-10

Checking Engine Oil Level

IMPORTANT: Avoid damage! Failure to check the oil level regularly could lead to serious engine problems if oil level is out of the operating range:

• Check oil level before operating.

• Check oil level when the engine is cold and not running.

• Keep oil level between the dipstick marks.

• Shut off engine before adding oil.

NOTE: Check oil twice a day if you run engine over 4 hours in a day. Make sure engine is cold when checking engine oil level.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Lift hood.

3. Clean area around dipstick to prevent debris from falling into crankcase.

Engine Oil

Use oil viscosity based on the expected air temperature range during the period between oil changes.

Service Engine - 33

SERVICE ENGINE

MX49394

Picture Note: Twin cylinder engine shown.

4. Remove dipstick (A). Wipe with clean cloth.

5. Ins tall and tighten dipstick.

6. Remove dipstick.

7. Check oil level on dipstick. Oil must be between ADD and FUL L marks.

8. If oil level is low, add oil to bring oil level no higher than FULL mark on

dipsti ck. D o no t overfill.

9. Ins tall and tighten dipstick. Lower hood.

MX49394

Picture Note: Twin cylinder engine shown.

4. Put drain pan under drain valve (A).

5. Rotat e and remove drain cap (B) and drain oil into oil drain pan. Allow oil to drain completely.

6. Remove dipstick (C).

Changing En gi ne Oi l an d Fi lte r

IMPORTANT: Avoid damage! Change the oil more often if the vehicle is used in extreme conditions:

• Extremely dusty condi tion s.

• Frequent slow or low-speed operation.

• Frequent short trips .

1. Run engine to warm oil.

2. Park machine safely. (See Parking Safely in the SAFETY section.)

3. Lift hood.

MX49395

Picture Note: Twin cylinder engine shown.

7. Replace oil filter (D), if equipped. a.Wipe dirt from ar o un d oi l filt e r. b.Place a drain pan or funnel under filter tray. c.Remove old filter and filter gasket and dispose of properly. Wipe up

any spilled oil. d.Put a light coat of fresh, clean oil on the new filter gask et. e.Install replacement oil filter by turning oil filter to the right (clockwise)

until the rubber gasket contacts filter base. Tighten filter an additional one-half turn.

8. Insta ll dr ai n ca p.

Service Engine - 34

SERVICE ENGINE

IMPORTANT: Avoid damage! Do not overfill. Overfilling can cause smoking, hard starting, fouling of spark plug, and oil saturation of air filter.

9. Add oil no higher than FULL mark on dipstick. Use approximately the amount of oil listed in the Specifications sect ion. Do not overfill.

10. Install dipstick.

11. Start and run engine at idle to check for leaks. Stop engine. Fix any leaks before operating.

12. Check oil level. Add oil if necessary.

Cleaning Air Intake Screen and Engine Fins

c CAUTION: Avoid injury! Compressed air can cause debris

to fl y a long distance.

• Clear work area of bystanders.

• Wear eye protection when using compressed air for cleaning

purposes.

• Reduce compressed air pressure to 210 kPa (30 psi).

IMPORTANT: Avoid damage! An obstructed air intake screen can cause engine damage due to overheating. Keep air intake screen and other external surfaces of the engine, including cooling fins, clean at all times to allow adequate air intake.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Lift hood.

2. Let engine cool.

3. Lift hood.

4. Clean dirt and debris from the air cleaner cover.

MX7680

5. Lift latch (A) to unlock cover (B). Lift cover forward and remove.

IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a dam ag ed filter element:

• Do not wash paper element.

• Do not attempt to clean paper element by tapping against

anothe r objec t.

• Do not use pressurized air to clean element.

• Replace element only if it is very dirty, damaged or th e seal is

cracked.

MX49394

Picture Note: Twin cylinder engine shown.

3. Clean air intake screen (A), cooling fins and external surf aces with rag, brush, vacuum or compressed air.

4. Lower hood.

Checking and Cleaning Air Cleaner Elements (D105 and D110)

1. Park machine safely. (See Parking Safely in the SAFETY section.)

MX46573

6. Inspec t t h e pap er fil t er el e men t (C ) w i thou t remo v in g i t. I f th e p ap er f il ter

element is damaged or dirty, replace with new filter:

• Clean air cleaner base very carefully, preventing any dirt from falling into carburetor.

• Carefully pull the paper eleme nt from the air cleaner elbow (D).

• Install new paper filter element back onto air cleaner elbow.

7. Install air cleaner cover and push latch down to lock.

8. Lower hood.

Checking and Cleaning Air Cleaner Elements (D130 and D140)

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Let engine cool.

Service Engine - 35

SERVICE ENGINE

3. Lift hood.

4. Clean dirt and debris from the air cleaner cover.

MX49397

5. Loosen four knobs (A) and remove cover (B).

IMPORTANT: Avoid damage! To prevent engine damage, do not allow any foreign objects to fall into the carburetor air intake.

c.Rinse precleaner thoroughly. Squeeze out excess water in a dry cloth until precleaner is completely dry.

9. Clean air cleaner housing carefully. Prevent any dirt from falling into

carburetor.

10. Install foam precleaner mesh side up.

11. Inst al l c artri dge. Ma k e s ure cartri dg e and se al are pr op erly se at ed an d

sealin g the carburetor air intake area.

12. Install air cleaner cover and tighten knobs. Do not overtighten.

13. Lo wer hood.

Checking and Cleaning Air Cleaner Elements (D120)

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Let engine cool.

3. Lift hood.

4. Clean dirt and debris from the air cleaner cover.

M96094

6. Do not drop anything into the carburetor air intake (C). If anything falls into the carburetor air intake it must be removed.

7. Lift out filter cartridge (D) and inspect it for damage.

IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a damaged filter element:

• Do not wash paper element.

• Do not attempt to clean paper element by tapping against

another object.

• Do not us e pressurized air to clean element.

• Replace element only if it is very dirty, damaged or the seal is

cracked.

MX49396

5. Loosen two knobs (A) and remove cover (B).

8. Inspect the foam precleaner (E) without removing it. If the foam precleaner is dirty:

a.Remove it from the filter carefully. b.Wash precleaner in a solution of warm water and liquid detergent.

Service Engine - 36

SERVICE ENGINE

IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a damaged filter element:

• Do not wash paper element.

• Do not attempt to clean paper element by tapping against

another object.

• Do not us e pressurized air to clean element.

• Replace element only if it is very dirty, damaged or the seal is

cracked.

6. Pull filter assembly from air cleaner base (C). Inspect the foam precleaner (D) without removing it . If the foam precleaner is dirty:

a.Remove it from the paper filter carefully. b.Wash precleaner in a solution of warm water and liquid detergent. Do

not use oil. c.Rinse precleaner thoroughly. Squeeze out excess water in a dry cloth

until precleaner is completely dry.

7. Inspect the paper filter element (E). If the paper filter element is damaged or dirty, replace with new filter.

8. Clean air cleaner base very carefully, preventing any dirt from falling into carburetor.

9. Ins tall foam precleaner on paper filter element.

10. Install new filter assembly back onto air cleaner base.

11. Install air cleaner cover and tighten two knobs.

12. Lo wer hood.

MX25902

Checking and Cleaning Air Cleaner Elements (D160 and D170)

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Let engine cool.

3. Lift hood.

4. Clean dirt and debris from the air cleaner cover.

MX49394

5. Loosen two knobs (A) and remove cover (B).

IMPORTANT: Avoid damage! Dirt and debris can enter the engine through a dam ag ed filter element:

• Do not wash paper element.

• Do not attempt to clean paper element by tapping against

anothe r objec t.

• Do not use pressurized air to clean element.

• Replace element only if it is very dirty, damaged or th e seal is

cracked.

MX25904

6. Pull filter assembly from air cleaner base (C). Inspect the foam

precleaner (D) without removing it. If the foam precleaner is dirty:

a.Remove it from the paper filter careful ly. b.Wash precleaner in a solution of warm water and liquid detergent. Do

not use oil. c.Rinse precleaner thoroughly. Squeeze out excess water in a dry cloth

until precleaner is completely dry.

7. Inspect the paper filter element (E). If the pape r filter element is

damaged or dirty, replace with new filter.

8. Clea n a i r cl ea ne r ba se v ery ca r eful l y, pre v e nti ng an y di rt fro m falling into

carburetor.

9. Install foam precleaner on paper filter element.

Service Engine - 37

SERVICE ENGINE

10. Install new filter assembly back onto air cleaner base.

11. Install air cleaner cover and tighten two knobs.

12. Lo wer hood.

Checking and Cleaning Emission Filter (If Equipped)

1. Park machine safely. (See Parking Safely in the SAFETY section.)

MX39589

2. Inspect filter (A) for dirt and damage, wash or replace if required. a.Remove cover (B) and remove emission filter (A) from under rear of

fend er deck. b.Wash foam filter in a solution of warm water and liquid detergent. Do

not use oil. c.Rinse filter thoroughly. Squeeze out excess water in a dry cloth until

filter is completely dry. If foam filter cannot be cleaned properly or is damaged, replace with a

new filter. d.Install foam air filter and secure with cover.

Checking Spark Plug

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Let engine cool.

3. Lift hood.

5. Remove spark plug(s).

6. Clean spark plug carefully with a wire brush.

7. Inspect spark plug for:

• Crack ed porcelain.

• Pitted or damaged electrodes.

• Other wear or damage.

8. Replace spark plug as necessary .

M85200

9. Check plug gap (B) with a wire feeler gauge. To change gap, move the outer electrode.

• Gap must be 0.76 mm (0.030 in.).

