TM145519-PDF- Download
TM145519-PDF- Download
XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles (SN. 010001-)
TECHNICAL MANUAL
XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles (SN. 010001-)
TM145519 01DEC18 (ENGLISH)
John Deere Horicon Works
Introduction
Foreword
Operation and tests sections help you identify the majority of routine failures 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
DX,TMIFC-19-20140415 and tests. Repair sections tell how to repair the components.
Section 10 - General Information
Group 10 - Safety
Group 20 - General Specifications
Group 30 - Fuel and Lubricants
Group 40 - Machine Specifications
Section 20 - Engine Repair
Group 10 - Engine
Section 30 - Electrical Repair
Group 10 - Wiring Harnesses
Section 40 - Power Train Repair
Group 10 - Transmission
Group 20 - Axles and Driveshaft
Group 30 - Mechanical Four Wheel Drive
Section 50 - Steering and Brake Repair
Group 10 - Steering
Group 20 - Brakes
Section 60 - Operator ` s Station Repair
Group 10 - Operator ` s Station
Section 70 - Miscellaneous Repair
Group 10 - Wheels
Group 20 - Hood, Cargo Box, and Bumper
Group 30 - Miscellaneous Repair
Section 220 - Engine Operation, Tests and Adjustments
Group 10 - Component Location
Group 20 - Theory of Operation
Group 30 - Diagnosis
Group 40 - Tests and Adjustments
Section 230 - Electrical Operation, Tests and Adjustments
Group 5 - General Information
Group 10 - Component Location
Group 20 - Theory of Operation
Group 30 - Schematics
Group 40 - Schematics, Kits
Group 50 - Connector Information
Group 60 - Tests and Adjustments
Section 240 - Control Unit Operation, Tests and Adjustments
Group 10 - Theory of Operation
Group 20 - Diagnostic Trouble Codes, ICC
Group 30 - Diagnostic Trouble Codes, ECU
Group 40 - Diagnostic Trouble Codes, SCU
Section 250 - Power Train Operation, Tests and Adjustments
Group 10 - Component Location
Group 20 - Theory of Operation
Group 30 - Diagnosis
Group 40 - Tests and Adjustments
Section 260 - Steering and Brake Operation, Tests and Adjustments
Group 10 - Component Location
Group 20 - Theory of Operation
Group 30 - Diagnosis
Group 40 - Tests and Adjustments
Group 10 - Service Tools and Kits
Section 299 - Service Tools
Group 10 - Safety
Recognize Safety Information...............................10-10-1
Understand Signal Words......................................10-10-1
Follow Safety Instructions......................................10-10-1
Practice Safe Maintenance....................................10-10-2
Use Proper Tools...................................................10-10-2
Handle Fluids Safely - Avoid Fires........................10-10-2
Drain Gasoline When Storing Machine.................10-10-3
Handling Batteries Safely......................................10-10-3
Prepare for Emergencies.......................................10-10-4
Park Machine Safely..............................................10-10-4
Support Machine Properly.....................................10-10-4
Wear Protective Clothing.......................................10-10-4
Work in Clean Area...............................................10-10-5
Service Machines Safely.......................................10-10-5
Work In Ventilated Area.........................................10-10-5
Illuminate Work Area Safely..................................10-10-5
Replace Safety Signs............................................10-10-6
Use Proper Lifting Equipment................................10-10-6
Keep ROPS Installed Properly 10-10-6
Follow Tire Recommendations 10-10-6
Decommissioning - Proper Recycling and Disposal 10-107 of Fluids and Components.............................
Group 10 Safety
Recognize Safety Information
Understand Signal Words
TS187-19:
Follow Safety Instructions
TS201-UN: Safety Messages
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 situation which, if not avoided, could result in death or serious 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
Carefully read all safety messages in this manual and on your machine safety signs Keep safety signs in good condition Replace missing or damaged safety signs. Be sure new equipment components and repair parts include the current safety signs. Replacement safety signs are available from your John Deere dealer
Therecanbeadditionalsafetyinformationcontainedonpartsand components sourced from suppliers that isnot reproduced in this operator′s manual.
Learn how to operate the machine and how to use controls properly Do not let anyone operate without instruction Keep your machine in proper working condition
Unauthorized
modifications to the machine may impair the function and/or safety and affect machine life
If you do not understand any part of this manual and need assistance, contact your John Deere dealer.
