John Deere Lawn Tractors LTR155 LTR166 & LTR180 Lawn Tractors Technical Manual – PDF DOWNLOAD

Description

John Deere Lawn Tractors LTR155 LTR166 & LTR180 Lawn Tractors Technical Manual – PDF DOWNLOAD

DESCRIPTION:

John Deere Lawn Tractors LTR155 LTR166 & LTR180 Lawn Tractors Technical Manual – PDF DOWNLOAD

INTRODUCTION:

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
• General Diagnostic Information
• Specifications
• Electrical Wiring Harness Legend
• Component Location
• System Schematic
• Wiring Harness
• Troubleshooting Chart
• Theory of Operation
• Diagnostics
• Tests & Adjustments
• Repair

TABLE OF CONTENTS:

John Deere Lawn Tractors LTR155 LTR166 & LTR180 Lawn Tractors Technical Manual – PDF DOWNLOAD

TM1768 – LTR155, LTR166 and LTR180 Lawn Tractor…………………………… 1
INTRODUCTION………………………………………………………. 3
SAFETY……………………………………………………………. 4
RECOGNIZE SAFETY INFORMATION…………………………………….. 4
REPLACE SAFETY SIGNS……………………………………………. 4
HANDLE FLUIDS SAFELY-AVOID FIRES…………………………………. 4
USE CARE IN HANDLING AND SERVICING BATTERIES………………………. 5
USE SAFE SERVICE PROCEDURES……………………………………… 5
SERVICE TIRES SAFELY……………………………………………. 7
AVOID INJURY FROM ROTATING BLADES, AUGERS AND PTO SHAFTS……………. 7
HANDLE CHEMICAL PRODUCTS SAFELY………………………………….. 7
LIVE WITH SAFETY……………………………………………….. 8
SPECIFICATIONS…………………………………………………….. 9
TORQUE SPECIFICATIONS…………………………………………… 13
METRIC FASTENER TORQUE VALUES………………………………… 13
GENERAL VEHICLE SPECIFICATIONS…………………………………… 11
KOHLER ENGINE—LTR155………………………………………… 11
BRIGGS & STRATTON ENGINE—LTR166………………………………. 11
KAWASAKI ENGINE—LTR180………………………………………. 11
ELECTRICAL…………………………………………………. 12
HYDROSTATIC TRANSAXLE……………………………………….. 12
PTO DRIVE………………………………………………….. 12
STEERING…………………………………………………… 12
IMPLEMENT LIFT……………………………………………… 12
TIRES……………………………………………………… 12
DIMENSIONS…………………………………………………. 12
REAR DISCHARGE MOWER DECK……………………………………. 0
DRAWBAR LOAD……………………………………………….. 0
GRASS COLLECTION SYSTEM……………………………………… 0
FUEL AND OIL SPECIFICATIONS……………………………………… 15
GASOLINE…………………………………………………… 15
GASOLINE STORAGE— NORTH AMERICA………………………………. 15
ENGINE OIL…………………………………………………. 16
ENGINE BREAK–IN OIL…………………………………………. 16
LUBRICANT SPECIFICATIONS………………………………………… 17
ANTI-CORROSION GREASE……………………………………….. 17
ALTERNATIVE LUBRICANTS………………………………………. 18
SYNTHETIC LUBRICANTS………………………………………… 18
LUBRICANT STORAGE…………………………………………… 18
MIXING OF LUBRICANTS………………………………………… 18
CHASSIS GREASE……………………………………………… 18
HYDROSTATIC TRANSMISSION OIL…………………………………. 19
PRODUCT IDENTIFICATION LOCATIONS…………………………………. 19
PRODUCT IDENTIFICATION NUMBER (PIN)…………………………… 19
ENGINE IDENTIFICATION NUMBER—KOHLER…………………………… 20
ENGINE IDENTIFICATION NUMBER—BRIGGS & STRATTON…………………. 20
ENGINE IDENTIFICATION NUMBER—KAWASAKI…………………………. 20
HYDROSTATIC TRANSAXLE IDENTIFICATION NUMBER……………………. 20
INCH FASTENER TORQUE VALUES………………………………….. 14
ENGINE – KOHLER……………………………………………………. 22
SPECIFICATIONS…………………………………………………. 23
GENERAL SPECIFICATIONS………………………………………. 23
TESTS & ADJUSTMENTS SPECIFICATIONS……………………………. 23
REPAIR SPECIFICATIONS……………………………………….. 24
TORQUE SPECIFICATIONS (Alphabetical)………………………….. 27
