How it Works
Toro
Loading...
07362
Operator's Manual
60 pgs2.38 Mb0
Operator's Manual
56 pgs10.2 Mb0

Toro 07362, 07362TC, 07364, 07364TC, Workman 3300–D Operator's Manual

...
Download
Page 1
FormNo.3359-781RevB
Workman
®
3300–D&4300–D
LiquidCooledDieselUtilityVehicle
ModelNo.07362—SerialNo.280000001andUp
ModelNo.07362TC—SerialNo.280000001andUp
ModelNo.07364—SerialNo.280000001andUp
ModelNo.07364TC—SerialNo.280000001andUp
Registeratwww.T oro.com.OriginalInstructions(EN)
Page 2
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.
YoumaycontactT orodirectlyatwww .Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol (Figure2),whichsignalsahazardthatmaycauseserious injuryordeathifyoudonotfollowtherecommended precautions.
Figure2
1.Safetyalertsymbol
©2007—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contactusatwww.Toro.com.
2
PrintedintheUSA.
AllRightsReserved
Page 3
Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
Supervisor’sResponsibilities.................................5
BeforeOperating.................................................5
WhileOperating...................................................5
Maintenance.........................................................7
SoundPowerLevel...............................................7
SoundPressureLevel...........................................7
VibrationLevel.....................................................7
SafetyandInstructionalDecals.............................8
Setup..........................................................................13
1InstalltheRearFenders....................................13
2InstalltheWheels............................................14
3InstalltheSteeringWheel.................................14
4InstalltheFrontFenders..................................15
5InstallROPS....................................................15
6ActivateandChargetheBattery........................16
7FullBedRemoval.............................................17
8Re-InstalltheFullBed......................................18
ProductOverview......................................................19
Controls.............................................................19
Specications.....................................................22
Attachments/Accessories...................................23
Operation...................................................................23
CheckCrankcaseOil..........................................23
FillFuelTank.....................................................24
CheckCoolingSystem........................................25
CheckTransaxle/HydraulicFluid......................25
CheckFrontDifferentialOil...............................26
CheckTorqueOfWheelNuts.............................26
CheckTirePressure............................................26
CheckBrakeFluid..............................................26
CheckFanBeltTension......................................27
Pre–startingChecks............................................27
StartingEngine...................................................27
DrivingVehicle..................................................28
StoppingVehicle................................................28
StoppingEngine.................................................28
NewVehicleBreak–in........................................28
CheckInterlockSystem......................................28
OperatingCharacteristics...................................29
Passengers..........................................................29
Speed.................................................................30
Turning..............................................................30
Braking..............................................................30
Tipovers.............................................................30
Hills...................................................................31
LoadingAndDumping.......................................31
UsingTheDifferentialLock...............................32
FourWheelDrive...............................................32
TransportingVehicle..........................................33
TowingVehicle...................................................33
TrailerT owing....................................................33
HydraulicControl...............................................34
Maintenance...............................................................36
RecommendedMaintenanceSchedule(s)................36
ServiceIntervalChart.........................................37
HeavyDutyOperation.......................................37
PremaintenanceProcedures....................................38
UsingBedSafetySupport...................................38
JackingVehicle...................................................39
Lubrication.............................................................40
GreasingBearingsandBushings.........................40
EngineMaintenance...............................................41
GeneralAirCleanerMaintenance
Practices.........................................................41
ServicingAirCleaner..........................................41
ChangingEngineOilAndFilter..........................42
CylinderHeadBolts...........................................42
EngineValveClearance......................................42
FuelSystemMaintenance.......................................43
FuelSystem........................................................43
BleedingAirFromInjectors...............................43
ElectricalSystemMaintenance................................44
Fuses..................................................................44
JumpStartingVehicle.........................................44
BatteryCare.......................................................44
DriveSystemMaintenance.....................................45
ChangeFrontDifferentialOil.............................45
InspectConstantVelocityBoot...........................45
AdjustingShiftCables........................................45
AdjustingHigh–lowCable..................................46
InspectTires......................................................46
FrontWheelToe................................................46
CoolingSystemMaintenance..................................47
RemovingDebrisFromEngineCooling
System............................................................47
ChangingEngineCoolant...................................47
BrakeMaintenance.................................................49
InspectBrakes....................................................49
BeltMaintenance....................................................49
AdjustingBelts...................................................49
ControlsSystemMaintenance.................................50
AdjustingAcceleratorPedal................................50
AdjustingBrakePedal.........................................51
AdjustingClutchPedal.......................................51
AdjustingParkingBrake.....................................52
HydraulicSystemMaintenance...............................53
ChangingTransaxle/HydraulicFluid.................53
ReplacingHydraulicFilter...................................53
CleaningHydraulicStrainer................................54
EmergencyBoxRaising......................................54
Storage.......................................................................56
BatteryStorage...................................................56
3
Page 4
Schematics.................................................................57
Safety
TheTOROWORKMANmeetstherequirementsof SAEJ2258.
Supervisors,operatorsandservicepersonsshouldbe familiarwiththefollowingstandardsandpublications: (Thematerialmaybeobtainedfromtheaddressshown).
•FlammableandCombustibleLiquidsCode:
ANSI/NFPA30
•NationalFireProtectionAssociation:
ANSI/NFPA#505;PoweredIndustrialTrucks
ADDRESS:
NationalFirePreventionAssociation
BarrymarchPark
Quincy,Massachusetts02269U .S.A
•ANSI/ASMEB56.8PersonalBurdenCarriers
ADDRESS:
AmericanNationalStandardsInstitute,Inc.
1430Broadway
NewYork,NewYork10018U.S.A.
•ANSI/UL558;InternalCombustionEngine PoweredIndustrialTrucks
TrucksADDRESS:
AmericanNationalStandardsInstitute,Inc.
1430Broadway
NewYork,NewYork10018U.S.A.
OR
UnderwritersLaboratories
333PngstenRoad
Northbrook,Illinois60062U.S.A.
SafeOperatingPractices
TheWorkmanisanoff–highwayvehicleonly, andisnotdesigned,equipped,ormanufactured foruseonpublicstreets,roadsorhighways.
TheWorkmanwasdesignedandtestedtooffersafe servicewhenoperatedandmaintainedproperly . Althoughhazardcontrolandaccidentprevention partiallyaredependentuponthedesignand congurationofthemachine,thesefactorsarealso
4
Page 5
dependentupontheawareness,concern,andproper trainingofthepersonnelinvolvedintheoperation, maintenanceandstorageofthemachine.Improperuse ormaintenanceofthemachinecanresultininjuryor death.
Thisisaspecializedutilityvehicledesignedforoff–road useonly .itsrideandhandlingwillhaveadifferent feelthanwhatdriversexperiencewithpassengercars ortrucks.Sotaketimetobecomefamiliarwithyour Workman.
NotalloftheattachmentsthatadapttotheW orkman arecoveredinthismanual.SeethespecicOperator’s Manualprovidedwithattachmentforadditionalsafety instructions.Readthesemanuals.
Toreducethepotentialforinjuryordeath,comply withthefollowingsafetyinstructions:
illegible,ordamaged,repairorreplaceitbefore operatingthemachine.
•Alwayswearsubstantialshoes.Donotoperate machinewhilewearingsandals,tennisshoesor sneakers.Donotwearloosettingclothingor jewelrywhichcouldgetcaughtinmovingpartsand causepersonalinjury.
•Wearingsafetyglasses,safetyshoes,longpantsanda helmetisadvisableandrequiredbysomelocalsafety andinsuranceregulations.
•Keepeveryone,especiallychildrenandpets,away fromtheareasofoperation.
•Beforeoperatingthevehicle,alwayscheckallparts ofthevehicleandanyattachments.Ifsomethingis wrong,stopusingvehicle.Makesureproblemis correctedbeforevehicleorattachmentisoperated again.
Supervisor’sResponsibilities
•Makesureoperatorsarethoroughlytrainedand familiarwiththeOperator’ sManualandalllabels onthevehicle.
•Besuretoestablishyourownspecialproceduresand workrulesforunusualoperatingconditions(e.g. slopestoosteepforvehicleoperation).Usethe3rd HighLockoutswitchifhighspeedcouldresultina safetyorvehicleabusesituation.
BeforeOperating
•Operatethemachineonlyafterreadingand understandingthecontentsofthismanual.A replacementmanualisavailablebysendingcomplete modelandserialnumberto:TheToroCompany, 8111LyndaleAvenueSouth,Minneapolis,Minnesota
55420.
•Neverallowchildrentooperatethevehicle.Never allowadultstooperateitwithoutproperinstructions. Onlytrainedandauthorizedpersonsshouldoperate thisvehicle.Makesurealloperatorsarephysically andmentallycapableofoperatingthevehicle.
•Thisvehicleisdesignedtocarryonlyyou,the operator,andonepassengerintheseatprovidedby themanufacturer.Nevercarryanyotherpassengers onthevehicle.
•Sincedieselfuelishighlyammable,handleit carefully.
–Useanapprovedfuelcontainer.
–Donotremovecapfromfueltankwhenengine
ishotorrunning.
–Donotsmokewhilehandlingfuel.
–Fillfueltankoutdoorsandtoaboutoneinch
belowtopoftank(bottomofllerneck).Do notoverll.
–Wipeupanyspilledfuel.
•Operatethevehicleonlyoutdoorsorinawell ventilatedarea.
•Useonlyanapprovednon–metal,portablefuel container.Staticelectricdischargecanignitefuel vaporsinaungroundedfuelcontainer.Removethe fuelcontainerfromthebedofthevehicleandplace onthegroundawayfromthevehiclebeforelling. Keepnozzleincontactwithcontainerwhilelling. Removeequipmentfromvehiclebedbeforelling.
•Checkthesafetyinterlocksystemdailyforproper operation.Ifaswitchshouldmalfunction,replace theswitchbeforeoperatingmachine.Afterevery twoyears,replacetheinterlockswitchesinthesafety system,whethertheyareworkingproperlyornot.
•Neveroperatethevehiclewhenundertheinuence ofdrugsoralcohol.
•Becomefamiliarwiththecontrolsandknowhowto stoptheenginequickly.
•Keepallshields,safetydevicesanddecalsinplace. Ifashield,safetydeviceordecalismalfunctioning,
WhileOperating
•Operatorandpassengershoulduseseatbeltsand remainseatedwheneverthevehicleisinmotion. Operatorshouldkeepbothhandsonsteeringwheel, wheneverpossibleandpassengershouldusehand holdsprovided.Keeparmsandlegswithinthe
5
Page 6
vehiclebodyatalltimes.Nevercarrypassengers intheboxoronattachments.Rememberyour passengermaynotbeexpectingyoutobrakeorturn andmaynotbeready.
•Neveroverloadyourvehicle.Nameplate(located undermiddleofdash)showsloadlimitsforvehicle. Neveroverllattachmentsorexceedthevehicle maximumGVW .
•Whenstartingtheengine:
–Sitonoperator’ sseatandensureparkingbrake
isengaged.
–DisengagePTO(ifsoequipped)andreturnhand
throttlelevertoOFFposition(ifsoequipped).
–Makesurethehydraulicliftleverisinthecenter
position.
–MoveshiftlevertoNEUTRALanddepress
clutchpedal.
–Keepfootoffacceleratorpedal.
–TurnignitionswitchtoONposition.When
glowplugindicatorgoesoff,engineisreadyto START.
–TurnignitionkeytoSTART.
Note:Theglowplugindicatorwillturnon,foran additional15seconds,whentheswitchreturnsto theSTARTposition.
•Usingthemachinedemandsattention.Failureto operatevehiclesafelymayresultinanaccident,tip overofvehicleandseriousinjuryordeath.Drive carefully.Topreventtippingorlossofcontrol:
–Useextremecaution,reducespeedandmaintain
asafedistancearoundsandtraps,ditches,creeks, ramps,anyunfamiliarareasorotherhazards.
–Watchforholesorotherhiddenhazards.
–Usecautionwhenoperatingvehicleonasteep
slope.Normallytravelstraightupanddown slopes.Reducespeedwhenmakingsharpturns orwhenturningonhillsides.Avoidturningon hillsideswheneverpossible.
–Useextracautionwhenoperatingvehicleonwet
surfaces,athigherspeedsorwithafullload. Stoppingtimewillincreasewithafullload.Shift intoalowergearbeforestartingupordowna hill.
–Whenloadingbed,distributeloadevenly .Use
extracautioniftheloadexceedsthedimensions ofthevehicle/bed.Operatevehiclewithextra cautionwhenhandlingoff–centerloadsthat cannotbecentered.Keeploadsbalancedand securetopreventthemfromshifting.
–Avoidsuddenstopsandstarts.Donotgofrom
reversetoforwardorforwardtoreversewithout rstcomingtoacompletestop.
–Donotattemptsharpturnsorabruptmaneuvers
orotherunsafedrivingactionsthatmaycausea lossofvehiclecontrol.
–Donotpassanothervehicletravelinginthesame
directionatintersections,blindspots,oratother dangerouslocations.
–Whendumping,donotletanyonestandbehind
vehicleanddonotdumploadonanyone’sfeet. Releasetailgatelatchesfromsideofbox,not frombehind.
–Keepallbystandersaway.Beforebackingup,
looktotherearandassurenooneisbehindthe vehicle.Backupslowly.
–Watchoutfortrafcwhennearorcrossingroads.
Alwaysyieldtherightofwaytopedestriansand othervehicles.Thisvehicleisnotdesignedfor useonstreetsorhighways.Alwayssignalyour turnsorstopearlyenoughsootherpersons knowwhatyouplantodo.Obeyalltrafcrules andregulations.
–Neveroperatevehicleinornearanareawhere
thereisdustorfumesintheairwhichare explosive.Theelectricalandexhaustsystems ofthevehiclecanproducesparkscapableof ignitingexplosivematerials.
–Alwayswatchoutforandavoidlowoverhangs
suchastreelimbs,doorjambs,overhead walkways,etc.Makesurethereisenoughroom overheadtoeasilyclearthevehicleandyour head.
–Ifeverunsureaboutsafeoperation,STOP
WORKandaskyoursupervisor.