DX,READ-19-20090616
Signal Words
Practice Safe Maintenance
Use Proper Tools
Handle Fluids Safely—Avoid Fires
Safety
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
Safety
Drain Gasoline When Storing Machine
Handling Batteries Safely
TS204-UN: Caution
TS227-UN: Storing Gasoline
Gasoline stored in fuel tank can explode
Never store equipment with gasoline in the tank inside a building where fumes may reach an open flame or spark
Always drain gasoline from fuel tank and carburetor bowl when storing machine Allow engine to cool before storing
DX,STORE2-19-19900126
TS203-UN: Caution
Battery gas can explode Keep sparks and flames away from batteries Use a flashlight to check battery electrolyte level
Never check battery charge by placing a metal object across the posts Use a voltmeter or hydrometer
Always remove grounded (-) battery clamp first and replace grounded clamp last
Sulfuric acid in battery electrolyte is poisonous and strong enough to burn skin, eat holes in clothing, and cause blindness if splashed into eyes
Avoid hazards by:
Filling batteries in a well-ventilated area
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:
hands after handling
Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm Wash
DX,WW,BATTERIES-19-20101202
Prepare for Emergencies
Park Machine Safely
Support Machine Properly
Wear Protective Clothing
Safety
TS291-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
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 station. in operator
DX,PARK-19-19900604
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
Work in Clean Area
Service Machines Safely
Work In Ventilated Area
Illuminate Work Area Safely
Safety
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
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
Replace Safety Signs
Use Proper Lifting Equipment
Keep ROPS Installed Properly
Follow Tire Recommendations
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
TS212-UN: Roll-Over Protective Structure
Make certain all parts are reinstalled correctly if the roll-over protective structure (ROPS) is loosened or removed for any reason Tighten mounting bolts to proper torque
The protection offered by ROPS will be impaired if ROPS is subjected to structural damage, is involved in an overturn incident, or is in any way altered by welding, bending, drilling, or cutting. A damaged ROPS should be replaced, not reused.
The seat is part of the ROPS safety zone Replace only with John Deere seat approved for your tractor
Any alteration of the ROPS must be approved by the manufacturer
DX,ROPS3-19-20111012
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
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
Protect Against High Pressure Spray
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
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
TS231-19: Safety Systems
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
Inspect O-ring boss seat for dirt or defects.
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
Angle 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
3/8-24 UNF 7/16-20 UNF 1/2-20 UNF 9/16-18 UNF 3/4-16 UNF 7/8-14 UNF 1-1/16-12 UN 1-3/16-12 UN 1-5/16-12 UN 1-5/8-12 UN 1-7/8-12 UN
General Specifications
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.
IMPORTANT:
Tighten fittings to 150% of listed torque value if indexing is necessary or if fitting is attached to an actuating device.
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.
Tighten fittings to 50% of listed torque value if used in aluminum housing
NOTE: When bolting aluminum parts, specified in table tighten to 80% of torque
Stud End O-ring Seal Torque for Straight and Adjustable Fittings*
HexLocknut HexStraight Fitting or Locknut
OUO6092,00010A4-19-20110531
CED,OUO1085,12-19-20000731
General Specifications
Metric Bolt and Screw Torque Values
TS1670-UN: Metric Bolt and Screw
Class 4 8Class 8 8 or 9 8Class 10 9Class 12 9
Lubricated Dry Lubricated Dry Lubricated Dry Lubricated Dry [‘Lubricated”means [ Dry”means [‘Lubricated”means [ Dry”means [‘Lubricated”means [‘Dry”means [‘Lubricated”means [‘Dry”means Boltcoated with a lubricantplain or zinccoated with a lubricantplain or zinccoated with a lubricantplain or zinccoated with a lubricantplain or zinc 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 Sizephosphate and oillubrication, orphosphate and oillubrication, orphosphate and oillubrication, orphosphate and oillubrication, or coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18coatings, or M20 andM6 to M18 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 use only, based on the strength of the bolt or Shear
screw DO NOT use these values if a different torque value or tightening
procedure is given for a specific application For stainless steel fasteners or for property class fasteners are used, tighten these to the strength of the original Make sure nuts on U-bolts, see the tightening instructions for the specific application Tighten fastener threads are clean and that you properly start thread engagement When possible, plastic insert or crimped steel type lock nuts by turning the nut to the dry torque lubricate plain or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, shown in the chart, unless different instructions are given for the specific unless different instructions are given for the specific application application
DX TORQ2-19-20110112
General Specifications
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 SAE Grade 1SAE Grade 5, 5 1 or 5 2SAE Grade 8 or 8 2 hex cap screws over 6 in (152 mm) long, and for all other types of bolts and screws of any length ]
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 ]
1-1/8
1-1/4 570 420 725 535
420 725 535 1280 945 1630 1200 2050 1500 2600 1920
1-3/8 750 550 950 700 750 550 950 700 1700 1250 2140 1580 2700 2000 3400 2500
1-1/2 990 730 1250 930 990 730 1250 930 2250 1650 2850 2100 3600 2650 4550 3350
Torque values listed are for general use only, based on the strength of the bolt or screw Replace fasteners with the same or higher grade If higher grade fasteners are DO NOT use these values if a different torque value or tightening procedure is given for a used, tighten these to the strength of the original Make sure fastener threads are specific application For plastic insert or crimped steel type lock nuts, for stainless steel clean and that you properly start thread engagement When possible, lubricate plain fasteners, or for nuts on U-bolts, see the tightening instructions for the specific application or zinc plated fasteners other than lock nuts, wheel bolts or wheel nuts, unless Shear bolts are designed to fail under predetermined loads Always replace shear bolts different instructions are given for the specific application with identical grade
DX,TORQ1-19-20110112
Fuel and Lubricants
Gasoline Engine Oil
Turf-Gard is a trademark of Deere & Company
Group 30 Fuel and Lubricants
Use oil viscosity based on the expected air temperature range during the period between oil changes.
