John Deere 3120, 3320, 3520, 3720 Compact Utility Tractors Service Technical Manual (TM2138)

tm2138 - 3120, 3320, 3520 and 3720 Compact Utility Tractors Repair Technical Manual.pdf

All Inclusive Diagnostics & Repair Service Technical Manual with Electrical Wiring Diagrams for John Deere 3120, 3320, 3520, 3720 Compact Utility Tractors, with all the shop information to maintain, diagnostic, repair, service like professional mechanics.

John Deere Compact Utility Tractors Models 3120, 3320, 3520 and 3720 workshop diagnosis operation tests repair service manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

Total Pages: 2,752 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
 Foreword
   Safety
      Safety
   Specifications and Information
      General Specifications
      Fuel and Lubricants
      Serial Number Locations
   Engine
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Tests and Adjustments
      Repair
   Electrical-NA
      General Information
      Specifications
      Component Location
      Schematics and Harnesses
      Schematics and Harnesses MY08
      Schematics and Harnesses MY13
      Common Schematics and Harnesses
      Operation and Diagnostics
      Tests and Adjustments
      Display Panel Tests and Adjustments
      SERVICEGARD™ Tests and Adjustments
      Service ADVISOR™ Test and Adjustments
      Repair
   Electrical-EEC
      Specifications
      Component Location
      Schematics and Harnesses
      Schematics and Harnesses MY08
      Schematics and Harnesses-MY13
      Common Schematics and Harnesses
      Troubleshooting
      Operation and Diagnostics
   Power Train-PRT
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Troubleshooting
      Tests and Adjustments
      Repair
   Power Train-Hydrostatic
      Specifications
      Component Location
      Schematics
      Theory of Operation
      Diagnostics
      Troubleshooting
      Tests and Adjustments
      Repair
   Power Train-Final Drive
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Troubleshooting
      Final Drive Troubleshooting
      Tests and Adjustments
      Repair
      PTO Theory of Operation
      PTO Repair
   Hydraulics
      Specifications
      Component Location
      Schematics
      Theory of Operation
      Diagnostics
      Tests and Adjustments
      Repair
   Steering
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Tests and Adjustments
      Repair
   Brakes
      Specifications
      Component Location
      Theory of Operation
      Diagnostics
      Tests and Adjustments
      Repair
   Miscellaneous
      Specifications
      Repair

tm2138 - 3120, 3320, 3520 and 3720 Compact Utility Tractors Repair Manual

Table of Contents

Foreword

Section 10: Safety

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Replace Safety Signs

Handle Fluids Safely—Avoid Fires

Prepare for Emergencies

Prevent Battery Explosions

Prevent Acid Burns

Wear Protective Clothing

Avoid High-Pressure Fluids

Avoid Heating Near Pressurized Fluid Lines

Service Machines Safely

Use Proper Tools

Park Machine Safely

Support Machine Properly

Use Proper Lifting Equipment

Work in Clean Area

Protect Against High Pressure Spray

Illuminate Work Area Safely

Work In Ventilated Area

Remove Paint Before Welding or Heating

Avoid Harmful Asbestos Dust

Service Tires Safely

Stay Clear of Rotating Drivelines

Service Cooling System Safely

Dispose of Waste Properly

Handle Chemical Products Safely

Live With Safety

Section 20: Specifications and Information

Group 05: General Specifications

Metric Bolt and Screw Torque Values

Metric Cap Screw Torque Values—Grade 7

Unified Inch Bolt and Screw Torque Values

Gasket Sealant Application

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for O-Ring Boss Fittings

Group 10: Fuel and Lubricants

Diesel Fuel

Handling and Storing Diesel Fuel

Diesel Engine Oil

Diesel Engine Break-In Oil

Alternative and Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Grease

Transmission and Hydraulic Oil

Heavy Duty Diesel Engine Coolant

Group 15: Serial Number Locations

Serial Numbers

Machine Product Identification Number

Engine and Turbocharger Serial Numbers

Section 30: Engine

Group 05: Specifications

General Specifications

Repair Specifications

Tests and Adjustment Specifications

Operational Tests

Torque Values, Non-Standard Fasteners

Special Tools

Other Materials

Group 10: Component Location

Air Cleaner and Intake Components

Turbocharge Components

Fuel Supply Components

Engine Throttle Components

Throttle Components—AutoHST

Group 15: Theory of Operation

Fuel System Operation

Cooling System Operation

Air Intake System

Turbocharger Operation

Lubrication System Operation

Group 20: Diagnostics

Engine Troubleshooting

Engine Oil Diagnostics

Excessive Fuel Consumption

Incorrect Manifold Pressure

Low Engine Compression

Engine Starting Problem

Engine Operation Poor

Engine Oil Pressure Low

Coolant Temperature Abnormal

Coolant in Oil or Oil in Coolant

Turbocharger Failure Analysis

Diagnostic Table

Check for Head Gasket Failures

Group 25: Tests and Adjustments

Check Air Intake System

Air Restriction Indicator Test

Check for Intake and Exhaust Restrictions

Fan/Alternator Drive Belt Adjustment

Throttle Rod Adjustment

Slow Idle Adjustment

Cylinder Compression Test

Valve Clearance Adjustment

Valve Lift Check

Radiator Bubble Test

Thermostat Opening Test

Radiator Pressure Cap Test

Cooling System Pressure Test

Engine Oil Pressure Test

Check for Excessive Engine Crankcase Pressure (Turbocharged Engines)

