XUV865R Cross-over Utility Vehicles

Whether it is a completely open operator station or a factory installed cab, the interior has been redesigned with comfort and ergonomics in mind.

• Gear shift control and differential shifter to the dash
• Tilt steering
• Bench seat with driver adjustment
• Three-wide seating 

Tilt steering (up position)

Tilt steering (down position)

Tilt steering

Bench seat adjustment

Three-wide seating for off-road use only (two-wide for road homologation)

Cab

• Functioning door windows – roll up and down

M cab door

• Fully opening front window with vent position

Side windows and front window	Venting position

• Automotive-style sealing

Door sealing

• Styled roof with channels designed-in to move water to the outside edges

Styled roof

• Molded-in pockets for front and rear light mounting
  • Keeps lights below the roof line for protection

Front roof light in base equipment	Rear roof light

• Easy-opening door handles and mechanisms

Inner door handle	Outer door handle

HVAC details

Automotive-style controls on the center of the dash are easy and convenient to reach for the operator or passengers

• Four dash vents
  • Adjustable louvers and face plates
• Windshield vents mounted on the top of the dash
  • Fast defrost
  • Efficient air flow
• Air filter on the passenger side of the cab at foot level
• Three fan speeds
  • 0: off
  • 1: low
  • 2: medium
  • 3: high
• Temperature adjustment knob
  • Counterclockwise for cooler temperature
  • Clockwise for warmer temperature
• Four air flow modes
  • Dash vents
  • Dash and floor vents
  • Defroster vents and floor vents
  • Defroster vents
• HVAC compressor on/off button
  • Pushing the button once turns the air conditioning on - indicator light illuminates blue
  • Push the button again to turn off the air conditioning
• Air flow constant with compressor on or off
• Turn compressor off for full engine power
• Gas machines have an idle bump to raise rpms to assist driving more power for the HVAC system
  • 1075 rpm in any gear at idle with air conditioning on
  • 1400 rpm when in neutral and the park brake is engaged
• HVAC - if equipped

HVAC controls

854-cc (52.1-cu in.) diesel engine

The machine is powered by an 854-cc (52.1-cu in.), 3-cylinder, liquid-cooled, four-cycle diesel engine. It produces 48 Nm (35.5-lb-ft) of torque at 2600 rpm.

The advanced engine delivers superb starting, idling, and throttle response during operation.

The engine offers the following performance and reliability features:

• Indirect-injection diesel with glow plugs ensures fast starts in cold temperatures
• 15.5 kW (22.8 hp*) at 3600 rpm according to ECE-R120 
• Overhead valve design for greater efficiency and fuel economy
• Spin-on oil filter for easy servicing
• Quiet operation through the entire rpm range
• Molybdenum-coated pistons
• High-stiffness cylinder block and gear case
• High-flow water pump and optimized water jackets maintain a steady operating temperature and eliminate hot spots
• Full-pressure lubrication system
• In-line mechanical fuel pump
• Five-point, rubber isolated for quiet operation and minimal vibration
• Dry replaceable dual-element air cleaner with remote intake and a restriction indicator
• See-through coolant recovery tank permits the operator to check the coolant level without removing the radiator cap
• Open front grille allows proper air flow and ventilation to the radiator.

* The engine horsepower information is provided by the engine manufacturer to be used for comparison purposes only. The actual operating horsepower will be less.

XUV front suspension detail

To complement the robust frame, the XUV is equipped with four-wheel independent suspension.

A dual A-arm front and rear suspension provides a smooth ride over challenging terrain and excellent hauling characteristics.

The entire suspension system has been optimized to handle cargo without compromising ride quality or vehicle stability.

Units have heavy-duty front and rear shocks installed from the factory.

• Higher spring rate and higher preload force versus standard springs prevent the vehicle from sagging with a heavy payload.
• These heavy-duty shocks help with the heavier weight of the cab and when attachments are installed – like blades.