10. Install and tighten spark plugs to 20 N•m (15 lb-ft).

11. Connect spark plug wire(s) and lower hood.

Adjustin g C arburetor

NOTE: Carburetor is calibrated by the engine manufacturer and is not adju stable.

If engine is operated at altitudes above 1829 m (6,000 ft), s ome carburetors may r equire a special high altit ude main jet. See your authorized dealer.

If engine is hard to start or runs rough, check the TROUBLE SHOOTING section of this manual.

Possible engine surging will occur at high throttle with transmission in N neutral and mower engagement lever disengaged. This is a normal condition due to the emission control system.

After per fo rming the check s in the tro ub leshoot ing section an d you r engi ne is still not performing correctly, contact your authorized dealer.

MX49394

Picture Note: Twin cylinder engine shown.

4. Disconnect spark plug wire(s) (A), one on each side on V-twin engines.

Service Engine - 38

Replacing Fuel Filter

NOTE: Change filter when fuel is low.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Let engine cool.

3. Lift hood.

4. Handle fuel safely. (See Handling Fuel Safely in the SAFETY section.)

5. Put a drain pan under fuel filter.

SERV I C E TR ANSMISSION

MX13768b

6. Slide hose clamps (A) away from fuel filter (B) using a pliers.

7. Disconnect hoses from filter, and raise fuel lines vertically to avoid fuel

drainage.

IMPORTANT: Avoid damage! Incorrect installation of fuel filter may cause engine damage. Install the filter with the arrow pointing in the direction of fuel flow (towards the engine) for proper operation.

8. Connect hoses to new filter making sure the filter arrow is pointed in the

direction of the fuel flow.

9. Install clamps and check for leaks.

10. Lo wer hood.

Service Transmission

c CAUTION: Avoid injury! Component is spring-assisted and

under tension. Injury can occur if spring-assisted component is released suddenly.

MX25905

3. Put a 15 mm closed wrench or a socke t on the idler sheave nut (A) and rotate clockwise to move idler sheave toward front of tractor and hold to release belt tension.

4. Remove belt (B) fr om drive sheave (C), and release tension on sheave nut (A).

5. To install the belt on the drive sheave, rotate idler sheave nut clockwise to mov e idler sheave to ward front of tractor, and install belt on drive sheave.

6. Release idler sheave nut to tighten belt.

Checking Transmi ssion

The transmission is a sealed componen t. No maintenance is required on this transmission. If you suspect any transmission problems, please contact your authorized dealer.

Service Mower

Removing or Installing Mower Drive Belt at Engine Drive Sheave (122 cm (48 in.) and 137 cm (54 in.) Mower Deck)

1. Park machine saf ely. (See Parking Safely in SAFETY section.)

2. Put lift lever in lowest position.

Removing Mower Deck

1. Park machine safely. (See Parking Safely in SAFETY sect io n.)

2. Put wood blocks under each side of mower deck.

3. Put attachment lift lever in lowest position, bringing mower deck down onto blocks.

MX7681a

Picture Note: 107 cm (42 in.) mower deck only.

4. On mac hi nes w i th 1 07 cm (4 2 i n .), d iscon ne ct mo we r en ga ge me nt dr ive

Service Transm ission - 39

SERVI C E MOW ER

cabl e (A) on left side of mower dec k.

a.Remove spring loc ki ng pi n (B ), p ul l a nd hold m o wer e nga ge ment dr iv e cable out, lift up and remove from bracket (C).

b.Remove cable spring (D) from idler sheave bracket (E).

c CAUTION: Avoid injury! Mower lift arms can pinch fingers.

Lift arms are spring loaded and can snap back when deck is removed.

Lock lift lever before pulling pin to remove mower deck.

MX16568

5. Remove spring locking pins and washers (F) and disconnect rear draft

arm (G) and adjustable lift links (H) on each side.

MX10514

Picture Note: 107 cm (42 in.) mower deck shown.

• On 107 cm (42 in.) mower deck only: Push mower engagement drive cable into clip (M) and hook end of cable spring with hardware (N) into peg on left side of machine frame.

Installing Mower Deck

1. Park machine safely. (See Parking Safely in SAFETY sect io n.)

2. Put attachment lift lever in the transport position.

3. Slide mower under machi ne.

4. Put wood blocks under each side of mower deck.

5. Put attachment lift lever in lowest position.

Picture Note: 107 cm (42 in.) mower deck shown.

6. Remove spring locking pin (I) and washer and front draft rod (J) from

mower deck bracket (K).

7. Remove mower drive belt from drive sheave (L).

8. Remove wood block s from both si de s and slide mower de ck ou t from

under the machine.

9. When operating the machine without the mower deck:

• Remove f ront draft rod from machine and attach it to the mower deck.

MX51680

MX16568

6. Fasten rear dra ft arm (A) and adjustable lift link (B), on each side, with washers and spring locking pins (C).

Service Mower - 40

SERVI C E MOW ER

IMPORTANT: Avoid damage! To prevent clutch da mage, make sure front draft rod is installed correctly. Secure rod with washer and spring locking pin on the left side of mower deck bracket.

Picture Note: 107 cm (42 in.) mower deck shown.

7. Install front draft rod (D) into mower deck bracket (E):

• For D105 models use the hole marked AUTO (shown).

• For all other models use the hole marked HYDRO (F).

8. Secure front draft rod with washer and spring locking pin (G).

MX51680

c CAUTION: Avoid injury! Component is spring-assisted and

under tensio n. Inju ry can occ ur if spr in g-a ss ist ed co mp one nt is released suddenly.

MX51680

• On 107 cm (42 in.) mower deck: Make sure belt is routed through both belt guides (J).

10. Remove wood blocks from both sides of mower deck.

11. On machines with 107 cm (42 in.) mower deck: Attach mower engagement drive cable.

MX25905

Picture Note: 122 cm (48 in.) mower deck used for photo purposes.

9. Put mower drive belt on engine drive sheave (H).

• On 122 cm (48 in.) and 137 cm (54 i n.) mower dec k s: Put a 15 mm closed wrench or a socket on the idler sheave nut (I) and rotate clockwise, moving idler sheave and tensioning arm toward front of tractor. Hold while installing belt on drive sheave.

Service Mower - 41

MX7681a

Picture Note: 107 cm (42 in.) mower deck only.

a.Route cable under mower belt and brake rod and attach cable spring (K) to idler sheave bracket (L).

b.Pull out on cable (M), align black end of cable with slot in bracket (N) and release cable in to slot. Secure with spring locking pin (O).

12. Level mower deck.

Replacing Mower Drive Belt (107 cm (42 in.) Mower Deck)

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Remove mower deck.

3. Remove drive belt:

SERVI C E MOW ER

a.Remove three capscrews and belt shield (A). b.Remove two capscrews and belt shield (B). c.Loosen sheaves (C). d.Remove mower belt.

4. Ins pect belt for wear or damage; replace as necessary.

5. Clean top surface of mower deck and sheaves.

6. Install belt on mower deck as shown. Make sure belt is in the groove of

each sheave.

7. Tighten sheaves to 47 N•m (35 lb-ft).

8. Ins tall belt shields.

9. Install mower deck.

10. Adjust mower belt tension and spindle brakes, if n ecessary.

Replacing Mower Drive Belt (122 cm (48 in.) and 137 cm (54 in.) Mower Decks)

1. Park machine saf ely. (See Parking Safely in SAFETY section.)

2. Remo ve mower dec k.

MX25906

a.Loosen left side sheaves (B) and (C). b.Remove mower b elt.

5. Inspect belt for wear or damage; replace as necessary.

6. Clean top sur face of mower deck and sheaves.

7. Install belt on mower deck as shown. Make sure belt is in the groove of each sheave.

8. Tighten sheaves to 47 N•m (35 lb-ft).

9. Insta ll be lt sh ie ld s.

10. Install mower deck.

Adjusting Mower Belt Tension (107 cm (42 in.) Mower Deck)

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Move mower engagement (PTO) lever or switch to OFF position.

MX7681a

3. Loosen nuts (A) and move cable bracket (B) away from the center of mower deck to tighten belt tension. Move bracket until almost all slack is out of cable but cable is not too tight. Tighten nuts.

Adjusting Spindle Brakes (107 cm (42 in.) Mower Deck)

Picture Note: 122 cm (48 in.) mower deck shown.

3. Remove five capscrews and left and right belt shields (A).

4. Remove drive belt.

c CAUTION: Avoid injury! The mower blades should stop in

approximately five seconds when the mower or PTO 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 your machine.

IMPO RTANT: Avoid damage! Avoid belt damage. Spindle brake engagement should be checked and corrected

every time the mower belt tension is adjusted. Mower belt tension should be adjusted, if required, before brakes

are adj us ted.

MX25907

Service Mower - 42

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Remove mower deck.

SERVI C E MOW ER

MX25908

3. Remove left and right belt shields, and adjust two blade brakes (A).

MX25909

4. Measure distance from spindle brake bracket (B) to nut (C) on end of

brake rod.

• Bracket to nut distance should be: 2 - 3 mm (0.08 - 0.12 in).

5. If adjustment is required, turn nut (C) on end of brake rod in correct

direction to set brake at proper distance from pulley.

6. Adjust both brakes.

7. Install left and right belt shields.

8. Install mower deck.

MX4897

Picture Note: Mower deck with side discharge used for illustration

3. Measu re distance (A) between blade tip and flat ground surf ace.

4. Rotat e blade 180° and measure distance between other blade tip and flat ground surface.

5. Install new blade if the difference between the two measurements is more than 3 mm (1/8 in.).

6. Repeat for all blades.

Servicing Mower Blades

c CAUTION: Avoid injury! Rotating blades are dangerous.