Fuel System Leakage Test

Bleed Fuel System

Fuel Supply Pump Pressure Test

Injection Pump Timing—EPA Engines

Fuel Injection Nozzle Test

Check for Exhaust Air Leaks (Turbocharger)

Turbocharger Oil Seal Leak Check

Turbocharger Waste Gate Test

Turbocharger Inspection

Crankshaft End Play Check

Timing Gear Backlash Check

Camshaft End Play Check

Connecting Rod Side Play Check

Connecting Rod Bearing Clearance Check

Crankshaft Main Bearing Clearance Check

Group 30: Repair

Glow Plug Removal and Installation (If Equipped)

Radiator Removal and Installation

Thermostat Removal and Installation

Water Pump Removal and Installation

Fuel Filter/Water Separator 3TNV

Secondary Fuel Filter 3TNV

Fuel Injection Pump

Fuel Injection Nozzles

Intake Manifold

Muffler Removal and Installation

Turbocharger Removal and Installation

Exhaust Manifold

Starting Motor Removal and Installation

Rocker Cover Removal and Installation

Engine Removal and Installation

Rocker Arm Assembly

Cylinder Head and Valves Removal and Installation

Cylinder Head and Valves Disassembly and Assembly

Valve Seats

Valve Recession

Valve Guides

Valve Springs

Grind Valve Seats

Lap Valves

Measure Piston-To-Cylinder Head Clearance

Piston and Connecting Rod

Piston Inspection

Cylinder Bore

Crankshaft Front Oil Seal

Crankshaft Rear Oil Seal

Crankshaft and Main Bearings

Flywheel and Coupling

Camshaft

Camshaft Followers

Timing Gear Cover

Idler Gear

Timing Gear Cover Mounting Plate

Oil Pan and Crankcase Housing Extension

Oil Pump (Engines 3TNV8x-JT, -MJT)

Oil Pump (Engines 3TNV8x-BJT, -BMJT, -BXJT)

Section 40: Electrical—NA

Group 05: General Information

Reading Electrical Schematics

Theory Of Operation Information

Diagnostic Information

Wire Color Abbreviation Chart

Common Circuit Tests

Conductors For 12 Volt Circuits

Group 10: Specifications

System Specifications

Essential or Recommended Tools

Other Materials

Group 15: Component Location

Load Center

Load Center—MY13

Display Panel

Display Panel—MY13

Group 20: Schematics and Harnesses

Main Schematic and Wiring Harness Legend—PRT and eHydro™

eHydro™—Schematic and Wiring Harness Legend

W1 Main Wiring Schematic—PRT and eHydro™ (Pre MY08)

W1 Main Wiring Harness—PRT and eHydro™ (Pre MY08)

W1 Main Wiring Harness Color Codes—PRT and eHydro™ (Pre MY08)

Load Center—PRT and eHydro™

W1 Main Wiring Harness Component Location—PRT, eHydro™, and Auto HST

W9 eHydro™ and Cruise Control Electrical Schematic (1 of 2)—Pre MY08

W9 eHydro™ Wiring Harness—Pre MY08

W9 eHydro™ Wiring Harness Component Location—Pre MY08

W9 eHydro™ Wiring Harness Color Codes—Pre MY08

W28 3rd, 4th and 5th Function Wiring Harness Color Codes (SN 710001— )

W28 3rd, 4th and 5th Function Wiring Harness (SN 710001— )

W28 3rd, 4th and 5th Function Wiring Schematic (SN 710001— )

Group 25: Schematics and Harnesses MY08

Main Schematic and Wiring Harness Legend—PRT, eHydro™, and Auto HST

W9 eHydro™/Auto HST—Schematic and Wiring Harness Legend

W1 Main Wiring Schematic—MY08

W1 Main Wiring Harness—MY08

W1 Main Wiring Harness Color Codes—MY08

W9 eHydro™/Auto HST and Cruise Control Electrical Schematic—MY08

W9 eHydro™/Auto HST Wiring Harness—MY08

W9 eHydro™/Auto HST Wiring Harness Color Codes—MY08

W9 eHydro™/Auto HST Wiring Harness—MY08

Group 30: Schematics and Harnesses MY13

Main Schematic and Wiring Harness Legend—PRT, eHydro™, and Auto HST

W9 eHydro™/Auto HST—Schematic and Wiring Harness Legend

W1 Main Wiring Schematic—MY13

W1 Main Wiring Harness—MY13

W1 Main Wiring Harness Color Codes—MY13

W9 eHydro™/Auto HST and Cruise Control Electrical Schematic—MY13

W9 eHydro™/Auto HST Wiring Harness—MY13

W9 eHydro™/Auto HST Wiring Harness Color Codes—MY13

W9 eHydro™/Auto HST Wiring Harness—MY13

Group 35: Common Schematics and Harnesses

W2 Headlights Wiring Harness

W2 Headlight/Horn Wiring Harness Color Codes

W3 and W4 Jumper Plug

W7 Left Rear Lights Wiring Harness—Pre MY08

W7 Left Rear Lights Wiring Harness—MY08 and MY13

W7 Left Rear Lights Wiring Harness Color Codes

W8 Right Rear Lights Wiring Harness—Pre MY08

W8 Right Rear Lights Wiring Harness—MY08 and MY13

W8 Right Rear Lights Wiring Harness Color Codes

W10 eHydro™/Auto HST Proportional Valve Wiring Harness

W10 eHydro™/Auto HST Proportional Valve Wiring Harness Color Codes

W11 eHydro™/Auto HST Cruise Control Wiring Harness (Standard)

