Boss Amp 250n Manual Lawn
JOHN DEERE WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION Lawn Tractors LTR155, LTR166 and LTR180 OMTM1768 FEBRUARY 2002 TECHNICAL MANUAL Litho in U.S.A. North American Version Litho in U.S.A. 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. Safety Specifications and Information Kohler Engine Briggs & Stratton Engine Kawasaki Engine Electrical Power Train (Hydrostatic) Steering 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 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. 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. Attachments All information, illustrations and specifications in this manual are based on the latest information available at the time of publication.
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The right is reserved to make changes at any time without notice. Miscellaneous COPYRIGHT© 2002 Deere and Co. John Deere Worldwide Commercial and Consumer Equipment Division Horicon, WI All rights reserved 3/6/02 1-1 SAFETY SAFETY RECOGNIZE SAFETY INFORMATION HANDLE FLUIDS SAFELY-AVOID FIRES BE PREPARED FOR EMERGENCIES 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 identifies the most serious hazards. Danger or Warning safety signs are located near specific hazards. CAUTION safety signs are used where general precautions should be used.
CAUTION also calls attention to safety messages in this manual. When you work around fuel, do not smoke or work near heaters or other fire hazards.
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Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
Boss Amp 250n Manual Lawn Mower
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. REPLACE SAFETY SIGNS Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement. 1-2 3/6/02 SAFETY USE CARE IN HANDLING AND SERVICING BATTERIES USE SAFE SERVICE PROCEDURES WEAR PROTECTIVE CLOTHING PREVENT BATTERY EXPLOSIONS. Keep sparks, lighted matches, and open flame away from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer. Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F). 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. PREVENT ACID BURNS. Sulfuric acid in battery electrolyte is poisonous.
It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes. Avoid acid burns by: 1. Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added.
Avoiding spilling or dripping electrolyte. Use proper jump start procedure. If you spill acid on yourself: 1. Flush your skin with water. Apply baking soda or lime to help neutralize the acid. Flush your eyes with water for 1015 minutes. Get medical attention immediately.
If acid is swallowed: 1. Drink large amounts of water or milk. Then drink milk of magnesia, beaten eggs, or vegetable oil. Get medical attention immediately.
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.
3/6/02 1-3 SAFETY PARK MACHINE SAFELY USING HIGH PRESSURE WASHERS Directing pressurized water at electronic/electrical components or connectors, bearings, hydraulic seals, fuel injection pumps or other sensitive parts and components may cause product malfunctions. Reduce pressure and spray at a 45 to 90 degree angle. 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.
Before working on the machine: 1. Lower all equipment to the ground. Stop the engine and remove the key.
Disconnect the battery ground strap. Hang a “DO NOT OPERATE” tag in operator station. WORK IN VENTILATED AREA SUPPORT MACHINE PROPERLY AND USE PROPER LIFTING EQUIPMENT 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. 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. 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. WORK IN CLEAN AREA Before starting a job: 1. Clean work area and machine.
Make sure you have all necessary tools to do your job. Have the right parts on hand. Read all instructions thoroughly; do not attempt shortcuts.
1-4 3/6/02 SAFETY 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.
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. SERVICE TIRES SAFELY HANDLE CHEMICAL PRODUCTS 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. 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. 3/6/02 1-5 SAFETY 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. 1-6 3/6/02 SPECIFICATIONS AND INFORMATION CONTENTS CONTENTS Page SPECIFICATIONS GENERAL VEHICLE SPECIFICATIONS. 3 KOHLER ENGINE—LTR155.
3 BRIGGS & STRATTON ENGINE—LTR166. 3 KAWASAKI ENGINE—LTR180.
3 ELECTRICAL. 4 HYDROSTATIC TRANSAXLE. 4 PTO DRIVE.
4 STEERING. 4 IMPLEMENT LIFT. 4 TIRES. 4 DIMENSIONS.
4 REAR DISCHARGE MOWER DECK. 4 DRAWBAR LOAD.
4 GRASS COLLECTION SYSTEM. 4 TORQUE SPECIFICATIONS. 5 METRIC FASTENER TORQUE VALUES. 5 INCH FASTENER TORQUE VALUES. 6 FUEL AND OIL SPECIFICATIONS. 7 GASOLINE.
7 GASOLINE STORAGE— NORTH AMERICA. 7 ENGINE OIL. 8 ENGINE BREAK–IN OIL. 8 LUBRICANT SPECIFICATIONS. 9 ANTI-CORROSION GREASE. 9 ALTERNATIVE LUBRICANTS.
10 SYNTHETIC LUBRICANTS. 10 LUBRICANT STORAGE. 10 MIXING OF LUBRICANTS.
10 CHASSIS GREASE. 10 HYDROSTATIC TRANSMISSION OIL. 11 PRODUCT IDENTIFICATION LOCATIONS.
11 PRODUCT IDENTIFICATION NUMBER (PIN). 11 ENGINE IDENTIFICATION NUMBER—KOHLER. 12 ENGINE IDENTIFICATION NUMBER—BRIGGS & STRATTON. 12 ENGINE IDENTIFICATION NUMBER—KAWASAKI. 12 HYDROSTATIC TRANSAXLE IDENTIFICATION NUMBER.
