Complete All Inclusive Technical Manual with electrical wiring diagrams for John Deere Gator Utility Vehicles TX and TX Turf, with workshop information to maintain, diagnose, repair, and service like professional mechanics.

John Deere Gator Utility Vehicle TX and TX Turf workshop technical service manual (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting) 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.

tm2241 - Gator Utility VehicleTX and TX Turf Technical Manual.pdf
tm2241 - Gator Utility VehicleTX and TX Turf Technical Manual.epub

Total Pages: 1,540 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

MAIN SECTIONS
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
Group 05: Fastener Torques
Metric Bolt and Screw Torque Values
Unified Inch Bolt and Screw Torque Values
Group 10: 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
Straight Fitting or Special Nut Torques
Metric Cap Screw Torque Values—Grade 7
Gasket Sealant Application
Group 15: General Information
Gasoline
Gasoline Storage
4—Cycle Gasoline Engine Oil
Break-In Engine Oil—4-Cycle Gasoline
Hydrostatic Transmission and Hydraulic Oil
Grease
Chain Lubricant
Alternative Lubricants
Synthetic Lubricants
Lubricant Storage
Mixing of Lubricants
Oil Filters
Brake Fluid
Group 20: Serial Number Locations
Product Serial Number
Engine Serial Number Location
Transaxle Serial Number Location
Section 30: Engine – FJ400D
Group 05: Specifications
General Specifications
Test and Adjustment Specifications
Repair Specifications
Torque Specifications
Special or Essential Tools
Other Materials
Group 10: Component Location
FJ400D Engine for TX
FJ400D Engine for TX Turf
Fuel System Components—Evaporative
Carburetor Components
Starting Motor Components TX
Group 15: Theory of Operation
Carburetor Fuel/Air
Governor Operation
Evaporative Emissions System Operation
Ignition Theory
Group 20: Diagnostics
System: Engine Troubleshooting Guide
System: Starting Motor Troubleshooting Guide
Group 25: Tests and Adjustments—General
Air Intake System Check
Choke Cable Adjustment (FJ400D)
Fuel Pump Pressure Test
Fuel Pump Flow Test (FJ400D)
Valve Clearance Check and Adjustment
Automatic Compression Release Test
Ignition Coil Air Gap Adjustment
Spark Test (FJ400D)
Oil Pressure Test
Crankcase Vacuum Test
Group 30: Tests and Adjustments—TX
Throttle Cable and Pedal Stop Adjustment (FJ400D)
Governor Static Adjustment
Slow Idle Speed Adjustment (FJ400D)
Fast Idle Speed Adjustment
Group 35: Tests and Adjustments—TX Turf
Transaxle Governor and Throttle Adjustment
Carburetor Idle Stop Screw Static Adjustment
Group 40: Repair
Muffler Removal and Installation
Fuel Pump Removal and Installation
Carburetor Removal and Installation (FJ400D)
Carburetor Disassembly and Assembly (FJ400D)
Engine Removal and Installation (FJ400D)
Crankcase Breather Inspection
Blower Housing Removal and Installation
Flywheel Removal and Installation (FJ400D)
Rocker Arm Removal and Installation
Push Rod Inspection
Cylinder Head Removal and Installation
Cylinder Head Disassembly and Assembly
Cylinder Head Inspection and Replacement
Recondition Valve Seats
Lap Valves
Crankcase Cover Removal and Installation (FJ400D)
Camshaft Removal and Installation
Camshaft Inspection
Automatic Compression Release
Balancer
Tappet Inspection and Replacement
Piston and Connecting Rod
Crankshaft Removal and Installation
Crankshaft Inspection
Analyze Crankshaft and Connecting Rod Wear
Crankshaft Oil Seal
Cylinder Block Inspection
Cylinder Deglazing
Cylinder Reboring
Oil Pump Disassembly and Assembly
Oil Pump Inspection
Governor—TX
Ignition Module Removal and Installation
Stator Removal and Installation
Section 30A: Engine – FH601D
Group 05: Specifications
Specifications
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Group 10: Component Location
FH601D Engine
Fuel System Components
Carburetor Components
Group 15: Theory of Operation
Carbureted Engine Fuel and Air System Operation
Governor Operation
Lubrication System Operation
Group 20: Diagnostics
System: Engine Troubleshooting Guide
Systems: Starting Motor Troubleshooting Guide
System: Diagnostic Table
Group 25: Tests and Adjustments
Air Intake System Check
Choke Cable Adjustment