W11 eHydro™/Auto HST Cruise Control Wiring Harness Color Codes (Standard)

W12 eHydro™/Auto HST Cruise Control Wiring Harness (Optional)

W12 eHydro™/Auto HST Cruise Control Wiring Harness Color Codes (Optional)

Group 40: Operation and Diagnostics

Power Circuit Operation—NA

Power Circuit Electrical Schematic—W1 PRT and eHydro™—Pre MY08

Power Circuit Electrical Schematic—W9 eHydro™—Pre MY08

Power Circuit Electrical Schematic—MY08

Power Circuit Electrical Schematic—W9 eHydro™/Auto HST—MY08

Power Circuit Electrical Schematic—MY13

Power Circuit Electrical Schematic—W9 eHydro™/Auto HST—MY13

Power Circuit Diagnosis—NA

Power Circuit Diagnosis—MY13

Cranking Circuit Operation—NA

Cranking Circuit Operation—MY13

Cranking Circuit Electrical Schematic—Pre MY08

Cranking Circuit Electrical Schematic—MY08

Cranking Circuit Electrical Schematic—MY13

Cranking Circuit Diagnosis

Cranking Circuit Diagnosis—MY13

Manifold Heater and Indicator Light Circuit Operation

Manifold Heater and Indicator Light Circuit Operation—MY13

Manifold Heater and Indicator Light Circuit Electrical Schematic—Pre MY08

Manifold Heater and Indicator Light Circuit Electrical Schematic—MY08

Manifold Heater and Indicator Light Circuit Electrical Schematic—MY13

Manifold Heater and Indicator Light Circuit Diagnosis

Manifold Heater and Indicator Light Circuit Diagnosis—MY13

Fuel Supply/Engine Shutoff Circuit Operation—NA

Fuel Supply/Engine Shutoff Circuit Operation—MY13

Fuel Supply/Fuel Pump/Engine Shutoff Circuit Electrical Schematic—Pre MY08

Fuel Supply/Fuel Pump/Engine Shutoff Circuit Electrical Schematic—MY08

Fuel Supply/Fuel Pump/Engine Shutoff Circuit Electrical Schematic—MY13

Fuel Supply/Engine Shutoff Circuit Diagnosis

Fuel Supply/Engine Shutoff Circuit Diagnosis—MY13

Charging Circuit Operation

Tachometer Circuit Operation

Tachometer Circuit Operation—MY13

Hour Meter Circuit Operation

Speedometer Circuit Operation—eHydro™ and Auto HST

Charging, Tachometer, Speedometer and Hour Meter Circuit Electrical Schematic—Pre MY08

Charging, Tachometer, Speedometer and Hour Meter Circuit Electrical Schematic—MY08

Charging, Tachometer, Speedometer and Hour Meter Circuit Electrical Schematic—MY13

