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OPERATOR’S MANUAL

North American Edition Printed in USA

Heavy Duty Blade 72-Inch

LP650461016991 Rev D

09/13/16English

Using Your Operator’s Manual

Read this entire operator’s manual, especially the safety information, before operating.

This manual is an important part of your machine. Keep all manuals in a convenient location so they can be accessed easily.

Use the safety and operating information in the attachment operator’s manual, along with the machine operator’s manual, to operate and service the attachment safely and correctly.

If your attachment manual has a section called Preparing the Machine, it means that you will have to do something to your tractor or vehicle before you can install the attachment. The Assembly and Installation sections of this manual provide information to assemble and install the attachment to your tractor or vehicle. Use the Service section to make any needed adjustments and routine service to your attachment.

If you have any questions or concerns with the assembly, installation, or operation of this attachment, see your local John Deere dealer.

Warranty information on this John Deere attachment can be found in the warranty statement included in this manual.

Introduction

Original instructions. All information, illustrations and specifications in

this manual are based on the latest information available at the time of

publication.

The right is reserved to make changes at any time without notice.

NOTE: It is recommended for best operation that all utility vehicles be equipped with a heavy-duty strut package and that models 625i and 855D be equipped with a high-output alternator.

2

Product Identification

Product Compatibility

This 72-Inch Heavy Duty Blade is compatible with 625i, 825i, and 855D XUV Series Gator™ Utility Vehicles.

Record Purchase Information

Record your purchase information in the spaces provided below.

DATE OF PURCHASE:

________________________________________

DEALER NAME:

________________________________________

DEALER PHONE:

________________________________________

Table of Contents

Introduction 2

Product Identification 2

Safety Labels 3

Safety 4

Assembly 6

Preparing Vehicle 8

Installing 12

Operation 20

Removing and Storing 22

Service 24

Troubleshooting 26

Specifications 31

Warranty 32

B

Safety Labels

CAUTION label cautioning operators to watch for sudden stops, and to travel at slow speed during operation.

3

Understanding The Machine Safety Labels

The machine safety labels shown in this section are placed in important areas on your machine to draw attention to potential safety hazards.

On your machine safety labels, the words DANGER, WARNING, and CAUTION are used with this safety-alert symbol. DANGER identifies the most serious hazards.

The operator’s manual also explains any potential safety hazards whenever necessary in special safety messages that are identified with the word, CAUTION, and the safety-alert symbol.

Replace missing or damaged safety labels. Use this operator’s manual for correct safety label placement.

There can be more safety information contained on parts and components sourced from suppliers that is not reproduced in this operator’s manual.

French and Spanish Safety Labels and Operator’s Manual

Operator’s manuals and safety labels with content in French or Spanish are available for this machine through authorized John Deere dealers. See your John Deere dealer.

Safety Label Locations

Jammed Blade Label

Sudden Stop Label

WARNING label describing potential for spring-loaded blade suddenly returing during operation.

Read Safety in Machine Operator’s Manual

Read the general safety operating precautions in your machine operator’s manual for additional safety information.

Safety

Operating Safely

• This attachment is intended for light duty moving of snow or other light, loose material and is not intended for digging or grading. Do not misuse this equipment.

• Do not exceed operating speed of 16 km/h (10 mph) when moving material with this attachment.

• Read, understand and follow all instructions in the manual and on the vehicle and attachment before operating.

• Only allow responsible adults who are familiar with the instructions to operate the machine.

• Inspect machine and attachment before you operate. Be sure hardware is tight. Repair or replace damaged, badly worn or missing parts. Be sure guards and shields are in good condition and fastened in place. Make any necessary adjustments before you operate.

• Check brake action before you operate. Adjust or service brakes as necessary.

• Stop machine if anyone enters the area.

• If you hit an object, stop and inspect the machine. Make repairs before you operate. Keep machine and attachments properly maintained and in good working order.

• Before operating, make sure all connections are tight and blade responds properly to controls. Check all connections periodically for tightness.

• Do not leave machine unattended when it is running.

• Only operate during daylight or with good artificial light.

• Be careful of traffic when operating near or crossing roadways.

• Do not wear radio or music headphones while operating the machine. Safe operation requires your full attention.

• Transport the blade with it raised to the highest position, it should be centered and not at an angle.

• Be aware of the position of the blade ends. Blade makes a wide arc when turning.

• Be aware of the possibility of objects hidden under the snow. Avoid holes, rocks, roots and other obstructions.

• Avoid the edges of ditches and banks to reduce the possibility of loss of control.

• When plowing material into a pile, travel in reverse before raising blade.

• Do not ram into a pile of material; slow down before contact is made.

• Lower attachment completely before leaving operator’s seat.

• Lower any attachment completely to the ground or to an existing attachment mechanical stop before servicing the attachment. Disengage all power and stop the engine. Lock park brake and remove the key.

• Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Replace all worn or damaged safety and instruction decals.

Parking Safely

1. Stop machine on a level surface, not on a slope.

2. Lower attachments to the ground.

3. Lock the park brake.

4. Stop the engine.

5. Remove the key.

6. Wait for engine and all moving parts to stop before you leave the operator’s seat.

7. Close fuel shut-off valve, if your machine is equipped.

8. Disconnect the negative battery cable or remove the spark plug wire (for gasoline engines) before servicing the machine.

Checking Area to be Cleared

• Thoroughly inspect the area where the equipment is to be used and remove all doormats, sleds, boards, wires and other foreign objects.

• Keep people and pets out of the work area. Keep children indoors when using blade. Turn the machine off if anyone enters the area.

• Be extremely careful if you must clear snow from a gravel surface. Adjust the blade height to clear a gravel surface.

4

Safety

Wear Appropriate Clothing

• Always wear eye protection when operating the machine.

• Wear close fitting clothing and safety equipment appropriate for the job.

• While operating this machine, always wear substantial footwear and long trousers. Do not operate the equipment when barefoot or wearing open sandals.

• Wear a suitable protective device such as earplugs. Loud noise can cause impairment or loss of hearing.

Avoid Injury From Hitting Obstructions

• Raise and center, not angle, attachment when you drive between jobs.

• Slow down when you remove snow. Be cautious on slopes, when you make turns or when close to buildings or trees.