•Donottouchengine,transaxle,radiator,muferor mufermanifoldwhileengineisrunningorsoon afterithasstoppedbecausetheseareasmaybehot enoughtocauseburns.
•Ifthemachineevervibratesabnormally,stop immediately,turnengineoff,waitforallmotion tostopandinspectfordamage.Repairalldamage beforeresumingoperation.
•Beforegettingofftheseat:
–Stopmovementofthemachine.
–Lowerbed.
–Shutengineoffandwaitforallmovementto
stop.
–Setparkingbrake.
6
Page 7
–Removekeyfromignition.
Maintenance
•Beforeservicingormakingadjustmentstothe machine,stopengine,setparkingbrakeandremove keyfromignitiontopreventaccidentalstartingof theengine.
•Neverworkunderaraisedbedwithoutplacingbed safetysupportonfullyextendedcylinderrod.
•Makesureallhydrauliclineconnectorsaretight,and allhydraulichosesandlinesareingoodcondition beforeapplyingpressuretothesystem.
•Keepbodyandhandsawayfrompinholeleaksor nozzlesthatejecthydraulicuidunderhighpressure. Usepaperorcardboard,nothands,tosearchfor leaks.Hydraulicuidescapingunderpressurecan havesufcientforcetopenetrateskinanddoserious damage.Ifuidisinjectedintotheskinitmustbe surgicallyremovedwithinafewhoursbyadoctor familiarwiththisformofinjuryorgangrenemay result.
•Beforedisconnectingorperforminganyworkon thehydraulicsystem,allpressureinsystemmust berelievedbystoppingengine,cyclingdump valvefromraisetolowerand/orloweringboxand attachments.Placetheremotehydraulicsleverin theoatposition.Ifboxmustbeinraisedposition, securewithsafetysupport.
•Tomakesureentiremachineisingoodcondition, keepallnuts,boltsandscrewsproperlytightened.
Alteringthisvehicleinanymannermayaffectthe vehicle’soperation,performance,durabilityoritsuse mayresultininjuryordeath.Suchusecouldvoid theproductwarrantyofTheTOROCompany.
•Thisvehicleshouldnotbemodiedwithoutthe TOROCompany’sauthorization.Directany inquiriestoTheTOROCompany,Commercial Division,VehicleEngineeringDept.,8111Lyndale Ave.So.,Bloomington,Minnesota55420–1196. USA
SoundPowerLevel
Thisunithasaguaranteedsoundpowerlevelof 100dBA/1pW ,basedonmeasurementsofidentical machinesperDirective2000/14/ECandamendments.
SoundPressureLevel
ThisunithasanequivalentcontinuousA-weighted soundpressureattheoperatorearof:88dB(A),based onmeasurementsofidenticalmachinesperDirective 98/37/ECandamendments.
VibrationLevel
Hand-Arm
Thisunitdoesnotexceedavibrationlevelof2.5m/s2at thehandsbasedonmeasurementsofidenticalmachines perISO5349procedures.
•Toreducepotentialrehazard,keeptheengine areafreeofexcessivegrease,grass,leavesand accumulationofdirt.
•Iftheenginemustberunningtoperforma maintenanceadjustment,keephands,feet,clothing, andanypartsofthebodyawayfromtheengineand anymovingparts.Keepeveryoneaway.
•Donotoverspeedenginebychanginggovernor settings.Maximumenginespeedis3650rpm.To assuresafetyandaccuracy ,haveanAuthorized TORODistributorcheckmaximumenginespeed withatachometer.
•Ifmajorrepairsareeverneededorassistanceis required,contactanAuthorizedT oroDistributor.
•Tobesureofoptimumperformanceandsafety, alwayspurchasegenuineTOROreplacementparts andaccessories.Replacementpartsandaccessories madebyothermanufacturerscouldbedangerous.
WholeBody
Thisunitdoesnotexceedavibrationlevelof0.5m/s2 attheposterior,basedonmeasurementsofidentical machinesperISO2631procedures.
7
Page 8
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.
93-9852
1.Warning—readtheOperator’sManual.2.Crushinghazard—installthecylinderlock.
93-9447
1.Warning—readtheOperator’sManual;removetheignition
93-9448
1.Warning—whenaddingfueltothetank,leave25mm betweenthefuelandthetopofthetank;readtheOperator’s
Manual.
keybeforeservicingorperformingmaintenanceonthe engineairintakesystem.
93-9442
1.Maximumtongueweight is90kg;maximumtrailer weightis680kg.
2.Forinformationon transmissionuid,read theOperator’sManual.
93-9879
1.Storedenergyhazard—readtheOperator’sManual.
93-6687
1.Donotstephere.
93-7814
1.Entanglementhazard,belt—stayawayfrommovingparts.
93-8071
1.Hotsurface/burnhazard—stayasafedistancefromthe hotsurface.
93-9850
1.Donotrepairorrevise—readtheOperator’sManual.
8
Page 9
93-9449
1.ReadtheOperator’s Manual.
2.Greaseevery100hours.
3.Addgrease(9grease points).
115-2320
1.Warning—donotoperate thevehicleonpublic streets,roads,orhighways.
2.Headlights5.Horn8.Hourmeter11.Engine—start
3.Engine—oil6.Battery9.Engine—stop
4.Engine—preheat7.Temperaturelevel10.Engine—run
1.Warning—avoidpinchpoints.
105-4215
1.Entanglementhazard,shaft—stayawayfrommovingparts, keepallguardsandshieldsinplace.
93-9862
9
Page 10
1.Electricalpowerpoint
106-2353
1.Slow
2.Fast
106-2355
3.Transmission—thirdhigh; nofastspeed
106-2377
1.Locked
2.Differentiallock9.Entanglementhazard,shaft—keepbystander’sasafe
3.Unlocked10.Retracthydraulics
4.Hydrauliclock11.Extendhydraulics
5.Engage12.Transmission—highspeed
6.Powertake-off(PTO)
7.Disengage14.Parkingbrake
8.Warning—readtheOperator’sManual.
distancefromthevehicle.
13.Transmission—lowspeed
10
Page 11
110-2599
1.Warning—readtheOperator’sManual.
2.Firehazard—stoptheenginebeforefueling.
3.Tippinghazard—readtheOperator’sManual,donotoperatethismachineunlessyouaretrained,usecautionanddriveslowly whendrivingonslopes,slowdownandturngradually ,donotexceed20mph(32kph),anddriveslowlyoverroughterrainor whencarryingafullorheavyload.
4.Crushing/dismembermenthazardofbystanders—keepbystandersasafedistancefromthevehicle,donotcarrypassengersin thecargobed,andkeeparmsandlegsinsideofthevehicleatalltimes.
5.Warning—stoptheengineandremovetheignitionkeybeforeleavingthevehicle.
93-6689
1.Warning—donotcarrypassengers.
98-9335
1.Cutting/dismembermenthazard,fan—stayawayfrom movingparts.
93–9868
1.Crushinghazardofhand—readtheOperator’sManual.
106-7894
1.Engine—start3.Headlights
2.Ignition4.Powerpoint
106-7767
1.Warning—readtheOperator’sManual;avoidtippingthe machine;weartheseatbelt;leanawayfromthedirection themachineistipping.
11
Page 12
93-9899
93-9899
1.Crushinghazard—installthecylinderlock.
1.Warning—readthe hydraulicoilpressure is124bar(1800psi)
2.CouplerA
106-7888
3.CouplerB
BatterySymbols
Someorallofthesesymbolsareonyourbattery
1.Explosionhazard
2.Nore,opename,or smoking.
3.Causticliquid/chemical burnhazard
4.Weareyeprotection9.Flusheyesimmediately
5.ReadtheOperator’s
Manual.
6.Keepbystandersasafe
7.Weareyeprotection;
8.Batteryacidcancause
10.Containslead;donot
distancefromthebattery.
explosivegasescan causeblindnessandother injuries
blindnessorsevereburns.
withwaterandgetmedical helpfast.
discard.
106-2384
12
Page 13
Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
1
2
3
4
5
MediaandAdditionalParts
Rearfender Bolts,3/8x1–1/4in Locknut,3/8 Supportplate Wheelnut10 Frontwheel2 Wheelnut10 Rearwheel2 Steeringwheel Cap Washer1 Foamseal1 Frontfender Sockethexheadbolt,#10x3/4”in. Washer,.210I.D.20 Locknut,#10 ROPSframe bolt1/2x3”in. Locknuts1/2
Qty.
10
10
10
Use
2
2 2
1 1
2
1 4 4
Mounttherearfenders.
Mountthewheels.
Installthesteeringwheel.
Installthefrontfenders.
MounttheROPS(RolloverProtection System)
Description
Operator’sManual
PartsManual1
Note:Determinetheleftandrightsideofthemachine fromthenormaloperatingposition.
Qty.
Use
1
Readbeforeoperatingthevehicle
Usetoreferencepartnumbers
1
InstalltheRearFenders
Partsneededforthisprocedure:
2
Rearfender
10
Bolts,3/8x1–1/4in
2
Locknut,3/8
2
Supportplate
Procedure
1.Loosenthelocknutsandboltssecuringtaillight bracketstorightandleftframebrackets(Figure3).
2.Pivottaillightbracketsrearwardandtightenbolts andlocknuts.
13
Page 14
Figure3
1.Fender
3.Securerearofeachtaillightbrackettorearof framebracketswitha5/16x1in.bolt,.344”I.D . atwasherandlocknut,asshowninFigure3.
2
InstalltheWheels
Partsneededforthisprocedure:
10Wheelnut
2Frontwheel
10Wheelnut
2Rearwheel
Procedure
1.Removelugnutssecuringwheelstowheelbrackets. Retainlugnuts.
2.Mountwheelsandinstalllugnuts.T orquelugnuts to45–65ft-lb.
Figure4
1.Fender
4.Looselysecureafendertoeachsideofframewith asupportplate,(5)3/8x1–1/4in.bolts,anda locknutasshowninFigure4.
Note:Weldnutsareinplacetosecure(4)ofthe bolts.
5.Tightenallfasteners.
2.Supportplate
Figure5
1.Wheel2.Wheelnut
14
Page 15
3
4
InstalltheSteeringWheel
Partsneededforthisprocedure:
1
Steeringwheel
1
Cap
1Washer
1Foamseal
Procedure
1.Removethejamnutfromthesteeringshaft.Slide thefoamseal,steeringwheelandwasheronto steeringshaft(Figure6).
2.Securesteeringwheeltoshaftwithjamnutand tightenitto10-15ft-lb.
3.Installcaptosteeringwheel.
InstalltheFrontFenders
Partsneededforthisprocedure:
2
Frontfender
10
Sockethexheadbolt,#10x3/4”in.
20Washer,.210I.D.
10
Locknut,#10
Procedure
1.Alignthevefendermountingholeswiththeholes ineachsideofbody(Figure7).
2.Mountafendertoeachsideofbodywith(5)#10x 3/4in.socketheadbolts,(10)atwashersand(5) #10locknuts.Positionawashernexttobolthead andlocknut.
Figure6
1.Steeringwheel3.Cap
2.Jamnut4.Washer
Figure7
1.Fender
15
Page 16
5
6
InstallROPS
Partsneededforthisprocedure:
1
ROPSframe
4
bolt1/2x3”in.
4
Locknuts1/2
Procedure
1.InserteachsideofROPSintomountingbracket oneachsideofvehicleframe,positioningROPSas showninFigure8.
Note:TheROPScoverplatemountingboltsmay havetobeloosenedtoinserttheROPSintothe mountingbrackets.
2.SecureeachsideofROPStomountingbracketswith (2)1/2–13x3”lg.boltsandlocknuts.
ActivateandChargethe Battery
NoPartsRequired
Procedure
Ifbatteryisnotlledwithelectrolyteoractivated,it mustberemovedfromvehicle,lledwithelectrolyte andcharged.Bulkelectrolytewith1.260specicgravity canbepurchasedfromalocalbatterysupplyoutlet.
Warning
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
Figure8
1.ROPS3.ROPScoverplate
2.Mountingbracket
Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.
•Donotdrinkelectrolyteandavoidcontact withskin,eyesorclothing.Wearsafety glassestoshieldyoureyesandrubbergloves toprotectyourhands.
•Fillthebatterywherecleanwaterisalways availableforushingtheskin.
1.Loosenknobssecuringbatterycovertobatterybase andslidecoveroff.
16
Page 17
Figure9
1.Batterycover3.Batterybase
2.Knob
2.Removebolt,washersandlocknutsecuringbattery holddowntobatterybase.Removeholddownand slidebatteryoutofbatterybase.
3.Removellercapsfrombatteryandslowlylleach celluntilelectrolyteisjustabovetheplates.
4.Replacellercapsandconnecta3to4ampbattery chargertothebatteryposts.Chargethebatteryata rateof3to4amperesfor4to8hours.
Chargingthebatteryproducesgassesthatcan explode.
Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.
5.Whenbatteryischarged,disconnectchargerfrom electricaloutletandbatteryposts.
Figure10
1.Positive(+)cable
6.Removellercaps.Slowlyaddelectrolytetoeach celluntillevelisuptollring.Installllercaps.
Important:Donotoverllbattery.Electrolyte willoverowontootherpartsofthevehicleand severecorrosionanddeteriorationwillresult.
7.Slidebatteryintobatterybasesobatteryterminals aretowardtherearofthevehicle.
8.Installthepositivecable(red)tothepositive(+) terminalandthenegativecable(black)tothe negative(—)terminalofthebatteryandsecure withboltsandnuts.Slidetherubberbootoverthe positiveterminaltopreventpossibleshort–outfrom occurring.
Incorrectbatterycableroutingcoulddamage themachineandcablescausingsparks.Sparks cancausethebatterygassestoexplode, resultinginpersonalinjury.
•Alwaysdisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.
•Alwaysconnectthepositive(red)battery cable
9.Installbatteryholddownandsecuretobasewith bolt,washersandlocknut.
10.Reinstallbatterycovertobatterybaseandtighten knobs.
17
Page 18
7
FullBedRemoval
Thefullbedweighsapproximately325pounds, sodonottrytoinstallorremoveitbyyourself. Useanoverheadhoistorgetthehelpoftwoor threeotherpeople.
