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Operating


Daily Operating Checklist

o Test safety systems.

o Check tire pressure.

o Check fuel level.

o Check engine oil level.

o Remove grass and debris from engine compartment, muffler area, and front grille, before and after operating machine.

o Check area below machine for leaks.

o Check brakes and park brake operation.

o Check coolant level.

o Check air restriction indicator.

o Tighten any loose hardware.

Avoid Damage to Plastic and Painted Surfaces

• Do not wipe plastic parts unless rinsed first.

• Insect repellent spray may damage plastic and painted surfaces. Do not spray insect repellent near machine.

• Be careful not to spill fuel on machine. Fuel may damage surface. Wipe up spilled fuel immediately.

Operator Station Controls


MX35827

A - Cargo Box Power Lift Switch (Optional)

B - Engine Oil Pressure Light

C - Glow Plug / Engine Coolant Temperature Light

D - Park Brake Light

E - Hour Meter

F - Headlight Switch

G - 12 VDC Accessory Outlet

H - Hazard Lights Switch (Optional)

I - Front Blade Lift/Lower Switch (Optional)

J - 2WD / 4WD Switch

K - Horn Switch (Optional)

L - Key Switch

M - Turn Signal Switch (Optional)


MX35564

Picture Note: Seat removed for clarity.

A - Fuel Gauge

B - Brake Pedal

C - Accelerator Pedal

D - Traction Assist Lever

E - Park Brake Lever

F - Transaxle Shift Lever

G - Fuel Tank Cap

Using Hand Holds


MX36049

Hand holds are provided for passenger balance. When a passenger is present, they shall use two of the four hand holds at all times while the machine is moving. The dash bar (A), OPS handle (B), side rail (C), and grab handle (D).

Adjusting Operator’s Seat

1. Stop machine and move transaxle shift lever to N (neutral) position.

2. Lock park brake.

c CAUTION: Avoid injury! Never adjust seat while machine is moving. Stop machine before adjusting seat to prevent loss of machine control.


MX35913

3. Push lever (A) to the left.

4. Slide seat forward or rearward to desired position.

5. Release lever.

Adjusting Passenger Seat

1. Tip seat forward.


MX31038

Picture Note: Rear position shown.

2. Hold onto seat and remove cap screws (A).

3. Slide seat to the forward (B) or rearward (C) position.

4. Position bottom of seat against bracket and align correct holes with holes in seat.

5. Install original hardware to secure seat.

6. Tighten seat bracket hardware to 10 N•m (7 lb-ft).

Using Seat Belt

NOTE: Shoulder harness is sensitive. An emergency lock device is built into the belt for your protection. To engage harness, pull harness slowly. Attempting to pull too fast or in a jerking motion will engage the locking mechanism and the harness will not release.

Periodically inspect seat belts for wear or damage. See Inspecting Seat Belt in the SERVICE MISCELLANEOUS section.


MX35574

Fasten Belt

1. Grasp outer seat belt connector (A) from behind seat, pull out and across body to inner connector (B), at inside of seat.

2. Push outer connector firmly into inner connector until it locks.

Release Belt

1. Press red button on inner connector to release seat belt.

Testing Safety Systems



c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

• Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

• Allow fresh outside air into the work area to clear the exhaust fumes out.

The safety systems installed on your machine should be checked before each machine use. Be sure you have read the machine operator manual and are completely familiar with the operation of the machine before performing these safety system checks.

Use the following checkout procedures to check for normal operation of machine.

If there is a malfunction during one of these procedures, do not operate machine. See your authorized dealer for service.

Perform these tests in a clear open area. Keep bystanders away.

Testing the Safety Start System

1. Sit on the operator’s seat.

2. Put key switch in OFF position.

3. Lock park brake.

4. Move transaxle shift lever forward to the high range position.

5. Turn key switch to start position. Engine should not crank. Turn key switch off.

6. Move transaxle shift lever to reverse position.

7. Turn key switch to start position. Engine should not crank. Turn key switch off.

Using Park Brake

c CAUTION: Avoid injury! Children or bystanders may attempt to move or operate an unattended machine.