Practice Safe Maintenance

• Only qualified, trained adults should service this machine.

• Understand service procedure before doing work. Keep area clean and dry.

• Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect.

• Never lubricate, service or adjust the machine or attachment while it is moving. Keep safety devices in place and in working condition. Keep hardware tight.

• Keep hands, feet, clothing, jewelry, and long hair away from any moving parts, to prevent them from getting caught.

• Lower any attachment completely to the ground or to an existing attachment mechanical stop before servicing the attachment. Disengage all power and stop the engine. Lock park brake and remove the key. Let machine cool.

• Disconnect battery or remove spark plug wire (for gasoline engines) before making any repairs.

• Before servicing machine or attachment, carefully release pressure from any components with stored energy, such as hydraulic components and springs.

• Release hydraulic pressure by lowering attachment or cutting units to the ground or to a mechanical stop and move hydraulic control levers.

• Securely support any machine or attachment elements that must be raised for service work. Use jack stands or lock service latches to support components when needed.

• Never run engine unless park brake is locked.

• Keep all parts in good condition and properly installed. Fix damage immediately. Replace worn or broken parts. Replace all worn or damaged safety and instruction decals.

• Check all hardware at frequent intervals to be sure the equipment is in safe working condition.

• Do not modify machine or safety devices. Unauthorized modifications to the machine or attachment may impair its function and safety.

Handling Waste Product and Chemicals

Waste products, such as, used oil, fuel, coolant, brake fluid, and batteries, can harm the environment and people:

• Do not use beverage containers for waste fluids – someone may drink from them.

• See your local Recycling Center or authorized dealer to learn how to recycle or get rid of waste products.

• A Material Safety Data Sheet (MSDS) provides specific details on chemical products: physical and health hazards, safety procedures, and emergency response techniques. The seller of the chemical products used with your machine is responsible for providing the MSDS for that product.

5

Assembly

Part List and Description

The blade attachment is shipped partially assembled in three boxes with the blade in one box, the blade frame assembly and associated hardware bags in another box. The hitch/ vehicle mount is in a separate box.

NOTE: If the vehicle is equipped with front receiver hitch, brush guard or winch, remove before installing hitch.

Heavy Duty Blade

Part Description Qty

Blade Weldment (A) (includes wear bar)

1

Frame Assembly (B) (includes hydraulic components)

1

Hitch Assembly (C) (includes vehicle mounting bracket)

1

Hitch Inner Pack (not shown) (includes wiring harness kit, remote control and parts bag 1016997)

1

Spring, Trip (not shown) 2

Bag of Parts (Marked Z-1880) Part Description Qty

Bracket, Spring 4

Bolt, Hex Head, 3/8 x 1-1/4 in. 2

Bolt, Hex Head, 3/8 x 2-1/2 in. 2

Lockwasher, 3/8 in. 2

Nut, Hex, 3/8 in. 2

Locknut, with Star Washer, 3/8 in. 2

Bag of Parts (Marked Z-1887) Part Description Qty

Bearing, Plated 2

Bolt, Hex Head, 5/8 x 2 in. 2

Washer, 5/8 in. 2

Lockwasher, 5/8 in. 2

Bag of Parts (Marked 1016997) Part Description Qty

Bolt, Carriage 1/4 x 3/4 in. 2

Bolt, Hex Hd 1/4 x 1 in. 3

Bolt, Hex Hd 1/2 x 2-1/2 in. 4

Nut, Hex 1/2 in. -13 4

Washer, Lock 1/2 in. 4

Washer, SAE Flat 1/4 in. 3

Nut, Nylon Lock 1/4 in. -20 5

Clevis Pin 1/2 x 1-3/4 4

Tie, Cable 7 in. 6

Clamp, 1/2 Conduit 2

Pin, tab lock, plated 2

Spring, Retainer 4

Bag, Plastic 8 x 10, 3 Mil 1

Tie, Cable 14 in. 5

A

BC

C

6

Assembly

Assembly Step 1

Attach Blade to Frame

NOTE: The required hardware for this step is found in the bag of parts marked Z-1887.

1. Position the frame assembly (A) at the back of the blade weldment (B) and secure with a plated bearing (C), 5/8 in. flat washer (D), 5/8 in. lockwasher (E) and 5/8 x 2 in. hex head bolt (F) at each side of the bottom of the frame assembly, installed from the outside, as shown.

Assembly Step 2

Install Trip Springs

NOTE: Spring Bracket must be installed under frame assembly for spring to operate properly. The required hardware for these steps is found in the bag of parts marked Z1880.

1. Position a spring bracket (A) under the left side mounting flange (B) at the bottom of the frame assembly, with the spring bracket oriented toward the outside, as shown. The hole in the spring bracket should be aligned under the outer hole in the mounting flange. Secure with a 3/8 x 1-1/4 in. hex head bolt (C), installed from the top, and a 3/8 in. lockwasher (D) and 3/8 in. hex nut (E), under the spring bracket. Tighten hardware securely.

NOTE: The locknut with star washer must only be threaded minimally onto the bolt initially, for easier connection of the trip spring to the upper spring bracket.

2. Install a 3/8 x 2-1/2 in. hex head bolt (F) down through a hole located at the top of the blade, just outside of the blade rib at the left side of the frame assembly. Install a spring bracket (A) on the bolt under the blade flange, and loosely thread a 3/8 in. locknut with star washer (G) onto the bolt until the end of the bolt just starts to show past the nut. Do not tighten hardware at this time.

3. Connect a Trip Spring (H) to the remaining mounting hole on the lower spring bracket (A), then connect the trip spring to the remaining hole in the upper spring bracket.

4. To tension the trip spring, completely tighten the upper spring bracket hardware.

5. Repeat procedure for other side.

7

Preparing Vehicle

Preparing Vehicle Step 1

Check Tire Pressure and Wheel Bolt Torque

See your utility vehicle operator’s manual:

• Check tire pressure with an accurate gauge. Make sure tires are at recommended air pressure.

• Check wheel bolts are tightened to specified torque value. Tighten bolts in proper sequence using a torque wrench.

Preparing Vehicle

If the vehicle is equipped with a front receiver hitch, it should be removed before installing the blade.