NoPartsRequired
Procedure
1.Startengine.Engagehydraulicliftleverandlower beduntilcylindersarelooseinslots.Releaseliftlever andturnoffengine.
2.Removelynchpinsfromouterendsofcylinderrod clevispins(Figure11).
6.Storecylindersinstorageclips.Engagehydrauliclift lockleveronvehicletopreventaccidentalextension ofliftcylinders.
8
Re-InstalltheFullBed
NoPartsRequired
Procedure
Note:Ifbedsideswillbeinstalledonatbed,itis
easiertoinstallthembeforebedisinstalledonvehicle.
Note:Assurerearpivotplatesareboltedtothebed frame/channelsothatlowerendanglestotherear (Figure12).
Figure11
1.Bedmountingplate4.Lynchpin
2.Cylinderrodend5.Rearslots(Fullbed)
3.Clevispin6.Frontslots(2/3bed)
3.Removeclevispinssecuringcylinderrodendsto bedmountingplatesbypushingpinstowardsinside (Figure12).
4.Removelynchpinsandclevispinssecuringpivot bracketstoframechannels(Figure12).
5.Liftbedoffvehicle.
Figure12
1.Leftrearcornerofbed4.Clevispin
2.Vehicleframechannel
3.Pivotplate
Note:Makesurespacerbracketsandwearblocks (Figure13)areinstalledorradiatorcovermaybe damaged.Carriageboltsheadstobepositionedinside themachine.
5.Lynchpin
18
Page 19
ProductOverview
Thefullbedweighsapproximately325pounds, sodonottrytoinstallorremoveitbyyourself. Useanoverheadhoistorgetthehelpoftwoor threeotherpeople.
Figure13
1.Spacerbracket3.Carriagebolt
2.Wearblock
Controls
Note:Determinetheleftandrightsideofthemachine
fromthenormaloperatingposition.
AcceleratorPedal
Theacceleratorpedal(Figure14)givestheoperatorthe abilitytovaryengineandgroundspeedofthevehicle, whenthetransmissionisingear.Depressingthepedal increasesengineRPMandgroundspeed.Releasing pedalwilldecreaseengineRPMandgroundspeedof themachine.
1.Assureliftcylindersarefullyretracted.
2.Carefullysetbedontovehicleframealigningrearbed pivotplateholeswithholesinrearframechannel andinstall(2)clevispinsandlynchpins(Figure12).
3.Withbedlowered,secureeachcylinderrodend,to appropriateslotsinbedmountingplateswithclevis pinandlynchpin.Insertclevispinfromoutsideof bedwithlynchpintowardoutside(Figure12).Rear slotsareforfullbedinstallationandfrontslotsare for2/3bedinstallation.
Note:Enginemayneedtobestartedtoextend orretractcylindersforalignmentwithholes.Keep
ngersout!
Note:Unusedslotcanbepluggedwithaboltand nuttopreventassemblyerrors.
4.Startengineandengagehydraulicliftlevertoraise bed.Releaseliftleverandturnoffengine.Installthe bedsafetysupporttopreventaccidentalloweringof thebed.RefertoUsingBedSafetySupport.
5.Installlynchpinstoinsideendsofclevispins.
Figure14
1.Acceleratorpedal3.Brakepedal
2.Clutchpedal
ClutchPedal
Theclutchpedal(Figure14)mustbefullydepressed todisengageclutchwhenstartingengineorshifting transmissiongears.Releasepedalsmoothlywhen transmissionisingeartopreventunnecessarywearon transmissionandotherrelatedparts.
Important:Donotrideclutchpedalduring operation.Clutchpedalmustbefullyoutorclutch willslipcausingheatandwear.Neverholdthe vehiclestoppedonahillusingtheclutchpedal. Damagetotheclutchmayoccur.
BrakePedal
Thebrakepedal(Figure14)isusedtoapplyservice brakestostoporslowvehicle.
Note:Ifautomatictailgatereleasehasbeen installedonbed,makesurefrontdumplinkrodhas beenplacedoninsideofleftsideclevispinbefore lynchpinisinstalled.
19
Page 20
Wornormisadjustedbrakesmayresultin personalinjury.Ifbrakepedaltravelstowithin 1–1/2”ofthevehicleoorboard,thebrakes mustbeadjustedorrepaired.
GearShiftLever
Fullydepressclutchpedalandmoveshiftlever(@@@5) intodesiredgearselection.Adiagramoftheshift patternisindicatedbelow .
Important:Donotshiftthetransaxletothereverse orforwardgearunlessthevehicleisstandingstill. Damagetotransaxlemayoccur.
Downshiftingfromtoohighaspeedcan causetherearwheelstoskidresultinginloss ofvehiclecontrolaswellasclutchand/or transmissiondamage.Shiftsmoothlytoavoid grindinggears.
DifferentialLock
Allowsrearaxletobelockedforincreasedtraction. Differentiallock(Figure16)maybeengagedwith vehicleinmotion.Moveleverforwardandtotheright toengagelock.
Figure16
1.Gearshiftlever4.Hydraulicliftlock
2.Parkingbrake
3.Hydraulicbedlift6.High–lowrangeshifter
5.Differentiallock
ParkingBrake
Whenevertheengineisshutoff,theparkingbrake (Figure16)mustbeengagedtopreventaccidental movementofthevehicle.Toengagetheparkingbrake, pullbackonlever.Todisengage,pushleverforward. Makesureparkingbrakeisreleasedbeforemoving vehicle.Ifvehicleisparkedonasteepgrade,makesure parkingbrakeisapplied.Also,shiftthetransmission into1stgearonauphillgradeorreverseonadownhill grade.Placechocksatthedownhillsideofwheels.
HydraulicLift
Raisesandlowersbed.Moverearwardtoraise,forward tolower(Figure16).
Important:Whenloweringbed,holdleverin forwardpositionfor1or2secondsafterbed contactsframetosecureitinloweredposition. Donotholdthehydraulicliftineithertheraiseor lowerposition,formorethan5seconds,oncethe cylindershavereachedtheendoftheirtravel.
HydraulicLiftLock
Note:Vehiclemotionplusaslightturnisrequiredto
engageordisengagedifferentiallock.
Turningwiththedifferentiallockoncanresult inlossofvehiclecontrol.Donotoperatewith differentiallockonwhenmakingsharpturnsor athighspeeds.Refertousingthedifferential lock.
Locksliftleversohydrauliccylindersdonotoperate whenvehicleisnotequippedwithabed(Figure16). ItalsolocksliftleverinONpositionwhenusingthe hydraulicsforattachments.
High–LowRangeShifter
Addsthreeadditionalspeedsforprecisespeedcontrol (Figure16).
•Vehiclemustbecompletelystoppedbeforeshifting betweenHighandLowrange.
•Shiftonlyonlevelground.
20
Page 21
•Depressclutchpedalfully.
•MoveleverfullyforwardforHighandfullyrearward forLow .
HIGHisforhigherspeeddrivingonlevel,drysurfaces withlightloads.
LOWisforlowspeeddriving.Usethisrangewhen greaterthannormalpowerorcontrolisrequired.For example,steepgrades,difcultterrain,heavyloads,slow speedbuthighenginespeed(spraying).
Important:ThereisalocationbetweenHIGHand LOWinwhichthetransaxleisinneitherrange. Thisshouldnotbeusedasaneutralposition becausethevehiclecouldmoveunexpectedlyifthe HIGH–LOWshifterisbumpedandthegearshift leverisingear.
CoolantTemperatureGaugeandLight
Registerscoolanttemperatureinengine.Operatesonly whenignitionswitchisinOnposition(Figure17). Indicatorlightwillilluminateifengineoverheats.
ChargeIndicator
Illuminateswhenbatteryisbeingdischarged.Iflight illuminatesduringoperation,stopvehicle,turnoff engineandcheckforpossiblecauses,suchasalternator belt(Figure17).
starts.ThekeywillmoveautomaticallytotheON position.Toshutengineoff,rotatekeycounterclockwise toOFFposition.
Figure17
1.Chargeindicator
2.Coolanttemperature gauge&light
3.Hourmeter
4.Ignitionswitch
5.3rdhighlockoutswitch
Important:Ifalternatorbeltislooseorbroken,do notoperatevehicleuntiladjustmentorrepairis complete.Failuretoobservethisprecautionmay resultindamagetotheengine.
Tocheckoperationofwarninglights:
•Applyparkingbrake.
•Turnignitionkeyto“ON”,butdonotstartengine. Thecoolanttemperature,chargeindicatorandoil pressurelightsshouldglow.Ifanylightdoesnot function,eitherabulbisburnedoutorthereisa malfunctioninthesystemwhichmustberepaired.
HourMeter
Indicatesthetotalhoursofmachineoperation.The hourmeter(Figure17)startstofunctionwheneverthe keyswitchisrotatedto“ON”positionorifengineis running.
IgnitionSwitch
Theignitionswitch(Figure17),usedtostartandstop theengine,hasthreepositions:OFF ,RUN(GLOW) andSTART .Rotatekeyclockwise—STARTposition —toengagestartermotor.Releasekeywhenengine
3rdHighLockoutSwitch
Movingswitch(Figure17)toslowpositionand removingkeywillpreventuseofthirdgearwheninthe Highrange.Enginewillshutoffifshiftleverismoved tothirdgearwheninHighrange.Keyisinstalledwith teethpointingdownward.Pushkeyintoturn.Keyis removableineitherposition.
GlowPlugIndicator
Glowplugindicator(Figure18)willglowredwhenthe glowplugsareactivated.
Important:Theglowplugindicatorwillturn on,foranadditional15seconds,whentheswitch returnstotheSTARTposition.
LightSwitch
Toggleswitch(Figure18)toactivateheadlights.Push toturnlights“ON”.
OilPressureWarningLight
Lightglows(Figure18)ifengineoilpressuredrops belowasafelevelwhileengineisrunning.Iflight
21
Page 22
ickersorremainsON,stopvehicle,turnoffengineand checkoillevel.Ifoillevelwaslow ,butaddingoildoes notcauselighttogooutwhenengineisrestarted,turn engineoffimmediatelyandcontactyourlocalTORO distributorforassistance.
Tocheckoperationofwarninglights:
1.Applyparkingbrake.
2.Turnignitionkeyto“ON”,butdonotstartengine. Theoilpressurelightshouldglowred.Iflightdoes notfunction,eitherabulbisburnedoutorthereisa malfunctioninthesystemwhichmustberepaired.
Note:Ifenginewasjustturnedoff,itmaytake1to2 minutesforlighttocomeon.
1.Passengerhandhold
SeatAdjustingLever
Figure19
2.Storagecompartment
FuelGauge
Showsamountoffuelintank.Operatesonlywhen ignitionswitchisin“ON”position(Figure18).
Figure18
1.Lightswitch
2.Oilpressurewarninglight5.Tachometer(Optional)
3.Fuelgauge6.Horn
4.Glowplugindicatorlight
HornButton
Pressingbuttonactivateshorn(Figure18).
Tachometer
Optional(Figure18).
PassengerHandHold
Ondashboard(Figure19).
Theseatscanbeadjustedforeandaftforoperator comfort(Figure20).
Figure20
1.Seatadjustinglever
Specications
Note:Specicationsanddesignaresubjecttochange
withoutnotice.
Dimensions
OverallWidth
OverallLength
BaseWeight(Dry
w/oatbed)
RatedCapacity (includes200lb. operator,200lb.
passengerandloaded
attachment).
Maximum.Gross
VehicleWeight
TowCapacity
63”
128.25”w/obed
130.38”w/fullbed
136.38”w/2/3bedinrearmounting location
Model07362–1929lbs. Model07364–2029lbs.
Model07362–2321lbs. Model07364–2221lbs.
4,250lbs.
Tongueweight200lbs. Maximumtrailerweight1,500lbs.
22
Page 23
Dimensions(cont'd.)
GroundClearance7”w/noload
WheelBase70”
WheelTread(center
linetocenterline)
Height
Front46” Rear47.7”
75”totopofROPS
Attachments/Accessories
AselectionofToroapprovedattachmentsand accessoriesareavailableforusewiththemachineto enhanceandexpanditscapabilities.Contactyour AuthorizedServiceDealerorDistributororgoto www.Toro.comforalistofallapprovedattachments andaccessories.
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
Beforeservicingormakingadjustmentstothe machine,stopengine,setparkingbrakeand removekeyfromtheswitch.Anyloadmaterial mustberemovedfrombedorotherattachment beforeworkingunderraisedbed.Neverwork underaraisedbedwithoutpositioningsafety supportonafullyinstalledcylinderrod.
CheckCrankcaseOil
ServiceInterval:Beforeeachuseordaily
Aftertherst50hours
Every150hours
Theengineisshippedwithapproximately3.5quarts (w/lter)ofoilinthecrankcase;however,levelofoil mustbecheckedbeforeandaftertheengineisrst started.
Note:Thebesttimetochecktheengineoiliswhen theengineiscoolbeforeithasbeenstartedforthe day.Ifithasalreadybeenrun,allowtheoiltodrain backdowntothesumpforatleast10minutesbefore checking.Iftheoillevelisatorbelowthe“add”mark onthedipstick,addoiltobringtheoilleveltothe“full” mark.DONOTOVERFILL.Iftheoillevelisbetween the“full”and“add”marks,nooiladditionisrequired.
1.Positionmachineonalevelsurface.
2.Removedipstickandwipeitwithacleanrag.Insert dipstickintotubeandmakesureitisseatedfully . Removedipstickandchecklevelofoil.
23
Page 24
Figure21
1.Dipstick
3.Theengineusesanyhigh-quality10W30detergent oilhavingtheAmericanPetroleumInstitute-API­“serviceclassication”CForhigher.Choosea viscosityaccordingtothetableinFigure22.
Note:Whenaddingoil,removedipsticktoallow properventing,pouroilslowlyandcheckthelevel oftenduringthisprocess.DONOTOVERFILL.
Important:Whenaddingengineoilorlling oil,theremustbeclearancebetweentheoilll deviceandtheoilllholeinthevalvecoveras showninFigure24.Thisclearanceisnecessary topermitventingwhenlling,whichprevents oilfromoverrunningintobreather.
