John Deere HPX 4X2 & 4X4 Gas Diesel Workshop Repair Service Manual TM2195 PDF - MJODTM2195.zip
This is a complete workshop service and repair manual featuring Electrical Wiring Diagrams for the John Deere HPX 4X2 and HPX 4X4 (Gas and Diesel) models, providing every technical detail you need to service, troubleshoot, fix, and rebuild your machine the way a professional technician would.
The John Deere HPX 4X2, HPX 4X4 (Gas and Diesel) workshop service repair manual covers the following:
* 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.
tm2195 - HPX 4X2, HPX 4X4 Gas and Diesel Technical Manual.pdf
tm2195 - HPX 4X2, HPX 4X4 Gas and Diesel Technical Manual.epub
PRODUCT DETAILS:
Total Pages: 2,012 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
TABLE OF CONTENTS....1
Section 10: Safety....26
Group 10: Safety....26
Recognize Safety Information....28
Understand Signal Words....29
Replace Safety Signs....30
Handle Fluids Safely—Avoid Fires....31
Prepare for Emergencies....32
Prevent Battery Explosions....33
Prevent Acid Burns....34
Wear Protective Clothing....36
Avoid High-Pressure Fluids....37
Avoid Heating Near Pressurized Fluid Lines....38
Service Machines Safely....39
Use Proper Tools....40
Park Machine Safely....41
Support Machine Properly....42
Use Proper Lifting Equipment....43
Work in Clean Area....44
Protect Against High Pressure Spray....45
Illuminate Work Area Safely....46
Work In Ventilated Area....47
Remove Paint Before Welding or Heating....48
Avoid Harmful Asbestos Dust....49
Follow Tire Recommendations....50
Stay Clear of Rotating Drivelines....51
Service Cooling System Safely....53
Dispose of Waste Properly....54
Handle Chemical Products Safely....55
Live With Safety....56
Section 20: Specifications Section 20: Specifications & Information{pgNO}57 Information....57
Group 10: Fastener Torques....57
Metric Bolt and Screw Torque Values....61
Unified Inch Bolt and Screw Torque Values....63
Group 20: O-Ring Seal Service Recommendations....57
Face Seal Fittings With Inch Stud Ends Torque....68
Face Seal Fittings With Metric Stud Ends Torque....70
O-Ring Face Seal Fittings....72
O-Ring Boss Fittings....74
Straight Fitting or Special Nut Torques....76
Metric Cap Screw Torque Values—Grade 7....77
Group 30: General Information....57
Gasoline....80
Gasoline Storage....82
Diesel Fuel....83
Diesel Fuel Lubricity....84
Diesel Fuel Storage....85
4 - Cycle Gasoline Engine Oil....86
Break-In Engine Oil - 4-Cycle Gasoline....87
4 - Cycle Diesel Engine Oil....88
Break-In Engine Oil - Diesel....89
Transaxle and MFWD Differential Oil....90
Alternative Lubricants....91
Synthetic Lubricants....92
Lubricant Storage....93
Mixing of Lubricants....94
Oil Filters....95
Brake Fluid....96
Chassis Grease....97
Group 40: Coolant....57
Recommended Engine Coolant....99
Group 50: Serial Number Locations....57
Product Serial Number....101
Gasoline Engine Serial Number Location....102
Diesel Engine Serial Number Location....103
Section 30: Engine - Gas (Liquid Cooled)....104
Group 10: Specifications and Tools....104
Specifications....1951
Service Equipment and Tools....287
Group 20: Component Location....295
Engine Compartment Location....121
Starting Motor....123
Fuel System Components....125
Coolant System Components....128
Group 30: Diagnostics....326
Engine Troubleshooting Guide....104
Starting Motor Troubleshooting....141
Group 40: Tests and Adjustments....104
Summary of References....1967
Governor: Static Adjustment....146
High Idle Speed Adjustment....148
Slow Idle Mixture and Governed Low Idle Adjustments....150
Throttle Cable Adjustment....153
Choke Cable Adjustment....156
Fuel Pump Pressure Test....158
Fuel Pump Flow Test....160
High Altitude Operation....162
Cylinder Compression Test....163
Valve Clearance Adjustment....165
Crankcase Vacuum Test....168
Oil Pressure Test....170
Radiator Cap Pressure Test....172
Thermostat Test....173
Group 50: Repair....104
