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Atlas JSV EFI 2016
Gravely Atlas JSV EFI 2016 User Manual
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2016
Atlas JSV EFI Service Manual
PN 21901443A
Printed in USA
Service Manual
2016
Atlas JSV EFI
21901443A
Models 996200, 996201 (SN 160101 +)
2
Table of Contents
Chapter 1 1 General Information
9
Table of Contents
9
Vehicle Identification
10
Gravely Identification Number
10
Engine Designation Number
10
Vehicle Identification Number (Vin) Designation
10
Vehicle and Engine Serial Number Locations
11
Vehicle Information
12
Special Tools Index
12
Specifications
16
2016 Atlas Jsv3000 Efi Overview
16
2016 Atlas Jsv3000 Efi Specifications
17
2016 Atlas Jsv6000 Efi Overview
18
Misc. Specifications and Charts
20
Master Torque List
20
Conversion Table
24
Standard Bolt Torque Specification
25
Metric Bolt Torque Specification
26
Sae Tap / Drill Sizes
27
Metric Tap / Drill Sizes
27
Decimal Equivalents
28
Chapter 2 Maintenance
29
General Information - Maintenance
31
Service Notes - Maintenance
31
Torque Specifications - Maintenance
31
Service Specifications - Maintenance
32
Break-In Period
33
Maintenance Chart Key
33
Periodic Maintenance Chart
33
Periodic Maintenance Overview
33
Pre-Ride - 50 Hour Maintenance Interval
34
50 - 500 Hour Maintenance Interval
35
Maintenance Quick Reference
36
Grease Lubrication Points
38
Lubricants, Maintenance and Service Products
40
Service Products and Lubricants
40
Frame, Nuts, Bolts, and Fasteners
41
General Vehicle Inspection and Maintenance
41
Pre-Ride / Daily Inspection
41
Shift Cable Inspection / Adjustment
42
Fuel Pump / Fuel Filters
43
Fuel System and Air Intake Maintenance
43
Fuel System Warning
43
Fuel Lines
44
Vent Line
44
Air Filter Service
45
Engine Intake Pre-Filter Screen Service
45
Engine Air Intake Exploded View
46
Engine Maintenance
47
Engine Oil Level
47
Engine Oil and Filter Change
48
Engine Crankcase Breather Hose Inspection
49
Engine Cylinder Leakdown Test
49
Valve Clearance Inspection
50
Exhaust - Spark Arrestor
51
Transmission and Front Gearcase Maintenance
52
Transmission Lubrication
52
Front Gearcase Lubrication
53
Coolant Level Inspection
54
Coolant Strength / Type
54
Cooling System Maintenance
54
Liquid Cooling System Overview
54
Cooling System Hoses
55
Coolant Drain / Fill
56
Radiator Inspection / Cleaning
56
Cvt / Final Drive / Wheel and Tire Maintenance
57
Cvt Drying
57
Cvt Intake Pre-Filter Service
57
Drive Shaft Boot Inspection
58
Wheel and Hub Torque Table
58
Tire Inspection
59
Tire Pressure
59
Wheel Installation
59
Wheel Removal
59
Battery Installation
60
Battery Maintenance
60
Battery Removal
60
Electrical and Ignition System Maintenance
60
Chassis / Engine Electrical Ground
61
Spark Plug Service
61
Steering Inspection
62
Steering Maintenance
62
Tie Rod End / Wheel Hub Inspection
62
Wheel Toe Alignment Inspection
62
Wheel Toe Adjustment
63
Shock Position Adjustment
64
Spring Pre-Load Adjustment
64
Suspension Inspection
64
Suspension Maintenance
64
Brake Fluid Inspection
65
Brake Hose and Fitting Inspection
65
Brake Pad / Disc Inspection
65
Brake System Maintenance
65
Chapter 3 Engine / Cooling System
67
General Information - Engine
70
Service Notes - Engine
70
Special Tools - Engine
70
Torque Specifications - Engine
71
Service Specifications - Engine
72
Engine Detail - Torque Values / Sequences / Assembly Notes
