JOHN DEERE L105 LAWN TRACTORS TM2185 SERVICE MANUAL

JOHN DEERE

WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION

2 1 8 5 F e b r u a r y

2 0 0 4

Lawn Tractors L105, L107 and L120 TM2185 FEBRUARY 2004

TECHNICAL MANUAL

Export 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 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 Information on 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 (B&S - V-Twin)

Materials

•Component

Harnesses

Electrical

Operation and

Diagnostics

Diagnostics

•Tests

and

•

Repair

•

Other

Engine (B&S - Single Cylinder)

Power Train (Hydrostatic)

Adjustments

Steering

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

Brakes

The bleed tabs for the pages of each section will align the sections listed on this page. Page numbering is c o n s e c u t i v e f r o m t h e b e g i n n i n g o f Attachments 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 Miscellaneous 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©

Introduction

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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 p r e c a u t i Signal o 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 Handling e 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, Washers 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 you wo 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 g 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 Asvi oc ikdn eb sr su sohr i n dg e aot rh .g Ir fi ni d t i ins g m a t e r i a 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 eh ne cnl os se er d a r e a , r e m o v e vicing, 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 a w ci u t hu m a nc leex ahna eurs ti s p ri e p ce o m m e n d e d t o extension. available, apply a mist of oil or wa I f y o u d o n o t h a v e a n e x h a u s t p i cp oe n et a x ti n e inns gi o an s, boeps et o n s t. hKe e e p 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 aEl xl pwl o r k o u t s i d e o r i n a w e l o s i v e s e p a r a t i o n o f a t il r 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 ts earni o d u ss o il n ve j un rt y por ro pd ee ral ty h. .

Remove paint before welding or heating: If you sand or a te taer mapnt at po p m 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 e Ddo u n s to . t W r oovuendt a t i r e u n i ee n 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 r epqaui inpt ms et n r it p ap ne d r , er xe pme or v 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 fAol rwe a w e l d i n g .

R e m o v e ys maintain the correct tire p solvent or paint stripper containers and other flammable t i r e s mended pres 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 o d i sa pb eo rv see t ahte l re ea cs ot m1 5 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 s NOT in front of or over the tire ass 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 job procedures and recommended equi

Dispose of Waste Properly

Improperly disposing of waste can environment and ecology. Potentia Keep hands and feet away while w mi at h c h Ji o nh e n i sD re ue n r en i en qg u. i Sp hmuet n t i n c l u d e 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 o cr o roel m b il d ad a no tv, e b m r aokwe e fr l u , ef is l, 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

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