Summary of References....1967
Muffler Removal and Installation....177
Engine Removal and Installation....179
Carburetor Repair....184
Intake Manifold Removal and Installation....189
Cylinder Head Removal and Installation....192
Cylinder Head Disassembly and Inspection....195
Crankcase Cover Removal and Installation....199
Crankcase Breather Inspection....202
Oil Pump Inspection....203
Oil Pump Installation....206
Camshaft Removal....208
Camshaft Inspection....209
Governor Removal and Inspection....210
Piston and Cylinder Removal....212
Piston Inspection....214
Piston Ring Installation....219
Cylinder Boring....221
Connecting Rod Bend and Twist Inspection....223
Crankshaft Inspection....225
Crankshaft Installation....228
Connecting Rod Assembly and Installation....229
Tappet and Camshaft Installation....231
Water Pump Removal and Installation....232
Water Pump Parts Inspection....234
Starting Motor Removal and Installation....235
Starting Motor Disassembly and Inspection....237
Section 40: Engine - Diesel....249
Group 10: Specifications—3TNE68....249
Engine Specifications....1951
Fuel System....255
Repair Specifications....1951
Service Equipment and Tools....287
Torque Specifications....1951
Checks Tests and Adjustment Specifications....1951
Other Material....290
Group 15: Specifications—3TNV70....249
Specifications....1951
Service Equipment and Tools....287
Other Material....290
Group 20: Component Location....295
Component Location....295
Group 30: Theory of Operation....249
Cooling System Theory of Operation....301
Lubrication System Theory of Operation....303
Fuel System Theory of Operation....305
Air System Theory of Operation....307
Group 40: Diagnostics....326
Engine Troubleshooting and Diagnostics....326
Engine Oil Diagnostics....326
Excessive Fuel Consumption....312
Incorrect Manifold Pressure....313
Low Engine Compression....314
Engine Starting Problem....315
Engine Operation Poor....318
Coolant Temperature Abnormal....324
Coolant in Oil or Oil in Coolant....325
Diagnostics....326
Group 50: Tests and Adjustments....249
Summary of References....1967
Air Restriction Indicator Test—Diesel....331
Slow Idle Speed Adjustment—Diesel....334
High Idle Speed Adjustment—Diesel....336
Throttle Cable Adjustment—Diesel....338
Valve Clearance Adjustment—Diesel....340
Valve Lift Check—Diesel....344
Cylinder Compression Test—Diesel....346
Water Pump and Alternator Drive Belt Adjustment—Diesel....348
Thermostat Test—Diesel....350
Radiator Bubble Test—Diesel....352
Cooling System Pressure Test—Diesel....353
Radiator Cap Pressure Test—Diesel....354
Engine Oil Pressure Test—Diesel....355
Injection Pump Timing—Diesel....357
Fuel Injection Nozzle Test—Diesel....358
Fuel Injection System Tests—Diesel....361
Injection Pump Static Timing Check—Diesel....364
Fuel System Air Bleeding—Diesel....368
Fuel Transfer Pump Flow Test—Diesel....369
Fuel Transfer Pump Pressure Test—Diesel....371
Group 60: Repair....250
Summary of References....1967
Engine Removal and Installation Diesel....377
Muffler Removal and Installation Diesel....388
Rocker Arm Cover Removal and Installation 3TNE68....390
Rocker Arm Cover Removal and Installation 3TNV70....392
Disassemble, Inspect, and Assemble Rocker Arm Assembly and Push Rods....394
Cylinder Head Removal and Installation Diesel 3TNE68....398
Cylinder Head Removal and Installation Diesel 3TNV70....402
Intake Manifold Removal and Installation Diesel 3TNE68....405
Exhaust Manifold Removal and Installation Diesel....406
Cylinder Head Recondition....408
Crankshaft Rear Oil Seal....421
Crankshaft Front Oil Seal....424
Timing Gear Cover Diesel 3TNE68....426
Timing Gear Cover Diesel 3TNV70....428
Camshaft End Play Check....431
Timing Gear Backlash Check....432
Idler Gear 3TNE68....434
Idler Gear 3TNV70....437
Cam Followers....440
Camshaft 3TNE68....443
Camshaft 3TNV70....451
Oil Pan and Strainer....459
Connecting Rod Side Play Check....460
Crankshaft End Play Check Diesel....461
