John Deere Gator Utility Vehicle TS, TH 6X4, and TH 6X4 Diesel Diagnosis and Repair Service Manual (TM2239)

tm2239 - Gator Utility Vehicle TS, TH 6X4,and TH 6X4 Diesel Technical Manual.pdf

Complete All Inclusive Technical Manual with electrical wiring diagrams for John Deere Gator Utility Vehicle TS, TH 6X4, and TH 6X4 Diesel, with all the shop information to maintain, diagnose, repair, rebuild like professional mechanics (Diagnosis, Operation, Tests, Repair, Service, Troubleshooting).

John Deere Gator Utility Vehicle TS, TH 6X4, and TH 6X4 Diesel workshop technical 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: 1,847 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

tm2239 - Gator™ Utility Vehicle TS, TH 6X4,and TH 6X4 Diesel

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

Follow Tire Recommendations

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 15: O-Ring Seal Service Recommendations

Face Seal Fittings With Inch Stud Ends Torque

Face Seal Fittings With Metric Stud Ends Torque

Service Recommendations For Flat Face O-Ring Seal Fittings

Service Recommendations for O-Ring Boss Fittings

Straight Fitting or Special Nut Torques

Metric Cap Screw Torque Values—Grade 7

Gasket Sealant Application

Group 20: General Information

Gasoline

Gasoline Storage

Diesel Fuel—North America

Diesel Fuel—Europe

Diesel Fuel Storage

Engine Oil

Engine Break-In Oil

4-Cycle Diesel Engine Oil—North America

Diesel Engine Oil—Europe

Transaxle Oil

Grease

Chain Lubricant

Alternative Lubricants

Synthetic Lubricants

Lubricant Storage

Mixing of Lubricants

Oil Filters

Group 25: Coolant

Diesel Engine Coolant

John Deere COOL-GARD™ II Coolant Extender

Group 30: Serial Number Locations

Product Serial Number

Engine Serial Number Location

Transaxle Serial Number Location

Section 30: Engine – Gas (FE290D, FE350D)

Group 05: Specifications

General Specifications

Specifications

Essential or Recommended Tools

Service Equipment and Tools

Other Material

Group 10: Component Location

Engine Components, FE290D, FE350D

Fuel System Components

Fuel System Components—Evaporative

Carburetor Components

Balancer Components

Starting Motor Components

Group 15: Theory of Operation

Lubrication System Operation

Hydraulic Lifter Operation

Evaporative Emissions System Operation

Carburetor Fuel and Air

Group 20: Diagnostics

Engine Troubleshooting Guide

Starting Motor Troubleshooting Guide (FE290D, FE350D)

Group 25: Tests and Adjustments

Throttle Cable and Pedal Stop Adjustment (FE290D, FE350D)

Choke Cable Adjustment (FE290D, FE350D)

Air Intake System Check

Governor Adjustment

Slow Idle Mixture Screw and Speed Adjustments

High Idle Speed Adjustment

Fuel Pump Pressure Test

Fuel Pump Flow Test (FE290D, FE350D)

Cylinder Compression Test (FE290D, FE350D)

Valve Clearance Adjustment (FE290D) (FE350-AS25, BS25, CS25)

Automatic Compression Release (ACR) Test

Crankcase Vacuum Test

Ignition Coil Air Gap Adjustment (FE290D, FE350D)

Oil Pressure Test

Group 30: Repair

Muffler Removal and Installation

Fuel Pump Removal and Installation

Carburetor Removal and Installation

Disassemble and Assemble Carburetor

Oil Filter and Adaptor

Engine Removal and Installation (FE290D, FE350D)

Inspect Crankcase Breather

Remove and Install Blower Housing

Remove and Install Flywheel

Remove and Install Rocker Arm (FE290D)

Remove and Install Rocker Arm (FE350D)

Inspect Rocker Arm

Remove and Install Cylinder Head

Disassemble and Assemble Cylinder Head

Inspect and Replace Cylinder Head

Recondition Valve Seats

Lap Valves

Remove and Install Crankcase Cover

Remove and Install Camshaft

Inspect Camshaft

Adjust Camshaft Axial Play (FE350D)

Inspect Automatic Compression Release (ACR)

Inspect and Replace Tappets (FE290D)

Replace Hydraulic Lifter (FE350D)

