Operating

Daily Operating Checklist

o Test safety systems.

o Check tire pressure.

o Check fuel level.

o Check engine oil level.

o Check transmission oil level.

o Check coolant level on liquid cooled engine.

o Remove grass and debris from machine.

o Clean air intake screen.

o Check area below machine for leaks.

Avoid Damage to Plastic and Painted Surfaces

· Do not wipe plastic parts unless rinsed first.

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

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

Operator Controls

MX2893

A - Cargo Box Dump Switch

B - Indicator Panel

C - Ignition Switch

D - Headlight Switch

E - Hourmeter

F - Steering Wheel Lock Cable

G - Accelerator

H - Brake Pedal

MX2892

A - Differential Lock Lever

B - Transaxle Shift Lever

C - Park Brake Lever

Miscellaneous Controls

W02238

A - Fuel Shut Off Valve

Indicator Panel

NOTE: Only one indicator bulb illuminates both Coolant Temperature (C) and Engine Preheat (D) Indicators at the same time.

W02256

A - Battery Discharge

B - Oil Pressure

C - Coolant Temperature

D - Engine Preheat

E - Park Brake

F - Differential Lock

Using Hand Holds

MX2881

Hand holds (A) are provided for passenger balance when driving over rough terrain. Use dash bar and side rails on seats for stability.

Adjusting Seats

1. Lift and tip vehicle seat forward.

NOTE: The back of the seat will hit the front of the fender. Use care when adjusting.

M78512

Picture Note: Operator seat shown.

2. Loosen hardware (A).

3. Slide seat forward or rearward to desired position.

NOTE: Left rear bolt position on passenger seat is intentionally left open, no bolt.

4. Tighten seat bracket hardware to 10 N·m (7 lb-ft).

NOTE: Lateral seat movement can be accomplished by removing seat hardware and moving seat to the other slotted seat position (B).

Testing Safety Systems

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

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

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

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

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

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

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

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

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

Testing the Safety Start System

1. Sit on the operator's seat.

W00927

2. Place key switch in STOP position (A).

3. Lock park brake.

4. Move transaxle shift lever to forward position.

5. Move key switch to start position (B). Engine should not crank. Turn key switch off.

6. Move transaxle shift lever to reverse position.

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

Using Fuel Shut-Off Valves

Turn the fuel shut-off valve(s) to the off (closed) position before transporting or storing the utility vehicle.

W02276

1. Raise cargo box to access fuel shut-off valve on fuel filter.

2. Turn lever (A) horizontal to "C" position to turn off fuel flow. Turn lever vertical to "O" position to turn on fuel flow.

Using Park Brake

NOTE: Pushing down on brake pedal while locking and unlocking park brake decreases effort required to apply park brake lever.

MX2882

Locking the Park Brake

1. Push down on brake pedal.

2. Pull up on lever (A) and latch into position.

Unlocking the Park Brake

1. Push down on brake pedal.

2. Pull up on lever (A).

3. Depress button (B).

4. Release lever down completely.

W02627

NOTE: Decal located on console below park brake lever.

Operating Differential Lock

MX2883

Differential lock (A) provides better traction when rear wheels start to slip. Engaging the differential lock will cause all rear wheels to turn together at equal speed.

c CAUTION: Avoid injury! Driving at speeds with the differential lock engaged may result in loss of steering control. Do not engage or turn with the differential lock on while operating vehicle at speeds in excess of 16 km/h (10 mph).

Engaging the Differential Lock


IMPORTANT: Avoid damage! Do not attempt to engage or disengage differential lock at high speeds. Lock pins will not engage, and damage will occur to transaxle and/or linkage. For differential lock to engage, the left and right side wheels must be turning at slightly different speeds.

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

W02631

2. Push differential lock lever forward to locked position (B):

· Differential lock will remain engaged as long as lever is forward.

· Panel indicator light will come on.

Disengaging the Differential Lock

NOTE: Panel light only indicates when lever is in ON or OFF position. To ensure true disengagement of differential lock, you must equalize torque on both axles.

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

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

3. Pull lever rearward to unlocked position (C). Panel indicator light will go off.

Using Transaxle Shift Lever


IMPORTANT: Avoid damage! Do not shift gears when vehicle is moving or with engine running above low idle speed. Stop vehicle motion and engage shift lever with a firm positive action. Gears may grind when shifting if engine idle speed is set higher than factory specification.

