Toro 07390 Workman HDX-Auto, 07390H Workman HDX-Auto, 07390TC Workman HDX-Auto Operator's Manual

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Page 1

FormNo.3392-863RevB

Workman

HDX-AutoUtility

Vehicle

ModelNo.07390—SerialNo.315000001andUp ModelNo.07390H—SerialNo.315000001andUp ModelNo.07390TC—SerialNo.315000001andUp

Registeratwww.T oro.com. OriginalInstructions(EN)

*3392-863*B

Page 2

ThisproductcomplieswithallrelevantEuropeandirectives. Fordetails,pleaseseetheseparateproductspecic DeclarationofConformity(DOC)sheet.

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Figure1

1.Modelandserialnumberlocation

Important:Theengineinthisproductisnotequipped withasparkarrestedmufer.Itisaviolationof CaliforniaPublicResourcecodeSection4442touse oroperatethisengineonanyforest-covered,brush covered,orgrass-coveredlandasdenedinCPRC4126. Otherstatesorfederalareasmayhavesimilarlaws.

Introduction

Thismachineisautilityvehicleintendedtobeusedby professional,hiredoperatorsincommercialapplications.It isprimarilydesignedforthetransportofimplementsusedin suchapplications.Thisvehicleallowsforthesafetransport ofanoperatorandonepassengerintheidentiedseats.The bedofthisvehicleisnotsuitableforanyriders.

Readthisinformationcarefullytolearnhowtooperateand maintainyourproductproperlyandtoavoidinjuryand productdamage.Youareresponsibleforoperatingthe productproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comforproduct safetyandoperationtrainingmaterials,accessoryinformation, helpndingadealer,ortoregisteryourproduct.

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhassafety messagesidentiedbythesafetyalertsymbol(Figure2), whichsignalsahazardthatmaycauseseriousinjuryordeath ifyoudonotfollowtherecommendedprecautions.

Figure2

1.Safety-alertsymbol

Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanicalinformation andNoteemphasizesgeneralinformationworthyofspecial attention.

Wheneveryouneedservice,genuineT oroparts,oradditional information,contactanAuthorizedServiceDealerorToro CustomerServiceandhavethemodelandserialnumbersof yourproductready.Figure1identiesthelocationofthe modelandserialnumbersontheproduct.Writethenumbers inthespaceprovided.

Contactusatwww.Toro.com.

PrintedintheUSA

AllRightsReserved

Page 3

Contents

Safety...........................................................................4

SafeOperatingPractices...........................................4

Supervisor’sResponsibilities.....................................4

BeforeOperating....................................................4

SafeHandlingofFuels.............................................4

Operation...............................................................5

Maintenance...........................................................6

RolloverProtectionSystem(ROPS)-Useand

Maintenance.......................................................6

Hauling..................................................................6

SoundPressure.......................................................7

Vibration................................................................7

SafetyandInstructionalDecals.................................7

Setup...........................................................................12

1InstallingtheSteeringWheel(TCandHModels

only).................................................................12

2InstallingtheROPS..............................................13

3ConnectingtheBattery(TCandHModels

only).................................................................13

4ConnectingtheCVTIntakeDuct(TCandH

Modelsonly)......................................................14

5CheckingtheFluidLevels.....................................15

ProductOverview.........................................................15

Controls...............................................................15

DashboardSwitches............................................17

InstrumentCluster..............................................17

Specications........................................................19

Attachments/Accessories........................................19

Operation....................................................................19

OperatingtheCargoBox.........................................19

CheckingtheFluidLevels........................................20

CheckingtheOilPressureWarningLight...................24

AddingFuel...........................................................25

CheckingtheTirePressure......................................26

RemovingDebrisfromtheCoolingSystem................26

PreformingPre-startChecks....................................26

StartingtheEngine.................................................27

DrivingtheVehicle.................................................27

StoppingtheVehicle...............................................27

StoppingtheEngine...............................................27

UsingtheSpeed-rangeControl................................27

UsingtheDifferentialLock......................................28

BreakinginaNewMachine......................................28

CheckingtheInterlockSystem.................................29

TransportingtheMachine........................................29

TowingtheMachine...............................................30

TowingaTrailerwiththeMachine.............................30

UsingtheHydraulicControl....................................30

OperatingTips......................................................31

Maintenance.................................................................34

RecommendedMaintenanceSchedule(s)......................34

HeavyDutyOperation............................................35

PremaintenanceProcedures........................................35

UsingtheBedSafetySupport...................................36

RemovingtheFullBed............................................36

InstallingtheFullBed.............................................37

JackingtheMachine................................................37

RemovingandInstallingtheHood............................38

Lubrication...............................................................39

GreasingtheBearingsandtheBushings.....................39

EngineMaintenance..................................................40

ServicingtheAirFilter............................................40

ChangingtheEngineOilandFilter...........................41

ReplacingtheSparkPlug.........................................42

FuelSystemMaintenance...........................................42

ReplacingtheFuelFilter..........................................42

InspectingtheCarbonCanisterAirFilter...................43

InspectingtheFuelLinesandConnections.................43

ElectricalSystemMaintenance....................................43

ServicingtheFuses.................................................43

Jump-StartingtheMachine......................................44

ServicingtheBattery...............................................45

DriveSystemMaintenance.........................................45

MaintainingtheTires,Wheels,and

Suspension........................................................45

MaintainingtheTransmission..................................47

MaintainingtheDifferentialandAxles.......................50

CoolingSystemMaintenance......................................51

ChangingtheEngineCoolant...................................51

BrakeMaintenance....................................................52

AdjustingtheParkingBrake.....................................52

AdjustingtheBrakePedal........................................53

ControlsSystemMaintenance.....................................54

ConvertingtheSpeedometer....................................54

AdjustingtheAcceleratorPedal................................54

HydraulicSystemMaintenance....................................57

ReplacingtheHydraulicFilter..................................57

ChangingtheHydraulicFluid...................................57

RaisingtheBoxinanEmergency..............................58

Storage........................................................................59

Troubleshooting...........................................................61

Page 4

Safety

ThemachinemeetstherequirementsofSAEJ2258.

SafeOperatingPractices

Important:Themachineisdesignedprimarilyasan

off-roadvehicleandisnotintendedforextensiveuse onpublicroads.

Whenusingthemachineonpublicroads,followall trafcregulationsanduseanyadditionalaccessories thatmayberequiredbylaw,suchaslights,turnsignals, slowmovingvehicle(SMV)sign,andothersasrequired.

TheW orkmanwasdesignedandtestedtooffersafeservice whenoperatedandmaintainedproperly.Althoughhazard controlandaccidentpreventionpartiallyaredependent uponthedesignandcongurationofthemachine,these factorsarealsodependentupontheawareness,concern,and propertrainingofthepersonnelinvolvedintheoperation, maintenanceandstorageofthemachine.Improperuseor maintenanceofthemachinecanresultininjuryordeath.

Thisisaspecializedutilityvehicledesignedforoff–roaduse only.Itsrideandhandlingwillhaveadifferentfeelthanwhat driversexperiencewithpassengercarsortrucks.Sotaketime tobecomefamiliarwithyourmachine.

Notalloftheattachmentsthatadapttothemachine arecoveredinthismanual.SeethespecicOperator’s Manualprovidedwitheachattachmentforadditionalsafety instructions.Readthesemanuals.

Toreducethepotentialforinjuryordeath,complywith thefollowingsafetyinstructions:

Supervisor’sResponsibilities

•Makesureoperatorsarethoroughlytrainedandfamiliar

withtheOperator’ sManualandalllabelsonthevehicle.

•Besuretoestablishyourownspecialproceduresand

workrulesforunusualoperatingconditions(e.g.slopes toosteepforthesafeoperationofthemachine).

BeforeOperating

•Operatethemachineonlyafterreadingandunderstanding

thecontentsofthismanual.Areplacementmanualis availablebysendingcompletemodelandserialnumber to:TheToro®Company,8111LyndaleAvenueSouth, Minneapolis,Minnesota55420.

•Thismachineisdesignedtocarryonlyyou,the

operator,andonepassengerintheseatprovidedbythe manufacturer.Nevercarryanyotherpassengersonthe vehicle.

•Becomefamiliarwiththecontrolsandknowhowtostop

theenginequickly.

•Neveroperatethemachinewhenundertheinuence

ofdrugsoralcohol.

•Alwayswearsubstantialshoes.Donotoperatethe

machinewhilewearingsandals,tennisshoes,orsneakers. Donotwearloosettingclothingorjewelrywhichcould getcaughtinmovingpartsandcausepersonalinjury.

•Wearingsafetyglasses,substantialsafetyshoes,long

pants,andahelmetisadvisableandrequiredbysome localsafetyandinsuranceregulations.

•Neverallowchildrentooperatethemachine.Never

allowadultstooperateitwithoutproperinstructions. Onlytrainedandauthorizedpersonsshouldoperate thismachine.Makesurealloperatorsarephysicallyand mentallycapableofoperatingthemachine.

•Keepeveryone,especiallychildrenandpets,awayfrom

theareasofoperation.

•Checkthesafetyinterlocksystemdailyforproper

operation.Ifaswitchshouldmalfunction,replacethe switchbeforeoperatingmachine.

•Keepallshields,safetydevicesanddecalsinplace.Ifa

shield,safetydeviceordecalismalfunctioning,illegible, ordamaged,repairorreplaceitbeforeoperatingthe machine.

•Beforeoperatingthevehicle,alwayscheckallpartsof

thevehicleandanyattachments.Ifsomethingiswrong, stopusingvehicle.Makesuretheproblemiscorrected beforevehicleorattachmentisoperatedagain.

•Useonlyanapprovednonmetal,portablefuelcontainer.

Staticelectricdischargecanignitefuelvaporsinafuel containerthatisnotgrounded.Removethefuelcontainer fromthebedofthemachineandplaceitontheground andawayfromthevehiclebeforelling.Keepthe nozzleincontactwiththecontainerwhilellingthefuel container.Removeequipmentfrombedofthemachine beforefuelingit.

•Operatethemachineonlyoutdoorsorinawellventilated

area.

SafeHandlingofFuels

•Toavoidpersonalinjuryorpropertydamage,use

extremecareinhandlinggasoline.Gasolineisextremely ammableandthevaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andothersources

ofignition.

•Useonlyanapprovedfuelcontainer.

•Neverremovefuelcaporaddfuelwiththeengine

running.

•Allowenginetocoolbeforerefueling.

•Neverrefuelthemachineindoors.

•Neverstorethemachineorfuelcontainerwherethereis

anopename,spark,orpilotlightsuchasonawater heateroronotherappliances.

•Neverllcontainersinsideavehicleoronatruckor

trailerbedwithaplasticliner.Alwaysplacecontainerson thegroundawayfromyourvehiclebeforelling.

Page 5

•Removeequipmentfromthetruckortrailerandrefuelit

ontheground.Ifthisisnotpossible,thenrefuelsuch equipmentwithaportablecontainer,ratherthanfroma fueldispensernozzle.

•Keepthenozzleincontactwiththerimofthefueltank

orcontaineropeningatalltimesuntilfuelingiscomplete. Donotuseanozzlelockopendevice.

•Iffuelisspilledonclothing,changeclothingimmediately.

•Neveroverllfueltank.Replacefuelcapandtighten

securely.

Operation

•Theoperatorandpassengershouldremainseatedand

usetheseatbeltswheneverthevehicleisinmotion.The operatorshouldkeepbothhandsonthesteeringwheel, wheneverpossible,andthepassengershouldusethehand holdsprovided.Keeparmsandlegswithinthevehicle bodyatalltimes.Nevercarrypassengersintheboxor onattachments.Rememberyourpassengermaynotbe expectingyoutobrakeorturnandmaynotbeready.

