John Deere HPX815E troubleshooting Technical information
HPX815E Gator™
Utility Vehicle (SN. 010001-)
DOWNLOAD TECHNICAL MANUAL
HPX815E Gator™ Utility Vehicle (SN. 010001-)
TM151019 01DEC18 (ENGLISH)
John Deere Horicon Works
Operation and tests sections help you identify the majority of
quickly.
This manual is written for an experienced technician. Essential Information is organized in groups for the various components tools required in performing certain service work are identified in requiring service instruction. At the beginning of each group are this manual and are recommended for use.summarylistingsofallapplicableessentialtools,service equipment and tools, other materials needed to do the job,
Live with safety: Read the safety messages in the introduction of service parts kits, specifications, wear tolerances, and torque this manual and the cautions presented throughout the text of the values. manual.
CAUTION:needed for diagnosis, analysis, testing, and repair.
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information
This is the safety-alert symbol. When you see this symbol on the Fundamental service information is available from other sources machine or in this manual, be alert to the potential for personal covering basic theory of operation, fundamentals of injury. troubleshooting, general maintenance, and basic type of failures and their causes.
Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
DX,TMIFC-19-20140415
Section 10 - General Information
Group 10 - Safety
Group 20 - General Specifications
Group 30 - Fuel, Lubricants, and Coolant
Group 40 - Machine Specifications
Section 20 - Engine Repair
Group 10 - Repair
Section 30 - Electrical Repair
Group 10 - General Information
Group 20 - Main Wire Harness
Group 30 - Wiring Harnesses, Kits
Group 40 - Repair
SeGc r t o io up n1400RP e o pa wirer Train Repair
Section 50 - Steering Repair
Group 10 - Repair
Section 60 - Brake Repair
Group 10 - Brake Repair
Section 70 - Miscellaneous Repair
Group 10 - Component Location
Group 20 - Repair
Section 220 - Engine Operation, Tests, and
Ad Gjr u o s u t p m 1 e 0 nt C s omponent Location
Group 20 - Theory of Operation
Group 30 - Diagnosis
Group 40 - Tests and Adjustments
Section 230 - Electrical Operation, Tests, and Adjustments
Group 10 - Component Location
Group 20 - Theory of Operation (Non - EEC)
Group 25 - Theory of Operation (EEC)
Group 30 - Diagnostics (Non - EEC)
Group 40 - Schematics
Group 50 - Schematics, Kits
Group 60 - Connector Information
Group 65 - Connector Information (EEC)
Group 70 - Tests and Adjustments
Section 240 - Control Unit Operation, Tests a nGd ro A u d p j1u0s tmThe e n o t r s y ofOperation
Group 20 - Diagnostic Trouble Codes, ICC
Group 30 - Service ADVISOR Readings
Group 40 - Tests and Adjustments
Section 250 - Power Train Operation, Tests, anGdroAud p j1u0st-mCoem nptsonent Location
Group 20 - Theory of Operation
Group 30 - Diagnostics
Group 40 - Tests and Adjustments
SeGc r t o io up n12060Com St p e o e n r e i n ntgLoa c n a d tioB n rake Operation,
Tests, and Adjustments
Group 20 - Theory of Operation
Group 30 - Diagnostics
Group 40 - Tests and Adjustments
Group 10 - Service Tools and Kits
Section 299 - Service Tools
Group 10 - Safety
Group 20 - General Specifications Service Recommendations for O - Ring Boss 10-20-1 Fittings ...........................................................
Service Recommendations For Flat Face O - Ring 10-20-2
Recognize Safety Information
Understand Signal Words
T81389-UN: Safety-alert symbol
This is a 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 precautions and safe operating practices.
DX,ALERT-19-19980929
DANGER; The signal word DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.
WARNING; The signal word WARNING indicates a hazardous sietruiaotuios n which, if not avoided, could result in death or injury.
CAUTION; The signal word CAUTION indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. CAUTION may also be used to alert against unsafe practices associated with events which could lead to personal injury.
A signal word DANGER, WARNING, or CAUTION is used withthesafety-alertsymbol.DANGERidentifiesthemostserious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safetysigns.CAUTIONalsocallsattentiontosafetymessagesin this manual.
DX,SIGNAL-19-20161005
TS187-19: Signal Words
Practice Safe Maintenance
Use Proper Tools
Handle Fluids Safely Avoid Fires
TS218-UN: Keep Area Clean
Understand service procedure before doing work. Keep area clean and dry.
Never lubricate, service, or adjust machine while it is moving. Keep hands, feet, and clothing away from power-driven parts. Disengage all power and operate controls to relieve pressure. Lower equipment to the ground. Stop the engine. Remove the key. Allow machine to cool.
Securely support any machine elements that must be raised for service work.
Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Remove any buildup of grease, oil, or debris.
On self-propelled equipment, disconnect battery ground cable () before making adjustments on electrical systems or welding on machine.
On towed implements, disconnect wiring harnesses from tractor before servicing electrical system components or welding on machine.
Falling while cleaning or working at height can cause serious injury. Use a ladder or platform to easily reach each location. Use sturdy and secure footholds and handholds.
DX,SERV-19-20170228
TS779-UN: Proper Tools
Use tools appropriate to the work. Makeshift tools and procedures can create safety hazards.
Use power tools only to loosen threaded parts and fasteners. For loosening and tightening hardware, use the correct size tools. DO NOT use U.S. measurement tools on metric fasteners. Avoid bodily injury caused by slipping wrenches.