Charging, Tachometer and Hour Meter Circuit Diagnosis

Charging, Tachometer and Hour Meter Circuit Diagnosis—MY13

Rear and Mid PTO Circuit Operation

Rear and Mid PTO Circuit Operation—MY13

Rear and Mid PTO Circuit Electrical Schematic—Pre MY08

Rear and Mid PTO Circuit Electrical Schematic—MY08

Rear and Mid PTO Circuit Electrical Schematic—MY13

Rear and Mid PTO Circuit Diagnosis

Rear and Mid PTO Circuit Diagnosis—MY13

MFWD Circuit Operation

MFWD Circuit Electrical Schematic—Pre MY08

MFWD Circuit Electrical Schematic—MY08

MFWD Circuit Electrical Schematic—MY13

MFWD Circuit Diagnosis

Light Circuit Operation

Lights Circuit Electrical Schematic—Pre MY08

Lights Circuit Electrical Schematic—MY08

Lights Circuit Electrical Schematic—MY13

Lights Circuit Diagnosis

Lights Circuit Diagnosis—MY13

Turn Signal Lights Circuit Operation—Pre MY08

Turn Signal Lights Circuit Operation—MY13

Turn Signal Lights Circuit Electrical Schematic—Pre MY08

Turn Signal Lights Circuit Electrical Schematic—MY08

Turn Signal Lights Circuit Electrical Schematic—MY13

Turn Signal Lights Circuit Diagnosis—Pre MY08

Turn Signal Lights Circuit Diagnosis—MY13

Display Panel Operation—Pre MY08

Display Panel Operation—MY08

Display Panel Operation—MY13

Display Panel LCD Message

Display Panel Diagnosis

Display Mode Switch Circuit Operation—NA

Display Mode Switch Circuit Electrical Schematic—Pre MY08

Display Mode Switch Circuit Electrical Schematic—MY08

Display Mode Switch Circuit Electrical Schematic—MY13

Display Mode Switch Circuit Diagnosis

Display Mode Switch Circuit Diagnosis—MY13

eHydro™—eMatchOS Electronic Drive Controller

Auto HST—eMatchOS Electronic Drive Controller—MY08

Auto HST—eMatchOS Electronic Drive Controller—MY13

eHydro™—Forward Drive Circuit Operation—Pre MY08

eHydro™—Forward Drive Circuit Operation—MY08

eHydro™—Forward Drive Circuit Operation—MY13

Auto HST—Forward Drive Circuit Operation

eHydro™—Forward Drive Circuit Electrical Schematic—Pre MY08

eHydro™/Auto HST—Forward Drive Circuit Electrical Schematic—MY08

eHydro™/Auto HST—Forward Drive Circuit Electrical Schematic—MY13

eHydro™—Forward Drive Circuit Diagnosis—Pre MY08

eHydro™—Forward Drive Circuit Diagnosis—MY08

eHydro™—Forward Drive Circuit Diagnosis—MY13

Auto HST—Forward Drive Circuit Diagnosis—MY08

Auto HST—Forward Drive Circuit Diagnosis—MY13

eHydro™—Reverse Drive Circuit Operation—Pre MY08

eHydro™—Reverse Drive Circuit Operation—MY08

eHydro™—Reverse Drive Circuit Operation—MY13

Auto HST—Reverse Drive Circuit Operation

Auto HST—Reverse Drive Circuit Operation—MY13

eHydro™—Reverse Drive Circuit Electrical Schematic—Pre MY08

Auto HST—Reverse Drive Circuit Electrical Schematic—MY08

Auto HST—Reverse Drive Circuit Electrical Schematic—MY13

eHydro™—Reverse Drive Circuit Diagnosis—Pre MY08

eHydro™—Reverse Drive Circuit Diagnosis—MY08

eHydro™—Reverse Drive Circuit Diagnosis—MY13

Auto HST—Reverse Drive Circuit Diagnosis

eHydro™—Cruise Control Circuit Operation (Standard)—Pre MY08

Auto HST—Cruise Control Circuit Operation (Standard)—MY08

Auto HST—Cruise Control Circuit Operation (Standard)—MY13

eHydro™—Cruise Control Circuit Electrical Schematic (Standard)—Pre MY08

eHydro™/Auto HST—Cruise Control Circuit Electrical Schematic (Standard)—MY08

eHydro™/Auto HST—Cruise Control Circuit Electrical Schematic (Standard)—MY13

eHydro™—Cruise Control Circuit Diagnosis (Standard)—Pre MY08

eHydro™—Cruise Control Circuit Diagnosis (Standard)—MY08

eHydro™—Cruise Control Circuit Diagnosis (Standard)—MY13

Auto HST—Cruise Control Circuit Diagnosis (Standard)

eHydro™—Cruise Control Circuit Operation (Optional)—Pre MY08

Auto HST—Cruise Control Circuit Operation (Optional)—MY08

Auto HST—Cruise Control Circuit Operation (Optional)—MY13

eHydro™—Cruise Control Circuit Electrical Schematic (Optional)—Pre MY08

eHydro™/Auto HST—Cruise Control Circuit Electrical Schematic (Optional)—MY08

eHydro™/Auto HST—Cruise Control Circuit Electrical Schematic (Optional)—MY13

eHydro™—Cruise Control Circuit Diagnosis (Optional)

eHydro™—Cruise Control Circuit Diagnosis (Optional)—MY13

Auto HST—Cruise Control Circuit Diagnosis (Optional)

