Complete service repair manual with Electrical Wiring Diagrams for John Deere XUV Gator Utility Vehicle 855D, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

John Deere XUV Gator Utility Vehicle 855D workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

tm107219 - John Deere XUV Gator Utility Vehicle 855D Technical Manual.pdf
tm107219 - John Deere XUV Gator Utility Vehicle 855D Technical Manual.epub

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Total Pages: 1,408 pages
File Format: PDF/EPUB/MOBI/AZW (PC/Mac/Android/Kindle/iPhone/iPad; bookmarked, ToC, Searchable, Printable)
Language: English

tm107219 - XUV Gator Utility Vehicle 855D

Table of Contents

Foreword

Section 10: General Information

Group 05: Safety

Recognize Safety Information

Understand Signal Words

Practice Safe Maintenance

Use Proper Tools

Handle Fluids Safely—Avoid Fires

Prevent Acid Burns

Prevent Battery Explosions

Handling Batteries Safely

Prepare for Emergencies

Park Machine Safely

Support Machine Properly

Wear Protective Clothing

Work in Clean Area

Service Machines Safely

Work In Ventilated Area

Illuminate Work Area Safely

Replace Safety Signs

Use Proper Lifting Equipment

Follow Tire Recommendations

Protect Against High Pressure Spray

Decommissioning — Proper Recycling and Disposal of Fluids and Components

Live With Safety

Group 10: General Specifications

Service Recommendations for O-Ring Boss Fittings

Service Recommendations For Flat Face O-Ring Seal Fittings

Metric Cap Screw Torque Values—Grade 7

Metric Bolt and Screw Torque Values

Unified Inch Bolt and Screw Torque Values

Group 15: Fuel, Lubricants, and Coolant

Transmission and Hydraulic Oil

Diesel Fuel—North America

Diesel Fuel—Europe

Diesel Fuel Storage

4-Cycle Diesel Engine Oil—North America

Diesel Engine Oil—Europe

Grease - North America

Grease - Europe

Mixing of Lubricants

Alternative Lubricants

Synthetic Lubricants

Lubricant Storage

Operating in Warm Temperature Climates

Diesel Engine Coolant (engine without wet sleeve cylinder liners)

John Deere COOL-GARD™ II Coolant Extender

Testing Diesel Engine Coolant

Group 20: Machine Specifications

Product Serial Number

Section 20: Engine Repair

Group 10: Engine

Summary of References

Essential or Recommended Tools

Other Material

Specifications

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 Switch

Remove and Install Thermostat

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

Section 30: Electrical Repair

Group 10: Wiring Harnesses (SN -060000)

Summary of References

Electrical Wiring Harness Legend (SN -060000)

Main Wiring Harness (SN -060000)

Main Harness Wire Color Codes (SN -060000)

W2 Battery Wiring Harness (SN -060000)

Battery Harness Wire Color Codes (SN -060000)

Group 15: Wiring Harnesses (SN 060001-100000)

Summary of References

Electrical Wiring Harness Legend (SN 060001-)

Main Wiring Harness (SN 060001-080000)

Main Harness Wire Color Codes (SN 060001-080000)

Main Wiring Harness (SN 080001-100000)

Main Harness Wire Color Codes (SN 080001-100000)

W2 Battery Wiring Harness (SN 060001-)

Battery Harness Wire Color Codes (SN 060001-)

Load Center (SN 060001-)

Group 20: Wiring Harnesses (SN 100001-)

Summary of References

Main Wiring Harness (SN 100001-)

Main Wiring Harness Color Codes (SN 100001-)

Main Wiring Harness Splice Table (SN 100001-)

Main Wiring Harness Terminal Table (SN 100001-)

Load Center (SN 100001-)