Use only service parts meeting John Deere specifications.
DX,REPAIR-19-19990217
TS227-UN: Avoid Fires
When you work around fuel, do not smoke or work near heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and debris. Do not store oily rags; they can ignite and burn spontaneously.
DX,FLAME-19-19980929
Prevent Acid Burns
Prevent Battery Explosions
Handling Batteries Safely
TS203-UN: 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 the hazard by:
Filling batteries in a well-ventilated area. Wearing eye protection and rubber gloves. Avoiding breathing fumes when electrolyte is added. Avoiding spilling or drippingelectrolyte.
Use proper jump start procedure.
If you spill acid on yourself:
Flush your skin with water.
Apply baking soda or lime to help neutralize the acid. Flush your eyes with waterfor15 30minutes.Get medical attention immediately.
If acid is swallowed:
Do not induce vomiting.
Drink large amounts of water or milk, but do not exceed 2 L (2 quarts). Get medical attention immediately.
DX,POISON-19-19930421
TS204-UN: Battery Explosions
Keepsparks,lightedmatches,andopenflameawayfromthetop of battery. Battery gas can explode.
Never check battery charge by placing a metal object across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm battery to 16°C (60°F).
DX,SPARKS-19-19930303
TS204-UN: Caution
TS203-UN: Caution
Always remove grounded (-) battery clamp first and replace grounded clamp last.
Sulfuric acid in battery electrolyte is poisonous and strong ebnlinodunghestsoifburn skin,eatholesinclothing, andcause splashed into eyes. Avoid hazards by:
Fillingbatteriesinawell-ventilatedarea
Wearing eye protection and rubber gloves
Avoiding use of air pressure to clean batteries
Avoiding breathing fumes when electrolyte is added
Avoiding spilling or dripping electrolyte
Using correct battery booster or charger procedure.
If acid is spilled on skin or in eyes:
Flush skin with water.
Apply baking soda or lime to help neutralize the acid. Flush eyes with water for 15 30 minutes. Get medical attention immediately.
If acid is swallowed:
Do not induce vomiting.
Drink large amounts of water or milk, but do not exceed 2 L (2 qt.).
Get medical attention immediately.
WARNING:Battery posts, terminals, and related accessories
Battery gas can explode. Keep sparks and flames away from contain lead and lead compounds, chemicals known to the State batteries. Use a flashlight to check battery electrolyte level.ofCaliforniatocausecancerandreproductiveharm.Wash hands after handling.
Never check battery charge by placing a metal object across the
DX,WW,BATTERIES-19-20101202 posts. Use a voltmeter or hydrometer.
Prepare for EmergenciesTS291-UN: First Aid Kit
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance service, hospital, and fire department near your telephone.
DX,FIRE2-19-19930303
Park Machine Safely
TS230-UN: Remove the Key
Before working on the machine:
Lower all equipment to the ground. Stop the engine and remove the key. Disconnect the battery ground strap. Hang a "DO NOT OPERATE" tag inoperator station.
DX,PARK-19-19900604
Support Machine Properly
Wear Protective Clothing
Work in Clean Area
Service Machines Safely
TS229-UN: Support Properly
Always lower the attachment or implement to the ground before youworkonthemachine.Iftheworkrequiresthatthemachineor attachment be lifted, provide secure support for them. If left in a raised position, hydraulically supported devices can settle or leak down.
Do not support the machine on cinder blocks, hollow tiles, or props that may crumble under continuous load. Do not work under a machine that is supported solely by a jack. Follow recommended procedures in this manual.
When implements or attachments are used with a machine, always follow safety precautions listed in the implement or attachment operator′s manual.
DX,LOWER-19-20000224
TS206-UN: Protective Clothing
Wear close fitting clothing and safety equipment appropriate to the job.
Prolonged exposure to loud noise can cause impairment or loss of hearing.
Wear a suitable hearing protective device such as earmuffs or earplugs to protect against objectionable or uncomfortable loud noises.
Operating equipment safely requires the full attention of the operator. Do not wear radio or music headphones while operating machine.
DX,WEAR-19-19900910
T6642EJ-UN: Clean Work Area
Before starting a job:
Clean work area and machine. Make sure you have all necessary tools to do your job. Have the right parts on hand. Read all instructions thoroughly; do not attempt shortcuts.
DX,CLEAN-19-19900604
TS228-UN: Moving Parts
Tie long hair behind your head. Do not wear a necktie, scarf, loose clothing, or necklace when you work near machine tools or moving parts. If these items were to get caught, severe injury could result.
Remove rings and other jewelry to prevent electrical shorts and entanglement in moving parts.
DX,LOOSE-19-19900604
Work In Ventilated Area
Illuminate Work Area Safely
Replace Safety Signs
Use Proper Lifting Equipment
TS220-UN: Engine exhaust fumes
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. Ifyoudonothaveanexhaustpipeextension,openthedoorsand get outside air into the area.
DX,AIR-19-19990217
TS223-UN: Work Area Safely
Illuminate your work area adequately but safely. Use a portable safety light for working inside or under the machine. Make sure the bulb is enclosed by a wire cage. The hot filament of an accidentally broken bulb can ignite spilled fuel or oil.
DX,LIGHT-19-19900604
TS201-UN: Safety Signs
Replace missing or damaged safety signs. See the machine operator’s manual for correct safety sign placement.
