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John deere 220 a walk behind greensmower service repair manual (sn 030001 and up)

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This technical manual provides information and instructions for servicing a John Deere 220A Walk-Behind Greensmower. The manual is organized by system to keep related information together. It includes sections on specifications, component locations, schematics, operation, troubleshooting, diagnostics, tests, adjustments and repairs. Safety information is provided throughout and proper protective equipment and service procedures are emphasized to avoid injury.

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TECHNICAL MANUAL Litho in U.S.A John Deere Lawn & Grounds Care Division 220A Walk-Behind Greensmower Serial No. (030001— ) TM1680 (01/Dec/96)
M83741
INTRODUCTION 11/14/96 1 - 1 This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: • Table of Contents • Specifications • Component Location • System Schematic • Theory of Operation • Troubleshooting Chart • Diagnostics • Tests & Adjustments • Repair Note: Depending on the particular section or system being covered, not all of the above groups may be used. Each section will be identified with a symbol rather than a number. The groups and pages within a section will be consecutively numbered. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. We appreciate your input on this manual. To help, there are postage paid post cards included at the back. If you find any errors or want to comment on the layout of the manual please fill out one of the cards and mail it back to us. COPYRIGHT© 1996 JOHN DEERE LAWN AND GROUNDS CARE DIVISION Horicon, Wisconsin All rights reserved General Information Specifications and Engine (Honda GX120) Electrical Handlebars and Controls Brakes Safety Miscellaneous Power Train Cutting Unit
SAFETY 1 - 2 12/6/96 RECOGNIZE SAFETY INFORMATION 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 precautions and safe servicing practices. Understand Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. HANDLE FLUIDS SAFELY-AVOID FIRES Be Prepared For Emergencies When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
SAFETY 12/6/96 1 - 3 USE SAFE SERVICE PROCEDURES Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. Service Machines Safely Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications. Park Machine Safely Before working on the machine: 1. Lower all equipment to the ground. 2. Stop the engine and remove the key. 3. Disconnect the battery ground strap. 4. Hang a “DO NOT OPERATE” tag in operator station. Support Machine Properly And Use Proper Lifting Equipment If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual. Work In Clean Area Before starting a job: 1. Clean work area and machine. 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts.
SAFETY 1 - 4 12/6/96 Illuminate Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. Work In Ventilated Area Engine exhaust fumes can cause sickness or death. If it is 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, open the doors and get outside air into the area. WARNING: 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. Remove Paint Before Welding Or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos 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 available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area. SERVICE TIRES SAFELY Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have 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 inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
SAFETY 12/6/96 1 - 5 AVOID INJURY FROM ROTATING BLADES, AUGERS AND PTO SHAFTS Keep hands and feet away while machine is running. Shut off power to service, lubricate or remove mower blades, augers or PTO shafts. HANDLE CHEMICAL PRODUCTS SAFELY 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 drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer. LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
SPECIFICATIONS AND GENERAL INFORMATION CONTENTS Page CONTENTS 12/9/96 2 - 1 SPECIFICATIONS AND GENERAL INFORMATION GENERAL SPECIFICATIONS VEHICLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 REPAIR INFORMATION METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 INCH FASTENER TORQUE VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 GASOLINE 4-CYCLE ENGINES—NORTH AMERICA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 4-CYCLE ENGINES—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 OILS AND LUBRICANTS 4-CYCLE GASOLINE ENGINE OIL—NORTH AMERICA. . . . . . . . . . . . . . . . . . . . 2-8 4-CYCLE GASOLINE ENGINE OIL—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 SPEED REDUCER OIL—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SPEED REDUCER OIL—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 REEL SUPPORT GREASE—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 REEL SUPPORT GREASE—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 ANTI-CORROSION GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 GREASE—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 GREASE—EUROPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 SYNTHETIC LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 MIXING OF LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 MACHINE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 CARBURETOR IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 OPERATIONAL CHECKOUT PROCEDURES ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 SPEED REDUCER OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 THROTTLE LEVER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 OPERATOR PRESENCE BAIL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 PARK BRAKE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 TRAVEL CLUTCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 REEL CLUTCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
