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JOHN DEERE Gator Light Duty Utility Vehicles CS and CX – TM2119 – TECHNICAL SERVICE REPAIR MANUAL – PDF Download
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JOHN DEERE Gator Light Duty Utility Vehicles CS and CX – TM2119 – TECHNICAL SERVICE REPAIR SHOP MANUAL
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JOHN DEERE Gator Light Duty Utility Vehicles CS and CX – TM2119 – TECHNICAL SERVICE REPAIR SHOP MANUAL
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JOHN DEERE Gator Light Duty Utility Vehicles CS and CX – TM2119 – TECHNICAL SERVICE REPAIR SHOP MANUAL
LANGUAGE:ENGLISH
PAGES:300
DOWNLOADABLE:YES
FILE TYPE:PDF
JOHN DEERE GATOR LIGHT DUTY UTILITY VEHICLES CS AND CX – TM2119 – TECHNICAL SERVICE REPAIR MANUAL – PDF DOWNLOAD:
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JOHN DEERE Gator Light Duty Utility Vehicles CS and CX – TM2119 – TECHNICAL SERVICE REPAIR SHOP MANUAL
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.
TABLE OF CONTENTS:
JOHN DEERE Gator Light Duty Utility Vehicles CS and CX – TM2119 – TECHNICAL SERVICE REPAIR SHOP MANUAL
TM2119 CS and CX Gator Light Duty 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 Parking 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 and 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 Break-In Engine Oil - 4-Cycle Gasoline................................... 20 Transaxle and Hydraulic Oil.............................................. 21 Alternative Lubricants................................................... 21 Synthetic Lubricants..................................................... 21 Lubricant Storage........................................................ 21 Mixing of Lubricants..................................................... 21 Oil Filters.............................................................. 21 Serial Number Locations...................................................... 22 Product Serial Number.................................................... 22 Engine Serial Number Location............................................ 22 Transaxle Serial Number Location......................................... 22 Engine - Gas 8HP................................................................. 23 Table of Contents............................................................ 23 Specifications............................................................... 25 General Specifications................................................... 25 Tests and Adjustments Specifications..................................... 25 Repair Specifications.................................................... 25 Torque Specifications.................................................... 27 Special or Essential Tools............................................... 28 Carburetor Jets.......................................................... 28 Other Materials.......................................................... 28 Component Location........................................................... 29 FE250D Engine............................................................ 29 Fuel System Components................................................... 30 Carburetor Components.................................................... 31 Balancer Components...................................................... 32 Starter Motor Components................................................. 33 Diagnostics.................................................................. 34 Engine Troubleshooting Guide............................................. 34 Tests and Adjustments........................................................ 35 Governor Static Adjustment............................................... 35 Throttle Cable Adjustment................................................ 36 Choke Cable Adjustment................................................... 36 Slow Idle Mixture Screw and Speed Adjustments............................ 37 Fast Idle Speed Adjustment............................................... 38 Fuel Pump Pressure Test.................................................. 39 Fuel Pump Flow Test...................................................... 39 Cylinder Compression Test................................................ 40 Valve Clearance Adjustment............................................... 40 Automatic Compression Release (ACR) Test................................. 41 Crankcase Vacuum Test.................................................... 42 Ignition Coil Air Gap Adjustment......................................... 42 Air Intake System Check.................................................. 43 Repair....................................................................... 44 Muffler Removal and Installation......................................... 44 Carburetor Removal and Installation...................................... 44 Carburetor Disassembly and Assembly...................................... 45 Engine Removal and Installation.......................................... 47 Breather Inspection and Replacement...................................... 48 Blower Housing Removal and Installation.................................. 49 Flywheel Removal and Installation........................................ 49 Rocker Arm Removal and Installation...................................... 49 Cylinder Head Removal and Installation................................... 50 Cylinder Head Disassembly and Assembly................................... 50 Cylinder Head Inspection and Replacement................................. 51 Recondition Valves and Seats............................................. 52 Crankcase Cover Removal and Installation................................. 53 Camshaft Removal and Installation........................................ 53 Camshaft Inspection...................................................... 54 Automatic Compression Release Inspection................................. 54 Tappets Inspection and Replacement....................................... 55 Piston and Connecting Rod Removal and Installation....................... 55 Piston/Connecting Rod Disassembly and Assembly........................... 55 Piston/Connecting Rod Inspection......................................... 56 Reciprocating Balancer................................................... 57 Crankshaft............................................................... 59 Crankshaft End Play Check................................................ 