JOHN DEERE - POWERtach
Transcription
JOHN DEERE - POWERtach
JOHN DEERE WORLDWIDE COMMERCIAL & CONSUMER EQUIPMENT DIVISION M163744 G0 Heavy Duty Blade 72-Inch OPERATOR’S MANUAL Original Instruction All information, illustrations and specifications in this manual are based on the latest information at the time of publication. The right is reserved to make changes at any time without notice. COPYRIGHT© 201 Deere & Co. John Deere Worldwide Commercial and Consumer Equipment Division All rights reserved Previous Editions COPYRIGHT© North American Version Litho in U.S.A. &/3_5HY%_ Introduction Using Your Operator’s Manual Table of Contents Read this entire operator’s manual, especially the safety information, before operating. Introduction 2 Product Identification This manual is an important part of your machine. Keep all manuals in a convenient location so they can be accessed easily. 2 Safety Labels3 Safety4 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. Assembly6 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. Operation20 Preparing Vehicle 8 Installing12 Removing and Storing 22 Service24 Troubleshooting26 Specifications 31 Warranty32 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. Product Identification Product Compatibility This 72-Inch Heavy Duty Blade is compatible with 625i, 825i, and 855D XUV Series Gator™ Utility Vehicles. 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. Record Purchase Information Record your purchase information in the spaces provided below. DATE OF PURCHASE: ________________________________________ DEALER NAME: 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. ________________________________________ DEALER PHONE: 2 Safety Labels Safety Label Locations B Understanding The Machine Safety Labels Jammed Blade Label 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. WARNING label describing potential for spring-loaded blade suddenly returing during operation. Replace missing or damaged safety labels. Use this operator’s manual for correct safety label placement. Sudden Stop Label 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. CAUTION label cautioning operators to watch for sudden stops, and to travel at slow speed during operation. 3 Safety Read Safety in Machine Operator’s Manual • Avoid the edges of ditches and banks to reduce the possibility of loss of control. Read the general safety operating precautions in your machine operator’s manual for additional safety information. • 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. 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. • 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. • 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. • 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. • 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. Parking Safely 1. Stop machine on a level surface, not on a slope. 2. Lower attachments to the ground. • Check brake action before you operate. Adjust or service brakes as necessary. 3. Lock the park brake. 4. Stop the engine. • Stop machine if anyone enters the area. 5. Remove the key. • 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. 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. • Before operating, make sure all connections are tight and blade responds properly to controls. Check all connections periodically for tightness. 8. Disconnect the negative battery cable or remove the spark plug wire (for gasoline engines) before servicing the machine. • Do not leave machine unattended when it is running. • Only operate during daylight or with good artificial light. Checking Area to be Cleared • Be careful of traffic when operating near or crossing roadways. • Thoroughly inspect the area where the equipment is to be used and remove all doormats, sleds, boards, wires and other foreign objects. • Do not wear radio or music headphones while operating the machine. Safe operation requires your full attention. • Keep people and pets out of the work area. Keep children indoors when using blade. Turn the machine off if anyone enters the area. • 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 extremely careful if you must clear snow from a gravel surface. Adjust the blade height to clear a gravel surface. • Be aware of the possibility of objects hidden under the snow. Avoid holes, rocks, roots and other obstructions. 4 Safety Avoid Injury From Hitting Obstructions • Do not modify machine or safety devices. Unauthorized modifications to the machine or attachment may impair its function and safety. • 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. Handling Waste Product and Chemicals Waste products, such as, used oil, fuel, coolant, brake fluid, and batteries, can harm the environment and people: Practice Safe Maintenance • Do not use beverage containers for waste fluids – someone may drink from them. • Only qualified, trained adults should service this machine. • See your local Recycling Center or authorized dealer to learn how to recycle or get rid of waste products. • Understand service procedure before doing work. Keep area clean and dry. • 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. • 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. • Keep hands, feet, clothing, jewelry, and long hair away from any moving parts, to prevent them from getting caught. Wear Appropriate Clothing • Do not operate the engine in a confined space where dangerous carbon monoxide fumes can collect. •Always wear eye protection when operating the machine. • 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. •Wear close fitting clothing and safety equipment appropriate for the job. • 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. 