John Deere Gator TS TH 6X4 Gas FE290D FE350D Diesel Repair Service Manual (TM2239) PDF - MJODTM2239.zip
Diagnosis and Repair Service Manual for John Deere Gator Utility Vehicle TS, TH 6X4, and TH 6X4 Diesel (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