Install Vehicle Mounting Bracket

1. Park vehicle on a level surface and set the parking brake.

2. Remove one bolt (A) and nut from skidplate.

3. Attach lower mounting bracket (B) corner as shown using bolt (A) and nut removed in step 1.

4. Remove existing bolt (C) and nut and bolts (D). Keep hardware you will re-install in next step.

5. Rotate bracket into place, and loosely secure with hardware removed in previous step.

8

Preparing Vehicle

Picture Note: Right (passenger’s side) shown.


Install Remote Control Bracket

NOTE: The required hardware for this step is found in the Bag of Parts, product no. 1016997.

1. Open the hood (A).

2. Remove storage tray (B) – as it cannot be reused – to gain easy access to the instrument panel support bar (C).

3. Pre-assemble the two conduit clamps (D) loosely to switch bracket (E) below the radiused flange (F), using two 1/4 x 3/4 in. carriage bolts (G) and 1/4 in. nylon insert locknuts (H).

Picture Note: Left (driver’s side) shown.

6. Loosely install right (E) and left (F) upper mounting brackets to front bumper with four 1/2 x 2-1/2 in. bolts (G), 1/2 in. lockwashers, and 1/2 in. nuts.

B

B

A

C

E

G

F

G

9

Preparing Vehicle

Picture Note: Shown with the remote control removed from bracket.

NOTE: With the storage tray removed, access to the instrument panel support bar can be done by reaching over the top of the instrument panel.

GD

H

G

E

F

5. From operator’s station, raise and mount the remote control bracket (E) to the instrument panel support bar (C) by fitting the radiused flange of the bracket up over the support bar and pivoting the loose clamps (D) over the other side of the support bar. Tighten bracket hardware only enough to hold the bracket in place, the bracket must still be able to slide on the support bar.

C

E


Installing Solenoid Assembly and Solenoid Bracket

E

B

C

D

A

1. Bolt the solenoid (A) to the solenoid bracket (B) using the the two 1/4 x 1 in. hex bolts (C), 1/4 in. nuts (D), and 1/4 in. flat washers (E) from hardware bag item no. 1016997.

2. Attach the solenoid bracket (with the solenoid mounted) on top of the frame on the RH side behind the glove compartment. Mount the bracket (B) to the sheetmetal plate (F) using a 1/4 x 1 in. hex bolt (G), 1/4 in. nut (D), 1/4 in. flat washer (E), and cable tie (H).

D

FG

H

10

B

ED

Preparing Vehicle


Remove Center Console

A

B

1. The vehicle center console cup holder must be removed to run the necessary wiring back to the battery. Using a flat screwdriver or similar tool, remove and retain the four plastic retainers (A) and the center console (B).

NOTE: The retainer studs are slotted. Do not force plastic retainer studs into anchors. To replace, line up slots with anchor and insert.

11

Installing

2. Rotate hitch up and install top two 1/2 x 1-3/4 in. clevis pins (E) and spring locking pins.

3. Securely tighten vehicle mounting bracket hardware (this hardware was left loose after installing the lower mounting bracket).

Installing Step 2

Loading Cargo Box with Ballast

CAUTION: Avoid injury! Loads can shift forward. Do not load cargo box above the height of load guard. Do not exceed load capacity of vehicle.

Add weight to the cargo box for proper traction and blade performance.

Recommended materials include sand or bagged material. If using another form of ballast, secure it from shifting before operating the vehicle.

See your utility vehicle Operator’s Manual for load recommendations. Do not exceed the load capacity.

Installing Step 3

Installing Hitch

NOTE: The required hardware for these steps is found in Bag of Parts marked 1016997.

1. Install hitch (A) to two tabs (B) on lower mounting bracket using two 1/2 x 1-1/4 in. clevis pins (C) & spring locking pins (D).

NOTE: Vehicle and blade should be on a firm level surface for ease of installation.

Installing Step 1

Remove Cover

To remove cover (A), remove the two 3/8 in. bolts (B) and the two 3/8 in. washers (C). Be sure to keep the bolts and washers for cover re-attachment.

A

B

C

A B

CD

CD

EE

12

Installing

13

Installing Step 5

Installing Wiring Harness No. 1009921

1. Harness 1009921 consists of two parts. Part A has a large connector on one end with a rubber cap and

three wires which are:

A1. Black (6 AWG) wire that is 84 in. long.A2. Red (6 AWG) wire that is 34 in. longA3. Black (16 AWG) wire that is 34 in. long

Part B consists of two (6 AWG) red wires which are:

B1 - Red (6 AWG) wire that is 60 in. long B2 - Red (6 AWG) wire that is 8 in. long

Wires B1 and B2 are connected with a 150 Amp fuse block.

2. Route 1009921 Part A on the right-hand side of the radiator with the large connector toward the front of the vehicle just behind the front grille.

3. Connect wire A2 to one large terminal on the solenoid as shown, slide the red rubber cap on to the wire end, and then tighten down the connection.

4. Connect wire A3 to the small terminal on the solenoid.

5. Connect wire B1 to one large terminal on the solenoid as shown, slide the red rubber cap on to the wire end, and then tighten down the connection.

Installing Step 4

Installing Wiring Harnesses

1. Before installing the wiring harnesses remove the seat and the center console.

6. Route wires B1 and A1 through the dashboard and along the center console to the battery compartment.

(NOTE: Route A1

next to B1)B1

B1 A1

A2

Red Rubber Cap

A3

Solenoid

NOTE: Do not operate the system unless the red rubber boots are installed on the ends of wires B1 and A2.

Installing

14

Installing Step 6

Installing Wiring Harness No. 1009918

1. Harness 1009918 consists of one main harness, a three-wire harness bundle and a single yellow wire.

The harness sections are:

A1. Main Harness 35-1/2 in. long with a male 8-pin connector on one end and a female 12-pin connector on the opposite.

A2. A three-wire bundle of red, black and orange wires that is 23-1/2 in. long.

A3. A single yellow wire that is 35 in. long ending in a male/female connection that fits the vehicle accessory plug.

2. Route the 12-pin female end of the main harness A1 under the instrument panel and into the vehicle cab.

3. Adjust the routing of the main harness A1 so that the opposite end of harness A1 follows alongside the main vehicle harness.

