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Assembly


Prepare Vehicle For Assembly

1. Remove top and sides of shipping crate.

2. Remove seats and packaged parts from vehicle.

3. Remove tires from cargo box and sides of vehicle.


MX33312

Picture Note: TH 6x4 model shown.

4. Locate two shipping brackets (A) on each side of vehicle frame.

5. Remove self-tapping screws (B) on each side. Retain these four screws to install the load guard later.

c CAUTION: Avoid injury! Cargo box is heavy. Use a safe lifting device or get an assistant to help lift, install or remove cargo box.

6. Lift cargo box off vehicle frame.

7. Remove self-tapping screws (C) and shipping brackets (A) on each side. Discard the shipping brackets.

8. Install two self-tapping screws (C) back into holes on the right side of vehicle previously removed. Install one of these screws into rear hole on left side of vehicle. Discard the last screw.


MX33313

Picture Note: TS and TH 6x4


MX34257

Picture Note: TX Models

9. Remove hardware (D) on each side of rear corner of frame area.


MX33314

10. Remove two self-tapping screws (E) on front foot platform. Discard the shipping hardware.

Install Wheels

c CAUTION: Avoid injury! The machine can fall or slip from an unsafe lifting device or supports.

• Use a safe lifting device rated for the load to be lifted.

• Lower machine onto jack stands or other stable supports and block wheels before servicing.

Install Rear Wheels TS and TH (All Wheels TX)

NOTE: Front wheels on TX models use the same procedure as rear wheel installation.

1. TH 6x4 only: Measure circumference of rear tires. Select the wheels with largest tire circumference for the most rearward position to provide the best ground contact for drive wheels.

2. Install plastic cap on each rear axle hub.

3. Raise rear of vehicle with a safe lifting device. Place support stands under vehicle.


MX33500

4. Attach each rear wheel to axle hub with valve stem to outside using five wheel bolts. Tighten wheel bolts evenly in proper sequence (A), (B), (C), (D), and (E) until snug. Finish tightening to 88 N•m (65 lb-ft) using a torque wrench.

5. Remove support stands and lower vehicle.

Install Front Wheels TS and TH

1. Raise front of vehicle with a safe lifting device. Place support stands under vehicle.

2. Slide front wheels onto front axle hubs.

IMPORTANT: Avoid damage! Over tightening front wheel bolts can result in bearing damage.



MX33641

3. Secure front wheels with M16x40 flange cap screws (A). Tighten cap screws to 88 N•m (65 lb-ft) using torque wrench.

4. Install plastic hub caps (B).

Checking Tire Pressure

c CAUTION: Avoid injury! Explosive separation of tire and rim parts is possible when they are serviced incorrectly:

• Do not attempt to mount a tire without the proper equipment and experience to perform the job.

• Do not inflate the tires above the recommended pressure.

• Do not weld or heat a wheel and tire assembly. Heat can cause an increase in air pressure resulting in an explosion. Welding can structurally weaken or deform the wheel.

• Do not stand in front or over the tire assembly when inflating. Use a clip-on chuck and extension hose long enough to allow you to stand to one side.

1. Check tires for damage.

NOTE: Refer to the SPECIFICATIONS section for tire pressures.

2. Check tire pressure with an accurate gauge.

3. Add or remove air, if necessary.

Install Steering Wheel

1. Remove and discard plastic protective cap from steering shaft.

2. Install steering wheel onto steering shaft. Turn steering wheel to position front wheels straight and facing forward.

3. Remove steering wheel.

4. Apply multi-purpose grease to steering shaft.


MX33317

5. Install steering wheel onto steering shaft with one spindle (A) positioned at 180? at bottom of wheel and spindles (B) at approximately 45? at top of wheel, as shown.

6. Install nut (C) and tighten to 38 N•m (28 lb-ft).


MX33318

7. Install cover (D) so the John Deere name is positioned properly.

Check Battery Voltage

c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode:

• Do not smoke or have open flame near battery.

• Wear eye protection and gloves.

• Never check battery charge by placing a metal object across the posts. Use a voltmeter or hydrometer.

• Do not jump start or charge a frozen battery. Warm battery to 16?C (60?F).


MX33315

Picture Note: TS model shown.

Locate access cover (A) on passenger side. Remove and discard fastener (B), pull back on latch (C), and remove panel.

Remove and discard the protective caps from the positive (+) and negative (-) terminals.

Battery is filled with acid and charged when it left the factory. To extend battery life, check voltage prior to delivery. Fully charge the battery if voltage is less than 12.6 volts.

Connect Battery


MX33294

Picture Note: TS model shown.

1. Install red positive battery cable (A) to positive (+) terminal first using M6x16 cap screw, flat washer, and nut. Tighten the connection.

2. Install black negative battery cable (B) to negative (-) terminal last using M6x16 cap screw, flat washer, and nut. Tighten the connection.

3. Apply petroleum jelly on battery terminals to help prevent corrosion.

4. Slide protective cover down the battery positive cable and seat it over the positive (+) terminal.


MX33315

Picture Note: TS model shown.

5. Install service access panel (C).

Install Seats

Standard Seat:


MX33319

1. Remove screws (A) from bottom of seat base bracket on each seat.


MX33320

2. Install seat bushings (B) onto support rail so tabs face toward rear of vehicle.


MX33429

3. Position seat base bracket onto support rail so hinges (C) fit around plastic bushing tabs.

NOTE: Install seat hardware in the correct slots in the bracket. Always use set of slots closest to center of vehicle when installing seat.


MX33430

4. Rotate seat bracket upward. Install original hardware in slots closest to center of vehicle to secure seat. Do not tighten completely.

