XUV855E, XUV855M, XUV855M S4 Gator™
Utility Vehicles (SN. 010001-)
Download Manual XUV855E
TECHNICAL MANUAL
XUV855E, XUV855M, XUV855M S4 Gator™ Utility Vehicles (SN. 010001-)
TM150119 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.
DOWNLOAD SERVICE MANUAL
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 - Engine
Section 30 - Electrical Repair
Group 10 - Wiring Harnesses
Group 20 - Wiring Harnesses, Kits
Section 40 - Power Train Repair
Group 10 - Transmission
Group 20 - Axles and Drive Shaft
Group 30 - Mechanical Four Wheel Drive
Section 50 - Steering and Brake Repair
Group 10 - Steering
Group 20 - Brakes
Section 60 - Miscellaneous Repair
Group 10 - Wheels
Group 20 - Hood, Cargo Box, and Bumper
Group 30 - Miscellaneous
Section 70 - Operator ` s Station 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 10 - Component Location
Group 20 - Theory of Operation
Group 30 - Wiring Schematics
Group 40 - Schematics, Kits
Group 50 - Tests and Adjustments
Group 60 - Connector Information
Section 240 - Control Unit Operation, Tests, and Adjustments
Group 10 - Theory of Operation
Group 20 - Diagnostic Trouble Codes, ICC
Group 30 - Diagnostic Trouble Codes, SCU
Group 40 - Service ADVISOR Readings
Group 50 - Tests and Adjustments
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
Section 270 - Miscellaneous Operation, Tests, and Adjustments
Group 10 - Component Location
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
Replace Safety Signs............................................10-10-1
Handle Fluids Safely - Avoid Fires........................10-10-2
Prepare for Emergencies.......................................10-10-2
Prevent Battery Explosions...................................10-10-2
Prevent Acid Burns................................................10-10-3
Wear Protective Clothing.......................................10-10-3
Avoid High - Pressure Fluids.................................10-10-3
Avoid Heating Near Pressurized Fluid Lines.........10-10-4
Service Machines Safely 10-10-4 Use
Proper Tools 10-10-4 Park Machine Safely 10-10-4 Support
Machine Properly 10-10-5 Use Proper Lifting Equipment 10-10-5 Work in Clean Area
10-10-5 Protect Against High Pressure Spray 10-10-5 Illuminate Work Area Safely 10-10-6 Work In Ventilated Area 10-10-6 Remove Paint Before Welding or Heating 10-10-6 Avoid Harmful Asbestos Dust 10-10-7 Service Tires Safely 10-10-7 Stay Clear of Rotating Drivelines 10-10-8 Service Cooling System Safely 10-10-8 DecommissioningProper Recycling and Disposal 10-10-9 of Fluids and Components.............................
Handle Chemical Products Safely.........................10-10-9
Live With Safety.....................................................10-10-9
Group 20 - General Specifications
Service Recommendations for O - Ring Boss 10-20-1
Fittings
Service Recommendations For Flat Face O - Ring 10-20-2
Seal Fittings...................................................
Metric Cap Screw Torque Values - Grade 7..........10-20-2
Metric Bolt and Screw Torque Values....................10-20-3
Unified Inch Bolt and Screw Torque Values..........10-20-4
Group 30 - Fuel, Lubricants, and Coolant
Diesel Fuel - North America..................................10-30-1
Diesel Fuel - Europe..............................................10-30-1
Diesel Fuel Storage...............................................10-30-2
4 - Cycle Diesel Engine Oil - North America 10-30-2
Diesel Engine Oil - Europe
From HY - GARD to BIO
-
Diesel Engine Coolant (engine without wet sleeve 10-30-6 cylinder liners)................................................
John Deere COOL - GARD™ II Coolant 10-30-6 Extender Testing Diesel Engine Coolant 10-30-7
Group 40 - Machine Specifications
Machine Specifications 10-40-1
Product Identification Number Location 10-40-1
Recognize Safety Information
Understand Signal Words
Replace Safety Signs
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
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
TS187-19: Signal Words
Handle Fluids Safely Avoid Fires
Prepare for Emergencies
Prevent Battery Explosions
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
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
TS204-UN: Battery Explosions
Keep sparks, lighted matches, and open flame away from the top 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
Prevent Acid Burns
Wear Protective Clothing
Avoid High-Pressure Fluids
X9811-UN: High Pressure
Inspect hydraulic hoses periodically–at least once per year–for leakage, kinking, cuts, cracks, abrasion, blisters, corrosion, exposed wire braid or any other signs of wear or damage
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 dripping electrolyte
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 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 quarts)
Get medical attention immediately.
TS206-UN: Protective Clothing
DX,POISON-19-19930421
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
Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.
Escaping fluid under pressure can penetrate the skin causing serious injury.
Avoid the hazard by relieving pressure before disconnecting hydraulic or other lines. Tighten all connections before applying pressure
Search for leaks with a piece of cardboard Protect hands and body from high-pressure fluids.