Harness

1009919

8-pin male

connectorA1

4. Attach the wires in the three wire bundle A2 to the solenoid as follows:

- Attach the red wire to the large terminal on the battery side of the solenoid.

- Attach the black wire to one small terminal on the solenoid.

- Atach the orange wire to the opposite small solenoid terminal.

5. Find the yellow and green vehicle accessory connection on the left-hand side of the steering column.

Attach the connector on the end of the yellow wire A3 to the vehicle accessory plug.

6. Cable tie the main harness A1 and the three-wire bundle of harness A2 as required to keep it from moving during operation.

NOTE: Cable ties are provided in parts bag 1016997.

Black wire

Red wire

A2

Orange wire

Installing

Installing Step 7

Installing Wiring Harness 1009920

1. Install the end of red wire to the positive terminal on the motor.

2. Install the end of black wire to the negative terminal on the motor.

3. Install the connector end of Harness 1009920 to the end of Harness 1009921.

Note: Harness 1009921 has the rubber cap (see photo above).

Red

Black

Photo 7A

Photo 7B

1009921

1009920

Installing Step 8

Installing Wiring Harness 1009919

1. Install the ends of Wiring Harness 1009919 that are marked UP and DOWN into the coils on the UP/DOWN valve.

2. The connection sequence for UP/DOWN wires is:

a) Install the UP wire connector into the top coil. b) Install the DOWN wire connector into the bottom coil.

3. Install the ends of Wiring Harness 1009919 that are marked LEFT and RIGHT into the coils located on the RIGHT/LEFT valve.

4. The connection sequence for RIGHT and LEFt wires is:

a) Install the RIGHT wire connector into the top coil. b) Install the LEFT wire connector into the bottom coil.

Photo 8A

UP COIL (TOP)RIGHT (TOP)

15

DOWN COIL (BOTTOM)

UP/DOWN VALVE

LEFT (BOTTOM)

RIGHT/LEFT VALVE

Installing

Photo 8B

5. Route Harness 1009919 around the left side of the radiator as shown.

6. Cable tie around all the wires of Harness 1009919. Fasten the tie about 4 inches behind the end connector.

7. Connect the 8-pin male connector on Harness 1009919 to the female connection on Harness 100918 as shown.

8. Cable tie Harness 1009918 to the existing vehicle wiring loom as shown.

9. Cable tie Harness 1009919 to the frame hood strut bracket as shown.

Cable Tie

Cable Tie (Step 6)

Cable Tie (Step 8)

Harness 1009919

Harness 1009918

Existing wiring harness loom

16

Installing

17

Installing Step 9

Battery Connection

Connect the end of wire B2 to the positive terminal on the battery as shown. Connect the end of wire A1 to the negative terminal on the battery.

B2

Attach A1 here

Installing Step 10

Installing Remote Control

1. Plug in Remote Control unit to wiring harness as shown.

2. Press hook-and-loop tape together, and remove film backing on one side to expose adhesive.

3. Apply hook-and-loop tape to back side of controller as shown.

4. Remove film backing, exposing adhesive on remaining side of hook-and-loop tape, and insert controller into controller bracket.

5. Press down firmly on controller to fully adhere hook-and-loop tape to controller and controller bracket.

Wiring Harness

Remote Control Connector

Remote Control Bracket

Remote Control

Installing

Fill to here

3. The operator will move the blade up, down, left and right, using the remote control. The second person will observe the oil level in the hydraulic tank. Do not let the oil completely empty the tank.

Installing Step 11

Commissioning Hydraulics

NOTE: Before commissioning the hydraulics, all previous steps in the installation section must be completed.

1. Remove the hydraulic tank filler breather cap, and using a small funnel fill the hydraulic tank to level as shown. Fill with “John Deere J20D Hydraulic Oil.”

NOTE: Care must be taken when filling hydraulic tank with hydraulic oil in Step 1, as to not spill hydraulic oil during the filling process. Hydraulic oil must be poured slowly in order to not overflow the tank fill neck. To aid in filling, a small straw or piece of tubing may be inserted down the fill neck and partially into the tank to allow excess air to escape during the filling process.

NOTE: Steps 2-4 will take take two people.

2. As one person sits in the cab and turns the key switch on, the other person will observe the oil level in the hydraulic tank.

18

4. Refill the hydraulic oil to the fill level shown and repeat Step 3 until the blade will move through its complete range without the oil level dropping in the hydraulic tank.

NOTE: During the commissioning procedure in Step 3, care must be taken not to injure the second person while they are observing the blade and the hydraulic oil level.

Installing

1. Place the blade on a flat surface that is accessible with the vehicle.

2. Move the vehicle behind blade and line up the blade with the hitch.

3. Tilt the hitch down in order to line up blade mounting forks (H) with the blade frame by depressing the DOWN button on the remote control; lower until the forks are parallel to the ground.

NOTE: The key switch must be turned to the RUN position for the remote control to function.

4. Slowly move the vehicle forward until the blade is fully seated in the blade mounting forks.

H

H

Test the UP/DOWN Function

1. Turn key switch to RUN position.

2. Depress the DOWN button on the remote control and the forks will lower.

3. Depress the UP button on the remote control and the hitch forks will raise.

Install Blade

NOTE: Vehicle and blade should be placed on a firm level surface for ease of installation.

19

5. Secure blade to hitch by inserting a tab lock pin (I) through both blade mounting forks.

NOTE: If you have trouble attaching hydraulic hoses, turn switch to RUN position and move remote control to different positions to alternate hydraulic pressure and try attaching.

6. Attach the color-coded hydraulic hose fittings on the blade attachment to the corresponding hitch manifold connections.

7. Connect the two hydraulic hoses together, as shown above, using one of the provided cable ties.

Test the LEFT/RIGHT Function

1. Turn key switch to RUN position.

2. Depress the LEFT button on the remote control and the blade will move left.

3. Depress the RIGHT button on the remote control and the blade will move right.

Installing Step 12

Re-attach Cover

Attach cover with the original two 3/8 in. bolts and the two 3/8 in. washers (refer to Step 1).