1. Stop machine.

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

W02621

3. Select a gear position:

· Forward (A) - Push shift lever forward.

· Reverse (B) - Push shift lever to right, then pull rearward.

4. Begin vehicle travel.

Starting the Engine

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

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

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

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

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


IMPORTANT: Avoid damage! Never use starting fluid to assist in starting the engine.

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

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

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

3. Move gearshift lever to N (Neutral) position.

c CAUTION: Avoid injury!

Do not start engine by shorting across starter terminals. Bypassing normal circuitry will allow vehicle to start in gear

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

4. Lock park brake.

W00927

5. Turn key switch to run position (A). Check the following indicator lights are on:

· Battery discharge indicator.

· Oil pressure indicator.

· Coolant temperature and engine preheat indicators for up to 8 seconds depending on air temperature.

6. Turn key to Start position (B) after coolant temperature and engine preheat indicators go out.


IMPORTANT: Avoid damage! Starter may be damaged if operated for more than 20 seconds at a time. Wait at least two minutes before trying again if engine does not start.

7. Release key to the Run position when engine starts.

· If engine does not start within five seconds, turn key to off and wait ten seconds before trying to start again.

· In very cold conditions, attempt starting engine three times only, then wait 5 minutes before trying again. This will allow time for starter to cool and prevent damage to starter.


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

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

Stopping Engine

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

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


IMPORTANT: Avoid damage! If engine has been running hard and is hot, do not stop engine immediately. Remove load from engine. Run engine at 1/3 to 1/2 throttle for several minutes to cool engine.

1. Stop vehicle.

2. Move gearshift lever to N (Neutral) position.

3. Lock park brake.

W00927

4. Turn key switch to STOP position (A).

5. Remove key.

Operating the Vehicle

1. Move transaxle shift lever to forward or reverse gear position as desired.

2. Look in the direction the vehicle will travel.

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

M97028

3. Push down accelerator pedal (A) slowly and smoothly to begin vehicle travel.

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

Raising and Lowering Cargo Box Using Power Lift

c CAUTION: Avoid injury! Help prevent bodily injury from unintentional lowering of the cargo box. Lock park brake while vehicle is on a level and stable surface before raising cargo box.


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

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

2. Turn key to run position.

M78469

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

NOTE: Allowing the Power Lift actuator clutch to slip briefly (click or ratchet) after cargo box is fully lowered will help keep cargo box secure and reduce rattling caused by travel vibrations.

4. Completely lower cargo box by pressing and holding bottom of rocker switch.

NOTE: Hour meter will run whenever key is in RUN position. Turn key to Stop position after using the Power LIft option.

5. Turn key to stop position.

Dumping a Load

c CAUTION: Avoid injury! Raising a loaded cargo box changes the center of gravity. Do not allow rear wheels to hang over the edge of a loading dock or ravine. The cargo box weight may shift over center and vehicle could tip over backwards.

M78552

1. Back up vehicle to dump site.

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

3. Release tailgate latches.


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

4. Raise cargo box to dump load.

5. Lower cargo box when empty.

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

Operating the Tailgate

Lower Tailgate Using Tailgate Support

NOTE: Use the tailgate support to carry a longer load with tailgate down.

MX2831

1. Pull tailgate support arm (A) out from under cargo box.

MX2890

2. Pull latch rod handles (B) up and towards center of tailgate at the same time to release tailgate latches from holes (C) in side panel.

MX2891

3. Lower tailgate (D) until resting on tailgate support arm. Latch hook/arm into tailgate.

4. Pull up tailgate to close and snap latch rods back into side panel holes at the same time.

5. Push tailgate support arm back under cargo box.

6. Push rod handles down to avoid snagging on clothing.

Lower Tailgate Without Tailgate Support

MX2890

1. Pull latch rod handles (A) up and towards center of tailgate at the same time to release tailgate latches from holes (B) in side panel.

MX3409

2. Lower tailgate (C).

3. Pull up tailgate to close and snap latch rod handles back into holes at the same time.

4. Push rod handles down to avoid snagging on clothing.

Latching the Tailgate to the Tailgate Support Arm

NOTE: The support arm has a latch handle (A) that will hold the lowered tailgate firmly to the support arm (B).