5 • 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. Assembly Part List and Description Bag of Parts (Marked Z-1880) Part 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. 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 Heavy Duty Blade Bag of Parts (Marked Z-1887) Part Description A C B Part Description Blade Weldment (A) (includes wear bar) Qty 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 6 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 C 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 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. 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. 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. 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. Preparing Vehicle Step 2 3. Attach lower mounting bracket (B) corner as shown using bolt (A) and nut removed in step 1. 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. 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 B E G A B C Picture Note: Right (passenger’s side) shown. F G Preparing Vehicle Step 3 Install Remote Control Bracket NOTE: The required hardware for this step is found in the Bag of Parts, product no. 1016997. Picture Note: Left (driver’s side) shown. 1. Open the hood (A). 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. 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). 9 Preparing Vehicle F Preparing Vehicle Step 4 D G Installing Solenoid Assembly and Solenoid Bracket B H A C E E Picture Note: Shown with the remote control removed from bracket. D 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. 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. E F C D G D B E H 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. 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). 10 Preparing Vehicle Preparing Vehicle Step 5 Remove Center Console NOTE: The retainer studs are slotted. Do not force plastic retainer studs into anchors. To replace, line up slots with anchor and insert. 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). 11 Installing Installing Step 1 A Remove Cover B D C D C B C A 1. Install hitch (A) to two tabs (B) on lower mounting bracket using two 1/2 x 1-1/4 in. clevis pins (C) and spring locking pins (D). 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. NOTE: Vehicle and blade should be on a firm level surface for ease of installation. Installing Step 2 Loading Cargo Box with Ballast E E 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. 2. Rotate hitch up and install top two 1/2 x 1-3/4 in. clevis pins (E) and spring locking pins. Installing Step 3 3. Securely tighten vehicle mounting bracket hardware (this hardware was left loose after installing the lower mounting bracket). Installing Hitch NOTE: The required hardware for these steps is found in Bag of Parts marked 1016997. 12 Installing NOTE: Do not operate the system unless the red rubber boots are installed on the ends of wires B1 and A2. Installing Step 4 Installing Wiring Harnesses 1. Before installing the wiring harnesses remove the seat and the center console. 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. long A3 - 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. B1 (NOTE: Route A1 next to B1) 6. Route wires B1 and A1 through the dashboard and along the center console to the battery compartment. B1 A1 A2 Red Rubber Cap Solenoid A3 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. 13 Installing 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. 8-pin male connector A2 Black wire Orange wire Red wire A1 4. Attach the wires in the three wire bundle A2 to the solenoid as follows: Harness 1009919 • 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. 2. Route the 12-pin female end of the main harness A1 under the instrument panel and into the vehicle cab. 6. Cable tie the main harness A1 and the three-wire bundle of harness A2 as required to keep it from moving during operation. 3. Adjust the routing of the main harness A1 so that the opposite end of harness A1 follows alongside the main vehicle harness. NOTE: Cable ties are provided in parts bag 1016997. 14 Installing Black UP COIL (TOP) Red RIGHT (TOP) LEFT (BOTTOM) UP/ DOWN VALVE DOWN COIL (BOTTOM) RIGHT/LEFT VALVE Photo 7A Photo 8A Installing Step 7 Installing Step 8 Installing Wiring Harness 1009920 Installing Wiring Harness 1009919 1. Install the end of red wire to the positive terminal on the motor. 1. Install the ends of Wiring Harness 1009919 that are marked UP and DOWN into the coils on the UP/DOWN valve. 2. Install the end of black wire to the negative terminal on the motor. 2. The connection sequence for UP/DOWN wires is: a) Install the UP wire connector into the top coil, and 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. 1009921 4. The connection sequence for RIGHT and LEFt wires is: a) Install the RIGHT wire connector into the top coil, and b) Install the LEFT wire connector into the bottom coil. 1009920 Photo 7B 3. Install the connector end of Harness 1009920 to the end of Harness 1009921. Note: Harness 1009921 has the rubber cap (see photo above). 15 Installing Cable Tie (Step 8) Harness 1009918 Harness 1009919 Cable Tie (Step 6) Existing wiring harness loom Cable Tie 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. 