Trusted Business
Verified & Licensed
Virus Free Files
100% Safe Downloads
Secure Payment
SSL Protected
Instant Delivery
Available Immediately
Sale!
John Deere Gator 4×2 4×6 Utility Vehicle Repair Manual – PDF DOWNLOAD
Original price was: $49.95.$22.95Current price is: $22.95.
Model Gator 4×2 4×6 Utility Vehicle Repair Manual
Instant PDF Download
Available immediately
Save to Your Device
Download & keep forever
Antivirus Scanned
100% virus-free
Trusted Worldwide
175,000+ customers
Description
John Deere Gator 4×2 4×6 Utility Vehicle Repair Manual
FILE DETAILS:
John Deere Gator 4×2 4×6 Utility Vehicle Repair Manual – PDF DOWNLOAD
LANGUAGE:ENGLISH
PAGES:692
DOWNLOADABLE:YES
FILE TYPE:PDF
JOHN DEERE GATOR 4X2 4X6 UTILITY VEHICLE REPAIR MANUAL – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
John Deere Gator 4×2 4×6 Utility Vehicle Repair Manual
Manual Description
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 and Information
• Identification Numbers
• Tools and Materials
• Component Location
• Schematics and Harnesses
• Theory of Operation
• Operation and Diagnostics
• Diagnostics
• Tests and Adjustments
• Repair
• Other
Synthetic Lubricants
Synthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements (industry classification and/or military specification) as shown in this manual. The recommended air temperature limits and service or lubricant change intervals should be maintained as shown in the operator’s manual, unless otherwise stated on lubricant label. Avoid mixing different brands, grades, or types of oil. Oil manufacturers blend additives in their oils to meet certain specifications and performance requirements. Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance.
Lubricant Storage
All machines operate at top efficiency only when clean lubricants are used. Use clean storage containers to handle all lubricants. Store them in an area protected from dust, moisture, and other contamination. Store drums on their sides. Make sure all containers are properly marked as to their contents. Dispose of all old, used containers and their contents properly.
Mixing of Lubricants
In general, avoid mixing different brands or types of lubricants. Manufacturers blend additives in their lubricants to meet certain specifications and performance requirements. Mixing different lubricants can interfere with the proper functioning of these additives and lubricant properties which will downgrade their intended specified performance.
TABLE OF CONTENTS:
John Deere Gator 4×2 4×6 Utility Vehicle Repair Manual
JOHN DEER GATOR 4X2 4X6 UTILITY VEHICLES.................................................... 1 INTRODUCTION............................................................................ 3 SAFETY.................................................................................. 5 Recognize Safety Information........................................................ 5 Understand Signal Words............................................................. 5 Replace Safety Signs................................................................ 5 Handle Fluids Safely - Avoid Fires.................................................. 5 Use Care In Handling and Servicing Batteries........................................ 5 Prevent Battery Explosions.......................................................... 6 Prevent Acid Burns.................................................................. 6 Wear Protective Clothing............................................................ 6 Use Care Around High-pressure Fluid Lines........................................... 6 Service Machines Safely............................................................. 7 Use Proper Tools.................................................................... 7 Park Machine Safely................................................................. 7 Support Machine Properly and Use Proper Lifting Equipment........................... 7 Work In Clean Area.................................................................. 7 Using High Pressure Washers......................................................... 7 Illuminate Work Area Safely......................................................... 7 Work In Ventilated Area............................................................. 8 Warning: California Proposition 65 Warning.......................................... 8 Remove Paint Before Welding or Heating.............................................. 8 Avoid Harmful Asbestos Dust......................................................... 8 Service Tires Safely................................................................ 8 Avoid Injury From Rotating Blades, Augers and PTO Shafts............................ 9 Service Cooling System Safely....................................................... 9 Handle Chemical Products Safely..................................................... 9 Dispose of Waste Properly........................................................... 9 Live With Safety.................................................................... 9 SPECIFICATIONS & INFORMATION............................................................ 11 Table of Contents................................................................... 11 Fastener Torques.................................................................... 13 Metric Fastener Torque Values................................................... 13 Inch Fastener Torque Values..................................................... 14 O-Ring Seal Service Recommendations................................................. 15 Face Seal Fittings With Inch Stud Ends Torque................................... 15 Face Seal Fittings With Metric Stud Ends Torque................................. 16 O-Ring Face Seal Fittings....................................................... 17 O-Ring Boss Fittings............................................................ 17 Straight Fitting Or Special Nut Torques......................................... 18 Metric Fastener Torque Value - Grade 7 (Special)................................ 18 General Information................................................................. 18 Gasoline........................................................................ 18 Gasoline Storage................................................................ 19 4 - Cycle Gasoline Engine Oil................................................... 19 Diesel Fuel..................................................................... 20 Diesel Fuel Lubricity........................................................... 20 Diesel Fuel Storage............................................................. 20 Break-In Engine Oil - 4-Cycle Gasoline.......................................... 20 4 - Cycle Diesel Engine Oil..................................................... 21 Break-In Engine Oil - Diesel.................................................... 21 Hydrostatic Transmission and Hydraulic Oil...................................... 22 Gear Case Oil................................................................... 23 Gear Transmission Grease........................................................ 23 Alternative Lubricants.......................................................... 23 Synthetic Lubricants............................................................ 24 Lubricant Storage............................................................... 24 Mixing of Lubricants............................................................ 24 Oil Filters..................................................................... 24 Coolant Specifications.............................................................. 24 Gasoline Engine Coolant......................................................... 24 Gasoline Engine Coolant Drain Interval.......................................... 25 Diesel Engine Coolant........................................................... 25 Diesel Engine Coolant Drain Interval............................................ 26 Serial Number Locations............................................................. 26 Product Serial Number........................................................... 26 Engine (FE290D) Serial Number Location.......................................... 26 Engine (FE620D) Serial Number Location.......................................... 27 Engine (3TN66C) Serial Number Location.......................................... 27 Transaxle Serial Number Location................................................ 27 ENGINE - GAS (AIR-COOLED)............................................................... 29 Table of Contents................................................................... 29 Specifications...................................................................... 31 General Specifications.......................................................... 31 Test and Adjustment Specifications.............................................. 31 Repair Specifications........................................................... 32 Special or Essential Tools...................................................... 35 Other Materials................................................................. 35 Component Location.................................................................. 36 FE290D Engine................................................................... 36 Carburetor Components........................................................... 37 Starter Motor Components........................................................ 39 Diagnostics......................................................................... 40 Engine Troubleshooting Guide.................................................... 