•Neveroverloadyourvehicle.Thenameplate(located

underthemiddleofthedash)showstheloadlimitsfor thevehicle.Neveroverllattachmentsorexceedthe vehiclemaximumgrossvehicleweight(GVW).

•Whenstartingtheengine:

–Sitonoperator’sseatandensurethattheparking

brakeisengaged.

–DisengagePTO(ifsoequipped)andreturnthehand

throttlelevertotheOffposition(ifsoequipped).

–Makesurethehydraulicliftleverisinthecenter

position.

–Pressinthebrakepedal.

–Keepyourfootoffoftheacceleratorpedal.

–TurntheignitionkeytotheStartposition.

•Usingthemachinedemandsattention.Failuretooperate

machinesafelymayresultinanaccident,tipoverofthe machine,andseriousinjuryordeath.Drivecarefully. Topreventtippingorlossofcontrol,takethefollowing precautions:

–Useextremecaution,reducespeed,andmaintain

asafedistancearoundsandtraps,ditches,creeks, ramps,anyunfamiliarareas,orotherhazards.

–Watchforholesorotherhiddenhazards.

–Usecautionwhenoperatingthevehicleonasteep

slope.Normally,travelstraightupanddownslopes. Reducespeedwhenmakingsharpturnsorwhen turningonhillsides.Avoidturningonhillsides wheneverpossible.

–Useextracautionwhenoperatingthemachineon

wetsurfaces,athigherspeeds,orwithafullload. Stoppingtimewillincreasewithafullload.

–Whenloadingthebed,distributetheloadevenly.

Useextracautioniftheloadexceedsthedimensions

ofthevehicle/bed.Operatethemachinewithextra cautionwhenhandlingoff-centerloadsthatcannot becentered.Keeploadsbalancedandsecureto preventthemfromshifting.

–Avoidsuddenstopsandstarts.Donotgofrom

reversetoforwardorforwardtoreversewithoutrst comingtoacompletestop.

–Donotattemptsharpturnsorabruptmaneuversor

otherunsafedrivingactionsthatmaycausealossof controlofthemachine.

–Donotpassanothermachinetravelinginthesame

directionatintersections,blindspots,oratother dangerouslocations.

–Whendumping,donotletanyonestandbehind

machineanddonotdumptheloadonanyone’sfeet. Releasethetailgatelatchesfromthesideofbox,not frombehind.

–Keepallbystandersaway .Beforebackingup,lookto

therearandensurethatnooneisbehindthevehicle. Backupslowly.

–Watchoutfortrafcwhennearorcrossingroads.

Alwaysyieldtherightofwaytopedestriansand othervehicles.Alwayssignalyourturnsorstopearly enoughsootherpersonsknowwhatyouplantodo. Obeyalltrafcrulesandregulations.

–Neveroperatethemachineinornearanareawhere

thereisdustorfumesintheairwhichareexplosive. Theelectricalandexhaustsystemsofthemachinecan producesparkscapableofignitingexplosivematerials.

–Alwayswatchoutforandavoidlowoverhangssuch

astreelimbs,doorjambs,overheadwalkways,etc. Makesurethereisenoughroomoverheadtoeasily clearthemachineandyourhead.

–Ifyouareeverunsureaboutthesafeoperationofthe

machine,stopyourworkandaskyoursupervisor.

•Beforegettingofftheseat:

–Stopmovementofthemachine.

–Lowerbed.

–Shutengineoffandwaitforallmovementtostop.

–Setparkingbrake.

–Removekeyfromignition.

•Donottouchengine,transmission,radiator,muferor

mufermanifoldwhileengineisrunningorsoonafter ithasstoppedbecausetheseareasmaybehotenough tocauseburns.

•Ifthemachineevervibratesabnormally,stopthemachine

immediately,turnengineoff,waitforallmotionto stopandinspectfordamage.Repairalldamagebefore resumingoperation.

•Lightningcancausesevereinjuryordeath.Iflightning

isseenorthunderisheardinthearea,donotoperate themachine;seekshelter.

Page 6

Maintenance

•Beforeservicingormakingadjustmentstothemachine,

movethemachinetoalevelsurface,stoptheengine,set theparkingbrake,andremovethekeyfromignitionto preventaccidentalstartingoftheengine.

•Neverworkunderaraisedbedwithoutplacingthe

bed-safetysupportontothefullyextendedbed-actuator rod.

•Makesureallhydraulicttingsaretight,andallhydraulic

hosesandlinesareingoodconditionbeforeapplying pressuretothesystem.

inquiriestoTheToro®Company,CommercialDivision, VehicleEngineeringDept.,8111LyndaleAve.So., Bloomington,Minnesota55420–1196USA.

RolloverProtectionSystem (ROPS)-UseandMaintenance

•TheROPSisanintegralandeffectivesafetydevice.Use

theseatbeltwhenoperatingthemachinewithROPS.

•Becertainthattheseatbeltcanbereleasedquicklyin

theeventofanemergency.

•Keepyourbodyandhandsawayfrompinholeleaksor

nozzlesthatejecthydraulicuidunderhighpressure. Usepaperorcardboard,notyourhands,tosearch forleaks.Hydraulicuidescapingunderpressurecan havesufcientforcetopenetrateskinandcauseserious damagetoyourbody.Ifuidisinjectedintotheskin,it mustbesurgicallyremovedwithinafewhoursbyadoctor familiarwiththisformofinjury,organgrenemayresult.

•Beforedisconnectingorperforminganyworkonthe

hydraulicsystem,allpressureinthehydraulicsystem mustberelievedbystoppingtheengineandcyclingthe hydrauliccontrolvalveforthebedliftfromraisetolower and/orloweringboxandattachments.Ifequipped, placetheremote-hydraulicsleverintheoatposition. Iftheboxmustbeinraisedposition,secureitwiththe bed-safetysupport.

•Tomakesuretheentiremachineisingoodcondition,

keepallnuts,bolts,andscrewsproperlytightened.

•Toreducethepotentialrehazard,keeptheenginearea

freeofexcessivegrease,grass,leaves,andaccumulation ofdirt.

•Iftheenginemustberunningtoperformamaintenance

adjustment,keephands,feet,clothing,andanypartsof thebodyawayfromtheengineandanymovingparts. Keepeveryoneaway.

•Checkcarefullyforoverheadclearances(i.e.branches,

doorways,electricalwires)beforedrivingunderany objectsanddonotcontactthem.

•KeeptheROPSinsafeoperatingconditionby

periodicallythoroughlyinspectingfordamageand keepingallmountingfastenerstight.

•ReplaceadamagedROPS.Donotrepairorrevise.

•DonotremovetheROPS.

•AnyalterationstoaROPSmustbeapprovedbythe

manufacturer.

Hauling

•Usecarewhenloadingorunloadingthemachineintoa

trailerortruck.

•Usefullwidthrampsforloadingmachineintotraileror

truck.

•Tiethemachinedownsecurelyusingstraps,chains,cable,

orropes.Bothfrontandrearstrapsshouldbedirected downandoutwardfromthemachine.

•Donotoverspeedtheenginebychangingthegovernor

settings.Themaximumenginespeedis3650rpm.To ensuresafetyandaccuracy,haveanAuthorizedToro Distributorcheckthemaximumenginespeedwitha tachometer.

•Ifmajorrepairsareeverneededorassistanceisrequired,

contactanAuthorizedToroDistributor.

•Tobesureofoptimumperformanceandsafety,always

purchasegenuineTororeplacementpartsandaccessories. Replacementpartsandaccessoriesmadebyother manufacturerscouldbedangerous.Alteringthismachine inanymannermayaffecttheoperation,performance, durabilityofthemachine,oritsusemayresultininjury ordeath.Suchusecouldvoidtheproductwarrantyof TheToro®Company.

•Thismachineshouldnotbemodiedwithout

authorizationfromTheToro®Company.Directany

Page 7

SoundPressure

Thisunithasasoundpressurelevelattheoperator’searof79 dBA,whichincludesanUncertaintyValue(K)of1dBA.

Thesoundpressurelevelwasdeterminedaccordingtothe proceduresoutlinedinENISO11201.

Vibration

Hand-Arm

•Measuredvibrationlevelforrighthand=0.3m/s

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential danger.Replaceanydecalthatisdamagedorlost.

•Measuredvibrationlevelforlefthand=0.4m/s

•UncertaintyValue(K)=0.2m/s

Measuredvaluesweredeterminedaccordingtotheprocedures outlinedinENISO20643.

WholeBody

•Measuredvibrationlevel=0.18m/s

•UncertaintyValue(K)=0.09m/s

Measuredvaluesweredeterminedaccordingtotheprocedures outlinedinEN1032.

106-6755

1.Enginecoolantunder pressure.

2.Explosionhazard—read theOperator'sManual.

1.Warning—donottouchthehotsurface.

1.Storedenergyhazard—readtheOperator'sManual.

3.Warning—donottouchthe hotsurface.

4.Warning—readthe

Operator'sManual.

115-2047

93-9879

115-7740

1.Warning—maximumtrailerweightis680kg(1500lb); maximumtongueweightis90kg(200lb).

2.Warning—trailerbrakesarerequiredwhentowinggreater than680kg(1500lb).Maximumtrailerweightwithtrailer brakesis1591kg(3500lb)maximumtongueweightwith trailerbrakesis273kg(600lb).

115-7756

1.Highowhydraulics—engaged

Page 8

115-7723

93-9899

1.Warning—thehydraulicoilpressureis124bar(1800psi).

2.CouplerA

3.CouplerB

93-9899

1.Crushinghazard—installthecylinderlock.

106-7767

1.Warning—readtheOperator'sManual;avoidtippingthe machine;weartheseatbelt;leanawayfromthedirection themachineistipping.

105-4215

1.Warning—avoidpinchpoints.

93-9850

1.Donotrepairorrevise—readtheOperator'sManual.

106-2353

1.Electricalpowerpoint

Page 9

115-7739

1.Falling,crushinghazard,bystanders—noriderson machine.

93–9868

1.Crushinghazardofhand—readtheOperator’sManual.

BatterySymbols

Someorallofthesesymbolsareonyourbattery .

105–7977

1.Tank2.Pressure

1.Explosionhazard

2.Nore,opename,or smoking.

3.Causticliquid/chemical burnhazard

4.Weareyeprotection9.Flusheyesimmediately

5.ReadtheOperator's

Manual.

6.Keepbystandersasafe distancefromthebattery.

7.Weareyeprotection; explosivegasescan causeblindnessandother injuries

8.Batteryacidcancause blindnessorsevereburns.

withwaterandgetmedical helpfast.

10.Containslead;donot discard.

115-2282

1.Warning—readtheOperator'sManual.

2.Warning—stayawayfrommovingpartsandkeepallguardsandshieldsinplace.

3.Crushing/dismembermenthazardofbystanders—keepbystandersasafedistancefromthevehicle,donotcarrypassengersin thecargobed,keeparmsandlegsinsideofthevehicleatalltimes,anduseseatbeltsandhandholds.

93-9852

1.Warning—readtheOperator’sManual.2.Crushinghazard—installthecylinderlock.

Page 10

127–8626

1.Powertake-off—15A5.Differentiallock—15A

2.Enginestart—10A

3.Hazards—10A7.Headlightsandrear

4.Engineignition—10A8.Horn—30A

6.Speedometer—10A

lights—15A

127–8760

1.Park4.Lowgear

2.Reverse5.Drive

3.Neutral

115-7746

1.Warning—donotoperatethismachineunlessyouaretrained.

2.Warning—locktheparkingbrake,stoptheengine,and removetheignitionkeybeforeleavingthemachine.

3.Firehazard—stoptheenginebeforefueling.

4.Tippinghazard—slowdownandturngradually,usecaution anddriveslowlywhendrivingonslopes,donotexceed32 kph(20mph),anddriveslowlyoverroughterrainorwhen carryingafullorheavyload.