Group 25: Wiring Harnesses, Kits

Summary of References

Cargo Box Lift Wiring Harness

Cargo Box Lift Harness Wire Color Codes

Light and Horn Wiring Harness

Light and Horn Wire Color Codes

Lights Wiring Harness, AM140950

Lights Wiring Harness, AM137558

Headlight Jumper Wiring Harness, AM147740

Turn Signal with Flasher Harness, AM143722

Taillight Harness, AM137737

Trailer Connector Wiring Harness

Backup Alarm Wiring Harness, AM144181

Cab Power Splitter Wiring Harness, AM140972

Canopy Wiring Harness, AM143139

Roof Work Lights Wiring Harness, AM146905

Beacon Light Wiring Harness, AM140971

Horn Wiring Harness, VGA10903

Winch Main Wiring Harness, AM144137

Winch Control Wiring Harness, AM142263

Group 30: MFWD Service Kit Wiring Harnesses

Summary of References

Wiring Harness AM145249

Wiring Harness AM146628

Wiring Harness AM147221

Section 40: Power Train Repair

Group 10: Transmission

Summary of References

Service Equipment and Tools

Other Material

Specifications

Change Transmission Oil

Clean Primary Drive Clutch

Remove and Install Clutch Housing (SN -060000)

Remove and Install Clutch Housing (SN 060001-)

Remove and Install Clutch (SN -060000)

Remove and Install Clutch (SN 060001-)

Repair Drive Clutch (SN -060000)

Repair Drive Clutch (SN 060001-)

Repair Driven Clutch (SN -060000)

Repair Driven Clutch (SN 060001-)

Remove Transmission

Install Transmission

Disassemble Transaxle

Assemble Transmission

Group 15: Axles and Drive Shaft

Summary of References

Essential or Recommended Tools

Specifications

Remove and Install EMFWD Driveshaft

Replace EMFWD Driveshaft Boot

Remove and Install Rear Axle Half Shaft

Remove and Install Front Axle Half Shaft

Repair CV Joint and Boots - Front Axle Half Shafts

Repair CV Joint and Boots - Rear Axle Half Shafts

Hub Removal

Hub Installation

Group 20: Mechanical Four Wheel Drive

Summary of References

Other Material

Specifications

Change EMFWD Front Differential Oil

Disassemble and Assemble Front Drive Gearbox

Remove and Install Front Differential

Disassemble Front Differential

Assemble Front Differential

Section 50: Steering and Brake Repair

Group 10: Steering

Summary of References

Other Material

Specifications

Remove and Install Steering Knuckle

Remove and Install Front Wheel Bearing

Remove and Install Ball Joint

Remove and Install Steering Wheel

Remove and Install Electric Power Assisted Steering (EPAS) Module

Remove and Install Steering Shaft

Remove and Install Steering Shaft (EPAS)

Replace Steering Shaft Bearing

Remove and Install Steering Gearbox

Remove and Install Front Coilover Shock Absorber

Remove and Install Rear Coilover Shock Absorber

Remove and Install Tie Rod End

Remove and Install Front Suspension Arm

Remove and Install Rear Axle Bearing Carrier

Remove and Install Rear Suspension Arm

Remove and Install Front Suspension Arm Bushing

Remove and Install Rear Suspension Arm Bushing

Remove and Install Rear Stabilizer Bar

Group 20: Brakes

Summary of References

Service Equipment and Tools

Other Material

Specifications

Replace Brake Pad

Remove and Install Master Cylinder

Remove and Install Brake Line

Remove and Install Brake Caliper

Remove and Install Brake Rotor

Remove and Install Brake Pedal

Remove and Install Park Brake Control Cable

Remove and Install Park Brake Lever

Disassemble and Assemble Park Brake

Section 60: Miscellaneous Repair

Group 10: Wheels

Summary of References

Specifications

Remove and Install Wheels

Group 15: Hood, Cargo Box, and Bumper

Summary of References

Specifications

Remove and Install Hood Latch

Remove and Install Hood

Remove and Install Front Bumper/Skid Plate

Remove and Install Cargo Box

Remove and Install Cargo Box Side

Group 20: Miscellaneous

Summary of References

Specifications

Remove and Install Headlight

Remove and Install Front Grille

Remove and Install Front Fender

Door Removal and Installation

Door Alignment

Door Latch Adjustment

Radiator Drain and Flush Procedure

Radiator Fill and Bleed Procedure

Remove and Install Radiator

Remove and Install Cooling Fan

Remove and Install Battery

Remove and Install Fuel Tank

Section 70: Operator’s Station Repair

Group 10: Operator’s Station and Seat

Summary of References

Specifications

Remove and Install Dash Panel

Remove and Install Seat

Remove and Install Bench Seat

Remove and Install Seat Base Cover

Remove and Install Seat Adjuster

Remove and Install Under Seat Storage Box (Bench Seat)