If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result Doctors unfamiliar with this type of injury should reference a knowledgeable medical source. Such information is available in English from Deere & Company Medical Department in Moline, Illinois, U.S.A., by calling 1-800-822-8262 or +1 309-748-5636
DX,FLUID-19-20111012
Safety
Avoid Heating Near Pressurized Fluid Lines
Service Machines Safely
Use Proper Tools
Park Machine Safely
TS953-UN: Flammable Spray
Flammable spray can be generated by heating near pressurized fluid lines, resulting in severe burns to yourself and bystanders. Do not heat by welding, soldering, or using a torch near pressurized fluid lines or other flammable materials. Pressurized lines can accidentally burst when heat goes beyond the immediate flame area.
DX TORCH-19-20041210
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
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
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
Support Machine Properly
Use Proper Lifting Equipment
Work in Clean Area
Protect Against High Pressure Spray
Safety
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
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
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
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
Illuminate Work Area Safely
Work In Ventilated Area
Remove Heating Paint
Before Welding or
TS220-UN: Toxic Fumes
Avoid potentially toxic fumes and dust
Hazardous fumes can be generated when paint welding, soldering, or using a torch. is heated by
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
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
Remove paint before heating:
Remove paint a minimum of 100 mm (4 in ) from area to be affected by heating. If paint cannot be removed, wear an approved respirator before heating or welding
If you sand or grind paint, avoid breathing the dust. Wear an approved respirator
If you use solvent or paint stripper, remove stripper with soap and water before welding. Remove solvent or paint stripper containers and other flammable material from area. Allow fumes to disperse at least 15 minutes before welding or heating
Do not use a chlorinated solvent in areas where welding will take place.
Do all work in an area that is well ventilated to carry toxic fumes and dust away
Dispose of paint and solvent properly
DX,PAINT-19-20020724
Avoid Harmful Asbestos Dust
Service Tires Safely
Avoid breathing dust that may be generated when handling components containing asbestos fibers Inhaled asbestos fibers may cause lung cancer.
Components in products that may contain asbestos fibers are brakepads, brakebandandlining assemblies, clutch plates, and somegaskets Theasbestosusedinthesecomponentsisusually found in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust containing asbestos is not generated.
Avoid creating dust. Never use compressed air for cleaning. Avoid brushing or grinding material containing asbestos. When servicing, wear an approved respirator A special vacuum cleaner is recommended to clean asbestos. If not available, apply a mist of oil or water on the material containing asbestos
Keep bystanders away from the area
TS211-UN: Explosive Tire and Rim Parts
DX,DUST-19-19910315
Explosive separation of a tire and rim parts can cause serious injury or death
Do not attempt to mount a tire unless you have the proper equipment and experience to perform the job
Always maintain the correct tire pressure Do not inflate the tires above the recommended pressure Never weld or heat a wheel and tire assembly. The heat can cause an increase in air pressure resulting in a tire explosion Welding can structurally weaken or deform the wheel.
Wheninflatingtires,useaclip-onchuckandextensionhoselong enough to allow you to stand to one side and NOT in front of or over the tire assembly. Use a safety cage if available.
Check wheels for low pressure, cuts, bubbles, damaged rims or missing lug bolts and nuts
DX,RIM-19-19900824
TS220-UN: Asbestos Dust
Stay Clear of Rotating Drivelines
H96219-UN: Drivelines
Service Cooling System Safely
Entanglement in rotating driveline can cause serious injury or death
Keep tractor master shield and driveline shields in place at all times Make sure rotating shields turn freely
Only use power take-off driveshafts with adequate guards and shields
Wear close fitting clothing Stop the engine and be sure that PTO driveline is stopped before making adjustments, connections, or cleaning out PTO driven equipment.
Do not install any adapter device between the tractor and the primary implement PTO driveshaft that will allow a 1000 rpm tractorshafttopowera540rpmimplementatspeedshigherthan 540 rpm
Do not install any adapter device that results in a portion of the rotating implement shaft, tractor shaft, or the adapter to be unguarded The tractor master shield shall overlap the end of the splined shaft and the added adaptor device as outlined in the table
The angle at which the primary implement PTO driveshaft can be inclined may be reduced depending on the shape and size of the tractor master shield and the shape and size of the guard of the primary implement PTO driveshaft.
Do not raise implements high enough to damage the tractor master shield or guard of primary implement PTO driveshaft. Detach the PTO driveline shaft if it is necessary to increase implement height. (See Attching/Detaching PTO Driveline)
When using Type 3/4 PTO, inclination and turning angles may be reduced depending on type of PTO master shield and coupling rails
DX,PTO-19-20170228
TS281-UN: Cooling System
Explosive release of fluids from pressurized cooling system can cause serious burns
Shut off engine Only remove filler cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely
DX,RCAP-19-19900604
TS1644-UN: Rotating Drivelines
Safety
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
Handle Chemical Products Safely
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
TS1132-UN: Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury
Potentially hazardous chemicals used with John Deere equipmentincludesuchitemsaslubricants,coolants,paints,and adhesives.