40 Starting Motor Troubleshooting Guide............................................ 41 Tests and Adjustments............................................................... 42 Governor Adjustment............................................................. 42 Choke Cable Adjustment.......................................................... 42 Slow Idle Mixture Screw and Speed Adjustments................................... 43 Fast Idle Speed Adjustment...................................................... 44 Throttle Cable Adjustment....................................................... 45 Pedal Stop Adjustment........................................................... 46 Fuel Pump Pressure Test......................................................... 46 Fuel Pump Flow Test............................................................. 47 Fuel Tank Gauge Test............................................................ 47 Fuel Tank Check Valve Test...................................................... 48 Cylinder Compression Test....................................................... 48 Valve Clearance Adjustment...................................................... 49 Automatic Compression Release (A.C.R.) Test..................................... 50 Crankcase Vacuum Test........................................................... 50 Oil Pressure Test............................................................... 51 Alternator Drive Belt Adjustment................................................ 52 Air Intake System Check......................................................... 53 Repair.............................................................................. 54 Muffler Removal and Installation................................................ 54 Engine Removal and Installation................................................. 54 Carburetor Removal and Installation............................................. 55 Carburetor Disassembly and Assembly............................................. 56 Crankcase Breather Inspection................................................... 56 Blower Housing Removal and Installation......................................... 57 Flywheel Removal and Installation............................................... 57 Rocker Arm Removal and Installation............................................. 58 Rocker Arm Inspection........................................................... 58 Cylinder Head Removal and Installation.......................................... 58 Cylinder Head Disassembly and Assembly.......................................... 59 Cylinder Head Inspection and Replacement........................................ 59 Recondition Valve Seats......................................................... 61 Lap Valves...................................................................... 62 Crankcase Cover Removal and Installation........................................ 62 Camshaft Removal and Installation............................................... 62 Camshaft Inspection............................................................. 63 Automatic Compression Release................................................... 64 Tappets Inspection and Replacement.............................................. 64 Piston and Connecting Rod....................................................... 64 Reciprocating Balancer.......................................................... 67 Crankshaft Removal and Installation............................................. 68 Crankshaft Inspection........................................................... 68 Crankshaft End Play Check....................................................... 69 Analyze Crankshaft and Connecting Rod Wear...................................... 69 Crankshaft End Play Adjustment.................................................. 69 Crankshaft Oil Seal - Flywheel End Replacement.................................. 70 Crankshaft Oil Seal - PTO End Replacement....................................... 70 Governor Shaft Oil Seal Replacement............................................. 70 Cylinder Block Inspection....................................................... 70 Cylinder Deglazing.............................................................. 71 Cylinder Reboring............................................................... 71 Oil Pump Disassembly and Assembly............................................... 72 Oil Pump Inspection............................................................. 72 Oil Filter Manifold Removal and Installation.................................... 73 Governor Inspection and Replacement............................................. 74 Governor Shaft Inspection and Replacement....................................... 74 Armature With Coil Removal and Installation..................................... 74 Ignitor Replacement............................................................. 75 Stator Removal and Installation................................................. 75 Starting Motor.................................................................. 75 Recoil Starter Disassembly and Assembly......................................... 77 Recoil Starter Spring Replacement............................................... 77 ENGINE - GAS (LIQUID-COOLED)............................................................ 79 Table of Contents................................................................... 79 Specifications...................................................................... 81 General Specifications.......................................................... 81 Test and Adjustment Specifications.............................................. 81 Repair Specifications........................................................... 82 Special or Essential Tools...................................................... 85 Other Materials................................................................. 85 Component Location.................................................................. 86 Engine Component Location....................................................... 86 Starting Motor.................................................................. 87 Diagnostics......................................................................... 88 Engine Troubleshooting Guide.................................................... 88 Starting Motor Troubleshooting Guide............................................ 89 Tests and Adjustments............................................................... 90 Governor Adjustment (FD620D-AS11)............................................... 90 Model: FD620D-AS11.......................................................... 90 (Chassis S/N 001001 - 014949)............................................... 90 Governor Adjustment (FD620D-BS11 - FS11)........................................ 90 Model: FD620D-BS11 - FS11................................................... 90 (Chassis S/N 014950 - 043829)............................................... 90 Governor Adjustment (FD620D-GS11 - HS11)........................................ 91 Model: FD620D-GS11 - HS11................................................... 91 (Chassis S/N 043830- )...................................................... 91 Fast Idle Speed Adjustment (FD620D-AS11)........................................ 92 Model: FD620D-AS11.......................................................... 92 (Chassis S/N 001001 - 014949)............................................... 92 Fast Idle Speed Adjustment (FD620D-BS11 - )..................................... 93 Model: FD620D-BS11 -........................................................ 93 (Chassis S/N 014950- )...................................................... 93 Slow Idle Mixture and Speed Adjustments (FD620D-AS11)........................... 94 Model: FD620D-AS11.......................................................... 94 (Chassis S/N 001001 - 014949)............................................... 94 Slow Idle Mixture and Speed Adjustments (FD620D-BS11 - )........................ 95 Model: FD620D-BS11 -........................................................ 95 (Chassis S/N 014950- )...................................................... 95 Choke Cable Adjustment.......................................................... 96 Throttle Cable Adjustment (FD620D-AS11)......................................... 97 Model: FD620D-AS11.......................................................... 97 (Chassis S/N 001001 - 014949)............................................... 97 Throttle Cable Adjustment (FD620D-BS11 - )...................................... 98 Model: FD620D-BS11 -........................................................ 98 (Chassis S/N 014950- )...................................................... 98 Pedal Stop Adjustment (FD620D-AS11)............................................. 99 Model: FD620D-AS11.......................................................... 99 (Chassis S/N 001001 - 014949)............................................... 99 Pedal Stop Adjustment (FD620D-BS11 - ).......................................... 99 Model: FD620D-BS11 -........................................................ 99 (Chassis S/N 014950- )...................................................... 