12 3/6/02 2-1 NOTES SPECIFICATIONS AND INFORMATION 2-2 3/6/02 SPECIFICATIONS & INFORMATION GENERAL VEHICLE SPECIFICATIONS GENERAL VEHICLE SPECIFICATIONS KOHLER ENGINE—LTR155 Make. Kohler Model / Model Number.
Command 15 QT / CV15S-41562 Power. 11.2 kW (15.0 hp) Displacement.426 cm3 (26.0 cu-in.) Cylinders. 1 Stroke/Cycle. 4 Valves. Overhead Valves Lubrication.Pressurized Gerotor Pump 0 – 413 kPa (0 – 60 psi) Oil Filter. Single Element, Full Flow, Spin-On Filter Crankcase Capacity (With Filter). 1.8 L (1.9 U.S.
Oz) Without Filter. 1.4 L (1.5 U.S. Oz) Cooling System. Air Cooled Air Cleaner. Paper with outer foam element Muffler. Horizontal discharge below frame BRIGGS & STRATTON ENGINE—LTR166 Make. Briggs & Stratton Series.
Vanguard V-Twin Type. 916928 Gasoline Model.
Boss Amp 250n Manual Lawn Tractor
303777 Horsepower. 11.94 kW (16.0 hp) Displacement.
480 cm3 (29.3 cu. In.) Cylinders. 2 Stroke/Cycle. 4 Valves. Overhead Valves Lubrication.
Pressurized 0 – 344 kPa (10 – 50 psi) Oil Filter. Full Flow Filter (w/o By-Pass Valve) Crankcase Capacity (With Filter).
1.5 L (1.6 U.S. Oz) Without Filter. 1.4 L (1.5 U.S. Oz) Cooling System. Air Cooled Air Cleaner. Paper with outer foam element Muffler. Horizontal discharge below frame KAWASAKI ENGINE—LTR180 Make.
Kawasaki Model. FH500V-AS32 V-Twin Horsepower. 12.7 kW (17.0 hp) Displacement.
494 cm3 (30.0 cu. In.) Cylinders. 2 Stroke/Cycle.
4 Valves. Overhead Valves Lubrication.
Pressurized Oil Filter. Single Element, Full Flow, Spin-On Filter Crankcase Capacity (With Filter).
1.7 L (1.8 U.S. Oz) Without Filter. 1.5 L (1.6 U.S. Oz) Cooling System. Air Cooled Air Cleaner.
Boss Amp 250n Manual Lawn Equipment
Paper with outer foam element Muffler. Horizontal discharge below frame 3/6/02 2-3 GENERAL VEHICLE SPECIFICATIONS SPECIFICATIONS & INFORMATION FUEL SYSTEM Aspiration.Natural Fuel Tank Location.Rear Fuel Tank Capacity.
6.0 L (1.6 U.S. Gal) Fuel Type (minimum octane). Unleaded Gasoline, 87 Octane Fuel Delivery. Float-Type Side Draft CArburetor Fuel Filter. Replaceable In-Line ELECTRICAL Ignition.Electronic Capacitor Discharge Ignition (CDI) Type of Starter.
Bendix Charging System. Flywheel Alternator Voltage. 12 BCI group.U-1 CCA rating (Amps At -18°C (0°F). 160 Reserve capacity (Minutes At 25 Amps). 20 Specific gravity (Minimum).1.225 points Electrolyte required fill (Approximate).
1.9 L (2.0 qt) Load test (Minimum). 255 amp for 15 seconds HYDROSTATIC TRANSAXLE Drive Train. Belt Drive Transaxle with foot-controlled variable speed drive Model.Tuff Torq® K46 Transaxle Travel Speed-Forward.
0 – 8.0 km/h (0 – 5.0 mph) Travel Speed-Reverse. 0 – 4.7 km/h (0 – 2.9 mph) Brake type.Single, Internal Wet Disc Brake PTO DRIVE Type. V-Belt Clutch Type. Mechanical Control. Lever on Dash STEERING Type.
Sector and Pinion Turning Radius. 38.1 cm (15 in.) IMPLEMENT LIFT Lift System.Manual Lift Lever Location. Left Side TIRES Size-Front. 15x6.00-6 Size-Rear. 20x10.00-8 Pressure-Front (with mower). 83 kPa (12 psi) Pressure-Rear (with mower). 55 kPa (8 psi) DIMENSIONS Wheelbase.
120 cm (47.2 in.) Overall Length. 197.7 cm (77.8 in.) With Grass Collector. 241.5 cm (95.1 in.) Overall Width (without mower). 92 cm (36.2 in.) Overall Height. 103 cm (40.6 in.) Net Weight (Approx.).