John Deere CS, CX Gator Light Duty Utility Vehicles Technical Manual TM2119 - PDF

JOHN DEERE

WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION

September 2005

Gator Light Duty Utility Vehicles and CX CS TM2119 SEPTEMBER 2005

TECHNICAL MANUAL

North American Version Litho In U.s.a.

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INTRODUCTION Manual Description

Safety This technical manual is written for a n experienced technician and contains sections that are specifically for this product. It is a part of a total product support program.

T h e m a n u a l i s o r g a n i z e d s o t h a t a l l t Specifications h e i n f o r m a tand i o n Information on a particular system is kept together. The order of grouping is as follows: •Table of Contents •Specifications and Information

Engine (FE250D)

•Identification Numbers

Engine (FE290D)

•Tools and Materials •Component Location •Schematics and Harnesses

Electrical

•Theory of Operation •Operation and Diagnostics • Diagnostics

Power Train

•Tests and Adjustments • Repair

Steering

• Other Note: Depending on the particular section or system being covered, not all of the above groups may be used.

Brakes

The bleed tabs for the pages of each section will align with the sections listed on this page. Page numbering is c o n s e c u t i v e f r o m t h e b e g i n n i n g o f t hMiscellaneous e Safety section through the last section.

We appreciate your input on this manual. If you find any errors or want to comment on the layout of the manual please contact us.

All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice.

COPYRIGHT© 2005 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT© 2003, 2004

Introduction

SAFETY Handle Fluids Safely - Avoid Fires

Safety

Be Prepared For Emergencies

Recognize Safety Information

MIF

This is the safety-alert symbol.

When you see this symbol on your machine or in this manual, be alert to the potential for personal injury.

Follow recommended

MIF

p r e c a u t i oSignal n s a Words nd safe servicing Understand •When you work around fuel, p r a c t i c e s . oA t UT sm work near A s i g n a l w o r d - D A N G E R , W A R N I N Gd , o o r n C I OoNk e- i so r e rGsE o i rse t hh ae z a r d s . u s e d w i t h t h e s a f e t y - a l e r t s y m b o l h. eDaAt N Rr i o d te hn et ri f fi e most serious hazards.

•Store flammable fluids away DANGER or WARNING safety signs are located near r on m s p e c i f i c h a z a r d s . G e n e r a l p r e c a u t fi o s af ri re e l ihsat ze adr do sn. D o n o t i n c i tt uo C A U T I O N s a f e t y s i g n s . C A U T I O N a lps roe scnsaeul rlr sai zt ae etdtoercnoptniuo tnanci n e rr es . safety messages in this manual.

•Make sure machine is clean of trash, grease, and

Replace Safety Signs

debris.

•Do not store oily rags; they can ignite and burn spontaneously.

Use Care In Handling and Servicing Batteries •Be prepared if a fire starts.

•Keep a first aid kit and fire extinguisher handy.

•Keep emergency numbers for doctors, ambulance sd ee rpvai rc tem , hospital, and fire t e l e p h o neen. t n e a r y o u r MIF

Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.

Safety - 1

MIF

SAFETY

such as earmuffs or earplugs to pro objectionable or uncomfortable loud •Keep sparks, lighted matches, and open flame away qd u ei p. m e n t s a f e l y r e q u i r e s f r o m t h e t o p o f b a t t e r y . B a t t e r y gOa ps ecr aa nt i n eg x p el o operator. Do not wear radio or musi • N e v e r c h e c k b a t t e r y c h a r g e b y p loapc ei n m emt aa cl hoi bn jee. c t r ag t ian g across the posts. Use a volt-meter or hydrometer.

•Do not charge a frozen battery; it may explode. Warm

Prevent Battery Explosions

battery to 16°C (60°F).

Use Care Around High-pressure Fluid Lines

Avoid High-Pressure Fluids

Prevent Acid Burns •Sulfuric acid in battery electrolyte is poisonous. It is strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes.

Avoid acid burns by: 1.Filling batteries in a well-ventilated area.

2.Wearing eye protection and rubber gloves.

3.Avoiding breathing fumes when electrolyte is added.