Page 11

127-8620

1.Headlights4.Horn7.Engine—start

2.Differentiallock—lock

3.Differentiallock—unlock

5.Engine—stop8.Brake

6.Engine—run

1.Parkingbrake

2.Unlock—hydraulicsystem

3.Lock—hydraulicsystem6.Transport

121-9890

4.Cylinderretract

5.Cylinderextend8.Slow

7.Fast

Page 12

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Steeringwheel

2 3

Cover Washer(5/8inch) ROPSframe Flange-headbolt(1/2x1-1/4inch)

Nopartsrequired

MediaandAdditionalParts

Description

Operator'sManual

PartsManual1

OperatorTrainingMaterial

CVTKit121-9853

Qty.

1 1 1 1 6

–

Readbeforeoperatingthevehicle.

Usetoreferencepartnumbers.

Viewbeforeoperatingthemachine.

ConnectingtheCVTIntakeDuct(TCandHModelsOnly)

Installthesteeringwheel.

MounttheROPS(RolloverProtection System).

Connectthebattery.

Connectthecontinuouslyvariable transmissionintakeduct.

Checktheengineoil,transaxle/hydraulic uid,coolant,andbrakeuidlevels.

Use

CVTAdapter127-8750

Note:Determinetheleftandrightsideofthemachinefromthenormaloperatingposition.

ConnectingtheCVTIntakeDuct(TCandHModelsOnly)

4.Securethesteeringwheeltotheshaftwiththenutand tightenitto27–34N-m(20-25ft-lb).

5.Installthecoveronthesteeringwheel(Figure3).

InstallingtheSteeringWheel (TCandHModelsonly)

Partsneededforthisprocedure:

Steeringwheel

Cover

Washer(5/8inch)

Procedure

1.Ifthecoverisinstalled,removetheitfromthehubof thesteeringwheel(Figure3).

2.Removethenutfromthesteeringshaft(Figure3).

3.Slidethesteeringwheelandwasherontothesteering shaft(Figure3).

Page 13

Figure3

1.Cover4.Steeringwheel

2.Nut

3.Washer(5/8inch)

5.Steeringshaft

Figure4

1.ROPSmountingbracket

3.SecureeachsideoftheROPSmountingbracketto frameofthemachinewith3ange-headbolt(1/2x 1-1/4inch).

4.Torquetheange-headboltsto115N-m(85ft-lb).

2.Flange-headbolt

InstallingtheROPS

Partsneededforthisprocedure:

ROPSframe

Flange-headbolt(1/2x1-1/4inch)

Procedure

1.Applymedium-grade(service-removable)thread lockingcompoundtothethreadsofthe6ange-head bolts(1/2x1-1/4inch).

2.AligneachsideoftheROPSwiththemountingholes oneachsideofframeofthemachineasshownin

Figure4.

ConnectingtheBattery(TC andHModelsonly)

NoPartsRequired

Procedure

WARNING

Incorrectbatterycableroutingcoulddamagethe machineandcablescausingsparks.Sparkscan causethebatterygassestoexplode,resultingin personalinjury.

•Alwaysdisconnectthenegative(black)battery cablebeforedisconnectingthepositive(red) cable.

•Alwaysconnectthepositive(red)batterycable rst.

1.Squeezethebatterycovertoreleasethetabsfromthe batterybase(Figure5).

Page 14

1.Batterycover

Figure5

ConnectingtheCVTIntake Duct(TCandHModelsonly)

NoPartsRequired

Procedure

Important:Removetheplasticbagcoveringtheendof

theCVTductbeforestartingtheengineofthemachine.

TheCVTkit121-9853andadapterkit127-8750isrequired forthisprocedure.

1.Loosenthehoseclampsecuringtheplasticbagatthe endoftheCVTintakehoseandremovethebag.

2.Removethebatterycoverfromthebatterybase(Figure

5).

3.Installthepositive-batterycable(red)ontothepositive (+)terminalofthebatteryandsecurethecablewith theboltsandnuts(Figure6).

Figure6

1.Insulatorboot (positive-batterycable)

2.Negative-batterypost

3.Negative-batterycable

Note:Discardplasticbag.

2.Raisethecargoboxbyperformingthefollowing:

A.Settheparkingbrake;refertoParkingBrake

(page16).

B.Starttheengine;refertoStartingtheEngine(page

27).

C.Movethehydraulic-liftleverbackwardtoraisethe

cargobox;refertoHydraulicLiftLever(page16).

D.Shutofftheengine;refertoStoppingtheEngine

(page27).

E.Removethebedsupportfromthestoragebrackets

onbackoftheROPSpanelandinstallthesupport ontothecylinderrodofthebedliftcylinder;refer toUsingtheBedSafetySupport(page36).

3.AligntheCVTintakehoseontotheintake-tube connectoratthebacksideoftheROPSpaneland tightenthehoseclamp(Figure7).

4.Slidetheinsulatorbootoverthepositiveterminal.

Note:Theinsulatorbootisusedtopreventapossible short-to-groundfromoccurring.

5.Installthenegative-batterycable(black)ontothe negative(–)terminalofthebatteryandsecurethecable withboltsandnuts.

6.Alignthebatterycovertothebatterybase(Figure5).

7.Squeezethebatterycover,alignthetabstothebattery base,andreleasethebatterycover(Figure5).

1.CVTintakehose

2.Hoseclamp

Figure7

3.Intake-tubeconnector

Page 15

4.Removethebedsupport,lowerthebed,shutoffthe engine,andremovethekeyfromtheignitionswitch.

ProductOverview

Controls

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

CheckingtheFluidLevels

NoPartsRequired

Procedure

1.Checktheengineoillevelbeforeandaftertheengineis rstoperated;refertoCheckingtheEngine-oilLevel

(page21).

2.Checkthetransmission-uidlevelbeforetheengineis rstoperated;refertoCheckingtheTransmission-uid

Level(page47).

3.Checktheengine-coolantlevelbeforetheengineisrst operated;referto(page).

4.Checkthebrakeuidlevelbeforetheengineisrst operated;refertoCheckingtheBrakeFluid(page24).

AcceleratorPedal

Theacceleratorpedal(Figure8)givestheoperatortheability tovarytheengineandgroundspeedofthevehiclewhenthe transmissionisingear.Pressingthepedalincreasestheengine speedandgroundspeed.Releasingthepedaldecreasesthe enginespeedandgroundspeedofthemachine.

Figure8

1.Brakepedal2.Acceleratorpedal

BrakePedal

Usethebrakepedal(Figure8)toapplytheservicebrakes tostoporslowthemachine.

CAUTION

Brakesthatarewornornotcorrectlyadjustedmay resultinpersonalinjury.Ifthebrakepedaltravels towithin3.8cm(1-1/2inches)ofthemachineoor board,adjustorrepairthebrakes.

TransmissionLever

Usethetransmissionlever(Figure9)toshiftthetransmission betweenP(park),R(reverse),N(neutral),L(lowforward), andD(drive)groundoperation.

Important:DonotshiftthetransmissiontotheReverse, Low,orDrivegearunlessthevehicleisstandingstilland theengineisatlowidle.Otherwiseyoumaydamage thetransmission.

Page 16

Figure9

HydraulicLiftLever

Thehydraulicliftraisesandlowersthebed.Movethe hydraulicliftleverrearwardtoraisethebed,andforwardto lowerit(Figure11).

Important:Whenloweringthebed,holdtheleverinthe forwardpositionfor1or2secondsafterthebedcontacts theframetosecureitintheloweredposition.Donot holdthehydraulicliftineithertheraiseorlowerposition formorethan5secondsoncethecylindershavereached theendoftheirtravel.

1.Transmissionlever

2.P(park)5.L(lowforward)

3.R(reverse)6.D(drive)

4.N(neutral)

ParkingBrake

Whenevertheengineisshutoff,settheparkingbrake(Figure

10)topreventaccidentalmovementofthevehicle.

•Tosettheparkingbrake,pullbackontheparking-brake

lever.

•Toreleasetheparkingbrake,pushtheleverforward.

Note:Releasetheparkingbrakebeforemovingthe vehicle.

•Ifyouparkthevehicleonasteepuphillordownhillgrade,

shiftthetransmissionintoP(park)andsettheparking brake.Placechocksatthedownhillsideofthewheels.

Figure11

1.Lowerthebed4.Unlocked

2.Raisethebed

3.Locked

5.Hydraulic-liftlock

6.Hydraulic-liftlever

Hydraulic-liftLock

Thehydraulic-liftlocklockstheliftleversothatthehydraulic cylindersdonotoperatewhenthevehicleisnotequipped withabed(Figure11).ItalsolockstheliftleverintheOn positionwhenusingthehydraulicsforattachments.

Speed-rangeLever

Usethespeed-rangelever(Figure12)toselect1of the4work-speedrangesforprecisecontrolofthe maximum-groundspeedoratransport-speedrangethatisfor movingthemachinebetweenjobsites.

1.Parking-brakelever

Figure10

Page 17

LightSwitch

Pushthelightswitchdowntotoggletheheadlightsonorpush thelightswitchuptotoggletheheadlightsoff(Figure13).

Differential-lockSwitch

Thedifferential-lockswitchallowsyoutolocktherearaxle forincreasedtraction.Pushthedifferential-lockswitch (Figure13)totogglethedifferentiallockonoroff.

Note:Youmaylockandunlockthedifferentialwhilethe vehicleisinmotion.

HornButton(TCmodelsonly)

Pressingthehornbuttonactivatesthehorn(Figure13).

Figure12

1.Speed-rangelever4.C(mid-highrange)

2.T(transportrange)5.B(mid-lowrange)

3.D(highrange)6.A(lowrange)

DashboardSwitches

IgnitionSwitch

Usetheignitionswitch(Figure13)tostartandstopthe engine.Ithas3positions:Off,Run,andStart.Rotatethekey clockwisetotheStartpositiontoengagethestartermotor. Releasethekeywhentheenginestarts.Thekeywillmove automaticallytotheOnposition.Toshuttheengineoff, rotatethekeycounterclockwisetotheOffposition.

PowerPoint

Usethepowerpointsocket(Figure13)topoweroptional 12-voltelectricalaccessories.

InstrumentCluster

Figure13

1.Highowhydraulicsswitch (TCmodelsonly)

2.Lightswitch

3.Differentialswitch8.Start

4.Hornbutton(TCmodels only)

5.Ignitionswitch

HighFlowHydraulicsSwitch(TCmodelsonly)

6.Off

7.On

9.Powerpoint

Pushtheswitchdowntostartthehighowhydraulicsand pushtheswitchuptoshutoffthehydraulics(Figure13).

Note:Youmustsetthehighowhydraulicsswitchtothe Offpositioninordertostarttheengine.

Figure14

1.Tachometer

2.Hourmeter

3.Speedometer

4.Fuelgauge

Tachometer

5.Charge-indicatorlight

6.Check-enginelight

7.Low-oilpressurelight

8.Coolant-temperature gauge

Thetachometerdisplaysthespeedoftheengine(Figure14).

Note:Thewhitetriangleindicatesthedesiredenginespeed for540rpmPTOoperation.

Page 18

Figure15

temperaturelightwillilluminateredandashiftheengine overheats.

FuelGauge

Thefuelgaugeshowstheamountoffuelinthetank.It displaysonlywhenignitionswitchisintheOnposition (Figure14).Theredsegmentofthedisplayindicateslow fuellevelandtheashing-redlightindicatesthatthefuelin thetankisnearempty .

PassengerHandHold

Thepassengerhandholdislocatedonthedashboard(Figure

16).

1.Enginespeed(inrpm)2.3300rpmfor540rpmPTO operation

HourMeter

Thehourmeterindicatesthetotalhoursofmachine operation.Thehourmeter(Figure14)startstofunction wheneverthekeyswitchisrotatedtotheOnpositionorif theengineisrunning.