DX,SIGNS1-19-19900604
TS226-UN: Proper Lifting Equipment
Lifting heavy components incorrectly can cause severe injury or machine damage.
Follow recommended procedure for removal and installation of components in the manual.
DX,LIFT-19-19900604
Follow Tire Recommendations
Protect Against High Pressure Spray
Decommissioning Proper Recycling and Disposal of Fluids and Components
TS1133-UN: Recycle Waste
Safety and environmental stewardship measures must be taken into account when decommissioning a machine and/or component. These measures include the following:
Use appropriate tools and personal protective equipment such as clothing, gloves, face shields or glasses, during the removal or handling of objects and materials.
Follow instructions for specialized components. Release stored energy by lowering suspended machine elements, relaxing springs, disconnecting the battery or other electrical power, and releasing pressure in hydraulic components, accumulators, and other similar systems.
H111235-UN: Read OM
Keep your machine in proper working order.
Use only prescribed tire sizes with correct ratings and inflate to the pressure specified in this manual.
Use of other than prescribed tires may decrease stability, affect steering, result in premature tire failure, or cause other durability or safety issues.
DX,TIRE,INFO-19-20140519
TS1343-UN: High Pressure Spray
Spray from high pressure nozzles can penetrate the skin and cause serious injury. Keep spray from contacting hands or body. If an accident occurs, see a doctor immediately. Any high pressure spray injected into the skin must be surgically removed within a few hours or gangrene may result. Doctors unfamiliar withthistypeofinjuryshouldreferenceaknowledgeablemedical source. Such information is available from Deere & Company Medical Department in Moline, Illinois, U.S.A.
DX,SPRAY-19-19920416
Minimize exposure to components which may have residue from agricultural chemicals, such as fertilizers and pesticides. Handle and dispose of these components appropriately.
Carefully drain engines, fuel tanks, radiators, hydraulic cylinders, reservoirs, and lines before recycling components. Use leak-proof containers when draining fluids. Do not use food or beverage containers.
Do not pour waste fluids onto the ground, down a drain, or into any water source.
Observe all national, state, and local laws, regulations, or ordinances governing the handling or disposal of waste fluids (example: oil, fuel, coolant, brake fluid); filters; batteries; and, other substances or parts. Burning of flammable fluids or components inotherthanspeciallydesignedincineratorsmaybe prohibited by law and could result in exposure to harmful fumes or ashes.
Service and dispose of air conditioning systems appropriately. Government regulations may require a certified service center to recover and recycle air conditioning refrigerants which could damage the atmosphere if allowed to escape.
Evaluate recycling options for tires, metal, plastic, glass, rubber, and electronic components which may be recyclable, in part or completely.
Contact your local environmental or recycling center, or your John Deere dealer for information on the proper way to recycle or dispose of waste.
DX,DRAIN-19-20150601
Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.
DX,LIVE-19-19920925
General Specifications
Service Recommendations for O-Ring Boss Fittings
Straight Fitting
T6243AE-UN: Straight Fitting
1 Inspect O-ring boss seat for dirt or defects.
2
Lubricate O-ring with petroleum jelly. Place electrical tape over threads to protect O-ring. Slide O-ring over tape and into O-ring groove of fitting. Remove tape. Tighten fitting to torque value shown on chart. A 3ngle Fitting
T6520AB-UN: Angle Fitting
LEGEND: A-Lock Nut
B-Backup Washer
C-Head End
Group 20 General Specifications
1. Back off lock nut (A) and backup washer (B) completely to head end (C) of fitting.
2. Turn fitting into threaded boss until backup washer contacts face of boss.
3. Turn fitting head end counterclockwise to proper index (maximum of one turn).
4. NOTE:
Do not allow hoses to twist when tightening fittings.
Hold fitting head end with a wrench and tighten locknut and backup washer to proper torque value.
General Specifications
1 Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.
Lubricate O-rings and install into grove using petroleum jelly to hold in place.
2 Index angle fittings and tighten by hand pressing joint . together to insure O-ring remains in place.
4. Tighten fitting or nut to torque value shown on the chart. Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings.
IMPORTANT:
Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating device.
Tighten fittings to 50% of listed torque value if used in aluminum housing.
NOTE:
When bolting aluminum parts, specified in table. tighten to
Boltcoated with a lubricantplain or zinccoated with a lubricantplain or zinccoated with a lubricantplain or zinccoated with a lubricantplain or
orsuch as engine oil,plated withoutsuch as engine oil,plated withoutsuch as engine oil,plated withoutsuch as engine oil,plated without
Screwfasteners withanyfasteners withanyfasteners withanyfasteners withany cSoizaetpinhgoss,pohraMte2a0nadnodiMllu6btroicMat1io8nco, oatripnhgoss, pohraMte20anadndoMill6ubtoricMa1ti8ocno,aotrinpghso,soprhMat2e0aannddoMil6lutboriMca1t8iocno,aotirnpghso , soprhMat2e0aannddMoil6lutborMica1t8ion, or larger fasteners withfasteners withlarger fasteners withfasteners withlarger fasteners withfasteners withlarger fasteners withfasteners with JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B,JDM F13C, F13F or F13JJDM F13B, zinc flake coating.]F13E or F13Hzinc flake coating.]F13E or F13Hzinc flake coating.]F13E or F13Hzinc flake coating.]F13E or F13H zinc flakezinc flakezinc flakezinc flake coating.] coating.] coating.] coating.]