I

Cable Tie (Step 7)

Operation

Operation Step 1

Daily Operating Checklist

q Check for loose or missing hardware.

q Make sure all hydraulic fittings and hoses are tight.

q Make sure attachment responds properly to controls.

q Check for debris build-up that could obstruct proper motion of the blade trip components.

q Wipe a light coat of oil over all exposed surfaces.

Operation Step 2

Using the Blade

Operation Step 3

Operating Modes

The 72 Inch Heavy Duty Blade can be configured to operate in two modes, Down Pressure and Floating. The hitch assembly is factory configured in the Floating mode.

• When blading snow or gravel it is recommended that that hitch assembly be placed in the Floating mode.

• When blading dirt or back dragging, the hitch should be placed in the Down Pressure mode.

Changing Operating Modes

NOTE: Key switch must be in RUN position for blade switch to function.

1. Park the vehicle safely. (See “Parking Safely” in the Safety section.)

2. Completely lower the hitch by depressing the Down button on the remote control.

Raising the Blade:

Depress the Up button (A) on the remote control to raise the blade to the desired height.

Lowering the Blade:

Depress the Down button (B) on the remote control to lower the blade to the desired height.

Moving the Blade Left:

Depress the Left button (C) on the remote control to move the blade to the desired angle.

Moving the Blade Right:

Depress the Right button (D) on the remote control to move the blade to the desired angle.

Remote Control:

• The remote control green light will be on during operation.

• The remote control is back lit for low light or night operation.

• The remote control has built-in logic to shut off any function after four seconds.

A

C

B

D

Remote Control

Green light

20

Operation

Picture Note: Floating mode shown.

3. Loosen the 1/2 in. hex head bolt (A) on the hitch.

BA

A

Transporting Blade

Avoid contact with objects such as trees or fences. Be aware of blade end position while transporting. Blade makes a wide arc when turning.

Transport with blade raised to the highest position and centered. Do not exceed 8 km/hr (5 mph).

Checking Blade for Obstructions

1. Lower blade to ground.

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

Picture Note: Down Pressure mode shown.

4. Change to the Down Pressure mode by turning the control plate (B) 90° and tighten the 1/2 in. hex head bolt (A).

CAUTION: Avoid injury! Fingers and hands can be pinched or crushed. Be aware of potential pinch points and keep hands away.

3. Check for obstructions around the springs and between the blade and blade frame. Use a long pry bar to remove obstructions.

21

Removing and Storing

Removing and Storing Step 1

Removing Ballast

C AU T I O N: Av oi d in jur y! Ma chin e c an become unstable when operating with attachment. Ballast is required when the attachment is installed.

When the attachment is removed, also remove any ballast that was added to the machine.

Use only attachments & accessories recommended by the manufacturer.

Remove any added ballast from machine.


Removing Blade

NOTE: Blade should be placed on a firm level surface for ease of removal.

1. Park the vehicle safely. (See “Parking Safely” in the Safety section.)

2. Lower blade to ground by moving and holding blade control lever forward to the Down position.

IA

3. Remove two tab lock pins (A) from blade mounting forks to disconnect blade. Install tab lock pins into the blade mounting forks for storage after removal.

NOTE: If there is difficulty removing hydraulic hoses, turn key switch to RUN position and move blade control lever to different positions to alternate hydraulic pressure, then turn key switch to OFF and disconnect hoses.

4. Disconnect the two blade hydraulic hoses (B) from the hitch manifold. Place attached dust covers over fittings to protect from foreign material and physical damage.

5. Start vehicle.

6. Slowly back vehicle until blade mounting forks (C) are clear of the blade.

7. Move blade control lever backward and hold in the UP position until blade mounting forks are fully raised.

8. Park vehicle safely. (See “Parking Safely” in the Safety section.)

IAB

22

Removing and Storing

9. Visually check that hitch (D) is raised completely.

10. Disable the blade actuator. Disconnect harness plug from back side of blade switch and secure switch harness from contact with moving parts.

11. Remove ballast from cargo box.


Storing Blade

1. Remove blade from vehicle.

2. Clean blade.

H

D

CAUTION: Avoid injury! Fuel vapors are explosive & flammable. Engine exhaust fumes contain carbon monoxide and can cause serious illness or death:

• Run the engine only long enough to move the machine to or from storage.

• Machine fires and structure fires can occur if a machine is stored before allowing it to cool, or if debris is not removed from around the engine and muffler, or if stored near combustible materials.

• Do not store vehicle with fuel in the tank inside a building where fumes may reach an open flame or spark.

• Allow the engine to cool before storing the machine in any enclosure.

3. Check for worn, missing, or damaged parts. Replace parts as needed.

4. Paint scratched or worn areas to prevent rust.

5. Store blade on a firm, level surface.

6. If storing blade outside:

- Block up blade and frame to prevent contact with ground moisture.

- Place a waterproof cover over blade and frame.


Removing the Hitch (If Necessary)

1. Disconnect Harness 1009919 (see Step 7 in Installing section).

2. Disconnect Harness 1009920 (see Step 6 in Installing section).

3. To remove the Hitch Assembly, follow Step 3 from the Installing section in reverse order. Remove the pins from the top of the hitch and allow it to swing down.

CAUTION: Avoid injury! When removing the hitch, care must be taken not to pinch hands and fingers between the moving parts.

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Service

Picture Note: Down Pressure mode shown.

3. If in the Down Pressure mode, loosen the 1/2 in. hex head bolt (A).

4. Loosen jam nut (B) on the hitch.

Service Intervals

Daily

• Check for loose or missing hardware.

• Make sure all hydraulic fittings and hoses are tight.

• Make sure attachment responds properly to controls.

• Check for debris build-up that could obstruct proper motion of the blade trip components.

Hydraulic Oil

The following hydraulic oil is preferred:

• John Deere J20D

Note: The hydraulic oil should be changed twice a year.

Adjusting Blade Height

The blade height at the full up or stow position should be approximately 30.5 cm (12 in.) from the center of the blade to the ground. Over time, as the shocks of the vehicle age, the vehicle may sit lower to the ground causing the blade height to be below 30.5 cm (12 in.).

When this occurs, the height of the blade needs to be adjusted to compensate.

Adjust Blade Height

NOTE: Key switch must be in RUN position for blade switch to function.

