John Deere XUV825E XUV825M XUV825M S4 Gator Utility Vehicle Workshop Repair Service Manual TM150019 PDF - MJODTM150019.zip
Full workshop service and repair manual, complete with electrical wiring diagrams, covering the John Deere XUV825E, XUV825M, and XUV825M S4 Gator Utility Vehicles — packed with every technical detail needed to service, troubleshoot, fix, and rebuild these machines the way professional technicians do.
The John Deere XUV 825E, XUV 825M, and XUV 825M S4 Gator Utility Vehicles (Serial No. 010001-) factory service repair manual contains:
* 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.
tm150019 - XUV825E, XUV825M, XUV825M S4 Gator Utility Vehicles (Serial No. 010001-) Technical Manual.pdf
tm150019 - XUV825E, XUV825M, XUV825M S4 Gator Utility Vehicles (Serial No. 010001-) Technical Manual.epub
PRODUCT DETAILS:
Total Pages: 1,503 pages
File Format: PDF (Internal Links, Bookmarked, Table of Contents, Searchable, Printable, high quality)
Language: English
TABLE OF CONTENTS
TABLE OF CONTENTS....1
Section 10: General Information....23
Group 05: Safety....23
Recognize Safety Information....26
Understand Signal Words....27
Replace Safety Signs....28
Handle Fluids Safely—Avoid Fires....29
Prepare for Emergencies....30
Prevent Battery Explosions....31
Prevent Acid Burns....32
Wear Protective Clothing....34
Avoid High-Pressure Fluids....35
Avoid Heating Near Pressurized Fluid Lines....36
Service Machines Safely....37
Use Proper Tools....38
Park Machine Safely....39
Support Machine Properly....40
Use Proper Lifting Equipment....41
Work in Clean Area....42
Protect Against High Pressure Spray....43
Illuminate Work Area Safely....44
Work In Ventilated Area....45
Remove Paint Before Welding or Heating....46
Avoid Harmful Asbestos Dust....47
Service Tires Safely....48
Stay Clear of Rotating Drivelines....49
Service Cooling System Safely....51
Decommissioning — Proper Recycling and Disposal of Fluids and Components....52
Handle Chemical Products Safely....53
Live With Safety....54
Group 10: General Specifications....1503
Service Recommendations for O-Ring Boss Fittings....57
Service Recommendations For Flat Face O-Ring Seal Fittings....59
Metric Cap Screw Torque Values—Grade 7....61
Metric Bolt and Screw Torque Values....62
Unified Inch Bolt and Screw Torque Values....64
Group 15: Fuel and Lubricants....24
Gasoline Engine Oil....68
Oil Filters....70
Gasoline Fuel for 4-Cycle Engines....71
Transmission and Hydraulic Oil....72
Multipurpose Extreme Pressure (EP) Grease....73
Mixing of Lubricants....74
Alternative and Synthetic Lubricants....75
Lubricant Storage....76
Group 20: Machine Specifications....1503
Machine Specifications....1503
Product Identification Number Location....81
Section 20: Engine Repair....82
Group 10: Repair....82
Summary of References....1502
Specifications....1503
Essential or Recommended Tools....1511
Service Equipment and Tools....1512
Other Material....1462
Remove and Install Engine....94
Remove and Install Valve Cover....106
Remove and Install Timing Belt....108
Remove and Install Water Pump....117
Remove and Install Cylinder Head....119
Remove and Install Intake Manifold....128
Remove and Install Exhaust Manifold....130
Recondition Cylinder Head....132
Remove and Install Oil Pan and Strainer....141
Remove and Install Oil Pump....143
Remove and Install Crankshaft Front Oil Seal....152
Remove and Install Camshafts....155
Check Crankshaft Main Bearing Clearance....165
Check Connecting Rod Bearing Clearance....167
Check Connecting Rod Side Play....169
Remove and Install Piston and Connecting Rod....170
Disassemble and Assemble Piston and Connecting Rod....173
Inspect Piston and Connecting Rod....177
Bore Cylinder....181
Remove and Install Crankshaft and Main Bearings....183
Inspect Crankshaft....189
Remove and Install Crankshaft Rear Oil Seal....191