2 - 2 12/9/96 GENERAL SPECIFICATIONS SPECIFICATIONS AND INFORMATION GENERAL SPECIFICATIONS VEHICLE SPECIFICATIONS ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Honda Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline, 25° Incline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GX120 K1LJD2 Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Natural Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 kW (4.0 hp) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 cm3 (7.2 cu in.) Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.7 in.) Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5:1 Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 +220/-150 rpm Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3450 ±150 rpm Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25° BTDC Valving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Splash Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced Air Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual-Element (Silent) Type Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Externally Vented Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In-line Engine Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.56 L (0.59 qt) Type of Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recoil Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 kg. (34.2 lb) FUEL SYSTEM Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On Engine Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (0.66 gal) Fuel (minimum octane) . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded Gasoline, 87 Octane Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gravity Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float-type Side Draft Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screen ELECTRICAL Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transistorized Magneto DRIVE TRAIN/TRAVELING DEVICE Traction Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smooth Surface, Dual Aluminium Traveling Speed Forward Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 km/h (5.5 mph) Mow Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 km/h (5.5 mph) Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Machined Steel, Solid or Grooved BRAKES Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Band Type, lever Activated
12/9/96 2 - 3 SPECIFICATIONS AND INFORMATION GENERAL SPECIFICATIONS CUTTING UNIT Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559 mm (22 in.) Cutting Height (minimum) Standard—3.0 mm Bedknife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 mm (1/8 in.) Optional—2.5 mm Bedknife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 mm (7/64 in.) Cutting Height (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 mm (7/8 in.) Frequency of Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.195 in.) Reel Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5 in.) Number of Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heat Treated Special Alloy Steel Grass Catcher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotational Moulded Poly Propylene WEIGHTS AND DIMENSIONS Weight (less GTC and Wheels, with Grass Catcher) . . . . . . . . . . . . . . . 99.5 kg (219 lb) Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 946 mm (37.25 in.) Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 940 mm (37.00 in.) Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.119 m (46.8 in.) WHEELS AND TIRES Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1-6 (2 pr) Tubeless Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125—140 kPa (18—20 psi) (Specifications and design subject to change without notice.)
2 - 4 12/9/96 METRIC FASTENER TORQUE VALUES SPECIFICATIONS AND INFORMATION METRIC FASTENER TORQUE VALUES Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya 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 TS1163 4.8 8.8 9.8 10.9 12.9 5 10 12 Property Class and Head Markings Property Class and Nut Markings 4.8 4.8 5 5 8.8 8.8 9.8 9.8 10.9 10.9 12.9 12.9 12.9 12 1210 10 10 10 10 DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same class. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication. Reference: JDS—G200.
12/9/96 2 - 5 SPECIFICATIONS AND INFORMATION INCH FASTENER TORQUE VALUES INCH FASTENER TORQUE VALUES Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2 Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya 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 1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5 5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26 3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46 7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75 1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115 9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160 5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225 3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400 7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650 1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975 1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350 1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950 1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550 1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 TS1162 1 or 2b 2 5 5.1 5.2 5 8 8.2 8 No Marks No Marks SAE Grade and Nut Markings SAE Grade and Head Markings DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same grade. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication. b “Grade 2” applies for hex cap screws (not hex bolts) up to 152 mm (6-in.) long. “Grade 1” applies for hex cap screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length. Reference: JDS—G200.
