JOHN DEERE L118,LAWN TRACTORS TM2026 TECHNICAL SERVICE MANUAL

JOHN DEERE

WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION

2026 February

2005

Lawn Tractors L100, L108, L110, L111, L118, L120, and L130 TM2026 FEBRUARY 2005

TECHNICAL MANUAL

North American Version Litho in U.S.A.

For the full PDF version of this manual, Please click on the above download PDF button.

INTRODUCTION Manual Description Introduction

T h i s t e c h n i c a l m a n u a l i s w r i t t e n f o Safety r an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program.

T h e m a n u a l i s o r g a n i z e d s o t h a t a l lSpecifications t h e i n f o r mand a t i oInformation n on a particular system is kept together. The order of grouping is as follows: •Table

of

Contents

•Specifications

and

•Identification

Numbers

•Tools

and

Information

Location

•Schematics

and

•Theory

of

•Operation •

Engine (Kohler - Single Cylinder)

Materials

•Component

Harnesses

Engine (B&S - V-Twin)

Operation and

Diagnostics

Diagnostics

•Tests

and

•

Repair

•

Other

Engine (B&S - Single Cylinder)

Engine (Kohler - V-Twin)

Adjustments

Electrical

NOTE: Depending on the particular section or system being covered, not all of the above groups may be used.

Power Train (Gear)

The bleed tabs for the pages of each section will align with the sections listed on this page. Page numbering is consecutive from the beginning of the Safety section Power Train (Hydrostatic) through the last section.

We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual Steering please contact us.

Brakes Attachments All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT© 2005 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions

Miscellaneous

COPYRIGHT©

2002,

2003,

2004

Introduction

SAFETY Handle Fluids Safely - Avoid Fires

Safety

Recognize Safety Information

Be Prepared For Emergencies

MIF

This is the safety-alert symbol.

When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow

recommended

Understand Signal p recautio n s aWords nd safe

MIF

A G, or CAUTION - is s e sr iv gi cn ianl g w o r d - D A N G E R , W A R N I N •W n N yGoEuR w k t iaf ri o used with the safety-alert symbo l . hDe A i doer n eu s nt dh e f u e l , p do not smoke or work near mroasct t isceer si .o u s h a z a r d s . heaters or other fire hazards.

DANGER or WARNING safety signs are located near bd l e o fnl u i d s a w a y s p e c i f i c h a z a r d s . G e n e r a l p r e c a u• S t it oo nr se af lr ae ml m i s at e CAUTION safety signs. CAUTION also calls attention to from fire hazards. Do not safety messages in this manual. ipnr ce isns eu rr ai zt e t ue rr es . e do rc opnutna ci n •Make sure machine is clean Replace Safety Signs of

trash,

debris.

•Do not can

grease,

store

ignite

oily

and

and rags;

they

burn

s p oCare n t a In n eHandling o u s l y . and Servicing Batteries Use •Be

prepared

•Keep a first extinguisher •Keep

if

a

aid kit handy.

emergency

doctors,

fire

and

Safety

-

1

fire

numbers

for

ambulance

sd ee rpvai rc tem , hospital, and t e l e p h o neen. t n e a r y o u r Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

MIF

starts.

fire

MIF

SAFETY

such as earmuffs or earplugs to pr objectionable or uncomfortable lo •Keep sparks, lighted matches, and open flame away f r o m t h e t o p o f b a t t e r y . B a t t e r y Ogpaesr ac tai nn ge xe pq l uo idpem. e n t s a f e l y r e q u i r operator. Do not wear radio or mu •Never check battery charge by o pp l ae cr iant g i n ag m m ea tcahl i no eb .j e c t across the posts. Use a volt-meter or hydrometer.

•Do not charge a frozen battery; it may explode. Warm

Prevent Battery Explosions

battery

to

16°C

Use Care Around High-pressure Fluid Lines

(60°F).

Avoid High-Pressure Fluids

Prevent Acid Burns •Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid acid burns by: 1.Filling

batteries

in

2.Wearing

eye

3.Avoiding

breathing

4.Avoiding

spilling

5.Use

proper

a

well-ventilated

protection

jump

or

and

fumes

rubber

when

area.

gloves.

electrolyte

is

added.