A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques
Check the MSDS before you start any job using a hazardous chemical That way you will know exactly what the risks are and how to do the job safely Then follow procedures and recommended equipment
(See your John Deere dealer for MSDS’s on chemical products used with John Deere equipment )
DX,MSDS,NA-19-19930303
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
TCT008637-UN: Straight Fitting
LEGEND:
A-Straight Boss Fitting
B-Straight Stud and Tube Nut
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.
3.Tighten fitting to torque value shown on chart.
Angle Fitting
TCT008638-UN: Angle Fitting
LEGEND:
A-Locknut
B-Washer
C-Head-End of 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.
3. Back-off locknut (A) and back-up washer (B) completely to head-end (C) of fitting.
4. Turn fitting into threaded boss until back-up washer contacts face of boss.
5. Turn fitting head-end counterclockwise to proper index (maximum of one turn).
6 NOTE:
Do not allow hoses to twist when tightening fittings
Hold fitting head-end with a wrench and tighten locknut and back-up washer to proper torque value
STUDENDO-RINGSEALTORQUEFORSTRAIGHTANDADJUSTABLE FITTINGS*
ThreadSizeStraightHexSizeLocknutHexSizeStraightFittingor LocknutToque
InchInchInchNmlb-ft
3/8-24 5/8 9/16
7/16-20 5/8 5/8
1/2-20 3/4 11/16
9/16-18 3/4 3/4
3/4-16 7/8 15/16
7/8-141 1/161 1/16
1 1/16-121 1/41 3/8
1 3/16-121 3/81 1/2
1 5/16-121 1/21 5/8
*Torque tolerance is +15 -20% unless otherwise specified
OUMX258,00000F8-19-20160120
General Specifications
Index angle fittings and tighten by hand pressing joint together to insure O-ring remains in place
TCT008639-UN: Flat Face Fittings LEGEND: A-O-ring B-Nut
1. Inspect the fitting sealing surfaces and O-ring. They must be free of dirt or defects.
2. Lubricate O-ring (A) and install into groove using petroleum jelly to hold in place.
Metric Cap Screw Torque Values Grade 7
NOTE:
When bolting aluminum parts, specified in table. tighten to 80% of torque
Unlessspecifiedotherwise,tightenfittingornut(B)totorque value shown on the chart Do not allow hoses to twist when tightening fittings, use backup wrench on straight hose couplings
FLATFACEO-RINGSEALFITTINGTORQUE*
NominalTubeODThreadSizeSwivelNutBulkheadNut mmininNmlb-ftNmlb-ft
3/16-12152112
220 8751 3/16-12152112
401 0001 7/16-12214158
751 2501 11/16-12286211
OUMX258,00000F9-19-20140812
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
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 ]
5/16
N
7/16
1-1/8
1-1/4 570 420 725 535 570 420 725 535 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, Lubricants, and Coolant
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 requirements of the geographical area in which they 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.
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. If a fuel of low or unknown lubricity is used, addition of John Deere PREMIUM DIESEL FUEL CONDITIONER at the specified concentration is recommended
Diesel fuel quality and fuel sulfur content must comply with all existing 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
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 fuel tank or service the fuel system.
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
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.
OUO1086 1000401-19-20120615
A cetane number greater than 50 is preferred, especially for air temperatures below-20°C (-4°F) or elevations above 1500 m (5000 ft).
In general, diesel fuels are blended to satisfy the low air temperaturerequirementsofthegeographicalareainwhichtheyCold Filter Plugging Point (CFPP) are sold
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 Sulfur Content of 0.05% (Max) equivalent properties:
If diesel fuel being used has a sulfur content greater than 0 05%, Cetane Number 40 (Min) reduce the service interval for engine oil and filter by 50%.
Consult your local diesel fuel distributor for properties of the diesel fuel available in your area.
OUO1086,1000402-19-20120615
Diesel Fuel Storage
IMPORTANT: IMPORTANT:
Fuel, Lubricants, and Coolant
prevent possible igniting of fumes by an open flame or spark; this includes any appliance with a pilot light.
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
Keep fuel in a safe, protected area and in a clean, properly marked (‘DIESEL FUEL”)container. DO NOT use deicers to attempt to remove water from fuel DO NOT depend on fuel filters to remove water from fuel. It is recommended that a water It is recommended that diesel fuel be stored ONLY in a clean, separator be installed 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
4-CycleDieselEngineOil—NorthTORQ-GARD SUPREMETorq-Gard Supreme™
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, provided they meet one of the following specifications:ThefollowingJohnDeereoilsarePREFERRED:
PLUS-50Plus-50™
Diesel Engine Oil Europe
Use oil viscosity based on the expected air temperature range during the period between oil changes.
ThefollowingJohnDeereoilsarePREFERRED:
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 Supreme is a trademark 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 SAE 5W-30
The following 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, provided they meet the following specification:
CCMC Specification D4 or Mercedes Benz MB228.1 or higher.