Remove Piston and Connecting Rod

Install Piston and Connecting Rod

Disassemble Piston and Connecting Rod

Assemble Piston and Connecting Rod

Inspect Piston and Connecting Rod

Reciprocating Balancer

Remove and Install Crankshaft

Analyze Crankshaft and Connecting Rod

Inspect Crankshaft

Crankshaft End Play Check

Adjust Crankshaft End Play

Replace Crankshaft Oil Seal

Inspect Cylinder Block

Measure Cylinder Bore

Deglaze Cylinder Bore

Rebore Cylinder

Disassemble and Assemble Oil Pump

Inspect Oil Pump

Inspect and Replace Governor

Inspect and Replace Governor Shaft

Replace Governor Shaft Oil Seal

Remove and Install Ignition Coil

Replace Ignition Module

Remove and Install Stator

Section 30A: Engine – Gas (FJ400D)

Group 05: Specifications

General Specifications

Test and Adjustment Specifications

Repair Specifications

Torque Specifications

Essential Tools

Other Materials

Group 10: Component Location

Summary of References

Engine Components (FJ400D)

Fuel System, Evaporative Emission Components (FJ400D)

Carburetor Components (FJ400D)

Starting Motor Components (FJ400D)

Group 15: Theory of Operation

Carburetor Fuel-Air

Governor Operation

Evaporative Emission Operation

Ignition Theory

Group 20: Diagnostics

Summary of References

System: Engine Troubleshooting Guide

System: Starting Motor Troubleshooting Guide

Group 25: Tests and Adjustments

Summary of References

Throttle Cable and Pedal Stop Adjustment (FJ400D)

Governor Static Adjustment (FJ400D)

Slow Idle Speed Adjustment (FJ400D)

Fast Idle Speed Adjustment (FJ400D)

Check Air Intake System (FJ400D)

Adjust Choke Cable (FJ400D)

Test Fuel Pump Pressure (FJ400D)

Test Fuel Pump Flow (FJ400D)

Check and Adjust Valve Clearance (FJ400D)

Test Automatic Compression Release (ACR) (FJ400D)

Adjust Ignition Coil Air Gap (FJ400D)

Test Spark (FJ400D)

Test Oil Pressure (FJ400D)

Test Crankcase Vacuum (FJ400D)

Group 30: Repair

Summary of References

Remove and Install Muffler (FJ400D)

Remove and Install Air Cleaner (FJ400D)

Remove and Install Fuel Pump (FJ400D)

Remove and Install Carburetor (FJ400D)

Disassemble and Assemble Carburetor (FJ400D)

Remove and Install Engine (FJ400D)

Inspect Crankcase Breather (FJ400D)

Remove and Install Blower Housing (FJ400D)

Remove and Install Flywheel (FJ400D)

Remove and Install Rocker Arm (FJ400D)

Remove and Inspect Push Rods (FJ400D)

Remove and Install Cylinder Head (FJ400D)

Disassemble and Assemble Cylinder Head (FJ400D)

Recondition Valve Seats (FJ400D)

Lap Valves (FJ400D)

Remove and Install Crankcase Cover (FJ400D)

Remove and Install Camshaft (FJ400D)

Inspect Camshaft (FJ400D)

Inspect Automatic Compression Release (ACR) (FJ400D)

Balancer Remove and Install (FJ400D)

Inspect and Replace Tappets (FJ400D)

Piston and Connecting Rod (FJ400D)

Remove and Install Crankshaft (FJ400D)

Inspect Crankshaft (FJ400D)

Analyze Crankshaft and Connecting Rod (FJ400D)

Crankshaft Oil Seal (FJ400D)

Inspect Cylinder Block (FJ400D)

Deglaze Cylinder (FJ400D)

Rebore Cylinder (FJ400D)

Disassemble and Assemble Oil Pump (FJ400D)

Inspect Oil Pump (FJ400D)

Remove and Install Ignition Module (FJ400D)

Remove and Install Stator (FJ400D)

Section 30B: Engine – Gas (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: Troubleshooting

Engine Troubleshooting Guide

Engine Runs Erratically/Loss Of Power

Starting Motor Troubleshooting Guide (FH601D)

Group 25: Diagnostics

Diagnostic Table

Group 30: Tests and Adjustments

Air Intake System Check

Choke Cable Adjustment (FH601D)