Dual A-arm independent front suspension features include:

• 200.7 mm (7.9 in.) of travel provides ample wheel travel to keep all four wheels on the ground for superior traction, excellent ride quality, and vehicle control
• Heavy-duty nodular cast-iron knuckles support the constant-velocity (CV) shaft and wheel
• Maintenance-free rubber torsional A-arm pivots for long life and quiet operation
• CV shaft protection from sticks that may puncture the rubber boot
• Coil-over shocks absorb the most demanding terrain

XUV rear suspension detail

XUV rear suspension detail

Dual A-arm independent rear suspension features include:

• Unequal length and dual A-arm construction for superior wheel control and travel
• 231.14 mm (9.1 in.) of total travel provides ample wheel travel to keep all four wheels on the ground for superior traction, excellent ride quality, and vehicle control
• Coil-over shocks absorb the most demanding terrain
• A-arms made from square/rectangular tubing reduce weight while remaining rigid
• Heavy-duty nodular cast-iron uprights support wheel loads with a double row of ball bearings
• CV driveshaft protection from sticks that may puncture the rubber boot
• Rear sway bar for lateral stability

The Gator™ XUV Crossover Series Utility Vehicle has a precision-engineered drivetrain system that fully utilizes engine power, optimizing acceleration, hauling, towing, and hill-climbing capabilities. Power is transmitted from the engine through a continuously-variable clutch system to the transaxle.

Key elements of the drive system include:

Variable-speed drive

Variable-speed drive

The variable-speed drive consists of two clutches and a drive belt:

• Drive clutch is attached to the engine.
• Driven clutch is attached to the transaxle.

Features include:

• The engine braking system utilizes a tight belt for operation, requiring an idler sleeve on the primary clutch for neutral. The secondary clutch is a build-on-shaft design that utilizes a cam to tune the acceleration and deceleration of the vehicle. The clutch will stay engaged, providing deceleration until approximately 5 km/h (3 mph).
• The continuously variable transmission (CVT) air intake draws in 50 percent more air versus previous designs to reduce heat and the amount of water ingestion into the CVT system. The system will reduce belt slippage and improve durability.
• A low- and high-speed forward gear offering:
  • Low range is 0 km/h to 47 km/h (0 mph to 29 mph), XUV835
  • Low range is 0 km/h to 24 km/h (0 mph to 15 mph), XUV865
  • High range is 0 km/h to 72 km/h (0 mph to 45 mph), XUV835
  • High range is 0 km/h to 51 km/h (0 mph to 32 mph), XUV865
• Ability to creep along slowly to maneuver in tight spaces
• Standard full-clutch enclosure with high speed fan provides longer belt and clutch life
• High-ratio clutches with three cam weights for maximum belt-clamp load in high torque conditions

NOTE: Delivery and torque to the ground depends on tire size, which is a function of nominal size and pressure.

How the variable-speed drive works:

1. As engine speed increases, the spring-loaded drive clutch is closed by weights being forced out by centrifugal force.
2. As the drive clutch closes, the belt rides up to the largest diameter of the drive clutch and forces open the driven clutch.
3. With the belt running in the smallest diameter of the driven clutch, the speed being transferred to the transaxle is increased.
4. The driven clutch is designed to sense varying loads (inclines, mud, etc.) and constantly adjusts drive speed upward or downward so that engine rpm remains optimal.

Transaxle, mechanical front-wheel drive (MFWD), and constant velocity (CV) shafts

Side view of CVT intake and clutch enclosure

Differential lock lever and MFWD switch

Rear view of transaxle and CV shafts

CV boot protection

Operator interface features:

• On-demand true four-wheel drive (4WD) system with an auto-locking front differential and dash-mounted electronic rocker switch is best in class. When the rocker switch is in the on 4WD position, the front differential will automatically lock for extra traction when needed, but when the rocker switch is in the off two-wheel drive (2WD) position, the vehicle will remain in 2WD.
• Provides exceptional traction in challenging conditions
• Maintains turf-friendly operation in 2WD mode
• Illuminated for visibility in low-light condition

Transaxle features:

• Two-speed, fully-enclosed oil bath transaxle allows for superior pulling ability
• Cast-aluminum design is the most robust in the industry
• Helical forward and reverse gears are used for quiet operation
• Rear traction assist (differential lock) is built in and can be engaged on demand
  • Allows locking the rear drive wheels together
  • Provides increased traction in tough spots

NOTE: Differential design reduces scuffing of the turf during turns because it allows the inside wheels to turn slower than the outside wheels.