16 Installing Installing Step 9 Installing Step 10 Battery Connection Installing Remote Control Wiring Harness B2 Attach A1 here Remote Control Connector 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. 1. Plug in Remote Control unit to wiring harness as shown. Remote Control Bracket Remote Control 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 hookand-loop tape to controller and controller bracket. 17 Installing Installing Step 11 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. Commissioning Hydraulics NOTE: Before commissioning the hydraulics, all previous steps in the installation section must be completed. 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. 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. 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. 18 Installing Test the UP/DOWN Function I 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. 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. H H 1. Place the blade on a flat surface that is accessible with the vehicle. Cable Tie (Step 7) 2. Move the vehicle behind blade and line up the blade with the hitch. 7. Connect the two hydraulic hoses together, as shown above, using one of the provided cable ties. 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. Test the LEFT/RIGHT Function NOTE: The key switch must be turned to the RUN position for the remote control to function. 1. Turn key switch to RUN position. 2. Depress the LEFT button on the remote control and the blade will move left. 4. Slowly move the vehicle forward until the blade is fully seated in the blade mounting forks. 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). 19 Operation Operation Step 1 Raising the Blade: Daily Operating Checklist q Check for loose or missing hardware. Depress the Up button (A) on the remote control to raise the blade to the desired height. q Make sure all hydraulic fittings and hoses are tight. Lowering the Blade: q Make sure attachment responds properly to controls. Depress the Down button (B) on the remote control to lower the blade to the desired height. q Check for debris build-up that could obstruct proper motion of the blade trip components. Moving the Blade Left: Depress the Left button (C) on the remote control to move the blade to the desired angle. q Wipe a light coat of oil over all exposed surfaces. Moving the Blade Right: Operation Step 2 Depress the Right button (D) on the remote control to move the blade to the desired angle. Using the Blade Green light Remote Control: • The remote control green light will be on during operation. • The remote control is back lit for low light or night operation. A C • The remote control has built-in logic to shut off any function after four seconds. D 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. B • 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. Remote Control 20 Operation 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. A 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: Floating mode shown. CAUTION: Avoid injury! Fingers and hands can be pinched or crushed. Be aware of potential pinch points and keep hands away. 3. Loosen the 1/2 in. hex head bolt (A) on the hitch. A B Picture Note: Down Pressure mode shown. 3. Check for obstructions around the springs and between the blade and blade frame. Use a long pry bar to remove obstructions. 4. Change to the Down Pressure mode by turning the control plate (B) 90° and tighten the 1/2 in. hex head bolt (A). 21 Removing and Storing Removing and Storing Step 1 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. Removing Ballast CAUTION: Avoid injury! Machine can become unstable when operating with attachment. Ballast is required when the attachment is installed. B AI When the attachment is removed, also remove any ballast that was added to the machine. Use only attachments and accessories recommended by the manufacturer. Remove any added ballast from machine. Removing and Storing Step 2 Removing Blade 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. 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.) 5. Start vehicle. 2. Lower blade to ground by moving and holding blade control lever forward to the Down position. AI 6. Slowly back vehicle until blade mounting forks (C) are clear of the blade. 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. 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.) 22 Removing and Storing 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. H D Removing and Storing Step 4 Removing the Hitch (If Necessary) 1. Disconnect Harness 1009919 (see Step 7 in Installing section). 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. 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. 11. Remove ballast from cargo box. Removing and Storing Step 3 Storing Blade CAUTION: Avoid injury! When removing the hitch, care must be taken not to pinch hands and fingers between the moving parts. CAUTION: Avoid injury! Fuel vapors are explosive and 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. 1. Remove blade from vehicle. 2. Clean blade. 23 Service Service Intervals IMPORTANT: Avoid damage! Operating in extreme conditions may require more frequent service intervals. A B 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: Picture Note: Down Pressure mode shown. • John Deere J20D Note: The hydraulic oil should be changed twice a year. 3. If in the Down Pressure mode, loosen the 1/2 in. hex head bolt (A). Adjusting Blade Height 4. Loosen jam nut (B) on the hitch. 