Torque values listed are for general
pro c pe drtuyrecliassgsifvaentefonrearssapreecuifsiceda,ptpiglihcatetinonheFsoertsotainlestsresntegethlfoafstheeneorrsigoinrafol.rMakesure nfausttseonnerUt-hbroealtds,ssaeretchleeatnigahntedntihnagtinyosturupcrotipoenrslyfosrtathrtetshpreacidfiecnagpapgliecmateionnt.WTihgh e t n e p nossible lpulbasritcicatienspelartinorocrrziimncpepdlastetedeflatsytpeenelorcskonthuetsrtbhyatnulroncinkgntuhtes,nwuttoelthbeoldtsryotrowrqhueeelnuts, s u h nolewsnsdiniftfheerecnhtainrts,turuncletisosndsifafreeregnivteinnsftorrutchtieonspseacrieficgiavpenplficoarttihoen.specific
application.
Unified Inch Bolt and Screw Torque Values
TS1671-UN: Unified Inch Bolt and Screw
SAE Grade 2 [Grade 2 applies for hex cap screws (not hex bolts) up to 6 in. (152 mm) long. Grade 1 applies for hAexEcGarpadsecr1eSwAsEoGverard6ein5,(51.152om5m.2) long, and for all other types of bolts and screws of any length.]
S r SAE Grade 8 or 8.2
Bolt Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry or [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means Screwcoated with a lubricantplain or zinccoated with aplain or zinccoated with aplain or zinccoated with a lubricantplain or zinc Sizesuch as engine oil,plated withoutlubricant such asplated withoutlubricant such asplated withoutsuch as engine oil,plated without fasteners withanyengine oil, fastenersanyengine oil, fastenersanyfasteners withany phosphate and oillubrication, orwith phosphate andlubrication, orwith phosphate andlubrication, orphosphate and oillubrication, or coatings, or 7/8 in. and1/4 to 3/4 in.oil coatings, or 7/8 in.1/4 to 3/4 in.oil coatings, or 7/8 in.1/4 to 3/4 in.coatings, or 7/8 in. and1/4 to 3/4 in. larger fasteners withfasteners withand larger fastenersfasteners withand larger fastenersfasteners withlarger fasteners withfasteners with JDM F13C, F13F or F13JJDM F13B,with JDM F13C, F13FJDM F13B,with JDM F13C, F13FJDM F13B,JDM F13C, F13F or F13JJDM F13B, zinc flake coating.]F13E or F13Hor F13J zinc flakeF13E or F13Hor F13J zinc flakeF13E or F13Hzinc flake coating.]F13E or F13H zinc flakecoating.]zinc flakecoating.]zinc flakezinc flake coating.] coating.] coating.] coating.]
Torque values listed are for general use only,based on the strength of the bolt or screw. R DeOplNaOceTfu a setetnheerssewviathlutehseifsamdieffeorrehnitgthoerrqgureadvaeluIf e h oig r htiegrhgternadinegfpasrotecneedrusrearies given for a s u p s ecdi,fitcigahptpenlictahteiosnetFootrhpelasstrtiecnigntsherotfotrhecroimrigpiendalstMeealkteypseurleocfkasntuentse,rfothrrsetaidnsleasrsesteel cleanandthatyouproperlystartthreadengagement.Whenpossible,lubricateplain foarszt i ennceprsla, toerdfofarsnteuntserosnoUh-beorltths,asne l eocthkentuigtsh,twenh i eneg l i bnos l ttrsuoctriownhsefeo l rntuhtes,supne l ceifs i sc application. Sdhifefearrebnotlitnssatrruecdtieosnigsnaerdetgoivfeanilfuonrdtherepsrpeedceiftiecramp ipnliecdatliooands. Always replace shear bolts
with identical grade.
Fuel, Lubricants,
and Coolant
Diesel Fuel North America
Use the proper diesel fuel to help prevent decreased engine performance and increased exhaust emissions. Failure to follow the fuel requirements listed below can void your engine warranty.
Contact your local fuel distributor for properties of the diesel fuel in your area.
In general, diesel fuels are blended to satisfy the low temperature requirementsof thegeographical areainwhichthey are marketed.
Diesel fuels specified to EN 590 or ASTM D975 are recommended.
Required fuel properties
In all cases, the fuel shall meet the following properties: Cetanenumberof45minimum.Cetanenumbergreaterthan50 is preferred, especially when temperatures are below-20°C (-4°F) or elevations above 1500 m (5000 ft).
Cold Filter Plugging Point(CFPP) below the expected low temperature ORCloud Pointat least 5°C (9°F) below the expected low temperature.
IMPORTANT:
Avoid Damage! Do not mix diesel engine oil or any other type of lubricating oil with diesel fuel.
Handling and Storing Diesel Fuel
CAUTION:
Avoid Injury! Handle fuel carefully. Do not fill the fuel tank when engine is running. Do not smoke while you fill the fueltank orservice the fuelsystem.
IMPORTANT:
Avoid Damage! Do not use galvanized containers diesel fuel stored in galvanized containers reacts with zinc coating in the container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters and damage fuel injectors and fuel pumps.
Fill fuel tank at end of each day’s operation to prevent water condensation and freezing during cold weather.