eHydro™—Load Match and Motion Match Circuit Operation—Pre MY08

eHydro™/Auto HST—Motion Match and Load Match Circuit Operation—MY08

eHydro™/Auto HST—Motion Match and Load Match Circuit Operation—MY13

eHydro™—Load Match and Motion Match Circuit Electrical Schematic—Pre MY08

eHydro™/Auto HST—Motion Match and Load Match Circuit Electrical Schematic—MY08

eHydro™/Auto HST—Motion Match and Load Match Circuit Electrical Schematic—MY13

eHydro™—Load Match and Motion Match Control Circuit Diagnosis

Auto HST—Motion Match Control Circuit Diagnosis

Group 45: Tests and Adjustments

Ground Circuit Test

Battery Voltage and Specific Gravity Test

Battery—Charge

Battery—Load Test

Alternator Regulated Voltage Test

Regulated Amperage and Voltage Test

Starting Motor Solenoid Test

Starting Motor Amperage Draw Test

Starting Motor No-Load Amperage Draw and RPM Test

Fuse Test

Manifold Heater Test

Engine Coolant Temperature Sensor Test

Engine Oil Pressure Switch Test

Relay Test

Key Switch Test

Light Switch Test

Sensing Switch Test

Turn Signal Switch Test

Rear PTO Switch Test

Rear PTO Switch Test—MY13

Rear PTO Solenoid Tests

Seat Switch Test

Cruise/Max Speed Switch Test—eHydro™/Auto HST

Res/+, Set/- Switch Test—eHydro™/Auto HST

Brake and Park Brake Switch Test

Air Filter Restriction Switch Test

Fuel Gauge Sensor Test

Fuel Shutoff Solenoid Test

Load Match Switch Test—eHydro™

Motion Match Switch Test—eHydro™/Auto HST

Display Mode Switch Test

Proportional Drive Solenoid Test—eHydro™/Auto HST

Horn Switch Test

FNR Switch Test—Auto HST

Group 50: Display Panel Tests and Adjustments

Display Panel Fault Codes—Auto HST/eHydro™

Display Panel Fault Code Chart—eHydro™

Display Panel Fault Code Chart MY13—eHydro™

Display Panel Fault Code Chart—Auto HST

Display Panel Fault Code Chart MY13—Auto HST

Configure the Display

Editing Tire Size Value

Editing Motion Match Settings—eHydro™/Auto HST

Editing Load Match Settings—eHydro™

Entering Diagnostic and Calibration Modes

eHydro™—Electronic Drive Controller System Calibration

Auto HST—Electronic Drive Controller System Calibration

eHydro™/Auto HST—Single Sensor Calibration

Group 55: SERVICEGARD™ Tests and Adjustments

Test Kit

eHydro™/Auto HST—Throttle Position Sensor Test and Adjustment

eHydro™—Forward and Reverse Pedal Sensor Test and Adjustment

Auto HST—Drive Pedal Sensor Test and Adjustment

eHydro™—MFWD Speed Sensor Test

Auto HST—MFWD Speed Sensor Test

Group 60: Service ADVISOR™ Test and Adjustments

eHydro™—Service ADVISOR™ Diagnostic Application

Retrieving Diagnostic Trouble Codes with Service ADVISOR™ Diagnostic Application™

Adding and Removing Data Points

Service ADVISOR™ Connection Procedure

HST/Auto-HST Troubleshooting Flowchart

eHydro™—eMatchOS Electronic Drive Controller Circuit Operation

eHydro™/Auto HST Potentiometer Calibration Using Service ADVISOR™

eHydro™—Control System Complete Calibration Using Service ADVISOR™

Auto HST—Control System Complete Calibration Using Service ADVISOR™

eHydro™—Forward and Reverse Threshold Calibration

Auto HST—Forward and Reverse Threshold Calibration

Controller Reprogramming

Group 65: Repair

Throttle Position Sensor Removal and Installation

Auto HST Direction Switch Replacement

Electronic Drive Controller Removal and Installation

Starting Motor Disassembly and Assembly

Starting Motor Inspection/Test

Starting Motor Gear Train

Starting Motor Solenoid

Alternator Components

Alternator Removal and Installation

Alternator Disassembly and Assembly

Fuel Gauge Sensor Removal and Installation

Section 50: Electrical—EEC

Group 05: Specifications

System Specifications

Essential or Recommended Tools

Other Materials

Group 10: Component Location

Display Panel

Load Center

Load Center—MY13

Group 15: Schematics and Harnesses

Main Schematic and Wiring Harness Legend—PRT and eHydro™ (Pre MY08)

eHydro™—Schematic and Wiring Harness Legend

Main Electrical Schematic (Pre MY08)

W1 Main Wiring Harness (Pre MY08)

W1 Main Wiring Harness Color Codes (Pre MY08)

Load Center—Pre MY08

W1 Main Wiring Harness Component Location (Pre MY08)

W9 eHydro™ and Cruise Control Electrical Schematic (1 of 2) (Pre MY08)

W9 eHydro™ Wiring Harness Color Codes

W9 eHydro™ Wiring Harness (Pre MY08)

W9 eHydro™ Wiring Harness Component Location (Pre MY08)

Group 20: Schematics and Harnesses MY08

Main Schematic and Wiring Harness Legend—PRT and eHydro™—MY08

eHydro™—Schematic and Wiring Harness Legend—MY08

Main Electrical Schematic—MY08

W1 Main Wiring Harness—MY08

W1 Main Wiring Harness Color Codes—MY08

Load Center—MY08

W1 Main Wiring Harness Component Location—MY08

W9 eHydro™ and Cruise Control Electrical Schematic—MY08

W9 eHydro™ Harness—MY08

W9 eHydro™/AutoHST Wiring Harness Color Codes—MY08

W9 eHydro™/AutoHST Wiring Harness—MY08

Group 25: Schematics and Harnesses—MY13

Main Schematic and Wiring Harness Legend—PRT and eHydro™—MY13

eHydro™—Schematic and Wiring Harness Legend—MY13

Main Electrical Schematic—MY13

W1 Main Wiring Harness—MY13

W1 Main Wiring Harness Color Codes—MY13

Load Center—MY13

W1 Main Wiring Harness Component Location—MY13

W9 eHydro™ and Cruise Control Electrical Schematic—MY13

W9 eHydro™ Harness—MY13

W9 eHydro™/AutoHST Wiring Harness Color Codes—MY13

W9 eHydro™/AutoHST Wiring Harness—MY13

Group 30: Common Schematics and Harnesses

W2 Headlight/Horn Wiring Harness

W2 Headlight/Horn Wiring Harness Color Codes

W3 and W4 Jumper Plug

W7 Left Rear Lights Wiring Harness

W7 Left Rear Lights Wiring Harness Color Codes

W8 Right Rear Lights Wiring Harness

W8 Right Rear Lights Wiring Harness Color Codes

W10 Proportional Valve Wiring Harness

W10 Proportional Valve Wiring Harness Color Codes

W11 Cruise Control Wiring Harness (Standard)

W11 eHydro™ Cruise Control Wiring Harness Color Codes (Standard)

