GATOR® Utility Vehicle 4x2 and 4x2 Trail PIN (039280-) 6x4 and 6x4 Trail PIN (039286-) Introduction Product Identification Safety Operating Replacement Parts Service Intervals Service Lubrication Service Engine Service Transmission Service Electrical Service Miscellaneous Troubleshooting. Using Troubleshooting Chart. View and Download John Deere Gator XUV 620i instruction manual online. Welcome to ManualMachine. You have been successfully registered. We have emailed you a verification link to to complete your registration. Please check your inbox, and if you can’t find it. This Technical Manual offers all the service and repair information for John Deere XUV 620i Gator Utility Vehicle. With this in-depth & highly detailed manual you will be able to work on your vehicle with the absolute best resources available, which will not only save you money in repair bills but will also help you to look after your bussiness. View and Download John Deere Gator XUV 620i instruction manual online.
Preparing Vehicle
Winch Mounting Applications
IMPORTANT: Avoid damage! Use winch in an approved mounting application for the utility vehicles specified. Installing winch to other utility vehicles or to areas of the machine not recommended will void the vehicle and attachment warranties. |
Model | Approved Winch Application |
|---|---|
HPX | Front and rear mount. |
XUV 620i, XUV 850D | Front and rear mount. |
T-Series | Front and rear mount. |
M-Gator A1 | Front and rear mount. |
Winch Mounting Requirements
IMPORTANT: Avoid damage! Use only approved John Deere brand parts for mounting the winch. Misuse, modification, or failure to use the correct mounting components will void the vehicle and attachment warranties. |
The following equipment must be installed to vehicle before mounting winch. See your John Deere dealer.
Front Mount Applications
• Receiver Front Hitch Kit
Rear Mount Applications
• Receiver Rear Hitch Kit
• Rear Mount Wiring Harness
• Heat Shield (XUV 620i only)
Requirements for Double Line Rigging (HPX, XUV Only)
IMPORTANT: Avoid damage! The winch cable hook must be secured at the receiver hitch when double line rigging. Never attach the hook to the carrier plate, bumper, vehicle frame, or any other part. |
NOTE: A clevis must be installed to receiver hitches when double line rigging. See your John Deere dealer for clevis.
At the time of winching, clevis must be installed at the side of the receiver that ensures the straightest pull.
MX31636
1. If holes are not in gusset (A), drill one 13 mm (1/2 in.) hole (B) at each side of gusset. Center each hole in the gusset to ensure equal metal thickness around the hole.
2. Remove all burrs from drill holes.
3. Install clevis to either hole.
Prepare Vehicle
All Models
1. Raise cargo box.
2. Park vehicle safely. (See Parking Safely in the SAFETY section.)
| c CAUTION: Avoid injury! The battery produces a flammable and explosive gas. The battery may explode: • Do not smoke or have open flame near battery. • Wear eye protection and gloves. • Do not allow direct metal contact across battery posts. • Remove negative cable first when disconnecting. • Install negative cable last when connecting. |
3. Disconnect negative (–) and positive (+) battery cables.
HPX, XUV 620i, XUV 850D
MX31378
1. Using a small screwdriver, pry up the four expansion rivets (A) from center console, and remove cup holder (B).
MX31375
2. Remove hood. Remove utility box (C) by lifting up and out toward front of machine.
Install Solenoid
All Models
MX39051
1. Disconnect remote control socket bullet connectors (A) from solenoid (B).
HPX, XUV 620i, XUV 850D Models
MX39052
1. Locate frame gusset (C) on passenger side of vehicle.
2. Install solenoid (B) with bullet connectors at the top, on inside of frame gusset with four M6x25 bolts (D), M6 flat washers (E), and M6 lockwashers and nuts (F) on the back side.
T-Series Models
MX39053
1. Remove hood, and locate frame gusset (C) on driver’s side of vehicle.
2. Install solenoid (B) with bullet connectors at the top, on inside of frame with two M6x25 bolts (D), M6 flat washers (top left and bottom right), and two M6 lockwashers and nuts on the inside.
M-Gator A1 Model
1. Remove hood.
MX46322
2. Remove two screws and glove box (A).
3. Measure up approximately 50 mm (2 in.) (B) and inward 42 mm (21/32 in.) (C) and position solenoid (D). Mark two holes (E).
NOTE: You may need to drill holes from inside of frame area.
MX46323
4. Remove solenoid and drill two 7 mm (1/4 in.) holes at two marked locations (E).
MX46324
5. Install solenoid (D) with two 6 mm bolts (F) and washers, with a lockwasher and nut on rear side.
6. Install glove box with two screws.
Install Remote Control
MX11452
1. Drill a 22 mm (7/8 in.) hole near lower left corner of glove box for mounting of remote control socket (A). Check for proper fit before drilling.