Remove and Install Center Console

Remove and Install Transaxle Control Lever Housing

Group 20: Occupant Protective Structure (OPS)

Summary of References

Specifications

Remove and Install Occupant Protective Structure (OPS)

Section 220: Engine Operation, Tests, and Adjustments

Group 10: Component Location

Summary of References

Fuel Filter Components

Engine Fuel System

Engine Mounts

Fuel System Components

Exhaust System Components (SN -080000)

Exhaust System Components (SN 080001-)

Coolant System Components

Group 15: Theory of Operation

Summary of References

Cooling System Operation

Lubrication System Operation

Fuel System Operation

Air System Operation

Group 20: Diagnosis

Engine Troubleshooting and Diagnostics

Diagnose Engine Oil

Diagnose Excessive Fuel Consumption

Diagnose Incorrect Manifold Pressure

Diagnose Low Engine Compression

Diagnose Engine Starting Problem

Diagnose Poor Engine Operation

Diagnose Abnormal Coolant Temperature

Diagnose Coolant in Oil or Oil in Coolant

Diagnose Engine

Group 25: Tests and Adjustments

Summary of References

Essential or Recommended Tools

Other Material

Specifications

Test Air Restriction Indicator

Adjust Fast Idle Speed

Adjust Slow Idle

Adjust Throttle Cable

Adjust Valve Clearance

Check Valve Lift

Test Cylinder Compression

Adjust Water Pump/Alternator Drive Belt

Test Thermostat

Test Radiator Bubble

Test Cooling System Pressure

Test Radiator Cap Pressure

Test Engine Oil Pressure

Test Fuel Injection System

Test Fuel Injection Nozzle

Adjust Injection Pump Timing

Check Injection Pump Static Timing

Bleed Fuel System Air

Test Fuel Transfer Pump Flow

Test Fuel Transfer Pump Pressure

Section 230: Electrical Operation, Tests, and Adjustments

Group 05: General Information

Operation and Diagnostics

Diagnostic Information

Wire Color Abbreviation Chart

Reading Electrical Schematics

Common Circuit Tests

Conductors for 12 Volt Circuits

Group 10: Component Location

Summary of References

Fuse Block and VCU Fuses (SN -060000)

Load Center Components (SN 060001-)

Group 15: Theory of Operation (SN -060000)

Summary of References

Power Circuit Operation (SN -060000)

Charging Circuit Operation (SN -060000)

Cranking Circuit Operation (SN -060000)

Seat Belt Circuit Operation (SN -060000)

Glow Plug Circuit Operation (SN -060000)

Fuel Shutoff Circuit Operation (SN -060000)

Engine Oil Pressure Light and Hour Meter Circuit Operation (SN -060000)

Park Brake Circuit Operation (SN -060000)

4WD Circuit Operation (SN -060000)

Engine Cooling Circuit Operation (SN -060000)

Headlight Circuit Operation (SN -060000)

Accessory Power Port Circuit Operation (SN -060000)

Cargo Box Lift Circuit Operation (SN -060000)

Group 20: Theory of Operation (SN 060001-)

Summary of References

Power Circuit Operation (SN 060001-080000)

Power Circuit Operation (SN 080001-100000)

Power Circuit Operation (SN 100001-)

Charging and Tachometer Circuit Operation (SN 060001-)

Seat Belt Circuit Operation (SN 060001-)

Park Brake Light and Warning Buzzer Circuit Operation (SN 060001-)

Cranking, Glow Plug, Fuel Gauge Circuit Operation (SN 060001-080000)

Cranking, Glow Plug, Fuel Gauge Circuit Operation (SN 080001-)

4WD and Speedometer Circuit Operation (SN 060001-100000)

4WD and Speedometer Circuit Operation (SN 100001-)

Engine Cooling Circuit Operation (SN 060001-)

Light Circuit Operation (SN 060001-080000)