SPECIAL OR REQUIRED TOOLS……………………………………. 28
OTHER MATERIALS…………………………………………….. 28
TROUBLESHOOTING………………………………………………… 29
ENGINE TROUBLESHOOTING………………………………………. 31
STARTER MOTOR TROUBLESHOOTING GUIDE…………………………… 35
TESTS AND ADJUSTMENTS…………………………………………… 36
THROTTLE CABLE ADJUSTMENT……………………………………. 36
CHOKE ADJUSTMENT……………………………………………. 36
GOVERNOR ADJUSTMENT…………………………………………. 37
FAST IDLE SPEED ADJUSTMENT…………………………………… 37
SLOW IDLE SPEED ADJUSTMENT…………………………………… 38
CYLINDER LEAK TEST………………………………………….. 38
AUTOMATIC COMPRESSION RELEASE (ACR) CHECK……………………… 40
CRANKCASE VACUUM TEST……………………………………….. 41
FUEL FLOW TEST……………………………………………… 42
OIL PRESSURE TEST…………………………………………… 43
FUEL AND AIR REPAIR…………………………………………….. 45
AIR INTAKE SYSTEM COMPONENTS…………………………………. 45
CARBURETOR REMOVAL AND INSTALLATION…………………………… 45
CARBURETOR INSPECTION……………………………………….. 46
ENGINE REPAIR………………………………………………….. 47
FUEL PUMP REMOVAL AND INSTALLATION……………………………. 47
ENGINE REMOVAL AND INSTALLATION………………………………. 47
ROCKER ARMS REMOVAL AND INSTALLATION………………………….. 50
CYLINDER HEAD REMOVAL AND INSTALLATION………………………… 50
VALVES AND SPRINGS REMOVAL AND INSTALLATION……………………. 51
CYLINDER HEAD INSPECTION…………………………………….. 51
VALVES INSPECTION…………………………………………… 51
VALVE GUIDES INSPECTION……………………………………… 52
VALVE SEATS RECONDITION……………………………………… 53
VALVES LAP…………………………………………………. 53
BREATHER INSPECTION…………………………………………. 53
FLYWHEEL REMOVAL AND INSTALLATION…………………………….. 54
CAMSHAFT REMOVAL AND INSTALLATION…………………………….. 55
CAMSHAFT INSPECTION…………………………………………. 55
CAMSHAFT END PLAY MEASUREMENT………………………………… 56
HYDRAULIC VALVE LIFTERS REMOVAL/INSTALLATION…………………… 56
HYDRAULIC VALVE LIFTERS INSPECTION……………………………. 57
BALANCER SHAFT REMOVAL AND INSTALLATION……………………….. 57
BALANCER SHAFT INSPECTION……………………………………. 58
GOVERNOR REMOVAL AND INSTALLATION…………………………….. 59
GOVERNOR INSPECTION…………………………………………. 59
PISTON ASSEMBLY REMOVAL……………………………………… 60
PISTON ASSEMBLY DISASSEMBLE………………………………….. 60
PISTON INSPECTION…………………………………………… 60
PISTON RING END GAP MEASUREMENT………………………………. 61
PISTON RING SIDE CLEARANCE MEASUREMENT………………………… 61
PISTON ASSEMBLY MEASUREMENT………………………………….. 61
PISTON ASSEMBLY…………………………………………….. 62
PISTON INSTALLATION…………………………………………. 63
CRANKSHAFT REMOVAL AND INSTALLATION…………………………… 63
CRANKSHAFT AND MAIN BEARING INSPECTION………………………… 64
CRANKSHAFT ALIGNMENT………………………………………… 65
OIL PAN REMOVAL AND INSTALLATION……………………………… 65
OIL PAN SEAL REMOVAL AND INSTALLATION…………………………. 66
CRANKCASE OIL SEAL REMOVAL AND INSTALLATION……………………. 66
OIL PICKUP INSPECTION……………………………………….. 66
OIL PUMP RELIEF VALVE INSPECTION……………………………… 67
OIL PUMP REMOVAL AND INSTALLATION…………………………….. 67
CYLINDER BLOCK REMOVAL/ INSTALLATION………………………….. 67
CYLINDER BLOCK INSPECTION……………………………………. 68
CYLINDER BORE DEGLAZING……………………………………… 68
STARTING MOTOR REMOVAL AND INSTALLATION……………………….. 69
STARTING MOTOR DRIVE REPLACEMENT……………………………… 69
ENGINE – BRIGGS & STRATTON………………………………………….. 71
SPECIFICATIONS…………………………………………………. 73
GENERAL SPECIFICATIONS………………………………………. 73
TESTS & ADJUSTMENTS SPECIFICATIONS……………………………. 73
