John Deere G100, G110 Garden Tractor TM2020 PDF Manual

JOHN DEERE

WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION

2020 February

2004

Garden Tractors G100 and G110 TM2020 FEBRUARY 2004

TECHNICAL MANUAL

North American Version Litho in U.S.A.

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 rSafety 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 l Specifications t h e i n f o r m and 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 •

Electrical

Materials

•Component

Harnesses

Power Train

Operation and

Diagnostics

Diagnostics

•Tests

and

•

Repair

•

Other

Engine (Kohler)

Steering

Adjustments

Attachments

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

Miscellaneous

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

with

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

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© 2004 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT© 2002, 2003

Introduction

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

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

p recautio n s aWords nd safe Understand Signal

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 yo de f u e l , u s e d w i t h t h e s a f e t y - a l e r t s y m b o l . hDeAn N G Eu R iwd oe rnkt i a f ir eo su n th 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 a ml im 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• tSi toonr se af rl e s ta eb dl e o fnl u i d s a w a y 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 Ogpa es r ac ta inn ge xepql u o idpem . ent safely requir operator. Do not wear radio or mus •Never check battery charge by p o lpaecr i antgi nag m meat cahl i o nb e 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

eEl seccat p ro i nl yg t ef l. u i d u n d e r p r e s s u r e p r o c e d u cr a eu . sing serious injury.

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 n t he ec t ai o c inds . b e f o r e a p p t ee nu tar lal l iczoen n o ri nl u e ta ek 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 1e0a r- c 1h5 f m If you spill acid on yourself:

4.Get

medical

attention

If acid is swallowed:

i m m e d i aatne dl y b. o d y f r o m h i g h p r e s s u r e f l u i d s If an accident occurs, see a doctor

injected into the skin must be sur of re w m ihl o k .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 d t ei cn a e l gs g o su , r co er . vSe ugceht ai bn lf eo r m a t i o n 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 fluid 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 c Proper e , n o Lifting 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 c Using 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 tr h e s e i t e m s w ge e c t i n g p r e s s ue rr i ez et do w a 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 u cl to . 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 g r aol t sh he or r st es n s i t i v e 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 it no j ep cr te i voenn tp ue m l epc st r oi c 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 yo k l sa 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 zI lal rudms i. nUa st ee p ou w re rw to or o l en es rasf .e tF yo rl i lgohots ef o 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 npdo rf ta as bt e n ri nwg o r k i n g i m a c h i n e .

M a k e s u r e t h e and tightening hardware, use the correct size tools. DO bulb is en ho o rf s a. n a c c i d e n t a l l y N O T u s e U . S . m e a s u r e m e n t t o o l s T oh ne m e tt r fi icl af m a setne tn e s p i l l e d f u e l o r o i l . se only Avoid bodily injury caused by slipping wrenches. U service parts meeting John Deere specifications.

Work In Ventilated Area 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

MIF

instructions

thoroughly; shor tcuts.

do

not

attempt

Safety

-

3

SAFETY 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 Service s i c k nTires e s s Safely or death. If it necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, doors and get outside air into the area.

open

is

the

Warning: California Proposition 65 Warning 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 Explosive separation of a defects, and other reproductive harm. serious injury or death.