OUO1086 1000405-19-20140612
Fuel, Lubricants, and Coolant
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
Precautions should be taken if BIO HY-GARD containers or equipment are stored for long periods of time in extremely cold temperatures. Freezing should be expected if BIO HY-GARD is Whenuseofabiodegradablelubricantisdesiredorrequired,BIOsubjected to the following temperatures: HY-GARD is recommended. BIO HY-GARD may be used under normal mowing conditions
DO NOT USE biodegradable lubricants in machines for the following operations:
Any machine used for scalping procedure.
Any verticut operation in temperatures exceeding 32°C (90°F)
BIO HY-GARD should be used only in cases where the benefits of its use offset the extra initial cost, the increased oil change cost and the potential increasing maintenance costs for 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 the fluid
Stored for six months at-18° to-23°C (-1° to-10°F)
Stored for seven days at-23° to-26°C (-10° to-15°F)
Stored for three days 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 at least 0°C (32°F) and maintained for 24-48 hours to ensure the fluid has reached a safe operating viscosity
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
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™ transmission and hydraulic oil may be used, if within the specified temperature range
Fuel, Lubricants, and Coolant
OtheroilsmaybeusedifaboverecommendedJohnDeereJohn Deere Standard JDM J20D. oils are not available, provided they meet one of the following specifications:Hy-Gard is a trademark of Deere & Company
John Deere Standard JDM J20C;
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 on a level surface.
Lower cutting units, stop engine, set park brake and remove key from ignition
Drain hydraulic reservoir.
Replace hydraulic filter.
Grease - North America
IMPORTANT:
Avoid Damage! ONLY use a quality grease application DO NOT mix any other greases application DO NOT use any BIOGREASE application
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 several times
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
The following John Deere greases are preferred for the cutting units and unit attachments:
JohnDeereGolfandTurfCuttingUnitGrease JohnDeereCornheadGrease JohnDeereCottonPickerSpindleGrease
Other greases may be used if above preferred John Deere greases are not available, provided they meet the following specifications:
The following John Deere greases are preferred for the machine and lift arms:
JohnDeereSpecialPurposeHDWaterResistant Grease
John Deere Multi-Purpose HD Lithium Complex Grease
Grease - Europe
Use the following grease based on the air temperature range
PolyureaGrease-NLGIGrade2
CalciumComplexGrease-NLGIGrade2. JohnDeereStandardJDMJ13E4-NLGIGrade2
OUO1086,1000409-19-20120615
ReelSupportGrease-JDMJ13E6,NLGIGrade0
Other greases may be used if above preferred John Deere Operating outside of the recommended grease air temperature greases are not available, provided they meet the following range may cause premature failures. specifications:
IMPORTANT:
Reel Support Grease Applications:
The following John Deere greases are PREFERRED:
Avoid Damage! ONLY use a quality grease application DO NOT mix any other greases application. DO NOT use any BIOGREASE application in in in in in in this this this this this this GREASE-GARD™-JDMJ13E4,NLGIGrade2
Alternative Lubricants
Polyurea Grease - NLGI Grade 2
Calcium Complex Grease - Grade 2
Lithium Complex Grease - NLGI Grade 0.
John Deere Standard JDM J13E4 - NLGI Grade 2
OUO1086 100040A-19-20120615
If alternative lubricants are to be used, it is recommended that the factory fill be thoroughly removed before switching to any alternative lubricant.
Use of alternative lubricants could cause reduced life of the OUO1086,100040B-19-20120615 component
Synthetic Lubricants
The recommended air temperature limits and service or lubricant changeintervalsshouldbemaintainedasshownintheoperator’s manual, unless otherwise stated on lubricant label.
Synthetic lubricants may be used in John Deere equipment if they meet the applicable performance requirements (industry Avoid mixing different brands, grades, or types of oil. Oil classification and/or military specification) as shown in this manufacturers blend additives in their oils to meet certain manual. specifications and performance requirements. Mixing different
Fuel, Lubricants, and Coolant
oils can interfere with the proper functioning of these additives
OUO1086,100040C-19-20120615 and degrade lubricant performance
Lubricant Storagecontamination.Storedrumsontheirsides.Makesureall
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
Mixing of Lubricantslubricantscaninterferewiththeproperfunctioningofthese
additives and lubricant properties which will downgrade their intended specified performance
In general, avoid mixing different brands or types of lubricants.
Manufacturers blend additives in their lubricants to meet certain specifications and performance requirements Mixing different
Oil FiltersMostJohnDeerefilterscontainpressurereliefandanti-drainback
IMPORTANT:
valves for better engine protection.
Avoid Damage! Filtration of oils is critical to proper lubrication performance. Always change filters regularly.
OUO1086,100040E-19-20120615
Other oil filters may be used if above recommended John Deere oil filters are not available, provided they meet the following specification:
OUO1086 100040F-19-20120615
The following John Deere oil filters are PREFERRED:
Automotiveandlighttruckengineoilfilters
Operatin g
Climates
in Warm Temperature
IMPORTANT:
John Deere engines are designed to operate using recommended engine coolants.
Always use a recommended engine coolant, even when operating in geographical areas where freeze protection is not required
Watermaybeusedascoolantinemergencysituationsonly Foaming, hot surface aluminum and iron corrosion, scaling, andcavitationoccurwhenwaterisusedasthecoolant,even when coolant conditioners are added.