IMPORTANT:
Avoid Damage! The fuel tank is vented through the filler cap. If a new cap is required, always replace it with an original vented cap.
Sulfur content
Fuel lubricityshould pass a minimum load level of 3100 grams as measured by ASTM D6078 or maximum scar diameter of 0.45 mm as measured by ASTM D6079 or ISO 12156-1.
ing emissions regulations for the area in which the engine operates.
Sulfur content less that 0.05% (500 ppm) is recommended for best performance.
Diesel fuel sulfur content greater than 0.5% (5000 ppm) should not be used.
Diesel Fuel Europe (5000 ft).
When fuel is stored for an extended period or if there is a slow turnover of fuel, add a fuel conditioner to stabilize the fuel and to prevent water condensation. Contact your fuel supplier for recommendations.
A cetane number greater than 50 is preferred, especially for airtemperaturesbelow-20°C(-4°F) orelevations above1500m
In general, diesel fuels are blended to satisfy the low air temperaturerequirementsofthegeographicalareainwhichtheyCold Filter Plugging Point (CFPP) aresold.
InEurope,dieselfuelisusuallyspecifiedtoEN590andsoldinfive The temperature at which diesel fuel begins to cloud or jell. Use different classes or six different grades.dieselfuelswithaCFPPwhichisatleast5°C(9°F)belowthe expected low air temperature.
If diesel fuels being supplied in your area DO NOT meet any of the above specifications, use diesel fuels with the following e
05% (Max)
r
(Mrvain l )forengineoilandfilterby50%.
If diesel fuel being used has asulfur content greater than0.05%,
Consult your local diesel fuel distributor for properties of the diesel fuel available in your area.
Diesel Fuel Storage
Fuel, Lubricants, and Coolant
prevent possible igniting of fumes by an open flame or spark; this includes any appliance with a pilot light.
IMPORTANT: IMPORTANT: Avoid Damage! DO NOT USE GALVANIZED Avoid Damage! Keep all dirt, scale, water, or other foreign CONTAINERS dieselfuelstoredingalvanizedcontainersmaterial out of fuel. reacts with zinc coating in the container to form zinc flakes. If fuel contains water, a zinc gel will also form. The gel and flakes will quickly plug fuel filters and damage fuel injectors and fuel pumps. marked (‘DIESELFUEL”)container. DONOTuse deicers to attempt to remove waterfrom fuel.DO NOTdepend on fuel filters to remove water from fuel. It is recommended that a water
Keep fuel in a safe, protected area and in a clean, properly
It is recommended that diesel fuel be stored ONLY in aclean, separator beinstalled in the storage tank outlet. BE SURE to approved POLYETHYLENE PLASTIC container WITHOUT any properly discard unstable or contaminated diesel fuel and/or their metalscreenorfilter.Thiswillhelppreventanyaccidentalsparkscontainers when necessary. from occurring. Store fuel in an area that is well ventilated to OUO1086,1000403-19-20120615
America OtheroilsmaybeusedifaboveJohnDeereoilsarenotavailable, provided they meet one of the following specifications: Use the appropriate oil viscosity based on the expected air temperaturerangeduringtheperiodbetweenrecommendedoilAPI Service Classifications CF or higher changes. Operating outside of these recommended oil air temperature ranges may cause premature engine failure.OtheroilsmaybeusedifaboveJohnDeereoilsarenotavailable, T ph ro e vf
ons:
TCAL25967-UN: North American Engine Oil
PLUS-50Plus-50™
Diesel Engine Oil Europe
Use oil viscosity based on the expected air temperature range during the period between oil changes.
The following John Deere oils are PREFERRED:
TORQ-GARD SUPREME®-SAE 15W-40.
SAE 15W-40 API Service Classification CF-4 or higher.
SAE 5W-30 API Service Classification CC or higher.
SAE 10W-30 API Service Classification CF or higher.
SAE 30 API Service Classification CF or higher.
Plus-50 is a trademark of Deere & Company Torq-Gard Supremeis atrademark of Deere & Company OUO1086,1000404-19-20120615
UNI-GARD® SAE 15W-40.
TORQ-GARD SUPREME SAE 5W-30.
TORQ-GARD SUPREME SAE 5W-30.
UNI-GARD SAE5W-30.
Thefollowing John Deere oils are also recommended, based on their specified temperature range:
TORQ-GARD SUPREME- SAE 10W-30.
UNI-GARD SAE 10W-30.
TORQ-GARD SUPREME SAE 30.
UNI-GARD SAE 30.
OtheroilsmaybeusedifaboveJohnDeereoilsarenotavailable, provide
or higher.
Biodegradable Oil Application
IMPORTANT:
Avoid Damage! Biodegradable oils, other than BIO HYGARD Hy-Gard™ , are not recommended.
Mixing of biodegradable oil and mineral oil will reduce the biodegradability of the lubricant in the machine. Mixing of HY-GARD and BIO HY-GARD will not result in performance deterioration.
Cold Weather Operation
PrecautionsshouldbetakenifBIOHY-GARDcontainers or equipment are stored for long periods of time in extremely cold temperatures.Freezing shouldbeexpectedif BIO HY-GARD is Whenuseofabiodegradablelubricantisdesiredorrequired,BIOsubjectedtothefollowingtemperatures: HY-GARDis recommended. BIO HY-GARD may be used under normal mowing conditions.
DONOT USEbiodegradablelubricantsinmachinesforthe following operations:
Any machine used for scalping procedure.
