TM121619 John Deere XUV855D S4 Gator Utility Technical Manual

TM121619 John Deere XUV855D S4 Gator Utility Technical Manual, Group 05 - SafetyGroup 10 - General SpecificationsGroup 15 - Fuel, Lubricants, and CoolantGroup 20 - Machine Specifications

1. XUV855D S4 Gator™
Utility V
ehicle T
echnical
Manual
SN: 010001-
TECHNICAL MANUAL
XUV855D S4 Gator™ Utility V
ehicle
TM121619
27FEB21
(ENGLISH)
John Deere Horicon W
orks
D
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A
D

S
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2. Introduction
Foreword
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.
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.
Operation and tests sections help you identify the majority of
routine failures quickly.
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.
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
TM121619 (27FEB21) XUV855D S4 Gator Utility Vehicle

3. Contents
Section 10 - General Information
Group 05 - Safety
Group 10 - General Specifications
Group 15 - Fuel, Lubricants, and Coolant
Group 20 - Machine Specifications
Section 20 - Engine Repair
Group 05 - Engine
Section 30 - Electrical Repair
Group 10 - Wiring Harnesses
Group 15 - MFWD Service Kit Wiring Harnesses
Group 20 - Wiring Harnesses, Kits
Section 40 - Power Train Repair
Group 10 - Transmission
Group 15 - Axles and Drive Shaft
Group 20 - Mechanical Four Wheel Drive
Section 50 - Steering and Brake Repair
Group 15 - Steering
Group 20 - Brakes
Section 60 - Miscellaneous Repair
Group 10 - Wheels
Group 15 - Hood, Cargo Box, and Bumper
Group 20 - Miscellaneous
Section 70 - Operator`s Station Repair
Group 10 - Operator`s Station and Seat
Group 20 - Occupant Protective Structure (OPS)
Section 220 - Engine Operation, Tests, and
Adjustments
Group 10 - Component Location
Group 15 - Theory of Operation
Group 20 - Diagnosis
Group 25 - Tests and Adjustments
Section 230 - Electrical Operation, Tests, and
Adjustments
Group 05 - General Information
Group 10 - Component Location
Group 15 - Theory of Operation
Group 20 - Operation and Diagnostics - Electronic
Controllers
Group 25 - MFWD Service Kit Operation and Wiring
Schematics
Group 30 - Diagnosis
Group 35 - Wiring Schematics
Group 40 - Schematics, Kits
Group 45 - Tests and Adjustments
Section 240 - Power Train Operation, Tests,
and Adjustments
Group 10 - Component Location
Group 15 - Theory of Operation
Group 20 - Diagnosis
Group 25 - Tests and Adjustments
Section 250 - Steering and Brake Operation,
Tests, and Adjustments
Group 10 - Component Location
Group 15 - Theory of Operation
Group 20 - Diagnosis
Group 25 - Tests and Adjustments
Section 260 - Miscellaneous Operation, Tests,
and Adjustments
Group 10 - Component Location
Section 299 - Service Tools
Group 10 - Service Tools and Kits
TM121619 (27FEB21) XUV855D S4 Gator Utility Vehicle

4. Section 10
General Information
Contents
Page
Group 05 - Safety
Recognize Safety Information................................10-05-1
Understand Signal Words......................................10-05-1
Replace Safety Signs.............................................10-05-1
Handle Fluids Safely-Avoid Fires...........................10-05-2
Prepare for Emergencies.......................................10-05-2
Prevent Battery Explosions....................................10-05-2
Prevent Acid Burns................................................10-05-3
Wear Protective Clothing.......................................10-05-3
Avoid High-Pressure Fluids....................................10-05-3
Avoid Heating Near Pressurized Fluid Lines..........10-05-4
Service Machines Safely........................................10-05-4
Use Proper Tools....................................................10-05-4
Park Machine Safely..............................................10-05-5
Support Machine Properly......................................10-05-5
Use Proper Lifting Equipment................................10-05-5
Work in Clean Area................................................10-05-6
Protect Against High Pressure Spray.....................10-05-6
Illuminate Work Area Safely...................................10-05-6
Work In Ventilated Area.........................................10-05-7
Remove Paint Before Welding or Heating.............10-05-7
Avoid Harmful Asbestos Dust................................10-05-7
Service Tires Safely...............................................10-05-8
Stay Clear of Rotating Drivelines...........................10-05-9
Service Cooling System Safely..............................10-05-9
Decommissioning - Proper Recycling and Disposal
of Fluids and Components..............................
10-05-10
Handle Chemical Products Safely..........................10-05-10
Live With Safety.....................................................10-05-11
Group 10 - General Specifications
Service Recommendations for O-Ring Boss 10-10-1
Page
Fittings.............................................................
Service Recommendations For Flat Face O-Ring
Seal Fittings.....................................................
10-10-2
Metric Cap Screw Torque Values-Grade 7.............10-10-2
Metric Bolt and Screw Torque Values.....................10-10-3
Unified Inch Bolt and Screw Torque Values............10-10-5
Group 15 - Fuel, Lubricants, and Coolant
Diesel Fuel-North America.....................................10-15-1
Diesel Fuel-Europe.................................................10-15-1
Diesel Fuel Storage................................................10-15-2
4-Cycle Diesel Engine Oil-North America...............10-15-2
Diesel Engine Oil-Europe.......................................10-15-2
Hydrostatic Transmission and Hydraulic Oil...........10-15-3
Biodegradable Oil...................................................10-15-3
Converting From HY-GARD to BIO HY-GARD.......10-15-4
Grease - North America..........................................10-15-4
Grease - Europe.....................................................10-15-4
Alternative Lubricants.............................................10-15-4
Synthetic Lubricants...............................................10-15-4
Lubricant Storage...................................................10-15-5
Mixing of Lubricants................................................10-15-5
Oil Filters................................................................10-15-5
Operating in Warm Temperature Climates.............10-15-5
Diesel Engine Coolant (engine without wet sleeve
cylinder liners).................................................
10-15-6
John Deere COOL-GARD II Coolant Extender......10-15-7
Testing Diesel Engine Coolant................................10-15-7
Group 20 - Machine Specifications
Machine Specifications...........................................10-20-1
Product Identification Number Location..................10-20-1
TM121619 (27FEB21) 10-1 XUV855D S4 Gator Utility Vehicle

5. Group 05
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
Understand Signal Words
TS187-19: Signal Words
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 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.
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
Safety
TM121619 (27FEB21) 10-05-1 XUV855D S4 Gator Utility Vehicle

6. 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
Safety
TM121619 (27FEB21) 10-05-2 XUV855D S4 Gator Utility Vehicle

7. 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
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.
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.
Safety
TM121619 (27FEB21) 10-05-3 XUV855D S4 Gator Utility Vehicle

8. 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
[phone].
DX,FLUID-19-20111012
Avoid Heating Near Pressurized Fluid
Lines
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
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
Safety
TM121619 (27FEB21) 10-05-4 XUV855D S4 Gator Utility Vehicle

9. 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
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
Safety
TM121619 (27FEB21) 10-05-5 XUV855D S4 Gator Utility Vehicle