MIF

dripping

start

eE lseccatpr ionl g y t fe l . u i d u n d e r p r e s s u r e p r o c e d ucr ae u. s i n g s e r i o u s i n j u r y .

can

Avoid injury from escaping fluid u the engine and relieving pressure 1.Flush your skin with water. disconnecting or connecting hydra 2 . A p p l y b a k i n g s o d a o r l i m e t o hTei lgph tneenu tarl al l ci zo en nt h eta ec i oc ni ds . b e f o r e a p p k ss . w i t h a p i e c e o f c a 3 . F l u s h y o u r e y e s w i t h w a t e r f o r S 1e 0a r -c h 1 5f o mr i nl e u at e If you spill acid on yourself:

4.Get

medical

attention

If acid is swallowed:

i m m e d i aa tnedl yb. o d y f r o m h i g h p r e s s u r e f l u i d If an accident occurs, see a docto

injected into the skin must be sur of re wm ihl ok u. r s o r g a n g r e n e m a y r e s u l t . this type of injury should referenc 2 . T h e n d r i n k m i l k o f m a g n e s i a , bme ea dt iecna le g gu s ,r coer . vSeugceht ai n b fl e so ormation oil.

Company Medical Department in M 3.Get medical attention immediately.

1.Drink

large

amounts

of

water

Avoid Heating Near Pressurized Fluid Lines

Wear Protective Clothing

MIF MIF

Flammable spray can be generated by heating near Wear close fitting clothing and safety equipment pressurized flui appropriate to the job.and bystanders. Do not heat by welding, so Prolonged exposure to loud noise can cause impairment or a torch loss of hearing. Wear a suitable hearing protective heat goes beyond the immediate flame area.

Safety

-

2

device

materia

SAFETY Support Machine Properly 1 . S t o p m a c h i n e o n a l e v e l s u r f a cProper e , n oLifting t o n Equipment a slope.

Parking Safely

2.Disengage 3.Lower

PTO

and

stop

attachments

4.Lock

park

5.Stop

engine.

6.Remove

to

Use

attachments.

the

ground.

brake.

key.

7.Wait for engine and all moving leave the operator’s station.

8.Close

and

fuel

shut-off

valve,

if

parts

your

to

stop

machine

is

before

you

equipped.

MIF

If you must work securely support

Service Machines Safely

on a lifted machi the machine or a

Do not support the machine on cin or props that may crumble under c work under a machine that is supp Follow recommended procedures in Lifting heavy components incorrec

MIF

injury or machine damage. Follow procedure for removal and installa manual.

Tie long hair behind your head. Do not wear a necktie, s c a r f , l o o s e c l o t h i n g , o r n e c k l a cUsing e w hHigh e n Pressure y o u w oWashers rk near m a c h i n e t o o l s o r m o v i n g p a r t s . IDf i rt eh ce ts i en gi t p em s w r e s s uer ri e z e tdo wg ae tt e r a t e l e c a u g h t , s e v e r e i n j u r y c o u l d r e s ucl ot .m p o n e n t s o r c o n n e c t o r s , b e a r i n R e m o v e r i n g s a n d o t h e r j e w e l r y i tnoj epcr tei vo en n p t uem l epcs t roi rc ao l t hs e h ro rstes n s i t i v e may cause product malfunctions. R and entanglement in moving parts. spray at a 45 to 90 degree angle.

Use Proper Tools

Illuminate Work Area Safely

Use tools appropriate to the work. Makeshift tools and a st e r ko l as r e a a d e q u a t p r o c e d u r e s c a n c r e a t e s a f e t y h a Izl al u r dms i. n U e yp oo uwre rw ot o sa o n l y t o l o o s e n t h r e a d e d p a r t s a np do rf taasbt leen e r sf .e tFyo rl i g l ohot s fe on ri nwgo r k i n g i a n d t i g h t e n i n g h a r d w a r e , u s e t hm e accohr i rneec. t Ms ai zk ee tsouor les . t h D eO b u l b i s e n T h e h o t f i l a m e n t o f a n accidentall NOT use U.S. measurement tools on metric fasteners. s p i l l e d f u e l o r o i l .

Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.

Work in Clean Area Before starting a job: 1.Clean

work

area

and

machine.

2.Make

sure

necessary job. on

you

tools

3.Have

the

to

have

all

do

your

right

parts

hand.

4.Read

all

instructions

thoroughly; shor tcuts.

do

not

attempt Safety

-

3

SAFETY Work In Ventilated Area

Avoid Harmful Asbestos Dust

Avoid breathing dust that may be handling components containing a Inhaled asbestos fibers may cause

MIF

Components in products that may fibers are brake pads, brake band clutch plates, and some gaskets. T these components is usually found some way. Normal handling is not airborne dust containing asbestos generated.

Avoid creating dust. Never use com E n g i n e e x h a u s t f u m e s c a n c a u s e A sv ioci kdn b e sr u s s ohri ndge aotrh g . rI if n idt i n i sg m a t e r i n e c e s s a r y t o r u n a n e n g i n e i n a nW h en c l o s e d a r e a , r e m o v e en servicing, wear an approved t h e e x h a u s t f u m e s f r o m t h e a r e av awc i ut u h ma nc l ee xahnaeur s it s pr i epceo m m e n d e d t o extension. available, apply a mist of oil or wa ep s te on s .t hKee e p I f y o u d o n o t h a v e a n e x h a u s t p icpoen te ax itne i nn sgi oans , b o doors and get outside air into the area.

Warning: California Proposition 65 Warning

bystand

Service Tires Safely

Gasoline engine exhaust from this product contains chemicals known to the State of California to cause birth defects, or other reproductive harm.

cancer,

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm.

Remove Paint Before Welding or Heating

Avoid potentially toxic fumes and dust. Hazardous fumes MIF can be generated when paint is heated by welding, s o l d e r i n g , o r u s i n g a t o r c h . D o aE l xl p w o r k o u t s i d e o r i n a w e l l o s i v e s e p a r a t i o n o f a t i lr e a n d v e n t i l a t e d a r e a . D i s p o s e o f p a i n st e ar n pe i odu ss o i l nv jeunr ty po rr o d e ra lt yh. .

Remove paint before welding or heating: If you sand or o uns ot .t W a tet ae rm apnt at o g r i n d p a i n t , a v o i d b r e a t h i n g t h eD d p pm r oo vu en dt a t i r e u n q au ii np tm se tnr ti papnedr , e rx epm e ro iveen c e t o p e r f o r e s p i r a t o r . I f y o u u s e s o l v e n t o rep stripper with soap and water beA f ol w r ea yws e m l d ai inngt. a R i ne m t ho ev ec o r r e c t t i r e p solvent or paint stripper containers and other flammable s i as b m a t e r i a l f r o m a r e a . A l l o w f u m e s t ti ro e d po e vr se e t h a te lreeacsot m1 m 5 ended pres a w h e e l a n d t i r e a s s e m bly. The hea minutes before welding or heating. in air pressure resulting in a tire structurally weaken or deform the

When inflating tires, use a clip-on hose long enough to allow you to NOT in front of or over the tire as if available.

Check rims

Safety

-

wheels

or

4

for

missing

low

lug

pressure,

bolts

and

cut

nuts

SAFETY Avoid Injury From Rotating Blades, Augers and PTO Shafts

Direct exposure to hazardous chem injury. Potentially hazardous chem Deere equipment include such item coolants, paints, and adhesives.

A Material Safety Data Sheet (MSD details on chemical products: phys safety procedures, and emergency Check the MSDS before you start a hazardous chemical. That way you the risks are and how to do the jo procedures and recommended equi

Dispose of Waste Properly

Improperly disposing of waste can environment and ecology. Potentia K e e p h a n d s a n d f e e t a w a y w h i l e wmi ta hc hJ ionhe n i sD er e u rnen ienqgu. i p Sm h ue tn t i n c l u d o f f p o w e r t o s e r v i c e , l u b r i c a t e ocr o ro el amnot v, eb m r a ok w e e fr l ub i l da , d fe i sl ,t e r s , a n d b augers or PTO shafts. containers when draining fluids. D beverage containers that may misl drinking from them. Do not pour w Service Cooling System Safely down a drain, or into any water so proper way to recycle or dispose o environmental or recycling center dealer.