Figure22
4.Ifoillevelislow,removellercapandaddenough oiltoraiseleveltoFULLmarkondipstick.
Figure23
1.Fillercap
Figure24
5.Installthedipstickrmlyinplace.
Important:Checklevelofoilevery8operating hoursordaily.Changeoilandlterinitiallyafter therst50hoursofoperation,thereafter,change oilandlterevery150hours.However,change oilmorefrequentlywhenengineisoperatedin extremelydustyordirtyconditions.
Note:Afterllingorchangingoil,startandrunthe engineatidlefor30seconds.Shutengineoff.W ait30 secondsandcheckoillevel.Addenoughoiltoraise leveltoFULLmarkondipstick.
FillFuelTank
Fueltankcapacityisapproximately7gallons.
TheenginerunsonNo.2–Dor1–Dautomotivetype dieselfuelwithaminimumcetaneratingof40.
Note:Highercetaneratedfuelmayberequired ifmachineistobeusedathighaltitudesand low-atmospherictemperatures.
1.Cleanareaaroundfueltankcap.
2.Removefueltankcap.
24
Page 25
Undercertainconditions,dieselfuelandfuel vaporsarehighlyammableandexplosive.A reorexplosionfromfuelcanburnyouand othersandcancausepropertydamage.
•Useafunnelandllthefueltankoutdoors, inanopenarea,whentheengineisoffand iscold.Wipeupanyfuelthatspills.
•Donotllthefueltankcompletelyfull.Add fueltothefueltankuntilthelevelis1in. (25mm)belowthebottomofthellerneck. Thisemptyspaceinthetankallowsthefuel toexpand.
•Neversmokewhenhandlingfuel,andstay awayfromanopenameorwherefuel fumesmaybeignitedbyaspark.
•Storefuelinaclean,safety-approved containerandkeepthecapinplace.
3.Filltanktoaboutoneinchbelowtopoftank, (bottomofllerneck).DONOTOVERFILL. Theninstallcap.
Iftheenginehasbeenrunning,thepressurized, hotcoolantcanescapeandcauseburns.
•Donotopentheradiatorcapwhenthe engineisrunning.
•Allowenginetocoolatleast15minutes oruntiltheradiatorcapiscoolenoughto touchwithoutburninghand.
•Usearagwhenopeningtheradiatorcap, andopenthecapslowlytoallowsteamto escape.
2.Checkcoolantlevel.Coolantshouldbeupto COLDlineonreservetank,whenengineiscold.
4.Wipeupanyfuelthatmayhavespilledtopreventa rehazard.
Figure25
1.Fueltankcap
CheckCoolingSystem
ServiceInterval:Beforeeachuseordaily
Capacityofcoolingsystemisapproximately4qts.
Thecoolingsystemislledwitha50/50solutionof waterandpermanentethyleneglycolanti–freeze.
1.Parkmachineonalevelsurface.
Figure26
1.Reservetank
2.Hotline
3.Coldline
3.Ifcoolantislow,removereservetankcapandadd a50/50mixtureofwaterandpermanentethylene glycolanti–freeze.DONOTOVERFILL.
4.Installreservetankcap.
CheckTransaxle/Hydraulic Fluid
ServiceInterval:Beforeeachuseordaily
ThetransaxlereservoirislledwithDexronIIlATF . Checklevelbeforeengineisrststartedandevery8 hoursordaily ,thereafter.Capacityofsystemis7.5qt.
1.Positionthevehicleonalevelsurface.
2.Cleanareaarounddipstick.
3.Unscrewdipstickfromtopoftransaxleandwipe itwithacleanrag.
25
Page 26
CheckTorqueOfWheelNuts
ServiceInterval:Aftertherst2hours
Aftertherst10hours
Every200hours
Failuretomaintainpropertorqueofthewheel nutscouldresultinfailureorlossofwheeland mayresultinpersonalinjury.
Torquethefrontandrearwheelnutsto45–65
Figure27
1.Dipstick
ft.-lb.
4.Screwdipstickintotransaxleandmakesureitis seatedfully.Unscrewdipstickandcheckuidlevel. Fluidshouldbeuptotopofatportionofdipstick. Iflevelislow ,addenoughuidtoachievethe properlevel.
CheckFrontDifferentialOil
Fourwheeldriveonly
ServiceInterval:Every100hours/Monthly
(whichevercomesrst)
Thedifferentialislledwith10W30oil.Capacityof systemis1qt.
1.Positionthevehicleonalevelsurface.
2.Cleanareaaroundll/checkplugonsideof differential.
3.Removell/checkplugandchecklevelofoil.Oil shouldbeuptohole.Ifoilislow,add10W30oil.
4.Re–installll/checkplug.
CheckTirePressure
ServiceInterval:Beforeeachuseordaily
Maximumairpressureinfronttiresis20psiandrear (24”)tiresis18psi.
1.Theairpressureneededisdeterminedbythe payloadcarried.
2.Thelowertheairpressure,thelessthecompaction andtiremarksareminimized.Lowerpressure shouldnotbeusedforheavypayloadsathigh speeds.Tiredamagemayresult.
3.Higherpressuresshouldbeusedforheavier payloadsathigherspeeds.Donotexceedthe maximumpressure.
CheckBrakeFluid
ServiceInterval:Beforeeachuseordaily
Every1,000hours/Every2years (whichevercomesrst)
Thebrakeuidreservoirisshippedfromthefactory lledwith“DOT3”brakeuid.Checklevelbefore engineisrststartedandevery8hoursordaily , thereafter.
1.Frontdifferential
2.Fill/checkplug
1.Parkmachineonalevelsurface.
2.Loosenknobsecuringcupholdertodash (Figure29).Removecupholderfromdash.
Figure28
3.Drainplug
26
Page 27
Figure29
1.Cupholder
3.FluidlevelshouldbeuptoFULLlineonreservoir.
2.Knob
Pre–startingChecks
Safeoperationbeginsbeforetakingthevehicleoutfor aday’swork.Youshouldchecktheseitemseachtime:
•Checktirepressure.
Note:Thesetiresaredifferentthancartires,they requirelesspressuretominimizeturfcompaction anddamage.
•Checkalluidlevelsandaddtheappropriate amountofTorospecieduids,ifanyarefound tobelow .
•Checkthefrontoftheradiator.Removeanydebris andcleantheradiatorscreen.
•Checkbrakepedaloperation.
•Checktoseethatthelightsandhornareworking.
•Turnsteeringwheeltotheleftandrighttocheck steeringresponse.
•Checkforoilleaks,loosepartsandanyother noticeablemalfunctions.Makesureengineisoff andallmovingpartshavestoppedbeforechecking foroilleaks,loosepartsandothermalfunctions.
Figure30
1.Brakeuidreservoir
4.Ifuidlevelislow,cleanareaaroundcap,remove reservoircapandlltoproperlevel.DONOT
OVERFILL.
5.Reinstallcupholdertodash.
CheckFanBeltTension
Checkallbeltsforwear,crackingorimpropertension. Checktensionbydepressingbeltatmidspanoffan anddriveshaftpulleyswith22lbs.offorce.Anew beltshoulddeect.48–.58in.Ausedbeltshould deect.55–.65in.Ifdeectionisincorrect,proceedto page45fortensioningprocedure.Ifcorrect,continue operation.
Important:Improperbelttensionmayresultin increasedsteeringeffort.
Ifanyoftheaboveitemsarenotcorrect,notifyyour mechanicorcheckwithyoursupervisorbeforetaking thevehicleoutfortheday .Yoursupervisormaywant youtocheckotheritemsonadailybasis,soaskwhat yourresponsibilitiesare.
StartingEngine
•Initialstartupofanewmachine.
•Enginehasceasedrunningduetolackoffuel.
•Maintenancehasbeenperformeduponfuelsystem components;i.e.,lterreplaced,separatorserviced, etc.
RefertoBleedingTheFuelSystem.
1.Sitonoperator’sseatandengageparkingbrake.
2.DisengagePTO(ifsoequipped)andreturnhand throttlelevertoOFFposition(ifsoequipped).
3.MoveshiftlevertoNEUTRALpositionand depressclutchpedal.
4.Makesurethehydraulicliftleverisinthecenter position.
5.Keepfootoffacceleratorpedal.
6.TurnignitionswitchtoONposition.Whenglow plugindicatorlightgoesoff,engineisreadyto START.
7.RotateignitionkeyswitchtoSTARTposition Releasekeyimmediatelywhenenginestartsand allowittoreturntoRUNposition.
27
Page 28
Note:Theglowplugindicatorwillturnon,foran additional15seconds,whentheswitchreturnstothe STARTposition.
Note:Donotrunstartermotormorethan10seconds atatimeorprematurestarterfailuremayresult.If enginefailstostartafter10seconds,turnkeytoOFF position.Recheckcontrolsandprocedures,wait10 additionalsecondsandrepeatstartingoperation
DrivingVehicle
1.Releaseparkingbrake.
2.Fullydepressclutchpedal.
3.Movegearshiftleverto1stgear.
4.Releaseclutchpedalsmoothlywhiledepressing acceleratorpedal.
5.Whenvehiclegainsenoughspeed,removefoot fromacceleratorpedal,fullydepressclutchpedal, movegearshiftlevertonextgearandreleaseclutch pedalwhiledepressingacceleratorpedal.Repeat procedureuntildesiredspeedisattained.
Note:Alwaysstopvehiclebeforeshiftingto reverseorforward.
Usethechartbelowtodeterminethegroundspeed ofthevehicleat3600RPM.
Gear
1L82.83:12.94.7
2L54.52:14.57.2
3L31.56:1
1H32.31:17.612.2
2H21.27:111.518.5
3H12.31:119.831.9
RL86.94:12.84.5
RH33.91:17.111.6
RangeRatio
Speed (mph)
7.7
Speed (kmh)
12.5
StoppingEngine
Tostopengine,rotateignitionkeytoOFFandengage parkingbrake.Removekeyfromswitchtoprevent accidentalstarting.
NewVehicleBreak–in
YourW orkmanisreadyforwork.T oprovideproper performanceandlongvehiclelife,followthese guidelinesfortherst100operatinghours.
•Checktheuidandengineoillevelsregularly andbealertforindicationsofoverheatinginany componentofthevehicle.
•Afterstartingacoldengine,letitwarmupforabout 15secondsbeforeshiftingintogear.
•Avoidracingtheengine.
•Toassureoptimumperformanceofthebrake system,burnish(break–in)thebrakesbeforeuse. Toburnishbrakes:Operatethevehicleatfullspeed for3minutes,applythebrakesfor30secondswhile drivingin1stgear.Repeatthesesteps20to30 times.T overifythebrakesarecompletelyburnished removeareartireandinspectthebrakedrumfor residue.Theresiduecolorshouldbelightgreyto almostwhitecolor.
•Varyvehiclespeedsduringoperation.Avoid excessiveidling.Avoidfaststartsandquickstops.
•Abreak–inoilfortheengineisnotrequired. Originalengineoilisthesametypespeciedfor regularoilchanges.
•RefertoMaintenancesectionofOperator’sManual foranyspeciallowhourchecks.
CheckInterlockSystem
Thepurposeoftheinterlocksystemistopreventthe enginefromcrankingorstartingunlesstheclutchpedal isdepressed.
Note:Avoidlongperiodsofengineidling.
Important:Donotholdfrontwheelsturned
againsttherightorleftstopsforlongerthan 5seconds.
6.Donotattempttopushortowvehicletogetit started.Damagetodrivetraincouldresult.
StoppingVehicle
Tostopmachine,removefootfromacceleratorpedal, depressclutchpedal,thendepressbrakepedal.
Toverifyclutchinterlockswitchoperation:
1.Sitonoperator’sseatandengageparkingbrake. MoveshiftlevertoNEUTRALposition.
Note:Enginewillnotcrankifhydraulicliftlever islockedintheforwardposition.
2.Withoutdepressingclutchpedal,rotatekey clockwisetostartposition.
3.Ifenginecranksorstarts,thereisamalfunctionin theinterlocksystemthatmustberepairedbefore operatingvehicle.
Toverifyhydraulicliftleverinterlock:
28
Page 29
1.Sitonoperator’sseatandengageparkingbrake. MoveshiftlevertoNEUTRALposition.Makesure thehydraulicliftleverisinthecenterposition.
2.Depressclutchpedal.
3.Movethehydraulicliftleverforwardandrotatekey clockwisetostartposition.
4.Ifenginecranksorstarts,thereisamalfunctionin theinterlocksystemthatmustberepairedbefore operatingvehicle.
Ifsafetyinterlockswitchesaredisconnected ordamagedthemachinecouldoperate unexpectedlycausingpersonalinjury.
•Donottamperwiththeinterlockswitches.
•Checktheoperationoftheinterlock switchesdailyandreplaceanydamaged switchesbeforeoperatingthemachine.
RefertoAttachmentOperator’sManualforprocedure oncheckingattachmentinterlocksystem.
OperatingCharacteristics
Driverandpassengershouldalwaysusetheseatbelts.
Ifyouarenotexperiencedatdrivingthevehicle, practicedrivingitinasafeareaawayfromother people.Besureyouarefamiliarwithallthevehicle’s controls,particularlythoseusedforbraking,steering andtransmissionshifting.Learnhowyourvehicle handlesondifferentsurfaces.Youroperatingskills willimprovewithexperience,butasinoperatingany vehicle,takeiteasyasyoubegin.Besureyouknow howtostopquicklyinanemergency.Ifyouneedhelp, askyoursupervisorforassistance.
Manyfactorscontributetoaccidents.Youhavecontrol overseveralofthemostimportant.Youractions, suchasdrivingtoofastforconditions,brakingtoo fast,turningtoosharp,andcombinationsofthese,are frequentcauseofaccidents.
Oneofthemajorcausesofaccidentsisfatigue.Besure totakeoccasionalbreaks.Itisveryimportantthatyou stayalertatalltimes.
Neveroperatethevehicle,oranyequipment,ifyou areundertheinuenceofalcoholorotherdrugs. Evenprescriptiondrugsandcoldmedicinescancause drowsiness.Readthelabelonthemedicineorcheck withyourdoctororpharmacistifyouareunsureabout acertainmedication.