Always lock the park brake and remove the key before leaving the machine unattended.

Locking the Park Brake:


MX31002

Picture Note: Seats removed for photo clarity.

1. Push down on brake pedal to hold machine in place.

2. Pull up on lever (A) and lock lever into position engaging park brake.

Unlocking the Park Brake:

1. Push down on brake pedal to hold machine in place.

2. Pull up on lever (A).

3. Depress button (B).

4. Release lever down completely.

Using Key Switch


MX35567, W00927

A - OFF Position - With key in off position, all switched power is off, and engine should not run.

B - ON Position - Turn key from off to this position and all switched power circuits will be energized. When the engine is cold, the glow plug / engine coolant light will illuminate for approximately 3 - 5 seconds.

C - START Position - Turn key to start position to start the engine. Release key after engine has started and it will automatically return to the on position. The engine will continue to run.

Using Headlights

Key switch must be in the run position to operate the lights. If the key switch is in the run position and the engine is not running, the battery will discharge if the lights are allowed to remain on for an extended period of time.


MX35568, MX30606

• Press at top of light switch (A) to turn headlights on.

• Press at bottom of light switch (A) to turn headlights off.

Using and Checking Instrument Panel


MX35827

A - Engine Oil Pressure Light - This light will turn on when the ignition key is in the ON position and the engine is not running. If this light turns on while the engine is running, engine oil pressure is too low. Stop engine.

c CAUTION: Avoid injury! The radiator will be hot and can burn skin. Built-up pressure may cause explosive release of coolant when the radiator cap is removed:

• Shut off the engine and allow to cool.

• Do not remove the cap unless the radiator and the engine are cool enough to touch with bare hands.

• Slowly loosen the cap to the first stop to release all pressure. Then remove the cap.

B - Glow Plug/Engine Coolant Temperature Light - This light will turn on when the key switch is placed in the ON position and the engine/glow plugs are cold. After approximately 3 - 5 seconds, the light will turn off. Additionally, this light will turn on when the engine coolant is approaching a dangerously hot temperature. If this light turns on during operation, remove load on machine immediately. Reduce engine to idle speed and check for something blocking air flow to the radiator and check engine coolant level. If light stays on after cleaning grille, stop engine.

C - Park Brake Light - This light will turn on when the key switch is in the ON position and the park brake is locked.

D - Hour Meter - The hour meter operates and displays when the engine is running. The hour meter shows the accumulated number of hours the engine has run. The hour meter is intended to provide a means of monitoring machine usage for maintenance purposes. Use the hour meter to determine when your machine has reached the recommended service intervals.

Using Accessory Outlet

c CAUTION: Avoid injury! Safe operation requires your full attention. Do not wear radio or music headphones while operating machine.

NOTE: Accessory must be rated at 10 amps or less.

The accessory plug does not turn off with the key switch. Items connected to the accessory plug will continue to draw power draining the battery.


MX35827

• Remove 12-volt outlet (A) cover and install accessory cord in outlet.

• Install cover in outlet after use.

Using Turn Signal Switch (Optional)

NOTE: Turn signals will continue to flash when the key is in the off position, draining the battery.


MX30608, MX35829

• Press at left end of turn signal switch (A) to signal a left turn.

• Press at right end of turn signal switch (A) to signal a right turn.

• Press at opposite end of turn signal switch (A) until switch is centered to turn signal light off.

Using Hazard Lights (Optional)

NOTE: Hazard lights will continue to flash when the key is in the off position, draining the battery.


MX30607, MX35830

• Press at top of hazard light switch (A) to turn hazard lights on.

• Press at bottom of hazard light switch (A) to turn hazard lights off.

Using Storage Tray

c CAUTION: Avoid injury! Never store flammable, heavy, or loose breakable objects in the storage tray. Always latch hood before operating machine.

IMPORTANT: Avoid damage! Do not store items that will not allow the hood to close properly. Properly secure loose or sharp items. These items may damage the storage tray or other items within the tray.