MIF

4.Avoiding spilling or dripping elE ec s ct ra opl iynt ge . f l u i d u n d e r p r e s s u r e c a n p 5 . U s e p r o p e r j u m p s t a r t p r o c e d u r ec .a u s i n g s e r i o u s i n j u r y .

Avoid injury from escaping fluid und If you spill acid on yourself: the engine and relieving pressure in 1.Flush your skin with water. disconnecting or connecting hydrau 2 . A p p l y b a k i n g s o d a o r l i m e t o h e Tl p un t r a l il z ce o tnhnee ca tci iodn. s b e f o r e a p p l y i gn h et e 3 . F l u s h y o u r e y e s w i t h w a t e r f o r 1 S0 e -a r1 c5 h mf o i nr ul teeask. s w i t h a p i e c e o f c a r d

4 . G e t m e d i c a l a t t e n t i o n i m m e d i a t ae nl yd . b o d y f r o m h i g h p r e s s u r e f l u i d s .

If an accident occurs, see a doctor i If acid is swallowed: injected into the skin must be surgi

1 . D r i n k l a r g e a m o u n t s o f w a t e r o rf e mwi l kh .o u r s o r g a n g r e n e m a y r e s u l t . D this type of injury should reference 2.Then drink milk of magnesia, beaten eggs, or vegetable medical source. Such information is oil.

Company Medical Department in Mol 3.Get medical attention immediately.

Avoid Heating Near Pressurized Fluid Lines

Wear Protective Clothing

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Flammable spray can be generated by heating near Wear close fitting clothing and safety equipment pressurized fluid li appropriate to the job.and bystanders. Do not heat by welding, solde Prolonged exposure to loud noise can cause impairment or a torch ne loss of hearing. Wear a suitable hearing protective device materials. heat goes beyond the immediate flame area.

Safety - 2

SAFETY Support Machine Properly Proper Lifting Equipment

Service Machines Safely

and

Use

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Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near MIF machine tools or moving parts. If these items were to get c a u g h t , s e v e r e i n j u r y c o u l d r e s u l tI .f y o u m u s t w o r k o n a l i f t e d m a c h i n

y ts e u lpepc ot r ti c tahl es h moar ct h R e m o v e r i n g s a n d o t h e r j e w e l r y t os epcruerveel n s ine or att a n d e n t a n g l e m e n t i n m o v i n g p a r t sD. o n o t s u p p o r t t h e m a c h i n e o n c i n d

or props that may crumble under co work under a machine that is suppo Use Proper Tools Follow recommended procedures in U s e t o o l s a p p r o p r i a t e t o t h e w o r k L. i M kg e sh h ei fatv yt o cool sm p an f t ai n od nents incorrectl procedures can create safety hazards. Use power tools o n l y t o l o o s e n t h r e a d e d p a r t s a n di nf jaus rt ye no er r m s . a Fc oh ri nl e o ods ae m n iangge . F o l l o w r e p r o c e d u r e f o r r e m o v a l and installati and tightening hardware, use the correct size tools. DO n ue at rl .i c f a s t e n e r s .

N O T u s e U . S . m e a s u r e m e n t t o o l s om n am Avoid bodily injury caused by slipping wrenches. Use only service parts meeting John Deere specifications.

Work In Clean Area

Parking Safely

Before starting a job: 1.Clean work area and machine.

2.Make

sure

you

necessary

tools

to

job.

the

right

3.Have

have do

all your

parts

on

hand.

Using High Pressure Washers

4.Read all instructions Directing pressurized water at elect thoroughly; do not attempt components or connectors, bearings shortcuts.

MIF injection pumps or other sensitive p r op de u. c t m a l f u n c t i o n s . R e 1 . S t o p m a c h i n e o n a l e v e l s u r f a c e ,m na oy t c oa nu sae spl o spray at a 45 to 90 degree angle.

2.Disengage and stop attachments.

3.Lower attachments to the ground.

4.Lock park brake.

Illuminate Work Area Safely

Illuminate your work area adequatel portable safety light for working ins machine. Make sure the bulb is encl 6.Remove key.