99 Fuel Pump Pressure Test.........................................................100 Fuel Pump Flow Test.............................................................100 High Altitude Operation.........................................................100 Cylinder Compression Test.......................................................100 Valve Clearance Adjustment......................................................101 Crankcase Vacuum Test...........................................................102 Fuel Tank Gauge Test............................................................103 Fuel Tank Check Valve Test......................................................103 Oil Pressure Test...............................................................104 Radiator Bubble Test............................................................105 Cooling System Test.............................................................105 Radiator Cap Pressure Test......................................................105 Thermostat Test.................................................................106 Air Filter and Air Restriction Indicator Tests (If Equipped)....................107 Repair..............................................................................108 Muffler Removal and Installation................................................108 Engine Removal and Installation.................................................109 Carburetor Repair...............................................................110 Float Level Adjustment..........................................................111 Intake Manifold Removal and Installation........................................111 Cylinder Head Removal and Installation..........................................112 Cylinder Head Disassembly and Inspection........................................113 Crankcase Cover Removal and Installation........................................114 Crankcase Breather Inspection...................................................115 Oil Pump Inspection.............................................................115 Oil Pump Installation...........................................................116 Camshaft Removal................................................................117 Camshaft Inspection.............................................................117 Governor Removal and Installation...............................................117 Pistons and Cylinders Removal and Cleaning......................................118 Piston Inspection...............................................................118 Piston Ring Installation........................................................121 Cylinder Boring.................................................................121 Connecting Rod Bend and Twist Inspection........................................122 Crankshaft Inspection...........................................................122 Crankshaft Installation.........................................................123 Connecting Rod Assembly and Installation........................................123 Tappet and Camshaft Installation................................................124 Water Pump Removal and Installation.............................................124 Water Pump Parts Inspection.....................................................125 Radiator Drain and Flush Procedure..............................................125 Radiator Fill and Bleed Procedure...............................................127 Starting Motor Removal and Installation.........................................128 Starting Motor Disassembly and Inspection.......................................129 ENGINE - DIESEL.........................................................................133 Table of Contents...................................................................133 Specifications......................................................................135 General Specifications..........................................................135 Repair Specifications...........................................................135 Special or Essential Tools......................................................143 Other Materials.................................................................143 Component Location..................................................................144 Fuel System Component Location..................................................144 Theory of Operation.................................................................145 Fuel System Operation...........................................................145 Cooling System..................................................................146 Lubrication System Operation....................................................147 Air System Operation............................................................148 Diagnostics.........................................................................149 Engine Troubleshooting Guide....................................................149 Troubleshooting Test Points.....................................................159 Tests and Adjustments...............................................................161 Cylinder Compression Test.......................................................161 Throttle Cable Adjustment.......................................................161 Slow Idle Adjustment............................................................162 Fast Idle Speed Adjustment (Engines -013716)....................................162 Fast Idle Speed Adjustment (Engines 013717- )...................................163 Valve Clearance, Check and Adjustment...........................................164 Valve Lift Check................................................................165 Fuel Injection Nozzle Test......................................................166 Fuel Injection Pump Timing Adjustment (Engines -013716).........................167 Injection Pump Static Timing (Engines 013717- ).................................169 Water Pump/Alternator Drive Belt Adjustment.....................................169 Thermostat Test.................................................................170 Radiator Bubble Test............................................................170 Cooling System Pressure Test....................................................171 Radiator Cap Pressure Test......................................................171 Engine Oil Pressure Test........................................................172 Fuel Transfer Pump Pressure Test................................................172 Fuel Drain Back Test............................................................173 Fuel System Bleeding............................................................173 Air Filter/Air Restriction Indicator Tests......................................173 Repair..............................................................................175 Engine Removal and Installation.................................................175 Muffler Removal and Installation................................................177 Rocker Arm Cover Removal and Installation.......................................178 Rocker Arm......................................................................178 Cylinder Head Removal and Installation..........................................180 Intake Manifold Removal and Installation........................................181 Exhaust Manifold Removal and Installation.......................................181 Cylinder Head Recondition.......................................................182 Crankshaft Rear Oil Seal........................................................186 Crankshaft Front Oil Seal.......................................................187 Timing Gear Cover...............................................................187 Camshaft End Play Check.........................................................188 Timing Gear Backlash Check......................................................188 Idler Gear......................................................................188 Cam Followers...................................................................189 Camshaft........................................................................190 Oil Pan and Strainer............................................................193 Connecting Rod Side Play Check..................................................193 Crankshaft End Play Check.......................................................194 Connecting Rod Bearing Clearance Check..........................................194 Crankshaft Main Bearing Clearance Check.........................................195 Piston-to-Cylinder Head Clearance...............................................195 Connecting Rod Repair...........................................................196 Pistons.........................................................................198 Cylinder Bore...................................................................201 Crankshaft and Main Bearings....................................................203 Flywheel........................................................................205 Flywheel Plate..................................................................205 Timing Gear Housing.............................................................206 Oil Pump........................................................................206 Oil Pressure Regulating Valve...................................................207 Coolant Temperature Switch......................................................208 Thermostat......................................................................208 Water Pump......................................................................208 Filling Coolant System (S/N -033432)............................................209 Filling Cooling System (S/N 033433- )...........................................210 Fuel Transfer Pump..............................................................210 Fuel Filter.....................................................................211 