10. 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 with this
type of injury should reference a knowledgeable medical source.
Such information is available from Deere & Company Medical
Department in Moline, Illinois, U.S.A.
DX,SPRAY-19-19920416
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
Safety
TM121619 (27FEB21) 10-05-6 XUV855D S4 Gator Utility Vehicle

11. 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
Remove Paint Before Welding or Heating
TS220-UN: Toxic Fumes
Avoid potentially toxic fumes and dust.
Hazardous fumes can be generated when paint is heated by
welding, soldering, or using a torch.
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
TS220-UN: Asbestos Dust
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
brake pads, brake band and lining assemblies, clutch plates, and
some gaskets. The asbestos used in these components is usually
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
Safety
TM121619 (27FEB21) 10-05-7 XUV855D S4 Gator Utility Vehicle

12. 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.
When inflating tires, use a clip-on chuck and extension hose long
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
Safety
TM121619 (27FEB21) 10-05-8 XUV855D S4 Gator Utility Vehicle

13. Stay Clear of Rotating Drivelines
TS1644-UN: Rotating Drivelines
H96219-UN: Drivelines
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
tractor shaft to power a 540 rpm implement at speeds higher than
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.
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.) 21 85 mm (3.35 in.)
3 45 mm (1.772 in.) 20 100 mm (4.00 in.)
4 57.5 mm (2.264 in.) 22 100 mm (4.00 in.)
DX,PTO-19-20170228
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
Safety
TM121619 (27FEB21) 10-05-9 XUV855D S4 Gator Utility Vehicle

14. 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.
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
in other than specially designed incinerators may be
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
Handle Chemical Products Safely
TS1132-UN: Material Safety Data Sheet
Direct exposure to hazardous chemicals can cause serious injury.
Potentially hazardous chemicals used with John Deere equipment
include such items as lubricants, 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
Safety
TM121619 (27FEB21) 10-05-10 XUV855D S4 Gator Utility Vehicle

15. Live With Safety
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
Safety
TM121619 (27FEB21) 10-05-11 XUV855D S4 Gator Utility Vehicle

16. Group 10
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.
STUD END O-RING SEAL TORQUE FOR STRAIGHT AND ADJUST ABLE
FITTINGS*
Thread SizeStraight Hex SizeLocknut Hex SizeStraight Fitting or Locknut
Toque
Inch Inch Inch N·m lb-ft
3/8-24 5/8 9/16 18 13
7/16-20 5/8 5/8 24 18
1/2-20 3/4 11/16 30 22
9/16-18 3/4 3/4 37 27
3/4-16 7/8 15/16 75 55
7/8-14 1 1/16 1 1/16 104 76
1 1/16-12 1 1/4 1 3/8 176 130
1 3/16-12 1 3/8 1 1/2 230 170
1 5/16-12 1 1/2 1 5/8 270 199
*Torque tolerance is +15 -20% unless otherwise specified.
OUMX258,00000F8-19-20160120
General Specifications
TM121619 (27FEB21) 10-10-1 XUV855D S4 Gator Utility Vehicle

17. Service Recommendations For Flat Face
O-Ring Seal Fittings
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.
3.Index angle fittings and tighten by hand pressing joint together
to insure O-ring remains in place.
4.Unless specified otherwise, tighten fitting or nut (B) to torque
value shown on the chart. Do not allow hoses to twist when
tightening fittings, use backup wrench on straight hose
couplings.
FLAT FACE O-RING SEAL FITTING TORQUE*
Nominal Tube O.D. Thread Size Swivel Nut Bulkhead Nut
mm in in N·m lb-ftN·m lb-ft
6.35 0.250 9/16-18 24 18 32 24
9.52 0.375 11/16-16 37 27 42 31
12.70 0.500 13/16-16 63 46 93 69
15.88 0.625 1-14 103 76 118 87
19.05 0.750 1 3/16-12 152 112 175 129
22.22 0.875 1 3/16-12 152 112 175 129
25.40 1.000 1 7/16-12 214 158 247 182
31.75 1.250 1 11/16-12 286 211 328 242
38.10 1.500 2-12 326 240 374 276
*Torque tolerance is +15 -20% unless otherwise specified.
OUMX258,00000F9-19-20140812
Metric Cap Screw Torque Values—Grade
7
NOTE:
When bolting aluminum parts, tighten to 80% of torque
specified in table.
Size N˙m (lb-ft)
M6 9.5—12.2 (7—9)
M8 20.3—27.1 (15—20)
M10 47.5—54.2 (35—40)
M12 81.4—94.9 (60—70)
M14 128.8—146.4 (95—108)
M16 210.2—240 (155—177)
CED,OUO1085,12-19-20000731
General Specifications
TM121619 (27FEB21) 10-10-2 XUV855D S4 Gator Utility Vehicle

18. Metric Bolt and Screw Torque Values
TS1742-UN: Metric Bolt and Screw
Bolt or
Screw
Size
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Hex Head [Hex
head column
values are valid
for ISO 4014
and ISO 4017
hex head, ISO
4162 hex socket
head, and ISO
4032 hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014 and
ISO 4017 hex
head, ISO 4162
hex socket head,
and ISO 4032
hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014 and
ISO 4017 hex
head, ISO 4162
hex socket head,
and ISO 4032
hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014 and
ISO 4017 hex
head, ISO 4162
hex socket head,
and ISO 4032
hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in
M6 3.6 31.9 3.9 34.5 6.7 59.3 7.3 64.6 9.8 86.7 10.8 95.6 11.5 102 12.6 112
N·m lb·ft N·m lb·ft N·m lb·ft N·m lb·ft
M8 8.6 76.1 9.4 83.2 16.2 143 17.6 156 23.8 17.6 25.9 19.1 27.8 20.5 30.3 22.3
N·m lb·ft N·m lb·ft N·m lb·ft
M10 16.9 150 18.4 13.6 31.9 23.5 34.7 25.6 46.8 34.5 51 37.6 55 40.6 60 44.3
N·m lb·ft
M12 — — — — 55 40.6 61 45 81 59.7 89 65.6 95 70.1 105 77.4
M14 — — — — 87 64.2 96 70.8 128 94.4 141 104 150 111 165 122
M16 — — — — 135 99.6 149 110 198 146 219 162 232 171 257 190
M18 — — — — 193 142 214 158 275 203 304 224 322 245 356 263
M20 — — — — 272 201 301 222 387 285 428 316 453 334 501 370
M22 — — — — 365 263 405 299 520 384 576 425 608 448 674 497
M24 — — — — 468 345 518 382 666 491 738 544 780 575 864 637
M27 — — — — 683 504 758 559 973 718 1080 797 1139 840 1263 932
M30 — — — — 932 687 1029 759 1327 979 1466 1081 1553 1145 1715 1265
M33 — — — — 1258 928 1398 1031 1788 1319 1986 1465 2092 1543 2324 1714
M36 — — — — 1617 1193 1789 1319 2303 1699 2548 1879 2695 1988 2982 2199
The nominal torque values listed are for general use only with the assumed wrenching
accuracy of 20%, such as a manual torque wrench.
DO NOT use these values if a different torque value or tightening procedure is given for a
specific application.
For lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening
instructions for the specific application.
Replace fasteners with the same or higher property class. If higher property class
fasteners are used, tighten these to the strength of the original.
Make sure that fastener threads are clean.
Apply a thin coat of Hy-Gard™ or equivalent oil under the head and on the threads of the fastener, as shown in the
following image.
Be conservative with the amount of oil to reduce the potential for hydraulic lockup in blind holes due to excessive
oil.
Properly start thread engagement.
General Specifications
TM121619 (27FEB21) 10-10-3 XUV855D S4 Gator Utility Vehicle