REPAIR SPECIFICATIONS……………………………………….. 73
TORQUE SPECIFICATIONS (Alphabetical)………………………….. 74
TROUBLESHOOTING………………………………………………… 75
ENGINE TROUBLESHOOTING………………………………………. 77
TESTS AND ADJUSTMENTS…………………………………………… 80
THROTTLE CABLE ADJUSTMENT……………………………………. 80
CHOKE CABLE ADJUSTMENT………………………………………. 80
FUEL SHUTOFF SOLENOID TEST…………………………………… 80
COMPRESSION TEST……………………………………………. 81
WITHOUT CYLINDER LEAK TESTER…………………………………. 81
WITH CYLINDER LEAK TESTER……………………………………. 81
GOVERNOR ADJUSTMENT…………………………………………. 83
VALVE CLEARANCE ADJUSTMENT…………………………………… 83
CYLINDER BALANCE TEST……………………………………….. 84
ENGINE OIL PRESSURE TEST…………………………………….. 84
FUEL AND AIR REPAIR…………………………………………….. 85
UPPER BLOWER HOUSING REMOVAL AND INSTALLATION………………….. 85
AIR CLEANER SERVICE…………………………………………. 86
CARBURETOR REMOVAL AND INSTALLATION…………………………… 86
CARBURETOR DISASSEMBLY………………………………………. 88
CARBURETOR INSPECTION……………………………………….. 90
CARBURETOR ASSEMBLY…………………………………………. 91
ENGINE REPAIR………………………………………………….. 93
ENGINE REMOVAL AND INSTALLATION………………………………. 93
CYLINDER AIR GUIDES REMOVAL AND INSTALLATION…………………… 96
INTAKE MANIFOLD REMOVAL AND INSTALLATION………………………. 96
CYLINDER HEAD REMOVAL AND INSTALLATION………………………… 96
CYLINDER HEAD INSPECTION AND REPAIR…………………………… 99
VALVES REMOVAL……………………………………………… 99
VALVES INSPECTION AND REPAIR…………………………………. 99
VALVES REAM…………………………………………………100
VALVES INSTALLATION………………………………………….101
PISTON, RINGS AND ROD REMOVAL AND INSTALLATION………………….101
PISTON INSPECTION……………………………………………102
CONNECTING ROD INSPECTION…………………………………….103
CYLINDER BORE INSPECTION……………………………………..105
CYLINDER BORE HONING…………………………………………105
CYLINDER BORE CLEANING……………………………………….105
RESIZING CYLINDER BORE……………………………………….106
FLYWHEEL REMOVAL AND INSTALLATION……………………………..107
CRANKSHAFT AND CAM GEAR REMOVAL AND INSTALLATION………………..108
MAGNETO BEARING INSPECTION……………………………………110
PTO BEARING REMOVAL AND INSTALLATION…………………………..111
BREATHER VALVE SERVICE……………………………………….112
OIL PUMP REMOVAL AND INSTALLATION……………………………..113
STARTING MOTOR REMOVAL AND INSTALLATION………………………..114
STARTING MOTOR DISASSEMBLY……………………………………114
STARTING MOTOR ASSEMBLY………………………………………116
STARTING MOTOR PINION GEAR REPLACEMENT…………………………118
ENGINE – KAWASAKI…………………………………………………..121
SPECIFICATIONS………………………………………………….123
GENERAL SPECIFICATIONS……………………………………….123
TEST AND ADJUSTMENT SPECIFICATIONS…………………………….123
REPAIR SPECIFICATIONS………………………………………..123
TORQUE SPECIFICATIONS………………………………………..125
SPECIAL OR REQUIRED TOOLS…………………………………….125
OTHER MATERIALS……………………………………………..126
COMPONENT LOCATION………………………………………………127
ENGINE EXTERIOR……………………………………………..127
CARBURETOR COMPONENTS………………………………………..128
ENGINE OIL FLOW CHART………………………………………..129
THEORY OF OPERATION……………………………………………..130
LUBRICATION SYSTEM OPERATION………………………………….130
TROUBLESHOOTING…………………………………………………131
ENGINE & FUEL SYSTEM TROUBLESHOOTING CHART……………………..131
ENGINE TROUBLESHOOTING GUIDE………………………………….133
STARTING MOTOR TROUBLESHOOTING GUIDE…………………………..137
TESTS AND ADJUSTMENTS……………………………………………138
THROTTLE CABLE ADJUSTMENT…………………………………….138
CHOKE CABLE ADJUSTMENT……………………………………….138