Fuel Tank Components............................................................211 Fuel Injection Nozzle...........................................................212 Fuel Injection Pump (Engines -013716)...........................................214 Fuel Injection Pump (Engines 013717- )..........................................215 Fuel Injection Pump Camshaft....................................................217 Governor........................................................................219 Starting Motor..................................................................222 Starting Motor Repair...........................................................222 Alternator......................................................................225 ELECTRICAL..............................................................................229 Table of Contents...................................................................229 Operation and Diagnostics...........................................................235 Operation and Diagnostics.......................................................235 Diagnostic Information..........................................................235 Wire Color Abbreviation Chart...................................................235 Reading Electrical Schematics...................................................236 Common Circuit Tests............................................................237 Conductors for 12 Volt Circuits.................................................237 Electrical Section Wiring Harness Legend - All Machines.........................238 Specifications - 4X2 Gas............................................................239 Battery:........................................................................239 Ignition:.......................................................................239 Spark Plug:.....................................................................239 Starting Motor:.................................................................239 Stator:.........................................................................239 Alternator: (FE290D)............................................................239 Lighting:.......................................................................239 Neutral Start Switch:...........................................................239 Component Locations.................................................................240 Component Location - 4X2 Gas....................................................240 Schematics and Harnesses - 4X2 Gas..................................................242 Electrical Schematic and Wiring Harness Legend - 4X2 Gas........................242 W1 Standard Electrical Schematic - 4X2 Gas......................................243 Wire Color Code Table - 4X2 Gas.................................................245 W1 Main Wiring Harness - 4X2 Gas................................................246 W1 Electrical Schematic with Auxiliary Alternator - 4X2 Gas.....................248 W29 Auxiliary Alternator Wiring Harness - 4X2 Gas...............................250 W29 Wiring Harness Wire Color Code Table - 4X2 Gas..............................252 W5 Engine Wiring Harness........................................................252 W6 Engine Wiring Harness........................................................252 W7 Engine Wiring Harness........................................................253 W4 Standard Headlight Wiring Harness............................................253 Operation and Diagnostics - 4X2 Gas.................................................254 Troubleshooting - 4X2 Gas.......................................................254 Power Circuit Operation - 4X2 Gas...............................................255 Power Circuit Schematic - 4X2 Gas...............................................256 Power Circuit Diagnosis - 4X2 Gas...............................................257 Cranking Circuit Operation - 4X2 Gas............................................259 Cranking Circuit Schematic - 4X2 Gas............................................259 Cranking Circuit Diagnosis - 4X2 Gas............................................260 Ignition Circuit Operation - 4X2 Gas............................................262 Ignition Circuit Schematic - 4X2 Gas............................................263 Ignition Circuit Diagnosis - 4X2 Gas............................................264 Charging Circuit Operation - Stator.............................................266 Charging Circuit Operation - Auxiliary Alternator (Option)......................266 Charging Circuit Schematic - Stator.............................................267 Charging Circuit Schematic - Auxiliary Alternator (Option)......................267 Charging Circuit Diagnosis - 4X2 Gas............................................268 Park Brake and Differential Lock Lights Operation - 4X2 Gas.....................270 Park Brake and Differential Lock Lights Schematic - 4X2 Gas.....................270 Park Brake Light Diagnosis - 4X2 Gas............................................271 Differential Lock Light Diagnosis - 4X2 Gas.....................................272 Standard Headlight Circuit Operation - 4X2 Gas..................................273 Standard Headlight Circuit Schematic - 4X2 Gas..................................273 Standard Headlight Circuit Diagnosis - 4X2 Gas..................................274 Specifications - 6X4 Gas............................................................276 Battery:........................................................................276 Ignition:.......................................................................276 Spark Plug:.....................................................................276 Starting Motor:.................................................................276 Alternator: (FD620D)............................................................276 Stator: (PIN FD620D038267-).....................................................277 Stator: (PIN FD620D009262 - FD620D038266).......................................277 Engine: Temperature:............................................................277 Radiator Core Temperature Switch:...............................................277 Lighting:.......................................................................277 Neutral Start Switch:...........................................................277 Component Location..................................................................278 Component Location - 6X4 Gas....................................................278 Schematics and Harnesses - 6X4 Gas..................................................280 Electrical Schematic and Wiring Harness Legend - 6X4 Gas........................280 W2 Standard Electrical Schematic - 6X4 Gas......................................281 W2 Main Wiring Harness - 6X4 Gas................................................283 W2 Main Wiring Harness Color Code Table - 6X4 Gas...............................285 W2 Electrical Schematic with Auxiliary Alternator - 6X4 Gas.....................286 W29 Auxiliary Alternator Wiring Harness - 6X4 Gas...............................288 W29 Wiring Harness Wire Color Code Table - 6X4 Gas..............................289 W4 Standard Headlight Wiring Harness - 6X4 Gas..................................290 W8 Engine Wiring Harness........................................................290 W9 Engine Wiring Harness........................................................291 W10 Engine Wiring Harness.......................................................291 W11 Engine Wiring Harness.......................................................292 W12 Engine Wiring Harness.......................................................292 W13 Engine Wiring Harness.......................................................292 Operation and Diagnostics - 6X4 Gas.................................................293 Troubleshooting - 6X4 Gas.......................................................293 Power Circuit Operation - 6X4 Gas...............................................294 Power Circuit Schematic - 6X4 Gas...............................................295 Power Circuit Diagnosis - 6X4 Gas...............................................296 Cranking Circuit Operation - 6X4 Gas............................................299 Cranking Circuit Schematic - 6X4 Gas............................................299 Cranking Circuit Diagnosis - 6X4 Gas............................................300 Ignition Circuit Operation - 6X4 Gas............................................302 Ignition Circuit Schematic - 6X4 Gas............................................302 Ignition Circuit Diagnosis - 6X4 Gas............................................303 Charging Circuit Operation - Stator.............................................305 Charging Circuit Operation - Auxiliary Alternator (Optional)....................305 Charging Circuit Schematic - Stator.............................................306 Charging Circuit Schematic - Auxiliary Alternator...............................306 Charging Circuit Diagnosis - 6X4 Gas............................................307 Indicator Lights Circuit Operation - 6X4 Gas....................................309 Indicator Lights Circuit Schematic - 6X4 Gas....................................310 Indicator Lights Circuit Diagnosis - 6X4 Gas....................................311 Fuel Pump and Fan Motor Operation - 6X4 Gas.....................................313 Fuel Pump and Fan Motor Schematic - 6X4 Gas.....................................313 Fuel Pump and Fan Motor Diagnosis - 6X4 Gas.....................................314 