19. Bolt or
Screw
Size
Class 4.8 Class 8.8 or 9.8 Class 10.9 Class 12.9
Hex Head [Hex
head column
values are valid
for ISO 4014
and ISO 4017
hex head, ISO
4162 hex socket
head, and ISO
4032 hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014 and
ISO 4017 hex
head, ISO 4162
hex socket head,
and ISO 4032
hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014 and
ISO 4017 hex
head, ISO 4162
hex socket head,
and ISO 4032
hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014 and
ISO 4017 hex
head, ISO 4162
hex socket head,
and ISO 4032
hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
TS1741-UN: Lubricant Locations
DX,TORQ2-19-20180530
General Specifications
TM121619 (27FEB21) 10-10-4 XUV855D S4 Gator Utility Vehicle

20. Unified Inch Bolt and Screw Torque Values
TS1671-UN: Unified Inch Bolt and Screw
Bolt or
Screw
Size
SAE Grade 1 [Grade 1 applies for hex
cap screws over 6 in (152 mm) long,
and for all other types of bolts and
screws of any length.]
SAE Grade 2 [Grade 2 applies for hex
cap screws (not hex bolts) up to 6 in
(152 mm) long.]
SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
Hex Head [Hex
head column
values are valid
for ISO 4014
and ISO 4017
hex head, ISO
4162 hex socket
head, and ISO
4032 hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014
and ISO 4017
hex head, ISO
4162 hex socket
head, and ISO
4032 hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014 and
ISO 4017 hex
head, ISO 4162
hex socket head,
and ISO 4032
hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014 and
ISO 4017 hex
head, ISO 4162
hex socket head,
and ISO 4032
hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in N·m lb·in
1/4 3.1 27.3 3.2 28.4 5.1 45.5 5.3 47.3 7.9 70.2 8.3 73.1 11.2 99.2 11.6 103
N·m lb·ft N·m lb·ft
5/166.1 54.1 6.5 57.7 10.290.2 10.9 96.2 15.7 139 16.8 149 22.2 16.4 23.7 17.5
N·m lb·ft N·m lb·ft
3/810.593.6 11.5 102 17.6 156 19.2 170 27.3 20.1 29.7 21.9 38.5 28.4 41.9 30.9
N·m lb·ft N·m lb·ft
7/1616.7 148 18.4 163 27.820.5 30.6 22.6 43 31.7 47.3 34.9 60.6 44.7 66.8 49.3
N·m lb·ft N·m lb·ft
1/225.919.1 28.2 20.8 43.131.8 47 34.7 66.6 49.1 72.8 53.7 94 69.3 103 75.8
9/1636.727.1 40.5 29.9 61.145.1 67.5 49.8 94.6 69.8 104 77 134 98.5 148 109
5/8 51 37.6 55.9 41.2 85 62.7 93.1 68.7 131 96.9 144 106 186 137 203 150
3/489.5 66 98 72.3 149 110 164 121 230 170 252 186 325 240 357 263
7/8144 106 157 116 144 106 157 116 370 273 405 299 522 385 572 422
1 216 159 236 174 216 159 236 174 556 410 609 449 785 579 860 634
1-1/8305 225 335 247 305 225 335 247 685 505 751 554 1110 819 1218 898
1-1/4427 315 469 346 427 315 469 346 957 706 1051 775 1552 1145 1703 1256
1-3/8564 416 618 456 564 416 618 456 1264 932 1386 1022 2050 1512 2248 1658
1-1/2743 548 815 601 743 548 815 601 1665 1228 1826 1347 2699 1991 2962 2185
The nominal torque values listed are for general use only with the assumed wrenching
accuracy of 20%, such as a manual torque wrench.
DO NOT use these values if a different torque value or tightening procedure is given for a
specific application.
For lock nuts, for stainless steel fasteners, or for nuts on U-bolts, see the tightening
instructions for the specific application.
Replace fasteners with the same or higher property class. If higher property class
fasteners are used, tighten these to the strength of the original.
Make sure that fastener threads are clean.
Apply a thin coat of Hy-Gard™ or equivalent oil under the head and on the threads of the fastener, as shown in the
following image.
Be conservative with the amount of oil to reduce the potential for hydraulic lockup in blind holes due to excessive
oil.
Properly start thread engagement.
General Specifications
TM121619 (27FEB21) 10-10-5 XUV855D S4 Gator Utility Vehicle

21. Bolt or
Screw
Size
SAE Grade 1 [Grade 1 applies for hex
cap screws over 6 in (152 mm) long,
and for all other types of bolts and
screws of any length.]
SAE Grade 2 [Grade 2 applies for hex
cap screws (not hex bolts) up to 6 in
(152 mm) long.]
SAE Grade 5, 5.1 or 5.2 SAE Grade 8 or 8.2
Hex Head [Hex
head column
values are valid
for ISO 4014
and ISO 4017
hex head, ISO
4162 hex socket
head, and ISO
4032 hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014
and ISO 4017
hex head, ISO
4162 hex socket
head, and ISO
4032 hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014 and
ISO 4017 hex
head, ISO 4162
hex socket head,
and ISO 4032
hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
Hex Head [Hex
head column
values are valid
for ISO 4014 and
ISO 4017 hex
head, ISO 4162
hex socket head,
and ISO 4032
hex nuts.]
Flange Head [Hex
flange column values
are valid for
ASMEB18.2.3.9M,
ISO4161, or EN1665
hex flange products.]
TS1741-UN: Lubricant Locations
DX,TORQ1-19-20180530
General Specifications
TM121619 (27FEB21) 10-10-6 XUV855D S4 Gator Utility Vehicle

22. Group 15
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:
Cetane number of 45 minimum.Cetane number greater than 50
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.
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.
Sulfur content
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.
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
Diesel Fuel—Europe
In general, diesel fuels are blended to satisfy the low air
temperature requirements of the geographical area in which they
are sold.
In Europe, diesel fuel is usually specified toEN590and sold in five
different classes or six different grades.
If diesel fuels being supplied in your area DO NOT meet any of the
above specifications, use diesel fuels with the following equivalent
properties:
Cetane Number 40 (Min)
A cetane number greater than 50 is preferred, especially for air
temperatures below -20°C (-4°F) or elevations above 1500 m
(5000 ft).
Cold Filter Plugging Point (CFPP)
The temperature at which diesel fuel begins to cloud or jell. Use
diesel fuels with a CFPP which is at least 5°C (9°F) below the
expected low air temperature.
Sulfur Content of 0.05% (Max)
If diesel fuel being used has a sulfur content greater than 0.05%,
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
Fuel, Lubricants, and Coolant
TM121619 (27FEB21) 10-15-1 XUV855D S4 Gator Utility Vehicle