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.). C 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.) D 2. Completely lower the hitch by depressing the Down button on the remote control. Picture Note: Floating mode shown. 5. Rotate the Control Plate (C) to the floating mode position to gain access to hex socket head bolt (D) for adjustment. 24 Service A C B D Picture Note: Floating mode shown. 2. Remove bolts (A) and nuts (B) securing wear bar (C) to blade. 6. Adjust blade to specified height by turning hex socket head bolt (D) to desired height using a 1/4 in. hex key wrench. 3. Evaluate the condition of the existing wear bar and hardware. • Turning bolt (D) clockwise lowers the blade, turning bolt (D) counterclockwise raises the blade. 4. Reverse and re-install, or replace wear bar depending on condition. Secure with original hardware, or replace hardware, as required. • For each full turn of bolt (D), the blade will raise or lower 25 mm (1 in.). 7. Tighten jam nut (B) securely. Servicing Blade 8. Rotate control plate (C) to either Floating or Down Pressure position, as desired, then tighten 1/2 in. hex head bolt (A) securely. AI 9. Check blade height in the full up position, repeat adjustment as necessary. B Reverse or Replace Blade Wear Bar CAUTION: Avoid injury! Crushing injury can occur if blade drops unexpectedly. Keep hands and feet from under raised blade. 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. 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 blade trip springs for tension and wear. 2. Check the hose-end quick disconnects for dirt and debris. 3. Check the blade for loose parts. 25 Troubleshooting Troubleshooting Locator Left / Right Valve Coils (2) Plc. Up / Down Valve Coils (2) Plc. Coil Nut Torque to 4-5 ft lb Coil Connectors (2) Plc. Coil Connectors (2) Plc. Check Valve Cross-over Relief Valve Blade Up Hose Filler / Breather Blade Down Hose Pump Return Hose Pump Pressure Hose Pump Relief Valve Pump Pressure Hose Pump Return Hose 26 Troubleshooting LEGEND Using Troubleshooting Chart 1) Remote control problems If you are experiencing a problem that is not listed in this chart, see your authorized dealer for service. 2) Electrical troubleshooting – Solenoid 3) Electrical troubleshooting – Motor When you have checked all the possible causes listed and you are still experiencing the problem, see your authorized dealer. 4) Electrical checks good, but pump does not run 5) Blade will not raise or lower, but motor runs Blade Troubleshooting 6) Blade will not move left or right, but motor runs If you are experiencing a problem that is not listed in this chart, see your authorized dealer for service. 7) Blade will not hold angle while plowing 8) Blade will not hold “up” position When you have checked all the possible causes listed and you are still experiencing the problem, see your authorized dealer. 9) Blade chatters while moving down 10) Hydraulic fluid is leaking 11) Blade trips too easily 12) Blade does not trip ISSUE 1 IF No Blade Functions Work CHECK PROCEDURE A - Check for blown fuse at battery connection. 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 and black harness wires are connected to the battery. 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. A - Check the remote control to main wiring harness under the dash is connected; if not, ensure it is connected. B - Check the vehicle accessory connection. 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. 27 Troubleshooting ISSUE 2 3 IF Up Function Works Down does not Down Function Works, Up does not CHECK PROCEDURE 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. A - Check the wiring harness to coil connection. 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. 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. A - Check the wiring harness to coil connection. 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. 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. 28 Troubleshooting ISSUE IF CHECK PROCEDURE 4 Right Function Works, Left does not A - Check the wiring harness to coil connection. 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 connected. 5 Right Function Works, Left does not 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. A - Check the wiring harness to coil connection. 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 connected. 6 Blade will not hold angle while plowing 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. 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. A - Check the wiring harness to coil connection. 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 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 ISSUE IF CHECK 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. 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 - Check that the check valve is not stuck open. C - Check that the orifice fitting is installed. PROCEDURE 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 tight 1/4 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. 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 - Check if trip springs are bent. 11 Blade does not trip A - Check trip spring tension is not too tight. B - Check if trip springs are bent. 12 Blade does not raise. Check if the trigger springs are not too tense. B - If the trip springs are bent then replace them. 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. 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. 30 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.) 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. 31 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