Thevehicleisdesignedwithsafetyinmind.Ithasfour wheelsforaddedstability.Itusesfamiliarautomotive stylecontrols,includingthesteeringwheel,brakepedal, clutchpedal,acceleratorpedal,andgearshifter.Itis importanttoremember,however,thatthisvehicleis notapassengercar.Itisaworkvehicleandisdesigned foroffroaduseonly.
TheWORKMANisanoff–highwayvehicle only,andisnotdesigned,equipped,or manufacturedforuseonpublicstreets,roads orhighways.
Thevehiclehasspecialtires,lowgearratios,alocking differential,andotherfeaturesthatgiveitextratraction. Thesefeaturesaddtotheversatilityofthevehiclebut, theycanalsogetyouintodangeroussituations.You mustkeepinmindthatthevehicleisnotarecreation vehicle.Itisnotanallterrainvehicle.And,itis denitelynotmeantfor“stuntdriving”or“horsing around”.Itisaworkvehicle,notaplayvehicle. Childrenshouldnotbeallowedtooperatethevehicle. Anyonewhooperatesthevehicleshouldhaveamotor vehiclelicense.
Oneofthemostimportantrulestofollowistogo slowerinunfamiliarareas.Itissurprisinghowmuch damageandinjurycommonthingscancause.Tree branches,fences,wires,othervehicles,treestumps, ditches,sandtraps,streams,andotherthingsfoundin mostparksandgolfcoursescanbehazardoustothe operatorandpassenger.
Avoiddrivingwhenitisdark,especiallyinunfamiliar areas.Ifyoumustdrivewhenitisdark,besuretodrive cautiously,usetheheadlights,andevenconsideradding additionallights.
Passengers
Wheneveryouhaveapassengerridinginthevehicle makesureheorsheiswearingtheseatbeltandholding onsecurely.Driveslowerandturnlesssharplybecause yourpassengerdoesnotknowwhatyouaregoingto donextandmaynotbepreparedforturning,stopping, accelerating,andbumps.
Youandyourpassengershouldremainseatedatall times,keepingarmsandlegsinsidethevehicle.The operatorshouldkeepbothhandsonsteeringwheel, wheneverpossibleandpassengershouldusehand holdsprovided(Figure31&Figure32).
29
Page 30
1.Passengerhandhold
Figure31
Turning
Turningisanotherimportantvariableleadingto accidents.Turningtoosharplyfortheconditionscan causethevehicletolosetractionandskid,oreventip over.
Wet,sandyandslipperysurfacesmaketurningmore difcultandrisky.Thefasteryouaregoing,theworse thissituationbecomesso,slowdownbeforeturning.
Duringasharpturnathigherspeeds,theinsiderear wheelmayliftoffoftheground.Thisisnotaawin thedesign,ithappenswithmostfourwheelvehicles includingpassengercars.Ifthishappens,youare turningtoosharplyforthespeedatwhichyouare traveling.Slowdown!
Braking
Itisgoodpracticetoslowdownbeforeyougetnear anobstacle.Thisgivesyouextratimetostoporturn away.Hittinganobstaclecandamagethevehicleand itscontents.Moreimportant,itcaninjureyouandyour passenger.Grossvehicleweighthasamajorimpact onyourabilitytostopand/orturn.Heavierloadsand heavierattachmentsmakeavehiclehardertostopor turn.Theheaviertheload,thelongerittakestostop
Figure32
1.Handhold&hiprestraint
Thereshouldneverbepassengersinthedumpboxor onanyattachments.Thevehicleismeanttohaveone driverandonlyonepassenger–nomore.
Speed
Speedisoneofthemostimportantvariablesleadingto accidents.Drivingtoofastfortheconditionscancause youtolosecontrolandhaveanaccident.Speedcan alsomakeaminoraccidentworse.Drivinghead–on intoatreeatslowspeedcancauseinjuryanddamage, but,drivingintoatreeathighspeedcandestroythe vehicleandkillyouandyourpassenger.
Neverdrivetoofastfortheconditions.Ifthereisany doubtabouthowfasttodrive,slowdown.
Whenusingheavyattachments(morethan1000 pounds),suchassprayers,topdressers,orspreaders, etc.,operatingspeedsshouldberestrictedbymoving 3rdhighlockoutswitchtoslow––position.
Thebrakingcharacteristicsalsochangewithnobedor attachmentonthevehicle.Faststopsmaycausethe rearwheelstolockupbeforethefrontwheelslock up,whichmayaffectthecontrolofthevehicle.Itis agoodideatodecreasevehiclespeedwithnobedor attachment.
Turfandpavementaremuchslipperierwhentheyare wet.Itcantake2to4timesaslongtostoponwet surfacesasondrysurfaces.
Ifyoudrivethroughstandingwaterdeepenoughtoget thebrakeswet,theywillnotworkwelluntiltheyare dry.Afterdrivingthroughwater,youshouldtestthe brakestomakesuretheyworkproperly.Iftheydonot, driveslowlyinrstgearwhileputtinglightpressureon thebrakepedal.Thiswilldrythebrakesout.
Donotdownshiftforbrakingonicyorslippery surfaces(wetgrass)orwhilegoingdownahillbecause enginebrakingmaycauseskiddingandlossofcontrol. Shifttoalowergearbeforestartingdownahill.
Tipovers
TheTOROWORKMANisequippedwitharollbar, hiprestraints,seatbeltsandhandhold.TheROPS system(RolloverProtectionSystem)usedonthevehicle
30
Page 31
willreducetheriskofseriousorfatalinjuryinthe unlikelyeventofatipover,althoughthesystemcannot protecttheoperatorfromallpossibleinjuries.
ReplaceadamagedROPS,donotrepairorrevise.Any alterationofROPSmustbeapprovedbymanufacturer.
Thebestwaytopreventaccidentsinvolvingutility vehiclesisthroughcontinuoussupervisionandtraining ofoperatorsandpayingconstantattentiontothearea inwhichvehicleisbeingoperated.
Thebestwayforoperatorstopreventseriousinjury ordeathtothemselvesorothers,istofamiliarize themselveswiththeproperoperationoftheutility vehicle,tostayalertandtoavoidactionsorconditions whichcouldresultinaaccident.Intheeventofatip over,theriskofseriousinjuryordeathwillbereduced iftheoperatorisusingtheROPSsystemandseatbelts andisfollowingtheinstructionsprovided.
Hills
Slowdownandshiftintoalowergearbeforestarting upordownahill.Ifyouhavetoturnwhileonahill, doitasslowlyandcautiouslyaspossible.Nevermake sharporfastturnsonahill.
Ifyoustallorbegintoloseheadwaywhileclimbing asteephill,quicklyapplythebrakes,shifttoneutral, restarttheengineandshifttoreverse.Atidlespeed, engineandtransaxledragwillaidthebrakesin controllingthevehicleonthehillandhelpyouback downthehillmoresafely.
Reducetheweightoftheloadifitisasteephillorifthe loadhashighcenterofgravity.Remember,loadscan shift.Securethem.
Note:TheWorkmanhasexcellenthillclimbingability. Thedifferentiallockwillincreasethisability .Hill climbingtractioncanalsobeincreasedbyaddingweight totherearofthevehicleinoneofthefollowingways:
•Addingweighttoinsideofbox,makingsureitis secured.
•Mountingwheelweightstorearwheels.
Tippingorrollingthevehicleonahillwillcause seriouspersonalinjury.
•Donotoperatethevehicleonsteepslopes.
•Ifenginestallsoryouloseheadwayonahill, neverattempttoturnvehiclearound.
•Alwaysbackstraightdownahillinreverse gear.
•Neverbackdowninneutralorwiththe clutchdepressed,usingonlythebrakes.
•Neverdriveacrossasteephill,alwaysdrive straightupordown.
•Avoidturningonahill.
•Don’t“droptheclutch”orslamonthe brakes.Suddenspeedchangecaninitiate tipover.
Useextracarewhenonhills.Nevergoonhillsthatare extremelysteep.Stoppingwhilegoingdownahillwill takelongerthanonlevelground.Turningwhilegoing upordownahillismoredangerousthanturningon thelevel.Turnswhilegoingdownhill,especiallywith thebrakeson,and,turninguphillwhiletraversinga hillareparticularlydangerous.Evenataslowspeed andwithoutaload,tipoversaremorelikelyifyouturn onahill.
•Addingliquidballast(calciumchloride)toreartires.
•Tractionwillincreasewithnopassengerinfront seat.
LoadingAndDumping
Theweightandpositionofthecargoandpassenger canchangethevehiclecenterofgravityandvehicle handling.Toavoidlossofcontrolresultinginpersonal injury,followtheseguidelines.
Donotcarryloadswhichexceedtheloadlimits describedonthevehicleweightlabel.
Thebedwilllowerwheneverthedumplever ispusheddown,evenwhentheengineisoff. TurningofftheenginewillNOTpreventthe boxfromlowering.Alwaysplacethesafety supportonextendedliftcylindertoholdboxup ifyouarenotgoingtoloweritrightaway.
31
Page 32
Thebedwilllowerwheneverthedumplever ispusheddown,evenwhentheengineisoff. TurningofftheenginewillNOTpreventthe boxfromlowering.Alwaysplacethesafety supportonextendedliftcylindertoholdboxup ifyouarenotgoingtoloweritrightaway.
Thevehiclehasseveralcombinationsofboxes, platforms,andattachmentsavailable.Thesecanbe usedinvariouscombinationsthatallowformaximum capacityandversatility .Thefullsizedboxis55inches wideby65incheslongandcanholdupto2000pounds ofevenlydistributedcargo.
Loadsvaryinhowtheyaredistributed.Sandspreads outevenlyandquitelow .Otheritems,suchasbricks, fertilizerorlandscapetimbers,stackhigherinthebox.
Theheightandweightoftheloadhasasignicant inuenceontipovers.Thehigheraloadisstacked, themorelikelythevehicleistotipover.Youmaynd that2000poundsstackstoohighforsafeoperation. Reducingthetotalweightisonewaytoreducetherisk ofatipover.Distributingtheloadaslowaspossibleis anotherwaytoreducetheriskofatipover.
Iftheloadispositionedtowardoneofthesides,itwill makethevehiclemuchmorelikelytotipoveronthat side.Thisisespeciallytruewhenturningiftheloadis ontheoutsideoftheturn.
Neverpositionheavyloadsbehindtherearaxle.Ifthe loadispositionedsofartotherearthatitisbehindthe rearaxle,itwillreducetheweightonthefrontwheels andthiswillreducesteeringtraction.Withtheloadall thewaytotheback,thefrontwheelscanevencome offofthegroundwhengoingoverbumpsorupahill. Thiswillresultinalossofsteeringandmayleadtothe vehicletippingover.
Therearcargospaceisintendedforloadcarrying purposesonly ,notforpassengers.
UsingTheDifferentialLock
Thedifferentiallockincreasesthevehicle’stractionby lockingtherearwheelssoonewheelwillnotspinout. Thiscanhelpwhenyouhaveheavyloadstohaulon wetturforslipperyareas,goinguphillsandonsandy surfaces.Itisimportanttorememberhowever,thatthis extratractionisonlyfortemporarylimiteduse.Itsuse doesnotreplacethesafeoperation,alreadydiscussed concerningsteephillsandheavyloads.
Thedifferentiallockcausestherearwheelstospinat thesamespeed.Whenusingdifferentiallockyour abilitytomakesharpturnsissomewhatrestrictedand mayscufftheturf.Usethedifferentiallockonlywhen needed,atslowerspeedsandonlyinrstorsecond gear.
Tippingorrollingthevehicleonahillwillcause seriousinjury.
•Theextratractionavailablewiththe differentiallockcanbeenoughtogetyou intodangeroussituationssuchasclimbing slopesthataretoosteeptoturnaround. Beextracarefulwhenoperatingwiththe differentiallockon,especiallyonsteeper slopes.
•Ifthedifferentiallockisonwhenmakinga sharpturnatahigherspeedandinsiderear wheelliftsofftheground,theremaybea lossofcontrolwhichcouldcausevehicleto skid(RefertosectiononDifferentialLock Operation).Usethedifferentiallockonly atslowerspeeds.
Asageneralrule,positiontheweightoftheload evenlyfromfronttorearandevenlyfromsideto side.
Ifaloadisnotsecured,oryouaretransportingaliquid inalargecontainersuchasasprayer,itcanshift.This shiftinghappensmostoftenwhileturning,goingupor downhills,suddenlychangingspeedsorwhiledriving overroughsurfaces.Shiftingloadscanleadtotipovers. Alwayssecureloadssothattheydonotshift.Never dumptheloadwhilethevehicleissidewaysonthehill.
Heavyloadsincreasestoppingdistanceandreduceyour abilitytoturnquicklywithouttippingover.
FourWheelDrive
FourWheelDriveOnly
The“ AutomaticonDemand”fourwheeldrivefeature, onthisvehicledoesnotrequireoperatoractivation. Thefrontwheeldriveisnotengaged(nopower deliveredtofrontwheels)untiltherearwheelsbegin tolosetraction.Thebi–directionalclutchsensesthe rearwheelsslipping,engagesthefrontwheeldriveand deliverspowertothefrontwheels.Thefourwheel
32
Page 33
drivesystemcontinuestodeliverpowertothefront wheelsuntiltherearwheelshaveenoughtractionto movethevehiclewithoutslipping.Oncethisoccurs, thesystemstopsdeliveringpowertothefrontwheels andthehandlingcharacteristicsbecomesimilartothat ofatwowheeldrivevehicle.Thefourwheeldrive systemfunctionsinbothfrowardandreverse,however, whenturningtherearwheelswillslipslightlymore beforepowerisdeliveredtothefrontwheels.
Tippingorrollingthevehicleonahillwillcause seriousinjury.
•Theextratractionavailablewiththefour wheeldrivefeaturecanbeenoughtogetyou intodangeroussituationssuchasclimbing slopesthataretoosteeptoturnaround. Becarefulwhenoperating,especiallyon steeperslopes.