Before adjusting or servicing mower:

• Disconnect spark plug wire(s) or battery negative (-) cable to prevent engine from starting accidentally.

• Always wear gloves when handling mower blades or working near bl ades.

Removing Mower Blades

1. Park machine safely. (See Parking Safely in SAFETY sect io n.)

2. Raise mower deck to gain access to mo wer blades. If necessary, remove mower deck.

3. Block mower blade with a piece of wood to prevent it from sp inning.

Checking for Bent Mower Blades

c CAUTION: Avoid injury! Blades are sharp. Always wear

gloves when handling blades or working near blades. Replace blades if defective. Never straighten or weld them.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Raise mower deck to highest position to access blades.

Service Mower - 43

4. Loosen and remove nut (A), washer (B), and blade (C).

MX16569

SERVI C E EL ECT R I CA L

5. Inspect blades; sharpen, balance or replace blades as necessary.

Installing Mower Blades

1. Position mower blade (C) with the cutting edge towards the ground.

2. Align the splined center hole in the blade with the splined spindle shaft

(D) and put the blade onto the mower spindle shaft.

3. Install washer, with cupped side towards blade, and install nut to secure

blade onto splined spindle shaft.

4. Block mower blade with a piece of wood to prevent spinning and tighten

nut:

• Using 15/16 in. socket, tighten 5/8 in. blade nut to 88 N•m (65 lb-ft).

Sharpening Blades

c CAUTION: Avoid injury! Blades are sharp. Always wear

gloves when handling blades or working near blades. Always wear safety eye protection when grinding.

• Sharpen blades with grinder, hand file, or electric blade sharpener.

• Keep origina l bevel ( A) wh en gr in di ng .

• Blade sho ul d have 0.40 mm (1/6 4 in . ) cut t in g ed ge (B) or les s.

• Balance blades before installing.

M61524

2. Put blade on nail in a vise. T u rn blade to horizontal position.

3. Check balance. If blade is not balanced, heavy end of blade will drop.

4. Grind bevel of heavy end. Do not change blade bevel.

Service Electrical

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

MIF

Balancing Blades

c CAUTION: Avoid injury! Blades are sharp. Always wear

gloves when handling blades or working near blades.

1. Clean blade.

Service Electrical - 44

c CAUTION: Avoid injury! The battery produces a flammable

and explosive gas. The battery may explode:

• Do not smo ke or have open flame near battery.

• Wear e ye protection and gloves.

• Do not allow direct metal contact across battery posts.

• Remove negative cable first when disconnecting.

• Install negative cable last when connecting.

Removing and Installing the Battery

Removing

1. Park machine safely and lift hood. (See Parking Safely in the SAFETY Section.)

SERVI C E EL ECT R I CA L

Using Booster Battery

MX49392

2. Disconnect negative (-) battery cable (A).

3. Push red cover (B) away from positive (+) battery terminal and remove

cable (C) from battery.

4. Remove battery.

Installing

1. Place battery into battery tray.

2. Connect positive (+) cable to positive (+) battery terminal first, then

negative (-) cable to negative (-) battery terminal.

3. Apply spray lubricant to terminal to help prevent corrosion.

4. Slide red cover over positive battery terminal.

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 wi th plain water and dry.

5. Clean terminals and battery cable ends w ith wire brush until bright.

6. Install battery.

7. Attach cables to battery terminals, beginning with the positive cable,

using washers and nuts.

8. Apply spray lubricant to terminal to prevent corrosion.

c CAUTION: Avoid injury! The battery produces a flammable

and explosive gas. The battery may explode:

• Do not smo ke or have open flame near battery.

• Wear e ye 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.

B A

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 (+) boo s ter 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 en d (F) of negative (–) booster cable to a metal part of the dis able d ma c hin e en gine block away from battery.

5. Start the engine of the disabled machine and run machine for several minutes.

6. Carefully disconnect the booster c ables in the e xact rev erse order: negative cable first and then the positive cable.

Replacing Headlight Bulb

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Lift hood.

Service Electrical - 45

SERVI C E MI SC ELLAN EO U S

MX46488

3. Turn bulb socket (A) 1/4 turn counterclockwise to remove.

4. Replace defective bulb with a new bulb.

5. Insert bulb socket into housing, push in and turn 1/4 turn clockwise to

install.

6. Lower hood.

Replacing Fuse

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Lift hood.

Service Miscellaneous

Using Prop e r F uel and Stab ilize r

IMPORTANT: Avoid damage! Using stale, contaminated or improper fuel can result in engine and fuel system damage. Repairs caused by stale, contaminated or improper fuel are not covered by wa rranty.

Use regular grade unleaded fuel with an octane rating of 87 octane or higher. Fuel bl ends containing up to 10% ethanol or up to 15% MTBE reformulated fuel are acceptable. Do not use fuel or additives containing methanol as engine damage can occur.

Always use fresh, clean fuel that is purchased in a quantity that can be used wit h in ap proximately 30 d a ys . F uel st ab il iz er sh ou ld a lw a y s b e a dd ed to the fuel each time fuel is purchased. Add stabilizer before fi lling the fu el container to insure proper mixing. Such practice helps prevent engine performance proble ms and allows fuel storage in the machine all year without draining.

Store fue l i n p la stic con t aine rs to red uce cond en sat ion . M ak e s ure th e ca p on the fue l co nt ai ner is ti ght t o red uc e f ue l cont a min at ion and e v a po rat i on. For best fuel storage life, use a self-sealing gas can.

Fuel is blended to give best seasonal performance. To avoid engine performance problems such as hard starting or vapor lock, use in-season fuel. Use fuel during warm weather that was purchased during that season, and use fuel during cold weather that was purch ased during that season.

Fuel can beco me sta le in mac hi ne s wit h en gine s th at are us ed seas on ally or infrequently during a season. Stale fuel can produce varnish and plug carburetor or EFI components which can affect engine performance.

Keep fuel storage container tightly covered and in a cool area out of direct sunlig ht. Fuel can break down and degrade if not sealed properly or exposed to sun and heat.

Condensation may collect in the fuel tank because of a variety of operating or environmental conditions and, over time, may affect your machine’s operation. Fill machine fuel tank at the en d of the day.

MX49392

3. Pull defective fuse (A) out of socket.

4. Check metal clip in fuse window and discard fuse if clip is broken.

5. Push new 20 amp fuse into socket.

6. Lower hood.

Service Miscellaneous - 46

Filling Fuel Tank

c CAUTION: Avoid injury! Fuel vapors are explosive and

flammable:

• Shut engine off before filling fuel tank.

• Allow engine to cool before refueling.

• Do not smoke while handling fuel.

• Keep fuel away from flames or sparks.

• Fill fuel tank outdoors or in well ventilated area.

• Clean up spilled fuel immediately.

• Use clean approved non-metal container to prevent static

electric discharge.

SERVI C E MI SC ELLAN EO U S

IMPORTANT: Avoid damage! Dirt and water in fuel can cause engine damage:

• Clean dirt and debris from the fuel tank opening.

• Use clean, fresh, stabilized fuel.

• Fill the fuel tank at the end of each day’s operation to keep

condensati on out of the fue l tank .

• Use a non-metallic funnel with a plastic mesh stra iner when filling the fuel tank or container.

Fill fuel tank at the end of each day’s operation to prevent condensation and freezing dur ing cold weather.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Allow engine to cool.

3. Remove any trash from area around fuel tank cap.

4. Remove fuel tank cap slowly to allow any pressure built up in tank to

escape.

5. Fill fuel tank only to bottom of filler neck. Do not overfill.

6. Do not continue to “top off” the tank once full.

7. Install fuel tank cap, and turn cap until it clicks.

Lifting Machine

1. Park machine safely . (See Parking Safely in the SAFETY section.)

c CAUTION: Avoid injury! The machine can fall or slip from

an unsafe lifting device or supports.

• Use a safe lifting device rated for the load to be lifted.

• Lower machine onto jack stands or other stable supports and

block wheels before servicing.

4. Safely lift front of machine at machine frame point (C). Place jack stands or other stable supports under frame on each side at location (B).

5. If only lifting front of machine, block rear wheels remaining on ground to avoid movement of machine.

6. To lower machine, lift front and/or rear of machine, and remove jack stand s or su ppor ts. Low e r mac hi ne.

MX49387

Checking Tire Pressure

1. Check tires for damage.

2. Check tire pressure with an accurate gauge.

3. Service tires safely. (See Tire Safety in the SAFETY section.)

4. Check that tires have equal air pressure. Add or remove air, if necessary.

5. Refer to side of tire for correct tire inflation pressure.

Removing and Installing Hood

Removing

Picture Note: Hydrostatic transmission model shown.

2. Safely lift rear of machine at machine frame point (A). Place jack stands

or other stable supports onto transaxle locations (B) where mounting bolts for frame come through.

3. If only lifting rear of machine, block front wheels remaining on ground to

avoid moveme nt of ma c hine.

MX40761

Service Miscellaneous - 47

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.

IMPORTANT: Avoid damage! Do not operate machine with hood open. Hood must be closed for proper engine cooling and exhaust.

1. Park machine safely. (See Parking Safely in the SAFETY section.)

2. Let engine cool.

SERVI C E MI SC ELLAN EO U S

Cleaning and Repairing Metal Surfaces

Cleaning:

Follow automotive practices to care for your vehicle painted metal surfaces. Use a high-quality automotive wax regularly to maintain the factory look of your vehicle’s painted surfaces.