MX31762

Storage tray (A) is located in front of machine under the hood. This is a convenient location to carry personal articles such as an Operator’s Manual, spare parts, first aid kit, and/or tools. The storage tray has a total volume of 7210 cc (440 in.3).

1. Open hood to access the storage tray.

2. Secure all items to prevent damage from movement while operating the machine.

3. Close hood.

Starting the Engine

c CAUTION: Avoid injury! Engine exhaust fumes contain carbon monoxide and can cause serious illness or death.

Move the machine to an outside area before running the engine.

Do not run an engine in an enclosed area without adequate ventilation.

• Connect a pipe extension to the engine exhaust pipe to direct the exhaust fumes out of the area.

• Allow fresh outside air into the work area to clear the exhaust fumes out.

1. Sit on operator seat. Do not start engine at this time.

2. Push down on accelerator pedal to check free movement of pedal assembly. Release pedal.

NOTE: The machine has a neutral start safety switch. The engine will not start unless the transaxle shift lever is in N (Neutral) position.

3. Verify that transaxle shift lever is in N (Neutral) position.

4. Verify that park brake is locked.

c CAUTION: Avoid injury! Do not start engine by shorting across starter terminals. Bypassing normal circuitry will allow vehicle to start in gear.

Do not use starting fluid to aid engine starting.

Never start engine while standing on ground. Start engine only from operator’s seat.

5. Turn key switch to the ON position.

6. Check that the following indicator lights are on.

• battery discharge light

• oil pressure light

• glow plug/coolant temperature light for approximately 3 - 5 seconds

7. When the glow plug/coolant temperature light turns off, turn key to START position.

IMPORTANT: Avoid damage! Starter may be damaged if operated continuously for extended periods of time. Allow starter to cool down after several starting attempts.


8. Release key to the ON position when engine starts.

• If engine does not start within five seconds, turn key to OFF position and wait ten seconds before trying to start again.

• Attempt starting engine five times only, then wait 5 minutes before trying again. This will allow time for starter to cool and prevent damage to starter.

IMPORTANT: Avoid damage! Do not operate the engine at full throttle or under load until engine has warmed up, or engine damage could occur.


9. Run engine at half speed for 2 or 3 minutes to warm the engine.

Stopping Engine

c CAUTION: Avoid injury! Children or bystanders may attempt to move or operate an unattended machine.

Always lock the park brake and remove the key before leaving the machine unattended.

IMPORTANT: Avoid damage! Do not stop engine immediately after hard or extended operation. Keep engine running at low idle for about 2 minutes to prevent heat build-up.


1. Stop machine.

2. Move transaxle shift lever to N (Neutral) position.

3. Lock park brake.

4. Turn key switch to OFF position.

5. Remove key.

Using Travel Controls

1. Stop machine.

2. Allow engine to come to a low idle speed.

IMPORTANT: Avoid damage! Do not shift gears when vehicle is moving or with engine running above low idle speed. Push down brake to stop vehicle motion and engage shift lever with a firm positive action.

Gears may grind when shifting if engine idle speed is set higher than factory specification.



VG11348, MX31002

3. Select a gear position:

• Forward - Push shift lever forward to either high (A) or low (B) range.

• Reverse - Push shift lever to left, then pull rearward to reverse (C) gear.

4. Use the traction assist and/or 4WD On-Demand as needed.

5. Look in the direction the vehicle will travel.

c CAUTION: Avoid injury! Reduce speed before braking or turning, when hauling loads, and while operating around obstacles or on hazardous off-road conditions.


MX35831

6. Push down accelerator pedal (D) slowly and smoothly to begin machine travel.

7. Release accelerator and apply brake pedal (E) evenly and firmly to slow down or stop.

Using Traction Assist


VG11348, MX31002

Traction Assist (A) provides better traction when rear wheels start to slip. Engaging the traction assist will cause both rear wheels to turn together at equal speed.

c CAUTION: Avoid injury! Driving at high speeds with the traction assist engaged may result in loss of steering control. Do not engage traction assist or turn with the traction assist engaged while operating machine at high speeds or on slopes.