Figure33
1.Eyeholesinframe
Figure34
1.Axletube2.Hitchplate
TransportingVehicle
Formovingthevehiclelongdistances,atrailershould beused.Makesurethevehicleissecuredtothetrailer. RefertoFigure33andFigure34forlocationoftie downpoints.
TowingVehicle
Incaseofemergency,thevehiclecanbetowedfora shortdistance.However,Torodoesnotrecommend thisasastandardprocedure.
Towingatexcessivespeedscouldcausevehicle tolosesteeringcontrol.Nevertowvehiclefaster than5MPH.
Towingthevehicleisatwopersonjob.Afxatow linetoholesinfrontframemember.Moveshifterto Neutralandreleaseparkingbrake.Ifmachinemustbe movedaconsiderabledistance,transportitonatruck ortrailer.
Note:Thepowersteeringwillnotfunction, makingitdifcult(increaseeffort)tosteer.
TrailerTowing
TheWorkmaniscapableofpullingtrailersand attachmentsofgreaterweightthanthevehicleitself.
Severaltypesoftowhitchesareavailableforthe Workman,dependingonyourapplication.Contact yourAuthorizedTORODistributorfordetails.
Whenequippedwithatowhitchboltedontorearaxle tube,yourWorkmancantowtrailersorattachments withaGrossTrailerWeight(GTW)upto1500lbs. Alwaysloadatrailerwith60%ofthecargoweightin thefrontofthetrailer.Thisplacesapproximately10% (200lbs.max.)oftheGrossTrailerWeight(GTW)on thetowhitchofthevehicle.
Whentowingeitherstandardtongueor5thwheel trailershavingaGrossTrailerWeight(GTW)inexcess of1500lbs.,useeitherachassismounteddrawbarhitch (ratedfor3500lb.GTW)or5thwheelkitwithbrakes. Trailerbrakesarerequiredwheneveratrailerover1500 lbs.GTWistowedbehindaWorkmanvehicle.
Whenhaulingcargoortowingatrailer(attachment),do notoverloadyourvehicleortrailer.Overloadingcan causepoorperformanceordamagetothebrakes,axle, engine,transaxle,steering,suspension,bodystructure ortires.
Important:T oreducepotentialfordriveline damage,uselowrange.
33
Page 34
Whentowing5thwheelattachments,likeafairway aerator,alwaysinstallthe”wheelybar”(included withthe5thwheelkit)topreventthefrontwheels fromliftingoffthegroundifthetowedattachments movementissuddenlyimpaired.
HydraulicControl
Thehydrauliccontrolsupplies“live”hydraulicpower fromthevehiclepumpwhenevertheengineisrunning. Thepowercanbeusedthroughthequickcouplersat therearofthevehicle.
Important:Ifmultiplevehiclesusethe sameattachment,crosscontaminationofthe transmissionuidmayoccur.Changethe transmissionuidmorefrequently
ControlLeverPositions
OffPosition
Thisisthenormalpositionforthecontrolvalvewhen itisnotbeingused.Inthispositiontheworkportsof thecontrolvalveareblockedandanyloadwillbeheld bythecheckvalvesinbothdirections.
Raise(QuickCoupler“A”Position)
Thisisthepositionwhichwillliftthebed,rearhitch attachmentorapplypressuretoquickcoupler”A ”. ThisalsoallowsreturnoilfromQuickcoupler”B”to owbackintothevalveandthenouttothereservoir. Thisisamomentarypositionandwhentheleveris releaseditspringreturnstothecenteroffposition.
Lower(QuickCoupler“B”Position)
Thispositionwilllowerthebed,rearhitchattachment orapplypressuretoquickcoupler”B”.Thisalso allowsreturnoilfromquickcoupler”A”toowback intothevalveandthenouttothereservoir.Thisisa momentarypositionandwhentheleverisreleasedit springreturnstothecenteroffposition.Momentarily holdingandthenreleasingthecontrolleverinthis positionwillprovideowtoquickcoupler”B”which providespowerdownontherearhitch.Whenreleased, itwillholdthedownpressureonthehitch.
Figure35
1.Quickcoupler“A”position2.Quickcoupler“B”position
OnPosition
ThispositionissimilartoLower(quickcoupler”B” position).Italsodirectsoiltoquickcoupler”B”except thattheleverisheldinthispositionbyadetentleverin thecontrolpanel.Thisallowsoiltoowcontinuously toequipmentthatusesahydraulicmotor.Thisposition mustonlybeusedonattachmentswithahydraulic motorattached.
Important:Ifusedwithahydrauliccylinderor noattachment,theOnpositioncausestheoil owtogooverareliefvalvewhichcandamage thehydraulicsystem.Usethispositiononly momentarilyorwithamotorattached.
Important:Checkhydraulicoillevelafter installationofattachment.Checkoperationof attachmentbycyclingattachmentseveraltimes topurgeairfromsystem,thenrecheckhydraulic oillevel.Attachmentcylinderwillslightlyaffect transaxleoillevel.Operationofvehiclewithlowoil levelcandamagepump,remotehydraulics,power steeringandvehicletransaxle.
Important:Ifusedwithahydrauliccylinder, holdingthecontrolleverinthelowerposition causestheoilowtogooverareliefvalvewhich candamagethehydraulicsystem.
34
Page 35
Hydraulicuidescapingunderpressurecan havesufcientforcetopenetrateskinanddo seriousdamage.Caremustbeusedwhen connectingordisconnectinghydraulicquick couplers.Stopengine,applyparkingbrake, lowerattachmentandplaceremotehydraulic valveinoatdetentpositiontorelievehydraulic pressurebeforeconnectingordisconnecting quickcouplers.
–Fittingsloose.
–Fittingmissingo–ring.
•Attachmentdoesnotfunction.
–Quickcouplersnotfullyengaged.
–Quickcouplersareinterchanged.
•Squealingnoise.
–RemotevalveleftinONdetentpositioncausing
hydraulicoiltoowoverreliefvalve.
•Enginewillnotstart.
QuickCouplerOperation
Connection
Important:Cleandirtfromquickcouplers
beforeconnecting.Dirtycouplerscanintroduce contaminationtohydraulicsystem
Pullbacklockingringoncoupler. Inserthosenippleintocoupleruntilitsnapsinto
position.
Disconnection
Note:Withboththevehiclesturnedoff,movethelift
leverbackandforthtoremovethesystempressureand easethedisconnectionofthequickcouplers.
Pullbacklockingringoncoupler.
Pullhosermlyfromcoupler.
Important:Cleanandinstalldustpluganddust coverstoquickcouplerendswhennotinuse.
–Hydraulicleverlockedinforwardposition.
Note:Whenattachingremoteequipmenttothequick couplers,determinewhichsiderequirespressure,then attachthathosetoquickcoupler”B”whichwillhave pressurewhenthecontrolleverispushedforwardor lockedintheONposition.
HydraulicControlTroubleShooting:
•Difcultyinconnectingordisconnectingquick couplers.
–Pressurenotrelieved(Quickcouplerunder
pressure).
•Powersteeringhard.
–Hydraulicoillevellow .
–Hydraulicoilhot.
–Pumpnotoperating.
•Hydraulicleaks.
35
Page 36
Maintenance
Determinetheleftandrightsideofthemachinefrom thenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst2hours
Aftertherst8hours
Aftertherst10hours
Aftertherst50hours
MaintenanceProcedure
•T orquethefrontandrearwheelnuts.
•Checkconditionandtensionofallbelts.
•T orquethefrontandrearwheelnuts.
•Checktheshiftcablesadjustment.
•Checktheshiftcablesadjustment.
•Replacethetransaxlelter.
•Replacethehydrauliclter.
•Changeoilandoillter.
•Changeoilandlter.
•Re–torquethecylinderheadbolts.
•Adjustenginevalveclearance.
Ifyouleavethekeyintheignitionswitch, someonecouldaccidentlystarttheengineand seriouslyinjureyouorotherbystanders.
Removethekeyfromtheignitionbeforeyoudo anymaintenance.
Beforeeachuseordaily
Every50hours
Every100hours
Every150hours
Every200hours
•Checkengineoillevel.
•Checkthelevelofcoolant.
•Checkthetransaxle/hydraulicuid.
•Checkthetirepressure.
•Checkthebrakeuidlevel.
•Drainwaterorothercontaminantsfromfuellter/waterseparator .
•Removedebrisfromengineareaandradiator.(Cleanmorefrequentlyindirty conditions.)
•Cleantheaircleanerlter.
•Checkthebatteryuidlevel.(Every30daysifinstorage)
•Checkthebatterycableconnections.
•Checktheleveloffrontdifferentialoil.
•Lubricateallbearingsandbushings.
•Checktheconditionofthetires.
•Changeoilandoillter.
•Changeoilandlter.
•T orquethefrontandrearwheelnuts
•Changetheaircleanerlter.
•Inspecttheconstantvelocitybootforcracks,holesoralooseclamp.
•Checktheshiftcablesadjustment.
•Checkthedifferentiallockcableadjustment.
•Inspectserviceandparkingbrakes.
•Checkconditionandtensionofallbelts.
•Checkbrakepedaladjustment.(Fronthoodcanberemovedtoeaseadjustment.)
•ChecktheClutchAdjustment.
•Checktheparkingbrakeadjustment.
36
Page 37
MaintenanceService
Every400hours
Interval
MaintenanceProcedure
•Checklinesandconnections.(Inspectfordeterioration,damage,orloose connections.)
•Replaceltercanister.
•Checkfrontwheeltoe-out.
•Visuallyinspectbrakesforwornbrakeshoes.
Every600hours
Every800hours
Every1,000hours
ServiceIntervalChart
•Checkthecylinderheadtorque.
•Adjustenginevalveclearance.
•Changethefrontdifferentialoil.
•Changethetransaxlehydraulicuidandlter,andcleanthestrainer.
•Replacethehydrauliclter.
•Cleanthehydraulicstrainer.
•Changethebrakeuid.
•Re–torquethecylinderheadbolts.
•Drain/ushthefueltank.
•Flush/replacethecoolantsystemuid.
Figure36
HeavyDutyOperation
Important:Ifthevehicleissubjectedtoanyoftheconditionslistedbelow,maintenanceshouldbe
performedtwiceasfrequently:
•Desertoperation
•Coldclimateoperation(below32degreesF)
•Trailertowing
•Frequentoperationondustyroads
•Constructionwork
37
Page 38
•Afterextendedoperationinmud,sand,water,orsimilardirtyconditions,haveyourbrakesinspectedandcleaned assoonaspossible.Thiswillpreventanyabrasivematerialfromcausingexcessivewear.
•Underfrequentheavydutyoperatingconditions,lubricateallgreasettings.
Onlyqualiedandauthorizedpersonnelshallbepermittedtomaintain,repair,adjustorinspect thevehicle.
Avoidrehazardsandhavereprotectionequipmentpresentintheworkarea.Donotuseanopen ametochecklevelorleakageoffuel,batteryelectrolyteorcoolant.Donotuseopenpansoffuel orammablecleaninguidsforcleaningparts.
Manyofthesubjectscoveredinthismaintenancesectionrequireraisingandloweringthebed.Thefollowing precautionsmustbetakenorseriousinjuryordeathcouldresult.
Beforeservicingormakingadjustmentstothemachine,stopengine,setparkingbrakeandremove keyfromignitionswitch.Anyloadmaterialmustberemovedfrombedorotherattachmentbefore workingunderraisedbed.Neverworkunderaraisedbedwithoutpositioningsafetysupportona fullyinstalledcylinderrod.
Aftermaintenanceiscompleted,removesafetysupport,slideitontostoragestudandlowerbed.
Premaintenance Procedures
3.Pushbedsupportontocylinderrod,makingsure supportendtabsrestonendofcylinderbarreland oncylinderrodend(Figure38).
UsingBedSafetySupport
1.Raisebeduntilliftcylindersarefullyextended.
2.Removebedsupportfromstoragebracketsonback ofROPSpanel(Figure379).
Figure38
1.Bedsupport3.Bed
2.Cylinderbarrel
Figure37
1.Bedsupport
38
Page 39
4.Tostorebedsupport,removebedsupportfrom cylinderandinsertintobracketsonbackofROPS panel.
5.Alwaysinstallorremovebedsupportfromoutside ofbed.
Donottrytolowerbedwithbedsafetysupport oncylinder.
JackingVehicle
Avehicleonajackmaybeunstableandslipoff ofthejack,injuringanyonebeneathit.
•Donotstartthevehiclewhilethevehicleis onajack.
•Alwaysremovethekeyfromtheswitch beforegettingoffofthevehicle.
•Blockthetireswhenthevehicleisonajack.
1.Donotstartenginewhilevehicleisonjack,because enginevibrationorwheelmovementcouldcause vehicletoslipoffjack.
2.Donotworkundervehiclewithoutjackstands supportingit.Thevehiclecouldslipoffjack,injuring anyonebeneathit.
Figure40
3.Thejackingpointatthefrontofthevehicleisunder thefrontcenterframesupportandattherearitis undertheaxletube.
4.Whenjackingupfrontofvehicle,alwaysplacea2x4 block(orsimilarmaterial)betweenjackandvehicle frame.
Figure39
1.Frontjackingpoint
39
Page 40
Lubrication
GreasingBearingsand Bushings
ServiceInterval:Every100hours
Thevehiclehasgreasettingsthatmustbelubricated regularlywithNo.2GeneralPurposeLithiumBase Grease.Ifmachineisoperatedundernormalconditions, lubricateallbearingsandbushingsafterevery100hours ofoperation.Morefrequentlubricationisrequiredif usedforheavydutyvehicleoperations.
Thegreasettinglocationsandquantitiesare:Steering pitmanarm(1)andSteeringballjointends(2) (Figure41),Tierodends(4)(Figure42),Frontball joints(4)(Figure42),Reardriveshafts(18)(Figure43), Pedalpivots(3)(Figure446);Frontpivotbushings(2) (Figure45)andAcceleratorarm(1)(Figure46).
Important:Whengreasingdriveshaftuniversal shaftbearingcrosses,pumpgreaseuntilitcomes outofall4cupsateachcross.