Standard Headlight Circuit Operation - 6X4 Gas..................................315 Standard Headlight Circuit Schematic - 6X4 Gas..................................315 Standard Headlight Circuit Diagnosis - 6X4 Gas..................................316 Specifications - 6X4 Diesel.........................................................317 Battery:........................................................................317 Starting Motor:.................................................................317 Alternator:.....................................................................317 Fuel Shutoff Solenoid:..........................................................317 Glow Plug:......................................................................317 Radiator Core Temperature Switch:...............................................317 Engine: Temperature:............................................................318 Lighting:.......................................................................318 Neutral Start Switch:...........................................................318 Component Location..................................................................319 Component Location - 6X4 Diesel.................................................319 Schematics and Harnesses - 6X4 Diesel...............................................321 3TN66C - JUV Engine Wiring Harnesses............................................321 Electrical Schematic and Wiring Harness Legend - 6X4 Diesel.....................322 W3 Standard Electrical Schematic - 6X4 Diesel (S/N - 003924)....................323 W3 Standard Electrical Schematic - 6X4 Diesel (S/N 003925 - 033000).............325 W3 Standard Electrical Schematic - 6X4 Diesel (S/N 033001 -)....................327 W3 Main Wiring Harness - 6X4 Diesel (S/N - 003924)..............................329 W3 Main Wiring Harness - 6X4 Diesel (S/N 003925 - 033000).......................331 W3 Main Wiring Harness - 6X4 Diesel (S/N 033001 -)..............................333 W3 Main Wiring Harness Wire Color Code Chart (S/N - 003924, 003925 - 033000)....335 W3 Main Wiring Harness Wire Color Code Chart (S/N 033001 -).....................336 Operation and Diagnostics...........................................................337 Troubleshooting - 6X4 Diesel....................................................337 Power Circuit Operation - 6X4 Diesel............................................338 Power Circuit Schematic - 6X4 Diesel............................................339 Power Circuit Diagnosis - 6X4 Diesel............................................340 Cranking Circuit Operation - 6X4 Diesel.........................................344 Cranking Schematic - 6X4 Diesel.................................................344 Cranking Circuit Diagnosis - 6X4 Diesel.........................................345 Glow Plug and Fuel Supply Operation - 6X4 Diesel................................347 Glow Plug and Fuel Supply Schematic - 6X4 Diesel................................349 Glow Plug and Fuel Supply Diagnosis - 6X4 Diesel................................352 Charging Circuit Operation - 6X4 Diesel.........................................354 Charging Circuit Schematic - 6X4 Diesel.........................................354 Charging Circuit Diagnosis - 6X4 Diesel.........................................355 Indicator Lights Operation - 6X4 Diesel.........................................357 Indicator Lights Schematic - 6X4 Diesel.........................................358 Indicator Lights Diagnosis - 6X4 Diesel.........................................359 Radiator Fan Motor Operation - 6X4 Diesel.......................................361 Headlights Operation - 6X4 Diesel...............................................361 Radiator Fan Motor and Headlights Schematic - 6X4 Diesel........................361 Radiator Fan Motor and Headlights Diagnosis - 6X4 Diesel........................362 Back-up Alarm Operation - 6X4 Diesel............................................364 Back-up Alarm Schematic - 6X4 Diesel............................................364 Back-up Alarm Diagnosis - 6X4 Diesel............................................365 Tests and Adjustments...............................................................366 Common Circuit Tests............................................................366 Ground Circuit Test.............................................................366 Battery Test....................................................................367 Charge Battery..................................................................368 Battery Load Test...............................................................368 Stator - Unregulated Voltage Output Test - Gas Engines..........................369 Stator - Regulated Amperage and Voltage Tests...................................370 Alternator - Unregulated Amperage Test - Diesel Engines.........................371 Auxiliary Alternator - Regulated Amperage and Voltage Tests.....................371 Starting Motor Solenoid Test....................................................372 Starting Motor Loaded Amperage Draw Test........................................373 Starting Motor No-load Amperage and rpm Tests...................................373 Spark Test - Gas Engines........................................................374 Spark Plug Cap Test - Gas Engines...............................................375 Brake Pedal Switch and Park Brake Switch Tests..................................375 Neutral Start Switch Test.......................................................376 Relay Test......................................................................376 Engine Oil Pressure Switch Test - 6X4’s.........................................377 Fuse Test.......................................................................377 Light Switch Test...............................................................378 Differential Lock Switch Test...................................................378 Key Switch Test.................................................................379 Fuel Shutoff Solenoid Test - Gas Engine.........................................379 Flywheel Magnet(s) Test - Gas Engines...........................................380 Bulb Test.......................................................................380 Ignition Coil Air Gap Adjustment - 4X2..........................................381 Pulser Coil Test - 6X4 Gas......................................................381 Ignition Module Test............................................................382 Ignition Coil Test..............................................................382 Radiator Core Temperature Switch Test - Removed.................................383 Engine Coolant Temperature Switch Test - 6X4’s..................................385 Unregulated Voltage Output Test - 6X4 Diesel....................................386 Unregulated Amperage Test - 6X4 Diesel..........................................386 Electrical System Amperage Draw Tests...........................................387 Glow Plug Relay Test............................................................388 Glow Plug Test..................................................................388 Fuel Shutoff Solenoid Test - Diesel Engine......................................389 Hazard Lights Switch Test.......................................................389 Turn Signal Switch Test.........................................................390 Horn Switch Test................................................................390 Ground Circuit Tests............................................................391 Cargo Box Lift Kit..................................................................393 Cargo Box Lift Specifications...................................................393 Component Location..................................................................394 Actuator Components.............................................................394 Cargo Box Lift System Components................................................395 Schematics and Harnesses............................................................395 Wiring Harness Legend - Cargo Box Lift Kit......................................395 W17 Cargo Box Lift Wiring Harness...............................................396 Cargo Box Lift Circuit Operation................................................397 Cargo Box Lift Circuit Schematic................................................398 Operation and Diagnostics...........................................................399 Cargo Box Lift Theory of Operation..............................................399 Cargo Box Lift System Troubleshooting Chart.....................................399 Cargo Box Lift Circuit Diagnosis................................................400 Cargo Box Tests and Adjustments.....................................................404 Cargo Box Motor Amperage Draw Test..............................................404 Cargo Box Repair....................................................................405 Actuator Repair Kits............................................................405 Replace Actuator Clutch.........................................................405 Replace Motor...................................................................405 Cover Tube Seal.................................................................405 Front Blade Kit.....................................................................406 Front Blade Lift Specifications.................................................406 Component Location..................................................................407 