All Inclusive Diagnostics & Repair Service Technical Manual for John Deere 3203 Compact Utility Tractors, with all the service information to maintain, diagnostic, repair, and service like professional mechanics.

John Deere Compact Utility Tractors Models 3203 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: 924 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
  Manual Description
   Safety
   Specifications & Information
   Engine - Diesel
   Electrical
   Power Train - Hydrostatic
   Power Train - Final Drive
   Hydraulics
   Steering
   Brakes
   Miscellaneous

tm1150 - Compact Utility Tractor 3203

Table of Contents

Manual Description

Section : Safety

Group : Safety

Recognize Safety Information

Understand Signal Words

Replace Safety Signs

Handle Fluids Safely - Avoid Fires

Use Care In Handling and Servicing Batteries

Prevent Battery Explosions

Prevent Acid Burns

Wear Protective Clothing

Use Care Around High-pressure Fluid Lines

Service Machines Safely

Use Proper Tools

Park Machine Safely

Support Machine Properly and Use Proper Lifting Equipment

Work In Clean Area

Using High Pressure Washers

Illuminate Work Area Safely

Work In Ventilated Area

Warning: California Proposition 65 Warning

Remove Paint Before Welding or Heating

Avoid Harmful Asbestos Dust

Service Tires Safely

Avoid Injury From Rotating Blades, Augers and PTO Shafts

Service Cooling System Safely

Dispose Of Waste Properly

Handle Chemical Products Safely

Live With Safety

Section : Specifications & Information

Group : General Specifications

Metric Fastener Torque Values

Metric Fastener Torque Values—Grade 7

Inch Fastener Torque Values

Gasket Sealant Application

Group : O-Ring Seal Service Recommendations

Face Seal Fittings with Inch Stud Ends Torque

Face Seal Fittings with Metric Stud Ends Torque

O-Ring Face Seal Fittings

O-Ring Boss Fittings

Group : Fuels and Lubricants

Diesel Fuel Specifications

Diesel Fuel Lubricity

Diesel Fuel Storage

Engine Oil

Engine Break–in Oil

Alternative Lubricants

Synthetic Lubricants

Lubricant Storage

Mixing Of Lubricants

Chassis Grease

Transaxle Oil

Group : Coolant Specifications

Engine Coolant

Engine Coolant Drain Interval

Group : Serial Number Locations

Machine Product Identification Number

Engine Serial Number

Section : Engine - Diesel

Group : Specifications

General Specifications

Tests and Adjustment Specifications

Repair Specifications

Operational Tests

Torque Values, Non-Standard Fasteners

Special Tools

Other Materials

Group : Component Location

Fuel Supply Components

Group : Theory of Operation

Fuel System Operation

Cooling System Operation

Lubrication System Operation

Group : Diagnostics

Engine Troubleshooting

Low Engine Output

Exhaust Abnormal Under Load

Engine Runs Rough

Excessive Fuel Consumption

Lubricating Oil

Temperature Problems

Low Compression

Incorrect Manifold Pressure

Starting Problems

Coolant in Oil or Oil in Coolant

Diagnostic Table

Check for Head Gasket Failures

Group : Tests and Adjustments

Check Air Intake System

Check for Intake and Exhaust Restrictions

Fan/Alternator Drive Belt Adjustment

Throttle Rod Adjustment

Slow Idle Adjustment

Thermostat Opening Test

Cylinder Compression Test

Valve Clearance Adjustment

Valve Lift Check

Radiator Bubble Test

Radiator Pressure Cap Test

Cooling System Pressure Test

Engine Oil Pressure Test

Engine Oil Consumption

Fuel System Leakage Test

Bleed Fuel System

Fuel Supply Pump Pressure Test

Injection Pump Timing

Fuel Injection Nozzle Test

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 : Repair

Radiator Removal and Installation

Thermostat Removal and Installation

Water Pump Removal and Installation

Fuel Filter/Water Separator

Secondary Fuel Filter

Fuel Injection Pump

