John Deere 3203 Compact Utility Tractor Diagnostic And Repair Manual TM1150

[Martin Welker]

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John Deere 3203 Compact Utility Tractor Diagnostic And Repair Manual TM1150
Size: 98.97 MB
Format: PDF
Language: English
Brand: John Deere
Type of Machine: Compact Utility Tractor
Type of Manual: Diagnostic And Repair Manual
Model: John Deere 3203 Compact Utility Tractor
Part Number: TM1150
Publication Date: 2007
Number of Pages: 461 Pages

Contents:
MANUAL DESCRIPTION
SAFETY
Safety
Recognize Safety Information
Understand Signal Words
Replace Safety Signs
Handle Fluids Safely - Avoid Fires
Use Care In Handling and Servicing Batteries
Prevent Battery Explosions
Prevent Acid Burns
Wear Protective Clothing
Use Care Around High-pressure Fluid Lines
Service Machines Safely
Use Proper Tools
Park Machine Safely
Support Machine Properly and Use Proper Lifting Equipment
Work In Clean Area
Using High Pressure Washers
Illuminate Work Area Safely
Work In Ventilated Area
Warning: California Proposition 65 Warning
Remove Paint Before Welding or Heating
Avoid Harmful Asbestos Dust
Service Tires Safely
Avoid Injury From Rotating Blades, Augers and PTO Shafts
Service Cooling System Safely
Dispose Of Waste Properly
Handle Chemical Products Safely
Live With Safety
SPECIFICATIONS & INFORMATION
General Specifications
Metric Fastener Torque Values
Metric Fastener Torque Values—Grade 7
Inch Fastener Torque Values
Gasket Sealant Application
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
Fuels and Lubricants
Diesel Fuel Specifications
Diesel Fuel Lubricity
Diesel Fuel Storage
Engine Oil
Engine Break–in Oil
Alternative Lubricants
Synthetic Lubricants
Lubricant Storage
Mixing Of Lubricants
Chassis Grease
Transaxle Oil
Coolant Specifications
Engine Coolant
Engine Coolant Drain Interval
Serial Number Locations
Machine Product Identification Number
Engine Serial Number
ENGINE - DIESEL
Specifications
General Specifications
Tests and Adjustment Specifications
Repair Specifications
Operational Tests
Torque Values, Non-Standard Fasteners
Special Tools
Other Materials
Component Location
Fuel Supply Components
Theory of Operation
Fuel System Operation
Cooling System Operation
Lubrication System Operation
Diagnostics
Engine Troubleshooting
Low Engine Output
Exhaust Abnormal Under Load
Engine Runs Rough
Excessive Fuel Consumption
Lubricating Oil
Temperature Problems
Low Compression
Incorrect Manifold Pressure
Starting Problems
Coolant in Oil or Oil in Coolant
Diagnostic Table
Check for Head Gasket Failures
Tests and Adjustments
Check Air Intake System
Check for Intake and Exhaust Restrictions
Fan/Alternator Drive Belt Adjustment
Throttle Rod Adjustment
Slow Idle Adjustment
Thermostat Opening Test
Cylinder Compression Test
Valve Clearance Adjustment
Valve Lift Check
Radiator Bubble Test
Radiator Pressure Cap Test
Cooling System Pressure Test
Engine Oil Pressure Test
Engine Oil Consumption
Fuel System Leakage Test
Bleed Fuel System
Fuel Supply Pump Pressure Test
Injection Pump Timing
Fuel Injection Nozzle Test
Crankshaft End Play Check
Timing Gear Backlash Check
Camshaft End Play Check
Connecting Rod Side Play Check
Connecting Rod Bearing Clearance Check
Crankshaft Main Bearing Clearance Check
Repair
Radiator Removal and Installation
Thermostat Removal and Installation
Water Pump Removal and Installation
Fuel Filter/Water Separator
Secondary Fuel Filter
Fuel Injection Pump
Fuel Injection Nozzles
Intake Manifold
Muffler Removal and Installation
Exhaust Manifold
Starting Motor Removal and Installation
Alternator Removal and Installation
Rocker Cover Removal and Installation
Engine Removal and Installation
Engine/Flywheel Housing Split
Rocker Arm Assembly