Repairing Minor Scratches (surface scratch):

1. Clean ar e a to be re pa ir e d tho r ou gh ly.

IMPORTANT: Avoid damage! Do not use rubbing compound on painted surfaces.

2. Use automotive polishing compound to remove surface scratches.

3. Apply wax to entire sur face.

MX46489

3. Open hood.

4. Disconnect wiring harness (A).

5. Appl y pres su re to “ Joh n” o n le ft s id e o f ho od a nd sl ow ly lo w er h oo d. L eft

side pivot should release after rotating closed approximately 45 degrees. Once left side pivot releases, slide out right side pivot. Lo wer hood slightly and lift hood from brackets (B).

Installing

1. Slid e r ight si de ho od pi v o t i nto tractor brac k et wit h ho od in open pos it i on

(left side pivot will slide into place as hood closes) and slowly close hood.

2. Connect wiring harness.

3. Close hood.

Cleaning Plastic Surfaces

IMPORTANT: Avoid damage! Improper care of machine plastic surfa ces can damage that surface:

• Do not wipe plastic surfaces when they are dry. Dry wiping will result in minor surface scratches.

• Use a soft, clean cloth (bath towel, diaper, automotive mitt).

• Do not use abrasive materials, such as polishing compounds,

on plastic surfaces.

Repairing Deep Scratches (bare metal or primer showing):

1. Clean area to be repaired with rubbing alcohol or mineral spirits.

2. Use paint stick with factory-matched colors available from your authoriz e d de al er to fill scratches. F ol lo w dire ct ions inc lu de d on paint st ic k for use and for drying.

3. Smooth out surface using an autom otive polish ing compound. Do not use power buffer.

4. Apply wax to surface.

Removing and Installing Front Wheel Assembly

Removing:

1. Park machine safely. (See Parking Safely in the SAFETY section.)

c CAUTION: Avoid injury! The machine can fall or slip from

an unsafe lifting dev ice or suppo r ts .

• Use a safe lifting device rated for the load to be lifted.

• Lower machine onto jack stands or other stable supports and

block wheels before servicing.

IMPORTANT: Avoid damage! Place jack stands under frame, not under transmission or engine, when raising or supporting machine.

1. Rins e h ood a nd en tir e ma chin e w it h cl ea n w ate r t o r emo v e di rt and du st

that may scratch the surface.

2. Wash surface with clean water and a mild liquid automotive washing

soap.

IMPORTANT: Avoid damage! Insect repellent spray may damage plastic and painted surfaces. Do not spray insect repellent near machine.

3. Dry thoroughly to avoid water spo ts.

4. Wax the surface with a liquid automotive wax. Use products that

specifically say “contains no abrasives.”

IMPORTANT: Avoid damage! Do not use a power buffer to remove wax.

5. Buff applied wax by hand using a clean, soft cloth .

Service Miscellaneous - 48

2. Safely lift and support machine. Place safe lifting device under end of front hanger bracket at location (A), and place jack stands or other stable supports under frame on each side at location (B). Block wheels

MX49387

SERVI C E MI SC ELLAN EO U S

remaining on the ground to prevent machine movement.

M89737

3. Remove plastic cap (C) from end of wheel hub.

c CAUTION: Avoid injury! Components are installed under

spring tension. Wear eye protection and use proper tools when installing and removing components with spring tension.

4. Install plastic cap (C ).

5. Safely remove jack stands and lower machine.

Removing and Installing Rear Wheel Assembly

Removing

1. Park machine safely. (See Parking Safely in the SAFETY section.)

c CAUTION: Avoid injury! The machine can fall or slip from

an unsafe lifting dev ice or suppo r ts .

• Use a safe lifting device rated for the load to be lifted.

• Lower machine onto jack stands or other stable supports and

block wheels before servicing.

IMPORTANT: Avoid damage! Place jack stands under frame, not under transmission or engine, when raising or supporting machine.

M89736

4. Remove snap ring (D) from end of axle.

5. Remove washer (E) and wheel from axle.

c CAUTION: Avoid injury! Explosive separation of tire and rim

parts is possible when they are serviced incorrectly:

• Do not attempt to mount a tire without th e proper equipment and experience to perform the job.

6. Take wheel assembly to an authorize d service dealer for repairs.

Installing

1. Grease spindles and wheel hub grease fittings with specified grease.

2. Install wheel and washer (E) on axle.

3. Install snap ring (D).

2. Safely lift and support machine. Place safe lifting device under transmission centered under machine frame point (A). Place jack stands or other stable supports on each si de (B) where moun ting bolts for frame come through. Block wheels remaining on the ground to prevent machine movement.

3. Remove plastic cap (C), snap ring (D), and washer (E).

MX40761

MX16572

Service Miscellaneous - 49

TROUBLESHOOTING

4. Remove wheel.

IMPORTANT: Avoid damage! Do not lose the shaft key. Key must be installed for wheels to rotate and tractor to move.

5. Remove shaft key (F) (shown on end of transmission shaft), two

washer s (G ) , exce pt for mo del D105, and spac e r (H) .

c CAUTION: Avoid injury! Explosive separation of tire and rim

parts is possible when they are serviced incorrectly:

• Do not attempt to mount a tire without th e proper equipment and experience to perform the job.

6. Take wheel assembly to an authorize d service dealer for repairs.

Installing

IMPORTANT: Avoid damage! Do not lose the shaft key. Key must be installed for wheels to rotate and tractor to move.

NOTE: Rear wheels are installed with valves to the outside.

1. Install two washers (G), except on model D105, spacer (H), and shaft

key (F).

2. Install rear wheel, washer (E), snap ring (D) and plastic cap (C).

3. Safely rem ove ja ck sta n d s and low er m ac hine.

Troubleshooting

Using Troubleshooting C hart

If you are experiencing a problem that is not listed in this chart, see your authorized dealer for ser vi c e.

When you have checked all the possible causes listed and you are still experiencing the p roblem, see y our authorized dealer.

Engine

IF CHECK

Engine Will Not Start

Engine Is Hard To Start

Engine Runs Unevenly

Engine Misses Under Load

Engine Vapor Locks

Brake pedal not de pressed. Mower is engaged. Spark plug wire is loose or disconnected. Improper fuel. Transmission is in reverse. Plugged fuel filter. Defective safety switch. Electr ical pr ob le m - See E l ectr ica l Troub l es hoo tin g

Section Carburetor is not adjusted properly or dirty.

Choke cable not adjusted properly. Plugged fuel filter. Faulty spark plug. Stale or improper fuel. Loose or corroded electrical connections. Improper engine oil viscosity.

Cooling fins plugged. Loose electrical connections. Choke or thro t tl e ca ble stickin g. Fuel line or fuel filter plugged. Stale or dirty fuel. Improper fuel. Air cleaner element plugged.

Faulty spark plug. Stale or dirty fuel. Plugged fuel filter.

Fuel tank vent plugged. Dirt in fuel filter. Cooling fins plugged. Loose hose connection at fuel filter or fuel pump.

IF CHECK

Poor Engine Performance

Dirt in fuel system or fuel is old. Replace fuel with fresh stabilized fuel. Obtain fuel from another suppli er before suspecting machine problems. Suppliers blend fuels differently and changing suppli ers will gener ally solve any performance problems.

Fuel blended with alcohol or ether may contribute to performance problems by causing gum and varnish deposits, especially if fuel is stored for several weeks or more. Obtain fresh fuel .

Engine Overheats Engine air intake screen plugged.

Engine Will Not Idle

Engine Knocks Stale or low octane fuel.

Engine Stops Or Misses When Operating On Hillsides

Engine Backfires Faulty spark plug.

Troubleshooting - 50

Cooling fins plugged. Engine oil low or too high. Engine operated too long at a slow idle speed.

Spark plug not gapped correctly. Faulty spark plug. Opera tor raising off the seat.

Engine overloaded. Low engine spe ed. Oil level low.

Fuel tank less tha n half ful l of fue l. Opera tor raising off of the seat.

Opera tor raising off of the seat.

TROUBLESHOOTING

IF CHECK

Engine Loses Power

Excessive Fuel Consumption

Black Exhaust Smoke

Engine St ops When REVERSE Foot Pedal Is Depressed And Attachment Is Engaged (Hydrostatic)

Engine St ops When Automatic Shift Lever Is Moved To The R (REVERSE) Positio n an d Attachment Is Engaged (Automatic)

Engine overheating. Too much oil in engine. Dirty air cleaner. Faulty spark plug . Travel speed is too fast for cond itions. Improper fuel.

Choke is not fully open.

Air filter is dirty or oil soaked. Choke partially engaged.

Normal condition. (See Using Reverse Implement Option in the OPERATING section.)

Electrical

IF CHECK

Starter Does Not Work Or Will Not T urn Engine

Battery Will Not Charge

Lights Do Not Work

Brake pedal is not depressed. Mower is engaged. Battery terminals are corroded. Battery no t charge d . Transmission is in reverse. Blown fuse. Fusible Link in starting circuit is blown - See your

author ized deal er Dead cell in the battery.

Battery cables and terminals are dirty . Low engine speed or excessive idling.

Light plug disconnected. Loose or burned out bulb.

Tr actor

IF CHECK

Tractor Vibrates Too Much Or Rattles Excessively

Tractor Will Not Move With Engine Running

Attachment drive belts worn or damaged. Traction drive belt damaged or worn. Dirt on drive sheaves. Blades bent or out of balance.