MIF

Live with Safety

MIF

Explosive release of fluids from pressurized cooling system can cause serious burns.

Shut

off

remove

machine. filler

cap

Only when

Handle Chemical Products Safely

cool

enough tS ol o two l uy c lho owsi et h r et o h af ni rd ss t. n b c aa p stop to relieve pressure before removing

MIF

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems.

Install all guards and shields.

completely.

MIF

Safety

-

5

SPECIFICATIONS & INFORMATION TABLE OF CONTENTS Table of Contents Specifications

&

Information

Fastener Torques..............................................9 Metric Fastener Torque Values......................9 Metric Fastener Torque Valu e Grade 7......10 General Information........................................13 Inch Fastener Torque Values.......................1 1 Gasoline ................................. ......................13 G a s roal g ine S . . t. o . . . . . . .e. .. .. .. .. .. .. .. .. .. 1. .3. . . . . . . . . . .

4 -Number C y c Locations...............................16 le Gasoline Serial Engine Oil......................14 Break-In Engine Oil 4-Cycle Gasoline........14 Alternative Lubricants.................. .................14 Synthetic Lubricants.................. ...................14 Lubricant Storage...................... ...................15 Mixing Of Lubricants.................. ...................15 Grease........................ ................................. .15 Chain Lubricant.................... ........................15 Hydrostatic Transmission Oil........................15 Machine

Product

Identification

Specifications

&

Information

Table

of

Contents

-

SPECIFICATIONS & INFORMATION FASTENER TORQUES Fastener Torques Metric Fastener Torque Values 4.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

5

10

10

12.9 12

10

12

10

5 5

Property Class and Nut Marking s

12.9

8.8

10

Property Class and Head Marking s

12

MIF

Class 4.8Class 8.8 or 9.8Class 10.9Class 12.9 Lubricated aDry aLubricated aDry aLubricated aDry aLubricated aDry a SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5 M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35 M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70 M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109 M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300 M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410 M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580 M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800 M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000 M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1500 M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 2000 M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500 DO NOT use these hand torque values if a different torque When bolt and nut combination fasteners are used, torque value or tightening procedure is given for a specific values should be applied to the NUT instead of the bolt application. Torque values listed are for general use only head. and include a ±10% variance factor. Check tightness of Tighten toothed or serrated-type lock nuts to the full torque fasteners periodically. DO NOT use air powered wrenches. value.

Shear bolts are designed to fail under predetermined loads. a “Lubricated” means coated with a lubricant such as Always replace shear bolts with identical grade. engine oil, or fasteners with phosphate and oil coatings.

Fasteners should be replaced with the same class. Make “Dry” means plain or zinc plated (Yellow Dichromate sure fastener threads are clean and that you properly start Specification JDS117) without any lubrication. thread engagement. This will prevent them from failing when tightening.Reference: JDS - G200 Specifications & Information Fastener Torques - 9

SPECIFICATIONS & INFORMATION FASTENER TORQUES Metric Fastener Torque Value - Grade 7 Size

Steel or Gray Iron Torque

Aluminum Torque

N•m lb-ft

N•m lb-ft

M6

11

8

8

6

M8

24

18

19

14

M10 52

38

41

30

M12 88

65

70

52

M14 138

102

111

82

M16 224

165

179

132

Specifications

&

Information

Fastener

Torques

-

10

SPECIFICATIONS & INFORMATION FASTENER TORQUES Inch Fastener Torque Values 1 or 2b