W12 Cruise Control Wiring Harness (Optional)

W12 eHydro™ Cruise Control Wiring Harness Color Codes (Optional)

Group 35: Troubleshooting

Display Panel Fault Codes

Display Panel Fault Code Chart

Group 40: Operation and Diagnostics

Power Circuit Operation

Power Circuit Electrical Schematic—W1 PRT and eHydro™ (Pre MY08)

Power Circuit Electrical Schematic—W9 eHydro™

Power Circuit Electrical Schematic—W1 PRT and eHydro™—MY08

Power Circuit Electrical Schematic—W1 PRT and eHydro™—MY13

Power Circuit Electrical Schematic—W9 eHydro™—MY08

Power Circuit Electrical Schematic—W9 eHydro™—MY13

Power Circuit Diagnosis

Power Circuit Diagnosis—MY13

Cranking Circuit Operation

Cranking Circuit Operation—MY13

Cranking Circuit Electrical Schematic—Pre MY08

Cranking Circuit Electrical Schematic—MY08

Cranking Circuit Electrical Schematic—MY13

Cranking Circuit Diagnosis

Cranking Circuit Diagnosis—MY13

Manifold Heater and Indicator Light Circuit Operation

Manifold Heater and Indicator Light Circuit Electrical Schematic—Pre MY08

Manifold Heater and Indicator Light Circuit Electrical Schematic—MY08

Manifold Heater and Indicator Light Circuit Electrical Schematic—MY13

Manifold Heater and Indicator Light Circuit Diagnosis

Fuel Supply/Engine Shutoff Circuit Operation

Fuel Supply/Engine Shutoff Circuit Operation—MY13

Fuel Supply/Engine Shutoff Circuit Electrical Schematic—Pre MY08

Fuel Supply/Engine Shutoff Circuit Electrical Schematic—MY08

Fuel Supply/Engine Shutoff Circuit Electrical Schematic—MY13

Fuel Supply/Engine Shutoff Circuit Diagnosis

Fuel Supply/Engine Shutoff Circuit Diagnosis—MY13

Charging Circuit Operation

Tachometer Circuit Operation

Tachometer Circuit Operation—MY13

Hour Meter Circuit Operation

Speedometer Circuit Operation (eHydro™)

Charge, Tachometer, Speedometer and Hour Meter Circuit Electrical Schematic—Pre MY08

Charge, Tachometer, Speedometer and Hour Meter Circuit Electrical Schematic—MY08

Charge, Tachometer, Speedometer and Hour Meter Circuit Electrical Schematic—MY13

Charge, Tachometer and Hour Meter Circuit Diagnosis

Charge, Tachometer and Hour Meter Circuit Diagnosis—MY13

Rear and Mid PTO Circuit Operations

Rear and Mid PTO Circuit Operation—MY13

Front PTO Circuit Operation

PTO Circuit Electrical Schematic—Pre MY08

PTO Circuit Electrical Schematic—MY08

PTO Circuit Electrical Schematic—MY13

Rear and Mid PTO Circuit Diagnosis Pre MY08/MY08

Rear and Mid PTO Circuit Diagnosis—MY13

Front PTO Circuit Diagnosis

Front PTO Circuit Diagnosis—MY13

MFWD Circuit Operation

MFWD Circuit Operation—MY13

MFWD Circuit Electrical Schematic—Pre MY08

MFWD Circuit Electrical Schematic—MY08

MFWD Circuit Electrical Schematic—MY13

MFWD Circuit Diagnosis

MFWD Circuit Diagnosis—MY13

Light Circuit Operation—Pre MY08

Light Circuit Operation—MY08

Light Circuit Operation—MY13

Brake Lights Circuit Operation

Lights Circuit Electrical Schematic—Pre MY08

Lights Circuit Electrical Schematic—MY08

Lights Circuit Electrical Schematic—MY13

Lights Circuit Diagnosis—Pre MY08

Lights Circuit Diagnosis—MY08

Lights Circuit Diagnosis—MY13

Brake Lights Circuit Diagnosis

Brake Lights Circuit Diagnosis—MY13

Hazard Lights Circuit Operation

Hazard Lights Circuit Operation—MY13

Hazard Lights Circuit Electrical Schematic

Hazard Lights Circuit Electrical Schematic—MY13

Hazard Lights Circuit Diagnosis

Hazard Lights Circuit Diagnosis—MY13

Turn Signal Lights Circuit Operation

Turn Signal Lights Circuit Operation—MY13

Turn Signal Circuit Electrical Schematic

Turn Signal Circuit Electrical Schematic—MY13

Turn Signal Lights Circuit Diagnosis

Display Panel Operation

Display Panel Operation—MY13

Display Panel LCD Message

Display Panel Diagnosis

Display Mode Switch Circuit Operation

Display Mode Switch Circuit Electrical Schematic Pre MY08

Display Mode Switch Circuit Electrical Schematic—MY08

Display Mode Switch Circuit Electrical Schematic—MY13

Display Mode Switch Circuit Diagnosis

eHydro™—eMatchOS Electronic Drive Controller

eHydro™—Forward Drive Circuit Operation

eHydro™—Forward Drive Circuit Electrical Schematic—Pre MY08

eHydro™—Forward Drive Circuit Electrical Schematic—MY08

eHydro™—Forward Drive Circuit Electrical Schematic—MY13

eHydro™—Forward Drive Circuit Diagnosis

eHydro™—Reverse Drive Circuit Operation

eHydro™—Reverse Drive Circuit Electrical Schematic—Pre MY08

eHydro™—Reverse Drive Circuit Electrical Schematic—MY08

eHydro™—Reverse Drive Circuit Electrical Schematic—MY13

eHydro™—Reverse Drive Circuit Diagnosis

eHydro™—Cruise Control Circuit Operation (Standard)

