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John Deere LTR155 LTR166 LTR180 Lawn Garden Tractor Service
John Deere LTR155 LTR166 LTR180 Lawn Garden Tractor Service Repair Manual – PDF Download
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Description
John Deere LTR155 LTR166 LTR180 Lawn Garden Tractor Service
Repair Manual
FILE DETAILS:
John Deere LTR155 LTR166 LTR180 Lawn Garden Tractor Service Repair Manual
LANGUAGE:ENGLISH
PAGES:436
DOWNLOADABLE:YES
FILE TYPE:PDF
JOHN DEERE LTR155 LTR166 LTR180 LAWN GARDEN TRACTOR SERVICE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere LTR155 LTR166 LTR180 Lawn Garden Tractor Service Repair Manual
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 LTR155 LTR166 LTR180 Lawn Garden Tractor Service Repair Manual
JOHN DEERE MODELS LTR155 LTR166 LTR180 LAWN AND GARDEN TRACTORS................. 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 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
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1 review for John Deere LTR155 LTR166 LTR180 Lawn Garden Tractor Service Repair Manual – PDF Download
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Ian Marlon –
Great product and service!