CHOKE PLATE CHECK AND ADJUSTMENT………………………………139
GOVERNOR ADJUSTMENT………………………………………….140
SLOW IDLE SPEED ADJUSTMENT……………………………………140
FAST IDLE SPEED ADJUSTMENT……………………………………141
VALVE CLEARANCE, CHECK AND ADJUSTMENT………………………….142
CYLINDER COMPRESSION PRESSURE TEST…………………………….143
CRANKCASE VACUUM TEST………………………………………..144
ENGINE OIL PRESSURE TEST……………………………………..145
FUEL PUMP TEST………………………………………………146
SPARK TEST………………………………………………….146
SPARK PLUG GAP………………………………………………147
REPAIR…………………………………………………………148
ENGINE REMOVAL AND INSTALLATION……………………………….148
AIR CLEANER ASSEMBLY…………………………………………150
CARBURETOR REMOVAL AND INSTALLATION……………………………150
FUEL PUMP REPLACEMENT………………………………………..152
BLOWER HOUSING REMOVAL AND INSTALLATION………………………..153
FLYWHEEL REMOVAL AND INSTALLATION……………………………..153
BREATHER INSPECTION………………………………………….154
ROCKER ARM REMOVAL AND INSTALLATION……………………………154
CYLINDER HEAD REMOVAL AND INSTALLATION…………………………155
CYLINDER HEAD INSPECTION……………………………………..156
RECONDITION VALVE SEATS………………………………………158
LAP VALVES………………………………………………….158
CRANKCASE COVER REMOVAL AND INSTALLATION……………………….159
PISTON AND CONNECTING ROD…………………………………….159
CAMSHAFT AND TAPPETS…………………………………………164
CRANKSHAFT AND MAIN BEARINGS………………………………….165
CRANKSHAFT OIL SEALS…………………………………………166
DEGLAZE CYLINDER BORE………………………………………..167
RESIZE CYLINDER BORE…………………………………………167
OIL PUMP……………………………………………………168
OIL FILTER MANIFOLD………………………………………….169
GOVERNOR INSPECTION AND REPLACEMENT……………………………169
GOVERNOR SHAFT INSPECTION AND REPLACEMENT………………………170
STATOR REMOVAL AND INSTALLATION……………………………….170
ARMATURE REMOVAL AND INSTALLATION……………………………..170
ARMATURE AIR GAP ADJUSTMENT…………………………………..171
STARTING MOTOR………………………………………………171
NO-LOAD AMPERAGE DRAW AND RPM TEST…………………………….173
STARTING SOLENOID TEST……………………………………….173
ELECTRICAL…………………………………………………………175
THEORY OF OPERATION INFORMATION…………………………………..179
DIAGNOSTIC INFORMATION……………………………………….179
WIRE COLOR ABBREVIATION CHART…………………………………179
READING ELECTRICAL SCHEMATICS…………………………………180
COMMON CIRCUIT TESTS…………………………………………181
CONDUCTORS FOR 12 VOLT CIRCUITS……………………………….181
SPECIFICATIONS………………………………………………….182
SCHEMATIC AND WIRING HARNESS LEGEND—LTR155……………………..184
COMPONENT LOCATION—LTR155…………………………………….185
ELECTRICAL SCHEMATIC—LTR155 w/3 AMP CHARGER…………………….186
W1 MAIN WIRING HARNESS—LTR155 w/3 AMP CHARGER…………………..188
ELECTRICAL SCHEMATIC—LTR155 w/15 AMP CHARGER……………………190
W1 MAIN WIRING HARNESS—LTR155 w/15 AMP CHARGER………………….192
ELECTRICAL SCHEMATIC—LTR155 w/4 POSITION KEY SWITCH……………..194
W1 MAIN WIRING HARNESS—LTR155 w/4 POSITION KEY SWITCH……………196
SCHEMATIC AND WIRING HARNESS LEGEND—LTR166……………………..198
COMPONENT LOCATION—LTR166…………………………………….199
ELECTRICAL SCHEMATIC—LTR166…………………………………..200
W1 MAIN WIRING HARNESS—LTR166…………………………………202
ELECTRICAL SCHEMATIC—LTR166 w/4 POSITION KEY SWITCH……………..204
W1 MAIN WIRING HARNESS—LTR166 w/4 POSITION KEY SWITCH……………206
SCHEMATIC AND WIRING HARNESS LEGEND—LTR180……………………..208
COMPONENT LOCATION—LTR180…………………………………….209
ELECTRICAL SCHEMATIC—LTR180…………………………………..210
W1 MAIN WIRING HARNESS—LTR180…………………………………212