Throttle Cable and Pedal Stop Adjustment (Gas)
Governor Adjustment
Fast Idle Speed Adjustment (Engine—Gas)
Slow Idle Speed Adjustment
Fuel Pump Pressure Test
Fuel Pump Flow Test
Cylinder Compression Test
Valve Clearance Adjustment
Crankcase Vacuum Tests
Oil Pressure Test (Engine—Gas)
Spark Test (Engine—Gas)
Ignition Coil Air Gap Adjustment (Engine—Gas)
Group 30: Engine Repair
Engine Exhaust System Removal and Installation
Fuel Pump Removal and Installation
Carburetor Removal and Installation (Engine—Gas)
Carburetor Disassembly and Assembly
Main Jet Replacement
Intake Manifold Removal and Installation
Engine Removal and Installation (Engine—Gas)
Blower Housing Removal and Installation (Engine—Gas)
Cylinder Head Removal and Installation (Engine—Gas)
Push Rod and Rocker Arm Removal and Installation
Valve Train Removal and Installation
Piston Removal and Installation
Inspect Piston and Cylinder
Cylinder Bore Honing
Cylinder Bore Resizing
Crankcase Cover Removal and Installation (Engine—Gas)
Crankcase Cover Inspection
Governor Assembly Removal and Installation
Governor Assembly Inspection
Camshaft/Tappet Removal and Installation
Camshaft Disassembly/Inspection
Crankshaft Removal and Installation
Crankshaft Inspection
Connecting Rod Inspection
Breather Valve Removal and Installation
Breather Valve Inspection
Oil Pump Removal and Installation
Oil Pump Inspection
Oil Pickup Removal and Installation
Flywheel Removal and Installation (Engine—Gas)
Stator Coil Inspection
Ignition Coil Removal and Installation
Starting Motor Removal and Installation
Section 40: Electrical
Group 05: General Information
Operation and Diagnostics
Diagnostic Information
Wire Color Abbreviation Chart
Reading Electrical Schematics
Common Circuit Tests
Conductors for 12 Volt Circuits
Group 10: Specifications
General Electrical Specifications
Essential or Recommended Tools
Group 15: Component Location
Main Wiring Harness—TX
Main Wiring Harness—TX Turf
Group 20: Schematics and Harnesses
Main Wiring Schematic—TX (SN -050000)
Main Wiring Schematic—TX (SN 050001-)
Main Wiring Schematic—TX Turf (SN -010588)
Main Wiring Schematic—TX Turf (SN 010589-)
Main Wiring Harness—TX (SN -016519)
Main Wiring Harness—TX (SN 016520-050000)
Main Wiring Harness—TX (SN 050001-)
Main Wiring Harnesses—TX Turf (Without Relay Module)
Main Wiring Harnesses—TX Turf (With Relay Module)
Main Wiring Harness Wire Color Codes—TX
Main Wiring Harness Wire Color Codes—TX Turf (SN -010588)
Main Wiring Harness Wire Color Codes—TX Turf (SN 010589-)
W2 Engine Wiring Harness—TX (SN -050000)
W2 Engine Wiring Harness—TX (SN 050001-)
W2 Engine Wiring Harness—TX Turf
A1 Module—TX Turf (SN 010589-)
Group 25: Operation and Diagnostics
Power Circuit Operation—TX and TX Turf
Power Circuit Schematic—TX
Power Circuit Schematic—TX Turf
System: Power Circuit Diagnosis—TX and TX Turf
Cranking Circuit Operation—TX
Cranking Circuit Schematic—TX
System: Cranking System Diagnosis—TX
Cranking Circuit Operation—TX Turf (SN -010000)
Cranking Circuit Schematic—TX Turf (SN -010000)
Neutral Cranking Circuit Schematic—TX Turf (SN -010000)
System: Cranking Circuit Diagnosis—TX Turf (SN -010000)
Cranking Circuit Operation—TX Turf (SN 010001-)
Cranking Circuit Schematic—TX Turf (SN 010001-)
Neutral Cranking Circuit Schematic—TX Turf (SN 010001-)
System: Cranking Circuit Diagnosis—TX Turf (SN 010001-)
Ignition Circuit Operation—TX
Ignition Circuit Wiring Schematic—TX
System: Ignition Circuit Diagnosis—TX
Ignition Circuit Operation—TX Turf
Ignition Circuit Schematic—TX Turf (SN -010000)
Ignition Circuit Schematic—TX Turf (SN 010001-)
System: Ignition Circuit Diagnosis—TX Turf (SN -010000)
Charging Circuit Operation—TX
Charging Circuit Schematic—TX
System: Charging Circuit Diagnosis—TX
Charging Circuit Operation—TX Turf
Charging Circuit Schematic—TX Turf (SN -010000)
Charging Circuit Schematic—TX Turf (SN 010001-)
System: Charging Circuit Diagnosis—TX Turf
Headlight Circuit Operation—TX and TX Turf
Headlight Circuit Schematic—TX and TX Turf
System: Headlight Circuit Diagnosis—TX and TX Turf
Park Brake Light Circuit Operation—TX
Park Brake Light Circuit Schematic—TX
System: Park Brake Light Diagnosis—TX
Park Brake Light Circuit Operation—TX Turf
Park Brake Light Circuit Schematic—TX Turf