Drain cooling system and refill with recommended engine coolant as soon as possible
DX,COOL6-19-20130515
Fuel, Lubricants, and Coolant
Diesel
Engine Coolant (engine without wet sleeve cylinder liners)
Preferred Coolants
The following pre-mix engine coolants are preferred:
JohnDeereCOOL-GARD™II
JohnDeereCOOL-GARDIIPG
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
COOL-GARD II 20/80
COOL-GARD II 30/70
COOL-GARD II 50/50
COOL-GARD II 55/45
COOL-GARD II PG 60/40
(16 °F)
°C (3 °F)
°C (-34 °F)
°C (-49 °F)
°C (-56 °F)
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 the following chemical and physical properties:
Is formulated with a nitrite-free additive package
Protects the cooling system metals (cast iron, aluminum alloys, and copper alloys such as brass) from corrosion
Water Quality
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 glycol base engine coolant concentrate.
COOL-GARD II 60/40
°C (-62 °F)
Not all COOL-GARD II pre-mix products are available in all Coolant Drain Intervals countries
Use COOL-GARD II PG when a non-toxic coolant formulation is required Drain and flush the cooling system and refill with fresh coolant at the indicated interval, which varies with the coolant used
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
The following engine coolant is also recommended:isused,reducethedrainintervalto2yearsor2000hoursof operation.
IMPORTANT:
John Deere COOL-GARD II Concentrate in a 40 60% mixture of concentrate with quality water
Do not use cooling system sealing additives or antifreeze that contains sealing additives
IMPORTANT:
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 excessive coolant is lost through leaks or overheating
IMPORTANT:
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
IMPORTANT:
Add the recommended concentration of COOL-GARD II Coolant Extender DO NOT add more than the recommended amount COOL-GARD is a trademark of Deere & Company DX,COOL16-19-20130515
Do not add 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
Add only the recommended concentration of John Deere COOLGARD II Coolant Extender. DO NOT add more than the recommended amount
Maintaining adequate concentrations of glycol and inhibiting additives in the coolant is critical to protect the engine and cooling 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 Coolant Conditioner should be added Coolant Test Strips
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
Machine Specifications
NOTE:
Specifications and design subject to change without notice
FuelSystem:
ElectricalSystem:
Alternator Battery Cold Cranking Amps
XUV855EXUV855MXUV855M S4
GroundSpeed:
Forward - Range LO
Forward - Range HI
Reverse Engine:
Make
Engine Power Information
Type
Model
Slow Idle Speed
Slow Idle Speed (Governed)
Fast Idle Speed
Cylinders
Displacement
Bore
Stroke
Injection
Cooling
Air Cleaner
Engine Shut Off
Summary of References
Remove and Install Engine
Remove and Install Muffler
Remove and Install Exhaust Manifold
Remove and Install Rocker Arm Cover
Remove and Install Rocker Arm and Push Rods
Remove and Install Cylinder Head
Recondition Cylinder Head
Remove and Install Rear Crankshaft Oil Seal
Remove and Install Front Crankshaft Oil Seal
Remove and Install Timing Gear Cover
Check Camshaft End Play
Check Timing Gear Backlash
Remove and Install Idler Gear
Remove and Install Cam Followers
Remove and Install Camshaft
Remove and Install Oil Pan and Strainer
Check Connecting Rod Side Play
Check Crankshaft End Play
Check Connecting Rod Bearing Clearance
Check Crankshaft Main Bearing Clearance
Remove, Inspect, and Install Connecting Rod
Steering:
TypeRack andRackandPinionwithElectronicPower Pinion Assist
Brakes:
Type All Wheel Hydraulic Disc
Capacities:
Fuel Tank 20 1 L (5 3 gal)
Crankcase (with Filter) 2 6 L (2 75 qt )
Transmission 4 3 L (4 5 qt )
EMFWD Front Differential 660 mL (22 oz )
Dimensions:
Overall Length with 3 0 m (119 in )3 9 m (155 in ) Bumper
Overall Width1 6 m (62 0 in )
Ground Clearance27 9 cm (11 0 in )
MX52301,00018BE-19-20171212
Disassemble and Assemble Pistons Cylinder Bore
Remove and Install Crankshaft and Main Bearings
Remove and Install Flywheel
Remove and Install Flywheel Plate
Remove and Install Timing Gear Housing
Remove and Install Oil Pump
Remove and Install Coolant Temperature Sensor
Remove and Install Thermostat
Oil Pressure Regulating Valve
Remove and Install Water Pump
Remove and Install Fuel Filter
Remove and Install Fuel Filter Assembly
Remove and Install Fuel Transfer Pump
Remove and Install Fuel Injection Nozzle
Remove and Install Fuel Injection Pump
Remove and Install Fuel Control and Governor Linkage
Remove and Install Fuel Shutoff Solenoid
Repair Starting Motor
Repair Alternator
MX52301,00018D0-19-20171213
Group 10 - Engine
Summary of References........................................