Remove and Install Alternator....194
Remove and Install Starting Motor....198
Replace Fuel Injector....203
Replace Exhaust Gas Oxygen Sensor....205
Replace Knock Sensor....206
Replace Camshaft Position Sensor....207
Replace Crankshaft Position Sensor....208
Replace Intake Manifold Pressure and Temperature Sensor....210
Replace Throttle Body....211
De-Pressurize Fuel System....213
Section 30: Electrical Repair....214
Group 10: Wiring Harnesses....214
Summary of References....1502
Main Wiring Harness S2....217
Main Wiring Harness S2 Color Codes....222
Main Wiring Harness S2 Splice Table....228
Main Wiring Harness S4 with EPAS....233
Main Wiring Harness S4 Color Codes....238
Main Wiring Harness S4 Splice Table....244
Speed Sensor Jumper Harness....249
EPAS Wire Harness (2 - Pass)....250
Engine Wiring Harness....251
Engine Wiring Harness Color Codes....254
Group 20: Wiring Harnesses, Kits....214
Summary of References....1502
Lights Wiring Harness, AM140950....258
Lights Wiring Harness, AM137558....260
Key Switch Adapter Harness [((MY -2018) (S.N -020000)) and ((MY 2019-) (S.N 020001-))]....214
Headlight Jumper Wiring Harness, AM147740....263
Turn Signal with Flasher Harness, AM143722....264
Trailer Connector Wiring Harness....266
Backup Alarm Wiring Harness, AM144181....267
Cab Power Splitter Wiring Harness, AM140972....269
Canopy Wiring Harness, AM143139....270
Roof Work Lights Wiring Harness, AM146905....272
Beacon Light Wiring Harness, AM140971....274
Horn Wiring Harness, VGA10903....275
Winch Main Wiring Harness, AM144137....276
Winch Control Wiring Harness, AM142263....277
Section 40: Power Train Repair....278
Group 10: Transmission....278
Summary of References....1502
Specifications....1503
Essential or Recommended Tools....1511
Other Material....1462
Change Transmission Oil....286
Clean Drive Clutch....288
Remove and Install Clutch Housing....292
Remove and Install Clutch....297
Repair Drive Clutch....305
Repair Driven Clutch....317
Remove Transmission....326
Install Transmission....332
Disassemble Transmission....343
AssembleTransmission....356
Group 15: Axles and Drive Shaft....278
Summary of References....1502
Essential or Recommended Tools....1511
Specifications....1503
Remove and Install EMFWD Driveshaft....373
Replace EMFWD Driveshaft Boot....383
Remove and Install Rear Axle Half Shaft....386
Remove and Install Front Axle Half Shaft....390
Repair CV Joint and Boots—Front Axle Half Shafts....393
Repair CV Joint and Boots—Rear Axle Half Shafts....396
Hub Removal....399
Hub Installation....400
Group 20: Mechanical Four Wheel Drive....278
Summary of References....1502
Specifications....1503
Other Material....1462
Change EMFWD Front Differential Oil....405
Disassemble and Assemble Front Drive Gearbox....407
Remove and Install Front Differential....421
Disassemble Front Differential....427
Assemble Front Differential....443
Section 50: Steering and Brake Repair....457
Group 10: Steering....457
Summary of References....1502
Other Material....1462
Specifications....1503
Remove and Install Steering Knuckle....464
Remove and Install Front Wheel Bearing....467
Remove and Install Ball Joint....468
Remove and Install Steering Wheel....469
Replace Steering Shaft Bearing....471
Remove and Install Electric Power Assisted Steering (EPAS) Module....472
Remove and Install Steering Shaft (EPAS)....477
Remove and Install Steering Gearbox....482
Remove and Install Front Coilover Shock Absorber....488
Remove and Install Rear Coilover Shock Absorber....490
Remove and Install Tie Rod End....492
Remove and Install Front Suspension Arm....494
Remove and Install Rear Axle Bearing Carrier....497
Remove and Install Rear Suspension Arm....503
Remove and Install Rear Stabilizer Bar....507
Remove and Install Front Stabilizer Bar....510
Group 20: Brakes....457
Summary of References....1502
Specifications....1503