2. Insert socket into hole from outside of glove box. Make sure keyway in socket faces down. Mark the socket mounting holes.
3. Remove the socket and drill two 5 mm (3/16 in.) holes.
MX11453
4. Route the socket wiring through hole from inside of glove box. Position socket in hole so keyway faces down. Secure with two M5x20 hex head bolts (B) at inside and two #10 flat washers, #10 lockwashers and M5 nuts at outside. Do not overtighten.
5. Plug remote control into socket and store in glove box.
MX39054
Picture Note: HPX and XUV Models
MX46325
Picture Note: M-Gator A1.
6. Route wires to solenoid (C).
7. Connect bullet connectors at solenoid - green to green (D), black to black (E).
IMPORTANT: Avoid damage! Make sure wires are not kinked or pulled tight against any metal edges of vehicle frame before securing with tie straps. |
8. Secure wiring harnesses:
• HPX, XUV 620i, XUV 850D: Coil the excess black socket wire and secure it to main wiring harness (F) with tie strap (G).
• M-Gator A1: Coil the excess black socket wire and secure with tie strap (G) under glove box (H).
MX31635
9. Route the red socket wire with connector (I) through chassis tunnel (J).
10. Connect red socket wire plug (K) to vehicle key switch connector (L).
Install Wiring for Front Mounting on Vehicle
| c CAUTION: Avoid injury! Damage to electrical cables and wires can result in serious injury or death caused by fire or electrocution. Do not route electrical wiring across sharp edges, through moving parts, or near hot surfaces. Keep wiring away from these hazards by securing with tie straps. Insulate all terminal connections with protective covers. |
MX11457
1. Locate the 1.6 m (64 in.) red and black battery cables. Identify the ring terminal ends with insulated covering (A).
Route Wiring (HPX, XUV 620i, XUV 850D)
MX31657
1. Route 1.6 m (64 in.) battery cable wiring (B) from battery into chassis tunnel (C) between seats. Pull harness through tunnel and up to solenoid.
MX31658
2. Secure battery cable wiring (B) to main harness (D) at center frame support using tie straps (E), keeping wiring away from shift linkages and moving parts.
MX31660
3. Route the ring terminal end of the 1.5 m (60 in.) front mount wiring harness (F) from the hitch receiver area up through tunnel (G) to the solenoid. Keep harness away from moving parts and secure to front wiring harness (H), front bumper and vehicle frame with tie straps.
MX31378
4. Install cup holder (I) onto center console, and secure with four expansion rivets (J).
Route Wiring (T-Series)
MX33315
1. Locate service access panel (B) under passenger seat. Pull back on latch (C) and remove panel.
MX33531
2. Route 1.6 m (64 in.) positive and negative battery cable wiring from battery through chassis tunnel (D) between seats. Pull harness through tunnel and up to solenoid. Tie off battery cable wiring to main harness (E), keeping wiring away from shift linkages and other moving parts.
3. Lower hood.
Route Wiring (M-Gator A1)
MX46325
1. Route negative (A) and positive (B) cables through square hole (C) in front frame, and through hole (D) in frame.
2. Route positive cable (B) to solenoid (E) terminal. Route negative cable (A) to solenoid terminal.
MX46326
3. Route opposite end connector (F) of front cables to front winch connector (G).
4. Secure cables to front brush guard (H) with tie straps (I).
5. Lower hood.
Complete Wiring Installation (All Models)
MX39074
Picture Note: Reference photo. Shown without terminal covers.
1. Connect wires to solenoid:
a. Slide a terminal cover over red battery cable and connect to red solenoid terminal (A).
b. Slide a terminal cover over black battery cable and connect to black solenoid terminal (B).
c. Slide a terminal cover over red cable from front mount wiring harness and connect to blue solenoid terminal (C).
d. Slide a terminal cover over black cable from front mount wiring harness and connect to yellow solenoid terminal (D).
e. Tighten all connections. Install terminal covers over the solenoid terminals.
2. Place flexible conduit over four harness wires right below solenoid, to avoid contact with sharp edges and moving parts.
Gator Xuv 620i Service Manual
3. Install a terminal cover over the end of each battery cable.
4. Install positive and negative battery cables to battery, and install terminal covers over the battery terminals.
MX11460
5. Install dust cover (E) to front mount wiring harness connector (F).
Install Wiring for Rear Mounting on Vehicle
MX31658
Picture Note: HPX, XUV, and T-Series.
MX38188
Picture Note: M-Gator A1.