Using single viscosity grade oils such as SAE 30 or SAE 40 can reduce oil consumption in air cooled engines
John Deere Turf-Gard™ is preferred.
The following oils are also recommended:
John Deere Plus-4™
John Deere Plus-50™ II
Other oils may be used if they meet one or more of the following:
ILSAC GF-5
API Service Category SN
API Service Category SM
API Service Category SL
API Service Category SJ
ACEA Oil Sequence A5
ACEA Oil Sequence A3
ACEA Oil Sequence A1
ACEA Oil Sequence C4
ACEA Oil Sequence C3
ACEA Oil Sequence C2
ACEA Oil Sequence C1
Plus-4 is a trademark of Deere & Company
Plus-50 is a trademark of Deere & Company
TS1734-UN: Oil Viscosities for Air Temperature Ranges
Oil FiltersAlways change filters regularly as specified in this manual.
Use filters meeting John Deere performance specifications
Filtration of oils is critical to proper operation and lubrication DX,FILT-19-19960318
DX,ENOIL2-19-20150720
Gasoline Fuel for 4-Cycle EnginesRefueloutdoors.DONOTsmokewhileyoufillthefueltank or service the fuel system Store fuel in properly identified
Useunleadedgasolinewithaminimumoctaneratingof87AKIpolyethylene containers. (anti-knock index) or 90 RON (research octane number)
Gasoline fuels specified to EN 228 or ASTM D4814 are
When storing fuel, add John Deere Gasoline Conditioner and recommended Stabilizer (or equivalent) at the specified concentration
IMPORTANT:
Fuel blends of unleaded gasoline with a maximum 10% ethanol or 15% MTBE (methyl tertiary-butyl ether) are also acceptable
CAUTION:
Reduce the risk of fire. Handle fuel carefully. DO NOT fill the fuel tank when the engine is running or hot Stop engine and allow it to cool for several minutes before filling fuel tank. Fill fuel tank only to the bottom of the filler neck.
DO NOT use methanol or fuel blends that contain methanol. Avoid spilling fuel Gasoline can damage plastic and painted surfaces
DO NOT mix oil with gasoline
DX,FUEL2-19-20130515
Fuel and Lubricants
Transmission and Hydraulic Oil
TS1739-UN: Oils for Air Temperature Ranges
Use oil viscosity based on the expected air temperature range during the period between oil changes.
The following oils are preferred:
John Deere Hy-Gard™
John Deere Low Viscosity Hy-Gard™
Other oils may be used if they meet one of the following:
John Deere Standard JDM J20C
John Deere Standard JDM J20D
Use John Deere Bio Hy-Gard™ II oil when a biodegradable fluid is required [Bio Hy-Gard II meets or exceeds the minimum biodegradability of 80% within 21 days according to CECL-33-T-82 test method Bio Hy-Gard II should not be mixed with mineral oils, because this reduces the biodegradability and makes proper oil recycling impossible ]
Hy-Gard is a trademark of Deere & Company
Bio Hy-Gard is a trademark of Deere & Company
DX,ANTI-19-20160825
TS1673-UN: Greases for Air Temperature Ranges
Use grease based on NLGI consistency numbers and expected air temperature range during the service interval
JohnDeereSDPolyureaGreaseispreferred
The following greases are also recommended: the
John Deere HD Lithium Complex Grease
John Deere HD Water Resistant Grease
John Deere GREASE-GARD™
Other greases may be used if they meet the following:
NLGI Performance Classification GC-LB
IMPORTANT:
Some types of grease thickeners are not compatible with others. Consult your grease supplier before mixing different types of grease
GREASE-GARD is a trademark of Deere & Company
DX,GREA1-19-20110414
Mixing of Lubricants
Mixing different oils can interfere with the proper functioning of these additives and degrade lubricant performance
In general, avoid mixing different brands or types of oil Oil ConsultyourJohnDeeredealertoobtainspecificinformationand manufacturers blend additives in their oils to meet certain recommendations specifications and performance requirements.DX,LUBMIX-19-19960318
Alternative and Synthetic Lubricants
Consult your John Deere dealer to obtain information and recommendations.
Conditions in certain geographical areas may require lubricant Synthetic lubricants may be used if they meet the performance recommendations different from those printed in this manual.requirements as shown in this manual.
Some John Deere brand coolants and lubricants may not be Thetemperaturelimitsandserviceintervalsshowninthismanual available in your location.apply to both conventional and synthetic lubricants.