Specifications........................................................
Essential or Recommended Tools.........................
Service Equipment and Tools................................
Other Material........................................................
Remove and Install Engine....................................
Remove and Install Muffler
Remove and Install Exhaust Manifold
Remove and Install Rocker Arm Cover
Remove and Install Rocker Arm and Push Rods
Remove and Install Cylinder Head
Recondition Cylinder Head
Remove and Install Rear Crankshaft Oil Seal
Remove and Install Front Crankshaft Oil Seal
Remove and Install Timing Gear Cover
Check Camshaft End Play
Check Timing Gear Backlash
Remove and Install Idler Gear
Remove and Install Cam Followers
Remove and Install Camshaft
Remove and Install Oil Pan and Strainer
Check Connecting Rod Side Play
Check Crankshaft End Play
Check Connecting Rod Bearing Clearance
and Install Crankshaft and Main 20-10-47 Bearings
Remove and Install Flywheel 20-10-50 Remove and Install Flywheel Plate 20-10-51
Remove and Install Timing Gear Housing 20-10-52 Remove and Install Oil Pump 20-10-53 Remove and Install Coolant Temperature 20-10-54 Sensor............................................................ Remove and Install Thermostat............................20-10-56 Oil Pressure Regulating Valve 20-10-57 Remove and Install Water Pump 20-10-58 Remove and Install Fuel Filter 20-10-58 Remove and Install Fuel Filter Assembly 20-10-59 Remove and Install Fuel Transfer Pump 20-10-61 Remove and Install Fuel Injection Nozzle 20-10-62
Remove and Install Fuel Injection Pump 20-10-65
Remove and Install Fuel Control and Governor 20-10-68 Linkage
Remove and Install Fuel Shutoff Solenoid 20-10-69 Repair Starting Motor 20-10-69 Repair Alternator 20-10-70
Summary of References
Remove and Install Engine
Remove and Install Muffler
Remove and Install Exhaust Manifold
Remove and Install Rocker Arm Cover
Remove and Install Rocker Arm and Push Rods
Remove and Install Cylinder Head
Recondition Cylinder Head
Remove and Install Rear Crankshaft Oil Seal
Remove and Install Front Crankshaft Oil Seal
Remove and Install Timing Gear Cover
Check Camshaft End Play
Check Timing Gear Backlash
Remove and Install Idler Gear
Remove and Install Cam Followers
Remove and Install Camshaft
Remove and Install Oil Pan and Strainer
Check Connecting Rod Side Play
Check Crankshaft End Play
Check Connecting Rod Bearing Clearance
Check Crankshaft Main Bearing Clearance
Remove, Inspect, and Install Connecting Rod
Disassemble and Assemble Pistons
Cylinder Bore
Remove and Install Crankshaft and Main Bearings
Remove and Install Flywheel
Remove and Install Flywheel Plate
Remove and Install Timing Gear Housing
Remove and Install Oil Pump
Remove and Install Coolant Temperature Sensor
Remove and Install Thermostat Oil Pressure Regulating Valve
Remove and Install Water Pump
Remove and Install Fuel Filter
Remove and Install Fuel Filter Assembly
Remove and Install Fuel Transfer Pump
Remove and Install Fuel Injection Nozzle
Remove and Install Fuel Injection Pump
Remove and Install Fuel Control and Governor Linkage
Remove and Install Fuel Shutoff Solenoid
Repair Starting Motor
Repair Alternator
MX52301
12 09 mm
Rocker Arm Shaft/Support–Wear LimitID (0 476 in )
0 02–0 05 mm
473 in )
Rocker Arm Shaft/SupportClearance (0 001–0 002 in )
0 13 mm
Rocker Arm Shaft/Support–Wear LimitClearance (0 005 in )
0–0 03 mm
Push Rod BendDistance (0 0–0 001 in )
26 N m
Rocker Arm Support BoltTorque (230 lb -in )
27 N m
Cylinder Head Bolt–First PassTorque (20 lb -ft )
54–58 N m
Cylinder Head Bolt–Final PassTorque (40–43 lb -ft )
0 05 mm or less
Cylinder Head Distortion–StandardOut-of-Flat (0 002 in or less)
0 15 mm
Cylinder Head Distortion–Wear LimitOut-of-Flat (0 006 in )
1 028 1 202
mm Intake Valve SeatWidth (0 041 0 047 in )
Exhaust Valve SeatWidth(0 051 0 060 in.)
