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 tools required in performing certain service work are identified in this manual and are recommended for use.
Information is organized in groups for the various components requiring service instruction. At the beginning of each group are summary listings of all applicable essential tools, service equipment and tools, other materials needed to do the job, service parts kits, specifications, wear tolerances, and torque values.
Live with safety: Read the safety messages in the introduction of this manual and the cautions presented throughout the text of the manual. CAUTION: This is the safety-alert symbol. When you see this symbol on the machine or in this manual, be alert to the potential for personal injury. Technical manuals are divided in two parts: repair and operation and tests. Repair sections tell how to repair the components.
TM145519 (01.12.2018)
Technical Manuals are concise guides for specific machines. They are on-the-job guides containing only the vital information needed for diagnosis, analysis, testing, and repair. Fundamental service information is available from other sources covering basic theory of operation, fundamentals of troubleshooting, general maintenance, and basic type of failures and their causes. DX,TMIFC-19-20140415
XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles
Contents 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
TM145519 (01.12.2018)
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
Section 299 - Service Tools Group 10 - Service Tools and Kits
XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles
Section 10
General Information Contents Page
Page
Protect Against High Pressure Spray................... . 10-10-7
Group 10 - Safety Recognize Safety Information .............................. . 10-10-1
Live With Safety ................................................... . 10-10-7
Understand Signal Words..................................... . 10-10-1
Group 20 - General Specifications
Follow Safety Instructions..................................... . 10-10-1
Service Recommendations for O - Ring Boss 10-20-1 Fittings........................................................... .
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
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
Park Machine Safely............................................. . 10-10-4
Group 30 - Fuel and Lubricants
Support Machine Properly .................................... . 10-10-4
Gasoline Engine Oil.............................................. . 10-30-1
Wear Protective Clothing ...................................... . 10-10-4
Oil Filters .............................................................. . 10-30-1
Work in Clean Area .............................................. . 10-10-5
Gasoline Fuel for 4 - Cycle Engines..................... . 10-30-1
Service Machines Safely ...................................... . 10-10-5
Transmission and Hydraulic Oil............................ . 10-30-2
Work In Ventilated Area ........................................ . 10-10-5
Grease.................................................................. . 10-30-2
Illuminate Work Area Safely ................................. . 10-10-5
Mixing of Lubricants ............................................. . 10-30-2
Replace Safety Signs ........................................... . 10-10-6
Alternative and Synthetic Lubricants .................... . 10-30-2
Use Proper Lifting Equipment............................... . 10-10-6
Lubricant Storage ................................................. . 10-30-3
Keep ROPS Installed Properly ............................. . 10-10-6
Group 40 - Machine Specifications
Follow Tire Recommendations ............................. . 10-10-6
Machine Specifications......................................... . 10-40-1
Decommissioning - Proper Recycling and Disposal 10-10-7 of Fluids and Components ............................ .
Product Identification Number Location ............... . 10-40-1
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XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles
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 with the safety-alert symbol. DANGER identifies the most serious hazards. DANGER or WARNING safety signs are located near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.
TS187-19: Signal Words
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.
Follow Safety Instructions
There can be additional safety information contained on parts and components sourced from suppliers that is not 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.
TS201-UN: Safety Messages
DX,READ-19-20090616
TM145519 (01.12.2018)
10-10-1
XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles
Safety
Practice Safe Maintenance
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
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
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
TM145519 (01.12.2018)
10-10-2
XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles
Safety
Drain Gasoline When Storing Machine
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
Handling Batteries Safely
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.
TS204-UN: Caution
If acid is spilled on skin or in eyes:
Flush skin with water. Apply baking soda or lime to help neutralize the acid. Flush eyes with water for 15—30 minutes. Get medical attention immediately. If acid is swallowed:
Do not induce vomiting. Drink large amounts of water or milk, but do not exceed 2 L (2 qt.). Get medical attention immediately. WARNING: Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. DX,WW,BATTERIES-19-20101202
TM145519 (01.12.2018)
10-10-3
XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles
Safety
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
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 in operator station. DX,PARK-19-19900604
Support Machine Properly
TS229-UN: Support Properly
Always lower the attachment or implement to the ground before you work on the machine. If the work requires that the machine or 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
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
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10-10-4
XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles
Safety
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
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
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. If you do not have an exhaust pipe extension, open the doors and get outside air into the area. DX,AIR-19-19990217
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
TM145519 (01.12.2018)
10-10-5
XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles
Safety
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
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
Keep ROPS Installed Properly
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
Follow Tire Recommendations
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
TM145519 (01.12.2018)
10-10-6
XUV835E, XUV835M and XUV835R Gator™ Utility Vehicles