2 - 6 12/9/96 GASOLINE SPECIFICATIONS AND INFORMATION GASOLINE 4–CYCLE ENGINES—NORTH AMERICA c CAUTION 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; • engine is running, STOP engine; • engine is hot, allow it to cool sufficiently first; • smoking. Help prevent fires: • fill gas tank to bottom of filler neck only; • be sure fill cap is tight after fueling; • clean up any gas spills IMMEDIATELY; • keep machine clean and in good repair–free of excess grease, oil, debris, and faulty or damaged parts; • any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling: • ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter. 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 day's operation to help prevent condensation from forming inside a partially filled tank; • keep up with specified service 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 butyl ether (MTBE) blends DO NOT exceed 15% by volume. IMPORTANT: DO NOT use METHANOL gasolines because METHANOL is harmful to the environment and to your health. GASOLINE STORAGE IMPORTANT: Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked (“UNLEADED GASOLINE”) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing unit or gasoline, it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. BE SURE to follow directions on container and to properly discard empty container. c WARNING 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. NO STATIC ELECTRIC DISCHARGE NO SMOKINGNO HOT ENGINESTOP ENGINE NO OPEN FLAME OR SPARK
12/9/96 2 - 7 SPECIFICATIONS AND INFORMATION GASOLINE 4–CYCLE ENGINES—EUROPE c CAUTION 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; • engine is running, STOP engine; • engine is hot, allow it to cool sufficiently first; • smoking. Help prevent fires: • fill gas tank to bottom of filler neck only; • be sure fill cap is tight after fueling; • clean up any gas spills IMMEDIATELY; • keep machine clean and in good repair–free of excess grease, oil, debris, and faulty or damaged parts; • any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling: • ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter. 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 day's operation to help prevent condensation from forming inside a partially filled tank; • keep up with specified service 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 butyl ether (MTBE) blends DO NOT exceed 15% by volume. IMPORTANT: DO NOT use METHANOL gasolines because METHANOL is harmful to the environment and to your health. GASOLINE STORAGE IMPORTANT: Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked (“UNLEADED GASOLINE”) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing unit or gasoline, it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. BE SURE to follow directions on container and to properly discard empty container. NO STATIC ELECTRIC DISCHARGE NO SMOKINGNO HOT ENGINESTOP ENGINE NO OPEN FLAME OR SPARK
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2 - 8 12/9/96 OILS AND LUBRICANTS SPECIFICATIONS AND INFORMATION OILS AND LUBRICANTS 4–CYCLE GASOLINE ENGINE OIL— NORTH AMERICA Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. NOTE: For a new or rebuilt engine, the oil should be changed after first 20 hours of use. The following John Deere oils are PREFERRED: • PLUS–4®—SAE 10W-30; • TORQ–GARD SUPREME® —SAE 5W-30. The following John Deere oils are also recommended, based on their specified temperature range: • TURF–GARD®—SAE 10W-30; • PLUS–4® —SAE 10W-40; • TORQ–GARD SUPREME® —SAE 30. Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: • SAE 5W-30—API Service Classification SG or higher; • SAE 10W-30—API Service Classification SG or higher; • SAE 30—API Service Classification SC or higher. John Deere Distributors: You may want to cross- reference the following publications to recommend the proper oil for your customers: • Module DX,ENOIL2 in JDS–G135; • Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide; • Lubrication Sales Manual PI7032. AIR TEMPERATURE M58275 SAE5W-30 PREFERRED SAE10W-30 SAE30 SAE10W-40
12/9/96 2 - 9 SPECIFICATIONS AND INFORMATION OILS AND LUBRICANTS 4–CYCLE GASOLINE ENGINE OIL— EUROPE Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. NOTE: For a new or rebuilt engine, the oil should be changed after first 20 hours of use. The following John Deere oils are PREFERRED: • UNI–GARD™—SAE 10W-30; • TORQ–GARD SUPREME®—SAE 5W-30; • UNI–GARD™—SAE 5W-30. The following John Deere oils are also recommended, based on their specified temperature range: • TORQ–GARD SUPREME®—SAE 10W-30; • UNI–GARD™—SAE 10W-40; • TORQ–GARD SUPREME® —SAE 30; • UNI–GARD™—SAE 30. Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: • CCMC Specification G4 or higher. John Deere Distributors: You may want to cross- reference the following publications to recommend the proper oil for your customers: • Module DX,ENOIL2 in JDS–G135; • Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide. AIR TEMPERATURE M58275 SAE5W-30 PREFERRED SAE10W-30 SAE30 SAE10W-40

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John deere 220 a walk behind greensmower service repair manual (sn 030001 and up)