Figure42
1.Wipegreasettingcleansoforeignmattercannotbe forcedintothebearingorbushing.
2.Pumpgreaseintothebearingorbushing.
3.Wipeoffexcessgrease.
Figure41
Figure43
Figure44
40
Page 41
EngineMaintenance
GeneralAirCleaner MaintenancePractices
ServiceInterval:Every50hours
Every200hours
•Inspectaircleanerandhosesperiodicallytomaintain maximumengineprotectionandtoensuremaximum servicelife.
Figure45
Figure46
•Checkaircleanerbodyfordamagewhichcould possiblycauseanairleak.Replaceadamagedair cleanerbody .
•Cleantheaircleanerlterevery50hoursandchange every200hours(morefrequentlyinextremedusty ordirtyconditions).
ServicingAirCleaner
1.Pulllatchoutwardandrotateaircleanercover counter–clockwise.
Figure47
1.Aircleanercover2.Filter
2.Beforeremovingthelter,uselowpressure air(40psi,cleananddry)tohelpremovelarge accumulationsofdebrispackedbetweentheoutside oftheprimarylterandthecanister.
Important:Avoidusinghighpressureairwhich couldforcedirtthroughthelterintotheintake tract.Thiscleaningprocesspreventsdebris frommigratingintotheintakewhentheprimary lterisremoved.
3.Removeandreplacetheprimarylter.
41
Page 42
Note:Cleaningoftheusedelementisnot recommendedduetothepossibilityofdamageto theltermedia.
4.Inspectthenewlterforshippingdamage,checking thesealingendofthelterandthebody.
Important:Donotuseadamagedelement.
5.Insertthenewlterbyapplyingpressuretotheouter rimoftheelementtoseatitinthecanister.
Important:Donotapplypressuretotheexible centerofthelter.
6.Cleanthedirtejectionportlocatedintheremovable cover.Removetherubberoutletvalvefromthe cover,cleanthecavity,andreplacetheoutletvalve.
7.Installthecoverorientingtherubberoutletvalvein adownwardposition–betweenapproximately5:00to 7:00whenviewedfromtheend.
8.Securethecoverlatches.Resettheindicatorifitis showingred,ifsoequipped.
ChangingEngineOilAndFilter
ServiceInterval:Aftertherst50hours
Every150hours
1.Raisebed(ifsoequipped)andplacesafetysupport onextendedliftcylindertoholdupbed.
2.Removedrainplugandletoilowintodrainpan. Whenoilstops,installdrainplug.
Figure49
1.Engineoillter
4.Addoiltocrankcase,refertoCheckEngineOil.
CylinderHeadBolts
ServiceInterval:Aftertherst50hours
Every600hours
Every1,000hours/Yearly(whichever comesrst)
EngineValveClearance
ServiceInterval:Aftertherst50hours
Every600hours/Y early(whichever comesrst)
Figure48
1.Engineoildrainplug
3.Removeoillter.Applyalightcoatofcleanoilto thenewltersealbeforescrewingiton.Screwlter onuntilgasketcontactsmountingplate,thentighten 1/2to2/3ofaturn.DONOTOVER–TIGHTEN.
42
Page 43
FuelSystem Maintenance
FuelSystem
FuelLinesandConnections
ServiceInterval:Every400hours/Yearly(whichever
comesrst)(Inspectfordeterioration, damage,orlooseconnections.)
Every1,000hours/Every2years (whichevercomesrst)
FuelFilter/WaterSeparator
ServiceInterval:Beforeeachuseordaily
Every400hours
Drainwaterorothercontaminantsfromfuellter/water separatordailybylooseningdrainplug(Figure50)on ltercanister.Tightenplugafterdraining.
5.Lubricategasketonltercanisterwithcleanengine oil.
6.Installltercanisterbyhanduntilgasketcontacts mountingsurface,thenrotateanadditional1/2turn.
BleedingAirFromInjectors
1.Raisebed(ifsoequipped)andplacesafetysupport onextendedliftcylindertoholdupbed.
2.LoosenthepipeconnectiontotheNo.1nozzleand holderassembly(Figure51).
1.Raisebed(ifsoequipped)andplacesafetysupport onextendedliftcylindertoholdupbed.
2.Fuellter/waterseparatorismountedoninnerside ofrightframerail.
Figure51
1.Fuelinjectors(3)
3.SlowlydepressacceleratorpedaltofullFAST position.
4.TurnkeyinkeyswitchtoSTARTpositionand watchfuelowaroundconnector.TurnkeytoOFF positionwhensolidowisobserved.
5.Tightenpipeconnectorsecurely .
6.Repeatsteps1-4onNo.2and3nozzles.
Figure50
1.Drainplug2.Filtercanister
3.Cleanareaaroundltercanistermountingsurface.
4.Removeltercanisterandcleanmountingsurface.
43
Page 44
ElectricalSystem Maintenance
JumpStartingVehicle
Fuses
Thefusesforthemachine’selectricalsystemarelocated underthecenterofthedashpanel.
Figure52
1.Fuses
Jumpstartingcanbedangerous.T oavoid personalinjuryordamagetoelectrical componentsinvehicle,observethefollowing warnings:
•Neverjumpstartwithavoltagesources greaterthan15voltsD.C.Thiswilldamage theelectricalsystem.
•Neverattempttojumpstartadischarged batterythatisfrozen.Itcouldruptureor explodeduringjumpstarting.
•Observeallbatterywarningswhilejump startingyourvehicle.
•Besureyourvehicleisnottouchingthe jumpstartvehicle.
•Connectingcablestothewrongpostcould resultinpersonalinjuryand/ordamageto theelectricalsystem.
1.Loosenknobssecuringbatterycovertobatterybase andslidecoveroff.
2.Connectajumpercablebetweenthepositiveposts ofthetwobatteries.Thepositivepostmaybe identiedbya“+”signontopofbatterycover.
3.Connectoneendoftheotherjumpercabletothe negativeterminalofthebatteryintheothervehicle. Thenegativeterminalhas“NEG”onthebattery cover.Donotconnecttheotherendofthejumper cabletothenegativepostofthedischargedbattery. Connectittotheengine.Donotconnectthejumper cabletothefuelsystem.
4.Starttheengineinthevehicleprovidingthejump start.Letitrunafewminutes,thenstartyourengine.
5.Removethenegativejumpercablerstfromyour engine,thenthebatteryintheothervehicle.
6.Reinstallbatterycovertobatterybaseandtighten knobs.
Figure53
BatteryCare
ServiceInterval:Every50hours(Every30daysifin
storage) Every50hours
1.Batteryelectrolytelevelmustbeproperlymaintained andthetopofthebatterykeptclean.lfthemachine isstoredinalocationwheretemperaturesare extremelyhigh,thebatterywillrundownmore
44
Page 45
rapidlythanifthemachineisstoredinalocation wheretemperaturesarecool.
DriveSystem Maintenance
Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.
•Donotdrinkelectrolyteandavoidcontact withskin,eyesorclothing.Wearsafety glassestoshieldyoureyesandrubbergloves toprotectyourhands.
•Fillthebatterywherecleanwaterisalways availableforushingtheskin.
2.Keeptopofbatterycleanbywashingperiodically withabrushdippedinammoniaorbicarbonateof sodasolution.Flushthetopsurfacewithwaterafter cleaning.Donotremovethellcapwhilecleaning.
3.Batterycablesmustbetightonterminalstoprovide goodelectricalcontact.
4.Ifcorrosionoccursatterminals,removebattery cover,disconnectcables,negative(–)cablerstand scrapeclampsandterminalsseparately.Reconnect cables,positive(+)cablerstandcoatterminals withpetroleumjelly .
5.Checktheelectrolytelevelevery50operatinghours or,ifmachineisinstorage,every30days.
ChangeFrontDifferentialOil
FourWheelDriveOnly
ServiceInterval:Every800hours
1.Positionvehicleonalevelsurface,stopengine, engageparkingbrakeandremovekeyfromignition switch.
2.Cleanareaarounddrainplugonsideofdifferential. Placedrainpanunderdrainplug.
Figure54
1.Frontdifferential
2.Fill/checkplug
3.Drainplug
6.Maintaincelllevelwithdistilledordemineralized water.Donotllcellsabovethebottomofthell ringinsideeachcell.
3.Removedrainplugandletoilowintodrainpan. Reinstallandtightenplugwhenoilstopsdraining.
4.Cleanareaaroundll/checkplugonsideof differential.
5.Removell/checkplugandadd10W30oiluntiloil isuptohole.
6.Re–installll/checkplug.
InspectConstantVelocityBoot
FourWheelDriveOnly
ServiceInterval:Every200hours
AdjustingShiftCables
ServiceInterval:Aftertherst10hours
Every200hours
1.MoveshiftlevertoNeutralposition.
2.Removeclevispinssecuringshiftcablestotransaxle shiftarms.
45
Page 46
Figure55
1.Shiftarm(1st–Rev .)3.Shiftarm(High–low)
2.Shiftarm(2nd–3rd)
3.Loosenclevisjamnutsandadjusteachclevisso cablefreeplayisequalforwardandbackwardrelative toholeintransaxleshiftarm(Withtransaxlelever freeplaytakenupinsamedirection).
mustbe.12.12“greateratthefrontofthetirethan attherear.
Figure56
1.Frontofvehicle3.Centertocenterdistance
2..12±.12inchgreaterthan rearoftire
2.Adjustthecenter–to–centerdistanceasfollows:
•Ontherightfrontwheel,loosenthejamnutsat bothendsofthetierod(Figure57).
4.Reinstallclevispinsandtightenjamnutsafter adjustmentshavebeenattained.
AdjustingHigh–lowCable
ServiceInterval:Aftertherst10hours
Every200hours
1.MovedifferentiallocklevertoOffposition.
2.Loosenjamnutssecuringdifferentiallockcableto bracketontransaxle.
3.Adjustjamnutstoobtain.035”±.025”gapbetween springhookandO.D.ofholeintransaxlelever.
4.Tightenjamnutsafteradjustmenthasbeenattained.
InspectTires
ServiceInterval:Every100hours
Operatingaccidents,suchashittingcurbs,candamagea tireorrimandalsodisruptwheelalignment,soinspect tireconditionafteranaccident.
Figure57
1.Tierod
•Ontheleftfrontwheel,loosenthejamnutsat bothendsoftheturnbuckle(Figure58).
•Rotatethetierodandturnbuckleevenlytomove thefrontofthetireinwardoroutwardtoachieve thecentertocenterdistancesfromfronttoback.
•Tightentierodandturnbucklejamnutswhen theadjustmentiscorrect.
•Checktomakesurethetiresturnanequal amounttotherightandtotheleft.Ifthetiresdo notturnequally ,refertotheWorkmanService Manualfortheadjustmentprocedure
FrontWheelToe
ServiceInterval:Every400hours/Yearly(whichever
comesrst)
1.Measurecenter–to–centerdistance(ataxleheight)at frontandrearofsteeringtires.Themeasurement
46
Page 47
1.Turnbuckle
Figure58
CoolingSystem Maintenance
RemovingDebrisFromEngine CoolingSystem
ServiceInterval:Beforeeachuseordaily(Cleanmore
frequentlyindirtyconditions.)
1.Turnengineoff.Cleanengineareathoroughlyof alldebris.
2.Liftandremoveradiatorscreenfromfrontof radiator.
Figure59
1.Radiatorscreen
3.Cleanradiatorandscreenthoroughlywith compressedair.
Note:Blowdebrisawayfromradiator.
ChangingEngineCoolant
ServiceInterval:Every1,000hours/Every2years
(whichevercomesrst)
1.Parkmachineonalevelsurface.
2.Raisebed(ifsoequipped)andplacesafetysupport onextendedliftcylindertoholdupbed.
47
Page 48
Iftheenginehasbeenrunning,thepressurized, hotcoolantcanescapeandcauseburns.
•Donotopentheradiatorcapwhenthe engineisrunning.
•Allowenginetocoolatleast15minutes oruntiltheradiatorcapiscoolenoughto touchwithoutburninghand.
•Usearagwhenopeningtheradiatorcap, andopenthecapslowlytoallowsteamto escape.
3.Removeradiatortankcap.
Figure60
1.Radiatorcap
4.Removereservetankcap.
Figure62
1.Bleedscrew
7.Removecoolantdrainplugfromengineandallow coolanttoowintodrainpan.Whencoolantstops, installdrainplug.
8.Slowlyllradiatorwitha50/50mixtureofwater andpermanentethyleneglycolanti–freeze.Install radiatorcap.
9.SlowlyllreservetankuntillevelreachesCOLDline. DONOTOVERFILL.Installreservetankcap.
10.Startengineandoperateuntilwarm.Tightenwater pumpbleedscrewwhenwaterappearsatthebleed screw.
11.Stopengine.Rechecklevelandreplenish,ifrequired.
Figure61
1.Reservetankcap
5.Opencoolantdraincockatbottomofradiatorand allowcoolanttoowintodrainpan.Whencoolant stops,closedraincock.
6.Openbleedscrewontopofwaterpump(Figure62).
48
Page 49
BrakeMaintenance
BeltMaintenance
InspectBrakes
ServiceInterval:Every200hours
Every400hours
Visuallyinspectbrakesforwornbrakeshoesafterevery 400hoursofoperation.
AdjustingBelts
ServiceInterval:Aftertherst8hours
Every200hours
Raisebed(ifsoequipped)andpositionsafetysupport onextendedliftcylindertoholdupbed.
Alternatorbelt
1.Checktensionbydepressingbeltatmidspanof crankshaftandalternatorpulleyswith22lbs.of force.Anewbeltshoulddeect.3–.5in.Ausedbelt shoulddeect.4–.55in.Ifdeectionisincorrect, proceedtonextstep.Ifcorrect,continueoperation.
2.Toadjustbelttension:
•Loosen(2)alternatormountingbolts.
Figure63
1.Alternatorbelt2.Alternatorbrace
•Usingabar,rotatealternatoruntilproperbelt tensionisattained,thentightenmountingbolts.