59 Crankshaft End Play Adjustment........................................... 60 Crankshaft Oil Seal - Flywheel End Replacement........................... 60 Crankshaft Oil Seal - PTO End Replacement................................ 60 Cylinder Block Inspection................................................ 60 Cylinder Deglazing....................................................... 61 Cylinder Reboring........................................................ 61 Governor Inspection and Replacement...................................... 62 Starting Motor........................................................... 62 Engine - Gas 10HP................................................................ 65 Table of Contents............................................................ 65 Specifications............................................................... 67 General Specifications................................................... 67 Test and Adjustment Specifications....................................... 67 Repair Specifications.................................................... 68 Special or Essential Tools............................................... 71 Carburetor Jets.......................................................... 71 Other Materials.......................................................... 71 Component Location........................................................... 72 FE290D Engine............................................................ 72 Fuel System Components................................................... 73 Carburetor Components.................................................... 74 Balancer Components...................................................... 75 Starter Motor Components................................................. 76 Diagnostics.................................................................. 77 Engine Troubleshooting Guide............................................. 77 Starting Motor Troubleshooting Guide..................................... 78 Tests and Adjustments........................................................ 79 Governor Static Adjustment............................................... 79 Choke Cable Adjustment................................................... 79 Throttle Cable Adjustment................................................ 80 Slow Idle Mixture Screw and Speed Adjustments............................ 81 Fast Idle Speed Adjustment............................................... 82 Fuel Pump Pressure Test.................................................. 82 Fuel Pump Flow Test...................................................... 83 Cylinder Compression Test................................................ 83 Valve Clearance Adjustment............................................... 84 Automatic Compression Release (ACR) Test................................. 85 Crankcase Vacuum Test.................................................... 85 Ignition Coil Air Gap Adjustment......................................... 86 Oil Pressure Test........................................................ 87 Air Intake System Check.................................................. 88 Repair....................................................................... 89 Muffler Removal and Installation......................................... 89 Carburetor Removal and Installation...................................... 89 Carburetor Disassembly and Assembly...................................... 90 Engine Removal and Installation.......................................... 92 Crankcase Breather Inspection............................................ 93 Blower Housing Removal and Installation.................................. 93 Flywheel Removal and Installation........................................ 94 Rocker Arm Removal and Installation...................................... 94 Rocker Arm Inspection.................................................... 94 Cylinder Head Removal and Installation................................... 95 Cylinder Head Disassembly and Assembly................................... 95 Cylinder Head Inspection and Replacement................................. 96 Recondition Valve Seats.................................................. 97 Lap Valves............................................................... 98 Crankcase Cover Removal and Installation................................. 98 Camshaft Removal and Installation........................................ 99 Camshaft Inspection...................................................... 99 Automatic Compression Release............................................100 Tappets Inspection and Replacement.......................................100 Piston and Connecting Rod................................................101 Reciprocating Balancer...................................................103 Crankshaft Removal and Installation......................................105 Crankshaft Inspection....................................................105 Crankshaft End Play Check................................................106 Analyze Crankshaft and Connecting Rod Wear...............................106 Crankshaft End Play Adjustment...........................................106 Crankshaft Oil Seal - Flywheel End Replacement...........................107 Crankshaft Oil Seal - PTO End Replacement................................107 Governor Shaft Oil Seal Replacement......................................107 Cylinder Block Inspection................................................107 Cylinder Deglazing.......................................................108 Cylinder Reboring........................................................108 Oil Pump Disassembly and Assembly........................................109 Oil Pump Inspection......................................................109 Oil Filter Manifold Removal and Installation.............................110 Governor Inspection and Replacement......................................110 Governor Shaft Inspection and Replacement................................111 Armature With Coil Removal and Installation..............................111 Stator Removal and Installation..........................................111 Starting Motor...........................................................111 Electrical.......................................................................115 Table of Contents............................................................115 General Information..........................................................117 Operation and