Parking brake locked. Bypass rod is pulled out.

Mower

IF CHECK

Dischar ge Chute Plugged Travel speed too fast.

Grass too long. Grass too wet. Engine rpm not at wide open

throttle. Restricted air flow. Belt installed incorrectly.

Patches Of Grass Uncut Trave l speed too fast.

Engine rpm not at wide open throttle.

Mower deck needs cleaning.

Belt Slipping Debris in sheaves .

Worn belt. Belt tension is incorrect.

Too Much Vibration Debris on mower deck or in

sheaves. Damaged drive belt. Damaged sheaves or sheaves out of

alignment. Blades out of balance.

Blades Scalping Grass Cutting too low.

Mower wheels not adjusted correctly.

Turning spee d too fast. Ridges in terrain. Rough or uneven terrain. Low tire pressure.

Mower Loads Down Tractor Engine rpm too low.

Travel speed too fast. Debris wrapped around mower

spindles.

Troubleshooting - 51

STORAGE

IF CHECK

Uneven Cut Mower deck not leveled properly.

Travel sp ee d too fast. Blades dull. Mower wheels not adjusted

correctly. Tire pressure unequa l.

Mower (Or Other Attachment) Stops When Vehicle Is Operated in REVERSE

Normal condition. (See Using Reverse Implement Option in the OPERATING section.)

Storage

Stor ing Safety

c CAUTION: Avoid injury! Fuel vapors are explosive and

flammable. Engine exhaust fumes contain carbon monoxide and can ca use serious illness or death:

• Run the engine only long eno ugh to move the machi ne to or from storage.

• Machine fires and structure fires can occur if a machine is stored before allowing it to cool, or if debris is not removed from around the engine and muffler, or if stored near combustible mat erials.

• Do not st ore vehicle with fuel in the tank inside a building where fumes may reach an open flame or spark.

• Allow the engine to cool before storing the machine in any enclosure.

Preparing Machine for Storage

1. Repair any worn or damaged parts. Replace parts if necessary . Tighten

loose ha rdw are .

2. Repair scratched or chipped metal surfaces to prevent rust.

3. Remove grass and debris from machine.

4. Clean under the deck and remov e grass and debris from inside chute

and bagg er.

5. Wash the machine and apply wax to metal and plastic surfaces.

6. Run machine for five minutes to dry belts and pulleys.

7. Apply light coat of engine oil to pivot and wear points to prevent rust.

8. Lubricate grease points and check tire pressure.

Preparin g Fu e l an d En gi ne Fo r St o ra g e

Fuel:

If y ou h a v e be en us ing “ St ab il i ze d Fu el ,” add stab il iz e d f u el t o t a nk un ti l the tank is full.

NOTE: Filling the fuel tank reduces the amount of air in the fuel tank and helps reduce deterioration of fuel.

If you are not using “Stabilized Fuel:”

1. Park machine safely in a well-ventilated area. (See Parking Safely in the

SAFETY section.)

NOTE: Try to anticipate the last time the machine will be used for the season so very little fuel is left in the fuel tank.

2. Turn on engi ne and allow to run until it runs o ut of fuel.

3. For machines equipped with key switch, turn key to off position.

IMPORTANT: Avoid damage! Stale fuel can produce varnish and plug carburetor or injector components and affect engine performance.

• Add fuel conditioner or stabilizer to fresh fuel before filling tank.

4. Mix fresh fuel and fuel stabilizer in separate container. Follow stabilizer instructions for mixing.

5. Fill fuel tank with stabilized fuel.

6. Run engine for a few minutes to allow fuel mixture to circulate through carburetor on gas engi ne or fuel injectors on diesel engine.

Engine:

Engine storage procedure should be used when vehi cle is not to be used for longer than 60 days.

1. Change engine oil an d filter while engine is warm.

2. Service air filter if necessary.

3. Clean debris from engine air intake screen .

4. On gas engines:

• Remove spark plugs. Put 30 mL (1 oz) of clean engine oil in cylinder(s).

• Install spark plugs, but do not connect spark plug wires.

• Crank the engine five or six times to allow oil to be distributed.

5. Clean the engine and engine compartment.

6. Remove battery.

7. Clean the batt ery and battery posts. Check the electrolyte level, if your battery is not maintenance free.

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

9. Store the battery in a cool, dry place where it will not freeze.

NOTE: The stored battery should be recharged every 90 days.

10. Charge the battery.

IMPORTANT: Avoid damage! Prolonged exposure to sunlight could damage the hood surface. Store machine inside or use a cover if stored outside.

11. Store the vehicle in a dry, protected place. If vehicle is stored outside, put a waterproof cover over it.

Removing Machine From Storage

1. Check tire pressure.

2. Check engine oil level.

3. Check battery electrolyte level, if your battery is not maintenance free. Charge battery if necessary.

4. Install battery.

5. On gas engines: Check spark plug gap. Install and tighten plugs to specified torque.

6. Lubricate all grease points.

7. Open fuel shut-off valve, if your machine is equipped.

Storage - 52

SPECIFICATIONS

8. Run the engine 5 minutes without the mower or any attachments

running to allow oil to be distributed throughout engine.

9. Be sure all shields and guards or deflectors are in place.

Specifications

Automatic Model D105

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton

Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31G777

Power Rating Information. . . . . . http://www.briggsandstratton.com/

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 cc (30.5 cu in.)

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.68 mm (3.57 in.)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77.72 mm (3.06 in.)

Ignition Module (Armatu re)

Air Gap . . . . . . . . . . . . . . . . . . . . . . 0.253 - 0.356 mm (0.010 - 0.014 in.)

Intake Valve

Clearance . . . . . . . . . . . . . . . . . . . . 0.076 - 0.127 mm (0.003 - 0.005 in.)

Exhaust Valve

Clearance . . . . . . . . . . . . . . . . . . . . . .0.13 - 0.18 mm (0.005 - 0.007 in.)

Spark Plug-Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

Spark Plug-Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (15 lb-ft)

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cartridge

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic

Transaxle Model . . . . . . . . . . . . . . . . General Transmission TM RT400

Travel Speed - Forward . . . . . . . . . . . . . . . . 0 - 8.9 km/h (0 - 5.5 mph)

Travel Speed - Reverse . . . . . . . . . . . . . . . . 0 - 4.8 km/h (0 - 3.0 mph)

Hydrostatic Mo de l D 11 0

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton

Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31P677

Power Rating Information. . . . . . . http://www.briggsandstratton.com

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 cc (30.5 cu in.)

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.60 mm (3.56 in.)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77.78 mm (3.06 in.)

Ignition Module (Armatu re)

Air Gap . . . . . . . . . . . . . . . . . . . . . . 0.253 - 0.356 mm (0.010 - 0.014 in.)

Intake Valve

Clearance . . . . . . . . . . . . . . . . . . . . 0.076 - 0.127 mm (0.003 - 0.005 in.)

Exhaust Valve

Clearance . . . . . . . . . . . . . . . . . . . . . .0.13 - 0.18 mm (0.005 - 0.007 in.)

Spark Plug-Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

Spark Plug-Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (15 lb-ft)

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cartridge

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic

Transaxle Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff Torq™ T40

Travel Speed - Forward . . . . . . . . . . . . . . . . 0 - 8.9 km/h (0 - 5.5 mph)

Travel Speed - Reverse . . . . . . . . . . . . . . . . 0 - 5.2 km/h (0 - 3.2 mph)

Hydrostatic Model D120

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton

Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331877

Power Rating Informatio n . . . . . . . http://w ww.briggs an ds tr atto n.c om

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 cc (33 cu in.)

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94.02 mm (3.70 in.)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77.78 mm (3.06 in.)

Ignition Module (Armature)

Air Gap . . . . . . . . . . . . . . . . . . . . . . 0.253 - 0.356 mm (0.010 - 0.014 in.)

Intake Valve

Clearance . . . . . . . . . . . . . . . . . . . . 0.076 - 0.127 mm (0.003 - 0.005 in.)

Exhaust Valve

Clearance . . . . . . . . . . . . . . . . . . . . . . 0.13 - 0.18 mm (0.005 - 0.007 in.)

Spark Plug-Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

Spark Plug-Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (15 lb-ft)

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Yes

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . Cartridge w/foam precleaner

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydrostatic

Transaxle Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff Torq™ T40

Travel Speed - Forward . . . . . . . . . . . . . . . . 0 - 8.9 km/h (0 - 5.5 mph)

Travel Speed - Reverse . . . . . . . . . . . . . . . . . 0 - 5.2 km/h (0 - 3.2 mph)

Hydrostatic Models D130 and D140

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton

Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407777

Power Rating Informatio n . . . . . . . http://w ww.briggs an ds tr atto n.c om

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 656 cc (40 cu in.)

Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.44 mm (2.97 in.)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73.41 mm (2.89 in.)

Ignition Module (Armature)

Air Gap . . . . . . . . . . . . . . . . . . . . . . 0.203 - 0.305 mm (0.008 - 0.012 in.)

Intake and Exhaust Valve

Clearance . . . . . . . . . . . . . . . . . . . . 0.102 - 0.152 mm (0.004 - 0.006 in.)

Spark Plug-Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

Spark Plug-Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (15 lb-ft)

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . Flat Panel w/Foam PreCleaner

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydrostatic

Transaxle Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tuff Torq

Travel Speed - Forward . . . . . . . . . . . . . . . . . 0 - 8.9 km/h (0 - 5.5 mph)

Travel Speed - Reverse . . . . . . . . . . . . . . . . . 0 - 5.2 km/h (0 - 3.2 mph)

T40

Hydrostatic Models D160 and D170

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Briggs & Stratton

Model Number (D160) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44M777

Model Number (D170) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44P777

Power Rating Informatio n . . . . . . . http://w ww.briggs an ds tr atto n.c om

Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 724 cc (44.2 cu in.)