1. Route the 3.7 m (144 in.) rear mount wiring harness (A) from solenoid through tunnel (B), following machine main harness (C).
2. For all models except M-Gator A1, secure rear mount wiring harness to machine main harness at center frame support using tie straps (D).
MX31657
3. HPX, XUV, and T-Series: Route the rear mount wiring harness (A) along machine main harness (C), past battery area, through hole in frame (E), to engine compartment.
Route Harness to Rear (HPX)
MX31659
1. Route harness along main harness to rear of vehicle.
2. Secure end of rear mount harness to rear tube of vehicle frame (A), and remainder of harness to rear vehicle wiring harness (B) with tie straps (C).
Route Harness to Rear (XUV 620i, XUV 850D)
MX38995
Picture Note: XUV 620i shown.
1. Route harness along main harness to rear of vehicle. Harness must go over rectangular frame crossmember (A), to the inside of the flange (B), then over the cargo box pivot tube. Let the end of the harness with connector hang down temporarily.
2. Secure to rear vehicle wiring harness with tie straps (C).
IMPORTANT: Avoid damage! Keep rear mount harness clear of exhaust and moving parts. |
MX38996
Picture Note: XUV 620i shown, rear view.
3. Bring the end of the rear mount harness over to the right side angle support (D), and secure to the support with a tie strap (C), just above the connector (E).
4. Install the dust cover (F) over the connector.
Route Harness to Rear (T-Series)
MX11458
1. Route harness exiting the chassis tunnel along the same path as the vehicle main wiring harness (A).
2. Secure rear mount harness to main harness, vehicle frame, and center frame support (B) as needed using tie straps.
Route Harness to Rear (M-Gator A1)
MX46327
1. Route harness along main harness (A) to rear of vehicle. Harness must go under flange (B). Let the end of the harness with connector hang down temporarily.
2. Secure to rear vehicle wiring harness and rear of frame with tie straps (C).
IMPORTANT: Avoid damage! Keep rear mount harness clear of exhaust and moving parts. |
MX46328
3. Bring the connector end (D) of the rear mount harness over to the center frame brace and to the rear winch harness connector (E).
4. Secure to the rear frame, along with two positive and negative battery cables (F) with tie straps (G).
Complete Harness Installation (All Models)
MX39074
Picture Note: Reference photo. Shown without terminal covers.
1. Connect wires to solenoid (some may already be connected if front mount is installed):
a. Slide a terminal cover over red battery cable and connect to red solenoid terminal (A).
b. Slide a terminal cover over black battery cable and connect to black solenoid terminal (B).
c. Put red cables from front and rear mount wiring harnesses back to back. Slide one terminal cover over both cables and connect to blue solenoid terminal (C).
d. Put black cables from front and rear mount wiring harnesses back to back. Slide one terminal cover over both cables and connect to yellow solenoid terminal (D).
e. Tighten all connections. Install terminal covers over the solenoid terminals.
2. Place flexible conduit over six harness wires right below solenoid, to avoid contact with sharp edges and moving parts.
3. Install a terminal cover over the end of each battery cable.
4. Install positive and negative battery cables to battery, and install terminal covers over the battery terminals.
Install Heat Shield (620i Only)
IMPORTANT: Avoid damage! Failure to install heat shield will result in damage to winch. |
MX39000
1. Locate the optional heat shield (A), then cut a piece of paper or cardboard (B) larger than the heat shield.
2. Fold the paper so that it will conform to the inside bend of the heat shield, and place the paper and heat shield on the edge of a table or workbench (C). The heat shield flange with mounting holes should be on the top surface of the bench or table, and the remainder of the heat shield should be angled downward.
3. Mark the outline (D) of the heat shield mounting flange, including the two clearance notches, and five mounting holes on the paper.
4. Cutout and discard the paper (E) above the flange.
MX39003
5. Place the remaining paper template (B) against the lower flange at the outside of the existing muffler shield (F). Position the template so that the two clearance notches are centered over the two angled weld burn marks (G), as shown. These weld burn marks show the location of the support brackets at the other side of the muffler shield. The paper template may have to be cut to clear the gussets (H) on the heat shield flange.
6. Mark the location of the five mounting holes (I) on the existing muffler shield flange, and drill 7 mm (9/32 in.) holes at those locations.
MX39001
7. Install the optional heat shield (A) at the inside of the lower flange of the existing muffler shield (F). The mounting flange is at the top, the shield is angled forward, and the clearance notches surround the two muffler support brackets.
MX39002
8. Secure the heat shield with five M6 self-tapping screws (J), installed from the rear, through the existing muffler shield into the optional heat shield.
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