Diagnostics................................................117 Diagnostic Information...................................................117 Wire Color Abbreviation Chart............................................117 Reading Electrical Schematics............................................118 Common Circuit Tests.....................................................119 Conductors for 12 Volt Circuits..........................................119 Specifications...............................................................120 General Electrical Specifications........................................120 Component Location...........................................................122 Main Wiring Harness......................................................122 Schematics and Harnesses.....................................................123 Electrical Schematic and Wiring Harness Legend...........................123 Standard Electrical Wiring Schematic..................................... 0 W1 Main Wiring Harness................................................... 0 Main Wiring Harness Wire Color Codes.....................................126 W2 Engine Wiring Harness.................................................127 W3 Engine Wiring Harness.................................................127 G2 Stator................................................................127 Operation and Diagnostics....................................................128 Power Circuit Operation..................................................128 Power Circuit Wiring Schematic........................................... 0 Power Circuit Diagnosis.................................................. 0 Cranking Circuit Operation............................................... 0 Cranking Circuit Wiring Schematic........................................ 0 Cranking Circuit Diagnosis...............................................131 Ignition Circuit Operation...............................................132 Ignition Circuit Wiring Schematic........................................133 Ignition Circuit Diagnosis...............................................133 Charging Circuit Operation............................................... 0 Charging Circuit Wiring Schematic........................................ 0 Charging Circuit Diagnosis...............................................135 Headlight Circuit Operation.............................................. 0 Headlight Circuit Wiring Schematic....................................... 0 Headlight Circuit Diagnosis..............................................137 Hourmeter Circuit Operation.............................................. 0 Hourmeter Circuit Wiring Schematic....................................... 0 Hourmeter Circuit Diagnosis.............................................. 0 Accessory Power Port Operation........................................... 0 Accessory Power Port Wiring Schematic.................................... 0 Accessory Power Port Diagnosis........................................... 0 Tests and Adjustments........................................................139 Common Circuit Tests.....................................................139 Ground Circuit Tests.....................................................139 Battery Test.............................................................140 Charge Battery...........................................................141 Battery Load Test........................................................142 Stator - Unregulated Voltage Output Test.................................142 Stator - Regulated Amperage and Voltage Tests............................143 Auxiliary Alternator Unregulated Amperage Test...........................144 Auxiliary Alternator Regulated Output Test...............................144 Starting Motor Solenoid Test.............................................145 Starting Motor Loaded Amperage Draw Test.................................146 Starting Motor No-Load Amperage and RPM Tests............................147 Spark Test...............................................................148 Spark Plug Cap Test......................................................148 Brake Pedal Switch Test..................................................149 Fuse Test................................................................149 Headlight Switch Test....................................................150 Light Switch Test (Optional Marker or Signal Lights).....................150 Raise/Lower Relay Test...................................................151 Flywheel Magnet(s) Test..................................................151 Bulb Test................................................................152 Ignition Coil Air Gap Adjustment.........................................152 Ignition Coil Test.......................................................153 Key Switch Test..........................................................154 Transmission Neutral Start Switch Test...................................154 Turn Signal Lights Switch Test...........................................155 Hazard Lights Switch Test................................................155 Horn Switch Test.........................................................156 Raise/Lower Switch Test..................................................156 Cargo Box Motor Amperage Draw Test.......................................157 Repair.......................................................................158 High Capacity Alternator Removal and Installation........................158 Starting Motor Removal and Installation..................................162 Starting Motor Disassembly and Assembly..................................163 Front Blade Motor Removal and Installation...............................165 Actuator Repair Kits.....................................................166 Replace Actuator Clutch..................................................166 Cargo Box Lift Motor - Replacement.......................................166 Cover Tube Seal..........................................................166 Theory of Operation..........................................................167 Optional Attachments Circuit Operation...................................167 Auxiliary Alternator Kit.....................................................168 Charging Circuit Operation - Auxiliary Alternator........................168 Charging Circuit Wiring Schematic - Auxiliary Alternator................. 0 Auxiliary Alternator Kit Wiring Harness.................................. 