23. Diesel Fuel Storage
IMPORTANT:
Avoid Damage! DO NOT USE GAL VANIZED
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.
It is recommended that diesel fuel be stored ONLY in a clean,
approved POLYETHYLENE PLASTIC container WITHOUT any
metal screen or filter. This will help prevent any accidental sparks
from occurring. Store fuel in an area that is well ventilated to
prevent possible igniting of fumes by an open flame or spark; this
includes any appliance with a pilot light.
IMPORTANT:
Avoid Damage! Keep all dirt, scale, water, or other foreign
material out of fuel.
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 separator be
installed in the storage tank outlet. BE SURE to properly discard
unstable or contaminated diesel fuel and/or their containers when
necessary.
OUO1086,1000403-19-20120615
4-Cycle Diesel Engine Oil—North America
Use the appropriate oil viscosity based on the expected air
temperature range during the period between recommended oil
changes. Operating outside of these recommended oil air
temperature ranges may cause premature engine failure.
The following John Deere oils are PREFERRED:
TCAL25967-UN: North American Engine Oil
PLUS-50Plus-50™
TORQ-GARD SUPREME Torq-Gard Supreme™
Other oils may be used if above John Deere oils are not available,
provided they meet one of the following specifications:
API Service Classifications CF or higher
Other oils may be used if above John Deere oils are not available,
provided they meet one of the following specifications:
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
Diesel Engine Oil—Europe
Use oil viscosity based on the expected air temperature range
during the period between oil changes.
The following John Deere oils are PREFERRED:
TCAL25968-UN: European Engine Oil
TORQ-GARD SUPREME®- SAE 15W -40.
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.
Other oils may be used if above John Deere oils are not available,
provided they meet the following specification:
CCMC Specification D4 or Mercedes Benz MB228.1
or higher.
OUO1086,1000405-19-20140612
Fuel, Lubricants, and Coolant
TM121619 (27FEB21) 10-15-2 XUV855D S4 Gator Utility Vehicle

24. Hydrostatic Transmission and Hydraulic
Oil
IMPORTANT:
Avoid Damage! Machine is filled with John Deere HY-GARD
Hy-Gard™ . (J20C) Transmission/Hydraulic Oil at the factory.
DO NOT mix oils. DO NOT use type ‘F” automatic transmission
fluid or J20D Low Viscosity HY-GARD.
TCAL30142-UN: Hydrostatic Hydraulic Oil
Use oil viscosity based on the expected air temperature range
during the period between oil changes.
John Deere J20C HY -GARD Transmission/Hydraulic Oil is
recommended. John Deere J20D Low V iscosity HY-GARD
Transmission/Hydraulic Oil may also be used.
Use John Deere BIO HY-GARD™ oil when a biodegradable fluid is
required.
Other oils may be used if above recommended John Deere oil is
not available, provided they meet the following specification:
John Deere Standard JDM J20C or J20D.
Hy-Gard is a trademark of Deere & Company
OUO1086,1000406-19-20120615
Biodegradable Oil
Application
IMPORTANT:
Avoid Damage! Biodegradable oils, other than BIO HY-GARD
Hy-Gard™ , are not recommended.
When use of a biodegradable lubricant is desired or required, BIO
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.
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.
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
subjected to the following temperatures:
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
OUO1086,1000407-19-20120615
Fuel, Lubricants, and Coolant
TM121619 (27FEB21) 10-15-3 XUV855D S4 Gator Utility Vehicle

25. Converting From HY-GARD to BIO HY-
GARD
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.
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.
OUO1086,1000408-19-20120615
Grease - North America
IMPORTANT:
Avoid Damage! ONLY use a quality grease in this application.
DO NOT mix any other greases in this application. DO NOT use
any BIOGREASE in this application.
The following John Deere greases are preferred for the machine
and lift arms:
John Deere Special Purpose HD Water Resistant
Grease.
John Deere Multi-Purpose HD Lithium Complex
Grease.
The following John Deere greases are preferred for the cutting
units and unit attachments:
John Deere Golf and Turf Cutting Unit Grease.
John Deere Cornhead Grease.
John Deere Cotton Picker Spindle Grease.
Other greases may be used if above preferred John Deere greases
are not available, provided they meet the following specifications:
Polyurea Grease - NLGI Grade 2.
Calcium Complex Grease - NLGI Grade 2.
John Deere Standard JDM J13E4 - NLGI Grade 2.
OUO1086,1000409-19-20120615
Grease - Europe
Use the following grease based on the air temperature range.
Operating outside of the recommended grease air temperature
range may cause premature failures.
IMPORTANT:
Avoid Damage! ONLY use a quality grease in this application.
DO NOT mix any other greases in this application. DO NOT use
any BIOGREASE in this application.
The following John Deere greases are PREFERRED:
GREASE-GARD™ - JDM J13E4, NLGI Grade 2.
Reel Support Grease - JDM J13E6, NLGI Grade 0.
Other greases may be used if above preferred John Deere greases
are not available, provided they meet the following specifications:
Reel Support Grease Applications:
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
Alternative Lubricants
Use of alternative lubricants could cause reduced life of the
component.
If alternative lubricants are to be used, it is recommended that
the factory fill be thoroughly removed before switching to any
alternative lubricant.
OUO1086,100040B-19-20120615
Synthetic Lubricants
Synthetic lubricants may be used in John Deere equipment if
they meet the applicable performance requirements (industry
classification and/or military specification) as shown in this manual.
The recommended air temperature limits and service or lubricant
change intervals should be maintained as shown in the operator’s
manual, unless otherwise stated on lubricant label.
Avoid mixing different brands, grades, or types of oil. Oil
manufacturers blend additives in their oils to meet certain
specifications and performance requirements. Mixing different oils
can interfere with the proper functioning of these additives and
degrade lubricant performance.
OUO1086,100040C-19-20120615
Fuel, Lubricants, and Coolant
TM121619 (27FEB21) 10-15-4 XUV855D S4 Gator Utility Vehicle

26. Lubricant Storage
All machines operate at top efficiency only when clean lubricants
are used. Use clean storage containers to handle all lubricants.
Store them in an area protected from dust, moisture, and other
contamination. Store drums on their sides. Make sure all
containers are properly marked as to their contents. Dispose of all
old, used containers and their contents properly.
OUO1086,100040D-19-20120615
Mixing of Lubricants
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
lubricants can interfere with the proper functioning of these
additives and lubricant properties which will downgrade their
intended specified performance.
OUO1086,100040E-19-20120615
Oil Filters
IMPORTANT:
Avoid Damage! Filtration of oils is critical to proper lubrication
performance. Always change filters regularly.
The following John Deere oil filters are PREFERRED:
Automotive and light truck engine oil filters.
Most John Deere filters contain pressure relief and anti-drainback
valves for better engine protection.
Other oil filters may be used if above recommended John Deere
oil filters are not available, provided they meet the following
specification:
ASTB Tested In Accordance With SAE J806.
OUO1086,100040F-19-20120615
Operating in Warm Temperature Climates
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.
IMPORTANT:
Water may be used as coolantin emergency situations only.
Foaming, hot surface aluminum and iron corrosion, scaling,
and cavitation occur when water is used as the coolant, even
when coolant conditioners are added.
Drain cooling system and refill with recommended engine
coolant as soon as possible.
DX,COOL6-19-20200217
Fuel, Lubricants, and Coolant
TM121619 (27FEB21) 10-15-5 XUV855D S4 Gator Utility Vehicle