Engaging the Traction Assist:

IMPORTANT: Avoid damage! Incorrectly engaging traction assist may damage the transaxle.

Reduce speed before engaging or disengaging traction assist.


1. Stop or reduce engine speed to 1\3 throttle or less.


MX35572 VG11348

2. Push traction assist lever (A) forward to locked position (B):

• Traction assist will remain engaged as long as lever is forward.

Disengaging the Traction Assist

NOTE: To ensure true disengagement of traction assist, you must equalize torque on both axles.

1. Stop or reduce engine speed to 1/3 throttle or less.

2. Drive the vehicle straight ahead at a constant speed.

3. Pull lever rearward to unlocked position (C).

Using 4WD On-Demand

4WD On-Demand enables the front wheels to drive, but torque will not be applied until rear wheels begin to slip.

c CAUTION: Avoid injury! 4WD On-Demand greatly increases traction and may make dangerously sloped terrain accessible, increasing possibility of a tip-over.

Use extra caution when driving on slopes. Use 4WD On-Demand when driving on slopes to increase traction.

Use 4WD On-Demand when driving on icy, wet or graveled surfaces; reduce speed to avoid skidding and loss of steering control.

IMPORTANT: Avoid damage! Engaging 4WD On-Demand when the machine is stopped and the rear wheels are spinning will damage the gears.



MX35563

• Push in on top of 2WD/4WD switch (A) to enable the 4WD On-Demand system.

• Push in on bottom of switch to disable the system.

c CAUTION: Avoid injury! Front implements may cause decreased traction at the rear wheels resulting in loss of control. Always operate machine with 4WD On-Demand engaged when front implements are attached.

Tips for operating 4WD On-Demand:

NOTE: Occasionally the 4WD On-Demand system will not disengage after a change in vehicle travel direction. This is known as “wedging”. If this does occur, the vehicle will exhibit higher than usual steering efforts and driveline wind-up. To disengage (un-wedge) the system, reverse the direction of vehicle travel.

• Maintain recommended front and rear tire pressures to ensure optimum performance on all surface conditions.

• Disable 4WD On-Demand when driving machine on paved or hard packed surfaces to increase front tire life and reduce drive train wear.

Raising and Lowering Cargo Box

Manual Lift

c CAUTION: Avoid injury!

Park machine on a level surface and lock park brake before manually raising and securing cargo box in raised position.

A cargo box containing material can be heavy. Empty some or all material until cargo box can safely be raised manually.

1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)

2. Empty cargo box by hand.


MX31003

3. Release latch (A) by pushing inward toward center of machine. Raise cargo box manually with lift handle (B) on side of cargo box.

c CAUTION: Avoid injury! Cargo box can fall if not secured properly. Remove key from ignition and lock support rod securely before doing any service under raised cargo box.


MX32406

4. Push support rod (C) down to lock into slot (D) when cargo box is fully raised.

5. To lower cargo box, raise cargo box slightly using lift handle.

6. Release support rod from latch slot by pulling up on lower end of rod.

NOTE: Lowering the box completely will allow the support rod to latch at the front of cargo box.

7. Slowly lower cargo box. Support rod will slide along slotted channel.

8. Push down on cargo box handle until support rod latches into cargo box with an audible snap.

Power Lift (Optional)

IMPORTANT: Avoid damage! A “hissing” or “squealing” sound when cargo box is fully raised or lowered or when box is heavily loaded indicates hydraulic system operating at pressure relief. To prevent unnecessary wear or damage, minimize operation at pressure relief. Do not operate the Power Lift actuator beyond full stroke or exceed the cargo box weight capacity.


1. Park the vehicle safely. (See Parking Safely in the SAFETY section.)

2. Turn key to ON position.


MX30610, MX30998

3. The cargo box switch (A) is located on the left side of the instrument panel.

4. Raise cargo box by pressing and holding top of rocker switch (B). Release switch when box is at desired dump height or when reaching maximum height.