  • 1. TECHNICAL MANUAL Litho in U.S.A John Deere Lawn & Grounds Care Division 220A Walk-Behind Greensmower Serial No. (030001— ) TM1680 (01/Dec/96)
  • 3. INTRODUCTION 11/14/96 1 - 1 This technical manual is written for an experienced technician and contains sections that are specifically for this product. It is a part of a total product support program. The manual is organized so that all the information on a particular system is kept together. The order of grouping is as follows: • Table of Contents • Specifications • Component Location • System Schematic • Theory of Operation • Troubleshooting Chart • Diagnostics • Tests & Adjustments • Repair Note: Depending on the particular section or system being covered, not all of the above groups may be used. Each section will be identified with a symbol rather than a number. The groups and pages within a section will be consecutively numbered. All information, illustrations and specifications in this manual are based on the latest information available at the time of publication. The right is reserved to make changes at any time without notice. We appreciate your input on this manual. To help, there are postage paid post cards included at the back. If you find any errors or want to comment on the layout of the manual please fill out one of the cards and mail it back to us. COPYRIGHT© 1996 JOHN DEERE LAWN AND GROUNDS CARE DIVISION Horicon, Wisconsin All rights reserved General Information Specifications and Engine (Honda GX120) Electrical Handlebars and Controls Brakes Safety Miscellaneous Power Train Cutting Unit
  • 4. SAFETY 1 - 2 12/6/96 RECOGNIZE SAFETY INFORMATION 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 precautions and safe servicing practices. Understand Signal Words A signal word—DANGER, WARNING, or CAUTION—is used with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. HANDLE FLUIDS SAFELY-AVOID FIRES Be Prepared For Emergencies When you work around fuel, do not smoke or work near heaters or other fire hazards. Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers. Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously. Be prepared if a fire starts. Keep a first aid kit and fire extinguisher handy. Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
  • 5. SAFETY 12/6/96 1 - 3 USE SAFE SERVICE PROCEDURES Wear Protective Clothing Wear close fitting clothing and safety equipment appropriate to the job. Prolonged exposure to loud noise can cause impairment or loss of hearing. Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises. Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine. Service Machines Safely Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result. Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts. Use Proper Tools Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards. Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications. Park Machine Safely Before working on the machine: 1. Lower all equipment to the ground. 2. Stop the engine and remove the key. 3. Disconnect the battery ground strap. 4. Hang a “DO NOT OPERATE” tag in operator station. Support Machine Properly And Use Proper Lifting Equipment If you must work on a lifted machine or attachment, securely support the machine or attachment. Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual. Lifting heavy components incorrectly can cause severe injury or machine damage. Follow recommended procedure for removal and installation of components in the manual. Work In Clean Area Before starting a job: 1. Clean work area and machine. 2. Make sure you have all necessary tools to do your job. 3. Have the right parts on hand. 4. Read all instructions thoroughly; do not attempt shortcuts.
  • 6. SAFETY 1 - 4 12/6/96 Illuminate Work Area Safely Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil. Work In Ventilated Area Engine exhaust fumes can cause sickness or death. If it is 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, open the doors and get outside air into the area. WARNING: 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. Remove Paint Before Welding Or Heating Avoid potentially toxic fumes and dust. Hazardous fumes can be generated when paint is heated by welding, soldering, or using a torch. Do all work outside or in a well ventilated area. Dispose of paint and solvent properly. Remove paint before welding or heating: If you sand or grind paint, avoid breathing the dust. Wear an approved respirator. If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating. Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos 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 available, apply a mist of oil or water on the material containing asbestos. Keep bystanders away from the area. SERVICE TIRES SAFELY Explosive separation of a tire and rim parts can cause serious injury or death. Do not attempt to mount a tire unless you have 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 inflating tires, use a clip-on chuck and extension hose long enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available. Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts.