Throttle Cable and Pedal Stop Adjustment (FH601D)

Governor Adjustment (FH601D)

Fast Idle Speed Adjustment

Slow Idle Speed Adjustment

Fuel Pump Pressure Test

Fuel Pump Flow Test (FH601D)

Cylinder Compression Test (FH601D)

Valve Clearance Adjustment (FH601D)

Crankcase Vacuum Test (FH601D)

Oil Pressure Test (FH601D)

Ignition Coil Air Gap Adjustment

Group 35: Engine Repair

Muffler Removal and Installation (FH601D)

Fuel Pump Removal and Installation (FH601D)

Carburetor Removal and Installation (FH601D)

Carburetor Disassembly and Assembly (FH601D)

Main Jet Replacement

Intake Manifold Removal and Installation

Engine Removal and Installation (FH601D)

Blower Housing Removal and Installation (FH601D)

Cylinder Head Removal and Installation (FH601D)

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 (FH601D)

Crankcase Cover Inspection

Governor Assembly Removal/Replacement

Governor Assembly Inspection

Camshaft/Tappet Removal and Installation

Camshaft Disassembly/Inspection

Crankshaft Removal/Replacement

Crankshaft Inspection

Connecting Rod Inspection

Breather Valve Removal and Installation

Breather Valve Inspection

Oil Pump Removal and Installation

Oil Pump Inspection (FH601D)

Oil Pickup Removal and Installation

Oil Screen Inspection/Cleaning

Flywheel Removal and Installation (FH601D)

Stator Coil Inspection

Ignition Coil Removal and Installation

Starting Motor Removal and Installation (FH601D)

Section 30C: Engine – Diesel (3TNV70, 3TNV74)

Group 05: Specifications

Specifications

Service Equipment and Tools

Other Material

Group 10: Component Location

Fuel System

Fuel Tank Components

Coolant System Components

Group 15: Theory of Operation

Cooling System Theory of Operation

Lubrication System Operation

Fuel System Theory of Operation

Air System Operation

Group 20: Diagnostics

Engine Troubleshooting and Diagnostics

Diagnose Engine Oil

Diagnose Excessive Fuel Consumption

Diagnose Incorrect Manifold Pressure

Diagnose Low Engine Compression

Diagnose Engine Starting Problem

Diagnose Poor Engine Operation

Diagnose Abnormal Coolant Temperature

Diagnose Coolant in Oil or Oil in Coolant

Diagnose Engine

Group 25: Tests and Adjustments

Summary of References

Air Restriction Indicator Test

Adjust Fast Idle Speed

Adjust Slow Idle

Throttle Cable Adjustment

Adjust Valve Clearance

Check Valve Lift

Test Cylinder Compression

Adjust Water Pump/Alternator Drive Belt

Test Thermostat

Test Radiator Bubble

Test Cooling System Pressure

Test Radiator Cap Pressure

Engine Oil Pressure Test

Test Fuel Injection System

Test Fuel Injection Nozzle

Adjust Injection Pump Timing

Check Injection Pump Static Timing

Bleed Fuel System Air

Test Fuel Transfer Pump Flow

Test Fuel Transfer Pump Pressure

Group 30: Repair

Summary of Reference

Engine Removal and Installation (Diesel—3TNV70)

Muffler Removal and Installation Diesel (3TNV70)

Exhaust Manifold Removal and Installation

Remove and Install Rocker Arm Cover

Remove and Install Rocker Arm and Push Rods

Cylinder Head Removal and Installation Diesel (3TNV70)

Recondition Cylinder Head

Remove and Install Rear Crankshaft Oil Seal

Remove and Install Front Crankshaft Oil Seal

Remove and Install Timing Gear Cover

Check Camshaft End Play

Check Timing Gear Backlash

Remove and Install Idler Gear

Remove and Install Cam Followers

Remove and Install Camshaft (3TNV70)

Remove and Install Oil Pan and Strainer

Check Connecting Rod Side Play

Check Crankshaft End Play

Check Connecting Rod Bearing Clearance

Check Crankshaft Main Bearing Clearance

Remove, Inspect, and Install Connecting Rod

Disassemble and Assemble Pistons

Cylinder Bore

Remove and Install Crankshaft and Main Bearings

Remove and Install Flywheel (3TNV70)