Fuel and Lubricants
Re-refined
Summary of References
Remove and Install Engine
Remove and Install Valve Cover
Remove and Install Timing Belt
Remove and Install Water Pump
Remove and Install Cylinder Head
Remove and Install Intake Manifold
Remove and Install Exhaust Manifold
Recondition Cylinder Head
Remove and Install Oil Pan and Strainer
Remove and Install Oil Pump
Remove and Install Crankshaft Front Oil Seal
Remove and Install Camshafts
Check Crankshaft Main Bearing Clearance
Check Connecting Rod Bearing Clearance
Check Connecting Rod Side Play
Remove and Install Piston and Connecting Rod
Disassemble and Assemble Piston and Connecting Rod
Inspect Piston and Connecting Rod Bore Cylinder
Remove and Install Crankshaft and Main Bearings
Inspect Crankshaft
Remove and Install Crankshaft Rear Oil Seal
Remove and Install Alternator
Remove and Install Starting Motor
Replace Fuel Injector
Replace Exhaust Gas Oxygen Sensor
Replace Knock Sensor
Replace Camshaft Position Sensor
Replace Crankshaft Position Sensor
Replace Intake Manifold Pressure and Temperature Sensor
Replace Throttle Body
BS62576,0001E69-19-20180215
Machine Specifications
Machine Specifications
NOTE:
Specifications and design subject to change without notice
GroundSpeed:
Forward HI
Forward LO
Low Idle Speed
Rev Limiter Speed
Cylinders
Displacement
Spark Plug Spark Plug Gap
Bore
Stroke Oil
Oil Filter
Cooling System (including recovery tank)
Air Cleaner
Engine Shut Off
FuelSystem:
Fuel System Pressure
ElectricalSystem:
72 km/h (45 mph)
47 km/h (29 mph)
53 km/h (33 mph) Chery Gas SQR372 FI
rpm
rpm 3 812 cm3(49 5 in 3) NGK BKR6 EGP
0 9 1 05 mm (0 035 0 041 in )
72 mm (2 835 in )
66 5 mm (2 618 in )
John Deere Plus-4™ or John Deere TURFGARD™ Spin On
5 0 L (5 2 qt ) Dry Replaceable Single Element with Remote Intake Key Switch 315 345 kPa (45 6 50 4 psi)
Product Identification Number Location
Type12 volt
StarterSolenoid Shift
BatteryBCI Group U1
Cold Cranking Amps @-18° C (0° F)480 amps
Charging System (@ Output at 1900 rpm)36 amps
Charging System (Rated Output at 6000 rpm)75 amps
Charging System Static Draw5 mA
PowerTrain:
Drive Belt Width (Nominal)31 75 mm (1 25 in )
Drivetrain
Enclosure
Clutch Engagement1350 rpm
Continuously Variable Transmission (CVT) with Clutch
Clutch Disengagement1250 rpm
Transmission OilHy-Gard™ J20C or J20D (Cold Weather)
EMFWD OilLow Viscosity Hy-Gard™ J20C
Steering:
TypeRack and Pinion
Brakes:
TypeAll Wheel Hydraulic Disc
Capacities:
Fuel Tank42 2 L (11 2 gal )
Crankcase (with Filter)2 2 L (2 3 qt )
Transmission3 8 L (4 0 qt )
EMFWD Front Differential590 mL (19 6 oz )
Dimensions:
Width (overall)1 62 m (63 7 in )
Length (with bumper)3 36 m (132 2 in )
Height (with Protective 1 98 m (78 25 in ) Structure)
Ground Clearance28 4 cm (11 2 in )
Plus-4 is a trademark of Deere & Company
TURF-GARD is a trademark of Deere & Company
Hy-Gard is a trademark of Deere & Company
BS62576 0001E5D-19-20180216
MXT021761-UN: Machine Product Identification Number Location Product identification number (A), also called serial number or chassis number, is on the frame behind the right front wheel.
MXT021762-UN: Engine Serial Number Location Engine identification number (B) is on the timing belt cover
Machine Specifications
MXT021763-UN: EPAS Serial Number Location
Electric Power Assisted Steering (EPAS) identification number (C) is on the module where shown.
BS62576,0001E5E-19-20180109
Group 10 - Engine
Summary of References
Essential or Recommended Tools
Service Equipment and Tools
Other Material
Specifications
Remove and Install Engine
Remove and Install Valve Cover
Remove and Install Timing Belt
Remove and Install Water Pump
Remove and Install Cylinder Head
Remove and Install Intake Manifold
Remove and Install Exhaust Manifold
Recondition Cylinder Head
Remove and Install Oil Pan and Strainer
Remove and Install Oil Pump
Remove and Install Crankshaft Front Oil Seal
Remove and Install Camshafts
Check Crankshaft Main Bearing Clearance
Check Connecting Rod Bearing Clearance
and Install Crankshaft and Main 20-10-49
Crankshaft Position Sensor
Intake Manifold Pressure and 20-10-62
Sensor.......................................