74
Main Engine Components - Torque Specification and Sequence
74
Crankcase / Timing Chain Guides / Oil Pickup / Regulator Valve
75
Cylinder / Oil Filter / Oil Pump / Breather
76
Camshafts / Cylinder Head / Flywheel / Idler Gears / Stator Cover
77
Spark Plug / Starter / Throttle Body / Valve Cover
78
Piston / Crankshaft / Balance Shaft
79
Cooling System Assembly View and Coolant Flow Diagram
80
Engine Cooling System Service
80
Cooling System Pressure Test
81
Cooling System Specifications
81
Radiator Cap Pressure Test
81
Radiator Fan Removal
82
Radiator Removal / Coolant Drain
82
Cooling System Bleeding Procedure
83
Thermostat Replacement
83
Water Pump Cover and Impeller Service (Stator Cover Remains on Engine)
84
Water Pump Mechanical Seal / Oil Seal Replacement
85
Accessible Engine Components
92
Engine Removal
92
Engine Service
92
Engine Installation
94
Engine Mounting and Torque Values
97
Engine Break-In Period
98
Engine Lubrication Specifications
98
Oil Pressure Test
98
Engine Oil Flow Chart
99
Setting Tdc (Top-Dead-Center)
100
Camshaft / Carrier Removal
101
Engine Disassembly / Inspection - Top End
101
Valve Cover Removal
101
Camshaft Sprocket Inspection
102
Camshaft Inspection
103
Exhaust Camshaft Decompression Mechanism
103
Cam Chain and Guide Service
104
Cylinder Head Removal
104
Cylinder Head Disassembly
105
Cylinder Head Inspection
106
Cylinder Head Warp Inspection
106
Valve Inspection
107
Combustion Chamber Cleaning
108
Valve Seat Reconditioning
108
Cylinder Removal
110
Cylinder Inspection
111
Piston Removal
111
Piston / Rod Inspection
112
Piston-To-Cylinder Clearance
112
Piston Ring Installed Gap
113
Cylinder Hone Selection / Honing Procedure
114
Honing to Oversize
114
Camshaft Installation / Timing
115
Camshaft Timing - Quick Reference
118
Valve Cover Installation
119
Engine Assembly - Top End
120
Piston Ring Installation
120
Cylinder Installation
121
Piston / Connecting Rod Assembly
121
Cylinder Head Assembly
122
Valve Sealing Test
123
Cylinder Head Installation
124
Valve Clearance Check / Adjustment
125
Intake Valve Lash - Tappet Selection Matrix
128
Exhaust Valve Lash - Tappet Selection Matrix
129
Crankcase Disassembly
130
Engine Disassembly / Inspection - Lower End
130
Flywheel / Stator Cover Removal
130
Starter One-Way Clutch Removal / Inspection
131
Stator Removal
132
Oil Pump Removal
133
Crankcase Breather Service
135
Oil Pump Assembly
135
Balance Shaft Removal / Inspection
136
Crankcase Separation
136
Crankshaft Removal
137
Crankshaft Inspection
138
Pto Side Crankcase Bearing Service
138
Mag Side Crankcase Bearing Service
140
Oil Pickup Assembly Inspection
140
Crankcase Inspection
141
Oil Pressure Regulator (Bypass) Valve Inspection
141
Crankcase Assembly - Pto Side
142
Engine Assembly - Lower End
142
Balance Shaft Installation / Timing
143
Final Crankcase Assembly
144
Flywheel Installation
145
Starter One-Way Clutch Installation
145
Stator / Stator Cover Installation
147
Engine Cooling System
148
Troubleshooting - Engine / Cooling System
148
Chapter 4 Fuel System
151
General Information - Fuel System
153
Service Notes - Fuel System
153
Special Tools - Fuel System
153
Service Specifications - Fuel System
155
Torque Specifications - Fuel System
155
Electronic Fuel Injection
156
Fuel System Component Locations
156
Fuel System Components
156
Fuel System Operation Overview
158
Initial Priming / Starting Procedure