The hot filament of an accidentally 7 . W a i t f o r e n g i n e a n d a l l m o v i n g sp pa ir ltl se dt of us et o e fi lo. r e y o u l po rb o leave the operator’s station.

5.Stop engine.

8.Close fuel shut-off valve, if your machine is equipped.

Safety - 3

SAFETY

Avoid creating dust. Never use comp Avoid brushing or grinding material When servicing, wear an approved re vacuum cleaner is recommended to available, apply a mist of oil or wat containing asbestos. Keep bystande

Work In Ventilated Area

Service Tires Safely

MIF

Engine exhaust fumes can cause sickness or death. If it is necessary to run an engine in an enclosed area, remove the exhaust fumes from the area with an exhaust pipe extension.

If you do not have an exhaust pipe extension, open the doors and get outside air into the area.

Warning: California Proposition 65 Warning

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Explosive separation of a tire and ri uu s ci tn jcuo rnyt ao irn d G a s o l i n e e n g i n e e x h a u s t f r o m t h i ss epr ri oo d s eath. c h e m i c a l s k n o w n t o t h e S t a t e o f CDaol i n f oo rt n ai at t te om cp at utsoe m c ao n u cn et r a, t i r e u n l e birth defects, or other reproductive harm. equipment and experience to perfor D i e s e l e n g i n e e x h a u s t a n d s o m e oAf l w i t as y cs o m n sa ti int tuaei n n t ts h ae r ec o r r e c t t i r e p r e known to the State of California to cause cancer, birth tires above the recommended pressu defects, and other reproductive harm. a wheel and tire assembly. The heat in air pressure resulting in a tire ex structurally weaken or deform the w Remove Paint Before Welding or Heating

n fal zaat ri d no g u tsi rf eusm , eu ss e a c l i p - o n c A v o i d p o t e n t i a l l y t o x i c f u m e s a n d Wdhues nt . i H h ao ts ee d l ob ny gw ee nl d o iunggh, t o a l l o w y o u t o s t can be generated when paint is he OT o f o or r i n o vae rw te hl le t i r e a s s e s o l d e r i n g , o r u s i n g a t o r c h . D o a l lN w o r ikn of ur o t sn i td e i f a v a i l a b l e . ventilated area. Dispose of paint and solvent properly.

R e m o v e p a i n t b e f o r e w e l d i n g o r h Ce h ae t icnkg w : Ihf e y o rp r e s s u r e , c u t s eo l su f soar n ldo w grind paint, avoid breathing the dust. Wear an approved s ir n ug r e s p i r a t o r . I f y o u u s e s o l v e n t o r prai imn st o s tr r m i pi ps e , gr el m o vbe o l t s a n d n u t s . stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating.

Avoid Harmful Asbestos Dust Avoid breathing dust that may be generated when handling components containing asbestos fibers.

Inhaled asbestos fibers may cause lung cancer.

Components in products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates, and some gaskets. The asbestos used in these components is usually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.

Safety - 4

SAFETY Avoid Injury From Rotating Blades, Augers and PTO Shafts

MIF

Dispose of Waste Properly

Improperly disposing of waste can t environment and ecology. Potentiall with John Deere equipment include coolant, brake fluid, filters, and bat containers when draining fluids. Do beverage containers that may mislea drinking from them. Do not pour wa down a drain, or into any water sour proper way to recycle or dispose of environmental or recycling center, o dealer.

Live With Safety

Keep hands and feet away while machine is running. Shut off power to service, lubricate or remove mower blades, augers or PTO shafts.

Handle Chemical Products Safely

MIF

Before returning machine to customer, make sure machine Direct exposure to hazardous chemicals can cause serious is functioning properly, injury. Potentially hazardous chemicals used with John especially the safety systems.

Deere equipment include such items as lubricants, Install all guards and shields. coolants, paints, and adhesives.

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A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques.

Check the MSDS before you start any job using a hazardous chemical. That way you will know exactly what the risks are and how to do the job safely. Then follow procedures and recommended equipment.