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79.25 mm (3.12 in.)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73.41 mm (2.89 in.)

Ignition Module (Arm ature) Air Gap 0.203 - 0.254 mm (0.008-0.010 in.)

Specifications - 53

SPECIFICATIONS

Intake and Exha us t V a lve Cl ear ance .0.102 - 0.152 mm ( 0 .004 - 0.0 06 in.)

Spark Plug-Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)

Spark Plug-Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 N•m (15 lb-ft)

Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Twin

Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Yes

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . Cartridge w/ Foam Precleaner

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydrostatic

Transaxle Model . . . . . . . . . . . . . . . . . . . . . . . . . . . .Tuff T orq™ HD K46

Travel Speed - Forward . . . . . . . . . . . . . . . . 0 - 8.9 km/h (0 - 5.5 mph)

Travel Speed - Reverse . . . . . . . . . . . . . . . . . 0 - 5.2 km/h (0 - 3.2 mph)

Electrical System

Charging System. . . . . . . . . . . . . . . . . . . . . . . . . . . . Regulated Circuit

Charging System Capacity (D100, D110, D120, D130, D140) . . 9 Amp

Charging System Capacity (D160, D170) . . . . . . . . . . . . . . . . . 16 Amp

Battery Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Volts

Battery Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BCI Group U1

Capacities

Models D105, D110, D120

Crankcase, with Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 1.4 L (1.5 qt)

Models D130, D140, D160, D170

Crankcase, with Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . 1.9 L (2.0 qt)

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 L (2.4 gal)

Fuel System (All Models)

Fuel Types (Recommended):

. . . . . . . . . . . . . . . . . . . . . . . .Regular Grade 87 Octane Unleaded Fuel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ethanol Blended Fuel (Up to 10%)

. . . . . . . . . . . . . . . . . . . . . . . . . . MTBE Reformulated Fuel (Up to 15%)

Recommended Lubricants (All Models)

Engine Oil:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TURF-GARD™

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PLUS 4™

Grease:

. . . . . . . . . . . . . . . . . . John Deere Multi-Purpose SD Polyurea Grease

. . . . . . . . . . .John Deere Multi-Purpose HD Lithium Complex Grease

(Specifications and design subject to change without notice)

Weight: D110, D120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204 kg (450 lb)

Weight: D130 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213 kg (470 lb)

Weight: D140, D160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238 kg (525 lb)

Weight: D170 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262 kg (579 lb)

Tires

Models D105, D110, D120

Size (Front). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 x 6.00 - 6

Size (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 x 8.0 - 8

Tire Pressure (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)

Tire Pressure (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa (10 psi)

Models D130, D140

Size (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 x 6.00 - 6

Size (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 x 10.00 - 8

Tire Pressure (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 kPa (14 psi)

Tire Pressure (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 kPa (10 psi)

Models D160, D170

Size (Front). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 x 6.5 - 8

Size (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 x 9.5 - 12

Tire Pressure (Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 kPa (12 psi)

Tire Pressure (Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 kPa (12 psi)

(Tire pressure information is also located on the sidewalls of the tires)

Mower Deck - 107 cm (42 in.)

Blades Rotary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Blade Nut Torque (w/ 5/8 in. Nut) . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)

Cutting Height (Approximately) . . . . . . . . . . . . 25 - 102 mm (1 - 4 in.)

Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1067 mm (42 in.)

Mower Deck - 122 cm (48 in.)

Blades Rotary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Blade Nut Torque (w/ 5/8 in. Nut) . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)

Cutting Height (Approximately) . . . . . . . . . . . . . 25 - 102 mm (1 - 4 in.)

Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1219 mm (48 in.)

Mower Deck - 137 cm (54 in.)

Blades Rotary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Blade Nut Torque (w/ 5/8 in. Nut) . . . . . . . . . . . . . . . . 88 N•m (65 lb-ft)

Cutting Height (Approximately) . . . . . . . . . . . . . 25 - 102 mm (1 - 4 in.)

Cutting Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1371 mm (54 in.)

Dimensions

Height (D105, D110). . . . . . . . . . . . . . . . . . . . . . . . . . . . 108 cm (42.5 in.)

Height (D120, D130). . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 cm (44.5 in.)

Height (D140, D160, D170) . . . . . . . . . . . . . . . . . . . . . . 114 cm (45.0 in.)

Length (Overall) (D105, D110, D120, D130, D140) . 175 cm (68.75 in.)

Length (Overall) D160, D170) . . . . . . . . . . . . . . . . . . 176 cm (69.25 in.)

Width (Mower Deck Chute Down) (D 105, D110, D120 , D130) . .131 cm (51.75 in.)

Width (Mower Deck Chute Down) (D140, D160) . . . . . . 152 cm (60 in.)

Width (Mower Deck Chute Down) (D170) . . . . . . . . . 174 cm (68.5 in.)

Weight: D105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 kg (442 lb)

Specifications - 54

WARRANTY

Warranty

Product Warranty

Product warranty is provided as part of John Deere’s support program for custo m ers who operat e and maintain their equipment as described in this manual.

Engine related warranties stated in this manual refer only to emissionsrelated parts and components of your engine. The complete engine warranty, less emission-related parts and com ponents, is pr ovided separately as the “Limited Warranty for New John Deere Equipment”.

California and U.S. EPA Emissions Control System Warranty Statement (Off-Road Gas Engines)

Y our Warranty Rights and Obligations

The California Air Resources Board, John Deere, and the United States Environmental Protection Agency are pleased to explain the emi s sions control system’s warranty on your model year 2013 or 2014 spark ignited off-road engine equipment. In California, new equipment that uses small or lar ge (l ess tha n 1 l ite r ) sp ark ign it ed off -r oa d engi ne s m us t be de si gn ed , built and equipped to meet the State’s stringent anti-smog standards. John Deere m ust warrant the emissions control system on your spark ignit ed off-road engine equipment for the period listed below provided there has been no abuse, neglect or improper maintenance of your equipment.

Your emissions control sys tem may include parts such as: carburetor s or fuel-injection system, ignition system, catalytic converters, fuel tanks, valves, filter s , cla mp s, co nnecto rs, an d ot h er as s ociated com p on en t s. Also included may be hoses, belts, sensors and other emission-related assemblies.

Where a warrantable condition exists, John Deere will repair your spark ignited off-road engine equipment at no cost to you including diagnosis, parts and labor.

Manufacturer’s Warranty Cov era ge:

This em issi ons con tro l sy st em is wa rr an ted for two year s. If an y emis sion s related part on your equipment is defective, the part will be repaired or replaced by John Deere.

Owner’s Warranty R esponsibili ties:

• As the spark ignited off-road equipment owner, you are responsible for

the performance of the required maintenance listed in your Operator’s Manua l. John Deere recommends that you retain all receipts covering maintenance on your spark ignited off-road engine equipment, but John Deere can not deny warranty solely for lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

• As the spark ignited off-road engine equipment ow ner, you s hould

however be aware that John Deere may deny you warranty coverage if your spark ignited off-road equipment or a part has failed due to ab use, negle c t, or improper maintenance or unapproved modifications.

• You are responsible for presenting your spark ignited off-road engine

equipment to an authorized John Deere Turf and Utility retailer as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days. If you have a question regarding your warranty coverage, you should contact your John Deere Turf and Utility retailer, or the Jo hn Deere Customer Contact Cent er at 1800-537-8233, or e-mail John Deere from www.Deere.com.

General Emissions Warranty Coverage:

The warranty period begins on the date the equipment is delivered to an ultimate purchaser. John Deere warrants to the ultimate purchaser and each subsequent purchaser that the spark ignited off-road engine equipm e nt is :

• Designed, built and equipped so as to conform to all applicable

regulations adopted by the California Air Resources Boar d;

•Designed, built and equipped so as to conform at the time of sale with

applicable U.S. Environmen tal Protecti on Agency regulations under 40 CFR Parts 1054 and 1060: and,

• Free from defect s in materials and workmanship which cause such engine to fa il to conform with applicable regulations for a period of two years of engine use from the date of sale to the ultimate purch aser.

Emissions Warranty Interpretation

• Any warranted part that is not scheduled for replacement as required by the maint e na nce inst ruct i on s i n th e Op erator’s Ma nual i s w ar ra nt e d f or tw o years. If any such part fails during t he period of warranty coverage it will be repaired or replaced by John Deere. Any such part repaired or replaced under warranty is warranted for the remaining warranty period.

• Any warranted part tha t is scheduled only for regular inspection in the maintenance instructions in the Operator’s Manual is warranted for two years. A statement in the Operator’s Manual to the effect of “repair or replace as necessary” does not reduce the period of warrant y coverage. Any suc h part repaired or replaced under warranty is warranted for the remaining warranty period.

• Any warranted part that is scheduled for replacement as required maintenance in the Operator’s Manual is warranted for the period of time prior to the fir st scheduled replacement point for that part. If the part fails prior to the fir s t scheduled replacement, t he part will be repaired or replaced by John Deere. Any such part repaired or replaced under warranty is warranted for the remainder of the period prior to the first schedul ed replacement point for the part.

• Repair or replacement of any warranted part under the warranty will be performed at no charge to the owner at any au thorized John Deere Turf and Utility retail er.

• The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, pr ovided such work is performed by John Deere.