  • 7. SAFETY 12/6/96 1 - 5 AVOID INJURY FROM ROTATING BLADES, AUGERS AND PTO SHAFTS Keep hands and feet away while machine is running. Shut off power to service, lubricate or remove mower blades, augers or PTO shafts. HANDLE CHEMICAL PRODUCTS SAFELY 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 drinking from them. Do not pour waste onto the ground, down a drain, or into any water source. Inquire on the proper way to recycle or dispose of waste from your local environmental or recycling center, or from your John Deere dealer. LIVE WITH SAFETY Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
  • 8. SPECIFICATIONS AND GENERAL INFORMATION CONTENTS Page CONTENTS 12/9/96 2 - 1 SPECIFICATIONS AND GENERAL INFORMATION GENERAL SPECIFICATIONS VEHICLE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 REPAIR INFORMATION METRIC FASTENER TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 INCH FASTENER TORQUE VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 GASOLINE 4-CYCLE ENGINES—NORTH AMERICA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 4-CYCLE ENGINES—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 GASOLINE STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 OILS AND LUBRICANTS 4-CYCLE GASOLINE ENGINE OIL—NORTH AMERICA. . . . . . . . . . . . . . . . . . . . 2-8 4-CYCLE GASOLINE ENGINE OIL—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 SPEED REDUCER OIL—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 SPEED REDUCER OIL—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 REEL SUPPORT GREASE—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 REEL SUPPORT GREASE—EUROPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 ANTI-CORROSION GREASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 GREASE—NORTH AMERICA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 GREASE—EUROPE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 ALTERNATIVE LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 SYNTHETIC LUBRICANTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 LUBRICANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 MIXING OF LUBRICANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14 SERIAL NUMBER LOCATIONS SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 MACHINE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 ENGINE SERIAL NUMBER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 CARBURETOR IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15 OPERATIONAL CHECKOUT PROCEDURES ENGINE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 SPEED REDUCER OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 THROTTLE LEVER CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17 OPERATOR PRESENCE BAIL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 PARK BRAKE CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18 TRAVEL CLUTCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19 REEL CLUTCH CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
  • 9. 2 - 2 12/9/96 GENERAL SPECIFICATIONS SPECIFICATIONS AND INFORMATION GENERAL SPECIFICATIONS VEHICLE SPECIFICATIONS ENGINE Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Honda Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Gasoline, 25° Incline Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GX120 K1LJD2 Aspiration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Natural Horsepower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.1 kW (4.0 hp) Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118 cm3 (7.2 cu in.) Stroke/Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cycle Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mm (2.4 in.) Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 mm (1.7 in.) Compression Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5:1 Slow Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400 +220/-150 rpm Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3450 ±150 rpm Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25° BTDC Valving. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead Valves Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Splash Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Forced Air Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dual-Element (Silent) Type Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Externally Vented Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .In-line Engine Oil Capacity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.56 L (0.59 qt) Type of Starter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Recoil Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.5 kg. (34.2 lb) FUEL SYSTEM Fuel Tank Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On Engine Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5 L (0.66 gal) Fuel (minimum octane) . . . . . . . . . . . . . . . . . . . . . . . . . . Unleaded Gasoline, 87 Octane Fuel Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Gravity Carburetor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Float-type Side Draft Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Screen ELECTRICAL Ignition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Transistorized Magneto DRIVE TRAIN/TRAVELING DEVICE Traction Roller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Smooth Surface, Dual Aluminium Traveling Speed Forward Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2 km/h (5.5 mph) Mow Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.4 km/h (5.5 mph) Front Roller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Machined Steel, Solid or Grooved BRAKES Park Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Band Type, lever Activated
  • 10. 12/9/96 2 - 3 SPECIFICATIONS AND INFORMATION GENERAL SPECIFICATIONS CUTTING UNIT Cutting Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 559 mm (22 in.) Cutting Height (minimum) Standard—3.0 mm Bedknife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 mm (1/8 in.) Optional—2.5 mm Bedknife . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8 mm (7/64 in.) Cutting Height (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22.2 mm (7/8 in.) Frequency of Clip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 mm (0.195 in.) Reel Diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 mm (5 in.) Number of Blades. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Heat Treated Special Alloy Steel Grass Catcher. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotational Moulded Poly Propylene WEIGHTS AND DIMENSIONS Weight (less GTC and Wheels, with Grass Catcher) . . . . . . . . . . . . . . . 99.5 kg (219 lb) Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 946 mm (37.25 in.) Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 940 mm (37.00 in.) Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1.119 m (46.8 in.) WHEELS AND TIRES Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4.1-6 (2 pr) Tubeless Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125—140 kPa (18—20 psi) (Specifications and design subject to change without notice.)
  • 11. 2 - 4 12/9/96 METRIC FASTENER TORQUE VALUES SPECIFICATIONS AND INFORMATION METRIC FASTENER TORQUE VALUES Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9 Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya 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 TS1163 4.8 8.8 9.8 10.9 12.9 5 10 12 Property Class and Head Markings Property Class and Nut Markings 4.8 4.8 5 5 8.8 8.8 9.8 9.8 10.9 10.9 12.9 12.9 12.9 12 1210 10 10 10 10 DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same class. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication. Reference: JDS—G200.