System: Park Brake Light Diagnosis—TX Turf
Park Brake Alarm Operation—TX Turf (SN 010001-)
Park Brake Alarm Schematic—TX Turf (SN 010001-)
System: Park Brake Alarm Diagnosis—TX Turf (SN 010001-)
Backup Alarm Operation—TX Turf
Backup Alarm Schematic—TX Turf
System: Backup Alarm Diagnosis—TX Turf
Hourmeter Circuit Operation—TX (SN -030000)
Hourmeter Operation—TX (SN 030001-)
Hourmeter Circuit Schematic—TX
System: Hourmeter Circuit Diagnosis—TX
Hourmeter Circuit Operation—TX Turf
Hourmeter Circuit Schematic—TX Turf (SN -010000)
Hourmeter Circuit Schematic—TX Turf (SN 010001-)
Hourmeter Circuit Diagnosis—TX Turf (SN -010000)
System: Hour Meter Circuit Diagnosis— (SN 010001-)
Power Port Operation—TX and TX Turf
Power Port Schematic—TX and TX Turf
System: Power Port Diagnosis—TX and TX Turf
Group 30: Tests and Adjustments
Ground Circuit Tests
Common Circuit Tests
Battery Test
Charge Battery
Battery Load Test
Stator—Unregulated Voltage Output Test—TX
Stator—Regulated Amperage and Voltage Tests—TX
Starting Motor Solenoid Test—TX
Starting Motor Loaded Amperage Draw Test—TX
Starting Motor No-Load Amperage and RPM Tests—TX
Starting Solenoid Test—Turf
Electrical System Amperage Draw Tests—Turf
Starting Motor/Generator No-Load Amperage and RPM Tests
Spark Plug Cap Test
Spark Test
Key Switch Test
Park Brake Switch, Throttle Switch, or Reverse Switch Test
Bulb Test
Relay Test
Headlight Switch Test (Standard)
Flywheel Magnet(s) Test
Fuse Test
Transmission Neutral Start Switch Test
Light Switch Test (Optional Marker or Signal Lights)
Turn Signal Lights Switch Test
Hazard Lights Switch Test
Horn Switch Test
Diode Test
Hour Meter/Service Indicator Test
Cargo Box Motor Amperage Draw Test
Cargo Box Raise/Lower Switch Test
Fuel Shutoff Solenoid Test
Group 35: Repair
Starting Motor Removal and Installation—TX
Starting Motor Disassembly and Assembly—TX
Starting Motor Inspection—TX
Starting Motor/Generator Removal and Installation—Turf
Starting Motor/Generator Disassembly and Assembly—Turf
Starting Motor/Generator Inspection—Turf
Group 40: Attachments Theory of Operation
Attachments Circuit Operation
Group 45: Optional Light Kits
Rear Marker/Brake Lights Kit Operation
Rear Marker/Brake Lights Kit Schematic (SN -50000)
Rear Marker/Brake Lights Wiring Harness (SN -50000)
Rear Marker/Brake Lights Kit Schematic (SN -50000)
Rear Marker/Brake Lights Kit Circuit Wiring Harness Color Codes
Rear Lights Kit Schematic (SN 50001-)
Rear Lights Adaptor Wiring Harness (SN 50001-)
Rear Lights Adaptor Schematic (SN 50001-)
Taillights Wiring Harness (SN 50001-)
Taillights Schematic (SN 50001-)
Brake Switch Circuit Wiring Harness
Brake Switch Circuit Schematic
Brake Switch Circuit Wiring Harness Color Codes
System: Rear Marker/Brake Lights Kit Diagnosis
Group 50: Optional Deluxe Light Kit
Turn Signal/Hazard/Marker/Brake Lights Operation
Turn Signal/Hazard/Marker/Brake Lights Kit Circuit Schematic
Signal Lights Wiring Harness
Front Signal Lights Wiring Harness Schematic
Front Signal Lights Wiring Color Codes
Rear Marker/Brake/Turn/Hazard Lights Circuit Wiring Harness
Rear Marker/Brake Lights Kit Circuit Schematic
Rear Marker/Brake Lights Kit Circuit Wiring Harness Color Codes
System: Turn Signal Lights Circuit Diagnosis
System: Hazard Lights Circuit Diagnosis
System: Rear Marker Lights Diagnosis
System: Brake Lights Diagnosis
Group 55: Front Blade Kit
Front Blade Kit Component Location
Front Blade Kit Operation
Front Blade Kit Wiring Schematic
Front Blade Kit Wiring Harness
Front Blade Kit Wiring Harness Schematic
Front Blade Kit Wiring Color Codes
Wiring Harness Legend—Front Blade Kit
System: Front Blade Kit Circuit Diagnosis
Group 60: Optional Gauges Kit
Optional Gauges Kit Operation
Optional Gauges Kit Wiring Schematic
Optional Gauges Kit Circuit Wiring Harness Color Codes
Wiring Harness Legend—Optional Gauges Kit
Group 65: Horn Kit
Horn Kit Component Location
Horn Kit Circuit Operation
Horn Kit Circuit Wiring Schematic
Horn Kit Wiring Harness
Horn Kit Wiring Harness Schematic
Horn Kit Circuit Wiring Harness Color Codes
Wiring Harness Legend—Horn Kit
System: Horn Kit Circuit Diagnosis
Group 70: Backup Alarm
Backup Alarm Kit Circuit Operation
Backup Alarm Kit Circuit Wiring Schematic