Throttle Body...........................................20-10-63
Engine
Summary of References
Remove and Install Engine
Remove and Install Valve Cover
Remove and Install Timing Belt
Remove and Install Water Pump
Remove and Install Cylinder Head
Remove and Install Intake Manifold
Remove and Install Exhaust Manifold
Recondition Cylinder Head
Remove and Install Oil Pan and Strainer
Remove and Install Oil Pump
Remove and Install Crankshaft Front Oil Seal
Remove and Install Camshafts
Check Crankshaft Main Bearing Clearance
Check Connecting Rod Bearing Clearance
Check Connecting Rod Side Play
Remove and Install Piston and Connecting Rod
Essential or Recommended Tools
NOTE:
Order tools from the SERVICEGARD™ Catalog
ESSENTIAL TOOLS listed are required to perform the job correctly and are obtainable only from the SERVICEGARD™ Catalog
Disassemble and Assemble Piston and Connecting Rod
Inspect Piston and Connecting Rod
Bore Cylinder
Remove and Install Crankshaft and Main Bearings
Inspect Crankshaft
Remove and Install Crankshaft Rear Oil Seal
Remove and Install Alternator
Remove and Install Starting Motor
Replace Fuel Injector
Replace Exhaust Gas Oxygen Sensor
Replace Knock Sensor
Replace Camshaft Position Sensor
Replace Crankshaft Position Sensor
Replace Intake Manifold Pressure and Temperature Sensor
Replace Throttle Body
Clutch Removal Tool JDG11200
BS62576,0001E69-19-20180215
Use to remove Clutch from Tapered Shaft by screwing tool into drive clutch
Valve Spring Compressor JDG10981
Use to remove intake & exhaust valves from the cylinder head Tool compresses the valve spring to allow removal of the valve spring retainers from the valve stem
Valve Stem Seal Protector JDG10984
Use to install valves into guides/seals without damaging the seals. Tool is bullet shaped & fits over the valve stem
Intake Valve Seal Installer JDG10979
Used to install intake valve guide to specified depth & to install the valve guide seal once the guide is in place
Exhaust Valve Seal Installer JDG10980
Used to install exhaust valve guide to specified depth and to install the valve guide once the guide is in place
Oil Seal Protector JDG10978
RECOMMENDED TOOLS, as noted, are suggested to perform thejobcorrectly.SometoolsmaybeavailablefromlocalSERVICEGARD is a trademark of Deere & Company suppliers or may be fabricated
Used to install front engine seal with crankshaft in the engine Two piece tool that includes a seal protector that fits over the end of the crankshaft & a seal installer to press the seal in place
MX52301,0001D83-19-20180214
Service Equipment and Tools
NOTE:
Order tools according to information given in the SERVICEGARD™ Catalog. Some tools may be available from a local supplier
Ridge Reamer JT07277
Use to remove carbon from liner bore prior to piston removal
Socket JDG10982
Use to aid in the removal & installation of the oxygen sensor
SERVICEGARD is a trademark of Deere & Company
MX52301,0001D84-19-20180214
Other Material
Number Name Use
587 Applied to mating surfaces of oil pan and Form-in-Place Gasket Loctite®(LOCTITE®)engine block
TY15130 (U S )Form-in-Place Gasket head
Number
TY12130 (U S )
N/A (U S )
J20D (U S )
Applied to mating surfaces of cylinder
545 Loctite®(U S )Thread LockerApplytothreadsofcamshaftsprocketbolt
N/A (U S )Plastigage®Used to measure bearing clearance
Name Use
Form-in-Place GasketApplytomatingsurfaceofengineblockfor Sealeroil seal case
Form-in-Place Gasket
Apply to transmission flange Sealant
Hy-GardUse to fill park brake assembly
Loctite is a trademark of Henkel Corporation Plastigage is a trademark of Perfect Circle Corporation
MX52301,0001D85-19-20180215
Specifications
Item MeasurementSpecification
73 N m
Front Engine Mount to Engine Block M10 BoltTorque (54 lb ft)
73 N m
Rear Engine Mount to Engine Block M10 BoltTorque (54 lb ft)
37 N m
Rear Engine Mount to Engine Block M8 BoltTorque (27 lb ft)
170 N m
Rear Engine Mounting Isolator to Carrier BoltTorque (125 lb·ft)
108 N m
Front Engine Mounting Isolator to Carrier NutTorque (80 lb ft)
37 N m
Shift Cable Bracket to Transmission BoltTorque (27 lb ft)
73 N m
Shift Cable Bracket to Right-Hand Brace NutTorque (54 lb ft)
37 N m
Left-Hand Brace to Transmission BoltTorque (27 lb ft)
73 N m
Left-Hand Brace to Engine Backing Plate NutTorque (54 lb ft)
80 N m
Flywheel BoltsTorque (60 lb ft)
67 8 N m
Primary Clutch Mounting BoltTorque (50 lb ft)
109 N m
