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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 Tighten loose hardware.

o Remove debris from engine compartment, especially around brake linkage on each side of the transaxle.

o Check to make sure air intake is clean.

o Check area below machine for leaks.

o Check brakes and park brake operation.

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.

Using Hand Holds


MX37244

Hand holds are provided for passenger balance. When a passenger is present, they shall use both of the hand holds at all times while the machine is moving: the dash bar (A), and the side rail (B) to the right of the seat.

Adjusting Standard Seat

1. Tip seat forward.

NOTE: If seat is removed, install seat hardware in the correct slots in the bracket. Always use set of slots closest to center of vehicle when installing seat.


MX33430

Picture Note: Passenger seat shown.

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

3. Slide seat forward or rearward for desired position.

4. Tighten seat cap screws to 10 N•m (7 lb-ft).

Adjusting Driver Seat with Lever System (If Equipped)

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

2. Lock park brake.


MX32935

3. Pull up on lever (A), and slide seat forward or rearward until seat locks in place (for desired position).

4. Release lever.

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


MX33434

5. If further adjustment is necessary, tip seat forward, hold onto seat, and loosen nuts (B).

6. Slide seat forward or rearward to desired position.

7. Tighten nuts to 24 N•m (18 lb-ft).

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 in STOP position.

3. Lock park brake.

4. Move gear shift lever to forward position.

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

6. Move gear shift lever to reverse position.

7. Move key to start position. Engine should not crank. Turn key 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.

Park Brake - Traction Assist (Differential Lock) Interlock Linkage

MX38370

The park brake lever (A) and traction assist lever (B) are connected by linkage which automatically moves the traction assist lever forward to the engaged position when the park brake lever is raised into it’s locked position. The park brake and differential lock lights in the instrument panel will both illuminate when the park brake is locked.

When the park brake lever is unlocked and pushed fully down, the traction assist lever may, or may not, return to the disengaged position automatically. The traction assist lever may have to be manually pulled back to the disengaged position, if desired.

The interlock linkage is designed so that when the park brake is in the unlocked position, the traction assist lever functions normally, independent from the park brake lever.

Locking the Park Brake:

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

2. Pull up on park brake lever (A) and lock lever into position engaging park brake. Traction assist lever (B) will pivot forward to the engaged position as the park brake lever is raised.

Unlocking the Park Brake:

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

2. Pull up on park brake lever (A).

3. Depress button (C).

4. Release park brake lever down completely.

5. Pull traction assist lever (B) back to disengage, if necessary.

Using Key Switch


W00927

Picture Note: Key switch label.

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

B - Run Position - Turn key from STOP to this position and all switched power circuits will be on.

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

Using Headlights

Ignition switch/Key must be in the run position to operate the lights. If the Ignition switch/key 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.

• Press top of light switch to turn headlights on.

NOTE: Be sure to turn lights off and turn the ignition switch/key to STOP position, or lights will discharge battery.

• Press bottom of light switch to turn headlights off.

Using and Checking Instrument Panel


MX37246

A - Voltmeter (Optional) - This gauge indicates system voltage. Indicator should be near center position while engine is running. If indicator is in either low or high (red) positions, stop engine and go through diagnostic procedures to repair problem.

B - Battery Discharge Light - This light will illuminate when the ignition key switch is in the run position and the engine is not running. If this light illuminates when the engine is running, see your John Deere dealer.

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.

C - Engine Coolant Temp / Glow Plug Light - This light will illuminate when the key switch is placed in the run position and the engine/glow plugs are cold. After approximately 3 - 5 seconds, the light will turn off. Additionally, this light will illuminate when the engine coolant is approaching a dangerously hot temperature. If this light illuminates 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, stop engine.

D - Speedometer (Optional) - The speedometer indicates machine speed in Km/hr (mph)

E - Park Brake Light - This light will illuminate when the key switch is in the run position and the park brake is locked.

F - Traction Assist (Differential Lock) Light - The traction assist light will illuminate when the traction assist lever is engaged and the differential lock system is engaged within the transaxle. Traction assist light will go out when lever is disengaged, and the differential lock system within the transaxle is disengaged.

G - Engine Oil Pressure Light - This light will illuminate when the ignition key is in the run position and the engine is not running. If this light illuminates while the engine is running, engine oil pressure is too low. Stop engine

IMPORTANT: Avoid damage! Hour meter will accumulate hours when the ignition/key switch is in the Run position. Turn key to STOP to avoid a false hour meter reading.


H - Hour Meter - The hour meter operates and displays when the key switch is in the run position. 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.

• Remove 12-volt outlet 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 ignition switch/key is in the STOP position, draining the battery.

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

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

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

Using Hazard Lights (Optional)

NOTE: Hazard lights will continue to flash when the ignition switch/key is in the STOP position, draining the battery.

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

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

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 ignition/key switch to the Run 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 ignition/key switch 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 ignition/key switch to the Run position when engine starts.

• If engine does not start within five seconds, turn ignition/key switch to STOP 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 ignition/key switch to STOP position.