Backup Alarm Kit Wiring Harness
Backup Alarm Kit Wiring Harness Schematic
Backup Alarm Kit Wiring Color Codes
Wiring Harness Legend—Backup Alarm Kit
System: Backup Alarm Kit Circuit Diagnosis
Group 75: Cargo Box Lift Kit
Cargo Box Actuator Components
Cargo Box Lift Theory of Operation
Cargo Box Lift Kit Circuit Operation
Cargo Box Lift Kit Circuit Schematic
Cargo Box Lift Kit Wiring Harness
Cargo Box Lift Kit Wiring Harness (Detail)
Cargo Box Lift Kit Wiring Harness Schematic
LH Cargo Box Lift Kit Wire Color Codes
Wiring Harness Legend—Cargo Box Lift Kit
System: Cargo Box Lift System Troubleshooting
System: Cargo Box Lift Kit Circuit Diagnosis
Group 80: Homologation Light Kits
Homologation Harness (SN 050001-)
Homologation Schematic (SN 050001-)
Group 85: Heater Kit
Heater Specifications
Heater Operation
Heater Troubleshooting
Heater Schematic
Heater Wiring Harness
System: Heater Diagnosis
Section 50: Power Train—Gear
Group 05: Specifications
Specifications
Essential or Recommended Tools
Other Material
Group 10: Component Location
Transaxle Case Components
Transaxle Gear Components
Differential Components—TX
Governor and Differential Components—Turf
Axle Components
Group 15: Theory of Operation
Clutch Operation
Group 20: Diagnostics
System: Powertrain Check Points
Group 25: Tests and Adjustments
Transaxle Shift Adjustment
Differential Lock Cable Adjustment—TX
Drive Train Performance Tests
Driven Clutch Back-Shifting Check
Group 30: Repair
Drive Clutch Removal and Installation
Driven Clutch Removal and Installation
Drive Clutch Disassembly and Assembly
Driven Clutch Disassembly and Assembly
Driven Clutch Ramp Button Replacement
Transaxle Removal and Installation
Axle Housing Removal and Installation
Axle Housing Disassembly and Assembly
Transaxle Disassembly and Assembly—TX
Transaxle Disassembly and Assembly—Turf
Section 60: Steering
Group 05: Specifications
Specifications
Group 10: Component Location
Steering Component Location
Group 15: Diagnostics
Symptom: Steering Diagnosis
System: Steering Check Points
Group 20: Tests and Adjustments
Toe-In Adjustment
Steering Wheel Removal, Installation, and Adjustment
Group 25: Repair
Tie Rod End Removal and Installation
Steering Assembly Removal and Installation
Spindle Shaft and Bushing Removal and Installation
Steering Rack Boot Removal and Installation
A-Arm Removal and Installation
Front Wheel Bearing Removal and Replacement
Section 70: Brakes
Group 05: Specifications
Specifications
Other Material
Group 10: Component Location
Brake System
Rear Brake Components (SN -30000)
Rear Brake Components (SN 30001-)
Brake System—Front (SN -30000)
Brake System—Rear (SN -30000)
Brake System—Front (SN 30001-)
Brake System—Rear (SN 30001-)
Group 15: Theory of Operation
Brake System
Group 20: Diagnostics
System: Brakes Diagnosis
Group 25: Tests and Adjustments
Check Brake Fluid Level
Master Cylinder Rod Adjustment
Bleeding Brakes
Bleeding Master Cylinder
Park Brake Adjustment
Group 30: Repair
Brake Pad Replacement
Park Brake Cable Replacement
Master Cylinder Removal and Installation
Brake Line Removal and Replacement
Brake Caliper Removal and Installation
Front Brake Rotor Removal and Installation
Rear Brake Rotor Removal and Installation
Brake Pedal Removal and Installation
Park Brake Lever Removal and Installation
Section 80: Miscellaneous
Group 05: Specifications
Fluid Capacities
General Specifications
Group 10: Tests and Adjustments
Shock Absorber Preload Adjustment (SN 50001-)
Group 15: Repair
Hood Removal and Installation
Front Bumper Removal and Installation
Front Grille Removal and Installation
Seat Removal and Installation
Seat Base Cover Removal and Installation
Dash Panel Removal and Installation
Headlight Housing Removal and Installation
Headlight Lamp Removal and Installation
Tail Lights Removal and Installation (SN 50001-)
Wheel Removal and Installation
Front Shock Absorber Removal and Installation
Rear Shock Absorber Removal and Installation
Carrier Frame Removal and Installation
Cargo Box Removal and Installation
Cargo Box Side Removal and Installation (SN 50001- )
Front Fender Removal and Installation
Rear Fender Removal and Installation (SN -50000)
Fuel Tank Removal and Installation