Any verticut operation in temperatures exceeding 32°C (90°F).
BIOHY-GARDshould be usedonlyin cases where thebenefits of its use offset the extra initial cost, the increased oil change costandthepotential increasing maintenancecostsfor hydraulic systems with high temperatures and heavy loads.
If the natural color of the fluid has become black, it is possible an overheating problem exists. Change operatinthgevifslucoidsity
Hy-Gard is a trademark of Deere & Company
If the fluid becomes milky, water contamination may be a problem. Investigate the source of the contamination.
Take fluid level reading when system is cold.
Transaxle and MFWD Differential Oil
Use the appropriate oil viscosity based on these air temperature ranges. Operating outside of these recommended oil air temperature ranges may cause premature hydrostatic transmission or hydraulic system failures
IMPORTANT:
Avoid Danger! Mixing of LOW VISCOSITY Hy-Gard™ and HyGard™ transmission oils is permitted. DO NOT mix any other oils in this transmission. DO NOT use engine oils or‘Type F”(Red) Automatic Transmission Fluid in this transmission
Stored for six months at-18° to-23°C (-1° to-10°F)
Storedfor seven days at-23° to-26°C (-10° to-15°F)
Storedforthreedays at-26° to-29°C(-15°to-20°F)
Stored for two days at-29° to-34°C (-20° to-30°F)
Stored for one day at-34°C (-30°F) and below.
IMPORTANT:
Avoid Damage! Equipment should not be started or any operation attempted until BIO HY-GARD has reached a safe operating viscosity.
If freezing of BIO HY-GARD is suspected, the container or equipment MUST be warmed to atleast 0°C(32°F) and maintainedfor24-48hourstoensurethefluidhasreachedasafe
OUO1086,1000407-19-20120615
TS1660-UN: Transaxle Oil Ranges
John Deere J20C Hy-Gard™ transmission and hydraulic oil is recommended. John Deere J20D Low Viscosity Hy-Gard™ transmissionandhydraulic oil may be used,if withinthe specified temperature range.
Fuel, Lubricants, and Coolant
OtheroilsmaybeusedifaboverecommendedJohnDeereJohn Deere Standard JDM J20D. oils are not available, provided they meet one of thefollowing specifications:Hy-Gard is a trademark of Deere & Company
JohnDeereStandardJDMJ20C;
Converting From HY-GARD to BIO HYGARD
Systems being converted from HY-GARD to BIO HY-GARD should follow the procedure listed below to obtain maximum lubricant biodegradability.
Park machine ona levelsurface.
Lower cutting units, stop engine, set park brake and remove key from ignition.
application. DO NOT mix any other greases in this application. DO NOT use any BIOGREASE in this application.
specifications:
The followingJohn Deere greasesare preferredfor the machine and lift arms:
John Deere Special Purpose HD Water Resistant Grease.
John Deere Multi-Purpose Complex Grease. HD Lithium
Grease - Europe
Use the following grease based on the air temperature range. Operating outside of therecommended grease airtemperature range may cause premature failures.
MX52301,0000312-19-20140414
Fill reservoir with BIO HY-GARD to appropriate level.
Start engine and bring to medium idle.
Turn steering wheel full stroke several times and cycle cutting units severaltimes.
Stop engine and check hydraulic oil level. Add BIO HY-GARD to appropriate level.
Operate machine under normal operating conditions for a minimum of two hours.
Repeat steps 1-8.
Follow recommended maintenance schedules.
OUO1086,1000408-19-20120615
The following John Deere greases are preferred for the cutting units and unit attachments:
John Deere Golf and Turf Cutting Unit Grease. John Deere Cornhead Grease.
John Deere Cotton Picker Spindle Grease.
Othergreasesmaybeusedif abovepreferredJohnDeere greases are not available, provided they meet the following Polyurea Grease - NLGI Grade 2.
Othergreasesmaybeusedif abovepreferredJohnDeere greases are not available, provided they meet the following specifications:
I RMeePlOSRuTpApoNrTt:Grease Applications: Avoid Damage! ONLY use a quality grease in this application. DO NOT mix any other application. DO NOT use any application. BIOGREASE in this greases in this
The following John Deere greases are PREFERRED:
GREASE-GARD™-JDM J13E4, NLGI Grade 2.
Alternative Lubricants
alternative lubricant.
Use of alternative lubricants could cause reduced life of the
If alternative lubricants areto be used, it is recommended that the factory fill be thoroughly removed before switching to any
OUO1086,100040B-19-20120615 component.
Synthetic Lubricants
manual,unlessotherwise statedonlubricantlabel. Synthetic lubricants may be usedin John Deere equipment if
The recommended airtemperature limits and service or lubricant changeintervalsshouldbemaintainedasshownintheoperator’s they meet the applicable performance requirements (industry Avoid mixing different brands, grades, or types of oil. Oil classification and/or military specification) as shown inthis manufacturers blend additives in their oils tomeet certain manual.specifications and performance requirements. Mixing different
oils can interfere with the proper functioning of these additives
OUO1086,100040C-19-20120615 and degrade lubricant performance.
containers are properly marked as to their contents. Dispose of all old, used containers and their contents properly. All machines operate at top efficiency only when clean lubricants
OUO1086,100040D-19-20120615 are used. Use clean storage containers to handle all lubricants. Store them in an area protected from dust, moisture, and other
additives and lubricant properties which will downgrade their intended specified performance.