MX3407

1. Pull the tailgate support arm out from under the cargo box.

2. Lower tailgate to support arm.

MX3408

3. Pull up on the latch handle (A) until it connects into slot of support arm.

4. To release tailgate, push in on handle (A) and return support arm to the stored position under the cargo box.

5. Close cargo box and be sure the latch rods snap securely into the holes in the side panels.

Lowering Cargo Box Side Panels

1. Lower the tailgate onto the tailgate support arm.

MX2895

2. Lift latch (A) at the front of cargo box to disengage latch pin (B) and pull on the side panel (C) to lower.

MX2896, MX3411

3. To raise side panel, lift latch (A) and raise panel (C) until the lower detent (D) in the latch engages latch pin (B).

4. Pull up tailgate (E) to close and snap latch rods back into holes at the same time.

5. Push rod handles down to avoid snagging on clothing.

Using Cargo Box Tie-down Rings

MX3413

1. Place your finger on the flat of the tie-down ring and push to access the ring loop (A).


IMPORTANT: Avoid damage! To avoid damage to side panels and tailgate, place bulk of load over the main cargo box area (B). Do not overload tailgate or side panels.

MX3414

2. Arrange load so that the weight is centered over the main cargo area (B).

3. Secure loads to the tie-down rings in a safe and secure manner.

Using Sling Load Portal® Rings

NOTE: The Sling Load Portals (A) located to the rear of the cargo box allow access to the rear lift rings.

MX3415

NOTE: There is a gap between the tab (B) and the frame stop (C). If necessary pry open the Sling Load Portal in the case of a tight condition.

MX3416

1. Reach under edge of cargo box to the tab (B) of the Sling Load Portal and swing open.

MX3418

2. Place an approved lifting device through the Sling Load Portal in the cargo box.

NOTE: Rings on the four corners of the vehicle are for lifting or tiedown. Rings (D) must be free to rotate.

MX3425

3. If not free to rotate, loosen nut until the rings (D) are free.

MX3419

4. Secure the lifting device to the lifting ring (D).

MX3502

5. There are two lifting rings (E) on the front of the vehicle also.

Loading the Cargo Box

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

· Properly install load guard.

· Do not load above height of load guard.

· Securely anchor all loads in cargo box.

· Do not load beyond maximum capacity.

W00906

Maximum payload capacity on level terrain for the cargo box for the M-GATOR is 450 kg (1000 lb).

Reduce load and ground speed when operating over rough or hilly terrain. Do not overload vehicle. Limit loads to those that can be safely controlled.

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

Do not load above load guard.

M78556

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

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

For example, dry sand weighing 450 kg (1000 lb) would be approximately 3/4 of cargo box volume for the M-GATOR.

Printed weight is normally on bagged and other material.

Using Pintle Hitch

MX3426

1. Remove wire lock (A) from lock pin (B) and remove lock pin.

MX3427

2. Pull the hitch lock (C) forward.

MX3428

3. Open pintle hitch jaw (D).

4. To lock hitch, install lock pin and wire lock.

Towing Loads

c CAUTION: Avoid injury! To help prevent personal injury due to loss of control or tipping, always tow a load slowly enough to maintain control. To provide adequate braking ability and traction do not tow a load unless vehicle cargo box is loaded.

· Do not tow a load unless the cargo box is loaded.

· Do not tow a load that exceeds 636 kg (1400 lb).

· Do not exceed a tongue weight of 45 kg (100 lb).

· Never exceed 16 km/h (10 mph) when towing a load. Tow load at a speed slow enough to maintain control.


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

W00934, W00935

MX2847

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

Transporting Vehicle

c CAUTION: Avoid injury! Use extra care when loading and unloading the machine into a trailer or a truck.


IMPORTANT: Avoid damage! Never tow the vehicle. Towing a vehicle will result in transaxle damage. Haul the vehicle on a heavy-duty trailer or on a full-size truck.

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

W00905

1. Drive utility vehicle onto the trailer or truck.

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

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

c CAUTION: Avoid injury! To help prevent the possibility of fire from fuel leakage, turn fuel shut-off valve off before transporting vehicle.

4. Turn fuel shut-off valve, if equipped, to off position during transport.

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

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