Remove and Install Flywheel Plate

Remove and Install Timing Gear Housing

Remove and Install Oil Pump

Coolant Temperature Switch

Remove and Install Thermostat

Remove and Install Water Pump

Fuel Filter Components

Remove and Install Fuel Transfer Pump

Remove and Install Fuel Injection Nozzle

Disassemble, Clean, Inspect, and Assemble Fuel Injector

Remove and Install Fuel Injection Pump

Remove and Install Fuel Control and Governor Linkage

Remove and Install Fuel Shutoff Solenoid

Starting Motor Removal and Installation

Repair Alternator

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 Specification

Service Equipment and Tools

Group 15: Component Location

Main Wiring Harness—TS Gators

Main Wiring Harness—TH Gas Gators

Main Wiring Harness—TH Diesel Gators

Cooling System Electrical Component Location—TH Diesel

Group 20: Schematics and Harnesses

Electrical Schematic and Wiring Harness Legend—TS and TH Gas Gators

Electrical Schematic and Wiring Harness Legend—TH Diesel Gator

Main Wiring Schematic—TS Gators (SN -100000)

Main Wiring Schematic—TS Gators (SN 100001-)

Main Wiring Harness—TS Gators (SN -100000)

Main Wiring Harness—TS Gators (SN 100001-)

Main Wiring Harness Wire Color Codes—TS Gators

Main Wiring Schematic—TH Gas Gators (SN -006629)

W1 Main Wiring Harness—TH Gas Gators (SN -006629)

Main Wiring Schematic—TH Gas Gators (SN 006630-)

W1 Main Wiring Harness—TH Gas Gators (SN 006630-)

Main Wiring Harness Wire Color Codes—TH Gas Gators

Main Wiring Schematic—TH Diesel Gators (SN -002013)

W1 Main Wiring Harness—TH Diesel Gators (SN -002013)

Main Wiring Schematic—TH Diesel Gators (SN 002014-050000)

W1 Main Wiring Harness—TH Diesel Gators (SN 002014-050000)

Main Wiring Schematic—TH Diesel Gators (SN 050001-110000)

W1 Main Wiring Harness—TH Diesel Gators (SN 050001-110000)

Main Wiring Schematic—TH Diesel Gators (SN 110001-)

W1 Main Wiring Harness—TH Diesel Gators (SN 110001-)

Main Wiring Harness Wire Color Codes—TH Diesel Gators

W2 Engine Wiring Harness—TS Gators

W2 Engine Wiring Harness—TH Gas Gators

W2 Engine Wiring Harness—TH Diesel Gators (glow plugs)

G2 Stator—Gas Engines

Group 25: Operation and Diagnostics

Power Circuit Operation—TS and TH Gas

Power Circuit Operation—TH Diesel

Power Circuit Schematic—TS Gas (SN -100000)

Power Circuit Schematic—TS Gas (SN 100001-)

Power Circuit Schematic—TH Gas

Power Circuit Schematic—TH Diesel

Power Circuit Diagnosis—TS and TH Gas

Power Circuit Diagnosis—TH Diesel

Cranking Circuit Operation—TS

Cranking Circuit Operation—TH Gas

Cranking Circuit Operation—TH Diesel

Cranking Circuit Schematic—TS

Cranking Circuit Schematic—TH Gas

Cranking Circuit Schematic—TH Diesel

Cranking System Diagnosis—TS

Cranking Circuit Diagnosis—TH Gas

Cranking Circuit Diagnosis—TH Diesel

Ignition Circuit Operation—TS and TH Gas

Ignition Circuit Wiring Schematic—TS

Ignition Circuit Wiring Schematic—TH Gas

Ignition Circuit Diagnosis—TS and TH Gas

Charging Circuit Operation—TS and TH Gas

Charging Circuit Operation—TH Diesel

Charging Circuit Schematic—TS (SN -100000)

Charging Circuit Schematic—TS (SN 100001-)

Charging Circuit Schematic—TH Gas

Charging Circuit Schematic—TH Diesel

Charging Circuit Diagnosis—TS

Charging Circuit Diagnosis—TH Gas

Charging Circuit Diagnosis—TH Diesel

Headlight Circuit Operation—TS and TH Gas

Headlight Circuit Operation—TH Diesel

Headlight Circuit Wiring Schematic—TS and TH Gas Gators

Headlight Circuit Wiring Schematic—TH Diesel

Headlight Circuit Diagnosis—TS and TH Gas

Headlight Circuit Diagnosis—TH Diesel

Fuel Shutoff Circuit Operation—TH Gas

Fuel Shutoff Circuit Operation—TH Diesel

Fuel Shutoff Circuit Wiring Schematic—TH Gas

Fuel Shutoff Circuit Wiring Schematic—TH Diesel (Run Position)