  • 12. 12/9/96 2 - 5 SPECIFICATIONS AND INFORMATION INCH FASTENER TORQUE VALUES INCH FASTENER TORQUE VALUES Grade 1 Grade 2b Grade 5, 5.1 or 5.2 Grade 8 or 8.2 Lubricateda Drya Lubricateda Drya Lubricateda Drya Lubricateda Drya 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 1/4 3.7 2.8 4.7 3.5 6 4.5 7.5 5.5 9.5 7 12 9 13.5 10 17 12.5 5/16 7.7 5.5 10 7 12 9 15 11 20 15 25 18 28 21 35 26 3/8 14 10 17 13 22 16 27 20 35 26 44 33 50 36 63 46 7/16 22 16 28 20 35 26 44 32 55 41 70 52 80 58 100 75 1/2 33 25 42 31 53 39 67 50 85 63 110 80 120 90 150 115 9/16 48 36 60 45 75 56 95 70 125 90 155 115 175 130 225 160 5/8 67 50 85 62 105 78 135 100 170 125 215 160 215 160 300 225 3/4 120 87 150 110 190 140 240 175 300 225 375 280 425 310 550 400 7/8 190 140 240 175 190 140 240 175 490 360 625 450 700 500 875 650 1 290 210 360 270 290 210 360 270 725 540 925 675 1050 750 1300 975 1-1/8 470 300 510 375 470 300 510 375 900 675 1150 850 1450 1075 1850 1350 1-1/4 570 425 725 530 570 425 725 530 1300 950 1650 1200 2050 1500 2600 1950 1-3/8 750 550 950 700 750 550 950 700 1700 1250 2150 1550 2700 2000 3400 2550 1-1/2 1000 725 1250 925 990 725 1250 930 2250 1650 2850 2100 3600 2650 4550 3350 TS1162 1 or 2b 2 5 5.1 5.2 5 8 8.2 8 No Marks No Marks SAE Grade and Nut Markings SAE Grade and Head Markings DO NOT use these hand torque values if a different torque value or tightening procedure is given for a specific application. Torque values listed are for general use only and include a ±10% variance factor. Check tightness of fasteners periodically. DO NOT use air powered wrenches. Shear bolts are designed to fail under predetermined loads. Always replace shear bolts with identical grade. Fasteners should be replaced with the same grade. Make sure fastener threads are clean and that you properly start thread engagement. This will prevent them from failing when tightening. When bolt and nut combination fasteners are used, torque values should be applied to the NUT instead of the bolt head. Tighten toothed or serrated-type lock nuts to the full torque value. a “Lubricated” means coated with a lubricant such as engine oil, or fasteners with phosphate and oil coatings. “Dry” means plain or zinc plated (yellow dichromate - Specification JDS117) without any lubrication. b “Grade 2” applies for hex cap screws (not hex bolts) up to 152 mm (6-in.) long. “Grade 1” applies for hex cap screws over 152 mm (6-in.) long, and for all other types of bolts and screws of any length. Reference: JDS—G200.
  • 13. 2 - 6 12/9/96 GASOLINE SPECIFICATIONS AND INFORMATION GASOLINE 4–CYCLE ENGINES—NORTH AMERICA c CAUTION 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; • engine is running, STOP engine; • engine is hot, allow it to cool sufficiently first; • smoking. Help prevent fires: • fill gas tank to bottom of filler neck only; • be sure fill cap is tight after fueling; • clean up any gas spills IMMEDIATELY; • keep machine clean and in good repair–free of excess grease, oil, debris, and faulty or damaged parts; • any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling: • ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter. 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 day's operation to help prevent condensation from forming inside a partially filled tank; • keep up with specified service 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 butyl ether (MTBE) blends DO NOT exceed 15% by volume. IMPORTANT: DO NOT use METHANOL gasolines because METHANOL is harmful to the environment and to your health. GASOLINE STORAGE IMPORTANT: Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked (“UNLEADED GASOLINE”) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing unit or gasoline, it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. BE SURE to follow directions on container and to properly discard empty container. c WARNING 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. NO STATIC ELECTRIC DISCHARGE NO SMOKINGNO HOT ENGINESTOP ENGINE NO OPEN FLAME OR SPARK
