JOHN DEERE XUV855M GATOR UTILITY VEHICLES TM150119 PDF

XUV855E, XUV855M, XUV855M S4 Gator™ Utility Vehicles (SN. 010001-)

TECHNICAL MANUAL XUV855E, XUV855M, XUV855M S4 Gator™ Utility Vehicles (SN. 010001-) TM150119 01DEC18 (ENGLISH)

John Deere Horicon Works

Introduction Foreword routine failures quickly.

Operation and tests sections help you identify the majority of

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.

Technical Manuals are concise guides for specific machines.

They are on-the-job guides containing only the vital information CAUTION:needed for diagnosis, analysis, testing, and repair.

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.

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XUV855E, XUV855M, XUV855M S4 Gator™ Utility Vehicles

Contents 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

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, Groupand 10 -Adjustments Component Location Tests, Group 20 - Theory of Operation Group 30 - Diagnosis Group 40 - Tests and Adjustments

Section - Miscellaneous Operation, Group 10270 - Component Location Tests, and Adjustments Group 10 - Service Tools and Kits

Section 299 - Service Tools

Section 230 - Electrical Operation, Tests,

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XUV855E, XUV855M, XUV855M S4 Gator™ Utility Vehicles

Section 10 Contents

General Information Page

Page

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 Decommissioning Proper Recycling and Disposal 10-10-9 of Fluids and Components.............................

Handle Chemical Products Safely.........................10-10-9

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....................................10-30-2 Biodegradable Oil..................................................10-30-3 Transaxle and MFWD Differential Oil....................10-30-3 Converting From HY - GARD to BIO HY - GARD.10-30-4 Grease - North America........................................10-30-4 Grease - Europe....................................................10-30-4 Alternative Lubricants............................................10-30-4 Synthetic Lubricants..............................................10-30-4 Lubricant Storage..................................................10-30-5 Mixing of Lubricants..............................................10-30-5 Oil Filters...............................................................10-30-5 Operating in Warm Temperature Climates............10-30-5 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

Live With Safety.....................................................10-10-9 Group 20 - General Specifications Service Recommendations for O - Ring Boss 10-20-1

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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

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XUV855E, XUV855M, XUV855M S4 Gator™ Utility Vehicles

For the full PDF version of this manual, Please click on the above download PDF button.

JOHN DEERE 2255 TRACTOR DIAGNOSTIC & REPAIR TECHNICAL MANUAL TM4401 - PDF

Safety

Group 10 Safety Recognize Safety Information

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.

Understand Signal Words

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.

TS187-19: Signal Words

DX,SIGNAL-19-20161005

Replace Safety Signs

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

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Safety

Handle Fluids Safely—Avoid Fires

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

Prepare for Emergencies

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

Prevent Battery Explosions

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

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Safety

Prevent Acid Burns

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.

DX,POISON-19-19930421

Wear Protective Clothing

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

Replace worn or damaged hose assemblies immediately with John Deere approved replacement parts.

Avoid High-Pressure Fluids

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

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.

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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

XUV855E, XUV855M, XUV855M S4 Gator™ Utility Vehicles

Safety

Avoid Heating Near Pressurized Fluid TS953-UN: Flammable Spray Flammable spray can be generated by heating near pressurized Lines 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

Service Machines Safely

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

Use Proper Tools

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

Park Machine Safely

TS230-UN: Remove the Key

Before working on the machine:

Lower all equipment to the ground.

Stop the engine and remove the key.

Disconnect the battery ground strap.

Hang a "DO NOT OPERATE" tag station.

in operator DX,PARK-19-19900604

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Safety

Support Machine Properly

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

Use Proper Lifting Equipment

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

Work in Clean Area

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

Protect Against High Pressure Spray

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

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Safety

Illuminate Work Area Safely

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

Work In Ventilated Area

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 Heating

Paint

Before Welding

or 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.

TS220-UN: Toxic Fumes

Avoid potentially toxic fumes and dust.

Hazardous fumes can be generated when paint welding, soldering, or using a torch.

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is heated by

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

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Safety Avoid breathing dust that may be generated when handling components containing asbestos fibers. Inhaled asbestos fibers may cause lung cancer.

Avoid Harmful Asbestos Dust

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.

DX,DUST-19-19910315

TS220-UN: Asbestos Dust

Service Tires Safely

TS211-UN: Explosive Tire and Rim Parts

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

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Safety Entanglement in rotating driveline can cause serious injury or death.

Stay Clear of Rotating Drivelines

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.

TS1644-UN: Rotating Drivelines

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.

H96219-UN: Drivelines

PTO Type

Diameter

Splines

n±5 mm (0.20 in.)

1

35 mm (1.378 in.)

6

85 mm (3.35 in.)

2

35 mm (1.378 in.)

2

85 mm (3.35 in.)

3

45 mm (1.772 in.)

1

100 mm (4.00

4

57.5 mm (2.264

2

in.)

in.)

0

(4.00 in.)

2

100

mm

DX,PTO-19-20170228

2

Service Cooling System Safely

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

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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

Live With Safety

Before returning machine to customer, make sure machine is functioning properly, especially the safety systems. Install all guards and shields.

DX,LIVE-19-19920925

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XUV855E, XUV855M, XUV855M S4 Gator™ Utility Vehicles

For the full PDF version of this manual, Please click on the above download PDF button.

JOHN DEERE 2255 TRACTOR DIAGNOSTIC & REPAIR TECHNICAL MANUAL TM4401 - PDF