Fuel Injection Nozzles

Intake Manifold

Muffler Removal and Installation

Exhaust Manifold

Starting Motor Removal and Installation

Alternator Removal and Installation

Rocker Cover Removal and Installation

Engine Removal and Installation

Engine/Flywheel Housing Split

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 Strainer

Oil Pump

Section : Electrical

Group : General Information

Reading Electrical Schematics

Theory Of Operation Information

Diagnostic Information

Wire Color Abbreviation Chart

Common Circuit Tests

Conductors For 12 Volt Circuits

Group : Specifications

System Specifications

Tools

Other Materials

Group : Component Location

Main Schematic and Wiring Harness Legend

W1 Main Wiring Schematic

W1 Main Wiring Harness

W1 Main Wiring Harness Color Codes

Load Center

W1 Main Wiring Harness Component Location

Group : Operation and Diagnostics

Power Circuit Operation

Power Circuit Electrical Schematic

Power Circuit Diagnosis

Cranking Circuit Operation

Cranking Circuit Electrical Schematic

Cranking Circuit Diagnosis

Manifold Heater and Indicator Light Circuit Operation

Manifold Heater and Indicator Light Circuit Electrical Schematic

Manifold Heater and Indicator Light Circuit Diagnosis

Fuel Supply/Engine Shutoff Circuit Operation

Fuel Supply/Fuel Pump/Engine Shutoff Circuit Electrical Schematic

Fuel Supply/Engine Shutoff Circuit Diagnosis

Charging Circuit Operation

Tachometer Circuit Operation

Hour Meter Circuit Operation

Charging, Tachometer, and Hour Meter Circuit Electrical Schematic

Charging, Tachometer and Hour Meter Circuit Diagnosis

PTO Circuit Operation

Rear PTO Circuit Electrical Schematic

PTO Circuit Diagnosis

Light Circuit Operation

Lights Circuit Electrical Schematic

Lights Circuit Diagnosis

Group : 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

Diode Test

Engine Coolant Temperature Sensor Test

Engine Oil Pressure Switch Test

Relay Test

Key Switch Test

Light Switch Test

Turn Signal Switch Test

Sensing Switch Test

PTO Switch Test

PTO Solenoid Test

Seat Switch Test

Fuel Gauge Sensor Test

Fuel Shutoff Solenoid Test

Group : Repair

Starting Motor Disassembly and Assembly

Starting Motor Inspection/Test

Starting Motor Gear Train

Starting Motor Solenoid

Fuel Gauge Sensor Removal and Installation

Section : Power Train - Hydrostatic

Group : Specifications

Hydrostatic Pump

Hydrostatic Motor

Torque Specifications

Special or Essential Tools

Other Materials

Group : Component Location

Machines Component Location

Forward and Reverse Pedals

Transmission

Transmission Components

Center Plate Components

Drive Shaft

Front Drive

Group : Schematics

Steering/Charge Pump Circuit Schematic

Group : Theory of Operation

Transmission Operation

Range Transmission Power Flow

Group : Diagnostics

Hydrostatic Power Train

Group : Troubleshooting

Troubleshooting

Group : Tests and Adjustments

Hydrostatic High Pressure Relief Test

Charge Pump Pressure Test and Adjustment

Hydraulic System Bleed Procedure

Hydrostatic Control Linkage Neutral Adjustment

Group : Repair

Forward and Reverse Pedals Assembly

Machine Splitting (Front)

Machine Splitting (Rear)

Hydrostatic Transmission Removal and Installation

Hydrostatic Transmission Disassembly

System Check/Relief Valve Inspection/Replacement

Charge Pressure Relief Valve Inspection/Replacement

Section : Power Train - Final Drive

Group : Specifications

General Specifications

Repair Specifications

Torque Specifications

Special or Essential Tools

Other Materials

Group : Component Location

Transmission

Main and Driven Shafts

Drive/Pinion Shaft

Range Shift

Differential Assembly

Rear Axle and Final Drive

Brake Assembly

PTO Clutch/Brake Assembly

Rear PTO Shaft

Transmission Housing

Front Drive (For MFWD)