0 Auxiliary Alternator Kit Wiring Harness Schematic........................ 0 Auxiliary Alternator Kit Wiring Harness Color Codes......................169 Auxiliary Alternator Circuit Diagnosis...................................169 Backup Alarm Kit.............................................................170 Backup Alarm Kit Circuit Component Location..............................170 Backup Alarm Kit Circuit Operation.......................................170 Backup Alarm Kit Circuit Wiring Schematic................................ 0 Backup Alarm Kit Wiring Harness.......................................... 0 Backup Alarm Kit Wiring Harness Schematic................................ 0 Backup Alarm Kit Wiring Color Codes......................................171 Wiring Harness Legend - Backup Alarm Kit.................................171 Backup Alarm Kit Circuit Diagnosis.......................................172 Horn Kit.....................................................................174 Horn Kit Component Location..............................................174 Horn Kit Circuit Operation...............................................174 Horn Kit Circuit Wiring Schematic........................................ 0 Horn Kit Wiring Harness.................................................. 0 Horn Kit Wiring Harness Schematic........................................ 0 Horn Kit Circuit Wiring Harness Color Codes..............................175 Wiring Harness Legend - Horn Kit.........................................175 Horn Kit Circuit Diagnosis...............................................175 Optional Light Kits..........................................................177 Rear Marker/Brake Lights Kit Component Location..........................177 Signal Lights Kit Component Location.....................................179 Rear Marker/Brake Lights Kit Operation................................... 0 Rear Marker/Brake Lights Kit - Wiring Schematic.......................... 0 Brake/Rear Marker Lights Kit - Wiring Harnesses..........................181 Rear Marker/Brake Lights Kit - Front Control Wiring Harness Schematic....182 Rear Marker/Brake Lights Kit Wire Color Codes............................182 Wiring Harness Legend - Rear Marker/Brake Lights Kit.....................182 Rear Marker/Brake Lights Kit Circuit Diagnosis...........................183 Turn Signal/Marker/Brake Lights Kit Operation (Signal Lights)............189 Wiring Harness Legend - Signal Lights Kit................................190 Front Turn Signal/Marker Lights Wiring Schematic......................... 0 Front Turn Signal/Marker Lights Wiring Harness........................... 0 Front Turn Signal/Marker Lights Wiring Color Codes....................... 0 Rear Turn Signal/Marker/Brake Lights Wiring Harness Schematic............191 Rear Turn Signal/Marker/Brake Lights Wiring Harness......................192 Rear Turn Signal/Marker/Brake Lights Wiring Color Codes..................192 Turn Signal/Marker/Brake Lights Kit Circuit Schematic.................... 0 Marker Lights Circuit Diagnosis..........................................194 Hazard Lights Circuit Diagnosis..........................................200 Turn Signal Lights Circuit Diagnosis.....................................206 Front Blade Kit..............................................................215 Front Blade Kit Component Location.......................................215 Front Blade Kit Operation................................................216 Front Blade Kit Wiring Schematic......................................... 0 Front Blade Kit Wiring Harness........................................... 0 Front Blade Kit Wiring Harness Schematic.................................217 Front Blade Kit Wiring Color Codes.......................................218 Wiring Harness Legend - Front Blade Kit..................................218 Front Blade Kit Circuit Diagnosis........................................219 Cargo Box Lift System Kit....................................................223 Cargo Box Lift Kit Component Location....................................223 Cargo Box Actuator Components............................................224 Cargo Box Lift Theory of Operation....................................... 0 Cargo Box Lift Kit Circuit Operation..................................... 0 Cargo Box Lift Kit Circuit Schematic..................................... 0 Cargo Box Lift Kit Wiring Harness........................................225 Cargo Box Lift Kit Wiring Harness (Detail)...............................225 Cargo Box Lift Kit Circuit Wiring Harness Schematic......................226 LH Cargo Box Lift Kit Wire Color Codes...................................226 Wiring Harness Legend - Cargo Box Lift Kit...............................227 Cargo Box Lift System Troubleshooting....................................227 Cargo Box Lift Kit Circuit Diagnosis.....................................228 Power Train - Gear...............................................................231 Table of Contents............................................................231 Specifications...............................................................233 General Specifications...................................................233 Transaxle Specifications.................................................233 Torque Specifications....................................................233 Other Materials..........................................................233 Special or Required Tools................................................234 Component Location...........................................................235 Transaxle Components.....................................................235 Transaxle Components.....................................................236 Axle Shaft Components....................................................237 Differential Components..................................................238 Theory of Operation..........................................................239 Clutch Operation.........................................................239 Diagnostics..................................................................240 Diagnostic Check Points..................................................240 Tests and Adjustments........................................................241 Transaxle Shift Adjustment...............................................241 Differential Lock Cable