Safety - 5

SPECIFICATIONS AND INFORMATION TABLE OF CONTENTS Table of Contents Specifications and Information

Fastener Torques..............................................9 Metric Fastener Torque Values......................9 Inch F a s Recommendations......11 tener Torque O-Ring Seal Service Values.......................10 Face Seal Fittings With Inch Stud Ends T . . o. . r. q ..u . .e . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .1. 1. . . . . . . . . . . . .

Face Seal Fittings With

Metric Stud Ends T . . o. . r. q . Information........................................14 .u . .e . . .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .1. 2. . . . . . . . . . . . .

General O-Ring Face Seal Fittings............................1 3 O-Ring Boss Fittings............................. .......13 Straight Fitting Or Special Nut Torques........13 M eNumber t r i c FLocations...............................17 astener Torque Serial Value - G rade 7 (Special)........................... ............................14 Gasoline ......................................... ..............14 G asoline S . . t. .o. .r .a. .g. .e. .. .1 .5. . . . . . . . . . . . . . . . . . . . . . . . . .

4 - Cycle Gasoline Engine Oil......................15 B r ec a Cy l ek -GI n a s Eo nl igni en. e. . . O . . i. l. 1 -5 4 Transaxle

Oil..................................... ...........16 A l t erri nc aa tni tvse. . . . . . . . . . . . . . . . . . . . . . . . .

L . .u . .b ......16 Specifications and Information Table of Contents - 7 Synthetic Lubricants.........................

SPECIFICATIONS AND INFORMATION FASTENER TORQUES Fastener Torques

Metric Fastener Torque Values 8.8

9.8

10.9

4.8

8.8

9.8

10.9

12.9

4.8

8.8

9.8

10.9

12.9

10

5

10

10

12.9 12

10

12

10

5 5

Property Class and Nut Marking s

12.9

10

4.8 Property Class and Head Marking s

12

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Class 4.8Class 8.8 or 9.8Class 10.9Class 12.9 Lubricated aDry aLubricated aDry aLubricated aDry aLubricated aDry a SIZE N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N•m lb-ft N M6 4.8 3.5 6 4.5 9 6.5 11 8.5 13 9.5 17 12 15 11.5 19 14.5 M8 12 8.5 15 11 22 16 28 20 32 24 40 30 37 28 47 35 M10 23 17 29 21 43 32 55 40 63 47 80 60 75 55 95 70 M12 40 29 50 37 75 55 95 70 110 80 140 105 130 95 165 120 M14 63 47 80 60 120 88 150 110 175 130 225 165 205 150 260 109 M16 100 73 125 92 190 140 240 175 275 200 350 225 320 240 400 300 M18 135 100 175 125 260 195 330 250 375 275 475 350 440 325 560 410 M20 190 140 240 180 375 275 475 350 530 400 675 500 625 460 800 580 M22 260 190 330 250 510 375 650 475 725 540 925 675 850 625 1075 800 M24 330 250 425 310 650 475 825 600 925 675 1150 850 1075 800 1350 1000 M27 490 360 625 450 950 700 1200 875 1350 1000 1700 1250 1600 1150 2000 1

M30 675 490 850 625 1300 950 1650 1200 1850 1350 2300 1700 2150 1600 2700 M33 900 675 1150 850 1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 37 M36 1150 850 1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750

DO NOT use these hand torque values if a different torque values should be

value or tightening procedure is given for a specific head. application. Torque values listed are for general use only Tighten toothed or serrated-type lock nuts to the full torque and include a ±10% variance factor. Check tightness of value. fasteners periodically. DO NOT use air powered wrenches. a “Lubricated” means coated with a lubricant such as Shear bolts are designed to fail under predetermined loads. engine oil, or fasteners with phosphate and oil coatings.

Always replace shear bolts with identical grade.

“Dry” means plain or zinc plated (yellow dichromate Fasteners should be replaced with the same grade. Make Specification JDS1 sR ue rf e e :n e r St h-r eGa2d0s0 .a r e c l e a n a n d t h a t y o u p r o p e r l y s t a r t e r feans ct e JD thread engagement. This will prevent them from failing when tightening.

When bolt and nut combination fasteners are used, torque Specifications and Information Fastener Torques - 9

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