W2 ENGINE WIRING HARNESS—LTR155 w/3 AMP CHARGER…………………214
W2 ENGINE WIRING HARNESS—LTR155 w/15 AMP CHARGER………………..214
W3 HEADLIGHT WIRING HARNESS—LTR155…………………………….214
Y1 FUEL SHUTOFF SOLENOID—LTR155 (optional)……………………..214
W2 & W3 ENGINE WIRING HARNESSES—LTR166…………………………215
W4 HEADLIGHT WIRING HARNESS—LTR166…………………………….215
W2 & W3 ENGINE WIRING HARNESSES—LTR180…………………………216
W4 HEADLIGHT WIRING HARNESS—LTR180…………………………….216
TROUBLESHOOTING…………………………………………………217
THEORY OF OPERATION AND DIAGNOSIS…………………………………218
POWER CIRCUIT OPERATION— LTR155 w/3 AMP CHARGER…………………218
POWER CIRCUIT SCHEMATIC—LTR155 w/3 AMP CHARGER………………….219
POWER CIRCUIT DIAGNOSIS—LTR155 w/3 AMP CHARGER………………….220
POWER CIRCUIT OPERATION— LTR155 w/15 AMP CHARGER………………..222
POWER CIRCUIT SCHEMATIC—LTR155 w/15 AMP CHARGER…………………223
POWER CIRCUIT DIAGNOSIS—LTR155 w/15 AMP CHARGER…………………224
POWER CIRCUIT OPERATION— LTR155 w/4 POSITION KEY SWITCH………….226
POWER CIRCUIT SCHEMATIC—LTR155 w/4 POSITION KEY SWITCH…………..227
POWER CIRCUIT DIAGNOSIS—LTR155 w/4 POSITION KEY SWITCH…………..228
POWER CIRCUIT OPERATION— LTR166 & LTR180……………………….230
POWER CIRCUIT SCHEMATIC—LTR166 w/3 POSITION KEY SWITCH…………..231
POWER CIRCUIT SCHEMATIC—LTR166 & 180 w/4 POSITION KEY SWITCH……..231
POWER CIRCUIT DIAGNOSIS—LTR166 & LTR180………………………..232
CRANKING CIRCUIT OPERATION— LTR155 w/3 AMP CHARGER………………234
CRANKING CIRCUIT SCHEMATIC—LTR155 w/3 AMP CHARGER……………….235
CRANKING CIRCUIT DIAGNOSIS—LTR155 w/3 AMP CHARGER……………….236
CRANKING CIRCUIT OPERATION— LTR155 w/15 AMP CHARGER……………..238
CRANKING CIRCUIT SCHEMATIC—LTR155 w/15 AMP CHARGER………………239
CRANKING CIRCUIT DIAGNOSIS—LTR155 w/15 AMP CHARGER………………240
CRANKING CIRCUIT OPERATION— LTR166 & LTR180…………………….242
CRANKING CIRCUIT SCHEMATIC—LTR166 w/3 POSITION KEY SWITCH………..243
CRANKING CIRCUIT SCHEMATIC – LTR166/180 w/4 POSITION KEY SWITCH…..243
CRANKING CIRCUIT DIAGNOSIS—LTR166……………………………..244
IGNITION & SHUTOFF CIRCUIT OPERATION—LTR155…………………….246
IGNITION & SHUTOFF CIRCUIT SCHEMATIC—LTR155 w/3 AMP CHARGER………247
IGNITION & SHUTOFF CIRCUIT DIAGNOSIS—LTR155 w/3 AMP CHARGER………248
IGNITION & SHUTOFF CIRCUIT SCHEMATIC—LTR155 w/15 AMP CHARGER……..250
CIRCUIT DIAGNOSIS—LTR155 w/15 AMP CHARGER………………………251
CIRCUIT SCHEMATIC—LTR155 w/4 POSITION KEY SWITCH………………..253
CIRCUIT DIAGNOSIS—LTR155 w/4 POSITION KEY SWITCH………………..254
IGNITION & SHUTOFF CIRCUIT OPERATION—LTR166 & LTR180…………….256
CIRCUIT SCHEMATIC—LTR166……………………………………..257
CIRCUIT SCHEMATIC—LTR166 & LTR180 w/4 POSITION KEY SWITCH………..258
IGNITION & SHUTOFF CIRCUIT DIAGNOSIS—LTR166 & LTR180…………….259
CHARGING & SHUNT CIRCUIT OPERATION—LTR155 w/3 AMP CHARGER………..262
CIRCUIT SCHEMATIC—LTR155 w/3 AMP CHARGER……………………….263
CHARGING & SHUNT CIRCUIT DIAGNOSIS—LTR155 w/3 AMP CHARGER………..264
CHARGING & SHUNT CIRCUIT OPERATION—LTR155 w/15 AMP CHARGER……….266
CIRCUIT SCHEMATIC—LTR155 w/15 AMP CHARGER………………………267
CHARGING & SHUNT CIRCUIT DIAGNOSIS—LTR155 w/15 AMP CHARGER……….268
CHARGING & SHUNT OPERATION— LTR155 w/4 POSITION KEY SWITCH……….270
CHARGING & SHUNT SCHEMATIC—LTR155 w/4 POSITION KEY SWITCH………..271