MIF

tire

and

Do not attempt to mount a tire un equipment and experience to perfo A v o i d p o t e n t i a l l y t o x i c f u m e s a n Ad l w d au ys st . mHaai znat radi o f u cmoer sr e c t t i r e p n u tsh e c a n b e g e n e r a t e d w h e n p a i n t i s th i er ae ts e ad b bo yv ew te hl d i n g , e recommended pres s o l d e r i n g , o r u s i n g a t o r c h . D o aal l wwh oe rekl o a bwl ye . l l T h e h e a au n td s it di ree oar s si ne m ventilated area. Dispose of paint and solvent properly. in air pressure resulting in a tire Remove paint before welding or heating: If you sand or structurally weaken or deform the grind paint, avoid breathing the dust. Wear an approved i ne gr , t ri er e respirator. If you use solvent or W ph ae i nn t i sn tf rl iapt p mso, v ue s e a c l i p - o n s t r i p p e r w i t h s o a p a n d w a t e r b e fhoor see wl o en l dgi ne gn . o R ue gm h ot vo e a l l o w y o u t o s s o l v e n t o r p a i n t s t r i p p e r c o n t a i nNeOr Ts a i nn df r oo tnht e or f f loar mom v ea rb lteh e t i r e a s s 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 i tf o a d v ai si lpaebr lsee. a t l e a s t 1 5 minutes before welding or heating.

Check wheels for low pressure, cut

Remove Paint Before Welding or Heating

rims

or

missing

lug

bolts

and

nuts

Avoid Harmful Asbestos Dust

A v o i d b r e a t h i n g d u s t t h a t m a y b Avoid e g e Injury n e r a From t e d Rotating w h e n Blades, Augers h a n d l i n g c o m p o n e n t s c o n t a i n i n gAnd a s PTO b e sShafts tos fibers.

Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

Avoid creating dust. Never use compressed air for cleaning.

Avoid brushing or grinding material containing asbestos.

When servicing, wear an approved respirator. A special vacuum cleaner is recommended to clean asbestos. If not MIF available, apply a mist of oil or water on the material eep containing asbestos. Keep bystaK nd r s haawn ad ys far no dm f te he et a rweaay. w h i l e m off power to service, lubricate or r augers or PTO shafts.

Safety

-

4

SAFETY

drinking from them. Do not pour w down a drain, or into any water so proper way to recycle or dispose o environmental or recycling center, dealer.

Service Cooling System Safely

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

Direct exposure to hazardous chemicals can cause serious injury. Potentially hazardous chemicals used with John Deere equipment include such items as lubricants, coolants, paints, and adhesives.

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

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

Dispose of Waste Properly Improperly disposing of waste can threaten the environment and ecology. Potentially harmful waste used with John Deere equipment include such items as oil, fuel, coolant, brake fluid, filters, and batteries. Use leakproof containers when draining fluids. Do not use food or beverage containers that may mislead someone into Safety

-

5

SPECIFICATIONS & INFORMATION TABLE OF CONTENTS Table of Contents Specifications

&

Information

Fastener Torques..............................................9 Metric Fastener Torque Values......................9 I n c hInformation........................................11 Fastener Torque General Values.......................1 0 Gasoline .................................. .....................11 G a s roal g ine S . . t. o . . . . . . . e. .. .. .. .. .. .. .. .. 1. .1 . . . . . . . . . . . . .

Engine Serial O i Number l . . . . . . Locations...............................15 ........................ .......................12 E ngine Break-In O . . .i .l .. .. .. .. 1. .2. . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic Transmission Oil........................13 Synthetic Lubricants.................. ...................13 Chassis Grease........................ ....................14 A l t e r n a t i tvse. . . . . . . . . . . . . . . . . .

L . . u. .b. .r . i . c. .a. n ......14 Lubricant Storage....................... ..................14 M i x i n g o ft s . . . . . . . . . . . . . . . . . . .

L . . u. .b. .r . i. c. .a. n .......14 Oil Filters........................ ..............................14 Product

Identification

Number Specifications

(PIN).............15 E n ee r I. .d. e Nn ug mi b . . n. .t. i. f. i. .c. a. .t. i. o. . n. . . .