27. Diesel Engine Coolant (engine without
wet sleeve cylinder liners)
Failure to follow applicable coolant standards and drain intervals
can result in severe engine damage that may not be covered
under warranty. Warranties including the emissions warranty are
not conditioned on the use of John Deere coolants, parts, or
service.
Preferred Coolants
The following pre-mix engine coolants are preferred:
John Deere COOL-GARD ™II
John Deere COOL-GARD II PG
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 0°C (32°F)
COOL-GARD II 20/80 -9°C (16°F)
COOL-GARD II 30/70 -16°C (3°F)
COOL-GARD II 50/50 -37°C (-34°F)
COOL-GARD II 55/45 -45°C (-49°F)
COOL-GARD II PG 60/40 -49°C (-56°F)
COOL-GARD II 60/40 -52°C (-62°F)
Not all COOL-GARD II pre-mix products are available in all
countries.
Use COOL-GARD II PG when a non-toxic coolant formulation is
required.
Additional Recommended Coolants
The following engine coolant is also recommended:
John Deere COOL-GARD II Concentrate in a
40—60% mixture of concentrate with quality water.
IMPORTANT:
When mixing coolant concentrate with water, do not use less
than 40% or greater than 60% concentration of coolant. Less
than 40% gives inadequate additives for corrosion protection.
Greater than 60% can result in coolant gelation and cooling
system problems.
Other Coolants
Other ethylene glycol or propylene glycol base coolants may be
used if they meet one of the following specifications:
Pre-mix coolant meeting ASTM D6210 requirements
Are nitrite-free
Is formulated with a 2-ethylhexanoic acid (2-EHA) free
additive package
Coolant concentrate meeting ASTM D6210
requirements in a 40—60% mixture of concentrate
with quality water intended for a 50/50 concentrate
Pre-mix coolant meeting ASTM D3306 requirements
Coolant concentrate meeting ASTM D3306
requirements in a 40—60% mixture of concentrate
with quality water intended for a 50/50 concentrate
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
Is formulated with a 2-ethylhexanoic acid (2-EHA) 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. Deionized or demineralized water is recommended for
mixing with ethylene glycol and propylene glycol base engine
coolant concentrate.
Coolant Drain Intervals
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
interval is 6 years or 6000 hours of operation.
If a coolant other than COOL-GARD II or COOL-GARD II PG
is used, reduce the drain interval to 2 years or 2000 hours of
operation. [Coolant analysis may extend the service interval of
other "Coolants" to a maximum not to exceed the interval of Cool-
Gard II coolants. Coolant analysis means taking a series of coolant
samples at 1000-hour increments beyond the normal service
interval until either the data indicate the end of useful coolant life or
the maximum service interval of Cool-Gard coolants is reached.]
IMPORTANT:
Do not use cooling system sealing additives or antifreeze that
contains sealing additives.
Do not mix ethylene glycol and propylene glycol base
coolants.
Do not use coolants that contain nitrites.
COOL-GARD is a trademark of Deere & Company
DX,COOL18-19-20200715
Fuel, Lubricants, and Coolant
TM121619 (27FEB21) 10-15-6 XUV855D S4 Gator Utility Vehicle

28. 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.
COOL-GARD II Coolant Extender is a chemically matched additive
system for use with all COOL-GARD II coolants. COOL-GARD
II Coolant Extender is not intended for use with nitrite-containing
coolants.
IMPORTANT:
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
The use of non-recommended supplemental coolant additives can
result in additive drop-out, gelation of the coolant, or corrosion of
cooling system components.
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
Testing Diesel Engine Coolant
Maintaining adequate concentrations of glycol and inhibiting
additives in the coolant is critical to protect the engine and cooling
system against freezing, corrosion, and cylinder liner erosion and
pitting.
Test the coolant solution at intervals of 12 months or less and
whenever excessive coolant is lost through leaks or overheating.
Coolant Test Strips
Coolant test strips are available from your John Deere dealer.
These test strips provide a simple, effective method to check the
freeze point and additive levels of your engine coolant.
When Using John Deere COOL-GARD II
John Deere COOL-GARD II Premix™ , COOL-GARD II PG Premix
and COOL-GARD II Concentrate are maintenance free coolants
for up to six years or 6000 hours of operation, provided that the
cooling system is topped off using only John Deere COOL-GARD
II Premix or COOL-GARD II PG premix. Test the coolant condition
annually with coolant test strips designed for use with John Deere
COOL-GARD II coolants. If the test strip chart indicates that
additive is required, add John Deere COOL-GARD II Coolant
Extender as directed.
Add only the recommended concentration of John Deere COOL-
GARD II Coolant Extender. DO NOT add more than the
recommended amount.
When Using Nitrite-Containing Coolants
Compare the test strip results to the supplemental coolant additive
(SCA) chart to determine the amount of inhibiting additives in your
coolant and whether more John Deere Liquid Coolant Conditioner
should be added.
Add only the recommended concentration of John Deere Liquid
Coolant Conditioner. DO NOT add more than the recommended
amount.
Coolant Analysis
For a more thorough evaluation of your coolant, perform a coolant
analysis. The coolant analysis can provide critical data such as
freezing point, antifreeze level, pH, alkalinity, nitrite content
(cavitation control additive), molybdate content (rust inhibitor
additive), silicate content, corrosion metals, and visual
assessment.
Contact your John Deere dealer for more information on coolant
analysis.
COOL-GARD is a trademark of Deere & Company
DX,COOL9-19-20110411
Fuel, Lubricants, and Coolant
TM121619 (27FEB21) 10-15-7 XUV855D S4 Gator Utility Vehicle

29. Group 20
Machine Specifications
Machine Specifications
NOTE:
Specifications and design subject to change without notice.
XUV855D S4
Ground Speed:
Forward - Range LO 0—24 km/h (0—15 mph)
Forward - Range HI 0—51 km/h (0—32 mph)
Reverse 0—27 km/h (0—17 mph)
Engine:
Make Yanmar
Engine Power Information
Type Diesel
Model 3TNV70
Slow Idle Speed 650—800 rpm
Slow Idle Speed (Governed) 1050 ± 25 rpm
Fast Idle Speed 3840 ± 25 rpm
Cylinders 3
Displacement 0.854 L (52.11 in.
3
)
Bore 70 mm (2.76 in.)
Stroke 74 mm (2.91 in.)
Injection Indirect
Cooling Liquid Cooled
Air Cleaner Dry Type Elements
Engine Shut Off Key Switch
Fuel System:
Type Mechanical Pump
Electrical System:
Type 12 Volt Negative Ground
Alternator 55 amp
Battery 12-volt
Cold Cranking Amps 480
Steering:
Type..............Rack and Pinion
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 Bumper..............2.92 m (115 in.)
Overall Width..............1.45 m (57 in.)
Ground Clearance..............26.2 cm (10.3 in.)
OUMX068,0000030-19-20160420
Product Identification Number Location
MXT008446-UN: Machine Product Identification Number Location
The product identification number (A) is located on the right-hand
side frame.
MXT005680-UN: Engine Serial Number Location
The engine identification number (B) is located on the engine valve
cover.
OUMX068,0000035-19-20141106
Machine Specifications
TM121619 (27FEB21) 10-20-1 XUV855D S4 Gator Utility Vehicle