Light Circuit Operation (SN 080001-)

Electric Power Assist Steering (EPAS) Operation (SN 060001-)

Group 25: Diagnosis (SN -060000)

Power Circuit Diagnosis (SN -060000)

Charging Circuit Diagnosis (SN -060000)

Cranking Circuit Diagnosis (SN -060000)

Seat Belt Circuit Diagnosis (SN -060000)

Glow Plug Circuit Diagnosis (SN -060000)

Fuel Shutoff Circuit Diagnosis (SN -060000)

Engine Oil Pressure Light Diagnosis (SN -060000)

Hour Meter Circuit Diagnosis (SN -060000)

Park Brake Circuit Diagnosis (SN -060000)

4WD Circuit Diagnosis (SN -060000)

Cooling Circuit Diagnosis (SN -060000)

Headlight Circuit Diagnosis (SN -060000)

Cargo Box Lift Circuit Diagnosis (SN -060000)

Group 30: Diagnosis (SN 060001-)

Power Circuit Diagnosis (SN 060001-)

Charging Circuit Diagnosis (SN 060001-)

Seat Belt Circuit Diagnosis (SN 060001-)

Park Brake Light and Warning Buzzer Circuit Diagnosis (SN 060001-)

Cranking Circuit Diagnosis (SN 060001-)

4WD Drive Circuit Diagnosis (EMFWD) (SN 060001-)

Cooling Circuit Electrical Diagnosis (SN 060001-)

Light Circuit Diagnosis (SN 060001-)

Cargo Box Lift Circuit Diagnosis (SN 060001-)

Group 32: Operation and Diagnostics - Electronic Controllers (SN 060001-)

Summary of References

On Board Diagnostics - VCU (SN 060001-)

Vehicle Control Unit (VCU) Operation (SN 060001-)

Display Panel Operation (SN 060001-)

Display Panel Replacement Programming (SN 060001-100000)

Display Panel Replacement Programming (SN 100001-)

Display Panel Tire Size Programming (SN 060001-)

Overtemp Input (SN 060001-)

Oil Pressure Input (SN 060001-)

Coolant Temperature Gauge (SN 060001-)

Fuel Level (SN 060001-)

Tachometer (SN 060001-)

Speedometer (SN 060001-)

EPAM Test (SN 060001-)

Group 34: MFWD Service Kit Operation and Wiring Schematics

Summary of References

Electrical Operation and Schematic (AM145249)

Electrical Operation and Schematic (AM146628)

Electrical Operation and Schematic (AM147221)

Group 35: Wiring Schematics (SN -060000)

Electrical Schematic Legend (SN -060000)

Main Schematic (SN -060000)

Group 40: Wiring Schematics (SN 060001-100000)

Summary of References

Electrical Schematic Legend (SN 060001-080000)

Main Schematic (SN 060001-080000)

Electrical Schematic Legend (SN 080001-100000)

Main Schematic (SN 080001-100000)

Group 45: Wiring Schematics (SN 100001-)

Summary of References

Electrical Schematic Legend (SN 100001-)

Main Schematic (SN 100001-)

Group 50: Schematics, Kits and Attachments

Summary of References

Light and Horn Schematic Legend

Light and Horn Schematic

Lights Wiring Schematic, AM140950

Lights Wiring Schematic, AM137558

Turn Signal with Flasher Schematic, AM143722

Taillight Schematic, AM137737

Backup Alarm Wiring Schematic, AM144181

Canopy Wiring Schematic, AM143139

Roof Work Lights Wiring Schematic, AM146905

Beacon Light Wiring Schematic, AM140971

Horn Wiring Schematic, VGA10903

OPS Rear Lights Wiring Schematic, AM146376

Winch Schematic

Group 55: Tests and Adjustments

Summary of References

Ground Circuit Test

Battery Test

Charge Battery

Load Test Battery

Clean Battery

Regulated Voltage Output Test

Starter Solenoid Test

Starter Loaded Amperage Draw Test

Starter No-Load Amperage and RPM Test

Key Switch Test

Park Brake Switch Test

Neutral Start Switch Test

Reverse Switch Test

Headlight Switch Test (Single)