Fuel Shutoff Circuit Wiring Schematic—TH Diesel (Start Position)

Fuel Shutoff Circuit Diagnosis—TH Gas

Fuel Shutoff Circuit Diagnosis—TH Diesel

Park Brake Light Circuit Operation—TS

Park Brake and Differential Lock Lights Circuit Operation—TH Gas

Park Brake and Differential Lock Lights Circuit Operation—TH Diesel

Park Brake Light Circuit Schematic—TS (SN -100000)

Park Brake Light Circuit Schematic—TS (SN 100001-)

Park Brake and Differential Lock Lights Circuit Schematic—TH Gas

Park Brake and Differential Lock Lights Circuit Schematic—TH Diesel

Park Brake Light Circuit Diagnosis—TS

Differential Lock and Park Brake Lights Diagnosis—TH Gas

Differential Lock and Park Brake Lights Diagnosis—TH Diesel

Hour Meter Circuit Operation—TS and TH Gas

Hour Meter Operation—TS (SN 30001-)

Hour Meter and Oil Pressure Light Circuit Operation—TH Diesel

Hour Meter Circuit Wiring Schematic—TS and TH Gas

Hour Meter and Oil Pressure Light Circuit Wiring Schematic—TH Diesel

Hour Meter Circuit Diagnosis—TS and TH Gas

Hour Meter and Oil Pressure Light Circuit Diagnosis—TH Diesel

Power Port Operation—TS and TH Gas

Power Port Operation—TH Diesel

Power Port Wiring Schematic—TS and TH Gas

Power Port Wiring Schematic—TH Diesel

Power Port Circuit Diagnosis—TS and TH Gas

Power Port Circuit Diagnosis—TH Diesel

Cooling System Circuit Operation—TH Diesel

Cooling System Circuit Electrical Schematic—TH Diesel

Cooling System Circuit Diagnosis—TH Diesel

Glow Plug Circuit Operation—TH Diesel

Glow Plug Circuit Electrical Schematic—TH Diesel

Glow Plug Circuit Diagnosis—TH Diesel

Group 30: Tests and Adjustments

Summary of References

Ground Circuit Tests

Charge Battery

Battery Load Test

Stator—Unregulated Voltage Output Test—TS

Stator—Unregulated Voltage Output Test—TH Gas

Stator—Regulated Amperage and Voltage Tests—TS and TH Gas

Regulator/Rectifier Test—TH Gas

Alternator Regulated Amperage and Voltage Test—TH Diesel

Alternator Unregulated Amperage Test—TH Diesel

Starting Motor Solenoid Test

Starting Motor Loaded Amperage Draw Test

Starting Motor No-Load Amperage and RPM Tests

Brake Lights Switch Test

Relay Test

Fuel Shutoff Solenoid Test—TH Diesel

Spark Test

Ignition Coil Air Gap Adjustment—TS and TH Gas

Spark Plug Cap Test

Spark Plug Gap Adjustment

Flywheel Magnet Test

Glow Plug Test—TH Diesel

Key Switch Test

Headlight Switch Test (2 Position)

Light Switch Test (3 Position)