30. Section 20
Engine Repair
Contents
Page
Group 05 - Engine
Summary of References........................................20-05-1
Specifications.........................................................20-05-2
Remove and Install Engine....................................20-05-5
Remove and Install Muffler....................................20-05-9
Remove and Install Exhaust Manifold....................20-05-10
Remove and Install Rocker Arm Cover..................20-05-11
Remove and Install Rocker Arm and Push Rods...20-05-13
Remove and Install Cylinder Head.........................20-05-16
Recondition Cylinder Head....................................20-05-18
Remove and Install Rear Crankshaft Oil Seal........20-05-25
Remove and Install Front Crankshaft Oil Seal.......20-05-27
Remove and Install Timing Gear Cover.................20-05-28
Check Camshaft End Play.....................................20-05-29
Check Timing Gear Backlash.................................20-05-29
Remove and Install Idler Gear...............................20-05-31
Remove and Install Cam Followers.......................20-05-32
Remove and Install Camshaft................................20-05-33
Remove and Install Oil Pan and Strainer...............20-05-36
Check Connecting Rod Side Play..........................20-05-37
Check Crankshaft End Play...................................20-05-37
Check Connecting Rod Bearing Clearance...........20-05-39
Check Crankshaft Main Bearing Clearance...........20-05-40
Remove, Inspect, and Install Connecting Rod.......20-05-41
Disassemble and Assemble Pistons......................20-05-44
Cylinder Bore.........................................................20-05-49
Remove and Install Crankshaft and Main
Bearings..........................................................
20-05-51
Remove and Install Flywheel.................................20-05-54
Remove and Install Flywheel Plate........................20-05-55
Remove and Install Timing Gear Housing.............20-05-56
Remove and Install Oil Pump.................................20-05-57
Remove and Install Coolant Temperature Switch..20-05-58
Remove and Install Thermostat.............................20-05-60
Remove and Install Water Pump...........................20-05-61
Remove and Install Fuel Filter...............................20-05-61
Remove and Install Fuel Filter Assembly...............20-05-62
Remove and Install Fuel Transfer Pump................20-05-64
Remove and Install Fuel Injection Nozzle..............20-05-65
Remove and Install Fuel Injection Pump................20-05-69
Remove and Install Fuel Control and Governor
Linkage...........................................................
20-05-72
Remove and Install Fuel Shutoff Solenoid.............20-05-73
Repair Starting Motor.............................................20-05-74
Repair Alternator....................................................20-05-78
TM121619 (27FEB21) 20-1 XUV855D S4 Gator Utility Vehicle

31. Group 05
Engine
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 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
OUMX068,0000111-19-20121029
Engine
TM121619 (27FEB21) 20-05-1 XUV855D S4 Gator Utility Vehicle