0 9 1 1 mm
Valve Face Margin–IntakeDistance(0 035 0 043 in )
1 0 1 2 mm
Valve Face Margin–ExhaustDistance(0 039 0 047 in )
0 51 mm
Valve Face Margin–Wear Limit (Intake and Exhaust)Distance (0 020 in )
Valve Face Angle–IntakeAngle30°
Valve Face Angle–ExhaustAngle45°
5 96 5 98 mm
Valve Stem–IntakeDiameter(0 235 0 235 in )
5 95 5 96 mm
Valve Stem–ExhaustDiameter(0 234 0 235 in )
5 90 mm
Valve Stem (Intake and Exhaust)–Wear LimitDiameter (0 232 in )
0 40 0 60 mm
Valve Recession (Intake and Exhaust)Distance(0 016 0 024 in ) 0 9 mm
Valve Recession (Intake)–Wear LimitDistance (0
(Exhaust)–Wear LimitDistance
Item MeasurementSpecification
0 03 0 05 mm
Intake (0 001 0 002 in )
0 04 0 07 mm
Exhaust (0 002 0 003 in )
ValveGuide-to-ValveStem(IntakeandExhaust)–Wear0 17 mm
Clearance Limit(0 007 in )
9 8 10 mm
Valve Guide HeightHeight(0 386 0 394 in )
37 8 mm
Valve Spring Free Length (C)Length (1 488 in )
1 3 mm
Maximum Spring Inclination (B)Distance (0 051 in )
Lower Valve Seat SurfaceAngle70°
Upper Valve Seat SurfaceAngle15° 11 N m
Seal Case-to-Block Cap ScrewsTorque (97 lb -in )
9 N m
Seal Case to Oil Pan Spacer Cap ScrewsTorque (80 lb -in )
83 N m
Flywheel BoltsTorque (61 lb -ft )
59 N m
Stub Shaft-to-Flywheel Cap ScrewsTorque (44 lb -ft )
37 N m
Clutch Mounting Cap ScrewTorque (27 lb -ft )
113–123 N m
Crankshaft Pulley Cap ScrewTorque (83–90 lb -ft )
9 N·m
Timing Cover Cap ScrewsTorque (80 lb -in )
0 05 0 15 mm
CamshaftEnd Play (0
0 06 0 12 mm
Timing GearBacklash (0
0 14 mm
Timing Gear (All)–Wear LimitBacklash (0 006 in)
0 006 in)
36.95–36.98 mm
Idler Gear Shaft–StandardDiameter (1 455–1 456 in )
36 90 mm
Idler Gear Shaft–Wear LimitDiameter (1 452 in )
Idler Gear Bushing–StandardID(1 4567–1 4577 in )
0 03–0 08 mm
Idler Gear Bushing OilClearance
0 18 mm
Idler Gear Bushing Oil–Wear LimitClearance (0 007 in )
37
1 308 1 52 mm
20 93–20 96 mm
Cam Follower–StandardDiameter (0 824–0 825 in )
20 90 mm
Cam Follower–Wear LimitDiameter (0.823 in.)
21 00–21 02 mm
Cam Follower Bore–StandardDiameter (0 827–0 828 in )
21 04 mm
Cam Follower Bore–Wear LimitDiameter (0 828 in )
0 13 mm
Cam Follower-to-Bore–Wear LimitClearance (0 005 in )
0 04–0 09 mm
Cam Follower-to-Bore–StandardClearance (0 002–0 004 in ) 11 N·m
Camshaft Cap ScrewsTorque (97 lb -in )
0 05–0 15 mm
Camshaft Side GapGap (0 002–0 006 in )
0 00–0 02 mm
Camshaft Bend–StandardDeflection (0 00–0 001 in )
0 05 mm
Camshaft Bend–Wear LimitDeflection (0 002 in )
34.14–34.27 mm
Camshaft Lobe–StandardHeight (1 343–1 349 in )
33 89 mm
Camshaft Lobe–Wear LimitHeight (1 334 in )
CamshaftGearSideandFlywheelEnd39 94–35 96 mm
Diameter Journals–Standard(1 572–1 573 in )
CamshaftGearSideandFlywheelEndJournals–Wear39 91 mm
Diameter Limit(1 571 in )
39 91–39 94 mm
Camshaft Intermediate Journal OD–StandardDiameter (1 571–1 572 in )
39 88 mm
Camshaft Intermediate Journal OD–Wear LimitDiameter (1 569 in )
40 0–40 08 mm
Camshaft Bushing–StandardDiameter (1.575–1.578 in.)
40 15 mm
Camshaft Bushing–Wear LimitDiameter (1 580 in )
0 04–0 14 mm
Camshaft Bushing to CamshaftClearance
Item
Camshaft Flywheel-End Bore ID’s:
Standard
Wear Limit
Oil Clearance
Oil 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
Top Ring–Wear Limit
Second Ring–Standard
Second Ring–Wear Limit
Oil Ring–Standard
Standard Piston Ring End Gap:
First Compression Ring–Standard
First Compression Ring–Wear Limit
Second Compression Ring–Standard
Second Compression Ring–Wear Limit
Oil Ring–Standard
Oil Ring–Wear Limit
Piston Pin–Standard
Piston Pin–Wear Limit
Piston Pin Bore–Standard
Piston Pin Bore–Wear Limit
Piston Pin Bore–Standard
Piston Pin Bore–Wear Limit
Piston Pin Bushing–Standard
MeasurementSpecification
40 0–40 03 mm (1 575–1 576 in )
40 1 mm (1 579 in )
0 04–0 09 mm (0 002–0 003 in )
11 N m
Torque (97 lb in)
25 N m
Torque (221 lb in)
20 N m
Torque (177 lb in)
0 20 0 40 mm
Clearance (0 008 0 016 in )
0 11 0 25 mm
End Play (0 004 0 010 in)
22 6 27 5 N m
Torque(16 6 20 2 lb ft)
(200 243 lb in)
0 02 0 06 mm
Clearance (0 001 0 002 in)
0 11 mm
Clearance (0 004 in)
75 5 81 5 N m
Torque (56 60 lb ft)
0 02 0 05 mm
Clearance (0 001 0 002 in)
0 12 mm
Clearance (0 005 in)
22 6–27 5 N m
Torque (16 6–20 2 lb -ft )
37 982–38 10
Diameter mm (1.495–1.496 in.)