MFWD Front Axle Housing and Differential

MFWD Final Drive

Group : Theory of Operation

Range Transmission

Differential Power Flow and Lock

MFWD Power Operation

MFWD Power Flow

Group : Diagnostics

Final Drive Diagnostic Checks

Diagnostics

PTO Diagnostics

Differential Lock Diagnostics

Group : Final Drive Troubleshooting

Final Drive Symptom Diagnosis

Group : Tests and Adjustments

Differential Pinion Shaft Adjustment

Differential Backlash Adjustment

Group : Repair

MFWD Output Shaft

Speed Range Transmission

Main Gear Disassembly/Assembly

Assemble Range Transmission

Final Drive Removal

Final Drive Installation

Final Drive Disassembly, Inspection, and Assembly

Differential Lock Fork

Differential Removal and Installation

MFWD Removal and Installation

MFWD Final Drive Cover

MFWD Spindle Shaft

MFWD Final Drive Housing

Spindle Housing

MFWD Differential

Pinion Depth Setup and Adjustment

Group : PTO Theory of Operation

PTO Clutch and Brake Theory of Operation

PTO Power Transmission

Group : PTO Repair

PTO Drive Shaft and Gears

PTO Clutch and Brake

Section : Hydraulics

Group : Specifications

Hydraulic Specifications

Repair Specifications

Torque Specifications

Group : Component Location and Schematics

Steering System Components

System Schematics

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

SCV and Rockshaft System Schematics

Group : Theory of Operation

Hydro Hydraulic Operation

Main PTO Clutch Operation

PTO Valve Operation

Rockshaft Operation

Group : Troubleshooting

Hydrostatic Troubleshooting

Rockshaft Hydraulics

Group : 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

PTO Clutch Pressure Test

Rockshaft Lift Cycle Test

Rockshaft Leakage Test

Rockshaft Position Feedback Linkage Adjustment

Group : Repair

Hydraulic Gear Pump

Rockshaft Removal and Installation

Rockshaft Disassembly and Assembly

Rockshaft Lift Arms Removal and Installation

Selective Control Valve (SCV)

Section : Steering

Group : Specifications

Steering

Torque Specifications

Special or Essential Tools

Group : Component Location

Steering Components

Steering System Schematic

Group : Theory of Operation

Steering

Group : Diagnostics

Steering System Check

Steering Operation

Group : Tests and Adjustments

Steering Pressure Check

Steering System Test

Toe-in Adjustment MFWD

Group : Repair

Steering Cylinder Removal and Installation MFWD

Steering Wheel Removal and Installation

Steering Control Unit (SCU) Removal and Installation

Tie Rod Removal and Installation MFWD

Section : Brakes

Group : Specifications

Brakes

Transaxle Oil

Torque Specifications

Group : Component Location

Brake Pedal and Linkage

Brake Pedal and Linkage (Exploded View)

Brake Assembly

Group : Theory of Operation

Brakes

Group : Diagnostics

Diagnostic Check Points

Brakes

Group : Tests and Adjustments

Brake Adjustment

Group : Repair

Brake Pedal Assembly Removal and Installation

Brake Shaft Removal and Installation

Brake Disassembly and Inspection

Brake Assembly

Section : Miscellaneous

Group : Specifications

General Specifications

Torque Specifications

Group : Repair

Front Wheel Removal and Installation

Rear Wheel Removal and Installation

Rear Fenders Removal and Installation

Seat and Seat Support Removal and Installation

Roll Over Protection System (ROPS)

Operator’s Foot Platforms

Hood Removal and Installation

Battery Removal and Installation

Control Panel Removal and Installation

Cowl Panel Removal and Installation

Fuel Tank Removal and Installation

John Deere Compact Utility Tractors 3203 Service Technical Manual (TM1150)