Fanbelt
1.Checktensionbydepressingbeltatmidspanoffan anddriveshaftpulleyswith22lbs.offorce.Anew beltshoulddeect.48–.58in.Ausedbeltshould deect.55–.65in.Ifdeectionisincorrect,proceed tonextstep.Ifcorrect,continueoperation.
2.Toadjustbelttension:
Loosenidlerpulleymountingnut,movepulleyto increasetensionandtightennut.
49
Page 50
Figure64
1.Fanbelt2.Idlerpulley
ControlsSystem Maintenance
AdjustingAcceleratorPedal
1.Positionvehicleonlevelsurface,stopengineand engagetheparkingbrake.
2.Adjustballjointonacceleratorcable(Figure65)to allow.100”–.250”ofclearancebetweenaccelerator pedalarmandtopofdiamondtreadoorplate (Figure66),whena25lb.forceisappliedtocenter ofpedal.Tightenlocknut.
Note:Enginemustnotberunningandreturn springmustbeattached.
Figure65
1.Acceleratorcable3.Locknut
2.Balljoint
50
Page 51
Figure66
1..200—.350inchClearance
3.Maximumhighidlespeed3650rpm.Highidlestop shouldnotbeadjusted.
AdjustingBrakePedal
ServiceInterval:Every200hours(Fronthoodcanbe
removedtoeaseadjustment.)
4.Adjustyokeuntilitsholesalignwithholeinbrake pedalpivot.Secureyoketopedalpivotwithclevis pinandcotterpin.
5.Tightenjamnutssecuringyoketomastercylinder shaft.
Note:Thebrakemastercylindermustrelieve pressurewhenproperlyadjusted.
Figure68
1.Brakepedal
2.Clutchpedal
1.Removecotterpinandclevispinsecuringmaster cylinderyoketobrakepedalpivot(Figure67).
Figure67
1.Mastercylinderyoke2.Brakepedalpivot
AdjustingClutchPedal
ServiceInterval:Every200hours
Note:Theclutchpedalcablecanbeadjustedatthebell housingorattheclutchpedalpivot.Thefronthoodcan beremovedtoeasetheaccesstopedalpivot.
1.Loosenthejamnutssecuringtheclutchcabletothe bracketonthebellhousing(Figure691).
Figure69
1.Clutchcable
2.Jamnuts4.Balljoint
3.Returnspring
2.Liftuponbrakepedal(Figure68)untilitcontacts frame.
3.Loosenjamnutssecuringyoketomastercylinder shaft(Figure67).
Note:Theballjointmayberemovedandrotated,if additionaladjustmentisrequired.
2.Disconnectthereturnspringfromtheclutchlever.
3.Adjustthejamnuts/orballjointuntilthebackrear edgeoftheclutchpedalis3.75”+.12”fromthetop
51
Page 52
oftheoorplatediamondpattern,whenan4lb. forceisappliedtothepedal(Figure70).
Figure70
1.Clutchpedal
Note:Forceisappliedsotheclutchreleasebearing lightlycontactspressureplatengers.
4.Tightenthejamnutsaftertheadjustmenthasbeen attained.
5.Recheckthe3.75”+.12”dimensionafterthe jamnutshavebeentightenedtoensureproper adjustment.Readjust,ifnecessary.
6.Reconnectthereturnspringtotheclutchlever.
pedalis1.25”±.12”fromoor.Ifanadjustmentis required,loosenswitchjamnutsandadjustupor down.
Figure72
1.Clutchswitch
AdjustingParkingBrake
ServiceInterval:Every200hours
1.Removerubbergripfromparkingbrakelever (Figure73)
Important:Makesuretherodendispositioned squarelyontheball,nottwisted,andremains paralleltotheclutchpedalafterthejamnutis tightened(Figure71).
Figure71
1.Clutchcablerodend
2.Clutchpedal
3.Rodendjamnut
4.Parallel
Figure73
1.Parkingbrakelever
2.Grip
2.Loosensetscrewsecuringknobtoparkingbrake lever(Figure74).
3.Rotateknobuntilaforceof30–40lbs.isrequired toactuatelever.
Note:Theclutchfreeplayshouldneverbeless than.75”.
7.Rechecktheclutchsafetyswitchadjustment (Figure72).Theenginemustnotcrankunlessclutch
52
Page 53
1.Parkingbrakelever
2.Knob
Figure74
3.Setscrew
HydraulicSystem Maintenance
ChangingTransaxle/ HydraulicFluid
ServiceInterval:Aftertherst10hours
Every800hours
1.Positionthevehicleonalevelsurface,stopengine, engagetheparkingbrakeandremovekeyfrom ignitionswitch.
2.Removedrainplugfromsideofreservoirandlet hydraulicuidowintodrainpan.Reinstalland tightenplugwhenhydraulicuidstopsdraining.
4.Tightensetscrewafteradjustmenthasbeenattained.
5.Installrubbergripontoparkingbrakelever.
Note:Cleanthehydraulicstrainer.Referto CleaningHydraulicStrainer.
Figure75
1.Hydraulicreservoir2.Drainplug
3.Fillreservoirwithapproximately7.5qt.ofDexron IIlATF .RefertoCheckingHydraulicFluid.
4.Startengineandoperatetollhydraulicsystem. Recheckoillevelandreplenish,ifrequired.
Important:Useonlyhydraulicuidsspecied. Otheruidscouldcausesystemdamage.
ReplacingHydraulicFilter
ServiceInterval:Aftertherst10hours
Every800hours
Important:Useofanyotherltermayvoidthe warrantyonsomecomponents.
1.Positionvehicleonalevelsurface,stopengine, engagetheparkingbrakeandremovekeyfrom ignitionswitch.
53
Page 54
2.Cleanareaaroundltermountingarea.Placedrain panunderlterandremovelter.
Figure76
1.Hydrauliclter2.Gasket
3.Lubricatenewltergasket.
4.Assureltermountingareaisclean.Screwlteron untilgasketcontactsmountingplate.Thentighten lterone–halfturn.
5.Startengineandletrunforabouttwominutesto purgeairfromthesystem.Stoptheengineand checkthehydraulicoillevelandforleaks.
CleaningHydraulicStrainer
ServiceInterval:Every800hours
1.Positionthevehicleonalevelsurface,stopengine, engagetheparkingbrakeandremovekeyfrom ignitionswitch.
2.Removedrainplug(Fig.58)fromsideofreservoir andlethydraulicuidowintodrainpan.
3.Noteorientationofhydraulichoseand90degree ttingconnectedtostraineronsideofreservoir. Removehydraulichoseand90degreetting.
4.Removestrainerandcleanbybackushingwitha cleandegreaser.Allowtoairdrybeforereinstalling.
Figure77
1.Hydraulicstrainer
5.Reinstallstrainer.
6.Reinstallhydraulichoseand90degreettingto strainerinsameorientation.
7.Reinstallandtightendrainplug.
8.Fillreservoirwithapproximately7.5qt.ofDexron IIlATF .RefertoCheckingHydraulicFluid.
EmergencyBoxRaising
(withoutstartingengine)
Theboxcanberaisedinanemergencybycranking starterorbyjumpinghydraulicsystem.
StarterMethod
•Crankstarterwhileholdingliftleverintheraise position.Runstarterfor15secondsthenwait60 secondsbeforeengagingstarteragain.
•Ifenginewillnotcrank,theloadandbox (attachment)mustberemovedtoserviceengineor transaxle.
•Backanothervehicleuptotherearofthedisabled vehicle.
54
Page 55
JumpingHydraulicSystem
Beforeservicingormakingadjustmentstothe machine,stopengine,setparkingbrakeand removekeyfromtheswitch.Anyloadmaterial mustberemovedfrombedorotherattachment beforeworkingunderraisedbed.Neverwork underaraisedbedwithoutpositioningsafety supportonafullyinstalledcylinderrod.
Note:Twohydraulichoses,eachwithamaleand femalequickcoupler,thattthevehiclecouplersare requiredtoperformthisoperation.
•Backanothervehicleuptotherearofthedisabled vehicle.
Important:Thevehicleshydraulicsystemuses DexronIIlATF .T oavoidsystemcontamination, makesurevehicleusedtojumphydraulicsystem usesanequivalentuid.
•Onbothvehicles,disconnectthetwoquickcoupler hosesfromthehosessecuredtothecouplerbracket (Figure78).
Figure79
1.Disconnectedhoses2.Jumperhoses
•Ontheothervehicle,connectthetwohosestothe couplerstillinthecouplerbracket(Connectthetop hosetothetopcouplerandthebottomhosetothe bottomcoupler(Figure80).Capunusedttings.
Figure78
1.Quickcouplerhoses
•Onthedisabledvehicle,connectthetwojumper hosestothehosesthatweredisconnected (Figure79).Capunusedttings.
Figure80
1.Jumperhoses
•Keepallbystandersawayfromthevehicles.
•Startsecondvehicleandmoveliftlevertotheraise positionwhichwillraisethedisabledbox.
•Movethehydraulicliftlevertotheneutralposition andengagetheliftleverlock.
•Installthebedsafetysupportontotheextendedlift cylinder.RefertoUsingtheBedSafetySupport.
Note:Withboththevehiclesturnedoff,move theliftleverbackandforthtoremovethesystem
55
Page 56
pressureandeasethedisconnectionofthequick couplers.
Storage
•Aftercompletingoperation,removejumperhoses andconnecthydraulichosestobothvehicles.
Important:Checkhydraulicuidlevels,inboth vehicles,beforeresumingoperation.
BatteryStorage
Ifthemachinewillbestoredformorethan30days, removethebatteryandchargeitfully.Eitherstore itontheshelforonthemachine.Leavethecables disconnectedifstoredonthemachine.Storethebattery inacoolatmospheretoavoidquickdeteriorationofthe chargeinthebattery.Topreventbatteryfromfreezing, makesureitisfullycharged.Thespecicgravityofa fullychargedbatteryis1.250.
Warning
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
W ash hands after handling .
56
Page 57
Schematics
HydraulicSchematic(Rev.A)
57
Page 58
ElectricalSchematic(Rev.A)
58
Page 59
Page 60
Toro General Commercial Products Warranty
A Two-Year Limited Warranty
Conditions and Products Covered
The Toro Company and its affi liate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product”) to be free from defects in materi­als or workmanship for two years or 1500 operational hours*, whichever occurs fi rst. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty state­ments for these products). Where a warrantable condition exists, we will repair the Product at no cost to you including diagnosis, labor, parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser.
* Product equipped with hour meter
Instructions for Obtaining Warranty Service
You are responsible for notifying the Commercial Products Dis­tributor or Authorized Commercial Products Dealer from whom you purchased the Product as soon as you believe a warrantable condition exists. If you need help locating a Commercial Products Distributor or Authorized Dealer, or if you have questions regard­ing your warranty rights or responsibilities, you may contact us at:
Toro Commercial Products Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 952-888-8801 E-mail: commercial.warrnty@toro.com
Owner Responsibilities
As the Product owner, you are responsible for required main­tenance and adjustments stated in your Operator’s Manual. Failure to perform required maintenance and adjustments can be grounds for disallowing a warranty claim.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the warranty period are defects in materials or workmanship. This warranty does not cover the following:
Product failures which result from the use of non-Toro
• replacement parts, or from installation and use of add-on, or modifi ed non-Toro branded accessories and products. A separate warranty may be provided by the manufacturer of these items. Product failures which result from failure to perform recom-
• mended maintenance and/or adjustments. Failure to properly maintain your Toro product per the Recommended Mainte­nance listed in the Operator’s Manual can result in claims for warranty being denied. Product failures which result from operating the Product in an
• abusive, negligent or reckless manner. Parts subject to consumption through use unless found to be
• defective. Examples of parts which are consumed, or used up, during normal Product operation include, but are not lim­ited to, brakes pads and linings, clutch linings, blades, reels, bed knives, tines, spark plugs, castor wheels, tires, fi lters, belts, and certain sprayer components such as diaphragms, nozzles, and check valves, etc. Failures caused by outside infl uence. Items considered to be
• outside infl uence include, but are not limited to, weather, stor- age practices, contamination, use of unapproved coolants,
Countries Other than the United States or Canada Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfi ed with your Distributor’s service or have diffi culty obtaining guarantee information, contact the Toro importer.
lubricants, additives, fertilizers, water, or chemicals, etc. Normal noise, vibration, wear and tear, and deterioration.
• Normal “wear and tear” includes, but is not limited to, dam-
• age to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows, etc.
Parts
Parts scheduled for replacement as required maintenance are war­ranted for the period of time up to the scheduled replacement time for that part. Parts replaced under this warranty are covered for the duration of the original product warranty and become the property of Toro. Toro will make the fi nal decision whether to repair any ex- isting part or assembly or replace it. Toro may use remanufactured parts for warranty repairs.
Note Regarding Deep Cycle Battery Warranty:
Deep cycle batteries have a specifi ed total number of kilowatt- hours they can deliver during their lifetime. Operating, recharging, and maintenance techniques can extend or reduce total battery life. As the batteries in this product are consumed, the amount of useful work between charging intervals will slowly decrease until the battery is completely worn out. Replacement of worn out batteries, due to normal consumption, is the responsibility of the product owner. Battery replacement may be required during the normal product warranty period at owner’s expense.
Maintenance is at Owner’s Expense
Engine tune-up, lubrication cleaning and polishing, replacement of fi lters, coolant, and completing Recommended Maintenance are some of the normal services Toro products require that are at the owner’s expense.
General Conditions
Repair by an Authorized Toro Distributor or Dealer is your sole remedy under this warranty.
Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing sub­stitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty. Except for the Emissions warranty referenced below, if applicable, there is no other express warranty. All implied warranties of merchantability and fi tness for use are limited to the duration of this express warranty.
Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you. This warranty gives you specifi c legal rights, and you may also have other rights which vary from state to state.
Note regarding engine warranty:
The Emissions Control System on your Product may be covered by a separate warranty meeting requirements established by the U.S. Environmental Protection Agency (EPA) and/or the California Air Resources Board (CARB). The hour limitations set forth above do not apply to the Emissions Control System Warranty. Refer to the Engine Emission Control Warranty Statement printed in your Operator’s Manual or contained in the engine manufacturer’s documentation for details.
Part No. 374-0031 Rev. D
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use