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

2. Completely lower the hitch by depressing the Down button on the remote control.

IMPORTANT: Avoid damage! Operating in extreme conditions may require more frequent service intervals.

BA

C

D


5. Rotate the Control Plate (C) to the floating mode position to gain access to hex socket head bolt (D) for adjustment.

24

Service


6. Adjust blade to specified height by turning hex socket head bolt (D) to desired height using a 1/4 in. hex key wrench.

• Turning bolt (D) clockwise lowers the blade, turning bolt (D) counterclockwise raises the blade.

• For each full turn of bolt (D), the blade will raise or lower 25 mm (1 in.).

7. Tighten jam nut (B) securely.

8. Rotate control plate (C) to either Floating or Down Pressure position, as desired, then tighten 1/2 in. hex head bolt (A) securely.

9. Check blade height in the full up position, repeat adjustment as necessary.

Reverse or Replace Blade Wear Bar

1. Raise blade slightly off the ground.

NOTE: The wear bar is a reversible design. Depending on the level of wear or damage, the wear bar can often be reversed and re-installed instead of replaced.

2. Check the blade trip springs for tension and wear.

3. Check the blade for loose parts.

Servicing Blade

C

D

A

B

CAUTION: Avoid injury! Crushing injury can occur if blade drops unexpectedly. Keep hands and feet from under raised blade.

2. Remove bolts (A) and nuts (B) securing wear bar (C) to blade.

3. Evaluate the condition of the existing wear bar and hardware.

4. Reverse and re-install, or replace wear bar depending on condition. Secure with original hardware, or replace hardware, as required.

IA

1. Disconnect the blade from the hitch assembly by removing the two latch pins (A) and the two hydraulic quick disconnects (B). Move the blade away from the hitch assembly.

2. Check the hose-end quick disconnects for dirt and debris.

B

25

Troubleshooting

26

Troubleshooting Locator

Left / Right Valve Coils(2) Plc.

Coil Nut Torque to 4-5 ft lb

Coil Connectors(2) Plc.

Cross-over Relief Valve

Up / Down Valve Coils (2) Plc.

Check Valve

Filler / Breather

Blade Up Hose

Blade Down Hose

Coil Connectors(2) Plc.

Pump ReturnHose

Pump Pressure Hose

Pump PressureHose

Pump Relief Valve

Pump Return Hose

Up / Down Valve Coils

(2) Plc.

Blade Up

Hose

Coil Nut Torque to 4-5 ft lb

Pump Return Hose

Left / Right Valve Coils (2) Plc.

Coil Connectors (2) Plc.

Check Valve

Blade Down Hose

Pump Pressure

Hose

Coil Connectors (2) Plc.

Pump Pressure Hose

Cross-Over Relief Valve

Filler / Breather

Pump Return Hose

Pump Relief Valve

Troubleshooting

Using Troubleshooting Chart

If you are experiencing a problem that is not listed in this chart, see your authorized dealer for service.

When you have checked all the possible causes listed and you are still experiencing the problem, see your authorized dealer.

Blade Troubleshooting

If you are experiencing a problem that is not listed in this chart, see your authorized dealer for service.

When you have checked all the possible causes listed and you are still experiencing the problem, see your authorized dealer.

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LEGEND

1. Remote control problems

2. Electrical troubleshooting – Solenoid

3. Electrical troubleshooting – Motor

4. Electrical checks good, but pump does not run

5. Blade will not raise or lower, but motor runs

6. Blade will not move left or right, but motor runs

7. Blade will not hold angle while plowing

8. Blade will not hold “up” position

9. Blade chatters while moving down

10. Hydraulic fluid is leaking

11. Blade trips too easily

12. Blade does not trip

ISSUE IF CHECK PROCEDURE

1 No Blade Functions Work

A - Check for blown fuse at battery connection.

B - Check that the red and black harness wires are connected to the battery.

A - Remove the seat, then remove the red rubber cover on top of the fuse connection. Using a volt meter, place the black voltmeter test lead on one side of the fuse and the red volt meter test lead on the opposite side of the fuse. Check for continuity. If continuity not present, replace fuse.

B - Check that the red harness power wire is connected to the positive battery terminal, and check that the black harness ground wire is connected to the negative battery terminal. If the wire is unconnected, connect it.

Check that all of the wiring harness cables are connected.

Check the main harness connection to the remote control, check the harness connections to the valve coils, and check the motor harness connection. If the harnesses are unconnected, connect them.

A - Check that the remote control green indicator light is on.

B - Check the vehicle accessory connection.

A - Check the remote control to main wiring harness under the dash is connected; if not, ensure it is connected.

B - Check that the yellow wire off of the main harness and the Gator yellow and black vehicle accessory connection (under the dash) are all connected; if not, ensure it is connected.

Check for voltage between the small terminals of the solenoid.

Turn the key switch to ON and press a function button on the remote control. Use a volt meter to check for voltage between the two small terminals on the solenoid. If no voltage is present, replace solenoid.

Check for power to each large solenoid terminal.

Turn the key switch to ON and press a function button on the remote control.

A - Use a volt meter to check for power at the large terminal on the battery side of the solenoid and ground. If no voltage is present, check whether the red power wire to the battery is broken or disconnected; replace the wire if necessary. If the wire is not broken, replace solenoid.

B - Use a volt meter to check for power at the large terminal on the motor side of the solenoid and ground. If not power is present, replace solenoid.

Troubleshooting

28


Check for voltage at the pump motor.

With the key switch on, press a function button on the remote control, then check for voltage at the pump using a volt meter by placing the black probe on the black motor wire and the red probe on the red motor wire. If no voltage present, replace the pump motor.

Check valve coils for operation. With the key switch on, press the UP button on the remote. Check if the up/down coils are firing by placing a standard 6-inch steel ruler on top of the coil. If the coil is firing it will become magnetized and the ruler will stick. Repeat this sequence for the up coil, down coil, the left coil and the right coil. If coil does not operate, replace it.

Check the oil level in the reservoir.

Inspect the reservoir oil level. The oil level should be just below the filler breather elbow connection in the tank. See Installing Step 9 for oil fill level. Refill with J20D John Deere Hydraulic oil.