Secondary Clutch Mounting BoltTorque (80 lb ft)
73 N·m
Exhaust Pipe to Manifold NutTorque (54 lb ft)
6 N m
Valve Cover BoltTorque (53 lb in)
5 mm
Timing Belt Tensioner to Water Pump HousingGap (0 2 in)
FingerPressureAppliedtoBeltatMid-PointBetween20 30 N
Pressure Cam and Crank Sprockets(4 6 lb)
5 mm
Timing BeltDeflection (0 2 in)
25 N m
Timing Belt Tensioner BoltTorque (18 lb ft)
98 N m
Crankshaft Pulley BoltTorque (72 lb·ft)
73 N m
Driveshaft Bearing BoltsTorque (54 lb ft)
20 N m
Water Pump BoltTorque (177 lb in)
Cylinder Head Bolts
30 N·m
Initial PassTorque (22 lb ft)
50 N m
Second PassTorque (37 lb·ft)
70 N m
Final PassTorque (51 lb ft)
6 N·m
Intake Manifold Mounting NutsTorque (53 lb in)
15 N m
Exhaust Manifold to Cylinder Head NutTorque (133 lb in)
0 08 mm
Cylinder Head FlatnessOut-of-Flat (0 003 in)
0 8 1 2 mm
Intake Valve Face MarginThickness (0 031 0 047 in)
0 8 1 2 mm
Exhaust Valve Face MarginThickness (0 031 0 047 in)
0 75 mm
Valve Face Margin Wear LimitThickness (0 030 in)
Intake Valve FaceAngle45°
Exhaust Valve FaceAngle45°
4 96 4 98 mm
Intake Valve StemDiameter (0 195 0 196 in)
4 95 4 97 mm
Exhaust Valve StemDiameter
5
Intake Valve GuideID
5
Exhaust Valve GuideID
Intake Valve Guide-to-Valve StemClearance
Item
Outer Rotor-to-Pump Body Wear Limit
Inner Rotor-to-Outer Rotor
Inner Rotor-to-Outer Rotor Wear Limit
Crankshaft Pulley Cap Screw
Timing Belt Tensioner Cap Screw
Intake Camshaft
Exhaust Camshaft
Camshaft End Play (Max)
Camshaft Bearing Cap Screw
Exhaust Camshaft
Coupling Flange Cap Screw
Hub Lock Nut
Intake Cam Front Journal
Intake Cam 2, 3 & 4th Journals
Exhaust Cam Front Journal
Exhaust Cam 2, 3 & 4th Journals
Main Bearing Cap Screw
Crankshaft Main Bearing
Crankshaft Main Bearing Wear Limit
Connecting Rod Cap Screw
Connecting Rod Bearing Oil
Connecting Rod Bearing Wear Limit
Connecting Rod Side Play
Connecting Rod Side Play Wear Limit
Connecting Rod Nut
Connecting Rod Bearing Clearance
Connecting Rod Bearing
Connecting Rod Bearing Wear Limit
Crankshaft Connecting Rod Journal
Piston Ring Groove Side Clearance
Top Piston Ring
Top Piston Ring (Max)
Second Piston Ring
Second Piston Ring (Max)
Piston Ring End Gap
Top Ring
Top Ring Wear Limit
Second Ring
Second Ring Wear Limit
Oil Control Ring
Oil Control Ring Wear Limit
Piston Pin Clearance
Piston Pin-to-Bore
Piston Pin-to-Bore Wear Limit
Cylinder Bore (Max)
Piston-to-Cylinder (Max)
Main Bearing Cap Screws
First Pass
MeasurementSpecification
0 25
End Play (0 004 0 007 in) 0 1 0 173 mm
End Play (0 004 0 007 in) 0 18 mm
End Play (0 007 in) 9±1 N m
Final Torque(80±9 lb in)
6±1 N m
Torque (53±17 lb in)
100±5 N m
Torque (73±7 lb ft)
25 97 mm
OD (1 022 in)
22 97 mm
OD (0.904 in)
29 967 mm
OD (1 18 in)
22 97 mm
OD (0 904 in)
78 N m
Torque (58 lb ft)
0 020 0 072 mm
Clearance (0 0008 0 0028 in)
0 15 mm
Clearance (0 006 in)
40 N m
Torque (30 lb ft)
0 020 0 044 mm
Clearance (0 001 0 002 in)
0 07 mm
Clearance (0 003 in)
0 15 0 24 mm
End Play (0 006 0 009 in)
0 30 mm
End Play (0 012 in)
40 N m
Torque (30 lb ft)
0 020 0 044 mm
Clearance (0 0008 0 002 in)
0 07 mm
Clearance (0 003 in)
36 984 37 mm
OD (1 456 1 457 in)
0 03 0 06 mm
Clearance (0 001 0 002 in)
0 12 mm
Clearance (0 005 in)
0 03 0 06 mm
Clearance (0 001 0 002 in)
0 11 mm
Clearance (0 004 in)
0.25 0.40 mm
Gap (0 010 0 016 in)
0 65 mm
Gap (0 026 in)
0 35 0 50 mm
Gap (0 014 0 020 in)
0 65 mm
Gap (0 026 in)
0 20 0 070 mm
Gap (0 008 0 028 in) 1 00 mm
Gap (0 075 in)
0 004 0 009 mm
Clearance (0 00015 0 00035 in)
0 015 mm
Clearance ( i )
Second Pass
Crankshaft
Crankshaft Connecting Rod Journal
Crankshaft Main Bearing Journal
MeasurementSpecification
48 N m Torque (36 lb ft)
70 5 N m
Torque (52 lb ft)
Radial0 03 mm
Runout(0 001 in)
36 984 37 mm
(1 456 1 457 in) 41 984 42 mm
Item
Crankshaft Main Bearing
Crankshaft Main Bearing Wear Limit
Oil Seal Case Cap Screws
Flywheel Mounting Cap Screw MeasurementSpecification
Remove and Install Engine
A-Bolts (2 Used)
B-Belt Cover
MXT022228-UN: Remove Coolant Hoses from Engine
LEGEND:
G-Coolant Hose
H-Coolant Hose
I-Bolt and Nut (2 Used)
J-Ignition Coil (3 Used)
K-Coolant Temperature Sensor
Disconnect coolant hoses (G) and (H)
CAUTION:
Avoid Injury! USE CAUTION AROUND MOVING PARTS
STOP the engine and remove the ignition key. Wait for all moving parts to STOP
Park machine safely on a hard level surface (See the‘Safety 12 Section” )
Remove cargo box. (SeeRemove and Install Cargo Box.)