Front Blade Lift System Components..............................................407 Schematics and Harnesses............................................................407 Wiring Harness Legend - Front Blade.............................................407 W27 Front Blade Relay Wiring Harness............................................408 W28 Front Blade Switch Wiring Harness...........................................409 W27 Front Blade Relay Wiring Harness Color Codes................................409 Operation and Diagnostics...........................................................410 Front Blade System Troubleshooting Chart........................................410 Front Blade Theory of Operation.................................................411 Front Blade Circuit Operation...................................................411 Front Blade Circuit Schematic...................................................412 Front Blade Circuit Diagnosis...................................................413 Front Blade Tests and Adjustments...................................................417 Front Blade Motor Amperage Draw Test............................................417 Front Blade Repair..................................................................417 Actuator Repair Kits............................................................417 Replace Actuator Clutch.........................................................417 Cover Tube Seal.................................................................418 Replace Motor...................................................................418 Hour Meter..........................................................................419 Wiring Harness Legend - Hour Meter..............................................419 W26 Hour Meter Wiring Harness...................................................419 W26 Hour Meter Wiring Harness Color Code Chart..................................419 Hour Meter Circuit Operation....................................................420 Hour Meter Circuit Schematic....................................................420 Hour Meter Circuit Diagnosis....................................................421 W18 North American/European Light and Horn Kit (Earlier Model)......................422 W18 Light and Horn Schematic and Wiring Harness Legend (Earlier Model)..........422 W18 Light and Horn Wiring Schematic (Earlier Model).............................423 W18 Light and Horn Wiring Harness (Earlier Model)...............................425 W20 Rear Lights Wiring Harness (Earlier Model, Left)............................427 W21 Rear Lights Wiring Harness (Earlier Model, Right)...........................427 W22 Front Position/Turn Wiring Harness (Earlier Model)..........................427 W25 Headlight Adaptor Wiring Harness (Earlier Model)............................428 W18 Light and Horn Wiring Harness Color Codes (Earlier Model)...................428 W20 Rear Lights Wiring Harness Color Codes (Earlier Model, Left)................429 W21 Rear Lights Wiring Harness Color Codes (Earlier Model, Right)...............429 W22 Front Position/Turn Wiring Harness Color Codes (Earlier Model)..............429 W25 Headlight Adaptor Wiring Harness Color Codes (Earlier Model)................429 Operation and Diagnostics...........................................................430 Light and Horn Kit (Earlier Model)..............................................430 Light and Horn Kit Power Circuit Operation (Earlier Model)......................431 Light and Horn Kit Power Circuit Electrical Schematic...........................432 Light and Horn Kit Power Circuit Diagnosis (Earlier Model)......................433 Turn Signal and Hazard Light Operation (Earlier Model)..........................435 Turn Signal and Hazard Light Electrical Schematic (Earlier Model)...............435 Turn Signal and Hazard Light Diagnosis (Earlier Model)..........................436 Light and Horn Circuit Operation (Earlier Model)................................439 Light and Horn Circuit Electrical Schematic (Earlier Model).....................440 Light and Horn Circuit Diagnosis (Earlier Model)................................441 W30 North American/European Light and Horn Kit (Later Model)........................445 W30 Schematic and Wiring Harness Legend (Later Model)...........................445 W30 Light and Horn Electrical Schematic (Later Model)...........................446 W30 Light and Horn Wiring Harness (Later Model).................................448 W20 Rear Position/Turn/Brake Wiring Harness (Later Model, Left).................450 W21 Rear Position Turn/Brake Wiring Harness (Later Model, Right)................450 W22 Front Position/Turn Wiring Harness (Later Model)............................450 W30 Light/Horn Wiring Harness Color Codes (Later Model).........................451 W20 Rear Position/Turn/Brake Wiring Harness Color Codes (Later Model, Left).....451 W21 Rear Position Turn/Brake Wiring Harness Color Codes (Later Model, Right)....451 W22 Front Position/Turn Wiring Harness Color Codes (Later Model)................451 Operation and Diagnostics...........................................................452 W30 North American/European Light and Horn Kit Operation (Later Model)..........452 Light and Horn Kit Power Circuit Operation (Later Model)........................453 Light and Horn Kit Power Circuit Electrical Schematic (Later Model).............454 Light and Horn Kit Power Circuit Diagnosis (Later Model)........................455 Turn Signal and Hazard Light Circuit Operation (Later Model)....................457 Turn Signal and Hazard Light Circuit Electrical Schematic (Later Model).........458 Turn Signal and Hazard Light Circuit Diagnosis (Later Model)....................459 Light and Horn Circuit Operation (Later Model)..................................462 Light and Horn Circuit Diagnosis (Later Model)..................................462 W19 Road Homologated Light and Horn Kit.............................................465 W19 Road Homologated Light and Horn Kit Schematic and Wiring Harness Legend.....465 W19 Road Homologated Light and Horn Schematic...................................466 W19 Homologated Light and Horn Wiring Harness...................................468 W20 Rear Position/Turn/Brake Wiring Harness, (Left).............................470 W21 Rear Position/Turn/Brake Wiring Harness, (Right)............................470 W22 Front Position/Turn Wiring Harness..........................................470 W23 Trailer Connector Wiring Harness............................................471 W24 License Plate Light Wiring Harness..........................................471 W19 Road Homologated Light and Horn Wiring Harness Color Codes..................472 W20 Rear Position/Turn/Brake Wiring Harness Color Codes (Left)..................473 W21 Rear Position/Turn/Brake Wiring Harness Color Codes (Right).................473 W22 Front Position/Turn Wiring Harness..........................................473 W23 Trailer Connector Wiring Harness............................................473 W24 License Plate Light Wiring Harness Color Codes..............................473 Operation and Diagnostics...........................................................474 Road Homologated Light and Horn Kit Operation...................................474 Road Homologated Light and Horn Kit Power Circuit Operation.....................475 Road Homologated Light and Horn Kit Power Circuit Electrical Schematic..........476 Road Homologated Light and Horn Kit Power Circuit Diagnosis.....................477 Road Homologated Turn Signal and Hazard Circuit Operation.......................479 Road Homologated Turn Signal and Hazard Circuit Electrical Schematic............480 Road Homologated Turn Signal and Hazard Circuit Diagnosis.......................481 Road Homologated Light and Horn Circuit Operation...............................485 Road Homologated Light and Horn Circuit Electrical Schematic....................486 Road Homologated Light and Horn Circuit Diagnosis...............................487 POWER TRAIN - GEAR......................................................................491 Table of Contents...................................................................491 Specifications......................................................................493 General Specifications..........................................................493 Repair Specifications...........................................................493 Other Materials.................................................................494 Component Location..................................................................495 Component Location - 4X2........................................................495 Component Location - 6X4........................................................496 Theory of Operation.................................................................497 Clutch Operation................................................................497 Transaxle Component Location and Operation......................................498 Transaxle Component Location....................................................499 Diagnostics.........................................................................500 Diagnostic Check Points.........................................................500 Tests and Adjustments...............................................................502 Drive Belt Check................................................................502 Transaxle Shift Linkage Adjustment..............................................502 Drive