eHydro™—Cruise Control Circuit Electrical Schematic (Standard)—Pre MY08

eHydro™—Cruise Control Circuit Electrical Schematic (Standard)—MY08

eHydro™—Cruise Control Circuit Electrical Schematic (Standard)—MY13

eHydro™—Cruise Control Circuit Diagnosis (Standard)

eHydro™—Cruise Control Circuit Operation (Option)

eHydro™—Cruise Control Circuit Electrical Schematic (Option)—Pre MY08

eHydro™—Cruise Control Circuit Electrical Schematic (Option)—MY08

eHydro™—Cruise Control Circuit Electrical Schematic (Option)—MY13

eHydro™—Cruise Control Circuit Diagnosis (Option)

eHydro™—Load Match and Motion Match Circuit Operation

eHydro™—Load Match and Motion Match Circuit Electrical Schematic—Pre MY08

eHydro™—Load Match and Motion Match Circuit Electrical Schematic—MY08

eHydro™—Load Match and Motion Match Circuit Electrical Schematic—MY13

eHydro™—Load Match and Motion Match Control Circuit Diagnosis

Section 60: Power Train—PRT

Group 05: Specifications

Repair Specifications

Torque Specifications

Essential or Recommended Tools

Other Material

Group 10: Component Location

Tunnel and Transmission Case

PRT Clutch

Drive/Pinion Shaft

4 Speed Gear Shaft

4 Speed Gear Shift

Range Shift

PRT Pedal and Shift Linkage

PRT Valve

Group 15: Theory of Operation

PRT Control Valve Operation

PRT Clutch Operation—Forward

PRT Clutch Operation—Reverse

Transmission Operation

Group 20: Diagnostics

PowrReverser™ (PRT) Power Train

Group 25: Troubleshooting

PowrReverser (PRT) Troubleshooting

Group 30: Tests and Adjustments

PRT Clutch Linkage Adjustment and Test

PRT Hydraulic Pressure Tests

Group 35: Repair

PRT Clutch Pedal and Linkage Removal and Installation

PRT Shift/Clutch Valve Removal and Installation

PRT Machine Splitting (Rear)

PRT Traction Clutch Removal and Installation

PRT Traction Clutch Disassembly and Assembly

Transmission Gear Set Removal and Installation

Section 70: Power Train—Hydrostatic

Group 05: Specifications

General Specifications

Essential or Recommended Tools

Other Material

Group 10: Component Location

Hydrostatic Machines Component Location

Transmission (Hydrostatic)

Hydrostatic Transmission Components

Hydrostatic Center Plate Components

Drive Shaft Components

Front Drive Components

Group 15: Schematics

Charge Pump Schematic, Hydro Transmission

Group 20: Theory of Operation

Hydrostatic Transmission Operation

Range Transmission Power Flow

Group 25: Diagnostics

Hydrostatic (eHydro™/AutoHST) Power Train

Group 30: Troubleshooting

Troubleshooting

Group 35: Tests and Adjustments

Hydrostatic High Pressure Relief Test

Charge Pump Pressure Test and Adjustment

Group 40: Repair

Forward and Reverse Pedal Sensors—eHydro™

Forward and Reverse Pedals—eHydro™

Drive Pedal Sensor—AutoHST

Drive Pedal—AutoHST

Machine Splitting (Front)

Machine Splitting (Rear)

Hydrostatic Transmission Removal and Installation

Hydrostatic Transmission Disassembly

System Check/Relief Valve Inspection/Replacement

Section 80: Power Train—Final Drive

Group 05: Specifications

General Specifications

Repair Specifications

Torque Specifications

Essential or Recommended Tools

Other Material

Group 10: Component Location

Transmission (eHydro™)

Main and Driven Shafts (eHydro™)

Drive/Pinion Shaft (eHydro™)

Drive/Pinion Shaft (PRT)

4 Speed Gear Shaft (PRT)

Range Shift

Differential Assembly

Rear Axle and Final Drive

Brake Component Location

PTO Clutch/Brake Assembly

PTO Rear Shaft

Rear and Mid PTO Shafts

Rear and Mid PTO Shift Assembly

Transmission Housing (eHydro™)

Front Drive (For MFWD)

MFWD Front Axle Housing and Differential

MFWD Final Drive Component Location

Group 15: Theory of Operation

Range Transmission—eHydro™

Range Transmission—PRT

Differential Power Flow and Lock

MFWD Power Operation

MFWD Front Axle

Group 20: Diagnostics

Symptom: PTO Diagnostics Table

Final Drive Diagnosis

Group 25: Troubleshooting

Troubleshooting Table

Group 30: Final Drive Troubleshooting

Final Drive Symptom Diagnosis

Differential Lock Symptom Diagnosis

Group 35: Tests and Adjustments

Differential Pinion Shaft Adjustment

Differential Backlash Adjustment

Group 40: Repair

MFWD Output Shaft

Speed Range Transmission (eHydro™)