CHARGING & SHUNT DIAGNOSIS—LTR155 w/4 POSITION KEY SWITCH………..272
CHARGING CIRCUIT OPERATION— LTR166…………………………….274
CHARGING CIRCUIT SCHEMATIC—LTR166 & LTR180……………………..275
CHARGING CIRCUIT DIAGNOSIS—LTR166……………………………..276
CHARGING CIRCUIT DIAGNOSIS—LTR180……………………………..276
PTO with RIO CIRCUIT OPERATION—LTR155………………………….278
PTO with RIO CIRCUIT SCHEMATIC—LTR155 w/3 AMP CHARGER……………279
PTO with RIO CIRCUIT SCHEMATIC—LTR155 w/15 AMP CHARGER…………..280
PTO with RIO CIRCUIT SCHEMATIC—LTR155 w/4 POSITION KEY SWITCH…….281
PTO with RIO CIRCUIT DIAGNOSIS—LTR155………………………….282
PTO with RIO CIRCUIT OPERATION—LTR166 w/3 POSITION KEY SWITCH…….284
PTO with RIO CIRCUIT SCHEMATIC—LTR166 w/3 POSITION KEY SWITCH…….285
PTO with RIO CIRCUIT DIAGNOSIS—LTR166w/3 POSITION KEY SWITCH……..286
PTO w/ RIO CIRCUIT OPERATION— LTR166/180 w/4 POSITION KEY SWITCH….288
PTO w/RIO CIRCUIT SCHEMATIC – LTR166/180 w/4 POSITION KEY SWITCH….289
PTO w/RIO CIRCUIT DIAGNOSIS—LTR166/180 w/4 POSITION KEY SWITCH……290
GRASS COLLECTION SYSTEM (GCS) CIRCUIT OPERATION— LTR155………….292
GCS CIRCUIT SCHEMATIC—LTR155 w/3 AMP CHARGER……………………293
(GCS) CIRCUIT DIAGNOSIS—LTR155 w/3 AMP CHARGER………………….294
GRASS COLLECTION SYSTEM OPERATION—LTR155 w/15 AMP CHARGER………..296
GRASS COLLECTION SYSTEM SCHEMATIC LTR—155 w/15 AMP CHARGER……….297
GRASS COLLECTION SYSTEM DIAGNOSIS—LTR155 w/15 AMP CHARGER………..298
GCS CIRCUIT OPERATION—LTR155 w/4 POSITION KEY SWITCH…………….300
GCS CIRCUIT SCHEMATIC—LTR 155 w/4 POSITION KEY SWITCH……………301
GCS CIRCUIT DIAGNOSIS—LTR155 w/4 POSITION KEY SWITCH…………….302
GRASS COLLECTION SYSTEM (GCS) CIRCUIT OPERATION— LTR166 & LTR180….304
GRASS COLLECTION SYSTEM (GCS) CIRCUIT SCHEMATIC—LTR166/180……….305
GRASS COLLECTION SYSTEM (GCS) CIRCUIT DIAGNOSIS—LTR166/180……….306
HEADLIGHT CIRCUIT OPERATION— LTR155 w/3 AMP CHARGER……………..308
LTR155 w/15 AMP CHARGER………………………………………308
LTR155 w/15 AMP CHARGER and 4 POSITION KEY SWITCH……………….308
W3 HEADLIGHT CIRCUIT SCHEMATIC—LTR155 w/3 AMP CHARGER……………309
LTR155 w/15 AMP CHARGER………………………………………309
LTR155 w/15 AMP CHARGER and 4 POSITION KEY SWITCH……………….309
HEADLIGHT CIRCUIT OPERATION— LTR166……………………………310
LTR166/180 w/4 POSITION KEY SWITCH…………………………….310
W4 HEADLIGHT CIRCUIT SCHEMATIC—LTR166………………………….311
LTR166/180 w/4 POSITION KEY SWITCH…………………………….311
HEADLIGHT WIRING HARNESS—LTR155/LTR166/LTR180…………………..311
HEADLIGHT CIRCUIT DIAGNOSIS—LTR155/LTR166/LTR180………………..312
TESTS AND ADJUSTMENTS……………………………………………314
GROUND CIRCUIT TESTS…………………………………………314
BATTERY VOLTAGE AND SPECIFIC GRAVITY TESTS……………………..314
BATTERY—LOAD TEST……………………………………………315
BATTERY—CHARGE………………………………………………315
STARTING MOTOR SOLENOID TEST………………………………….316
STARTING MOTOR AMPERAGE DRAW—NO-LOAD…………………………..317
STARTING MOTOR AMPERAGE DRAW—LOADED……………………………318
REGULATED AMPERAGE TEST………………………………………319
REGULATED VOLTAGE TEST……………………………………….319
FLYWHEEL MAGNET TEST…………………………………………320
ALTERNATOR DC OUTPUT TEST— LTR155 w/3 AMP CHARGER……………….320
STATOR OUTPUT TEST w/15 AMP CHARGER……………………………321
ALTERNATOR DIODE TEST— LTR155 w/3 AMP CHARGER…………………..321
ALTERNATOR DC OUTPUT TEST— LTR166……………………………..322