Connecting Rod Bearing Clearance Check....463
Crankshaft Main Bearing Clearance Check....465
Piston to Cylinder Head Clearance....467
Connecting Rod Repair....469
Pistons....473
Cylinder Bore....482
Crankshaft and Main Bearings....487
Flywheel Removal and Installation....493
Flywheel Plate....495
Timing Gear Housing....497
Oil Pump Removal and Installation Diesel 3TNE68....500
Oil Pump Removal and Installation Diesel 3TNV70....503
Oil Pressure Regulating Valve....507
Coolant Temperature Switch....509
Thermostat Removal and Installation....510
Water Pump Removal and Installation—Diesel....512
Fuel Filter Removal and Installation....514
Fuel Filter Assembly Removal and Installation....516
Fuel Transfer Pump Diesel 3TNE68....518
Fuel Transfer Pump Diesel 3TNV70....519
Fuel Injection Nozzle....521
Fuel Injector Pump Diesel 3TNE68....527
Fuel Injection Pump Diesel 3TNV70....533
Fuel Injection Pump Camshaft 3TNE68....537
Governor 3TNE68....543
Fuel Control and Governor Linkage....546
Fuel Shutoff Solenoid Removal and Installation....549
Starting Motor Removal and Installation Diesel....551
20 Amp Alternator....553
40 Amp Alternator....557
Section 50: Electrical....565
Group 10: General Information....565
Reading Electrical Schematics....577
Theory Of Operation Information....579
Diagnostic Information....580
Wire Color Abbreviation Chart....581
Common Circuit Tests....582
Conductors For 12 Volt Circuits....584
Group 20: Specifications....1951
Gasoline Engine Machines....586
Diesel Engine Machines....587
Fuses....588
Group 30: Component Location (SN -040000)....565
Summary of References....1967
Electrical Components—Gas Engines (SN -040000)....592
Electrical Components—Diesel Engines (SN -040000)....594
Electrical Schematic and Wiring harness Legend (Gas and Diesel Engines SN -040000)....596
Group 35: Component Location (SN 040001-)....565
Summary of References....1967
Electrical Components—Gas Engines (SN 040001-080000)....600
Electrical Components—Gas Engines (SN 080001-)....602
Electrical Components—Diesel Engines (SN 040001-080000)....604
Electrical Components—Diesel Engines (SN 080001-110000)....606
Electrical Components—Diesel Engines (SN 110001-)....608
Electrical Schematic and Wiring Harness Legend (SN 040001-080000)....610
Electrical Schematic and Wiring Harness Legend (Gas Engines SN 080001-)....612
Electrical Schematic and Wiring Harness Legend (Diesel Engines SN 080001-110000)....614
Electrical Schematic and Wiring harness Legend (Diesel Engines SN 110001-)....616
Group 40: Schematics and Harnesses (SN -040000)....565
Summary of References....1967
Main Schematic (Gas Engines SN -040000)....620
Main Wiring Harness (Gas Engines SN -040000)....624
Main Harness Wire Codes (Gas Engines SN -040000)....628
W2 Engine Wiring Harnesses (Gas Engines SN -040000)....631
Main Schematic (Diesel Engines SN -040000)....632
Main Wiring Harness (Diesel Engines SN -040000)....635
Main Harness Wire Color Codes (Diesel Engines SN -040000)....639
Group 41: Schematics and Harnesses (SN 040001-110000)....566
Summary of References....1967
Main Wiring Schematic (Gas Engines SN 040001-080000)....644
Main Wiring Harness (Gas Engines SN 040001-080000)....648
Main Harness Wire Color Codes (Gas Engine SN 040001-080000)....652
Main Wiring Schematic (Gas Engines SN 080001-110000)....655
Main Wiring Harness (Gas Engines SN 080001-110000)....660
Main Harness Wire Color Codes (Gas Engine SN 080001-110000)....665
W2 Engine Wiring Harnesses (Gas Engine SN 040001-)....668
Main Schematic (Diesel Engines SN 040001-080000)....669
Main Wiring Harness (Diesel Engines SN 040001-080000)....672
Main Harness Wire Color Codes (Diesel Engines SN 040001-080000)....676
Main Schematic (Diesel Engines SN 080001-110000)....679
Main Wiring Harness (Diesel Engines SN 080001-110000)....682
Main Harness Wire Color Codes (Diesel Engines SN 080001-110000)....686
Battery Wiring Harness—Diesel (SN 040001-)....689