Remove two bolts (A) and remove belt cover (B).
Drain coolant from the engine 13
MXT022227-UN: Driveshaft Coupling
LEGEND:
C-Screw
D-Coupling
E-Bolts (2 Used)
F-Bearing
Remove screw (C) and slide coupling (D) away from the transmission output shaft
Remove bolts (E) from the driveshaft bearing (F)
Machines equipped with HVAC: Remove air conditioner compressor (See Remove Air Conditioner Compressor )14
Machines equipped with HVAC: Remove hose connected to T-fitting.
Remove two bolts and nuts (I) securing the oxygen sensor
shield and exhaust pipe to the exhaust manifold.
Mark and disconnect connectors to ignition coils (J).
Disconnect coolant temperature sensor (K)
CAUTION:
Avoid Injury! Gasoline is flammable. DO NOT SMOKE. Always work in a well-ventilated area away from open flame or spark-producing equipment, including equipment that utilizes pilot lights.
MXT022229-UN: Fuel Hose Connector
LEGEND:
L-Fuel Hose Connector
M-Hose
Disconnect fuel hose connector (L) at the injector rail. Plug end of the fuel hose
Disconnect hose (M) from valve cover
MXT022230-UN: Fuel Injector Connectors24. LEGEND:
N-Fuel Injector Connectors
O-Camshaft Position Sensor
Mark fuel injector connectors (N) to correspond with the cylinder number to aid in reassembly and disconnect the fuel injectors
Disconnect the camshaft position sensor (O)
Throttle Cable and Harness Connectors
LEGEND:
P-Clip
Q-Nut
R-Intake Manifold Temperature and Pressure Sensor S-Knock Sensor
T-Exciter Wire
U-Spring Locking Pin
Remove clip (P) from the throttle cable end Loosen nut (Q) and disconnect throttle cable and move aside
Disconnect the intake manifold temperature and pressure sensor (R)
Disconnect the knock sensor (S)
Disconnect positive (+) battery cable (T) and exciter wire from the starting motor solenoid
Remove spring locking pin (U) and drilled pin from the shift cable yoke.
Disconnect the throttle position sensor.
Disconnect the idle air control actuator.
MXT022232-UN: Intake Hose and Clutch Cover LEGEND: V-Intake Hose
W-Clutch Cover
Remove intake hose (V) and clutch cover (W). Refer to Clutch Housing Removal (See Remove and Install Clutch Housing )
LVAL22465-UN: Fan and Clutch Retaining Bolt LEGEND: X-Drive Belt
Y-Clutch Retaining Bolt Z-Fan
Remove drive belt (X).
Remove clutch retaining bolt (Y) and fan (Z)
MXT022231-UN:
28
LVAL22466-UN: Clutch
LEGEND:
aa-JDG11200 Clutch Removal Tool
Install JDG11200 Clutch Removal Tool(aa) Hold clutch and tighten tool until clutch pops off tapered shaft.
LVAL22467-UN: Driven Clutch Retaining Bolt
LEGEND:
ab-Driven Clutch Retaining Bolt
Remove driven clutch retaining bolt (ab) and slide clutch off shaft
NOTE:
Keep track of different bolt lengths and locations for reassembly purposes
MXT022233-UN: Components hidden for a better view
LEGEND:
ac-Crankshaft Position Sensor
Disconnect crankshaft position sensor (ac)
Remove throttle cable from the tab on top of the inner clutch enclosure
Mark location of the bolts (arrows) for the inner clutch enclosure to aid in reassembly Bolts are not all the same length. Remove all bolts securing inner clutch enclosure to engine and transmission
MXT022234-UN: Backing Plate to Transmission Brace
LEGEND:
ad-Bolt, M8 (3 Used)
ae-Brace
af-Bolt, M10 (2 Used)
ag-Pin
Remove three M8 bolts (ad) securing brace (ae) to transmission
Remove two M10 bolts (af) and flange nuts securing brace to the engine backing plate
Remove brace being careful to keep pin (ag) with brace
LVAL22470-UN: Clutch Stub Shaft
LEGEND:
ah-Bolt (4 Used)
Remove four bolts (ah) remove the shaft
LVAL22471-UN: Crankshaft Position Sensor
LEGEND:
ai-Bolt (2 Used)
aj-Crankshaft Position Sensor
ak-Bolt (6 Used)
Remove two bolts (ai) securing crankshaft position sensor (aj) and remove the sensor.