32. Specifications
Item MeasurementSpecification
Engine Mount Shoulder Bolt Torque
24 N·m
(18 lb.-ft.)
Rear Engine Mounting Isolator to Carrier BoltTorque
170 N·m
(125 lb.-ft.)
Front Engine Mounting Isolator to Carrier NutTorque
108 N·m
(80 lb.-ft.)
Engine Bracket Cap Screws Torque
73 N·m
(54 lb.-ft.)
Engine Mount to Engine Bolts Torque
73 N·m
(54 lb.-ft.)
Engine Rear Isolator Bolts Torque
24 N·m
(18 lb.-ft.)
Plate to Engine Back Plate Bolts Torque
73 N·m
(54 lb.-ft.)
Transaxle Side Plates to Engine Mount BoltsTorque
73 N·m
(54 lb.-ft.)
Engine Oil Capacity
2.6 L
(2.75 qt)
Muffler Mounting Nuts Torque
28 N·m
(248 lb.-in.)
Exhaust Manifold to Cylinder Head Cap ScrewTorque
28 N·m
(248 lb.-in.)
Rocker Arm Cover Bolt Torque
11 N·m
(97 lb.-in.)
Rocker Arm Shaft–Standard OD
11.97–11.98 mm
(0.471–0.472 in.)
Rocker Arm Shaft–Wear Limit OD
11.95 mm
(0.470 in.)
Rocker Arm Shaft/Support–Standard ID
12.00–12.02 mm
(0.472–0.473 in.)
Rocker Arm Shaft/Support–Wear Limit ID
12.09 mm
(0.476 in.)
Rocker Arm Shaft/Support Clearance
0.02–0.05 mm
(0.001–0.002 in.)
Rocker Arm Shaft/Support–Wear Limit Clearance
0.13 mm
(0.005 in.)
Push Rod Bend Distance
0–0.03 mm
(0.0–0.001 in.)
Rocker Arm Support Bolt Torque
26 N·m
(230 lb.-in.)
Cylinder Head Bolt–First Pass Torque
27 N·m
(20 lb.-ft.)
Cylinder Head Bolt–Final Pass Torque
54–58 N·m
(40–43 lb.-ft.)
Cylinder Head Distortion–Standard Out-of-Flat
0.05 mm (0.002 in.)
or less
Cylinder Head Distortion–Wear Limit Out-of-Flat
0.15 mm
(0.006 in.)
Intake Valve Seat Width
1.028–1.202 mm
(0.041–0.047 in.)
Exhaust Valve Seat Width
1.308–1.52 mm
(0.051–0.060 in.)
Valve Face Margin–Intake Distance
0.9–1.1 mm
(0.035–0.043 in.)
Valve Face Margin–Exhaust Distance
1.0–1.2 mm
(0.039–0.047 in.)
Valve Face Margin–Wear Limit (Intake and
Exhaust)
Distance
0.51 mm
(0.020 in.)
Valve Face Angle–Intake Angle 30°
Valve Face Angle–Exhaust Angle 45°
Valve Stem–Intake Diameter
5.96–5.98 mm
(0.234–0.235 in.)
Valve Stem–Exhaust Diameter
5.95–5.96 mm
(0.234–0.235 in.)
Valve Stem (Intake and Exhaust)–Wear Limit Diameter
5.90 mm
(0.232 in.)
Valve Recession (Intake and Exhaust) Distance
0.40–0.60 mm
(0.016–0.024 in.)
Valve Recession (Intake)–Wear Limit Distance
0.9 mm
(0.035 in.)
Valve Recession (Exhaust)–Wear Limit Distance
0.8 mm
(0.03 in.)
Valve Guide ID–Standard ID
6.0–6.01 mm
(0.236–0.237 in.)
Valve Guide ID–Wear Limit ID
6.08 mm
(0.239 in.)
Valve Guide-to-Valve Stem (Intake and
Exhaust)–Knurling Range
Clearance
0.15–0.17 mm
(0.006–0.007 in.)
Valve Guide-to-Valve Stem Oil Clearance:
Intake
0.03–0.05 mm
(0.001–0.002 in.)
Exhaust
0.04–0.07 mm
(0.002–0.003 in.)
Item MeasurementSpecification
Valve Guide-to-Valve Stem (Intake and
Exhaust)–Wear Limit
Clearance
0.17 mm
(0.007 in.)
Valve Guide Height Height
9.8–10 mm
(0.386–0.394 in.)
Valve Spring Free Length (C) Length
37.8 mm
(1.488 in.)
Maximum Spring Inclination (B) Distance
1.3 mm
(0.051 in.)
Lower Valve Seat Surface Angle 70°
Upper Valve Seat Surface Angle 15°
Seal Case-to-Block Cap Screws Torque
11 N·m
(97 lb.-in.)
Seal Case to Oil Pan Spacer Cap Screws Torque
9 N·m
(80 lb.-in.)
Flywheel Bolts Torque
83 N·m
(61 lb.-ft.)
Stub Shaft-to-Flywheel Cap Screws Torque
59 N·m
(44 lb.-ft.)
Clutch Mounting Cap Screw Torque
67.8 N·m
(50 lb.-ft.)
Crankshaft Pulley Cap Screw Torque
113–123 N·m
(83–90 lb.-ft.)
Timing Cover Cap Screws Torque
9 N·m
(80 lb.-in.)
Camshaft End Play
0.05–0.15 mm
(0.002–0.006 in.)
Backlash
0.06–0.12 mm
(0.002–0.005 in.)
Timing Gear (All)–Wear Limit Backlash
0.14 mm
(0.006 in.)
Idler Gear Shaft–Standard Diameter
36.95–36.98 mm
(1.455–1.456 in.)
Idler Gear Shaft–Wear Limit Diameter
36.90 mm
(1.452 in.)
Idler Gear Bushing–Standard ID
37.0–37.025 mm
(1.4567 –1.4577 in.)
Idler Gear Bushing Oil Clearance
0.03–0.08 mm
(0.001–0.003 in.)
Idler Gear Bushing Oil–Wear Limit Clearance
0.18 mm
(0.007 in.)
Cam Follower–Standard Diameter
20.93–20.96 mm
(0.824–0.825 in.)
Cam Follower–Wear Limit Diameter
20.90 mm
(0.823 in.)
Cam Follower Bore–Standard Diameter
21.00–21.02 mm
(0.827–0.828 in.)
Cam Follower Bore–Wear Limit Diameter
21.04 mm
(0.828 in.)
Cam Follower-to-Bore–Wear Limit Clearance
0.13 mm
(0.005 in.)
Cam Follower-to-Bore–Standard Clearance
0.04–0.09 mm
(0.002–0.004 in.)
Camshaft Cap Screws Torque
11 N·m
(97 lb.-in.)
Camshaft Side Gap Gap
0.05–0.15 mm
(0.002–0.006 in.)
Camshaft Bend–Standard Deflection
0.00–0.02 mm
(0.00–0.001 in.)
Camshaft Bend–Wear Limit Deflection
0.05 mm
(0.002 in.)
Camshaft Lobe–Standard Height
34.14–34.27 mm
(1.343–1.349 in.)
Camshaft Lobe–Wear Limit Height
33.89 mm
(1.334 in.)
Camshaft Gear Side and Flywheel End
Journals–Standard
Diameter
39.94–35.96 mm
(1.572–1.573 in.)
Camshaft Gear Side and Flywheel End
Journals–Wear Limit
Diameter
39.91 mm
(1.571 in.)
Camshaft Intermediate Journal OD–Standard Diameter
39.91–39.94 mm
(1.571–1.572 in.)
Camshaft Intermediate Journal OD–Wear LimitDiameter
39.88 mm
(1.569 in.)
Camshaft Bushing–Standard Diameter
40.0–40.08 mm
(1.575–1.578 in.)
Camshaft Bushing–Wear Limit Diameter
40.15 mm
(1.580 in.)
Camshaft Bushing-to-Camshaft Clearance
0.04–0.14 mm
(0.002–0.005 in.)
Camshaft Intermediate Bore ID’s:
Standard
40.0–40.03 mm
(1.575–1.576 in.)
Wear Limit
40.1 mm
(1.579 in.)
Oil Clearance
0.07–0.12 mm
(0.003–0.005 in.)
Camshaft Flywheel-End Bore ID’s:
Engine
TM121619 (27FEB21) 20-05-2 XUV855D S4 Gator Utility Vehicle