Train Performance Tests...................................................503 Secondary Clutch Back-Shifting Check............................................504 Secondary Clutch Spring Torsion Check...........................................505 Clutch Center Distance (6X4 Diesel Only)........................................506 Differential Lock Linkage Adjustment............................................508 Drive Chain Adjustment - 6X4’S..................................................510 Repair..............................................................................511 Serial Number Breaks............................................................511 Primary Clutch Cam Weights......................................................511 Primary Clutch Removal..........................................................511 Primary Clutch Repair...........................................................511 Secondary Clutch................................................................512 Transaxle Removal and Installation..............................................514 Drive Axle Removal and Installation - 4X2.......................................523 Drive Axle Disassembly - 4X2....................................................523 Drive Axle Assembly - 4X2.......................................................524 Drive Axle Removal and Installation - 6X4.......................................525 Drive Axle Disassembly - 6X4....................................................525 Drive Axle Assembly - 6X4.......................................................526 STEERING................................................................................527 Table of Contents...................................................................527 Specifications......................................................................529 Service and Adjustment Specifications...........................................529 Torque Specifications...........................................................529 Component Location..................................................................530 Steering Component Location.....................................................530 Diagnostics.........................................................................531 Troubleshooting.................................................................531 Steering Troubleshooting Test Points............................................536 Tests and Adjustments...............................................................538 Toe-In Adjustment...............................................................538 Steering Wheel Adjustment.......................................................538 Repair..............................................................................539 Steering Wheel and Shaft Removal and Installation...............................539 Tie Rod End Replacement.........................................................539 Steering Assembly Removal and Installation......................................540 Spindle Shaft and Bushing Removal and Installation..............................540 BRAKES..................................................................................543 Table of Contents...................................................................543 Specifications......................................................................545 Brake Specifications............................................................545 Other Materials.................................................................545 Component Location..................................................................546 Transaxle Brake Components......................................................546 System Brake Components.........................................................547 Diagnostics.........................................................................548 Troubleshooting Guide...........................................................548 Diagnosis Test/Check Points.....................................................552 Theory of Operation.................................................................553 Brake Operation.................................................................553 Tests and Adjustments...............................................................554 Brake Adjustments...............................................................554 Repair..............................................................................555 Brake Removal and Installation..................................................555 ATTACHMENTS.............................................................................557 Table of Contents...................................................................557 Specifications, Rotary Broom........................................................559 Rotary Broom Specifications.....................................................559 Component Location, Rotary Broom....................................................560 Rotary Broom....................................................................560 Hydraulic and Electrical Components.............................................561 Electrical, Rotary Broom............................................................563 Schematic And Wiring Harness Legend.............................................563 Rotary Broom Electrical Schematic (1 of 2)......................................564 Rotary Broom Electrical Schematic (2 of 2)......................................565 W1 Main Wiring Harness (1 of 2).................................................566 W1 Main Wiring Harness (2 of 2).................................................567 W2 Control Panel Wiring Harness.................................................568 W3 Jumper Wiring Harness........................................................568 W4 Power Supply Wiring Harness..................................................569 W5 Engine Wiring Harness........................................................569 W1 Main Wiring Harness Color Codes..............................................570 W2 Control Panel Wiring Harness Color Codes.....................................570 W3 Jumper Wiring Harness Color Codes............................................571 W4 Power Supply Wiring Harness Color Codes......................................571 W5 Engine Wiring Harness Color Codes............................................571 Operation and Diagnostics, Rotary Broom Electrical..................................572 Power Circuit Operation.........................................................572 Power Circuit Electrical Schematic..............................................573 Power Circuit Diagnosis.........................................................574 Charging Circuit Operation......................................................579 Charging Circuit Electrical Schematic...........................................579 Charging Circuit Diagnosis......................................................580 Lift/Lower Circuit Operation....................................................582 Lift Circuit Electrical Schematic...............................................583 Lift Circuit Diagnosis..........................................................584 Right and Left Angle Circuit Operation..........................................587 Right and Left Angle Circuit Electrical Schematic...............................588 Right and Left Angle Circuit Diagnosis..........................................589 PTO Circuit Operation...........................................................593 PTO Circuit Electrical Schematic................................................594 PTO Circuit Diagnosis...........................................................595 Tests and Adjustments, Rotary Broom Electrical......................................598 Angle and Lift/Lower Switch Test................................................598 PTO Switch Test.................................................................598 Relay Test......................................................................599 Seat Switch Test................................................................599 PTO Clutch Test.................................................................600 Diode Test......................................................................600 Ignition On/Off Switch Test.....................................................600 Solenoid Coil Test..............................................................601 Engine Oil Switch Test..........................................................601 Stator Output Test..............................................................602 Spark Test......................................................................602 Ignition Coil Air Gap Adjustment................................................603 Spark Plug Gap Adjustment.......................................................603 Spark Plug Cap Test.............................................................604 Ignition Coil Test..............................................................604 Flywheel Magnet Test............................................................605 Hydraulics, Rotary Broom............................................................606 Hydraulic Schematic.............................................................606 Operation and Diagnostics, Rotary Broom Hydraulics..................................607 Hydraulic System................................................................607 Diagnostics.........................................................................608 Lift Circuit....................................................................608 Lower