SAE Gra de and Head Markings

8

5.2

5.1

5

8.2

No Marks

5

2

SAE Gra de and Nut Markings

8

No Marks

MIF

Grade

1Grade

L u b r i c a t e d SIZE 1 / 4

N•m 3 . 7

5 / 1 6 3/8

14

7/16 1 / 2

3 3

9 / 1 6

lb-ft

a L u b r i c a t e d

or

5.2Grade

a D r y

lb-ft

4 . 7

3 . 5

6

4 . 5

7 . 5

5 . 5

5 . 5

1 0

7

9

1 5

1 1

2 0

17

13

22

16

27

20

35

16

28 4 2

3 6 5 0

20 3 1

6 0

6 7

3 / 4

1 2 0

8 7

7 / 8

1 9 0

1 4 0

1 2

35 5 3

3 9

44 6 7

32 5 0

N•m

a D r y

a L u b r i c a t e d

N•m

lb-ft

7

1 2

9

1 3 . 5

1 0

1 5

2 5

1 8

2 8

2 1

3 5

2 6

26

44

33

50

36

63

46

9 . 5

41

100

1 2 . 5

52

80

75

1 1 0

8 0

1 2 0

9 0

1 5 0

1 1 5

9 0

1 5 5

1 1 5

1 7 5

1 3 0

2 2 5

1 6 0

6 2

1 0 5

7 8

1 3 5

1 0 0

1 7 0

1 2 5

2 1 5

1 6 0

2 1 5

1 6 0

3 0 0

2 2 5

1 5 0

1 1 0

1 9 0

1 4 0

2 4 0

1 7 5

3 0 0

2 2 5

3 7 5

2 8 0

4 2 5

3 1 0

5 5 0

1 9 0

1 4 0

2 4 0

1 7 5

4 9 0

3 6 0

6 2 5

4 5 0

7 0 0

5 0 0

2 9 0

2 1 0

3 6 0

2 7 0

2 9 0

2 1 0

3 6 0

2 7 0

7 2 5

5 4 0

9 2 5

6 7 5

1 0 5 0

7 5 0

1 - 1 / 8

4 7 0

3 0 0

5 1 0

3 7 5

4 7 0

3 0 0

5 1 0

3 7 5

9 0 0

6 7 5

1 1 5 0

8 5 0

1 4 5 0

1 - 1 / 4

5 7 0

4 2 5

7 2 5

5 3 0

5 7 0

4 2 5

7 2 5

5 3 0

1 3 0 0

9 5 0

1 - 3 / 8

7 5 0

5 5 0

9 5 0

7 0 0

7 5 0

5 5 0

9 5 0

7 0 0

1 7 0 0

1 2 5 0

1 - 1 / 2

1 0 0 0

DO

NOT

use

7 2 5

1 2 5 0

these

9 2 5

hand

9 9 0

torque

7 2 5

1 2 5 0

values

if

9 3 0 a

2 2 5 0

1 6 5 0

1 2 0 0

2 1 5 0

1 6 5 0

different

a

N•m

9 5

1 7 5

1 2 5

1 7

lb-ft

70

6 3

58

N•m

a D r y

5 6

2 4 0

7 0

8.2

lb-ft

55 8 5

or

7 5

8 5

4 5

26

8

a L u b r i c a t e d

N•m

5 / 8

1

5.1

lb-ft

2 5

4 8

5,

N•m

10

22

a D r y

2 . 8

7 . 7

2bGrade

2 8 5 0

torque

8 7 5 1 3 0 0

1 0 7 5

2 0 5 0

1 5 5 0

4

1 5

2 7 0 0

2 1 0 0

When

2

3 6

bolt

value or tightening procedure is given for a specific values should be application. Torque values listed are for general use only head. a n dT ii gn hc tl u d e t oa o ±t h1 e0 d% ovr a sr iear nr ca et e fda- ct ty op re. lCohcek c kn ut ti sg ht ton et hs es o en f uf l l t o r q u e fasteners periodically. DO NOT use air powered wrenches. value.

Shear bolts are designed to fail under predetermined loads. a “Lubricated” means coated with a lubricant such as Always replace shear bolts with identical grade. engine oil, or fasteners with phosphate and oil coatings.

Fasteners should be replaced with the same grade. Make “Dry” means sure fastener threads are clean and that you properly start Specifica thread engagement. This will prevent them from failing b “Grade 2” applies for hex cap screws (Not Hex Bolts) up w h e n t i g h t e n i n g .

Specifications

&

Information

Fastener

Torques

-

11

For the full PDF version of this manual, Please click on the above download PDF button.