Cylinder Head and Valves Removal and Installation
Cylinder Head and Valves Disassembly and Assembly
Valve Seats
Valve Recession
Valve Guides
Valve Springs
Grind Valve Seats
Lap Valves
Measure Piston-To-Cylinder Head Clearance
Piston and Connecting Rod
Piston Inspection
Cylinder Bore
Crankshaft Front Oil Seal
Crankshaft Rear Oil Seal
Crankshaft and Main Bearings
Flywheel and Coupling
Camshaft
Camshaft Followers
Timing Gear Cover
Idler Gear
Timing Gear Cover Mounting Plate
Oil Pan and Strainer
Oil Pump
ELECTRICAL
General Information
Reading Electrical Schematics
Theory Of Operation Information
Diagnostic Information
Wire Color Abbreviation Chart
Common Circuit Tests
Conductors For 12 Volt Circuits
Specifications
System Specifications
Tools
Other Materials
Component Location
Main Schematic and Wiring Harness Legend
W1 Main Wiring Schematic
W1 Main Wiring Harness
W1 Main Wiring Harness Color Codes
Load Center
W1 Main Wiring Harness Component Location
Operation and Diagnostics
Power Circuit Operation
Power Circuit Electrical Schematic
Power Circuit Diagnosis
Cranking Circuit Operation
Cranking Circuit Electrical Schematic
Cranking Circuit Diagnosis
Manifold Heater and Indicator Light Circuit Operation
Manifold Heater and Indicator Light Circuit Electrical Schematic
Manifold Heater and Indicator Light Circuit Diagnosis
Fuel Supply/Engine Shutoff Circuit Operation
Fuel Supply/Fuel Pump/Engine Shutoff Circuit Electrical Schematic
Fuel Supply/Engine Shutoff Circuit Diagnosis
Charging Circuit Operation
Tachometer Circuit Operation
Hour Meter Circuit Operation
Charging, Tachometer, and Hour Meter Circuit Electrical Schematic
Charging, Tachometer and Hour Meter Circuit Diagnosis
PTO Circuit Operation
Rear PTO Circuit Electrical Schematic
PTO Circuit Diagnosis
Light Circuit Operation
Lights Circuit Electrical Schematic
Lights Circuit Diagnosis
Tests and Adjustments
Ground Circuit Test
Battery Voltage and Specific Gravity Test
Battery - Charge
Battery - Load Test
Alternator Regulated Voltage Test
Regulated Amperage and Voltage Test
Starting Motor Solenoid Test
Starting Motor Amperage Draw Test
Starting Motor No-Load Amperage Draw and RPM Test
Fuse Test
Manifold Heater Test
Diode Test
Engine Coolant Temperature Sensor Test
Engine Oil Pressure Switch Test
Relay Test
Key Switch Test
Light Switch Test
Turn Signal Switch Test
Sensing Switch Test
PTO Switch Test
PTO Solenoid Test
Seat Switch Test
Fuel Gauge Sensor Test
Fuel Shutoff Solenoid Test
Repair
Starting Motor Disassembly and Assembly
Starting Motor Inspection/Test
Starting Motor Gear Train
Starting Motor Solenoid
Fuel Gauge Sensor Removal and Installation
POWER TRAIN - HYDROSTATIC
Specifications
Hydrostatic Pump
Hydrostatic Motor
Torque Specifications
Special or Essential Tools
Other Materials
Component Location
Machines Component Location
Forward and Reverse Pedals
Transmission
Transmission Components
Center Plate Components
Drive Shaft
Front Drive
Schematics
Steering/Charge Pump Circuit Schematic
Theory of Operation
Transmission Operation
Range Transmission Power Flow
Diagnostics
Hydrostatic Power Train
Troubleshooting
Troubleshooting
Tests and Adjustments
Hydrostatic High Pressure Relief Test
Charge Pump Pressure Test and Adjustment
Hydraulic System Bleed Procedure
Hydrostatic Control Linkage Neutral Adjustment
Repair
Forward and Reverse Pedals Assembly
Machine Splitting (Front)
Machine Splitting (Rear)
Hydrostatic Transmission Removal and Installation
Hydrostatic Transmission Disassembly
System Check/Relief Valve Inspection/Replacement
Charge Pressure Relief Valve Inspection/Replacement
POWER TRAIN - FINAL DRIVE
Specifications
General Specifications
Repair Specifications
Torque Specifications
Special or Essential Tools