• Neutral start safety interlock for engine ignition system
• Large, sealed bearings are located inside the housing for better protection and durability
• Contains gear case for transferring power to the MFWD
• Splined shaft interfaces for maximum torque transfer and durability
• All drive gears machined from highest grade gear steel
• Protected by a skid plate

MFWD features:

• Electronic design is auto-locking for ease of use
  • Performs like a locking differential when engaged, but like an open differential when cornering
  • Offers positive engagement of both front wheels in forward and reverse as a differential package
  • Automatic engagement on the fly—no shift linkages required
  • Protected by a skid plate and frame

Drive shaft features:

• Rear CV shaft diameter measures 27 mm (1.1 in.) and is designed for peak engine and braking torque
• Front CV shaft diameter measures 23 mm (0.91 in.) and is designed for peak engine torque
• Propshaft is designed for peak engine torque
• All CV shaft and propshaft joints are maintenance free and protected by exclusive thermoplastic elastomer (TPE) boots for durability

Cargo box shown with optional light protectors

Top view of cargo box

The deluxe cargo box consists of a 15 percent glass-filled polypropylene composite material that eliminates rust and dents and reduces noise. Base equipment includes a spray-in cargo box liner and rear cargo box lights. Optional rear light protectors are an available kit.

Deluxe cargo box tailgate

Tailgate handle

Tailgate open

Tailgate lowered to 150 degrees

The tailgate can be opened or removed for easier cleanout and to carry longer items. The tailgate has been improved, features truck-like performance, and can be operated with one hand.

The standard-installed lanyards can also be removed to lower the tailgate to 150 degrees for convenient loading and unloading tasks.

Deluxe cargo box tilt

Cargo box power lift in base

The Gator™ XUV865R Series is equipped with the cargo box power lift in base. This is one of the most important accessories for increasing work efficiency.

The power lift offers the following features:

• Capable of lifting a maximum vehicle cargo box load
• Lifts box to 49 degrees from horizontal for ease of service and cargo box load removal
• Quick horizontal-to-49-degree time
• Compact design fits nicely around transmission and linkages, providing full protection
• Fully sealed and weatherproof hydraulic design does not require maintenance and is built for maximum durability
• Driven by proven electric motor and gear pump
• Electric motor protected by a circuit breaker
• Integrated check valve assures load holding
• Overload relief valve protects against misuse

Integrated tie-down points

Integrated tie-down point in cargo-box bed

Additional tie-down points (TH 6X4 shown)

The deluxe cargo box offers integrated tie-down points for increased versatility. Tie-down points are located in the following areas:

• Four corners inside the cargo box bed
• Four points on the load guard directly behind the operator station (A)
• Tie-down bars on either side of the cargo box (B)
• Six points on the underside of the cargo box frame (circled)

Converting deluxe cargo box to a flatbed

XUV835 Cab shown

XUV835M Cab shown

Optional accessories for the deluxe cargo box:

• See attachment Value Selling Navigator information

Specifications

CAUTION: Carrying extra-long cargo that extends beyond the box can adversely affect stability.

Equipped with power steering

This Gator™ XUV Crossover Utility Vehicle is equipped with power steering and a dual A-arm front suspension. These automotive-type systems exhibit excellent handling characteristics, as well as responsive steering and low steering effort:

• Steel ball-bearings secure the steering shaft and deliver smooth, responsive operation
• Completely sealed rack and pinion for long life
• Low steering ratio (lock-to-lock) provides more responsive steering and less operator input
• Shaft U-joints are phased for a smooth, uninterrupted motion of the steering wheel
• Tilt steering wheel

Electric power-assist steering system

Electric power-assist steering (EPAS) system has advanced features:

• Anti-kickback feature reduces the amount of steering unwinding when traversing difficult terrain. The system is speed-sensing and adjusts steering effort as the speed of the vehicle changes.
  • As speed increases, there is less steering assist for improved road feel.
  • As speed decreases, steering assist increases to give lower steering efforts for improved maneuverability.
• A warning/functional light on the instrument panel provides self-diagnostics and a warning light in the situation of no assist.
• Torque sensor measures steering wheel input so the on-board computer can provide the appropriate output for various driving situations.