Speedometer

Thespeedometerregistersthegroundspeedofthevehicle (Figure14).Thespeedometerisinmph,butyoucaneasily convertedthespeedometertokm/h.RefertoConverting

theSpeedometer(page54).

CheckEngineLight

Thecheckenginelight(Figure14)willilluminatetonotify operatorofaenginemalfunction.

ContactyourauthorizedToroservicedealer.

OilPressureWarningLight

Figure16

1.Passengerhandhold

2.Storagecompartment

SeatAdjustingLever

Usetheseatadjustmentlevertoadjusttheseatforwardor backwardforoperatorcomfort(Figure17).

Theoilpressurewarninglightilluminates(Figure14)ifthe engineoilpressuredropsbelowasafelevelwhiletheengine isrunning.

Important:Ifthelightickersorremainson,stopthe vehicle,turnofftheengine,andchecktheoillevel.Ifthe oillevelwaslow,butaddingoildoesnotcausethelight togooutwhentheengineisstarted,turntheengine offimmediatelyandcontactyourAuthorizedService Distributorforassistance.

CoolantT emperatureGaugeandLight

Thecoolanttemperaturegaugedisplaysthecoolant temperatureoftheengine.Thelightoperatesonlywhenthe ignitionswitchisinOnposition(Figure14).Thecoolant

Figure17

1.Seat-adjustinglever

Page 19

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

Dimensions

OverallWidth160cm(63inches)

withoutbed—326cm(128inches);

OverallLength

BaseWeight(Dry)

RatedCapacity

(includes91kg(200

lb)operator,91kg

(200lb)passengerand

loadedattachment)

MaximumGross

VehicleWeight

TowCapacityTongueweight:272kg(600lb);

GroundClearance18cm(7inches)withnoload

WheelBase

WheelTread(center

linetocenterline)

Height

withfullbed—331cm(130inches); with2/3bedinrearmounting location—346cm(136inches)

Model07390—866kg(1905lb); Model07390H—866kg(1905lb); Model07390TC—887kg(1951lb)

Model07390—1498kg(3295lb); Model07390TC—1477kg(3249lb); Model07090H—1498kg(3298lb)

2363kg(5210lb)

Maximumtrailerweight:1587kg (3,500lb)

118cm(70inches)

Front:117cm(46inches);Rear:121 cm(48inches)

191cm(75inches)totopofROPS

Operation

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

CAUTION

Youmaybeinjuredorkillediftheraisedbedofthe machinefallsonyou.

Beforeworkingunderaraisedbed,removeany cargoandpositionthesafetysupportonthefully extendedcylinderrod.

OperatingtheCargoBox

RaisingtheCargoBox

WARNING

Drivingthevehiclewiththecargoboxraisedmay causethevehicletotiporrolleasier.Thebox structuremaybecomedamagedifyouoperatethe vehiclewiththeboxraised.

•Onlyoperatethevehiclewhenthecargoboxis down.

•Afterdumpingaload,lowerthecargobox.

Attachments/Accessories

AselectionofToroapprovedattachmentsandaccessoriesis availableforusewiththemachinetoenhanceandexpand itscapabilities.ContactyourAuthorizedServiceDealeror Distributororgotowww .Toro.comforalistofallapproved attachmentsandaccessories.

CAUTION

Ifaloadisconcentratednearthebackofthecargo boxwhenyoureleasethelatches,thetailgatemay unexpectedlytipopen,injuringyouorbystanders.

•Centertheloadinthecargobox,ifpossible.

•Ensurethatnooneisleaningovertheboxor standingbehinditwhenreleasingthetailgate latches.

•Removeallcargofromtheboxbeforeliftingthe boxuptoservicethemachine.

1.Settheparkingbrake;refertoParkingBrake(page16).

2.Starttheengine;refertoStartingtheEngine(page27).

3.Movetheleverbackwardtoraisethecargoboxtothe desiredposition.(Figure18).

Note:Ifyouaremaintainingthemachineandneedto havetheboxraised,securetheboxwiththebedsafety support;refertoUsingtheBedSafetySupport(page

36).

Page 20

Figure18

1.Cargo-boxlever

LoweringtheBox

WARNING

Theweightoftheboxmaybeheavy.Handsor otherbodypartscouldbecrushed.

Keephandsandotherbodypartsclearwhen loweringthebox.

Figure19

1.Latchhandle3.Latchpin

2.Latchgate

1.Ensurethattheparkingbrakeisset;refertoParking

Brake(page16).

2.Ifthebedsupportisinstalled,removetheit;referto

UsingtheBedSafetySupport(page36).

3.Starttheengine;refertoStartingtheEngine(page27).

4.Movetheleverforwardtolowerthecargobox(Figure

18).

OpeningtheTailgate

1.Ensurethatthecargoboxisdownandlatched.

2.Openthelatchesontheleftandrightsideofthecargo box(Figure19)andlowerthetailgate.

CheckingtheFluidLevels

PreparingtoChecktheFluidLevels

1.Movethemachinetoalevelsurface.

2.ShiftthetransmissiontotheParkposition,shutoff theengine,settheparkingbrake,andremovethekey fromtheignitionswitch.

3.Allowthemachinetocoolbeforeyouchecktheuid levelsofthemachine.

4.Checkthefollowing:

Note:Checkingtheengineoil,hydraulicuidlevel,or coolantlevelrequiresraisingandloweringthecargo boxofthemachine;refertoOperatingtheCargoBox

(page19).

•CheckingtheEngine-oilLevel(page21)

•CheckingtheHydraulicFluid(page22)

•(page)

•CheckingtheBrakeFluid(page24)

Page 21

CheckingtheEngine-oilLevel

G016095

ServiceInterval:Beforeeachuseordaily—Checkthe

engine-oillevel.(Checktheoillevel beforeandaftertheengineisrststarted anddailythereafter.)

3.Removedipstickandchecktheleveloftheoil(Figure

21).

4.Iftheoillevelislow,removethellercap(Figure21) andaddenoughoiltoraisetheleveltotheFullmark onthedipstick.

OilType:ahigh-quality10W-30APIserviceclassication SJorhigher.

RefertothetableinFigure20foroilviscosityaccording ambientairtemperature.

Figure20

Note:Theengineisshippedwithapproximately2.0L(2.1

qt)ofoilinthecrankcase(includingtheoillter).

Note:Thebesttimetochecktheengineoiliswhenthe engineiscoolbeforeithasbeenstartedfortheday.Ifthe enginehasalreadybeenrun,shutitoffandwaitforatleast 10minutesbeforecheckingtheoillevel.

1.Removethedipstick(Figure21)andwipeitwitha cleanrag.

Note:Whenaddingoil,removedipsticktoallow properventing.Slowlypourtheoilintothellerneck, andchecktheleveloftenduringthisprocess.Donot

overlltheenginewithoil.

Figure22

1.Notetheclearancebetweenthelldeviceandtheoilll neck

Important:Whenaddingengineoilorllingoil, theremustbeclearancebetweentheoillldevice andtheoilllneckinthevalvecoverasshownin

Figure22.Thisclearanceisnecessarytopermit

ventingwhenaddingoil.

Figure21

1.Dipsticktube3.Fillercap

2.Fillerneck4.Dipstick

2.Insertthedipstickintothetubeandmakesurethat itisseatedfully.

5.Installthellercapontothellerneck(Figure21).

6.Firmlyinstallthedipstickintothedipsticktube(Figure

21).

Page 22

CheckingtheHydraulicFluid

ServiceInterval:Beforeeachuseordaily(Checkthelevelof

hydraulicuidbeforetheengineisrst startedanddailythereafter.)

HydraulicFluidType:MobilM15

HydraulicFluidCapacity:(Non-TCmodel):7.5l(2US

gallons)

HydraulicFluidCapacity:(Non-TCmodelwiththeHigh FlowHydraulicKit(option)orTCModel):15.1l(4US gallons)

WARNING

Hydraulicuidescapingunderpressurecan penetrateskinandcauseinjury.

•Makesurethatallhydraulicuidhosesand linesareingoodconditionandallhydraulic connectionsandttingsaretightbefore applyingpressuretothehydraulicsystem.

•Keepyourbodyandhandsawayfrompinhole leaksornozzlesthatejecthighpressure hydraulicuid.

Figure23

HydraulicFluidLevel(Non-TCmodels)

1.Cap

2.Dipstick3.Fillerneck

•Usecardboardorpapertondhydraulicleaks.

•Safelyrelieveallpressureinthehydraulicsystem beforeperforminganyworkonthehydraulic system.

•Seekimmediatemedicalattentionifuidis injectedintoyourskin.

1.Cleantheareaaroundthellerneckandthecapofthe hydraulicreservoir(Figure23andFigure24).

Figure24

HydraulicFluidLevel(Non-TCmodelwiththeHighFlow

HydraulicKit(option)orTCmodel)

1.Cap

2.Dipstick3.Fillerneck

Page 23

2.Removethecapanddipstickfromthellerneckofthe

G019522

reservoirandwipethedipstickcleanwitharag(Figure

23andFigure24).

3.Insertthedipstickintothellerneck;thenremoveit andchecktheuidlevel(Figure23andFigure24).

•Non-TCmodel:theuidlevelshouldbebetween

thelowerindentedareaonthedipstick.

•Non-TCmodelwiththeHighFlowHydraulic

Kit(option)orTCmodel:theuidlevelshould bebetweentheupperindentedareaonthedipstick.

4.Ifthelevelislow ,addthespeciedhydraulicuidinto thereservoirtoraisetheleveltothemiddleofthe indentedareaonthedipstick(Figure23andFigure24).

5.Installthedipstickandcaptothellerneckofthe reservoir(Figure23andFigure24).

CheckingtheCoolantLevel

ServiceInterval:BeforeeachuseordailyChecktheCoolant

levelattheoverowreservoironly.Do Notremovetheradiatorcap.(Checkthe coolantlevelbeforetheengineisrst startedanddailythereafter.)

Figure25

1.Coolantreservetank

Coolanttype:a50/50solutionofwaterandpermanent ethyleneglycolantifreeze

1.Parkthemachineonalevelsurface.

CAUTION

Iftheenginehasbeenrunning,the pressurized,hotcoolantcanescapeandcause burns.

•Donotopentheradiatorcap.

•Allowtheenginetocoolatleast15minutes oruntiltheradiatorcapiscoolenoughto touchwithoutburningyourhand.

•Usearagwhenopeningthereservetank cap,andopenthecapslowlytoallow steamtoescape.

•Donotcheckthecoolantlevelatthe radiator;checkthecoolantlevelonlyatthe reservetank.

2.Checkthecoolantlevelatthereservetank(Figure25).

3.Ifcoolantislow ,removethereservetankcapandadda 50/50mixtureofwaterandpermanentethylene-glycol antifreeze.

Note:Donotoverll.

4.Installthereserve-tankcap.

Note:Thecoolantshouldbeuptothebottomof thellerneck.

Page 24

CheckingtheBrakeFluid

ServiceInterval:Beforeeachuseordaily—Checkthebrake

uidlevel.(Checkthelevelbeforethe engineisrststartedanddailythereafter.)

Every1,000hours/Every2years(whichevercomes rst)—Changethebrakeuid.

Brakeuidtype:DOT3brakeuid

Note:Thebrake-uidreservoirisshippedfromthefactory lledwithDOT3brakeuid.

Thebrake-uidreservoirislocatedunderthehoodandbelow thedash.

1.Parkthemachineonalevelsurface.

2.Removethehood;refertoRemovingtheHood(page

38).

3.Checktheuidlevelinthebrake-uidreservoir(Figure

26andFigure27).

Note:TheuidlevelshouldbeuptotheFullline onthereservoir.