Circuit...................................................................610 Right Angle Circuit.............................................................612 Left Angle Circuit..............................................................614 Tests and Adjustments, Rotary Broom Hydraulics......................................616 System Pressure Relief Test and Adjustment......................................616 Pump Flow Test..................................................................617 Repair, Rotary Broom Hydraulics.....................................................619 Motor and Pump Assembly Removal and Installation................................619 Angle Cylinder Removal and Installation.........................................620 Lift Cylinder Removal and Installation..........................................620 Repair, Rotary Broom Miscellaneous..................................................621 Bearing Replacement.............................................................621 ROTARY BROOM ENGINE.....................................................................625 Table of Contents...................................................................625 Specifications......................................................................627 General Specifications..........................................................627 Adjustment Specifications.......................................................627 Repair Specifications...........................................................627 Torque Specifications...........................................................630 Tools and Materials.................................................................632 Special or Required Tools.......................................................632 Other Materials.................................................................632 Component Location..................................................................633 Engine Components...............................................................633 Diagnostics.........................................................................634 Engine Troubleshooting..........................................................634 Tests and Adjustments...............................................................637 Fuel System Tests...............................................................637 Fuel Flow Test..................................................................637 Governor Cross Shaft Position Adjustment........................................637 Governor Lever Adjustment.......................................................638 Slow Idle Speed Adjustments.....................................................638 Fast Idle Speed Adjustments.....................................................638 Cylinder Compression Test.......................................................639 Crankcase Vacuum Test...........................................................639 Automatic Compression Release (ACR) Check.......................................641 Valve Tappet Clearance Adjustment...............................................641 Adjusting Drive Belt Tension....................................................642 Repair..............................................................................643 Brush Head Drive Belt Removal and Installation..................................643 PTO Clutch Removal and Installation.............................................643 Air Cleaner Assembly Removal and Installation...................................644 Fuel Tank Removal and Installation..............................................645 Fuel Sediment Bowl Cleaning.....................................................645 Muffler Removal and Installation................................................646 Spark Plug Removal and Installation.............................................646 Engine Removal and Installation.................................................646 External Governor and Throttle Linkage Removal and Installation.................647 Carburetor Removal and Installation.............................................648 Carburetor Disassembly and Assembly.............................................648 Blower Housing Removal and Installation.........................................650 Flywheel Removal, Inspection, and Installation..................................651 Ignition Coil Removal and Installation..........................................652 Stator and Protective Shield Removal and Installation...........................653 Valve Cover/Breather Removal and Installation...................................653 Cylinder Head Removal and Installation..........................................654 Rocker Arm and Push Rod Removal and Installation................................654 Valve Removal, Inspection, and Installation.....................................655 Valve Face Reconditioning.......................................................655 Valve Lapping...................................................................656 Valve Condition.................................................................656 Gear Reduction Assembly Removal and Installation................................657 Closure Plate Removal and Installation..........................................658 Oil Sensor Removal and Installation.............................................659 Governor Gear Removal and Installation..........................................660 Governor Cross Shaft Removal and Installation...................................660 Balance Shaft Removal and Installation..........................................661 Camshaft and Tappet Removal and Installation....................................662 Piston Removal and Installation.................................................663 Piston Ring Installation........................................................664 Measuring Piston to Bore Clearance..............................................664 Cylinder De-glazing.............................................................664 Cylinder Resizing...............................................................665 Crankshaft Removal, Inspection, and Installation................................666 Crankcase Inspection............................................................666 Oil Seal and Bearing Removal and Installation...................................666 Retractable Starter Removal and Installation....................................667 Retractable Starter Rope Replacement............................................667 Pawl Removal and Replacement....................................................668 Recoil Spring, Pulley, and Housing Replacement..................................669 MISCELLANEOUS...........................................................................671 Table of Contents...................................................................671 Specifications......................................................................673 General Specifications..........................................................673 Tests and Adjustments...............................................................674 Hood Adjustment.................................................................674 Shock Ride Height and Spring Preload Adjust.....................................674 Repair..............................................................................675 Shock Absorber Replacement......................................................675 Front Wheel Removal and Installation............................................676 Wheel Bearing Replacement.......................................................676 A-Arm Removal and Installation..................................................676 INDEX...................................................................................679 A...................................................................................679 B...................................................................................679 C...................................................................................679 D...................................................................................680 E...................................................................................681 F...................................................................................684 G...................................................................................685 H...................................................................................685 I...................................................................................686 L...................................................................................686 M...................................................................................686 N...................................................................................686 O...................................................................................686 P...................................................................................687 R...................................................................................687 S...................................................................................689 T...................................................................................690 U...................................................................................691 V...................................................................................691 W...................................................................................691
PLEASE NOTE:
- This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
- Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