NOTE: Allowing the Power Lift hydraulics to operate at pressure relief briefly (less than one second) after cargo box is fully lowered will help keep cargo box secure and reduce rattling caused by travel vibrations.

5. Completely lower cargo box by pressing and holding bottom of rocker switch (C).

6. Turn key to OFF position.

Emptying Cargo Box

c CAUTION: Avoid injury! Raising a loaded cargo box changes the center of gravity. Keep vehicle a safe distance from the edge of ravine or drop-off when raising cargo box to empty.

A loaded cargo box can be very heavy. Do not attempt to manually raise a loaded cargo box. Unload cargo box before raising it by hand.


M78552

1. Back up vehicle to dump site.

2. Park the vehicle safely. (See Parking Safely in the SAFETY section.)

3. Open tailgate.

IMPORTANT: Avoid damage! Stop emptying immediately if actuator clutch slippage occurs. Lower cargo box completely and remove excess load by hand before dumping.


4. Raise cargo box to dump load.

5. Lower cargo box when empty.

6. Close tailgate. Do not drive vehicle with cargo box in raised position.

Operating the Tailgate

c CAUTION: Avoid injury! Riders can fall off and be injured or killed. Do not allow riders in the cargo box or on the tailgate.


MX31765

1. Push in and down on loop (A) of tailgate latch rods to unhook rods from slot (B) in tailgate.

2. Pull latch rods out and down.

c CAUTION: Avoid injury! When raising or lowering tailgate, latch rods can swing abruptly towards operator. Slowly lower or raise tailgate to make sure latch rods do not injure operator.


MX31766

3. Lower tailgate until it rests on ends of latch rods (C).

IMPORTANT: Avoid damage! Do not drive vehicle with tailgate unsupported and hanging down. Lugs on tires will contact tailgate causing structural damage.



MX31009


MX31765

4. To raise tailgate, slowly push tailgate upward. Push inward and upward on loop (A) of latch rod to engage rod in slot (B) in tailgate.

Removing Tailgate


MX31006

1. Remove and retain rubber hose sleeves from latch rod ends (A).

2. Raise tailgate slightly and rotate latch rods to disengage from slots (B) in cargo box sides.

3. Remove latch rods from sides of tailgate.

4. Support tailgate by hand.


MX31008

5. Remove retaining ring (C) and bushing (D) from each tailgate rod end.

6. Slide tailgate sideways so tailgate rod end is clear of the cargo box bracket.

7. Pull the detached end of tailgate away from the cargo box just enough to clear the cargo box bracket and allow the tailgate to slide in opposite direction to complete removal.

8. To install, reverse the steps.

Installing Tailgate Latch Rods


MX31768

1. Identify right (A) and left (B) latch rods.


MX31769

Picture Note: Left side shown.

2. Route latch rod through tailgate opening (C) as shown.


MX31770, MX31771

3. Raise tailgate slightly from horizontal position. Insert end of latch rod through slot (D) in cargo box bracket. Rotate rod around the bracket to secure.

4. Install rubber hose sleeve onto rod end (E).


MX31765

5. Raise tailgate, push inward and upward on latch rod to engage rod in slot (F) in top rail.

Loading the Cargo Box

c CAUTION: Avoid injury! The utility vehicle may become unstable if the cargo box is loaded incorrectly. Avoid loose and shifting loads or uneven loading of material.

• Do not load above height of load guard.

• Securely anchor all loads in cargo box.

• Do not load beyond maximum capacity.


M78553

Maximum payload capacity on level terrain for the cargo box is 408 kg (900 lb).

Reduce load by half when operating over rough, hilly, or steep terrain. Do not overload vehicle. Limit loads to those that can be safely controlled.

Reduce speed and exercise extreme caution when operating over rough, hilly, or steep terrain.

Securely anchor and evenly distribute loads in cargo box, when loading objects into vehicle. Shifting loads will affect stability.

Do not load above load guard.