Neutral Start Switch Test

Park Brake or Differential Lock Switch Test

Cooling Fan Temperature Switch Test—TH Diesel

Engine Coolant Temperature Switch Test

Turn Signal Lights Switch Test

Hazard Lights Switch Test

Raise/Lower Switch Test

Horn Switch Test, Push

Diode Test

Engine Oil Pressure Switch Test

Bulb Test

Fuse Test

Group 35: Repair

Summary of References

Alternator Disassembly, Inspection, and Assembly—TH Diesel

Starting Motor Removal and Installation—TS FE290D, FE350D Engine

Starting Motor Removal and Installation—TS FJ400D Engine

Starting Motor Removal and Installation—TH Gas

Starting Motor Solenoid Tests—All Models

Starting Motor Test—Gas Engine Models

Starting Motor Disassembly and Assembly—TS and TH Gas

Starting Motor Inspection—TS and TH Gas

Winch Remote Switch Test

Group 40: Attachments Theory of Operation

Attachments Circuit Operation

Group 45: Optional Light Kits

Rear Marker/Brake Lights Kit Operation—TS and TH Gas

Rear Marker/Brake Lights Kit Operation—TH Diesel

Rear Marker/Brake Lights Kit Schematic—TS and TH Gas

Rear Marker/Brake Lights Kit Schematic—TH Diesel

Rear Marker/Brake Lights Circuit Wiring Harness

Rear Marker/Brake Lights Kit Circuit Schematic

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

Rear Marker/Brake Lights Kit Diagnosis TS and TH

Group 50: Optional Deluxe Light Kit

Turn Signal/Hazard/Marker/Brake Lights Operation—TS and TH Gas

Turn Signal/Hazard/Marker/Brake Lights Operation—TH Diesel

Turn Signal/Hazard/Marker/Brake Lights Kit Circuit Schematic—TS and TH Gas

Turn Signal/Hazard/Marker/Brake Lights Kit Circuit Schematic—TH Diesel

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

Turn Signal Lights Circuit Diagnosis

Hazard Lights Circuit Diagnosis

Rear Marker Lights Diagnosis—TS & TH

Brake Lights Diagnosis- TS and TH

Group 55: Homologated Light and Horn—Diesel

Homologated Light and Horn Wiring Harness (SN -050000)

Homologated Light and Horn Schematic (SN -050000)

Homologated Light and Horn Wiring Harness (SN 050001-)

Homologation Schematic (SN 050001-)

Light and Horn Kit Harness Wire Color Codes

Homologated Lights Circuit Diagnosis

Homologated Horn Circuit Diagnosis

Group 60: Hydraulic Front Implement Lift Kit

Hydraulic Front Implement Lift Operation—TS and TH Gas

Hydraulic Front Implement Lift Operation—TH Diesel

Hydraulic Front Implement Lift Circuit Schematic—TS and TH Gas

Hydraulic Front Implement Lift Circuit Schematic—TH Diesel

Hydraulic Front Implement Lift Wiring Harness

Hydraulic Front Implement Lift Schematic

Hydraulic Front Implement Lift Wiring Color Codes

Hydraulic Front Implement Lift Circuit Diagnosis

Group 65: Optional Gauges Kit

Gauges Kit Component Location—TS & TH Gators

Gauges Kit Operation

Gauges Kit Wiring Schematic—TS and TH Gas

Gauges Kit Wiring Schematic—TH Diesel

Gages Kit Wiring Harness

Gauges Kit Circuit Wiring Harness Color Codes

Group 70: Horn Kit

Horn Kit Component Location

Horn Kit Circuit Operation

Horn Kit Circuit Wiring Schematic—TS and TH Gas Gators

Horn Kit Circuit Wiring Schematic—TH Diesel Gators

Horn Kit Wiring Harness

Horn Kit Wiring Harness Schematic

Horn Kit Circuit Wiring Harness Color Codes

Horn Kit Circuit Diagnosis

Group 75: Backup Alarm

Backup Alarm Kit Circuit Operation—T-Series Gas (SN -050000)

Backup Alarm Kit Circuit Operation—T-Series Gas (SN 050001-)

Backup Alarm Kit Circuit Operation—TH Diesel (SN -050000)

Backup Alarm Kit Circuit Operation—TH Diesel (SN 050001-)