33. Item MeasurementSpecification
Standard
40.0 –40.03 mm
(1.575–1.576 in.)
Wear Limit
40.1 mm
(1.579 in.)
Oil Clearance
0.04–0.09 mm
(0.002–0.003 in.)
Oil Strainer to-Block Cap Screws Torque
11 N·m
(97 lb.-in.)
Oil Pan-to-Engine Cap Screws Torque
25 N·m
(221 lb.-in.)
Oil Pan-to-Timing Gear Housing Cap Screws Torque
20 N·m
(177 lb.-in.)
Connecting Rod
Connecting Rod Cap Screw Torque
22.6–27.5 N·m
(16.6–20.2 lb.-ft.)
Connecting Rod Bearing–Standard Diameter
37.982–38.10 mm
(1.495–1.496 in.)
Connecting Rod Bearing Thickness
1.50–1.51 mm
(0.059 in.)
Connecting Rod Bearing–Standard Clearance
0.02–0.06 mm
(0.001–0.002 in.)
Connecting Rod Bearing–Wear Limit Clearance
0.11 mm
(0.004 in.)
Connecting Rod Diameter
41.000–41.018 mm
(1.614—1.615 in.)
Connecting Rod Side Play Clearance
0.20–0.40 mm
(0.008–0.016 in.)
Connecting Rod Cap Bolts Torque
22.6–27.5 mm
(16.6–20.2 lb.-ft.)
Connecting Rod-to-Crankshaft–Standard Clearance
0.02–0.06 mm
(0.001–0.002 in.)
Connecting Rod-to-Crankshaft–Wear Limit Clearance
0.11 mm
(0.004 in.)
Crankshaft
Crankshaft Pulley Cap Screw Torque
113–123 N·m
(83–90 lb.-ft.)
Crankshaft End Play
0.11–0.25 mm
(0.004–0.010 in.)
Main Bearing Cap Screws (Oil Applied) Torque
75.5–81.5 N·m
(56–60 lb.-ft.)
Crankshaft Main Bearing–Standard Clearance
0.02–0.05 mm
(0.001–0.002 in.)
Crankshaft Main Bearing–Wear Limit Clearance
0.12 mm
(0.005 in.)
Main Bearing Cap Screws Torque
75.5–81.5 N·m
(55.6–60 lb.-ft.)
Crankshaft
Radial
Runout
0.02 mm
(0.001 in.)
Crankshaft Connecting Rod Journal–Standard OD
37.962–37.952 mm
(1.652 in.)
Crankshaft Main Bearing Journal–Standard OD
43.970–43.980 mm
(1.731–1.732 in.)
Crankshaft Main Bearing Journal–Wear Limit OD
46.90 mm
(1.846 in.)
Main Bearing –Standard ID
43.98–44.00 mm
(1.731–1.732 in.)
Main Bearing Thickness
2.01 mm
(0.079 in.)
Main Bearing Oil Clearance Clearance
0.02–0.05 mm
(0.001–0.002 in.)
Main Bearing Oil Clearance–Wear Limit Clearance
0.12 mm
(0.005)
Seal Case-to-Block Cap Screws Torque
11 N·m
(97 lb.-in.)
Piston Ring Groove Clearance:
Top Ring–Standard Clearance
0.06–0.10 mm
(0.002–0.004 in.)
Top Ring–Wear Limit Clearance
0.20 mm
(0.0079 in.)
Second Ring–Standard Clearance
0.05 - 0.09 mm
(0.002 - 0.0035 in.)
Second Ring–Wear Limit Clearance
0.20 mm
(0.008 in.)
Oil Ring–Standard Clearance
0.02–0.06 mm
(0.001–0.002 in.)
Standard Piston Ring End Gap:
First Compression Ring–Standard Gap
0.15–0.30 mm
(0.006–0.012 in.)
First Compression Ring–Wear Limit Gap
0.39 mm
(0.015 in.)
Second Compression Ring–Standard Gap
0.18–0.33 mm
(0.007–0.013 in.)
Second Compression Ring–Wear Limit Gap
0.42 mm
(0.017 in.)
Oil Ring–Standard Gap
0.15–0.35 mm
(0.006–0.014 in.)
Item MeasurementSpecification
Oil Ring–Wear Limit Gap
0.44 mm
(0.017 in.)
Piston Pin–Standard Diameter
22.00 mm
(0.866 in.)
Piston Pin–Wear Limit Diameter
21.97 mm
(0.865 in.)
Piston Pin Bore–Standard Diameter
22.00–22.01 mm
(0.866–0.867 in.)
Piston Pin Bore–Wear Limit Diameter
22.04 mm
(0.868 in.)
Piston Pin Bore–Standard Clearance
0.03–0.05 mm
(0.001–0.002 in.)
Piston Pin Bore–Wear Limit Clearance
0.11 mm
(0.004 in.)
Piston Pin Bushing–Standard Diameter
22.03–22.04 mm)
(0.867–0.868 in.
Piston Pin Bushing–Wear Limit Diameter
22.07 mm
(0.869 in.)
Piston Pin–Standard Clearance
0.03–0.05 mm
(0.001–0.002 in.)
Piston Pin–Wear Limit Clearance
0.11 mm
(0.004 in.)
Measuring Distance (A) Distance
22–25 mm
(0.866–0.984in.)
Standard Sized Piston Diameter
69.96–69.99 mm
(2.754–2.756 in.)
Standard Sized Piston–Wear Limit Diameter
69.91 mm
(2.752 in.)
Standard Size Cylinder Bore Diameter
70.01–70.02 mm
(2.756–2.757 in.)
Cylinder Bore–Wear Limit Diameter
70.20 mm
(2.764 in.)
Piston-to-Cylinder Clearance
0.03–0.05 mm
(0.001–0.002 in.)
Cylinder Out-of-Round
0.00–0.01 mm
(0–0.000 in.)
Cylinder–Wear Limit Out-of-Round
0.03 mm
(0.001 in.)
Cylinder Taper
0.00–0.01 mm
(0–0.0004 in.)
Cylinder–Wear Limit Taper
0.03 mm
(0.001 in.)
Main Bearing Cap Screws Torque
75.5–81.5 N·m
(55.6–60 lb.-ft.)
Crankshaft
Radial
Runout
0.02 mm
(0.001 in.)
Crankshaft Connecting Rod Journal–Standard OD
41.95–41.96 mm
(1.652 in.)
Crankshaft Connecting Rod Journal–Wear LimitOD
41.90 mm
(1.647 in.)
Crankshaft Main Bearing Journal–Standard OD
46.95–46.96 mm
(1.848–1.849 in.)
Crankshaft Main Bearing Journal–Wear Limit OD
46.90 mm
(1.846 in.)
Main Bearing –Standard ID
46.98–47.00 mm
(1.849–1.85 in.)
Main Bearing Thickness
2.01 mm
(0.079 in.)
Main Bearing Oil Clearance Clearance
0.02–0.05 mm
(0.001–0.002 in.)
Main Bearing Oil Clearance–Wear Limit Clearance
0.12 mm
(0.005)
Flywheel Bolts Torque
80.4–86.4 N·m
(59–63 lb.-ft.)
Clutch Bolt Torque
37 N·m
(26 lb.-ft.)
Flywheel Plate Cap Screws Torque
49 N·m
(36 lb.-ft.)
Timing Gear Housing Mounting Cap Screws Torque
11 N·m
(97 lb.-in.)
Oil Pump Outer Rotor-to-Timing Cover–StandardClearance
0.12–0.21 mm
(0.005–0.008 in.)
Oil Pump Outer Rotor-to-Timing Cover–Wear LimitClearance
0.30 mm
(0.012 in.)
Oil Pump Inner-to-Outer Rotor Clearance Clearance
0.16 mm
(0.006 in.)
Oil Pump Rotors-to-Timing Cover–Standard Clearance
0.02–0.07 mm
(0.001–0.003 in.)
Oil Pump Rotors-to-Timing Cover–Wear Limit Clearance
0.12 mm
(0.005 in.)
Thermostat Housing Cap Screws Torque
20 N·m
(177 lb.-in.)
Water Pump Mounting Cap Screws Torque
25 N·m
(221 lb.-in.)
Fuel Injector Torque
49–59 N·m
(36–43 lb.-ft.)
Engine
TM121619 (27FEB21) 20-05-3 XUV855D S4 Gator Utility Vehicle

34. Item MeasurementSpecification
Fuel Injector Fuel Return Line Nuts Torque
24–33 N·m
(18–24 lb.-ft.)
Fuel Injector Nozzle Torque
29–49 N·m
(21–36 lb.-ft.)
Fuel Injector Separator Plate Wear–Maximum Out-of-Flat
0.10 mm
(0.0039 in.)
Injector Pump Mounting Nuts Torque
22.5–28.4 N·m
(17–21 lb.-ft.)
Injector Pump Drive Gear Nut Torque
58–68 N·m
(43–50 lb.-ft.)
Injector Gear Cover Cap Screws Torque
9 N·m
(80 lb.-in.)
Item MeasurementSpecification
Fuel Injector Line Nuts Torque
29.4–34.4 N·m
(22–25 lb.-ft.)
Starting Motor Cap Screw Torque Torque
24 N·m
(216 lb.-in.)
Slip Ring Diameter (Minimum) Diameter
14.0 mm
(0.55 in.)
Alternator Brush Exposed Length (Minimum) Length
4.5 mm
(0.17 in.)
OUMX068,0000205-19-20150120
Engine
TM121619 (27FEB21) 20-05-4 XUV855D S4 Gator Utility Vehicle

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