With the EPAS system, the operator maintains a direct mechanical linkage from the steering wheel to the front wheels. The power steering system interfaces mechanically with the steering system by being inserted between the steering wheel and the rack-and-pinion assembly.

A differential torque sensor is integrated into the power steering assembly. The circuit board assembly is also integral with the power steering assembly.

Power steering does not reduce turning radius but significantly reduces steering effort by approximately 85 percent compared to models without power steering.

EPAS interface diagram

EPAS interface diagram

The numbered descriptions refer to the EPAS interface diagram shown above:

1. Torque sensor
2. Electronic control unit (ECU)
3. Fail-safe relay
4. Current/thermal control circuit
5. Reduction gears
6. DC motor
7. Rack and pinion
8. Function/warning light
9. Key power and ground
10. Vehicle speed sensor
11. Instrument cluster
12. Relay module

Adding attachments and accessories is made easier by the inclusion of some main wiring harnesses that facilitate efficient hook-up.

Roof harness electrical port

Main vehicle harness – winch connection

This Gator™ XUV Crossover Utility Vehicle is equipped with power steering and a dual A-arm front suspension. These automotive-type systems exhibit excellent handling characteristics, as well as responsive steering and low steering effort:

• Steel ball-bearings secure the steering shaft and deliver smooth, responsive operation
• Completely sealed rack and pinion for long life
• Low steering ratio (lock-to-lock) provides more responsive steering and less operator input
• Shaft U-joints are phased for a smooth, uninterrupted motion of the steering wheel
• Tilt steering wheel

Electric power-assist steering system

Electric power-assist steering (EPAS) system has advanced features:

• Anti-kickback feature reduces the amount of steering unwinding when traversing difficult terrain.
• The system is speed-sensing and adjusts steering effort as the speed of the vehicle changes.
  • As speed increases, there is less steering assist for improved road feel.
  • As speed decreases, steering assist increases to give lower steering efforts for improved maneuverability.
• A warning/functional light on the instrument panel provides self-diagnostics and a warning light in the situation of no assist.
• Torque sensor measures steering wheel input so the on-board computer can provide the appropriate output for various driving situations.

With the EPAS system, the operator maintains a direct mechanical linkage from the steering wheel to the front wheels. The power steering system interfaces mechanically with the steering system by being inserted between the steering wheel and the rack-and-pinion assembly.

A differential torque sensor is integrated into the power steering assembly. The circuit board assembly is also integral with the power steering assembly.

Power steering does not reduce turning radius but significantly reduces steering effort by approximately 85 percent compared to models without power steering.

EPAS interface diagram

EPAS interface diagram

The numbered descriptions refer to the EPAS interface diagram shown above:

1. Torque sensor
2. Electronic control unit (ECU)
3. Fail-safe relay
4. Current/thermal control circuit
5. Reduction gears
6. DC motor
7. Rack and pinion
8. Function/warning light
9. Key power and ground
10. Vehicle speed sensor
11. Instrument cluster
12. Relay module

The R trim is cab only and comes with a tan interior, cargo box power lift, roof-mounted light-emitting diode (LED) work lights, and heating, ventilation, and air conditioning (HVAC) as standard equipment. Electrical wiring for increased flexibility for attachments also comes standard.

R-trim level tan interior

• Headliner is standard
• Tan cloth 40/60 bench seat
• A and B post covers
• Rear panel cover
• Tan door panels
• Interior rearview mirror
• Sun visorsDome light
• Standard LED headlights with high and low beams
• Focused beam LED lights
• Cargo box power lift
• Windshield wiper and washer

Standard headliner

Tan cloth bench seat

Post cover

Post cover

Rear panel cover

Tan door panels

Rearview mirror

Sun visor

Sun visor

Dome light

LED headlight

Focused beam LED light

Cargo box power lift

Windshield wiper

Windshield washer