Check that oil is clean and not contaminated.

A - Inspect the oil color in the plastic reservoir looking for dark or discolored oil.B - Inspect the oil in the plastic reservoir looking for particles floating in the oil.C - Remove the check valve. Inspect the oil film on it, looking for metal shavings or bits of dirt, then wash the valve spool in clean hydraulic fluid and replace the valve (torque to 20 ft-lb). If contamination is found during any of the previous troubleshooting procedures, replace pump motor and valves.

2 Up Function Works Down does not

A - Check the wiring harness to coil connection.

B - Check that the wiring harness for the valve coils and the main harness are connected.

A - Inspect the connection between the wiring harness and the up coil connection. Verify they are connected; if not, connect.

B - Check that the wiring harness for the valve coils and the main harness are connected under the hood and verify they are connected. If harnesses are not connected, ensure they are connected.

Check valve coil for operation. With the key switch on, press the UP button on the remote. Check if the up coil is firing by placing a standard 6-in. steel ruler on top of the solenoid. If the coil is firing it will become magnetized and the ruler will stick. If the coil does not operate, replace coil.

Check the valve condition. Disconnect the wiring harness connections from the up/down valve coil.Remove the coil nut from the top of the up/down valve stem. Remove the valve coils, and remove the up/down valve from the manifold. Inspect the valve spool and look for metal flakes or dirt. Wash the valve spool in clean hydraulic oil and replace it back into the manifold (torque to 20 ft-lb) reinstall valve coils and coil nut (torque to 4-5 ft-lb) re-connect the coil wiring harness and recheck function. If contamination is found or the valve does not function, replace the valve.

3 Down Function Works, Up does not



A - Inspect the connection between the wiring harness and the down coil connection and verify they are connected; if not connected, ensure they are connected.

B - Check that the wiring harness for the valve coils and the main harness are connected under the hood and verify they are connected. If harnesses are not connected, ensure they are connected.

Check valve coil for operation. With the key switch on, one person will depress the down button on the remote. The second person will check if the down solinoid is firing by placing a standard 6-in. steel ruler on top of the solenoid. If the solenoid is firing it will become magntized and the ruler will stick. If the coil does not operate, replace coil.

Check the valve condition. Disconnect the wiring harness connections from the up/down valve coil.Remove the coil nut from the top of the up/down valve stem. Remove the valve coils, and remove the up/down valve from the manifold. Inspect the valve spool and look for metal flakes or dirt. Wash the valve spool in clean hydraulic oil and replace it back into the manifold (torque to 20 ft-lb) reinstall valve coils and coil nut (torque to 4-5 ft-lb) re-connect the coil wiring harness and recheck function. If contamination is found or the valve does not function, replace the valve.

Troubleshooting


4 Right Function Works, Left does not



A - Inspect the connection between the wiring harness and the down coil connection and verify they are connected. Verify they are connected; if not, connect.

B - Check that the wiring harness for the valve coils and the main harness are connection under the hood and verify they are connected. Verify they are connected; if not, connect.

Check valve coil for operation. With the key switch on, press the right button on the remote control. Check if the right coil is firing by placing a standard 6-inch steel ruler on top of the coil; if the coil is firing it will become magnetized and the ruler will stick. If coil does not operate, replace it.

Check the valve condition. Disconnect the wiring harness connections from the right/left valve coil.Remove the coil nut from the top of the right/left valve stem.Remove the valve coils, and remove the up/down valve from the manifold.Inspect the valve spool and look for metal flakes or dirt.Wash the valve spool in clean hydraulic oil and replace it back into the manifold (torque to 20 ft-lb), then reinstall valve coils and coil nut (torque to 4-5 ft-lb) reconnect coil wiring harness and recheck function. If the coil does not operate, replace coil.

5 Right Function Works, Left does not



A - Inspect the connection between the wiring harness and the down coil connection and verify they are connected. If harnesses are not connected, ensure they are connected.

B - Check that the wiring harness for the valve coils and the main harness are connection under the hood and verify they are connected. If harnesses are not connected, ensure they are connected.

Check valve coil for operation. With the key switch on one person will depress the left button on the remote. The second person will check if the left solenoid is firing by placing a standard 6-inch steel ruler on top of the solenoid,if the solenoid is firing it will become magnetized and the ruler will stick. If coil does not operate, replace it.

Check the valve condition. Disconnect the wiring harness connections from the right/left valve coil.Remove the coil nut from the top of the right/left valve stem. Remove the valve coils, and remove the right/left valve from the manifold. Inspect the valve spool and look for metal flakes or dirt. Wash the valve spool in clean hydraulic oil and replace it back into the manifold (torque to 20 ft-lb) reinstall valve coils and coil nut (torque to 4-5 ft-lb) reconnect coil wiring harness and recheck function. If contamination is found or the valve does not function, replace the valve.

6 Blade will not hold angle while plowing



A - Inspect the connection between the wiring harness and the left/right coil connections and verify they are connected. If harnesses are not connected, ensure they are connected.

B - Check that the wiring harness for the valve coils and the main harness are connection under the hood and verify they are connected. If harnesses are not connected, ensure they are connected.

Check the left/right valve condition.

Disconnect the wiring harness connections from the right/left valve coil.Remove the coil nut from the top of the right/left valve stem.Remove the valve coils, and remove the up/down valve from the manifold.Inspect the valve spool and look for metal flakes or dirt.Wash the valve spool in clean hydraulic oil and replace it back into the manifold (torque to 20 ft-lb) reinstall valve coils and coil nut (torque to 4-5 ft-lb) reconnrct coil wiring harness and recheck function. If contamination is found or the valve does not function, replace the valve.

Check the cross-over relief valve.

Remove the cross-over relief valve from the manifold and inspect the valve spool look for metal flakes and dirt. Wash the valve spool in clean hydraulic fluid and install it back into the manifold (torque to 20 ft-lb).

29

Troubleshooting


7 Blade will not stay up when parked

Remove the check valve, then examine it.

Remove the check valve from the manifold and inspect the valve spool looking for dirt and metal chips. Wash the valve spool in clean hydraulic oil and replace it back into the manifold (torque to 20 ft-lb). If the check valve does not function after reinstall, replace it.