tm2241 - Gator™ Utility VehicleTX and TX Turf

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

Group 05: Fastener Torques

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Group 10: 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

Straight Fitting or Special Nut Torques

Metric Cap Screw Torque Values—Grade 7

Gasket Sealant Application

Group 15: General Information

Gasoline

Gasoline Storage

4—Cycle Gasoline Engine Oil

Break-In Engine Oil—4-Cycle Gasoline

Hydrostatic Transmission and Hydraulic Oil

Grease

Chain Lubricant

Alternative Lubricants

Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Oil Filters

Brake Fluid

Group 20: Serial Number Locations

Product Serial Number

Engine Serial Number Location

Transaxle Serial Number Location

Section 30: Engine – FJ400D

Group 05: Specifications

General Specifications

Test and Adjustment Specifications

Repair Specifications

Torque Specifications

Special or Essential Tools

Other Materials

Group 10: Component Location

FJ400D Engine for TX

FJ400D Engine for TX Turf

Fuel System Components—Evaporative

Carburetor Components

Starting Motor Components TX

Group 15: Theory of Operation

Carburetor Fuel/Air

Governor Operation

Evaporative Emissions System Operation

Ignition Theory

Group 20: Diagnostics

System: Engine Troubleshooting Guide

System: Starting Motor Troubleshooting Guide

Group 25: Tests and Adjustments—General

Air Intake System Check

Choke Cable Adjustment (FJ400D)

Fuel Pump Pressure Test

Fuel Pump Flow Test (FJ400D)

Valve Clearance Check and Adjustment

Automatic Compression Release Test

Ignition Coil Air Gap Adjustment

Spark Test (FJ400D)

Oil Pressure Test

Crankcase Vacuum Test

Group 30: Tests and Adjustments—TX

Throttle Cable and Pedal Stop Adjustment (FJ400D)

Governor Static Adjustment

Slow Idle Speed Adjustment (FJ400D)

Fast Idle Speed Adjustment

Group 35: Tests and Adjustments—TX Turf

Transaxle Governor and Throttle Adjustment

Carburetor Idle Stop Screw Static Adjustment

Group 40: Repair

Muffler Removal and Installation

Fuel Pump Removal and Installation

Carburetor Removal and Installation (FJ400D)

Carburetor Disassembly and Assembly (FJ400D)

Engine Removal and Installation (FJ400D)

Crankcase Breather Inspection

Blower Housing Removal and Installation

Flywheel Removal and Installation (FJ400D)

Rocker Arm Removal and Installation

Push Rod Inspection

Cylinder Head Removal and Installation

Cylinder Head Disassembly and Assembly

Cylinder Head Inspection and Replacement

Recondition Valve Seats

Lap Valves

Crankcase Cover Removal and Installation (FJ400D)

Camshaft Removal and Installation

Camshaft Inspection

Automatic Compression Release

Balancer

Tappet Inspection and Replacement

Piston and Connecting Rod

Crankshaft Removal and Installation

Crankshaft Inspection

Analyze Crankshaft and Connecting Rod Wear

Crankshaft Oil Seal

Cylinder Block Inspection

Cylinder Deglazing

Cylinder Reboring

Oil Pump Disassembly and Assembly

Oil Pump Inspection

Governor—TX

Ignition Module Removal and Installation

Stator Removal and Installation

Section 30A: Engine – FH601D

Group 05: Specifications

Specifications

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Group 10: Component Location

FH601D Engine

Fuel System Components

Carburetor Components

Group 15: Theory of Operation

Carbureted Engine Fuel and Air System Operation

Governor Operation

Lubrication System Operation

Group 20: Diagnostics

System: Engine Troubleshooting Guide

Systems: Starting Motor Troubleshooting Guide

System: Diagnostic Table

Group 25: Tests and Adjustments

Air Intake System Check

Choke Cable Adjustment

Throttle Cable and Pedal Stop Adjustment (Gas)

Governor Adjustment

Fast Idle Speed Adjustment (Engine—Gas)

Slow Idle Speed Adjustment

Fuel Pump Pressure Test

Fuel Pump Flow Test

Cylinder Compression Test

Valve Clearance Adjustment

Crankcase Vacuum Tests

Oil Pressure Test (Engine—Gas)

Spark Test (Engine—Gas)

Ignition Coil Air Gap Adjustment (Engine—Gas)

Group 30: Engine Repair

Engine Exhaust System Removal and Installation

Fuel Pump Removal and Installation

Carburetor Removal and Installation (Engine—Gas)

Carburetor Disassembly and Assembly

Main Jet Replacement

Intake Manifold Removal and Installation

Engine Removal and Installation (Engine—Gas)

