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

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)

Introduction

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

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

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

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

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

–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

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

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

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

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

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

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

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

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

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

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

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