In general, avoid mixing different brands or types of lubricants.
OUO1086,100040E-19-20120615 Manufacturers blend additives in their lubricants to meet certain specifications and performance requirements. Mixing different
Avoid Damage! Filtration of oils is critical to proper lubrication performance. Always change filters regularly.
specification:
The following John Deere oil filters are PREFERRED:
Automotive and light truck engine oil filters.
Operatin g
Climates in Warm Temperature
Other oil filters may be used if above recommended John Deere
OUO1086,100040F-19-20120615
IMPORTANT:
Water may be used as coolantin emergency situations only. Foaming, hot surface aluminum and iron corrosion, scaling, John Deere recommended engine coolants. engines are designed to operate using
Always use a recommended engine coolant, even when operating in geographical areas where freeze protection is not required.
andcavitationoccurwhenwaterisusedasthecoolant,even when coolant conditioners are added.
Drain cooling system and refill with recommended engine coolant as soon as possible.
DX,COOL6-19-20130515
Diesel Engine Coolant (engine without wet sleeve cylinder liners)
Preferred Coolants
The following pre-mix engine coolants are preferred:
John Deere COOL-GARD™II
John Deere COOL-GARD II PG
COOL-GARD II pre-mix coolant is available in several concentrations with different freeze protection limits as shown in the following table.
COOL-GARD II pre-mix Freeze Protection Limit
COOL-GARD II Water-Base 0 °C (32 °F)
COOL-GARD II 20/80 -9 °C (16 °F)
COOL-GARD II 30/70 -16 °C (3 °F)
COOL-GARD II 50/50 -37 °C (-34 °F)
COOL-GARD II 55/45 -45 °C (-49 °F)
COOL-GARD II PG 60/40 -49 °C (-56 °F) glycol basCeOeOnL-gGiAnReDcIIo6o0/l4a0nt concen trate. -52 °C (-62 °F)
Not all COOL-GARD II pre-mix products are available in all c C o o un o t l r a ie n s t Drain Intervals
Use COOL-GARD II PG when a non-toxic coolant formulation is trheequinirdeicdatDedraiinntearnvdalf , l wushhicthhveacroieosliwnigthsyth
Coolant concentrate meeting ASTM D6210 requirements in a 40 60% mixture of concentrate with quality water
Pre-mix coolant meeting ASTM D3306 requirements
Coolant concentrate meeting ASTM D3306 requirements in a 40 60% mixture of concentrate with quality water
If coolant meeting one of these specifications is unavailable, use a coolant concentrate or pre-mix coolant that has a minimum of thefolloIs
Water quality is important to the performance of the cooling system. Distilled, deionized, or demineralized water is recommended for mixing with ethylene glycol and propylene
When COOL-GARD II or COOL-GARD II PG is used, the drain Additional Recommended Coolantsinterval is 6 years or 6000 hours of operation. If a coolant other than COOL-GARD II or COOL-GARD II PG
Do not use cooling system sealing additives or antifreeze
When mixing coolant concentrate with water, do not use Do not mix ethylene glycol and propylene glycol base less than 40% or greater than 60% concentration of coolant. coolants. Less than 40% gives inadequate additives for corrosion protection.Greaterthan60%canresultincoolantgelationDo not use coolants that contain nitrites. and cooling system problems.
COOL-GARD is a trademark of Deere & Company DX,COOL18-19-20130515
Other Coolants
Other ethylene glycol or propylene glycol base coolants may be used if they meet one of the following specifications:
Pre-mix coolant requirements meeting ASTM D6210
John Deere COOL-GARD™ II Coolant Extender
Some coolant additives gradually deplete during engine operation. For COOL-GARD™ II pre-mix and COOL-GARD II Concentrate, replenish coolant additives between drain intervals by adding COOL-GARD II Coolant Extender. COOL-GARD II Coolant Extender should not be added unless indicated by COOL-GARD II Test Strips. These test strips provide a simple, effective method to check the freeze point, additive levels, and pH of your engine coolant.
Test the coolant solution at intervals of 12 months and whenever IeMxcPeOssRivTeAcNoTo:lant is lost through leaks or overheating. Do not use COOL-GARD II Test Strips with COOL-GARD II PG.
Fuel, Lubricants, and Coolant
COOL-GARD II Coolant Extender is a chemically matched The use of non-recommended supplemental coolant additives additive system for use with all COOL-GARD II coolants. COOL- can result in additive drop-out, gelation of the coolant, or GARDIICoolantExtenderisnotintendedforusewithnitrite-corrosion of cooling system components. containing coolants.
Add the recommended concentration of COOL-GARD II Coolant
I C MPORTANT: Extender. DO NOT add more than the recommended amount.
trademark of Deere & Company
DOo OnL -oGtARa dDdis a supplemental coolant additive when the cooling system is drained and refilled with any of the following:
John Deere COOL-GARD II
John Deere COOL-GARD II PG
Testing Diesel Engine Coolant
recommended amount.
Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling
Add only the recommended concentration of John Deere COOLGARD II Coolant Extender. DO NOT add more than the systemagainstfreezing,corrosion,andcylinderlinererosionandWhen Using Nitrite-Containing Coolants pitting.