  • 14. 12/9/96 2 - 7 SPECIFICATIONS AND INFORMATION GASOLINE 4–CYCLE ENGINES—EUROPE c CAUTION 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; • engine is running, STOP engine; • engine is hot, allow it to cool sufficiently first; • smoking. Help prevent fires: • fill gas tank to bottom of filler neck only; • be sure fill cap is tight after fueling; • clean up any gas spills IMMEDIATELY; • keep machine clean and in good repair–free of excess grease, oil, debris, and faulty or damaged parts; • any storage of machines with gas left in tank should be in an area that is well ventilated to prevent possible igniting of fumes by an open flame or spark, this includes any appliance with a pilot light. To prevent fire or explosion caused by STATIC ELECTRIC DISCHARGE during fueling: • ONLY use a clean, approved POLYETHYLENE PLASTIC fuel container and funnel WITHOUT any metal screen or filter. 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 day's operation to help prevent condensation from forming inside a partially filled tank; • keep up with specified service 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 butyl ether (MTBE) blends DO NOT exceed 15% by volume. IMPORTANT: DO NOT use METHANOL gasolines because METHANOL is harmful to the environment and to your health. GASOLINE STORAGE IMPORTANT: Keep all dirt, scale, water or other foreign material out of gasoline. Keep gasoline stored in a safe, protected area. Storage of gasoline in a clean, properly marked (“UNLEADED GASOLINE”) POLYETHYLENE PLASTIC container WITHOUT any metal screen or filter is recommended. DO NOT use de-icers to attempt to remove water from gasoline or depend on fuel filters to remove water from gasoline. Use a water separator installed in the storage tank outlet. BE SURE to properly discard unstable or contaminated gasoline. When storing unit or gasoline, it is recommended that you add John Deere Gasoline Conditioner and Stabilizer (TY15977) or an equivalent to the gasoline. BE SURE to follow directions on container and to properly discard empty container. NO STATIC ELECTRIC DISCHARGE NO SMOKINGNO HOT ENGINESTOP ENGINE NO OPEN FLAME OR SPARK
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  • 16. 2 - 8 12/9/96 OILS AND LUBRICANTS SPECIFICATIONS AND INFORMATION OILS AND LUBRICANTS 4–CYCLE GASOLINE ENGINE OIL— NORTH AMERICA Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. NOTE: For a new or rebuilt engine, the oil should be changed after first 20 hours of use. The following John Deere oils are PREFERRED: • PLUS–4®—SAE 10W-30; • TORQ–GARD SUPREME® —SAE 5W-30. The following John Deere oils are also recommended, based on their specified temperature range: • TURF–GARD®—SAE 10W-30; • PLUS–4® —SAE 10W-40; • TORQ–GARD SUPREME® —SAE 30. Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: • SAE 5W-30—API Service Classification SG or higher; • SAE 10W-30—API Service Classification SG or higher; • SAE 30—API Service Classification SC or higher. John Deere Distributors: You may want to cross- reference the following publications to recommend the proper oil for your customers: • Module DX,ENOIL2 in JDS–G135; • Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide; • Lubrication Sales Manual PI7032. AIR TEMPERATURE M58275 SAE5W-30 PREFERRED SAE10W-30 SAE30 SAE10W-40
  • 17. 12/9/96 2 - 9 SPECIFICATIONS AND INFORMATION OILS AND LUBRICANTS 4–CYCLE GASOLINE ENGINE OIL— EUROPE Use the appropriate oil viscosity based on the expected air temperature range during the period between recommended oil changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure. NOTE: For a new or rebuilt engine, the oil should be changed after first 20 hours of use. The following John Deere oils are PREFERRED: • UNI–GARD™—SAE 10W-30; • TORQ–GARD SUPREME®—SAE 5W-30; • UNI–GARD™—SAE 5W-30. The following John Deere oils are also recommended, based on their specified temperature range: • TORQ–GARD SUPREME®—SAE 10W-30; • UNI–GARD™—SAE 10W-40; • TORQ–GARD SUPREME® —SAE 30; • UNI–GARD™—SAE 30. Other oils may be used if above John Deere oils are not available, provided they meet one of the following specifications: • CCMC Specification G4 or higher. John Deere Distributors: You may want to cross- reference the following publications to recommend the proper oil for your customers: • Module DX,ENOIL2 in JDS–G135; • Section 530, Lubricants & Hydraulics, of the John Deere Merchandise Sales Guide. AIR TEMPERATURE M58275 SAE5W-30 PREFERRED SAE10W-30 SAE30 SAE10W-40