Figure27

1.Brake-uidreservoir

4.Iftheuidlevelislow,performthefollowing:

A.Cleantheareaaroundthecapforthereservoir

(Figure27).

B.Removethereservoircap(Figure27).

C.AddthespeciedbrakeuidtotheFulllineon

thereservoir(Figure27).

Note:Donotoverllthebrake-uidreservoir.

D.Installthecap(Figure27).

5.Installthehood;refertoRemovingtheHood(page38).

CheckingtheOilPressure WarningLight

ServiceInterval:Beforeeachuseordaily

Note:Ifyoujuststoppedtheengine,itmaytake1to2 minutesforthelighttocomeon.

1.Brake-uidreservoir

1.Applytheparkingbrake.

2.TurntheignitionkeytotheOnposition,butdonot starttheengine.

Note:Theoilpressurelightshouldglowred.

Figure26

Note:Ifthelightdoesnotfunction,eitherabulb

isburnedoutorthereisamalfunctioninthesystem whichmustberepaired.

Page 25

AddingFuel

DANGER

Fueltankcapacity:25L(6.5USgallons).

•Forbestresults,useonlyclean,fresh(lessthan30days

old),unleadedgasolinewithanoctaneratingof87or higher((R+M)/2ratingmethod).

•ETHANOL:Gasolinewithupto10%ethanol(gasohol)

or15%MTBE(methyltertiarybutylether)byvolume isacceptable.EthanolandMTBEarenotthesame. Gasolinewith15%ethanol(E15)byvolumeisnot approvedforuse.Neverusegasolinethatcontainsmore than10%ethanolbyvolume,suchasE15(contains15% ethanol),E20(contains20%ethanol),orE85(contains upto85%ethanol).Usingunapprovedgasolinemay causeperformanceproblemsand/orenginedamage whichmaynotbecoveredunderwarranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuelcontainers

overthewinterunlessafuelstabilizerisused.

•Donotaddoiltogasoline.

DANGER

Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

•Beforeremovingthefueltankcap,makesure thatthevehicleispositionedonalevelsurface. Openthefueltankcapslowly.

Incertainconditionsduringfueling,static electricitycanbereleased,causingaspark,which canignitethegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

•Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.

•Donotllgasolinecontainersinsideavehicleor onatruckortrailerbed,becauseinteriorcarpets orplastictruckbedlinersmayinsulatethe containerandslowthelossofanystaticcharge.

•Whenpractical,removegas-poweredequipment fromthetruckortrailerandrefueltheequipment withitswheelsontheground.

•Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.

•Ifyoumustuseagasolinedispensernozzle,, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.

1.Cleantheareaaroundthefuel-tankcap(Figure28).

2.Removethefuel-tankcap(Figure28).

•Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanygasoline thatspills.

•Neverllthefueltankinsideanenclosedtrailer.

•Donotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthelevelis25mm (1inch)belowthebottomofthellerneck.This emptyspaceinthetankallowsthegasolineto expand.

•Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.

•Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.

•Donotoperatethemachinewithouttheentire exhaustsysteminplaceandinproperworking condition.

Figure28

1.Fuel-tankcap

3.Fillthetanktoabout1inchbelowthetopofthetank, (bottomofthellerneck),theninstallthecap.

Note:Donotoverllthefueltankwithfuel.

4.Wipeupanyfuelthatmayhavespilledtopreventa rehazard.

Page 26

CheckingtheTirePressure

ServiceInterval:Beforeeachuseordaily

Themaximumairpressureinthefronttiresis220kPa(32 psi)andthereartiresis124kPa(18psi).

Checkthetirepressurefrequentlytoensureproperination. Ifthetiresarenotinatedtothecorrectpressure,thetread willwearprematurely.

Figure29showsanexampleoftirewearcausedbyunder

ination.

Figure29

1.Under-inatedtire

Figure30showsanexampleoftirewearcausedbyover

ination.

Figure31

1.Radiatorscreen

2.Latch

4.Ifsoequipped,rotatethelatchesandpivottheoil coolerawayfromtheradiator(Figure32).

Figure32

1.Radiatorhousing3.Latches

2.Oilcooler

Figure30

1.Over-inatedtire

RemovingDebrisfromthe CoolingSystem

ServiceInterval:Beforeeachuseordaily(Cleanitmore

frequentlyindirtyconditions.)

1.Shutofftheengine.

2.Cleantheengineareathoroughlyofalldebris.

3.Unlatchandremovetheradiatorscreenfromthefront oftheradiator(Figure31).

5.Cleantheradiator,oilcooler,andscreenthoroughly withcompressedair.

Note:Blowdebrisawayfromtheradiator.

6.Installthecoolerandscreentotheradiator.

PreformingPre-startChecks

Safeoperationbeginsbeforetakingthevehicleoutforaday’ s work.Y oushouldchecktheseitemseachtime:

•Checkthetirepressure.

Note:Thesetiresaredifferentthancartires,theyrequire lesspressuretominimizeturfcompactionanddamage.

•Checkalluidlevelsandaddtheappropriateamountof

Torospecieduids,ifanyarefoundtobelow.

•Checkthefrontoftheradiator.Removeanydebrisand

cleantheradiatorscreen.

•Checkthebrakepedaloperation.

•Checktheoilpressurewarninglight.

•Checktoseethatthelightsareworking.

Page 27

•Turnthesteeringwheeltotheleftandrighttocheckthe

steeringresponse.

•Stoptheengineandwaitformovingpartstostop,then

checkforoilleaks,looseparts,andanyothernoticeable malfunctions.

GearSpeed(kmh)Speed(mph)

R(reverse)

L(lowforward)

D(Drive)

0to210to13

0to180to11

0to320to20

Ifanyoftheaboveitemsarenotcorrect,notifyyourmechanic orcheckwithyoursupervisorbeforetakingthevehicleout fortheday.Yoursupervisormaywantyoutocheckother itemsonadailybasis,soaskwhatyourresponsibilitiesare.

StartingtheEngine

Important:Donotattempttopushortowvehicletoget

itstarted.Damagetothedrivetraincouldresult.

Note:Referto(page).

1.Sitontheoperatorseatandengagetheparkingbrake.

2.DisengagethePTOandhighowhydraulics(ifso equipped)andmovethehandthrottlelevertotheOff position(ifsoequipped).

3.MovethetransmissionlevertotheP(park)position.

4.Ensurethatthehydraulic-liftleverisintheOffposition (center).

5.Pressthebrakepedal.

Note:Keepyourfootofftheacceleratorpedal.

6.Insertkeyintoignitionswitchandrotateitclockwise tostarttheengine.

Note:Avoidlongperiodsofengineidling.

Note:LeavingignitionswitchintheOnpositionfor

longperiodsoftimewithoutrunningtheenginewill dischargethebattery.

StoppingtheVehicle

Note:Referto(page).

Tostopthevehicle,removeyourfootfromtheaccelerator pedal,thenpressthebrakepedal.

StoppingtheEngine

Note:Referto(page).

1.Ensurethatthemachineisstopped.

2.MovethetransmissionlevertotheP(Park)position.

3.Settheparkingbrake.

4.RotatetheignitionkeytotheOffpositionandremove thekeyfromtheswitch.

Note:Releasekeywhenenginestarts.

Note:Theengineoilpressurewarninglightshould

turnoff.

Important:Topreventoverheatingofthestarter motor,donotengagestarterlongerthan15 seconds.After15secondsofcontinuouscranking, wait60secondsbeforeengagingstartermotor again.

DrivingtheVehicle

Note:Referto(page).

1.Pressthebrakepedal.

2.Releasetheparkingbrake.

3.Movethetransmissionlevertothedesiredgear.

4.Releasetheservicebrakeandgraduallypressinthe acceleratorpedal.

Important:Alwaysstopthevehiclebeforeshifting toreverseaforwardgearortoaforwardgearfrom reverse.

Usethechartbelowtodeterminethegroundspeed ofeachgearwhenoperatingthemachinewiththe speed-rangecontrolintheT(transport)position.

UsingtheSpeed-rangeControl

Usetheleverofthespeed-rangecontroltolimitthe maximumgroundspeedofthemachineforoperationsthat requireaconstantspeedlikesprayingandtopdressing.The speed-rangelever(Figure33)isusedtoselect1ofthe4 work-speedrangesthatareusedtolimitmaximumground speedoratransport-speedrangethatisusedwhenyoumove themachinebetweenjobsites.

Note:Youmustreleasetheacceleratorpedalinorderto shiftbetweenspeedranges,butyoudonotneedtostopthe machineinordertoshift.

•Movethespeed-rangeleverintothedetentfor

speedrangesA,B,C,andDwhenprecisecontrolof maximum-groundspeedisdesired.

•Movethespeed-rangelevertotransportpositionby

movingthespeed-rangeleveroutofthedetentforrange A,B ,C,orD,thenforwardtotheTposition.

Note:Usethespeed-rangecontroltolimitthe maximum-groundspeedineachrangeby4to18kmh(2.5to 11mph)withthetransmissionleverintheLlow(forward) positionor8to32kmh(5to20mph)withthetransmission leverintheintheDdriveposition.

Page 28

Figure33

1.Speed-rangelever4.C(mid-highrange)

2.T(transportrange)5.B(mid-lowrange)

3.D(highrange)6.A(lowrange)

Thedifferentiallockcausestherearwheelstospinatthe samespeed.Whenusingdifferentiallockyourabilitytomake sharpturnsissomewhatrestrictedandmayscufftheturf.Use thedifferentiallockonlywhenneededandatslowerspeeds.

Note:Vehiclemotionplusaslightturnisrequiredtoengage ordisengagedifferentiallock.

•Pressthedifferential-lockswitchuptolockthedifferential

(Figure34).

Note:Thelightinthedifferential-lockswitchwill illuminatewhentheswitchisinthelockposition.

•Pressthedifferential-lockswitchuptounlockthe

differential(Figure34).

UsingtheDifferentialLock

WARNING

Tippingorrollingthevehicleonahillcancausea seriousinjury.

•Theextratractionavailablewiththedifferential lockcanbeenoughtogetyouintodangerous situationssuchasclimbingslopesthataretoo steeptoturnaround.Beextracarefulwhen operatingwiththedifferentiallockon,especially onsteeperslopes.

•Ifthedifferentiallockisonwhenmakinga sharpturnatahigherspeedandtheinsiderear wheelliftsofftheground,theremaybealossof controlwhichcouldcausevehicletoskid.Use thedifferentiallockonlyatslowerspeeds.

CAUTION

Turningwiththedifferentiallockoncanresult inlossofvehiclecontrol.Donotoperatewith differentiallockonwhenmakingsharpturnsorat highspeeds.

Thedifferentiallockincreasesthetractionofthevehicleby lockingtherearwheelssothat1wheelwillnotspinout. Thiscanhelpwhenyouhaveheavyloadstohaulonwet turforslipperyareas,goinguphills,andonsandysurfaces. Itisimportanttorememberthatthisextratractionisonly fortemporarylimiteduse.Itsusedoesnotreplacethesafe operationalreadydiscussedconcerningsteephillsandheavy loads.

Figure34

1.Lockposition (differential-lockswitch)

2.Unlockposition (differential-lockswitch)

BreakinginaNewMachine

ServiceInterval:Aftertherst100hours

•Checktheuidandengineoillevelsregularlyandbealert

forindicationsofoverheatinginanycomponentofthe vehicle.

•Afterstartingacoldengine,letitwarmupforabout15

secondsbeforeshiftingintogear.

Note:Allowmoretimetowarm-uptheenginewhen operatingincoldambienttemperatures.

•Avoidracingtheengine.

•Toensureoptimumperformanceofthebrakesystem,

burnish(break–in)thebrakesbeforeuse.Toburnishthe brakes,bringthevehicleuptofullspeed,applythebrakes torapidlystopthevehiclewithoutlockingupthetires. Repeatthis10times,waiting1minutebetweenstopsto avoidoverheatingthebrakes.Thisismosteffectiveifthe vehicleisloadedwith454kg(1000lb).