Blower Housing Removal and Installation (Engine—Gas)

Cylinder Head Removal and Installation (Engine—Gas)

Push Rod and Rocker Arm Removal and Installation

Valve Train Removal and Installation

Piston Removal and Installation

Inspect Piston and Cylinder

Cylinder Bore Honing

Cylinder Bore Resizing

Crankcase Cover Removal and Installation (Engine—Gas)

Crankcase Cover Inspection

Governor Assembly Removal and Installation

Governor Assembly Inspection

Camshaft/Tappet Removal and Installation

Camshaft Disassembly/Inspection

Crankshaft Removal and Installation

Crankshaft Inspection

Connecting Rod Inspection

Breather Valve Removal and Installation

Breather Valve Inspection

Oil Pump Removal and Installation

Oil Pump Inspection

Oil Pickup Removal and Installation

Flywheel Removal and Installation (Engine—Gas)

Stator Coil Inspection

Ignition Coil Removal and Installation

Starting Motor Removal and Installation

Section 40: Electrical

Group 05: General Information

Operation and Diagnostics

Diagnostic Information

Wire Color Abbreviation Chart

Reading Electrical Schematics

Common Circuit Tests

Conductors for 12 Volt Circuits

Group 10: Specifications

General Electrical Specifications

Essential or Recommended Tools

Group 15: Component Location

Main Wiring Harness—TX

Main Wiring Harness—TX Turf

Group 20: Schematics and Harnesses

Main Wiring Schematic—TX (SN -050000)

Main Wiring Schematic—TX (SN 050001-)

Main Wiring Schematic—TX Turf (SN -010588)

Main Wiring Schematic—TX Turf (SN 010589-)

Main Wiring Harness—TX (SN -016519)

Main Wiring Harness—TX (SN 016520-050000)

Main Wiring Harness—TX (SN 050001-)

Main Wiring Harnesses—TX Turf (Without Relay Module)

Main Wiring Harnesses—TX Turf (With Relay Module)

Main Wiring Harness Wire Color Codes—TX

Main Wiring Harness Wire Color Codes—TX Turf (SN -010588)

Main Wiring Harness Wire Color Codes—TX Turf (SN 010589-)

W2 Engine Wiring Harness—TX (SN -050000)

W2 Engine Wiring Harness—TX (SN 050001-)

W2 Engine Wiring Harness—TX Turf

A1 Module—TX Turf (SN 010589-)

Group 25: Operation and Diagnostics

Power Circuit Operation—TX and TX Turf

Power Circuit Schematic—TX

Power Circuit Schematic—TX Turf

System: Power Circuit Diagnosis—TX and TX Turf

Cranking Circuit Operation—TX

Cranking Circuit Schematic—TX

System: Cranking System Diagnosis—TX

Cranking Circuit Operation—TX Turf (SN -010000)

Cranking Circuit Schematic—TX Turf (SN -010000)

Neutral Cranking Circuit Schematic—TX Turf (SN -010000)

System: Cranking Circuit Diagnosis—TX Turf (SN -010000)

Cranking Circuit Operation—TX Turf (SN 010001-)

Cranking Circuit Schematic—TX Turf (SN 010001-)

Neutral Cranking Circuit Schematic—TX Turf (SN 010001-)

System: Cranking Circuit Diagnosis—TX Turf (SN 010001-)

Ignition Circuit Operation—TX

Ignition Circuit Wiring Schematic—TX

System: Ignition Circuit Diagnosis—TX

Ignition Circuit Operation—TX Turf

Ignition Circuit Schematic—TX Turf (SN -010000)

Ignition Circuit Schematic—TX Turf (SN 010001-)

System: Ignition Circuit Diagnosis—TX Turf (SN -010000)

Charging Circuit Operation—TX

Charging Circuit Schematic—TX

System: Charging Circuit Diagnosis—TX

Charging Circuit Operation—TX Turf

Charging Circuit Schematic—TX Turf (SN -010000)

Charging Circuit Schematic—TX Turf (SN 010001-)

System: Charging Circuit Diagnosis—TX Turf

Headlight Circuit Operation—TX and TX Turf

Headlight Circuit Schematic—TX and TX Turf

System: Headlight Circuit Diagnosis—TX and TX Turf

Park Brake Light Circuit Operation—TX

Park Brake Light Circuit Schematic—TX

System: Park Brake Light Diagnosis—TX

Park Brake Light Circuit Operation—TX Turf

Park Brake Light Circuit Schematic—TX Turf

System: Park Brake Light Diagnosis—TX Turf

Park Brake Alarm Operation—TX Turf (SN 010001-)

Park Brake Alarm Schematic—TX Turf (SN 010001-)

System: Park Brake Alarm Diagnosis—TX Turf (SN 010001-)

Backup Alarm Operation—TX Turf

Backup Alarm Schematic—TX Turf

System: Backup Alarm Diagnosis—TX Turf

Hourmeter Circuit Operation—TX (SN -030000)