Headlight Switch Test (2 Position) (AM144577)

Light Switch Test (3 Position)

4WD Switch Test

4WD Switch Test (AM142314)

Throttle Switch Test

Brake Lights Switch Test

Raise/Lower Switch Test

Raise/Lower Switch Test (AM142315)

Relay Test

Radiator Coolant Temperature Switch Test

Engine Coolant Temperature Switch Test

Coolant Temperature Sensor Test

Engine Oil Pressure Switch Test

Glow Plug Test

Seat Belt Switch Test

Fuel Shutoff Solenoid Test

Speed Sensor Test

4WD Solenoid Test

Diode Test

Warning Alarm Test

Horn Switch Test, Push

Horn Switch Test, Toggle

Section 240: Power Train Operation, Tests, and Adjustments

Group 10: Component Location

Summary of References

Power Train Components

Front Axle Components

Rear Axle Components

MFWD Driveline Components

Front Drive Gear Box Components

EMFWD Front Differential Components

Transaxle Components

Differential Components

Transaxle Input (SN -060000)

Transaxle Input (SN 060001-)

Shift Linkage Components

Primary Clutch (SN -060000) Components

Primary Clutch (SN 060001-) Components

Secondary Clutch (SN -060000) Components

Secondary Clutch (SN 060001-) Components

Transmission Mounts Components

Group 15: Theory of Operation

Summary of References

Power Transfer Operation

Drive Clutch Operation (SN -060000)

Drive Clutch Operation (SN 060001-)

Clutch Operation (SN -060000)

Clutch Operation (SN 060001-)

EMFWD Operation

MFWD Anti-Wedging (SN -100000)

Group 20: Diagnosis

Diagnose Drive Train

Diagnose Primary Clutch

Diagnose Clutch System

Group 25: Tests and Adjustments

Summary of References

Adjust Differential Lock

Adjust Transmission Shift

Clutch Sheave Alignment (SN 060001-)

Section 250: Steering and Brake Operation, Tests, and Adjustments

Group 10: Component Location

Summary of References

Steering Components

Front Suspension Components

Rear Suspension Components

Brake System Components

Brake System Components - Front

Brake System Components - Rear

Park Brake Components

Park Brake Housing Components

Group 15: Theory of Operation

Summary of References

Steering System Operation

Brake System Operation

Group 20: Diagnosis

Diagnose Steering Pulls in One Direction

Diagnose Steering Wanders or Vibrates

Diagnose Wheel Bearing Noise

Diagnose Steering Hard in Left, Right, or Both Directions

Diagnose Steering Locks in Hard Left or Right Turn

Diagnose Steering Wheel Pulls Upwards

Diagnose Steering Wheel Spins Freely

Diagnose Noise During Turns Over Rough Terrain

Diagnose Hydraulic Brakes

Diagnose Brakes Will Not Engage or Show Poor Response

Diagnose Brake Effort Excessive

Diagnose Brakes Will Not Release

Diagnose Brakes Are Noisy or Chattering

Diagnose Excessive Brake Pad Wear

Diagnose Excessive Brake Pedal Travel

Diagnose Brakes Pull Left or Right

Diagnose Pedal Feels Hard With Little Travel

Diagnose Park Brake Will Not Engage or Hold

Diagnose Park Brake Will Not Release

Group 25: Tests and Adjustments

Summary of References

Other Material

Specifications

Center Steering Rack

Center Steering Wheel

Adjust Suspension

Adjust Toe-In

Adjust Rear Wheel Camber

Check Brake Fluid Level

Check Park Brake Lubricating Oil Level

Adjust Master Cylinder Rod

Bleed Brakes

Bleed Master Cylinder

Burnish Brakes

Section 260: Miscellaneous Operation, Tests, and Adjustments

Group 10: Component Location

Summary of References

Body Components

Seat and Seat Support Components

Bench Seat Components

Fuel System Components (SN -060000)

Fuel System Components (SN 060001-)

Section 299: Service Tools

Group 10: Service Tools and Kits

Essential or Recommended Tools

Service Kits

John Deere XUV Gator Utility Vehicle 855D Repair Service Manual (TM107219)