158
Fuel Tank Exploded View
159
Fuel Tank Service
159
Fuel Line Removal / Installation
160
Fuel Tank Removal
160
Fuel Tank Installation
161
Fuel Pump Service
162
Fuel Pump Test
162
Fuel Sender Test
162
Operation Overview
162
Fuel Pump Replacement
164
Ecu Service
167
Electronic Control Unit (Ecu)
167
Operation Overview
167
Ecu Replacement
168
Electronic Throttle Control (Etc)
169
Etc Replacement
169
Etc Test
169
Operation Overview
169
Cps Test
170
Crankshaft Position Sensor (Cps)
170
Operation Overview
170
Cps Replacement
171
Operation Overview
172
T-Map Sensor Replacement
172
T-Map Sensor Test
172
Temp / Manifold Absolute Pressure Sensor (T-Map)
172
Ect Sensor Test
173
Engine Coolant Temperature Sensor (Ect)
173
Operation Overview
173
Ect Sensor Replacement
174
Operation Overview
175
Pedal Position Sensor (Pps)
175
Pps Replacement
175
Pps Test
175
Fuel Injector Service
176
Fuel Injector Troubleshooting
176
Operation Overview
176
Fuel Injector Replacement
177
Fuel Injector Test
177
Fuel System Diagnostics
179
Instrument Cluster Trouble Code Display
179
Fuel System Troubleshooting
183
Diagnostic Software Version
184
Digital Wrench Operation
184
Digital Wrench® Diagnostic Software Overview
184
Ecu Replacement
184
Guided Diagnostic Available
184
Special Tools
184
Digital Wrench® - Diagnostic Connector
185
Digital Wrench® Communication Errors
185
Digital Wrench® Serial Number Location
185
Digital Wrench® Version and Update
185
Digital Wrench Updates
186
Digital Wrench® Feature Map
188
Engine Controller Reprogramming (Reflash)
189
Chapter 5 Cvt System
193
General Information - Cvt System
194
Service Notes - Cvt System
194
Special Tools - Cvt System
194
Service Specifications - Cvt System
195
Torque Specifications - Cvt System
195
Cvt Break-In (Drive Belt / Clutches)
196
Cvt System Overview
196
Drive Clutch Operation
196
Driven Clutch Operation
196
Maintenance / Inspection
196
Overheating / Diagnosis
197
Cvt Covers and Ducting Components
198
Cvt System Service
198
Cvt Disassembly
199
Cvt Assembly
200
Belt Removal
201
Drive Belt Service
201
Belt Inspection
202
Belt Installation
202
Drive Clutch Exploded View
203
Drive Clutch Service
203
Bearing Inspection
204
Clutch Disassembly
204
Drive Clutch Spring Inspection
205
Shift Weight Inspection
205
Button to Tower Clearance Inspection
206
Spider Removal
206
Clutch Inspection
207
Roller, Pin, and Thrust Washer Inspection
207
Bushing Service
209
Moveable Sheave Bushing Inspection
209
Clutch Assembly
211
Driven Clutch Service
212
Exploded View
212
Clutch Disassembly / Inspection
213
Clutch Assembly
214
Troubleshooting
216
Chapter 6 Transmission
219
General Information - Transmission
220
Service Notes - Transmission
220
Service Specifications - Transmission
220
Special Tools - Transmission
220
Torque Specifications - Transmission
220
Shift Lever Removal / Installation
221
Shift Lever Service
221
Shift Cable Adjustment
222
Shift Cable Inspection
222
Shift Cable Service
222
Transmission Removal
223
Transmission Installation
226
Transmission Mounting Torque Values
230
Differential Operation
231
Transmission Service
231
Transmission Disassembly
232
Gear Cluster Disassembly
235
Snorkel Shaft Removal / Disassembly
236
Planetary Differential Disassembly
237
Planetary Differential Bushing Replacement
238
Planetary Differential Assembly
240
Gear / Shaft / Bearing Inspection
241
Snorkel Gear Backlash Procedure