Backup Alarm Kit Circuit Wiring Schematic—T-Series Gas

Backup Alarm Kit Circuit Wiring Schematic—TH Diesel

Backup Alarm Kit Wiring Harness

Backup Alarm Kit Wiring Harness Schematic

Backup Alarm Kit Wiring Color Codes

T-Series Backup Alarm Kit Circuit Diagnosis

Group 80: Cargo Box Lift Kit

Cargo Box Actuator Components

Cargo Box Lift Theory of Operation

Cargo Box Lift Kit Circuit Operation—TS and TH Gas

Cargo Box Lift Kit Circuit Operation—TH Diesel

Cargo Box Lift Kit Circuit Schematic—TS and TH Gas

Cargo Box Lift Kit Circuit Schematic—TH Diesel

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

Cargo Box Lift System Troubleshooting

Cargo Box Lift Kit Circuit Diagnosis—TS and TH Gas Gators

Cargo Box Lift Kit Circuit Diagnosis—TH Diesel Gators

Group 85: Winch

Specifications

Winch Circuit Schematic—TS and TH Gas

Winch Circuit Schematic—TH Diesel

Winch Wiring Harnesses

Winch Wiring Harness Color Codes

Relay Block and Remote Switch

Winch Theory of Operation

Winch Circuit Diagnostics

Group 90: Heater Kit

Heater Specifications

Heater Operation

Heater Troubleshooting

Heater Schematic

Heater Wiring Harness

Heater Diagnosis

Section 50: Power Train

Group 05: Specifications

Specifications

Essential or Recommended Tools

Other Material

Group 10: Component Location

Summary of References

Transaxle Case Components

Transaxle Gear Components

TH 6X4—Axle Housing Components

TS—Axle Housing Components

Differential Components

Differential Shift Components

Drive Clutch

Driven Clutch

Group 15: Theory of Operation

Clutch Operation

Group 20: Diagnostics

Diagnostic Check Points

Group 25: Tests and Adjustments

Summary of References

Transaxle Shift Adjustment

Differential Lock Cable Adjustment

Differential Lock Switch Adjustment—TH

Drive Train Performance Tests

Driven Clutch Back-Shifting Check

Clutch Center Distance Check—Diesel Machines

Drive Chain Adjustment—TH

Group 30: Repair

Summary of References

Drive Clutch Removal and Installation—TS

Drive Clutch Removal and Installation—TH

Driven Clutch Removal and Installation

Drive Clutch Disassembly and Assembly

Driven Clutch Disassembly and Assembly

Driven Clutch Ramp Button Replacement

Transaxle Removal and Installation—TS

Transaxle Removal and Installation—TH

Transaxle Disassembly and Assembly

Axle Shaft Seal Removal and Installation

Section 60: Steering

Group 05: Specifications

Specifications

Group 10: Component Location

Steering Component Location

Group 15: Diagnostics

Troubleshooting

Steering System Checks

Group 20: Tests and Adjustments

Summary of References

Toe-In Adjustment

Steering Wheel Removal, Installation, and Adjustment

Group 25: Repair

Summary of References

Tie Rod End Removal and Installation

Steering Assembly Removal and Installation

Spindle Shaft and Bushing Removal and Installation

Steering Rack Boot Removal and Installation

Section 70: Brakes

Group 05: Specifications

Specifications

Other Material

Group 10: Component Location

Brake and Brake Cable

Transaxle Brake

Park Brake and Differential Lock Linkage

Group 15: Theory of Operation

Brake Operation

Park Brake and Differential Lock Operation

Group 20: Diagnostics

Diagnosis Test/Check Points

Troubleshooting Guide

Group 25: Tests and Adjustments

Summary of References

Brake Function Test

Brake Pedal Freeplay Adjustment

Brake Adjustment

Group 30: Repair

Summary of References

Brake Cable Removal and Installation

Brake Pedal Assembly Removal and Installation

Parking Brake Removal and Installation

Brake Rods Removal and Installation

Brake Disc Assembly Removal and Installation

Section 80: Miscellaneous

Group 05: Specifications

Specifications

Group 10: Repair

Summary of References

Hood Removal and Installation

Front Skid Plate Removal and Installation

Front Grille Removal and Installation

Seat Removal and Installation

Seat Base Cover Removal and Installation

Battery Removal and Installation—Gas Engine Models

Battery Removal and Installation—Diesel Models

Shock Absorber Removal and Installation

Control Arm Removal and Installation

Front Wheel Removal and Installation

Front Wheel Bearing Replacement

Rear Wheel Removal and Installation

Cargo Box Removal and Installation

Cargo Box Side Removal and Installation (SN 50001- )

Dash Panel Removal and Installation

Headlight Lamp Housing Removal and Installation

Fuel Tank Removal and Installation

Fuel Tank Removal and Installation TS (SN 100001-)

Carbon Canister Removal and Installation (SN 100001-)

Front Fender Removal and Installation

Rear Fender Removal and Installation—TS Gators

Rear Fender Removal and Installation—TH Gators

Servicing Cooling System

Front Radiator Removal and Installation

Side Radiator Removal and Installation