Hourmeter Operation—TX (SN 030001-)

Hourmeter Circuit Schematic—TX

System: Hourmeter Circuit Diagnosis—TX

Hourmeter Circuit Operation—TX Turf

Hourmeter Circuit Schematic—TX Turf (SN -010000)

Hourmeter Circuit Schematic—TX Turf (SN 010001-)

Hourmeter Circuit Diagnosis—TX Turf (SN -010000)

System: Hour Meter Circuit Diagnosis— (SN 010001-)

Power Port Operation—TX and TX Turf

Power Port Schematic—TX and TX Turf

System: Power Port Diagnosis—TX and TX Turf

Group 30: Tests and Adjustments

Ground Circuit Tests

Common Circuit Tests

Battery Test

Charge Battery

Battery Load Test

Stator—Unregulated Voltage Output Test—TX

Stator—Regulated Amperage and Voltage Tests—TX

Starting Motor Solenoid Test—TX

Starting Motor Loaded Amperage Draw Test—TX

Starting Motor No-Load Amperage and RPM Tests—TX

Starting Solenoid Test—Turf

Electrical System Amperage Draw Tests—Turf

Starting Motor/Generator No-Load Amperage and RPM Tests

Spark Plug Cap Test

Spark Test

Key Switch Test

Park Brake Switch, Throttle Switch, or Reverse Switch Test

Bulb Test

Relay Test

Headlight Switch Test (Standard)

Flywheel Magnet(s) Test

Fuse Test

Transmission Neutral Start Switch Test

Light Switch Test (Optional Marker or Signal Lights)

Turn Signal Lights Switch Test

Hazard Lights Switch Test

Horn Switch Test

Diode Test

Hour Meter/Service Indicator Test

Cargo Box Motor Amperage Draw Test

Cargo Box Raise/Lower Switch Test

Fuel Shutoff Solenoid Test

Group 35: Repair

Starting Motor Removal and Installation—TX

Starting Motor Disassembly and Assembly—TX

Starting Motor Inspection—TX

Starting Motor/Generator Removal and Installation—Turf

Starting Motor/Generator Disassembly and Assembly—Turf

Starting Motor/Generator Inspection—Turf

Group 40: Attachments Theory of Operation

Attachments Circuit Operation

Group 45: Optional Light Kits

Rear Marker/Brake Lights Kit Operation

Rear Marker/Brake Lights Kit Schematic (SN -50000)

Rear Marker/Brake Lights Wiring Harness (SN -50000)

Rear Marker/Brake Lights Kit Schematic (SN -50000)

Rear Marker/Brake Lights Kit Circuit Wiring Harness Color Codes

Rear Lights Kit Schematic (SN 50001-)

Rear Lights Adaptor Wiring Harness (SN 50001-)

Rear Lights Adaptor Schematic (SN 50001-)

Taillights Wiring Harness (SN 50001-)

Taillights Schematic (SN 50001-)

Brake Switch Circuit Wiring Harness

Brake Switch Circuit Schematic

Brake Switch Circuit Wiring Harness Color Codes

System: Rear Marker/Brake Lights Kit Diagnosis

Group 50: Optional Deluxe Light Kit

Turn Signal/Hazard/Marker/Brake Lights Operation

Turn Signal/Hazard/Marker/Brake Lights Kit Circuit Schematic

Signal Lights Wiring Harness

Front Signal Lights Wiring Harness Schematic

Front Signal Lights Wiring Color Codes

Rear Marker/Brake/Turn/Hazard Lights Circuit Wiring Harness

Rear Marker/Brake Lights Kit Circuit Schematic

Rear Marker/Brake Lights Kit Circuit Wiring Harness Color Codes

System: Turn Signal Lights Circuit Diagnosis

System: Hazard Lights Circuit Diagnosis

System: Rear Marker Lights Diagnosis

System: Brake Lights Diagnosis

Group 55: Front Blade Kit

Front Blade Kit Component Location

Front Blade Kit Operation

Front Blade Kit Wiring Schematic

Front Blade Kit Wiring Harness

Front Blade Kit Wiring Harness Schematic

Front Blade Kit Wiring Color Codes

Wiring Harness Legend—Front Blade Kit

System: Front Blade Kit Circuit Diagnosis

Group 60: Optional Gauges Kit

Optional Gauges Kit Operation

Optional Gauges Kit Wiring Schematic

Optional Gauges Kit Circuit Wiring Harness Color Codes

Wiring Harness Legend—Optional Gauges Kit

Group 65: Horn Kit

Horn Kit Component Location

Horn Kit Circuit Operation

Horn Kit Circuit Wiring Schematic

Horn Kit Wiring Harness

Horn Kit Wiring Harness Schematic

Horn Kit Circuit Wiring Harness Color Codes

Wiring Harness Legend—Horn Kit

System: Horn Kit Circuit Diagnosis

Group 70: Backup Alarm

Backup Alarm Kit Circuit Operation

Backup Alarm Kit Circuit Wiring Schematic

Backup Alarm Kit Wiring Harness

Backup Alarm Kit Wiring Harness Schematic

Backup Alarm Kit Wiring Color Codes

Wiring Harness Legend—Backup Alarm Kit

System: Backup Alarm Kit Circuit Diagnosis

Group 75: Cargo Box Lift Kit

Cargo Box Actuator Components

Cargo Box Lift Theory of Operation

Cargo Box Lift Kit Circuit Operation

Cargo Box Lift Kit Circuit Schematic

Cargo Box Lift Kit Wiring Harness

Cargo Box Lift Kit Wiring Harness (Detail)