Remove bolts (ak) and remove the flywheel
LVAL22472-UN: Backing Plate
LEGEND:
al-Cap Screw (4 Used)
Removefourcapscrews(al)andremovebackingplatefrom the engine.
MXT022235-UN: Shift Cable Bracket
LEGEND:
am-Bolt, M8 (4 Used)
Remove four M8 bolts (am) securing the shift cable bracket to the transmission
Remove M10 bolt and lock nut securing the bracket to the engine brace and move bracket aside.
Disconnect alternator wiring.
Remove the clamp securing the engine wiring harness to the cylinder head
Disconnect the oil pressure switch.
Disconnect the oxygen sensor.
Maneuver the engine wiring harness clear of the engine and set aside
Attach engine hoist to engine lifting brackets and raise hoist enoughtosupportenginewhenenginemountsareremoved
MXT022236-UN: Rear Skid Plate
LEGEND:
an-Rear Skid Plate
Remove rear skid plate (an).
MXT022239-UN: Components hidden for a better view LEGEND:
aq-Bolt and Washer ar-Bolt, M10 (4 Used) as-Bolt, M8
Remove bolt and washer (aq) from the rear engine isolator
MXT022237-UN: Components hidden for a better view
LEGEND: engine mount to the engine block
ao-Nut and Bolt
Viewed
51 Remove four M10 bolts (ar) and M8 bolt (as) securing rear
ap-Bolt, M10 (6 Used)52.Carefully raise engine from the machine. Remove nut and bolt (ao) from the front engine isolator
Remove six M10 bolts (ap) securing front engine mount to Installation the engine block
Installation is the reverse of removal
1 Carefully lower engine into machine Tighten engine mounting bolts to specifications.
Install bolt and washer into the rear engine isolator. Tighten to specification
Item Measurement Specification
170 N m Rear Engine Mounting Isolator to Carrier BoltTorque (125 lb ft)
Install front engine isolator bolt and nut. Tighten to specification.
Item Measurement Specification
108 N m Front Engine Mounting Isolator to Carrier NutTorque (80 lb ft)
Machines equipped with HVAC: Install air conditioner compressor (See Install Air Conditioner Compressor )
MXT022238-UN:
from under the rear of the machine
Install shift cable bracket to transmission and right-hand 15 brace Tighten bolts and flange nut to specification
Item Measurement Specification 16.
37 N m
Shift Cable Bracket to Transmission BoltTorque (27 lb ft)
73 N m
Shift Cable Bracket to Right-Hand Brace NutTorque (54 lb ft)
Install backing plate to the engine.
Install crankshaft position sensor 17.
Install left-hand brace to backing plate and transmission 18.
Make sure that the brace locating pin is seated in the backing plate Tighten bolts and flange nuts to specification 19
Item Measurement Specification
37 N m
Left-Hand Brace to Transmission BoltTorque (27 lb·ft)
73 N·m20
Left-Hand Brace to Engine Backing Plate NutTorque (54 lb ft) 21.
Use a medium strength thread locker on flywheel bolts and install the flywheel. Tighten bolts to specifications.22.
Item Measurement Specification
Flywheel BoltsTorque (60 lb ft)
Install inner clutch enclosure
Install primary and secondary clutches and tighten to specification.
Item Measurement Specification
67 8 N mPrimary Clutch Mounting BoltTorque (50 lb ft)
109 N m
80 N·m23.
Clean exhaust pipe and exhaust manifold flanges of any old gasket material Install a new manifold gasket
Installexhaustpipeandoxygensensorshieldtotheexhaust manifold with two bolts and nuts Tighten nuts to specifications.
Item Measurement Specification
73 N·m Exhaust Pipe to Manifold NutTorque (54 lb ft)
Connect all engine wiring connectors
Attach throttle cable to throttle lever and adjust cable. (See Throttle Cable Adjustment )
Connect coolant hoses Check condition of hoses and replace as necessary.
Attach ground wire to the engine bracket.
Attach battery positive (+) cable and solenoid exciter wire to starting motor solenoid
Connect fuel line.
NOTE:
Oil level must be at the full mark with the cap screwed tight while the engine is cold To make sure that level is correct, start engine and run at 4500 rpm for one minute Stop engine and check oil level
Fill engine to proper level with oil of correct specifications
Fill coolant to the correct level (See Fill and Bleed Coolant System.)
Check clutch alignment (SeeClutch Sheave Alignment )
Secondary Clutch Mounting BoltTorque (80 lb ft) 24.
Install drive belt
Install outer clutch enclosure
Attach negative (-) cable to battery.
OUMX068,00013FB-19-20180216
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