242
Transmission Assembly
245
Troubleshooting
250
Troubleshooting Checklist
250
Exploded View
251
Transmission Exploded View
251
Chapter 7 Final Drive
253
General Information - Final Drive
254
Service Notes - Final Drive
254
Service Specifications - Final Drive
254
Special Tools - Final Drive
254
Torque Specifications - Final Drive
254
Bearing Carrier Removal / Inspection
255
Front Bearing Carrier Service
255
Bearing Replacement
256
Bearing Carrier Installation
257
Front Drive Shaft Installation
258
Front Drive Shaft Removal
258
Front Drive Shaft Service
258
Front Propshaft Removal / Installation
259
Front Propshaft Removal / Installation - Crew
259
Front Propshaft Service
259
Propshaft U-Joint Disassembly
261
Propshaft U-Joint Service
261
Propshaft U-Joint Assembly
262
Front Gearcase Exploded View
264
Front Gearcase Service
264
All Wheel Drive Operation
265
Awd Diagnosis
266
Front Gearcase Removal
267
Front Gearcase Disassembly / Inspection
268
Front Gearcase Assembly
271
Front Gearcase Installation
273
Rear Drive Shaft Installation
275
Rear Drive Shaft Removal
275
Rear Drive Shaft Service
275
Drive Shaft / CV Joint Handling Tips
276
Drive Shaft Service
276
Outer CV Joint / Boot Replacement
276
Inner Plunging Joint / Boot Replacement
278
Drive Shaft Cutaway View
281
Chapter 8 Body / Steering / Suspension
283
General Information - Body / Steering / Suspension
285
Service Notes - Body / Steering / Suspension
285
Special Tools - Body / Steering / Suspension
285
Decal Replacement
286
Torque Specifications - Body / Steering / Suspension
286
Cab Frame
287
Cab Frame Assembly View - Jsv3000
287
Chassis Assembly Views
289
Main Frame / Frame Supports - Jsv3000
289
Body Components Assembly Views
291
Dash Panels / Glove Box
291
Hood / Front Fenders / Front Fascia
292
Floor / Rear Fenders / Skid Plate / Storage - Jsv3000
293
Seat Mounting / Seat Belts - Jsv3000
296
Rear Cargo Box Service
298
Tailgate / Cargo Box Panels Assembly View
298
Cargo Box Installation
300
Cargo Box Removal
300
Body Component Removal
301
Front Fascia Removal
301
Hood Removal
301
Lower Seat Base Removal
301
Dash Panels / Glove Box Removal
302
Front Fenders Removal
302
Rocker Panel Removal - Jsv3000
303
Rocker Panel Removal - Jsv6000
304
Front Floor Removal
305
Main Floor Removal
305
Rear Floor Removal - Jsv6000
306
Steering Assembly Service
308
Steering Assembly View
308
Steering Shaft Removal (Non-Eps)
309
Steering Wheel Removal (Non-Eps)
309
Steering Shaft Bearing Replacement
310
Assembly View
311
Front Lower A-Arm Installation
312
Front Lower A-Arm Removal
312
Front Upper A-Arm Installation
313
Front Upper A-Arm Removal
313
Ball Joint Removal
314
Ball Joint Service
314
Ball Joint Service Preparation
314
Ball Joint Installation
315
Exploded View
317
Rear Suspension Link and Axle Brace
317
Rear Upper Suspension Link Installation
318
Rear Upper Suspension Link Removal
318
Rear Lower Suspension Link Installation
319
Rear Lower Suspension Link Removal
319
Rear Axle Brace Removal
320
Rear Axle Bearing Replacement
321
Rear Axle Brace Installation
322
Shock / Spring Service
323
Shocks Assembly View
323
Shock Removal / Installation
324
Spring Replacement
324
Chapter 9 Brake System
325
General Information - Brake System
327
Service Notes - Brake System
327
Service Specifications - Brake System
328
Torque Specifications - Brake System
328
Brake System Assembly View
329