Essential or Recommended Tools....1511
Other Material....1462
Replace Brake Pad....520
Remove and Install Master Cylinder....524
Remove Front Brake Hose....529
Install Front Brake Hose....532
Remove Rear Brake Hose....536
Install Rear Brake Hose....540
Remove and Install Rear Brake Line—Front....544
Remove and Install Rear Brake Line—Center....547
Remove and Install Rear Brake Line—Rear....550
Remove and Install Brake Caliper....552
Remove and Install Brake Rotor....556
Remove and Install Brake Pedal....559
Replace Park Brake Control Cable....561
Remove and Install Park Brake Lever....566
Remove, Service, and Replace Park Brake....569
Section 60: Miscellaneous Repair....579
Group 10: Wheels....579
Summary of References....1502
Specifications....1503
Remove and Install Wheels....583
Group 15: Hood, Cargo Box, and Bumper....579
Summary of References....1502
Specifications....1503
Remove and Install Hood Latch....587
Remove and Install Hood....589
Remove and Install Front Bumper/Skid Plate....590
Remove and Install Cargo Box....592
Remove and Install Cargo Box Side....594
Group 20: Miscellaneous....579
Summary of References....1502
Remove and Install Headlight....601
Remove and Install Front Grille....603
Remove and Install Front Fender....604
Door Removal and Installation....606
Door Alignment....608
Door Latch Adjustment....609
Drain and Flush Radiator....610
Fill and Bleed Coolant System....613
Remove and Install Radiator....615
Remove and Install Cooling Fan....617
Remove and Install Intermediate Coolant Tubes....620
Remove and Install Battery....624
Remove and Install Fuel Tank....625
Remove and Install Fuel Pump....627
Fuel Pump Disassembly and Assembly....629
Section 70: Operator’s Station Repair....632
Group 10: Operator’s Station and Seat....632
Summary of References....1502
Specifications....1503
Remove and Install Dash Panel....636
Remove and Install Front Seat....639
Remove and Install Rear Seat....642
Remove and Install Front Seat Base Cover....643
Remove and Install Front Under Seat Storage Box....646
Remove and Install Rear Under Seat Storage Box and Battery Cover....647
Remove and Install Transaxle Control Lever Housing....648
Group 20: Occupant Protective Structure (OPS)....632
Summary of References....1502
Remove and Install Occupant Protective Structure (OPS)....652
Section 220: Engine Operation, Tests, and Adjustments....658
Group 10: Component Location....658
Summary of References....1502
Engine Intake Components....661
Engine Exhaust Components....663
Engine Mounting Components....665
Engine Coolant Lines Components....667
Engine Block and Head Components....668
Engine Crankshaft and Pistons Components....670
Engine Valve Train Components....672
Group 20: Diagnosis....658
Diagnose Engine Malfunctions....658
Group 25: Tests and Adjustments....658
Summary of References....1502
Specifications....1503
Service Equipment and Tools....1512
Other Material....1462
Adjust Throttle Cable....697
Check Idle Speed....701
Test Fuel Pump and Regulator Pressure....702
Test Cylinder Compression Pressure....704
Test Cylinder Leak-Down....706
Crankcase Vacuum Test....710
Adjust Valve Clearance....712
Test Oil Pressure....716
Test Thermostat....718
Section 230: Electrical Operation, Tests, and Adjustments....720
Group 05: General Information....720
Operation and Diagnostics....726
Diagnostic Information....727
Common Circuit Tests....728
Conductors for 12 Volt Circuits....730
Group 10: Component Location....720
Summary of References....1502
Load Center S2....733
Load Center S4....735
ICC Pinout....737
ICC Signal Locations....738
ECU Signal Locations....740
Engine to Main Wiring Harness Signals and Locations (C10)....743
Group 15: Theory of Operation....720
Summary of References....1502
Power Circuit Operation....746
Cranking Circuit Operation....753
Run Circuit Operation....757