M78556

Avoid concentrated loads at rear or side of cargo box to prevent vehicle from tipping over. Be sure load is evenly distributed.

Because there is a big difference in weight between dry and wet sand, the only way of getting true weight of the load you are carrying is by using a scale.

For example, dry sand weighing 250 kg (550 lb) would be approximately 1/2 of cargo box volume.

Printed weight is normally on bagged and other material.

Towing Loads

c CAUTION: Avoid injury! Excessive towed load can cause loss of traction and loss of control on slopes. Stopping distance increases with speed and weight of towed load.

Do not tow a load that exceeds the maximum allowable towing load for this vehicle, as specified in this operator’s manual.

• To provide adequate braking ability and traction, weight of towed load (trailer plus cargo) must never exceed the vehicle payload (operator plus passenger plus cargo box load).

• Do not tow a load that exceeds the maximum allowable towing load for this vehicle, as specified in this operator’s manual.

• Do not tow a load that exceeds 590 kg (1300 lb).

• Do not exceed a tongue weight of 59 kg (130 lb).

• Tow load at a speed slow enough to maintain control.

IMPORTANT: Avoid damage! Extreme angles such as high railroad crossings can place high bending loads on hitch connection (A). Traversing terrain where the preceding conditions exist, use a ball type hitch.



M78554

• Always use approved hitch and hitch point provided for the utility vehicle. DO NOT modify the hitch or hitch point in any way.

Using Correct Tires and Inflation

When replacing tires, always check the tire on the opposite side of the vehicle for excessive tread wear. Excessive variations in tread wear between opposite tires may cause the vehicle to pull to one side.

Tires

c CAUTION: Avoid injury! Help prevent severe bodily injury or death, failure to observe these recommendations may result in loss of stability and operator control.

Use of John Deere approved original equipment or optional equipment is recommended. To ensure maximum machine performance and ride quality, do not mix size, type, or placement of tires. Failure to place tires per the guidelines could result in reduced machine performance, diminished traction and poor handling.

All Trail II tires

• 24x9.5-10 tires installed on front.

• 24x10.5-10 tires installed on rear.

AT489 tires

• 24x9.5-10 tires installed on front.

• 24x12.0-10 tires installed on rear.

These are directional tires. Directional type tires have directional arrows located on the tire sidewall. These tires should be installed with the directional arrow pointing in the forward direction of travel.

Turf Trac RS tires

• 24x9.5-10 tires installed on front.

• 24x12.0-10 tires installed on rear.

Inflation

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.

IMPORTANT: Avoid damage! Over inflation may damage tires and diminish ride quality. Under inflation could cause wheel damage when riding over rough terrain.


NOTE: Improper tire pressure can make it difficult to disengage 4WD On-Demand.

An accurate low pressure gauge is available at your John Deere dealer.

1. Check tires for damage.

2. Check tire pressure with an accurate gauge.

3. Add or remove air, if necessary.

Tire

Pressure

Front

97 kPa (14 psi)

Rear

97 kPa (14 psi)


Tire Chains

IMPORTANT: Avoid damage! Loose tire chains can cause machine damage. Periodically check chain tightness and adjust as necessary.


Chains are available for all four wheels from your John Deere dealer.

Transporting Vehicle

IMPORTANT: Avoid damage! Never tow the machine above 40 km/h (25 mph). Towing a machine at speeds above 40 km/h (25 mph) will result in transaxle damage. To avoid damage, haul the machine on a heavy-duty trailer or on a full-size truck.

Never use a car type dolly with the front wheels on the dolly.


NOTE: Space limitations may vary from one truck manufacturer to another. Short bed trucks do not have the necessary length requirement to accommodate the machine.


M78557

1. Drive utility vehicle onto the trailer or truck.

2. Leave transaxle shift lever in forward or reverse gear.

3. Park vehicle safely (See Parking Safely in the SAFETY section.)

4. Fasten vehicle to trailer or truck with straps, chains, or cables.

5. Equip the trailer or truck with all the necessary lights and signs required by local, state, provincial, or federal laws.