Adjustment.......................................241 Drive Train Performance Tests............................................242 Secondary Clutch Back-Shifting Check.....................................242 Repair.......................................................................243 Drive Clutch Removal and Installation....................................243 Driven Clutch Ramp Shoe Replacement......................................244 Transaxle Removal and Installation.......................................244 Transaxle Disassembly and Assembly.......................................245 Steering.........................................................................253 Table of Contents............................................................253 Specifications...............................................................255 General Specifications...................................................255 Service and Adjustment Specifications....................................255 Torque Specifications....................................................255 Component Location...........................................................256 A-Arm Suspension Components..............................................256 Steering Components......................................................257 Diagnostics..................................................................258 Steering Diagnostics.....................................................258 Steering Troubleshooting Test Points.....................................262 Tests and Adjustments........................................................264 Toe-In Adjustment........................................................264 Steering Wheel Adjustment................................................265 Repair.......................................................................265 Tie Rod End Replacement..................................................265 Steering Wheel and Steering Cable Installation and Removal...............266 Steering Assembly Removal and Installation...............................266 A-Arm Removal and Installation...........................................268 Brakes...........................................................................271 Table of Contents............................................................271 Specifications...............................................................273 General Specifications...................................................273 Component Location...........................................................274 Parking Brake and Brake Cable Components.................................274 Transaxle Brake Components...............................................276 Theory of Operation..........................................................277 Brake Operation..........................................................277 Diagnostics..................................................................278 Troubleshooting Guide....................................................278 Diagnosis Test/Check Points..............................................281 Tests and Adjustments........................................................282 Inspecting Brake Cables and Brake Function...............................282 Brake Spring Adjustment..................................................283 Repair.......................................................................284 Brake Cable Removal and Installation.....................................284 Brake Pedal Assembly Removal.............................................284 Parking Brake Removal and Installation...................................285 Miscellaneous....................................................................287 Table of Contents............................................................287 Specifications...............................................................289 General Specifications...................................................289 Repair.......................................................................290 Opening and Closing Hood.................................................290 Hood Removal and Installation............................................290 Front Grill Removal and Installation.....................................290 Shock Absorber Replacement...............................................291 Front Wheel Removal and Installation.....................................291 Front Wheel Bearing Replacement..........................................292 Index............................................................................293 A............................................................................293 B............................................................................293 C............................................................................293 D............................................................................294 E............................................................................294 F............................................................................297 G............................................................................297 H............................................................................297 I............................................................................297 K............................................................................298 L............................................................................298 M............................................................................298 O............................................................................298 P............................................................................298 R............................................................................298 S............................................................................299 T............................................................................299 U............................................................................300 V............................................................................300 W............................................................................300
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1 review for JOHN DEERE Gator Light Duty Utility Vehicles CS and CX – TM2119 – TECHNICAL SERVICE REPAIR MANUAL – PDF Download
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Zaire Dennis –
Would’ve been good to see a preview of a few pages to see scan quality; it’s pretty good, but not great.