5. Remove key (if key operated).

Using Travel Controls

1. Push down brake to stop vehicle.

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.



M151644, MX32938

3. Select a gear position:

• Forward - Push shift lever to right, then push forward to (A) gear.

• Neutral - Push shift lever to right then to center (neutral) position (B).

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

4. Use the traction assist 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.


MX32936

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

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

Using Traction Assist (Differential Lock)


MX32938

Traction assist (A) is a differential lock system which provides better traction to the rear wheels when needed. Engaging the traction assist will cause both rear wheels to turn together at equal speed.

The traction assist light will turn on when the traction assist lever is engaged and the differential lock system within the transaxle is engaged. Traction assist light will go out when lever is disengaged, and the differential lock system within the transaxle is disengaged.

Interlock linkage connects the park brake lever and traction assist lever so that the traction assist is automatically engaged when the park brake is in the locked position. When the park brake lever is in the unlocked position, the traction assist lever functions normally, as described in this section.

c CAUTION: Avoid injury! Driving at high speed with the traction assist engaged may result in loss of steering control. Do not engage traction assist while operating vehicle at speeds in excess of 16 km/h (10 mph).

Turning with the traction assist engaged increases the turning radius of the machine. Do not turn with the traction assist engaged while operating vehicle at speeds in excess of 16 km/h (10 mph).

Engaging the Traction Assist:

IMPORTANT: Avoid damage! Using the traction assist function improperly can damage the transaxle:

• Reduce speed and allow drive wheels to rotate at same speed before engaging or disengaging traction assist.

• Disengage traction assist when driving on dry asphalt or concrete.

• Use traction assist only when necessary for improved ground engagement.


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


M151644, MX32938

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

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

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

3. Reduce engine speed to 1\3 throttle or less.

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.


MX37142

3. Release latch (A) by pushing inward toward center of vehicle. 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.


MX37143

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 “clicking” or “ratcheting” sound when cargo box is fully raised or lowered or when box is heavily loaded indicates actuator clutch slippage. To prevent unnecessary wear or damage, keep clutch slippage to a minimum. 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 run position.

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

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

NOTE: Allowing the Power Lift actuator clutch to slip briefly (click or ratchet) 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.

IMPORTANT: Avoid damage! Hour meter will accumulate hours when the ignition/key switch is in the Run position. Turn key to STOP to avoid a false hour meter reading.


6. Turn key to STOP position.

Operating the Tailgate

c CAUTION: Avoid injury! Seating is provided for the operator and one passenger. Do not allow riders in the cargo box or on the tailgate. Extra riders can fall off and be seriously injured or killed.


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 outward abruptly towards operator. Stand in center of tailgate and slowly lower or raise tailgate to make sure latch rods do contact operator.


MX31766

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

IMPORTANT: Avoid damage! Lower tailgate completely to unload cargo box only. Never drive with the tailgate hanging down. Tailgate can contact tires and cause damage.


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


W00906

Maximum payload capacity on level terrain for the cargo box is 544 kg (1200 lb).

Reduce load by half when using run-flat (extended mobility) tires.

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 544 kg (1200 lb) would be approximately 3/4 of cargo box volume.

Printed weight is normally on bagged and other material.

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! A “clicking” or “ratcheting” sound when cargo box is fully raised or lowered or when box is heavily loaded indicates actuator clutch slippage. To prevent unnecessary wear or damage, keep clutch slippage to a minimum. Do not operate the Power Lift actuator beyond full stroke or exceed the cargo box weight capacity.


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.

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 + cargo) must never exceed the vehicle payload (operator + passenger + cargo box load).

• DO NOT tow a load that exceeds 635 kg (1400 lb):

• DO NOT exceed a tongue weight of 45 kg (100 lb).

• Never exceed 16 km/h (10 mph) when towing a load. 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.



W00934, W00935

• 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

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.

Knobby tires

• 22.5x10-8 tires installed on front.

• 25x12-9 tires installed on rear.

Heavy Duty All Purpose (HDAP)

• 22.5x10-8 tires installed on front.

• 25x13-9 tires installed on rear.

Turf

• 22.5x10-8 tires installed on front.

• 25x12-9 tires installed on rear.

Run-Flat - EMT (Extended Mobility Tire)

• 22x11-10 tires installed on front.

• 25x11-10 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.


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 and Rear
(Knobby, Turf, and Heavy Duty All Purpose (HDAP)

41 kPa (6 psi)

Front and Rear
(Run-Flat - EMT (Extended Mobility Tire))

28-34 kPa (4-5 psi)


Tire Chains

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


NOTE: For TH 6x4 and M-Gator models, chains are available for rearmost wheels only.

Chains are available for rear wheels only from your John Deere dealer.

Transporting Vehicle

IMPORTANT: Avoid damage! Never tow the vehicle above 32 km/h (20 mph). Towing a vehicle at speeds above 32 km/h (20 mph) will result in transaxle damage. To avoid damage, haul the vehicle 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.


W00905

1. Back utility vehicle onto the trailer or truck.

2. Leave gear 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.

6. Remove or secure optional attachments, if equipped.