1 50–1 51 mm
Thickness (0 059 in )
0 02–0 06 mm
Clearance (0 001–0 002 in )
0 11 mm
Clearance (0 004 in )
22 6–27 5 N m
Torque (200–243 lb.-in.)
0.06 0.10 mm
Clearance (0 002 0 004 in )
0 20 mm
Clearance (0 0079 in )
0 05 0 09 mm
Clearance (0 002 0 0035 in )
0 20 mm
Clearance (0 008 in )
0 02 0 06 mm
Clearance (0 001 0 002 in.)
0 15 0 30 mm
Gap (0 006 0 012 in )
0 39 mm
Gap (0 015 in )
0 18 0 33 mm
Gap (0 007 0 013 in )
0 42 mm
Gap (0 017 in )
0 15 0 35 mm
Gap (0.006 0.014 in )
0 44 mm
Gap (0 017 in )
22 00 mm
Diameter (0 866 in )
21 97 mm
Diameter (0 865 in )
22 00 22 01
mm
Diameter (0 866 0 867 in )
22 04 mm
Diameter (0 868 in )
0.03 0.05 mm
Clearance (0 001 0 002 in )
0 11 mm
Clearance (0 004 in )
22 03 22 04
Diameter mm) (0 867 0 868 in
Item
Piston Pin Bushing–Wear Limit
Piston Pin–Standard
Piston Pin–Wear Limit
Measuring Distance (A)
Standard-Sized Piston
Standard-Sized Piston–Wear Limit
Standard Size Cylinder Bore
Cylinder Bore–Wear Limit
Piston-to-Cylinder
Cylinder
Cylinder–Wear Limit
Cylinder
Cylinder–Wear Limit
Main Bearing Cap Screws
Crankshaft
Crankshaft Connecting Rod Journal–Standard
Crankshaft Connecting Rod Journal–Wear Limit
Crankshaft Main Bearing Journal–Standard
Crankshaft Main Bearing Journal–Wear Limit
Main Bearing–Standard
Main Bearing
Main Bearing Oil Clearance
Main Bearing Oil Clearance–Wear Limit
Flywheel Bolts
Clutch Bolt
Flywheel Plate Cap Screws
Timing Gear Housing Mounting Cap Screws
Oil Pump Outer Rotor-to-Timing Cover–Standard
Oil Pump Outer Rotor-to-Timing Cover–Wear Limit
Oil Pump Inner-to-Outer Rotor Clearance
Oil Pump Rotors-to-Timing Cover–Standard
Oil Pump Rotors-to-Timing Cover–Wear Limit
Thermostat Housing Cap Screws
Water Pump Mounting Cap Screws
Fuel Injector
Fuel Injector Fuel Return Line Nuts
Fuel Injector Nozzle
Fuel Injector Separator Plate Wear–Maximum
Injector Pump Mounting Nuts
Injector Pump Drive Gear Nut
Injector Gear Cover Cap Screws
Fuel Injector Line Nuts
Starting Motor Cap Screw Torque
Item
Slip Ring Diameter (Minimum)
Alternator Brush Exposed Length (Minimum)
MeasurementSpecification
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
Service Equipment and Tools
NOTE:
Order tools according to information given in the SERVICEGARD™ Catalog Some tools may be available from a local supplier.
Valve Spring Compressor JDE138
Used to remove and install valve components Valve Guide Driver JDG504 Used to install valve guides
SERVICEGARD is a trademark of Deere & Company
Other Material
Number
N/A (U S )
MX52301,0001892-19-20171206
Name Form-In-Place Gasket
) Use Apply to mating surfaces of rear oil seal case
MX52301,0001890-19-20171206
RECOMMENDED TOOLS, as noted, are suggested to perform the job correctly Some tools may be available from local suppliers or may be fabricated.
Clutch Removal Tool JDG1641
Used to remove the clutch Magnetic Follower Holder Kit.......D15001NU Used to remove cam followers Nozzle Cleaning Kit JDF13 Used to clean fuel injector nozzles
SERVICEGARD is a trademark of Deere & Company
MX52301,000188F-19-20171206
Number PM37465 (U S ) N/A (U S )
Name Use John Deere™ Form-In-Place Apply to timing gear cover mating surfaces Gasket Thread Lock (MediumApply to threads of timing gear housing Strength)cap screws
MX52301 0001891-19-20171206