Main Gear Disassembly/Assembly

Assemble Range Transmission (eHydro™)

Final Drive Removal

Final Drive Installation

Final Drive Disassemble, Inspect, and Assemble

Differential Lock Fork

Differential Removal and Installation

MFWD Drive Shaft Removal and Installation

MFWD Removal and Installation

MFWD Final Drive Cover Removal and Inspection

MFWD Spindle Shaft

MFWD Final Drive Housing

MFWD Spindle Housing

MFWD Differential

Pinion Depth Setup and Adjustment

Group 45: PTO Theory of Operation

PTO Clutch and Brake Theory of Operation

Power Transmission—Rear PTO

Power Transmission—Mid PTO

Group 50: PTO Repair

PTO Drive Shaft and Gears

Rear and Mid PTO Shifter

PTO Clutch and Brake

Mid PTO

Section 90: Hydraulics

Group 05: Specifications

Hydraulic Specifications

Repair Specifications

Torque Specifications

Group 10: Component Location

Steering System Components, PowrReverser™

Steering System Components, eHydro™

Rockshaft Piston, Rod, and Rate of Drop Valve

Rockshaft Control Valve, Plunger Assembly and Controls

Rockshaft and Lift Arms (Exploded View)

SCV Component Location

SCV and Rockshaft System Components

Group 15: Schematics

Steering System Schematics, PowrReverser™

Steering System Schematics, eHydro™

SCV and Rockshaft System Schematics (SN —710000)

Dual or Triple SCV Schematics (SN —710000)

2-Spool SCV Schematics (SN 710001— )

3rd, 4th, and 5th SCV Schematics (SN 710001— )

Manifold Block Schematics

Diverter Valve Schematic (SN —710000)

Diverter Valve Schematic (SN 710001— )

Group 20: Theory of Operation

PowrReverser™ Hydraulic Operation

eHydro™ Hydraulic Operation

Main PTO Clutch Operation

PTO Valve Operation

Rockshaft Operation

Diverter Valve (SN —710000)

Diverter Valve (SN 710001— )

Group 25: Diagnostics

Hydrostatic (eHydro™) Troubleshooting

Rockshaft Hydraulics

Group 30: Tests and Adjustments

Hydraulic System Bleed Procedure

Rate of Drop/Stop Valve Adjustment

Lift Arms Adjustment

System Pressure/Flow Test

System Pressure Adjustment

Steering Pressure Test

Charge Pressure Test—eHydro™

PTO Clutch Pressure Test

Rockshaft Lift Cycle Test

Rockshaft Leakage Test

Rockshaft Position Feedback Linkage Adjustment

Group 35: Repair

Hydraulic Gear Pump

Rockshaft Removal and Installation

Rockshaft Disassembly and Assembly

Rockshaft Lift Arms Removal and Installation

Selective Control Valve (SCV) (SN —710000)

Selective Control Valve (SCV) (SN 710001— )

Power Beyond Filter Replacement

Section 100: Steering

Group 05: Specifications

Steering

Torque Specifications

Lubrication Interval

Essential or Recommended Tools

Group 10: Component Location

Steering Components—eHydro™

Steering System Schematic

Group 15: Theory of Operation

All Models

eHydro™ Model

PowrReverser™ Model

Group 20: Diagnostics

Steering System Check

Steering Operation

Group 25: Tests and Adjustments

Steering Pressure Check

Steering System Test

Toe-in Adjustment MFWD

Group 30: Repair

Steering Cylinder Removal and Installation

Steering Wheel Removal and Installation

Tilt Steering Mechanism Removal and Installation

Steering Control Unit (SCU) Removal and Installation

Tie Rod Removal and Installation

Section 110: Brakes

Group 05: Specifications

Brakes

Transaxle Oil

Torque Specifications

Group 10: Component Location

Brake Housing

Brake Pedals and Linkage—eHydro™

Brake Pedals and Linkage—eHydro™ (Exploded View)

Brake Pedals and Linkage—AutoHST

Brake Pedals and Linkage—PRT

Brake Assembly

Group 15: Theory of Operation

Brakes

Group 20: Diagnostics

Brake Pedals and Linkage Checks

Brake Operation Problems

Internal Components

Group 25: Tests and Adjustments

Brake Adjustment

Parking Brake Adjustment

Group 30: Repair

Brake Pedal Assembly Removal and Installation

Brake Shaft Removal and Installation

Brake Disassemble and Inspect

Brake Assemble

Section 120: Miscellaneous

Group 05: Specifications

Torque Specifications

Group 10: Repair

Front Wheel Removal and Installation

Rear Wheel Removal and Installation

Rear Fenders Removal and Installation

Rear Breakaway Coupler Removal and Installation

Seat and Seat Support Removal and Installation

Seat Closeout Removal and Installation

Roll Over Protection System (ROPS)

Operator Platform Removal and Installation

Battery Removal and Installation

Fuse Panel Cover Removal and Installation

Cowl Panel Removal and Installation

Control Panel Removal and Installation

Hood Removal and Installation

Fuel Tank Removal and Installation

Throttle Cable Replacement/Adjustment (Auto HST)

Three Point Hitch Removal and Installation