Cargo Box Lift Kit Wiring Harness Schematic

LH Cargo Box Lift Kit Wire Color Codes

Wiring Harness Legend—Cargo Box Lift Kit

System: Cargo Box Lift System Troubleshooting

System: Cargo Box Lift Kit Circuit Diagnosis

Group 80: Homologation Light Kits

Homologation Harness (SN 050001-)

Homologation Schematic (SN 050001-)

Group 85: Heater Kit

Heater Specifications

Heater Operation

Heater Troubleshooting

Heater Schematic

Heater Wiring Harness

System: Heater Diagnosis

Section 50: Power Train—Gear

Group 05: Specifications

Specifications

Essential or Recommended Tools

Other Material

Group 10: Component Location

Transaxle Case Components

Transaxle Gear Components

Differential Components—TX

Governor and Differential Components—Turf

Axle Components

Group 15: Theory of Operation

Clutch Operation

Group 20: Diagnostics

System: Powertrain Check Points

Group 25: Tests and Adjustments

Transaxle Shift Adjustment

Differential Lock Cable Adjustment—TX

Drive Train Performance Tests

Driven Clutch Back-Shifting Check

Group 30: Repair

Drive Clutch Removal and Installation

Driven Clutch Removal and Installation

Drive Clutch Disassembly and Assembly

Driven Clutch Disassembly and Assembly

Driven Clutch Ramp Button Replacement

Transaxle Removal and Installation

Axle Housing Removal and Installation

Axle Housing Disassembly and Assembly

Transaxle Disassembly and Assembly—TX

Transaxle Disassembly and Assembly—Turf

Section 60: Steering

Group 05: Specifications

Specifications

Group 10: Component Location

Steering Component Location

Group 15: Diagnostics

Symptom: Steering Diagnosis

System: Steering Check Points

Group 20: Tests and Adjustments

Toe-In Adjustment

Steering Wheel Removal, Installation, and Adjustment

Group 25: Repair

Tie Rod End Removal and Installation

Steering Assembly Removal and Installation

Spindle Shaft and Bushing Removal and Installation

Steering Rack Boot Removal and Installation

A-Arm Removal and Installation

Front Wheel Bearing Removal and Replacement

Section 70: Brakes

Group 05: Specifications

Specifications

Other Material

Group 10: Component Location

Brake System

Rear Brake Components (SN -30000)

Rear Brake Components (SN 30001-)

Brake System—Front (SN -30000)

Brake System—Rear (SN -30000)

Brake System—Front (SN 30001-)

Brake System—Rear (SN 30001-)

Group 15: Theory of Operation

Brake System

Group 20: Diagnostics

System: Brakes Diagnosis

Group 25: Tests and Adjustments

Check Brake Fluid Level

Master Cylinder Rod Adjustment

Bleeding Brakes

Bleeding Master Cylinder

Park Brake Adjustment

Group 30: Repair

Brake Pad Replacement

Park Brake Cable Replacement

Master Cylinder Removal and Installation

Brake Line Removal and Replacement

Brake Caliper Removal and Installation

Front Brake Rotor Removal and Installation

Rear Brake Rotor Removal and Installation

Brake Pedal Removal and Installation

Park Brake Lever Removal and Installation

Section 80: Miscellaneous

Group 05: Specifications

Fluid Capacities

General Specifications

Group 10: Tests and Adjustments

Shock Absorber Preload Adjustment (SN 50001-)

Group 15: Repair

Hood Removal and Installation

Front Bumper Removal and Installation

Front Grille Removal and Installation

Seat Removal and Installation

Seat Base Cover Removal and Installation

Dash Panel Removal and Installation

Headlight Housing Removal and Installation

Headlight Lamp Removal and Installation

Tail Lights Removal and Installation (SN 50001-)

Wheel Removal and Installation

Front Shock Absorber Removal and Installation

Rear Shock Absorber Removal and Installation

Carrier Frame Removal and Installation

Cargo Box Removal and Installation

Cargo Box Side Removal and Installation (SN 50001- )

Front Fender Removal and Installation

Rear Fender Removal and Installation (SN -50000)

Fuel Tank Removal and Installation

John Deere Gator Utility Vehicle TX and TX Turf Diagnostic and Repair Service Manual (TM2241)