ALTERNATOR DIODE TEST— LTR166…………………………………322
VOLTAGE REGULATOR/RECTIFIER TEST—LTR155 w/15 AMP CHARGER…………323
VOLTAGE REGULATOR/RECTIFIER TEST—LTR180 w/13 AMP CHARGER…………323
DIODE TEST………………………………………………….324
RELAY TEST………………………………………………….324
3 POSITION KEY SWITCH TEST……………………………………325
4 POSITION KEY SWITCH TEST……………………………………325
BRAKE AND RIO SWITCH TEST…………………………………….326
PTO SWITCH TEST……………………………………………..326
RIS SWITCH TEST……………………………………………..327
SEAT SWITCH TEST…………………………………………….327
SEAT SWITCH TEST (USED W/4 POSITION KEY SWITCH)…………………328
GCS BAG IN PLACE SWITCH TEST………………………………….328
GCS BAG FULL SWITCH TEST……………………………………..329
GCS ENABLE SWITCH TEST……………………………………….329
GCS BAG FULL ALARM TEST………………………………………330
FUEL SHUTOFF SOLENOID TEST……………………………………330
SPARK TEST………………………………………………….330
IGNITION DIODE TEST (LTR166)………………………………….331
REPAIR…………………………………………………………332
RIO SWITCH ADJUSTMENT………………………………………..332
STATOR & IGNITION MODULE REMOVAL AND INSTALLATION— LTR155………..333
STARTING MOTOR REMOVAL AND INSTALLATION—LTR155………………….334
STARTING MOTOR DRIVE REPLACEMENT—LTR155………………………..334
BRUSH REPLACEMENT AND ARMATURE TEST—LTR155……………………..335
STATOR AND IGNITION MODULE REMOVAL AND INSTALLATION— LTR166………337
STARTING MOTOR REMOVAL AND INSTALLATION—LTR166………………….338
STARTING MOTOR DISASSEMBLY— LTR166…………………………….338
STARTING MOTOR ASSEMBLY— LTR166……………………………….340
STARTING MOTOR PINION GEAR REPLACEMENT—LTR166…………………..342
POWER TRAIN – HYDROSTATIC……………………………………………345
SPECIFICATIONS………………………………………………….347
TORQUE SPECIFICATIONS………………………………………..347
COMPONENT LOCATION………………………………………………348
DRIVE COMPONENTS…………………………………………….348
BRAKE PEDAL AND LINKAGE………………………………………350
FORWARD AND REVERSE PEDALS AND LINKAGE…………………………351
THEORY OF OPERATION……………………………………………..352
TRACTION DRIVE BELT SYSTEM……………………………………352
TRANSAXLE…………………………………………………..352
FORWARD AND REVERSE PEDALS……………………………………352
FREEWHEEL SYSTEM…………………………………………….354
BRAKE SYSTEM………………………………………………..354
TROUBLESHOOTING…………………………………………………356
DIAGNOSTICS…………………………………………………….358
TESTS AND ADJUSTMENTS……………………………………………359
TRACTION DRIVE SYSTEM TEST……………………………………359
BRAKE LINKAGE ADJUSTMENT……………………………………..359
DRIVE BELT TENSION ADJUSTMENT…………………………………360
NEUTRAL CREEP ADJUSTMENT……………………………………..360
FORWARD AND REVERSE PEDAL ADJUSTMENT…………………………..361
TRANSPORT (FREEWHEEL) TEST……………………………………361
REPAIR…………………………………………………………362
TRANSAXLE REMOVAL AND INSTALLATION…………………………….362
TRACTION DRIVE BELT REMOVAL AND INSTALLATION……………………364
TRACTION DRIVE BELT TENSIONER ASSEMBLY…………………………366
CONTROL PEDALS AND LINKAGE……………………………………367
CROSS SHAFT ASSEMBLY…………………………………………370
SHOCK ABSORBER REMOVAL AND INSTALLATION………………………..371
BRAKE PEDAL AND LINKAGE………………………………………371
STEERING…………………………………………………………..375
SPECIFICATIONS………………………………………………….377
TORQUE SPECIFICATIONS………………………………………..377
COMPONENT LOCATION………………………………………………378
REPAIR…………………………………………………………379
STEERING GEAR ASSEMBLY REMOVAL AND INSTALLATION…………………379
FRONT AXLE REMOVAL AND INSTALLATION……………………………380
ATTACHMENTS………………………………………………………..383
SPECIFICATIONS………………………………………………….385