•Varyvehiclespeedsduringoperation.Avoidexcessive

idling.Avoidfaststartsandquickstops.

•Abreak–inoilfortheengineisnotrequired.The

originalengineoilisthesametypespeciedforregular oilchanges.

•RefertoHeavyDutyOperation(page35)foranyspecial

low-hourchecks.

Page 29

CheckingtheInterlockSystem

ServiceInterval:Beforeeachuseordaily

Thepurposeoftheinterlocksystemistopreventtheengine fromcrankingorstartingunlessthebrakepedalispressed andthehydraulicliftleverintheNeutralposition.

1.Sitontheoperator’sseatandengagetheparkingbrake.

2.MovetheshiftlevertotheNeutralpositionandensure thatthehydraulicliftleverisinthecenterposition.

3.SetthehighowhydraulicswitchtotheOnposition.

4.Pressbrakepedal.

CAUTION

Ifsafetyinterlockswitchesaredisconnectedor damaged,themachinecouldoperateunexpectedly causingpersonalinjury.

•Donottamperwiththeinterlockswitches.

•Checktheoperationoftheinterlockswitches dailyandreplaceanydamagedswitchesbefore operatingthemachine.

Note:RefertoAttachmentOperator’sManualforprocedures oncheckingtheattachmentinterlocksystem.

VerifyingtheHydraulicLiftLever InterlockSwitch

1.Sitontheoperator’ sseatandsettheparkingbrake.

2.MovetheshiftlevertotheNeutralposition,ensure thatthehydraulicliftleverisinthecenterposition.

3.IfNon-TCmodelwiththeHighFlowHydraulicKit (option)orTCmodel,setthehighowhydraulic switchtotheOffposition.

4.Pressbrakepedal.

5.Movethehydraulicliftleverforwardandrotatethe ignitionkeyclockwisetothestartposition.

5.Rotatetheignitionkeyclockwisetothestartposition.

Ifenginecranksorstarts,thereisamalfunctioninthe interlocksystemthatmustberepairedbeforeoperating vehicle.

TransportingtheMachine

Formovingthemachinelongdistances,useatrailer.Make surethatthemachineissecuredtothetrailer.RefertoFigure

35andFigure36forthelocationofthetie-downpoints.

Important:Trailersweighingover680kg(1500lb)are requiredtobeequippedwithtrailerbrakes.

Note:Loadthemachineonthetrailerwiththefrontofthe machinefacingforward.Ifthatisnotpossible,securethe hoodofthemachinetotheframewithastraporremovethe hoodandtransportandsecureitseparately,otherwisethe hoodmayblowoffduringtransport.

Ifenginecranksorstarts,thereisamalfunctioninthe interlocksystemthatmustberepairedbeforeoperating vehicle.

VerifyingtheBrakePedalInterlock Switch

1.Sitontheoperator’ sseatandsettheparkingbrake.

2.MovetheshiftlevertotheNeutralposition,ensure thatthehydraulicliftleverisinthecenterposition.

3.IfNon-TCmodelwiththeHighFlowHydraulicKit (option)orTCmodel,setthehighowhydraulic switchtotheOffposition.

4.Rotatetheignitionkeyclockwisetothestartposition.

Note:Donotpressthebrakepedal

Ifenginecranksorstarts,thereisamalfunctioninthe interlocksystemthatmustberepairedbeforeoperating vehicle.

VerifyingtheHighFlowSwitchInterlock

Non-TCmodelwiththeHighFlowHydraulicKit(option) orTCmodel

Figure35

1.Eyeholeinframe(eachside)

Figure36

1.Axle2.Hitchplate

Page 30

TowingtheMachine

Incaseofanemergency ,themachinecanbetowedfora shortdistance.However,Torodoesnotrecommendthisas astandardprocedure.

Important:Ifmultiplevehiclesusethesame attachment,crosscontaminationofthehydraulicuid mayoccur.Changethehydraulicuidmorefrequently.

HydraulicControlPositions

WARNING

Towingatexcessivespeedscouldcausemachine tolosesteeringcontrol.Nevertowmachinefaster than8kph(5mph).

Towingthemachineisa2-personjob.Afxatowlineto holesinthefrontframemember.MovetheshiftertoNeutral andreleasetheparkingbrake.Ifthemachinemustbemoved aconsiderabledistance,transportitonatruckortrailer.

Note:Thepowersteeringwillnotfunction,makingit difculttosteer.

TowingaTrailerwiththe Machine

Thismachineiscapableofpullingtrailersandattachmentsof greaterweightthanthemachineitself.

Severaltypesoftowhitchesareavailableforthismachine, dependingonyourapplication.ContactyourAuthorized Distributorfordetails.

•OffPosition

Thisisthenormalpositionforthecontrolvalvewhenit isnotbeingused.Inthispositiontheworkportsofthe controlvalveareblockedandanyloadwillbeheldbythe checkvalvesinbothdirections.

•Raise(QuickCouplerAposition)

Thishydraulicliftleverpositionliftsthebedcylindersora rearhitchattachmentbyapplyingRaisehydraulicpressure throughquickcouplerA.Thisalsoallowsthereturnoilto owthroughquickcouplerB,backthroughthecontrol valve,andthenintothereservoir.Thisisamomentary position;whenthehydraulicliftleverisreleased,aspring returnsthelevertotheCenterOffposition.

Whenequippedwithatowhitchboltedontotherearaxle, yourmachinecantowtrailersorattachmentswithagross trailerweight(GTW)upto1587kg(3500lb).Alwaysloada trailerwith60%ofthecargoweightinthefrontofthetrailer. Thisplacesapproximately10%(272kg(600lb)max.)ofthe grosstrailerweight(GTW)onthetowhitchofthemachine.

Trailerbrakesarerequiredwheneveryoutowatrailerover 680kg(1500lb)GTWistowedbehindthismachine.

Whenhaulingcargoortowingatrailer(attachment),donot overloadyourmachineortrailer.Overloadingcancausepoor performanceordamagetothebrakes,axle,engine,transaxle, steering,suspension,bodystructure,ortires.

Important:Toreducepotentialfordrivelinedamage, uselowrange.

Whentowing5thwheelattachments,likeafairwayaerator, alwaysinstallthewheelybar(includedwiththefthwheelkit) topreventthefrontwheelsfromliftingoffthegroundifthe towedattachmentsmovementissuddenlyimpaired.

UsingtheHydraulicControl

Thehydrauliccontrolsupplieshydraulicpowerfromthe machinepumpwhenevertheengineisrunning.Usethe quickcouplersattherearofthemachinetoprovidehydraulic powerforrearhitchattachments.

Figure37

1.QuickcouplerAposition2.QuickcouplerBposition

•Lower(QuickCouplerBposition)

Thispositionlowersthebedorarearhitchattachmentby applyingLowerhydraulicpressurethroughquickcoupler B.Thisalsoallowsthereturnoiltoowthroughquick couplerA,backthroughthecontrolvalve,andtheninto thereservoir.Thisisamomentaryposition;whenthe hydraulicliftleverisreleased,aspringreturnsthecontrol levertotheCenterOffposition.Momentarilyholding andthenreleasingthehydraulicliftleverinthisposition willprovideowtothequickcouplerB,whichprovides Lowerhydraulicpressuretothebedcylindersorarear hitchattachment.Whenthehydraulicliftleverisreleased, theLowerhydraulicpressuretothebedcylindersora rearhitchattachmentishydraulicallylocked.

Important:Ifusedwithahydrauliccylinder, holdingthehydraulicliftleverintheLowerposition

Page 31

causestheoilowtogooverareliefvalve,whichcan damagethehydraulicsystem.

•Onposition

ThispositionissimilartoLower(quickcouplerB position).Italsodirectshydraulicoiltoquickcoupler Bexceptthattheleverisheldinthispositionbythe hydraulic-liftlockinthecontrolpanel.Thisallowsoil toowcontinuouslytoequipmentthatusesahydraulic motor.Usethispositiononlywhenyouareoperatingthe machinewithanattachmentwithahydraulicmotor.

Important:Ifyouareusingthemachinewitha hydrauliccylinderornoattachment,theOnposition causestheoilowtogooverareliefvalve,whichcan damagethehydraulicsystem.Usethispositiononly momentarilyorwithamotorattached.

Important:Checkthehydraulicoillevelafter installinganattachment.Checktheoperationof theattachmentbycyclingitseveraltimestopurge airfromsystem,thencheckthehydraulicoillevel. Theattachmentcylinderwillslightlyaffecttransaxle oillevel.Operatingthemachinewithlowoillevel candamagethepump,remotehydraulics,power steering,andthemachinetransaxle.

CAUTION

Hydraulicuidescapingunderpressurecan havesufcientforcetopenetrateskinanddo seriousdamage.Caremustbeusedwhen connectingordisconnectinghydraulicquick couplers.Stoptheengine,applytheparking brake,lowertheattachment,andplacethe remotehydraulicvalveintheoatdetent positiontorelievehydraulicpressurebefore connectingordisconnectingquickcouplers.

2.Pullthehosermlyfromthecoupler.

Important:Cleanandinstallthedustplugand dustcoverstothequickcouplerendswhennot inuse.

OperatingTips

OperatingCharacteristics

Themachineisdesignedwithsafetyinmind.Itusesfamiliar automotivestylecontrols,includingthesteeringwheel,brake pedal,andacceleratorpedal,.Itisimportanttoremember, however,thatthismachineisnotapassengercar.Itisawork vehicleandisdesignedforoffroaduseonly.

WARNING

Themachineisdesignedprimarilyasanoff-road vehicleandisnotintendedforextensiveuseon publicroads.

Occasionaluseonpublicroadwaysshouldonlybe undertakenwithrespecttolocaltrafcregulations andusinganyadditionalaccessoriesthatmaybe requiredbylocallaw(includingbutnotlimitedto lights,turnsignals,slowmovingvehicle(SMV) sign,etc).

Themachinehasspecialtires,lowgearratios,alocking differential,andotherfeaturesthatgiveitextratraction. Thesefeaturesaddtotheversatilityofthevehiclebut,they canalsogetyouintodangeroussituations.Youmustkeepin mindthatthevehicleisnotarecreationvehicle,itisnotanall terrainvehicle,and,itisdenitelynotmeantforstuntdriving orhorsingaround.Itisaworkvehicle,notaplayvehicle. Childrenshouldnotbeallowedtooperatethemachine. Anyonewhooperatesthemachinemustbeproperlytrained.

ConnectingtheQuickCouplers

Important:Cleandirtfromquickcouplersbefore

connecting.Dirtycouplerscanintroducecontamination intothehydraulicsystem.

1.Pullbackthelockingringonthecoupler.

2.Insertthehosenippleintothecoupleruntilitsnaps intoposition.

Note:Whenattachingremoteequipmenttothequick couplers,determinewhichsiderequirespressure,thenattach thathosetoquickcouplerBwhichwillhavepressurewhen thecontrolleverispushedforwardorlockedintheOn position.

DisconnectingtheQuickCouplers

Note:Withboththemachineandattachmentturnedoff,

movetheliftleverbackandforthtoremovethesystem pressureandtomakedisconnectingthequickcouplerseasier.

1.Pullbackthelockingringonthecoupler.

Thedriverandpassengershouldalwaysusetheseatbelts.

Ifyouarenotexperiencedatdrivingthemachine,practice drivingitinasafeareaawayfromotherpeople.Besure youarefamiliarwithallthemachine’scontrols,particularly thoseusedforbraking,steering,andtransmissionshifting. Learnhowyourmachinehandlesondifferentsurfaces. Youroperatingskillswillimprovewithexperience,butasin operatinganyvehicle,takeiteasyasyoubegin.Besureyou knowhowtostopquicklyinanemergency.Ifyouneedhelp, askyoursupervisorforassistance.