Test the coolant solution at intervals of 12 months or less and Compare the test strip results to the supplemental coolant whenever excessive coolant is lost through leaks or overheating.additive(SCA)charttodeterminetheamountofinhibiting additives in your coolant and whether more John Deere Liquid C Coooo lal na t nCo tnTdi e ti s on t eSrtsr hiopus ldbeadded.
Add only the recommended concentration of John Deere Liquid Coolant Conditioner. DO NOT add more than the recommended Coolant test strips are available from your John Deere dealer. amount. These test strips provide a simple, effective method to check the freeze point and additive levels of your engine coolant.
Coolant Analysis
When Using John Deere COOL-GARD II
Foramorethoroughevaluationofyourcoolant,performacoolant analysis. The coolant analysis can provide critical data such John Deere COOL-GARD II Premix™ , COOL-GARD II PG as freezing point, antifreeze level, pH, alkalinity, nitrite content Premix and COOL-GARD II Concentrate are maintenance free (cavitation control additive), molybdate content (rust inhibitor coolants for up to six years or 6000 hours of operation, provided additive), silicate content, corrosion metals, and visual that the cooling system is topped off using only John Deere assessment. COOL-GARD II Premix or COOL-GARD II PG premix. Test the coolant condition annually with coolant test strips designed for Contact your John Deere dealer for more information on coolant use with John Deere COOL-GARD II coolants. If the test strip analysis. chartindicatesthatadditiveisrequired,addJohnDeereCOOL-COOL-GARD is a trademark of Deere & Company GARD II Coolant Extender as directed.DX,COOL9-19-20110411
Machine Specifications
NOTE:
Ground Speed:
Forward - Range LO
HPX 815EHPX8 15E (EEC)
Fuel System:
Type Mechanical Pump Electrical System:
Alternator 40 A Battery 12 volt Cold Cranking Amps 480 HPX 815E HPX815E (EEC)
Specificationsanddesignsubjecttochangewithoutnotice. Type 12 Volt Negative Ground HPX 815E HPX815E (EEC)
0 20 km/h (0 12
Forward - Range HI mph) 0 40 km/h (0
Reverse 25 mph) 0 20 km/h (0 Engine: 12 mph)
Make
Engine Power Information Yanmar
Type
Model Diesel
Slow Idle Speed 3TNV70
Slow Idle Speed (Governed) 650 800 rpm
Fast Idle Speed 1050±25 rpm
Cylinders 3840±25 rpm
Displacement 3
Bore 0.854 L (52.11 in.3)
Stroke 70 mm (2.75 in) 74 mm (2.91 in)
Injection Indirect
Cooling Liquid Cooled Air Cleaner Dry-Type Elements
Engine Shut Off Key Switch
Product Serial Number
Steering:
TypeRack and Pinion Brakes:
Type All Wheel Hydraulic Disc
Capacities:
Fuel Tank 20.0 L (5.25 gal) Crankcase (with Filter) 2.2 L (2.3 qt) Transmission 4.5 L (4.8 qt) EMFWD Front Differential 150 mL (5 oz) Cooling System (Including Recovery Tank) 5.0 L (5.2 qt)
Dimensions:
Overall Length with Bumper2.87 m (113 in)
Overall Width1.52 m (60.0 in)
Overall Height with OPS1.87 m (73.5 in)
Ground Clearance15.2 cm (6.0 in)
MX52301,00018E2-19-20180122
MXT022127-UN: Product S.N. Location LEGEND:
A-Product Identification Number
The13-digitproductidentificationnumber(A)isontheright-hand side frame.
MX52301,00018E3-19-20180122
Machine Specifications
Engine Serial Number Location
MXT010283-UN: Diesel Engine S.N. Location Engine serial number (A) is on valve cover. The model number designates the engine type.
BS62576,00020AD-19-20180122
Group 10 - Repair
Summary of References........................................
Essential or Recommended Tools.........................
Service Equipment and Tools................................
Other Material........................................................
3 C 3 a m 8 9 s h m a m f t Lobe–Wear LimitHeight 39.94–35.96 Camshaft Gear Side and Flywheel End mm Journals–Standard (1.572–1.573 in) CamshaftGearSideandFlywheelEndJournals–Wear39 91 mm Limit(1.571 in) Exhaust (0.002 0.003 in)
Strainer to-Block Cap Screws Oil Pan-to-Engine Cap Screws Oil Pan-to-Timing Gear Housing Cap Screws
Connecting Rod Side Play
Crankshaft
Connecting Rod Cap Screw
Connecting Rod-to-Crankshaft–Standard
Connecting Rod-to-Crankshaft–Wear Limit
Main Bearing Cap Screws (Oil Applied)
Crankshaft Main Bearing–Standard
Crankshaft Main Bearing–Wear Limit
Connecting Rod Cap Screw
Connecting Rod Bearing–Standard
Connecting Rod Bearing
Connecting Rod Bearing–Standard
Connecting Rod Bearing–Wear Limit
Connecting Rod Cap Screw
Piston Ring Groove Clearance:
Top Ring–Standard
Clearance (0.008 0.016 in) 0.11 0.25 mm End Play(0.004 0.010
Standard-Sized Piston
Standard-Sized Piston–Wear Limit
Standard Size Cylinder Bore
Cylinder Bore–Wear Limit
Piston-to-Cylinder
81.5 N·m (T5o6r qu6e0lb·ft) 0.02 0.05 mm Clearance (0.001 0.002 in) 0.12 mm (0.005 in) 22.6–27.5 N·m