8 The blade chatters while moving

A - Check the oil level in the hydraulic tank.

B - Check that the check valve is not stuck open.

C - Check that the orifice fitting is installed.

A - Inspect the reservoir oil level. The oil level should be just below the filler-breather elbow connection in the tank. See Installing Step 9 for oil fill level. Refill with J20D John Deere Hydraulic oil.

B - Remove the check valve from the manifold and inspect the valve spool looking for dirt and metal chips. Wash the valve spool in clean hydraulic oil and replace back into the manifold (torque to 20 ft-lb). If the check valve does not function after reinstall, replace it.

C - Check that the orifice fitting is installed on the rod end port of the up/down cylinder. The fitting will be screwed to the end of the elbow that is installed into the rod end port of up/down cylinder. The hose will be screwed onto the end of the fitting. Replace the orifice fitting if not installed.

9 Hydraulic fluid is leaking Check all hose connections and all fittings in the manifold and pump.

Look over the hose connections from the pump to the motor. Look over the hose connections from the up/down cylinder to the manifold. Look over all the fittings installed in the pump and the manifold.The torque values are as follows: (Tighten hoses and fittings as required.)3/8 hose end 37 deg. flare fitting = 1-1/4 flats from finger tight1/4 hose end 37 deg. flare fitting = 2 flats from finger tight-4 SAE. O ring fittings = 15 ft-lb-6 SAE. O ring fittings = 35 ft-lb

10 Blade trips too easily A - Check trip spring tension.

B - Check if trip springs are bent.

A - The trip springs are attached to a bracket at the top of the blade. Tighten the nuts holding the spring bracket 1/2" for each spring.If the blade still trips then tighten the spring bracket nuts 1/2" more.

B - If the trip springs are bent then replace them.

11 Blade does not trip A - Check trip spring tension is not too tight.

B - Check if trip springs are bent.

A - The trip springs are attached to a bracket at the top of the blade. Loosen the nuts holding the spring bracket 1/2" for each spring.If the blade still does not trip then loosen the spring bracket nuts 1/2" more.

B - If the trip springs are bent then replace them.

12 Blade does not raise. Check if the trigger springs are not too tense.

The springs are attached to the bracket at the top of the blade. Loosen the nuts holding the mounting bracket 1/2 inch on each side. If the blade still does not trigger, loosen the nuts again 1/2 inch.

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Specifications

Heavy Duty 72-Inch Blade

Cutting Width

Blade Straight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 m (72 in.)

Blade Angled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7 m (66.75 in.)

Range of Lift

Above Ground Level . . . . . . . . . . . . . . . . . . . . . . . . 30.5 cm (12 in.)

Below Ground Level . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6 cm (3 in.)

Angling Positions:

Three . . . . . . . . . . . . . . . . . . . straight 0°, angled right or left 22°

Weight (All Parts) . . . . . . . . . . . . . . . . . . . . . . . . . . 124 kg (275 lb)

Recommended Lubricants

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . John Deere Low Viscosity HY-GARD J20D

( Specifications and design subject to change without notice ).

31

Getting Quality Service

John Deere Quality Continues with Quality Service

John Deere provides a process to handle your questions or prolems, should they arise, to ensure that product quality continues with quality parts and service support.

Follow the steps below to get answers to any questions you may have about your product.

1. Refer to your attachment and machine operator manuals.

2. In North America or Canada, call John Deere Special Services at 1-866-218-8622 and provide product serial number (if available) and model number.

Warranty

Limited Warranty for New John Deere Licensed Products

A. General Provisions – The warranties described below are provided by manufacturer, Brinly Hardy Company, on John Deere Licensed products to the original purchaser of new Lawn and Garden attachments from authorized John Deere Dealers & Retailers. Under these warranties, the manufacturer will repair or replace, at its option, any covered part found to be defective in material or workmanship during the applicable warranty term. The purchaser will be responsible, however, for any service call and / or transportation of product to and from the dealer’s place of business, for any premium charged for overtime labor requested by the purchaser, and for any service and/or maintenance not directly related to any defect covered under the warranties below.

B. What is warranted – All parts of any new John Deere Licensed product, are warranted for the number of months specified below. When you call please have the serial number, if applicable, and model number.

C. What is not warranted – 1) Used products; (2) Any product that has been altered or modified in ways not approved by the manufacturer; (3) Depreciation or damage caused by normal wear, lack of reasonable and proper maintenance, failure to follow operating instructions, misuse, lack of proper protection during storage, or accident; (4) normal maintenance parts and service.

D. Securing Warranty Service – To secure warranty service, the purchaser must (1) report the product defect to an authorized dealer, or to the manufacturer by calling 866-218-8622, and request repair within the applicable warranty term, (2) present evidence of the warranty start date, and (3) make the product available to the dealer or service center within a reasonable period of time.

E. Limitation of implied warranties and other remedies – To the extent permitted by law, neither John Deere nor any company affiliated with it makes any warranties, representations or promises as to the quality, performance or freedom from defect of the equipment covered by this warranty. Implied warranties of merchantability and fitness for a particular purpose, to the extent applicable, shall be limited in duration to the applicable period of warranty set forth on this page. The purchaser’s only remedies in connection with the breach or performance of any warranty on the John Deere Lawn and Garden attachments are those set forth on this page. In no event will the Dealer, John Deere or the manufacturer be liable for incidental or consequential damages. (Note: Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages so the above limitations and exclusions may not apply to you.) This warranty gives you specific legal right, and you may also have other rights, which vary from state to state.

F. No Dealer Warranty – The selling Dealer makes no warranty of its own and the Dealer has no authority to make any representation or promise on the behalf of John Deere or the manufacturer to modify the terms or limitations of the warranty in any way.

Manufacturer’s Lawn & Garden Attachments *Warranty Term

Steel Frame 2 Years

Transmission (gearbox) 2 Years

Poly Hoppers & Beds 2 Years

Wheels 1 Year

Hydraulics 1 Year

Drive Gears 1 Year

Other normal wear parts 1 Year

* Each Warranty Term begins on the date of product delivery to the purchaser.

Register your John Deere Licensed Product by completing and mailing in the enclosed Warranty Registration Card.

For Customer Service: Please call 866-218-8622

32