Manyfactorscontributetoaccidents.Youhavecontrolover severalofthemostimportant.Youractions,suchasdriving toofastforconditions,brakingtoofast,turningtoosharp, andcombinationsofthese,arefrequentcauseofaccidents.

Oneofthemajorcausesofaccidentsisfatigue.Besureto takeoccasionalbreaks.Itisveryimportantthatyoustay alertatalltimes.

Neveroperatethemachine,oranyequipment,ifyou areundertheinuenceofalcoholorotherdrugs.Even

Page 32

prescriptiondrugsandcoldmedicinescancausedrowsiness. Readthelabelonthemedicineorcheckwithyourdoctoror pharmacistifyouareunsureaboutacertainmedication.

Oneofthemostimportantrulestofollowistogoslowerin unfamiliarareas.Itissurprisinghowmuchdamageandinjury commonthingscancause.Treebranches,fences,wires,other vehicles,treestumps,ditches,sandtraps,streams,andother thingsfoundinmostparksandgolfcoursescanbehazardous totheoperatorandpassenger.

Avoiddrivingwhenitisdark,especiallyinunfamiliarareas.If youmustdrivewhenitisdark,besuretodrivecautiously,use theheadlights,andevenconsideraddingadditionallights.

CarryingPassengers

Wheneveryouhaveapassengerridinginthemachinemake sureheorsheiswearingtheseatbeltandholdingonsecurely . Driveslowerandturnlesssharplybecauseyourpassenger doesnotknowwhatyouaregoingtodonextandmaynotbe preparedforturning,stopping,accelerating,andbumps.

Youandyourpassengershouldremainseatedatalltimes, keepingarmsandlegsinsidethemachine.Theoperator shouldkeepbothhandsonsteeringwheel,wheneverpossible, andthepassengershouldusethehandholdsprovided(Figure

38andFigure39).

Figure39

1.Handholdandhiprestraint

Neverallowpassengersinthedumpboxoronany attachments.Themachineismeanttohave1driverandonly 1passenger—nomore.

ControllingtheSpeedoftheVehicle

Speedisoneofthemostimportantvariablesleadingto accidents.Drivingtoofastfortheconditionscancauseyou tolosecontrolandhaveanaccident.Speedcanalsomakea minoraccidentworse.Drivinghead-onintoatreeatslow speedcancauseinjuryanddamage,but,drivingintoatreeat highspeedcandestroythemachineandkillyouandyour passenger.

Neverdrivetoofastfortheconditions.Ifthereisanydoubt abouthowfasttodrive,slowdown.

Whenusingheavyattachments,morethan454kg(1000lb), suchassprayers,topdressers,orspreaders,etc.,restrictyour operatingspeedbyselectinglowrange.

1.Passengerhandhold

Figure38

EnsuringProperTurning

Turningisanotherimportantvariableleadingtoaccidents. Turningtoosharplyfortheconditionscancausethemachine tolosetractionandskid,oreventipover.

Wet,sandy,andslipperysurfacesmaketurningmoredifcult

2.Storagecompartment

andrisky .Thefasteryouaregoing,theworsethissituation becomesso,slowdownbeforeturning.

Duringasharpturnathigherspeeds,theinsiderearwheel mayliftofftheground.Thisisnotaawinthedesign,it happenswithmostfourwheelmachinesincludingpassenger cars.Ifthishappens,youareturningtoosharplyforthespeed atwhichyouaretraveling.Slowdown!

EnsuringProperBraking

Itisgoodpracticetoslowdownbeforeyougetnearan obstacle.Thisgivesyouextratimetostoporturnaway. Hittinganobstaclecandamagethemachineanditscontents.

Page 33

Moreimportant,itcaninjureyouandyourpassenger.Gross machineweighthasamajorimpactonyourabilitytostopor turn.Heavierloadsandheavierattachmentsmakeamachine hardertostoporturn.Theheaviertheload,thelongerit takestostop.

Thebrakingcharacteristicsalsochangewithnobedor attachmentonthemachine.Faststopsmaycausetherear wheelstolockupbeforethefrontwheelslockup,whichmay affectthecontrolofthemachine.Itisagoodideatodecrease machinespeedwithnobedorattachment.

Turfandpavementaremuchslipperierwhentheyarewet. Itcantake2to4timesaslongtostoponwetsurfacesas ondrysurfaces.

OperatingtheMachineonHills

WARNING

Tippingorrollingthemachineonahillwillcause seriouspersonalinjury.

•Donotoperatethemachineonsteepslopes.

•Ifenginestallsoryouloseheadwayonahill, neverattempttoturnmachinearound.

•AlwaysbackstraightdownahillinReverse.

•NeverbackdowninNeutralusingonlythe brakes.

Ifyoudrivethroughstandingwaterdeepenoughtogetthe brakeswet,theywillnotworkwelluntiltheyaredry.After drivingthroughwater,youshouldtestthebrakestomake surethattheyworkproperly.Iftheydonot,driveslowly whileputtinglightpressureonthebrakepedal.Thiswilldry outthebrakes.

PreventingTipOvers

Themachineisequippedwitharollbar,hiprestraints,seat belts,andhandhold.TheROPSsystem(RolloverProtection System)usedonthemachinewillreducetheriskofserious orfatalinjuryintheunlikelyeventofatipover,althoughthe systemcannotprotecttheoperatorfromallpossibleinjuries.

ReplaceadamagedROPS,donotrepairit.Anyalterationof theROPSmustbeapprovedbythemanufacturer.

Thebestwaytopreventaccidentsinvolvingutilitymachines isthroughcontinuoussupervisionandtrainingofoperators andpayingconstantattentiontotheareainwhichmachine isbeingoperated.

Thebestwayforoperatorstopreventseriousinjuryordeath tothemselvesorothers,istofamiliarizethemselveswiththe properoperationoftheutilitymachine,tostayalertandto avoidactionsorconditionswhichcouldresultinaaccident. Intheeventofatipover,theriskofseriousinjuryordeath willbereducediftheoperatorisusingtheROPSsystemand seatbeltsandisfollowingtheinstructionsprovided.

•Neverdriveacrossasteephill,alwaysdrive straightupordown.

•Avoidturningonahill.

•Don’tslamonthebrakes.Asuddenspeed changecaninitiateatipover.

Useextracarewhenonhills.Nevergoonhillsthatare extremelysteep.Stoppingwhilegoingdownahillwilltake longerthanonlevelground.Turningwhilegoingupor downahillismoredangerousthanturningonthelevel. Makingturnswhilegoingdownhill,especiallywiththebrakes on,andturninguphillwhiletraversingahillareparticularly dangerous.Evenataslowspeedandwithoutaload,tipovers aremorelikelyifyouturnonahill.

Ifyouhavetoturnwhileonahill,doitasslowlyand cautiouslyaspossible.Nevermakesharporfastturnsona hill.

Ifyoustallorbegintoloseheadwaywhileclimbingasteep hill,quicklyapplythebrakes,shifttoNeutral,restartthe engineandshifttoReverse.

Reducetheweightoftheloadifitisasteephilloriftheload hashighcenterofgravity .Remember,loadscanshift,so securethem.

Note:Themachinehasexcellenthill-climbingability.The differentiallockwillincreasethisability.Hillclimbingtraction canalsobeincreasedbyaddingweighttotherearofthe machineinoneofthefollowingways:

•Addingweighttoinsideofbox,makingsurethatitis

secured

•Mountingwheelweightstorearwheels

•Addingliquidballast(calciumchloride)toreartires

•Nothavingapassengerinthefrontseat

Page 34

Maintenance

Determinetheleftandrightsidesofthemachinefromthe normaloperatingposition.

Note:LookingforanElectricalSchematicorHydraulicSchematic foryourmachine?Downloadafreecopyoftheschematicby visitingwww.Toro.comandsearchingforyourmachinefrom theManualslinkonthehomepage.

WARNING

Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.

Avoidrehazardsandhavereprotection equipmentpresentintheworkarea.Donotusean openametochecklevelorleakageoffuel,battery electrolyte,orcoolant.Donotuseopenpansoffuel orammablecleaninguidsforcleaningparts.

RecommendedMaintenanceSchedule(s)

CAUTION

Notproperlymaintainingthemachinecould damageitand/orcauseinjurytoyouorbystanders.

Allowonlyqualiedandauthorizedpersonnelto maintain,repair,adjust,andinspectthemachine.

CAUTION

Ifyouleavethekeyintheignitionswitch,someone couldaccidentlystarttheengineandseriously injureyouorotherbystanders.

Removethekeyfromtheignitionbeforeyoudoany maintenance.

MaintenanceService

Interval

Aftertherst2hours

Aftertherst10hours

Aftertherst50hours

Aftertherst100hours

Beforeeachuseordaily

MaintenanceProcedure

•Torquethefrontandrearwheelnuts.

•Checktheadjustmentoftheparkingbrake.

•Replacethehydrauliclter.

•Changetheengineoilandlter.

•Inspectopeningonlter.

•Checkthetransmissionuidlevel.

•Performthebreaking-inanewmachineguidelines.

•Checktheengine-oillevel.(Checktheoillevelbeforeandaftertheengineisrst startedanddailythereafter.)

•Checkthehydraulic-uidlevel.(Checkthelevelofhydraulicuidbeforetheengine isrststartedanddailythereafter.)

•Checkthelevelofthecoolant.ChecktheCoolantlevelattheoverowreservoir only.DoNotremovetheradiatorcap.(Checkthecoolantlevelbeforetheengineis rststartedanddailythereafter.)

•Checkthebrakeuidlevel.(Checkthelevelbeforetheengineisrststartedand dailythereafter.)

•Checktheoil-pressurewarninglight.

•Checkthetirepressure.

•Removedebrisfromtheengineareaandradiator.(Cleanitmorefrequentlyin dirtyconditions.)

•Checktheoperationoftheinterlocksystem.

Every50hours

Every100hours

•Checktheconditionofthebattery(every30daysifthebatteryisinstorage).

•Checkthebatterycableconnections.

•Greaseallbearingsandbushings(lubricatemorefrequentlyinheavyduty applications).

•Checktheconditionofthetires.

•Checktheconstantvelocitybootsfordamageandleakinglubricant.

Page 35

MaintenanceService

Every200hours

Every400hours

Interval

MaintenanceProcedure

•Changetheair-cleanerlter(morefrequentlyindustyordirtyconditions).

•Changetheengineoilandlter.

•Inspectopeningonlter.

•Torquethefrontandrearwheelnuts

•Checktheuidlevelinthereservoirforthespeedcontrolcylinder.

•Checktheadjustmentoftheparkingbrake.

•Checktheadjustmentofthebrakepedal.

•Inspecttheserviceandparkingbrakes.

•Inspectorreplacethesparkplug.

•Replacethefuellter.

•Checkthefuellinesandconnections.

•Checkthefrontwheelalignment.

•Checkthetransmissionuidlevel.

•Checktheconditionofthedrivebelt.

•Cleantheclutches.

•Visuallyinspectthebrakesforwornbrakeshoes.

Every800hours

Every1,000hours

Yearly

•Replacethehydrauliclter.

•Changethehydraulicuidandcleanthestrainer.

•Changethebrakeuid.

•Drain/ushthefueltank.

•Flush/replacethecoolantsystemuid.

•Completealloftheyearlymaintenanceproceduresspeciedintheengineowner's manual.

HeavyDutyOperation

Important:Ifthemachineissubjectedtoanyofthefollowingconditionslistedbelow,performthemaintenance

proceduresathalftherecommendedserviceinterval.:

•Operatingthemachineinadesertenvironment

•Operatingthemachineinacoldclimate—below0degreesC(32degreesF)

•Usingthemachinetotowatrailer

•Frequentlyoperatingthemachineondustyroads

•Usingthemachineforconstructionwork

•Afterusingthemachineinmud,sand,water,orsimilardirtyconditionsforanextendedtime

Note:Haveyourbrakesinspectedandcleanedassoonaspossibleaftereachuse.Thiswillpreventanyabrasivematerial fromcausingexcessivebrakewear.