Brake System Service
329
Brake Bleeding / Fluid Change
330
Master Cylinder Installation
332
Master Cylinder Removal
332
Master Cylinder Service
332
Brake Pedal Removal
333
Foot Brake Pedal Service
333
Installation
333
Front Brake Pad Service
334
Pad Removal
334
Pad Assembly / Installation
335
Pad Inspection
335
Brake Burnishing Procedure
336
Caliper Assembly View
337
Front Caliper Service
337
Caliper Disassembly
338
Caliper Removal
338
Caliper Inspection
339
Caliper Assembly
340
Caliper Installation
340
Disc Inspection
342
Disc Runout
342
Front Brake Disc Service
342
Disc Replacement
343
Pad Inspection
344
Pad Removal
344
Rear Brake Pad Service
344
Brake Burnishing Procedure
345
Pad Installation
345
Caliper Assembly View
346
Caliper Removal
346
Rear Caliper Service
346
Caliper Disassembly
347
Caliper Assembly
348
Caliper Inspection
348
Caliper Installation
349
Rear Brake Disc Service
351
Chapter 10 Electrical
355
General Information - Electrical System
357
Service Notes - Electrical
357
Service Specifications - Electrical
358
Special Tools - Electrical
358
Torque Specifications - Electrical
358
Brake Light Switch
359
Headlamp Switch
359
Switches / Controls
359
Awd / 2Wd / Turf Switch
360
Ignition Key Switch
360
Transmission (Gear Position) Switch
361
Speed Sensor Location
362
Speed Sensor Testing
362
Vehicle Speed Sensor Service
362
Differential Solenoid Circuit Operation
363
Differential Solenoid Overview
363
Rear Diff Solenoid Service
363
Instrument Cluster Service
364
Overview
364
Rider Information Display
365
Information Display Area
366
Diagnostic Mode
368
Instrument Cluster Pinouts
369
Instrument Cluster Trouble Code Display
369
Instrument Cluster Removal
374
Instrument Cluster Installation
375
All Wheel Drive Coil Service
376
Diagnosing System Failures
376
Operation Overview
376
Headlight Adjustment
377
Headlight Bulb Replacement
377
Headlight Service
377
Headlight Housing Removal
378
Led Lamp Replacement
379
Tail Light / Brake Light Service
379
Fuel Sender Service
380
Testing
380
Cooling System Break-Out Diagram
381
Cooling System Service
381
Coolant Temperature Sensor
382
Fan Control Circuit Bypass Test
382
Fan Control Circuit Operation / Testing
382
Ignition Coil / Ht Lead Replacement
383
Ignition Coil Service
383
Ignition Coil Tests
383
Operation Overview
383
Fuse Box: Fuses / Relays / Circuit Break Service
384
Overview / Operation
384
Fuse Box Detail View
385
Relay Operation
385
Charging System "Break Even" Test
387
Charging System Service
387
Current Draw - Key off
387
Charging System Stator (Alternator) Tests
388
Regulator / Rectifier Operation
389
Stator (Alternator) Replacement
389
Charging System Testing Flow Chart
391
Battery Service
392
Battery Specifications
392
General Battery Information
392
Battery off Season Storage
393
Battery Terminal Block
393
Battery Testing
393
Load Test
393
Ocv - Open Circuit Voltage Test
393
Battery Charging Procedure
394
Starter Motor Removal
395
Starter System Service
395
Troubleshooting
395
Voltage Drop Test
395
Starter Motor Installation
396
Starter Solenoid Bench Test
396
Starter Solenoid Operation
396
Starting System Testing Flow Chart
398
4
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Gravely Atlas JSV EFI 2016 Specifications
General
Brand
Gravely
Model
Atlas JSV EFI 2016
Category
Offroad Vehicle
Language
English
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