COMPONENT LOCATION………………………………………………386
MOWER DECK (S/N –020000)……………………………………..386
MOWER DECK PTO LINKAGE……………………………………….387
GRASS COLLECTOR MOUNTING HARDWARE……………………………..388
GRASS COLLECTOR BUCKET……………………………………….389
MOWER DECK LIFT LINKAGE—LTR155/166…………………………….390
MOWER DECK LIFT LINKAGE—LTR180………………………………..391
TROUBLESHOOTING…………………………………………………392
DIAGNOSTICS…………………………………………………….393
BLADES WILL NOT ROTATE……………………………………….393
DRIVE BELT SLIPS…………………………………………….394
DRIVE BELT WILL NOT STAY ON SHEAVES……………………………395
VIBRATION…………………………………………………..396
UNEVEN CUTTING OR STRIPING……………………………………397
TESTS AND ADJUSTMENTS……………………………………………398
DECK LEVELING……………………………………………….398
MOWER BLADE TIMING BELT ADJUSTMENT…………………………….399
BLADE BRAKE ADJUSTMENT……………………………………….401
MOWER DRIVE BELT TENSION ADJUSTMENT……………………………402
FILL SENSOR ADJUSTMENT……………………………………….403
GRASS COLLECTOR LATCHING ADJUSTMENT……………………………404
REPAIR…………………………………………………………404
MOWER DECK REMOVAL AND INSTALLATION—LTR155/166………………….404
MOWER DECK REMOVAL AND INSTALLATION—LTR180……………………..405
MOWER DRIVE BELT REMOVAL AND INSTALLATION—LTR155/166…………….405
MOWER DRIVE BELT REMOVAL AND INSTALLATION—LTR180………………..406
SPINDLES REMOVAL AND INSTALLATION……………………………..406
MOWER BLADE TIMING BELT REMOVAL AND INSTALLATION………………..408
BLADE BRAKE REMOVAL AND INSTALLATION…………………………..411
MOWER BLADE REMOVAL AND INSTALLATION…………………………..412
MOWER DECK LIFT LINKAGE REMOVAL/INSTALLATION—LTR155/ 166…………412
MOWER DECK LIFT LINKAGE REMOVAL/INSTALLATION—LTR180……………..415
GRASS COLLECTOR REMOVAL AND INSTALLATION……………………….418
MISCELLANEOUS………………………………………………………421
SPECIFICATIONS………………………………………………….423
TESTS AND ADJUSTMENTS……………………………………………424
TIRE PRESSURE ADJUSTMENT……………………………………..424
REPAIR…………………………………………………………424
FRONT WHEEL REMOVAL AND INSTALLATION…………………………..424
FRONT WHEEL BEARING REPAIR……………………………………425
REAR WHEEL REMOVAL/ INSTALLATION………………………………425
FUEL TANK REMOVAL AND INSTALLATION…………………………….426
HOOD REMOVAL AND INSTALLATION…………………………………426
SEAT AND SUPPORT REMOVAL AND INSTALLATION………………………427
INDEX……………………………………………………………..429
B……………………………………………………………..429
C……………………………………………………………..429
D……………………………………………………………..430
E……………………………………………………………..430
F……………………………………………………………..431
G……………………………………………………………..431
H……………………………………………………………..432
I……………………………………………………………..432
K……………………………………………………………..432
L……………………………………………………………..433
M……………………………………………………………..433
P……………………………………………………………..434
R……………………………………………………………..434
S……………………………………………………………..434
T……………………………………………………………..434

IMAGES PREVIEW OF THE MANUAL:

JOHN DEERE LAWN TRACTORS LTR155 LTR166 & LTR180 LAWN TRACTORS TECHNICAL MANUAL – PDF DOWNLOAD:

PLEASE NOTE:

• This is not a physical manual but a digital manual – meaning no physical copy will be couriered to you. The manual can be yours in the next 2 mins as once you make the payment, you will be directed to the download page IMMEDIATELY.
• This is the same manual used by the dealersinorder to diagnose your vehicle of its faults.
• Require some other service manual or have any queries: please WRITE to us at [email protected]

S.V