&

Information

Table

of

Contents

-

SPECIFICATIONS & INFORMATION FASTENER TORQUES Fastener Torques

Metric Fastener Torque Values 4.8

Class

M8

12

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

12

10

10

5

12.9

10

10

12

MIF

N•m

4.8

8.8

5

4.8Class

M6

4.8

5

Lubricated SIZE

10.9

10

Property Class and Nut Marking s

9.8

12

Property Class and Head Marking s

12.9

8.8

aDry

lb-ft

3.5

8.8

6

or

9.8Class

aLubricated

N•m

4.5

9

lb-ft

6.5

8.5

15

11

22

16

8.5 20

12.9

aDry

aLubricated

lb-ft

N•m

lb-ft

17

15

N•m

11

28

10.9Class

13

32

9.5

24

40

30

11.5

37

19

47

N•m

lb-ft

N•

14.5

35

17

29

21

43

32

55

40

63

M12

40

29

50

37

75

55

95

70

110

80

M14

63

47

80

60

120

150

110

175

M16

100

73

M18

135

100

175

M20

190

140

240

180

375

275

475

350

530

400

675

500

625

460

800

M22

260

190

330

250

510

375

650

475

725

540

925

675

850

625

1075

M24

330

250

425

310

650

475

825

600

925

675

1150

850

1075

800

135

M27

490

360

625

450

950

700

1200

875

1700

1250

1600

115

M30

675

490

850

625

1300

950

1650

1200

M33

900

675

1150

850

1750

1300

M36

1150

850

1450

1075

2250

these

hand

torque

DO

NOT

use

92

190

125

140

260

240

195

175

330

75

55

140

105

130

95

130

225

165

205

150

260

109

275

200

350

225

320

240

400

250

60

28

lb-ft

aD

23

125

80

N•m

aLubricated

M10

88

47

12

aDry

375

2200

1650

1350

if

a

165

350

1000

1350

2500

2100

70

475

1850

1650

2850

values

275

95

440

2300

1850

3200

120

560

1700

3150

2350

different

325

torque

41

2150

2350

4050

300

1

2900

3000

3

When

b

value or tightening procedure is given for a specific values should application. Torque values listed are for general use only head. a do eta a rr ri aa n e - ft ay cp teo rl o . cCkh en cu kt s t it go h tt h n ee sf su lol f t o r q u e Tn i gdh it ne cn l ut o h e±d1 0o%r v se t ec d 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” mea sure fastener threads are clean and that you properly start Specif thread engagement. This will prevent them from failing Reference: JDS - G200. when tightening.

Specifications

&

Information

Fastener

Torques

-

9

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

Lubricated SIZE 1/4

3.7

5/16

14

7/16

22

9/16

lb-ft

36

5/8

67

3/4

120

87

7/8

190

140

1

50

7

9

15

25

18

16

27

20

35

26

44

33

35

53

45 62

150

9.5

20

31

85

lb-ft

11

20

60

N•m

15

22

39

N•m

44

67

5.5

32

50

55

N•m

13.5

10

28

21

26

50

36

35 63

lb-ft 17

80

58

100

75

63

110

80

120

90

150

115

125

90

155

115

175

130

225

70

105

78

135

100

170

125

215

160

215

190

140

240

175

300

225

375

280

140

240

175

490

360

lb-ft

N•m

12.5

52

95

190

N•m

aD

46

56

175

aLubricated

70

85

41

12

aDry

75

110

240

26

8.2

lb-ft

9

12

or

aLubricated

7.5

6

8

aDry

4.5

13

42

5.2Grade

3.5

17

25

or

lb-ft

7

28

5.1

N•m

10

16

48

4.7

5,

aLubricated

5.5

10

33

aDry

2.8

7.7

3/8

1/2

N•m

2bGrade

625

160

160 300

425

450

225

310

700

550

500

400

875

65

290

210

360

270

290

210

360

270

725

540

925

675

1050

750

1300

97

1-1/8

470

300

510

375

470

300

510

375

900

675

1150

850

1450

1075

18

1-1/4

570

425

725

530

570

425

725

530

1300

950

1-3/8

750

550

950

700

750

550

950

700

1700

1250

1-1/2

1000

725

1250

DO

NOT

use

these

925 hand

990

725

torque

1250

930

values

if

2250 a

1650

1200

2150

1650

1550

2850

different

2050

2700

2100

torque

1500

200

3600

Tighten

value or tightening procedure is given for a specific value. application. Torque values listed are for general use only a “Lubricated” means coated with a lubricant such as and include a ±10% variance factor. Check tightness of engine oil, or fasteners with phosphate and oil coatings. fasteners periodically. DO NOT use air powered wrenches.