• John Deer e wil l re pai r damag es to ot her eng i ne c ompon en ts proximately caused b y a failure under warrant y of any emissions-related wa rranted part.

• Add-on or modified parts that are not exempted by the California Air Resources Board may not be used. The use of any non-exempted add-on or modified parts will be grounds for disallowing a warranty claim. John Deere will not be liable to warrant failures of warranted parts caused by the use of a non-exempted add-on or modified part.

Emission Warranty Parts List

Coverage under thi s warranty extends only to the parts listed below (the emissions control system parts) to the extent these parts were on the engine and equipment purchased.

Fuel Metering System:

• Carburetor and internal parts (or fuel injection syste m ).

• Air/fuel ratio feedback and control system.

• Cold start en richment system. Evaporative System:

• Fuel tank, fuel cap and tether.

• Fuel hose, line, fittings, clamps.

• Fuel pump, fuel shut-off valve.

• Fuel vapor hoses, fittings.

• Carbon canister.

• Rollover/slant valve for fuel vapor control.

• Purge and vent line. Air Induction System:

• Air cleaner

• Intake manifold.

Warranty - 55

WARRANTY

Ignition System:

• Spark plugs.

• Magneto or electronic ignition system.

• Spark advance/retard system.

Exhaust System:

• Exhaus t ma ni fold.

• Catalyst muffler.

Miscellaneous Items Used in Above Systems

• Vacuum and temp er a tur e swit ch es.

• Electronic controls.

• Hoses, belts, conn ec t o rs and assem b lie s.

Limited Liability

a) The lia bi lit y of Jo hn De ere u nd er t hi s Em is sions Con t ro l S ys te m Warranty is limited solely to the remedying of defects in materials or workmanship. This warranty does not cover inconvenience or l oss of use of the non - road equ i pme nt or eng in e or t ran sp ortat io n of the eq ui pm ent or engine to or from the John Deere Turf and Utility retailer. John Deere shall not be liable for any other ex pense, loss, or damage, whether direct, incidental, consequential (except as listed above under “coverage”) or exemplar y arising in connect i on wi th the sale or us e of or ina bi lity to use the non-road equipment or engine for any other purpose.

b) No express emissions control system warranty is given by John Deere with r espe ct t o the eq ui pm en t and en gi ne ex ce pt as sp eci fic al ly se t f o rth in this document. Any emissions control system warranty implied by law, inclu ding any warranty of merchantability or fitness for a particular purpose, is expressly limited to the emissions control system warranty terms set forth in this document.

c) No dealer is authorized to modify this Federal, California and John Deere Emissions Control System Warranty.

Tire Warranty

John Deere warranty applies for tires avai lable through the John Deere parts system. For tires not available through the John Deere parts system, the tire manufacturer’s warranty applicable to your machine may not apply outsi de the U.S. (See your John Deere dealer for specific inf ormation.)

Limited Battery Warranty

NOTE: Applicable in North America only. For complete machine warranty, reference a copy of the John Deere warranty statement. Contact your John Deere dealer to obtain a copy.

is determined from the Warranty Code printed at the top of the battery and chart below. Installation costs are not covered by warranty after 90 days from the date of purchase.

THIS WARRANTY DOES NOT COVER

A. Breakage of the container, cover, or terminals. B. Depreciation or damage caused by lack of reasonable and necessary

maintenance or by improper maintenance. C. Transportation, mailing, or service call charges for warranty service.

LIMITATION OF IMPLIED WARRANTIES AND PURCHASER’S REMEDIES

To the extent permitted by law, neither John Dee re nor any company affiliated with it makes any warranties, representations, or promises as to the quality, performance or freedom from defect of the products cove red by this warranty. IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, TO THE EXTENT APPLICABLE, SHALL BE LIMITED IN DURA TION TO THE APPLICABLE ADJUSTMENT PERIOD SET FORTH HERE. THE PURCHASER’S ONLY REMEDIES IN CONNECTION WITH THE BREACH OR PERFORMANCE OF ANY WARRANTY ON JOHN DEERE BATTERIES ARE THOSE SET FORTH HERE. IN NO EVENT WILL THE DEALER, JOHN DEERE OR ANY COMPANY AFFILIA TED WITH JOHN DEERE BE LIABLE FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES. (Note: Some stat es do not al lo w l im itat i on s on ho w long an imp l ied w a rr ant y la st s or the exclusion or limitation of incidental or consequential damages. So these limi tat ions and e xclu sion s may no t apply to you. ) This w arrant y giv es you specific legal rights, and you may also have some rights which vary from sta t e to st at e.

NO DEALER WARRANT Y

The selling dealer makes no warranty of it’s o wn and the dealer has no authority to make any representation or promise on behalf of John Deere, or to modify the terms or limitations of this warranty in any way.

PRO RATA MONTHS OF ADJUSTMENT

NOTE: If your battery is not labeled with a warranty code, it is a warranty code B.

Warranty Code Warranty Period

A 40 Months B 36 Months C 24 Months

TO SECURE WARRANTY SERVICE

The purchaser must request warranty service from a John Deere deal er authorized to sell John Deere batteries, and present the battery to the dealer with the top cover plate codes intact.

FREE REPLACEMENT

Any new batte ry which bec om es unservic ea ble (not merel y dis c ha r ge d ) due to defects in ma te r i al or wor k m an s hip wi th in 90 days of pu r ch a se wil l be replaced free of charge. Installation costs will be covered by warranty if (1) the unserviceable battery was installed by a John Deere factory or dealer, (2) failure occurs within 90 days of purchase, and (3) the replacement batte ry is installed by a Joh n Deere dealer.

PRO RATA ADJUST MENT

Any new batte ry which bec om es unservic ea ble (not merel y dis c ha r ge d ) due to defects in material or workmanship more than 90 days after purchase, but before the expiration of the applicable adjustment period, will be replaced upon payment of the battery’s current list price less a pro rata c r edit for unused mo nt h s of s ervi ce . T he ap pl ic abl e ad ju stmen t pe riod

Warranty - 56

INDEX

Index

Accessories, Using ................................................................................31

Air Cleaner Elements (D105 and D110), Checking and Cleaning Air Clean er Ele m en t s (D120), Ch ec k ing and Cl ea nin g Air Cleaner Elements (D130 and D140), Checking and Cleaning Air Cleaner Elements (D160, D170), Checking and Cleaning Air Cleaner Elements (Single Cylinder Briggs and Stratton), Checking and Cleaning Air Intake Screen, Cleaning Attachment Engagement Switch or Lever, Testing Automatic Transmission, Using Travel Controls on Axle, Lubricating Front

Bagger, Unplugging ...............................................................................29

Balancing Blades Battery and Terminals, Cleaning Batter y, Charge and C onnect at Assem bly Battery, Removing and Installing Battery, Service Safely Battery, Using Booster Belt, Adjusti ng Tens io n (10 7 cm (42 in .) Mo wer D eck) Belt, Installing and Removing Mower Drive at Engine Drive Sheave (122 cm (48 i n.) and 137 (54 in.) Decks) Belt, Replacing Mower Driv e (107 cm (42 in.) Mower Deck) Belt, Replacing Mower Drive (137 cm (54 in.) and 137 cm (54 in.) Decks) 42 Blades, Balancing Blades, Checking Mower Blades, Servicing Mower Blades, Sharpening Brake Switch, Testing Park Brake, Testing Park Brake, Using Park Bulb, Replacing Headlight

Capacities .............................................................................................. 54

Carburetor, Adjusting Certification Label Controls on Automatic Transmission, Using Travel Controls on Hydrostatic Transmission, Using Travel Controls, Operator Station (D105) Controls, Operator Station (D110, D120, D130) Controls, Operator Station (D140, D160, D170) Cruise Control, Using Customer Service Cutting Height, Adjustin g

Daily Operating Checklist ......................................................................21

Deck, Adjusting Mower Level Deck, Installing Mower Deck, Removing Mower Dimensions, Machine

Electrical Specifications .........................................................................54

Electrical Troubleshooting Emission Compliance Period Emission Control System Certification Label Emission Filter, Checking and Cleaning Engagement Clutch, Break In Electric

................................................................................................. 36

................................................................... 35

........................................................................... 32

................................................................................... 44

...........................................................45

............................................16

........................................................... 44

.......................................................................... 44

........................................................................... 45

....................................................... 39

.................................................................................. 44

....................................................................... 43

............................................................................... 44

....................................................................24

...............................................................................24

..................................................................................25

.....................................................................45

............................................................................. 38

.................................................................................... 7

......................................................... 18

.............................................................................28

.................................................................................. 57

....................................................................... 21

................................................................ 21

........................................................................... 40

......................................................................... 39

............................................................................ 54

.....................................................................51

................................................................... 7

........................................... 6

................................................ 38

................................................... 16

.......................... 36

................................24

............................... 26

.......................... 42

............................... 26

............................. 27

....................................19

....................................20

......... 35

............... 37

.................41

Engine Fins, Cleaning Engine Oil Engine Oil Level, Checking Engine Oil and Filter, Changing Engine Specifications Engine Troubleshooting Engine W arr a nt y Mainte na nc e St a tem e n t Engine and Fuel Storage, Preparing Engine, Idl in g Engine, Starting Engine, Stopping

Filter, Changing Engine Oil ....................................................................34

Filter, Checking and Cleaning Emission Filter, Replacing Fuel Front Axle, Lubricating Front Wh eel Assembly, Removing and Installing Fuel Filter, Replacing Fuel Safety Fuel Storage Fuel Tank, Filling Fuel Types Recommended Fuel, Using Proper Fuse, Replacing