5. Slide seat forward or rearward to desired position.

6. Tighten seat cap screws to 9 N•m (80 lb-in).

7. Repeat for opposite side.

Driver Seat with Lever System:


MX33431

1. Remove hex flange nuts (A) and metal bushings with seat glide spacers from bottom of seat pivot bracket (B) on each seat.

NOTE: If installing a cab onto machine, loosen socket head screws (C) and slide seat forward within the slots. Tighten screws to 9 N•m (80 lb-in).


MX33749

2. Keep four plastic washers (D) and seat adjust lever (E) on seat mount bracket.


MX33432

3. Install seat bushings (F) onto support rail so tabs face toward the rear of the vehicle.


MX33433

4. Position seat pivot bracket (B) onto support rail so hinges (G) fit around bushing tabs.

IMPORTANT: Avoid damage! Be sure not to lose or displace the plastic washers (D) or seat adjust lever (E) when raising seat into mounting position.



MX33964

5. Rotate seat pivot bracket (B) upward, and install seat assembly to the seat pivot bracket, using care not to lose or displace the plastic washers (D) or seat adjust lever (E).

6. Install four seat glide spacers (H) and four metal bushings (I).

NOTE: Make sure to align the metal bushings (I) with the holes of the plastic washers (D), in addition to aligning the glide spacers (H) with the slots of the pivot bracket prior to tightening the nuts, or the assembly will not slide freely.

7. Loosely install four hex flange nuts (A) and move seat assembly back and forth, and side-to-side to set the seat glide spacer (H) and metal bushings (I) into the slots of the pivot bracket (B) and the holes of the plastic washers (D).

8. Tighten nuts (A) to 25 N•m (18 lb-ft).

9. Lower seat, and slide seat forward or rearward to desired position, by holding the seat adjust lever (E) up. Release the lever to lock the seat into position.

Install Spark Arrestor (TS)


MX32941

1. Loosen screw installed in spark arrestor assembly (A) and place onto muffler exhaust pipe. Tighten screw.

Install Belly Pan Button Plug


MX33708

1. Snap the button plug (A) into the hole (B) located at the front of the belly pan on the underside of the vehicle.

Install Cargo Box with Power Lift Kit

A cargo box power lift kit is available as an option. When installing the Power Lift for Cargo Bed Kit, see the separate installation instructions included in the kit.

Continue on in the assembly instructions with “Install Load Guard” procedure after power lift kit and cargo box have been installed.

Install Cargo Box with Prop Rod

c CAUTION: Avoid injury! Cargo box is heavy. Use a safe lifting device or get an assistant to help lift, install or remove cargo box.


MX33435

Picture Note: TS model shown.

1. Position cargo box onto vehicle frame so hinges (A) are positioned inside pivot brackets (B).

2. Secure cargo box using M12x90 cap screws and flange locknuts (C). Install cap screw with threads to the outside of vehicle.

3. Tighten cap screws until pivot brackets contact ends of hinge.

4. Apply a spray lubricant to the pivot hardware, hinges, and pivot brackets.


MX33436


MX31392

5. To install cargo box support rod, have a second person raise and hold cargo box securely.

6. Install 90? end (D) of support rod into hole (E) in cargo box channel, as shown. To secure top end of rod, install push-on nut (F) to a depth of 20 mm (0.79 in.).

7. Lower opposite end of support rod, and push inward on rod forcing it over sill (G).

8. Route end (H) of support rod into slot (I).

9. To lower cargo box, raise cargo box slightly using lift handle on side of cargo box.

10. Release support rod from latch slot (I) by pulling up on lower end of rod.

11. Lower the cargo box, and push down on cargo box handle until support rod latches into cargo box with an audible snap.

Install Load Guard

1. Raise and secure cargo box.


M78495

2. Install load guard (A) to cargo box so bottom lip (B) is positioned on underside of box and square tube frame (C) is to the inside of box.

3. Secure bottom of load guard with six M8x20 carriage bolts, flat washers, and flange locknuts (D). Tighten locknuts to 25 N•m (18 lb-ft).

4. Attach both sides of load guard using two self-tapping screws (E) retained from shipping brackets on cargo box.

Remove Protective Film

Remove Hood


MX33959

1. Stand in front of vehicle, and grasp hood near arrow marks (A). Pull out firmly.

IMPORTANT: Avoid damage! When removing hood (B), set hood in an upright position and not on top side of hood.


2. Pull forward on hood (B) and remove hood from under dash panel (C).

Remove Protective Film

• Remove white protective film (D) from around fenders and hood.

Install Hood

1. Install hood (B) under dash panel (C).

2. Pivot hood downward, pushing near arrows (A) to secure rubber retainers on hood tabs onto molded retainers on front fenders.

Clean and Polish Plastic Hood and Fenders

IMPORTANT: Avoid damage! Improper care of machine plastic surfaces can damage the surface:

• Do not wipe plastic surfaces when they are dry. Dry wiping will result in surface scratches.

• Use only cheesecloth for wiping surfaces.

• Do not use abrasive materials, such as polishing compounds, on plastic surfaces.

• Do not spray insect repellent near machine.


1. Remove any dust or dirt with water.

2. Dry thoroughly to avoid water spots.

3. Spray PLEDGE®1 onto plastic surfaces and leave on for 30 to 60 seconds.

4. Use a dry soft cloth to wipe off to bring out lustre.

Check Fluid Levels

• Check all fluid levels.

Check Machine Safety System

Perform safety system check to make sure the electronic safety interlock circuit is functioning properly. Perform all tests. (See Testing Safety System in the OPERATING section.)

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PLEDGE® is a Registered Trademark of S.C. Johnson, Co.