XUV865E, XUV865M and XUV865R Gator Utility Vehicle Repair Guide
XUV855E, XUV855M, XUV855M S4 Gator Utility Vehicle Repair Guide
Table of Contents – TM160619 Technical Manual
Section 10 — General Overview
- 10.1 Safety Instructions
- 10.2 Standard Specifications
- 10.3 Fuel Types and Lubrication Guidelines
- 10.4 Machine Configuration and Specs
Section 20 — Engine Repair Procedures
- 20.1 Overview and Safety Notes
- 20.2 Removal & Installation
- 20.3 Engine Disassembly and Reassembly
- 20.4 Inspection Guidelines
Section 30 — Fuel, Air Intake & Cooling System Repairs
- 30.1 Introductory Information
- 30.2 Component Removal and Installation
XUV865M Gator Utility Vehicle Repair Guide
Section 40 — Electrical System Repairs
- 40.1 System Overview
- 40.2 Component Replacement
- 40.3 Disassembly & Reassembly
- 40.4 Visual and Functional Inspection
Section 50 — Drivetrain Service
- 50.1 System Description
- 50.2 Drivetrain Removal & Installation
- 50.3 Component Breakdown and Assembly
- 50.4 Inspection Checks
Section 60 — Steering and Brakes
- 60.1 Introduction
- 60.2 System Removal and Reinstallation
- 60.3 Component Service Procedures
Section 80 — Attachment Systems & Machine-Specific Repairs
- 80.1 Overview
- 80.2 Removal and Installation
Section 90 — Operator Station Repair
- 90.1 Introductory Information
- 90.2 Removal and Installation
- 90.3 Station Disassembly and Reassembly
- 90.4 Inspection and Testing
XUV865R Gator Utility Vehicle Technical Manual
Diagnostic Sections
Section 210 — System-Wide Diagnostic Overview
- 210.1 General Diagnostic Information
Section 211 — Diagnostic Trouble Codes (DTCs)
- AMS Control Systems
- ATC Electronic Unit
- CRH Control Logic
- ICC Interface Controls
- JDL Telematics & Monitoring
- SCU System Controller
- USC AutoTrac™ Functions
Section 212 — Accessing Diagnostic Tools
- Engine Systems
- Fuel, Air Intake & Cooling
- Electrical Components
- ECU (Electronic Control Units)
- Transmission & Drivetrain
- Steering and Brake Systems
- Attachments & Implements
Section 220 — Engine System Diagnostics
- General Info & Checks
- Functional Overview
- Adjustment Procedures
- Troubleshooting Techniques
Section 230 — Fuel, Air, Cooling System Diagnostics
- Overview and Theory
- Circuit Schematics
- Adjustment and Testing
- Problem Identification
Section 240 — Electrical Diagnostics
- Overview
- Theory of Operation by Subsystem:
- Starting & Charging
- Steering and Brakes
- Operator Station
- CAN Bus
- Engine
- Lighting
- Drivetrain
- Air & Cooling
- Schematics by Subsystem
- Diagnostic Procedures
Section 245 — ECU Troubleshooting
- System Overview
- Operational Theory
- Circuit Diagrams
- ECU-Specific Diagnostics
Section 249 — Electrical Connectors Reference
- XA: Assemblies
- XB: Sensors
- XE: Lighting
- XF: Fuses
- XG: Charging Circuits
- XH: Alarms
- XK: Relays
- XM: Motors
- XR: Resistors
- XS: Switches
- XV: Diodes
- XW: Terminals
- XX: Inline Connectors
- XY: Solenoids
Section 250 — Drivetrain System Diagnostics
- Theory and Function
- Tests and Adjustments
- Problem Diagnosis
Section 260 — Steering and Brake Diagnostics
- System Theory
- Schematics
- Test Procedures
- Troubleshooting
Section 280 — Attachments & Implements Diagnostics
- Operational Concepts
- Troubleshooting Procedures
Section 290 — Operator Station Diagnostics
- General Overview
- Pre-check Procedures
- HVAC System Theory
- HVAC Wiring Schematics
- HVAC Component Mapping
- Tests & Calibration
- Diagnostic Workflows
Section 300 — Special Tools and Kits
- Recommended Tools
- Service Kits List
Manual Structure and Use
This technical manual is organized into categories:
- Repair Instructions — Covers step-by-step procedures to service machine components.
- Operation and Tests — Guides technicians in identifying and correcting issues efficiently.
Each section is streamlined to provide essential tools, specifications, wear limits, and torque data. These job-site references are designed to aid technicians during real-time diagnostics and repairs, offering only the most relevant technical information.