Grease ...................................................................................................32

Headlight Bulb, Replacing ......................................................................45

Headlights, Using Hood, R em ov in g and Insta ll ing Hourmeter, Using

Identific a tio n N umbe r s ..............................................................................1

Key Swit c h, Using ..................................................................................25

Label, Certification ...................................................................................7

Labels, Safety (No Text) Labels, Safety (Text) Leveling Mower Deck Lifting Machine Literatur e, Serv ic e Lubricants, Recommended

Mach in e, Li f ti ng ......................................................................................47

Machine , Moving by Hand Machine , Transporting on Trailer Material Collection System, Unplugging Metal Surfaces, Repairing and Cleaning Moving Ma chine by Hand Mower Blades, Checking Mower Blades, Choosing Mower Blades, Servicing Mower D ec k 122 cm (48 in.), Speci fic a tio ns Mower D ec k 137 cm (54 in.), Speci fic a tio ns Mower Deck Level, Adjusting Mower Deck, Adjusting Belt Tension (107 cm (42 in.) Deck) Mower Deck, Adjusting Cutting Height Mower Deck, Adjusting Spindle Brakes (107 cm (42 in.) Deck) Mower Deck, Adjusting Wheels Mower Deck, Cleaning Mower Deck, Drive Belt Replacement (107 cm (42 in.) Deck)

...............................................................................................33

.............................................................................................13

...........................................................................................52

............................................................................35

....................................................................33

.............................................................34

.............................................................................53

.........................................................................50

..............................................33

......................................................52

.........................................................................................26

......................................................................................26

....................................................................................26

.................................................38

.............................................................................38

...........................................................................32

...................................48

.............................................................................38

....................................................................................46

....................................................................54

.................................................................................46

.....................................................................................46

...................................................................................25

..............................................................47

...................................................................................25

...........................................................................4

................................................................................3

.............................................................................21

.......................................................................................47

..................................................................................56

....................................................................54

......................................................................29

...........................................................29

.................................................29

................................................48

.......................................................................29

........................................................................43

.......................................................................31

........................................................................43

..........................................54

.................................................................21

.................42

...................................................21

..............................................................23

...........................................................................28

.............42

...............41

Index - 57

GETTING QUALITY SERVICE

Mower Deck, Drive Belt Replacement (122 cm (48 in.) and 137 cm (54 in.) Decks)

....................................................................................................42

Mower Deck, Engaging and Disengaging Mower Deck, Installing Deck Mower Deck, Lubricating Pivot Points Mower Deck, Removing Deck Mower Deck, Removing and Installing Drive Belt at Engine Sheave (122 cm (48 i n.) and 137 (54 in.) Decks) Mower Deck, Specifications (107 cm (42 in.) Mower Deck, Unplugging Mower Troubleshooting Mowing Tips

...........................................................................................31

................................................................. 40

............................................................... 39

....................................................................... 29

.........................................................................51

..............................................28

................................................... 32

....................................................... 39

........................................ 54

OMGX22464J6 ........................................................................................0

Oil Level, Checking Engine Oil and Fil ter , Chan ging Engi ne Oil, Engine Operating Checklist, Daily Operator Station Controls (D105) Operator Station Controls (D110, D120, D130) Operator Station Controls (D140, D160, D170)

............................................................................................. 33

....................................................................33

.............................................................34

.....................................................................21

.......................................................... 18

.....................................19

.....................................20

Park Brake, Testing ...............................................................................24

Park Brake, Testing Switch Park Brake, Using Parts Catalog Parts, Replacement Plastic And Painted Surfaces, Avoid Damage To Plastic Surfaces, Cleaning

..................................................................................25

.........................................................................................56

....................................................................24

...............................................................................56

..................................21

.....................................................................48

Rear Wh eel Assembly, Removing and Installing ................................... 49

Reverse Implement Option, Testing Reverse Implement Option, Using the

......................................................25

................................................... 27

Safety Label Location (No Text) .............................................................. 4

Safety Label Location (Text) Safety Systems, Testing Safety, Tire Seat Switch, Testing Seat, Adjusting Service Intervals Service Literature Service Reminder, Using Sharpening Blades Spark Arrestor, Using Spark Plug, Checking Specifications Specifications, 107 cm (42 in.) Mower Deck Spindle Brakes 107 cm (4 2 in.) Mower Deck, Adjusting Stablizer, Using Proper Fuel Stopping Engine Storag e, Pre pa ring Fuel an d Eng in e f or Storage, Preparing Machine for Storage, Removing Machine from Storing Safety

............................................................................................13

....................................................................................... 21

.................................................................................... 32

................................................................................... 56

................................................................................44

.........................................................................................53

.................................................................................... 26

........................................................................................52

.................................................................... 3

........................................................................ 24

..............................................................................24

....................................................................... 25

..............................................................................9

............................................................................38

.......................................... 54

........................42

.................................................................. 46

................................................ 52

.............................................................52

......................................................... 52

Techni cal Manu al ...................................................................................56

Testing Safety Systems Tire Chains, Using Tire Pre ssure, Checking Tire Specifications Tractor Troubleshooting Transmission, Checking (See your John Deere dealer)

.........................................................................24

................................................................................. 30

........................................................................ 47

.................................................................................54

......................................................................... 51

........................ 39

Transporting Machine on Trailer Travel C ontrols on Hydr ostatic Transmission, Using Troubleshooting Chart

............................................................................50

............................................................29

.............................27

Warra n ty Mainte na nc e St a tem e n t , En gi ne .............................................33

Warranty Registration, Refer to the Production Identification Section Warrant y, Product Wash Port, Usin g Weights, Using Wheel Assembly, Removing and Installing Front Wheel Assembly, Removing and Installing Rear Wheels, Adjusting Mower Deck

..................................................................................55

...................................................................................28

.......................................................................................30

...................................48

...................................49

..............................................................23

.....2

Getting Quality Service

Service Literature

If you would like a copy of the Parts Catalog or T echnical Manual for this machine call:

• U.S. & Canada: 1-800-522-7448.

• All Other Regions: Your John Deere dealer.

Parts

We recommend John Deere quality parts and lubricants, available at your John Deere dealer.

When you o r de r parts, y ou r Joh n D eer e d ea ler nee ds the se ri al n umb er or product identification number (PIN) for your machine or attachment. These are the numbers that you recorded in the Product Identification section of this manual.

Order Service Pa rts Online

Visit http://JDParts.deere. com for y our Internet co nnection to parts ordering and information.

John Deere Quality Continues with Quality Service

John Deere provides a process to handle your quest ions or problems, should they arise, to ensure that product quality continues with your John Deere de aler’s parts and service support.

Follow the steps below to get answers to any questions you may have about your product .

1. Refer to the appropriate attachment, machine or equipment operator manuals.

2. Contact your John Deere dealer with unanswered questions.

3. In North America or Canada, call the John Deere Customer Contact Center.

• Call 1-800-537-8233 and provide product serial number and model number.

Getting Quality Service - 58

Service Record

Record Service Dates

SERVICE RECORD

Oil Change Oil Filter Change

(If Equipped)

Lubricate Machine

Air Cleaner Element Check/ Clean

Fuel Filter Change

Service Record - 59

SERVICE RECORD

Service Record - 60

SERVICE RECORD

Service Record - 61

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

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

Thank Yo u for Purchasing a John Deere Product

Using Your Operator’s Manual

Special Messages

Product Identification

Record Identification Numbers

Lawn Tractors

Machine Product Identification Number Location

Engine Seri al Num be r Loca tion

Regist er Your Product and Warranty Onli ne

Safety Labels

Safety Label Location (Text)

Safety Label Loc a tion (No Text)

Understanding The Machine Safety Labels

Warning MX4878

DANGER

ROTATING BLADES CUT OFF ARMS AND LEGS

DANGER M128699

DANGER

ROTA TING BL ADE

DANGER - M89504

ROTA TING BL ADE

THROWN OB JECTS

WARNING

AVOID SERIOUS INJURY OR DEATH

DANGER GX23479

Warning M159705

Prevent Equipment Fires

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

Emission Control System Certification Label

Emission Compliance Period

Certification

Canadian Electromagnetic Compatibility (EMC) Compliance

Pictoria l Safety Signs

Avoid In jury From Rotating Blades - M118041

WARNING M128484

Avoid Injury From Battery Gases and Acids

Avoid In jury From Getting Caught in Belt - M136436

WARNING GX24503

WARNING GX21121

Warning - Hot Surfaces

WARNING - GX23479

Avoid Injury From Tipping

Avoid Injury From Rotating Blades and Thrown Objects

Avoid Inju ry

Read Operators Manual

Keep Children Away From Mower

Avoid Injury: Use Transmission Bypass Rod Safely

SAFETY

Operating Safely

Using a Spark Arrestor

Checking Mowing Area

Parking Safely

Rotating Blades are Dangerous

HELP PREVENT SERIOU S OR FATAL ACCIDENTS:

Protect Children

Operating on Slopes

Identify Slopes for Safe Operation

Measuring Slopes

Operate Safely on Slopes

Operating Near Hazards

Keep Riders Off

Tow ing Loads S afely

Wear Appropriate Clothing

Driving Safely on Public Roads

Practice Safe Maintenance

Avoid High Pressure Fluids

Prevent Fires

Handling Fuel Safely

Tire Safety

Checking Wheel Hardware

Handling Waste Product and Chemicals

MAC HINE CLEANOUT

Prevent Fires

ASSEMBLY

Check Tire Pressure