“Dry” means plain or zinc plated (yellow dichromate Shear bolts are designed to fail under predetermined loads. Specif Always replace shear bolts with identical grade. b “Grade 2” applies for hex cap screws (Not Hex Bolts) up Fasteners should be replaced with the same grade. Make to 152 mm sure fastener threads are clean and that you properly start screws ove thread engagement. This will prevent them from failing bolts and s w R eh feenr et ni g ch e :t eJ nDi Sn g- . G 2 0 0 When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head.

Specifications

&

Information

Fastener

Torques

-

10

SPECIFICATIONS & INFORMATION GENERAL INFORMATION RFG (reformulated) gasoline is acc designed for use of regular unlead (that were designed for leaded fue accelerated valve and seat wear.

General Information Gasoline

c CAUTION: Avoid Injury! Gasoline is HIGHLY FLAMMABLE, handle it with care.

DO NOT refuel machine while: •Indoors, always fill gas tank outdoors; •Machine is near an open flame or sparks; MIF

•Engine is running, STOP engine; •Engine is hot, allow it to cool sufficiently first; • smoking.

IMPORTANT: Avoid damage! California Proposition 65 Warning: Gasoline engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

Help prevent fires: •Fill gas tank to bottom of filler neck only; •Be sure fill cap is tight after fueling;

Gasoline Storage

•Clean up any gas spills IMMEDIATELY;

IMPORTANT: Avoid damage! Keep all dirt, scale, •Keep machine clean and in good repair - free water or other foreign material out of gasoline. of excess grease, oil, debris, and faulty or damaged K e e p parts. gasoline stored in a safe, protected area. Storage of g a s Any o l istorage ne in a c l e awith n , gas p rleft op rly marked (“UNLEADED of machines inetank GASOLINE”) POLYETHYLENE PLASTIC container should be in an area that is well ventilated to WITHOUT any metal screen or filter is recommended. DO prevent possible igniting of fumes by an open NOT use de-icers to attempt to remove water from gasoline ornspark, o r dflame epe d o this n fincludes u e l fany i l tappliance ers to remove water from gasoline. with a pilot light.

Use a water separator installed in the storage tank outlet.

B E To SU R E tfire o or p explosion r o p e r lcaused y d i by s cSTATIC ard unstable or contaminated prevent g a s ELECTRIC o l i n e .DISCHARGE W h e n during s t o rfueling: ing the machine or gasoline, it is recommended that you add John Deere Gasoline •ONLY use a clean, approved Conditioner and Stabilizer (TY15977) or an equivalent to t h e POLYETHYLENE g a s o l i n ePLASTIC . B E fuel S Ucontainer R E t o and follow directions on container or filter. a n dfunnel t o WITHOUT p r o p e any r l ymetal d i sscreen card empty container.

To avoid engine damage: •DO

NOT

mix

oil

with

gasoline;

•ONLY use clean, fresh unleaded gasoline with an octane rating (anti-knock index) of 87 or higher; •fill gas tank at the end of each prevent tank; •keep

condensation

up

with

from

specified

day's

forming

service

operation

inside

a

to

help

partially

filled

intervals.

Use of alternative oxygenated, gasohol blended, unleaded gasoline is acceptable as long as: •the ethyl or grain alcohol blends DO NOT exceed 10% by volume or •methyl tertiary exceed

15%

by

butyl

ether

(MTBE)

blends

DO

NOT

volume

Specifications

&

Information

General

Information

-

11

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