Other Materials
Component Location
Transmission
Main and Driven Shafts
Drive/Pinion Shaft
Range Shift
Differential Assembly
Rear Axle and Final Drive
Brake Assembly
PTO Clutch/Brake Assembly
Rear PTO Shaft
Transmission Housing
Front Drive (For MFWD)
MFWD Front Axle Housing and Differential
MFWD Final Drive
Theory of Operation
Range Transmission
Differential Power Flow and Lock
MFWD Power Operation
MFWD Power Flow
Diagnostics
Final Drive Diagnostic Checks
Diagnostics
PTO Diagnostics
Differential Lock Diagnostics
Final Drive Troubleshooting
Final Drive Symptom Diagnosis
Tests and Adjustments
Differential Pinion Shaft Adjustment
Differential Backlash Adjustment
Repair
MFWD Output Shaft
Speed Range Transmission
Main Gear Disassembly/Assembly
Assemble Range Transmission
Final Drive Removal
Final Drive Installation
Final Drive Disassembly, Inspection, and Assembly
Differential Lock Fork
Differential Removal and Installation
MFWD Removal and Installation
MFWD Final Drive Cover
MFWD Spindle Shaft
MFWD Final Drive Housing
Spindle Housing
MFWD Differential
Pinion Depth Setup and Adjustment
PTO Theory of Operation
PTO Clutch and Brake Theory of Operation
PTO Power Transmission
PTO Repair
PTO Drive Shaft and Gears
PTO Clutch and Brake
HYDRAULICS
Specifications
Hydraulic Specifications
Repair Specifications
Torque Specifications
Component Location and Schematics
Steering System Components
System Schematics
Rockshaft Piston, Rod, and Rate of Drop Valve
Rockshaft Control Valve, Plunger Assembly and Controls
Rockshaft and Lift Arms (Exploded View)
SCV Component Location
SCV and Rockshaft System Components
SCV and Rockshaft System Schematics
Theory of Operation
Hydro Hydraulic Operation
Main PTO Clutch Operation
PTO Valve Operation
Rockshaft Operation
Troubleshooting
Hydrostatic Troubleshooting
Rockshaft Hydraulics
Tests and Adjustments
Hydraulic System Bleed Procedure
Rate of Drop/Stop Valve Adjustment
Lift Arms Adjustment
System Pressure/Flow Test
System Pressure Adjustment
Steering Pressure Test
Charge Pressure Test
PTO Clutch Pressure Test
Rockshaft Lift Cycle Test
Rockshaft Leakage Test
Rockshaft Position Feedback Linkage Adjustment
Repair
Hydraulic Gear Pump
Rockshaft Removal and Installation
Rockshaft Disassembly and Assembly
Rockshaft Lift Arms Removal and Installation
Selective Control Valve (SCV)
STEERING
Specifications
Steering
Torque Specifications
Special or Essential Tools
Component Location
Steering Components
Steering System Schematic
Theory of Operation
Steering
Diagnostics
Steering System Check
Steering Operation
Tests and Adjustments
Steering Pressure Check
Steering System Test
Toe-in Adjustment MFWD
Repair
Steering Cylinder Removal and Installation MFWD
Steering Wheel Removal and Installation
Steering Control Unit (SCU) Removal and Installation
Tie Rod Removal and Installation MFWD
BRAKES
Specifications
Brakes
Transaxle Oil
Torque Specifications
Component Location
Brake Pedal and Linkage
Brake Pedal and Linkage (Exploded View)
Brake Assembly
Theory of Operation
Brakes
Diagnostics
Diagnostic Check Points
Brakes
Tests and Adjustments
Brake Adjustment
Repair
Brake Pedal Assembly Removal and Installation
Brake Shaft Removal and Installation
Brake Disassembly and Inspection
Brake Assembly
MISCELLANEOUS
Specifications
General Specifications
Torque Specifications
Repair
Front Wheel Removal and Installation
Rear Wheel Removal and Installation
Rear Fenders Removal and Installation
Seat and Seat Support Removal and Installation
Roll Over Protection System (ROPS)
Operator’s Foot Platforms
Hood Removal and Installation
Battery Removal and Installation
Control Panel Removal and Installation
Cowl Panel Removal and Installation
Fuel Tank Removal and Installation