PremaintenanceProcedures

Manyofthesubjectscoveredinthismaintenancesectionrequireraisingandloweringthebed.Thefollowingprecautionsmust betakenorseriousinjuryordeathcouldresult.

Important:Beforeservicingormakingadjustmentstothemachine,stoptheengine,settheparkingbrake,and removethekeyfromtheignitionswitch.Removeanyloadmaterialfromthebedorotherattachmentbeforeworking underaraisedbed.Neverworkunderaraisedbedwithoutpositioningthesafetysupportonafullyextended cylinderrod.

Page 36

UsingtheBedSafetySupport

RemovingtheFullBed

Important:Alwaysinstallorremovethebedsupport

fromtheoutsideofthebed.

1.Raisethebeduntiltheliftcylindersarefullyextended.

2.Removethebedsupportfromthestoragebracketson backoftheROPSpanel(Figure40).

Figure40

1.Bedsupport

Fullbedweight:approximately147.5kg(325lb)

1.Starttheengine.

2.Movethehydraulicliftleverforwardandlowerthe beduntilthecylinderrodendsarelooseintheslots(

HydraulicLiftLever(page16)).

3.Releasetheliftleverandturnofftheengine.

4.Removethelynchpinsfromtheouterendsofthe cylinderrodclevispins(Figure42).

3.Pushthebedsupportontothecylinderrod,making surethatthesupportendtabsrestontheendof cylinderbarrelandonthecylinderrodend(Figure41).

Figure41

1.Bedsupport3.Bed

2.Cylinderbarrel

4.Whennished,removethebedsupportfromthe cylinderandinsertitintothebracketsonthebackof theROPSpanel.

Important:Donottrytolowerbedwithbed safetysupportoncylinder.

Figure42

1.Cylinderrodend

2.Bedmountingplate

3.Clevispin6.Frontslot(2/3bed)

4.Lynchpin

5.Rearslot(Fullbed)

5.Removetheclevispinssecuringthecylinderrodends tothebedmountingplatesbypushingthepinstoward theinside(Figure42).

6.Removethelynchpinsandclevispinssecuringthe pivotbracketstotheframechannels(Figure42).

7.Liftthebedoffthemachine.

Important:Thefullbedweighsapproximately

147.5kg(325lb),sodonottrytoinstallorremove itbyyourself.Useanoverheadhoistorgetthe helpof2or3otherpeople.

8.Storethecylindersinthestorageclips.

9.Setthehydraulicliftlockleveronthemachinetothe Lockposition;referto.

Note:Lockthelevertopreventtheliftcylindersfrom extending.

Page 37

InstallingtheFullBed

Fullbedweight:approximately147.5kg(325lb)

Note:Ifthebedsideswillbeinstalledontheatbed,itis easiertoinstallthembeforeinstallingthebedonthemachine.

Note:Ensurethattherearpivotplatesareboltedtothebed frame/channelsothatlowerendanglestotherear(Figure43).

Figure43

1.Leftrearcornerofbed4.Clevispin

2.Framechannel5.Lynchpin

3.Pivotplate

intherearframechannelandinstall2clevispinsand lynchpins(Figure44).

Important:Thefullbedweighsapproximately

147.5kg(325lb),sodonottrytoinstallorremove itbyyourself.Useanoverheadhoistorgetthe helpof2or3otherpeople.

3.Withthebedlowered,secureeachcylinderrodend,to theappropriateslotsinthebedmountingplateswitha clevispinandlynchpin.

Note:Youmayneedtostarttheenginetoextendor retractthecylinderstoalignthemwiththeholes.Keep

ngersaway!

4.Inserttheclevispinfromoutsideofthebedwiththe lynchpintowardtheoutside(Figure44).

Note:Therearslotsareforafullbedinstallationand frontslotsarefora2/3bedinstallation.

Note:Theunusedslotcanbepluggedwithaboltand anuttopreventassemblyerrors.

5.Starttheengineandengagethehydraulicliftleverto raisethebed.

6.Releasetheliftleverandturnofftheengine.

7.Installthebedsafetysupporttopreventaccidental loweringofthebed.RefertoUsingtheBedSafety

Support(page36).

8.Installthelynchpinstotheinsideendsoftheclevis pins.

Note:Installthespacerbracketsandwearblocks(Figure44) withthecarriageboltheadspositionedinsidethemachine.

Figure44

1.Wearblock

2.Spacerbracket

1.Ensurethattheliftcylindersarefullyretracted.

2.Carefullysetthebedontotheframeofthemachine, aligningtherearbedpivotplateholeswiththeholes

3.Carriagebolt

Note:Iftheautomatictailgatereleasehasbeen installedonthebed,ensurethatthefrontdumplink rodhasbeenplacedontheinsideoftheleftsideclevis pinbeforethelynchpinisinstalled.

JackingtheMachine

DANGER

Amachineonajackmaybeunstableandslipoffof thejack,injuringanyonebeneathit.

•Donotstarttheenginewhilethemachineis onajack.

•Alwaysremovethekeyfromtheswitchbefore gettingoffofthemachine.

•Blockthetireswhenthemachineisonajack.

•Donotworkunderthemachinewithoutjackstands

supportingit.Themachinecouldslipoffajack,injuring anyonebeneathit.

•Whenjackingupthefrontofthemachine,alwaysplacea

2x4block(orsimilarmaterial)betweenthejackandthe machineframe.

•Thejackingpointatthefrontofthemachineisunderthe

frontcenterframesupport(Figure45).Attherearofthe machine,thejackingpointisundertheaxle(Figure46).

Page 38

1.Frontjackingpoints

Figure45

Figure47

1.Hood

2.Pivotthebottomofthehoodupwarduntilyoucanpull thetopmountingtabsfromtheframeslots(Figure47).

3.Pivotthetopofhoodforwardandunplugthewire connectorsfromtheheadlights(Figure47).

Figure46

1.Rearjackingpoints

RemovingandInstallingthe Hood

RemovingtheHood

Removethehoodasfollows:

1.Whilegraspingthehoodintheheadlightopenings,lift upthehoodtoreleasethelowermountingtabsfrom theframeslots(Figure47).

4.Removethehood.

InstallingtheHood

1.Connectthelights.

2.Insertthetopmountingtabsintotheframeslots (Figure47).

3.Insertthelowermountingtabsintotheframeslots (Figure47).

4.Ensurethatthehoodisfullyengagedinthetop,sides, andbottomgrooves.

Page 39

Lubrication

GreasingtheBearingsandthe Bushings

ServiceInterval:Every100hours(lubricatemorefrequently

inheavydutyapplications).

Lubricationtype:No.2general-purpose,lithium-based grease

Important:Whengreasingthedriveshaftuniversal shaftbearingcrosses,pumpgreaseuntilitcomesout ofall4cupsateachcross.

1.Wipeeachgreasettingcleansothatforeignmatter cannotbeforcedintothebearingorbushing.

Springtower(2);refertoFigure49

2.Connectthegreaseguntothegreasetting.

3.Pumpgreaseintoeachbearingorbushing.

4.Wipeoffanyexcessgrease.

Thegreasettinglocationsandquantitiesareasfollows:

•Balljoints(4);refertoFigure48

•Pivotmounts(2);refertoFigure48

•Steeringcylinder(2);refertoFigure48

•Tierods(2);refertoFigure48

Figure49

•Brake(1);refertoFigure50

•Throttle(1);refertoFigure50

Figure48

Figure50

Page 40

•DriveshaftU-joints(2);refertoFigure51

•Slidingyolk(1);refertoFigure51

Figure51

EngineMaintenance

ServicingtheAirFilter

ServiceInterval:Every200hours—Changetheair-cleaner

lter(morefrequentlyindustyordirty conditions).

Inspecttheairlterandhosesperiodicallytomaintain maximumengineprotectionandtoensuremaximumservice life.Checktheair—ltercoverandhousingfordamage whichcouldpossiblycauseanairleak.Replaceanydamaged air-ltercomponents.

Inspectandchangetheairlterasdescribedinthefollowing procedure:

1.Pullthelatchoutwardandrotatetheair-ltercover counterclockwise(Figure52).

Figure52

1.Latch4.Dustvalve

2.Air-ltercover5.Air-lterhousing

3.Airlter

2.Beforeremovingthelter,uselowpressureair(40psi, cleananddry)tohelpremovelargeaccumulationsof debrispackedbetweentheoutsideoftheairlterand theair-lterhousing.

Important:Avoidusinghighpressureair,which couldforcedirtthroughthelterintotheintake tract.Thiscleaningprocesspreventsdebrisfrom migratingintotheintakewhentheprimarylter isremoved.

3.Removeairlterfromthehousing(Figure52).

Note:Donotcleanausedlterelementbecauseyou maydamageltermedia.

4.Wipecleantheinterioroftheair-ltercoverand housing(Figure52).

5.Removetherubberdustvalvefromthecover(Figure

52).

Page 41

6.Cleanthedirtejectionportlocatedintheair-cleaner cover,thedustvalvecavity,andthenreplacethedust valve(Figure52).

7.Inspectthenewairlterforshippingdamage,checking thesealingendofthelterandthebody.

Important:Donotuseadamagedelement.

8.Insertthenewairlterbyapplyinglightpressuretothe outerrimoftheltertoseatitintheair-lterhousing (Figure52).

9.Aligntheair-ltercoverwiththedustvalveatthe6 o’clockpositionwhenviewedfromtheleftendofthe cover(Figure52).

10.Securethelatchoftheair-ltercover(Figure52).

Figure54

Note:Resettheindicatorifitisshowingred(ifso

equipped).

ChangingtheEngineOiland Filter

ServiceInterval:Aftertherst50hours

Every200hours

Engine-oilcapacity:2.0L(2.1quarts)ofoilinthecrankcase (includingtheoillter)

OilType:ahigh-quality10W-30APIserviceclassication SJorhigher.

ChooseaviscosityaccordingtothetableinFigure53.

1.Engine-oildrainplug

2.Forward

3.Removethedrainplugandletoilowintoadrainpan (Figure54).

Note:Whentheoilstopsdraining,installthedrain plug.

4.Removetheoillterfromthelteradapter(Figure55).

Figure53

1.Raisethebed(ifsoequipped)andplacethebedsafety supportontheextendedliftcylindertoholdupthe bed;refertoRaisingtheCargoBox(page19)and

UsingtheBedSafetySupport(page36).

2.Alignadrainpanwitha2.5L(3.0quarts)capacity undertheoil-drainplugfortheengine(Figure54).

Figure55

1.Forward3.Filteradapter

2.Oillter

5.Wipecleanthesealingbaseoftheofthelteradapter (Figure55).

6.Applyalightcoatofcleanoiltothesealofthenew lter.

7.Installthelteruntilthegasketcontactsthesealingbase ofthelteradapter,thentightenthelterclockwise andadditional1/2to2/3ofaturn(Figure55).

Note:Donotovertightentheengineoillter.

8.Addthespeciedoiltothecrankcaseoftheengine; refertoCheckingtheEngine-oilLevel(page21).

9.Lowerthebed;refertoLoweringtheBox(page20).

Page 42

ReplacingtheSparkPlug

G019300

1 2

FuelSystem

ServiceInterval:Every400hours

Sparkplugtype:ChampionRC14YC

Airgap:0.76mm(0.030inch)

1.Cleantheareaaroundthesparkplugsoforeignmatter cannotfallintothecylinderwhenyouremovethe sparkplug.

2.Pullwiresoffthesparkplugandremovetheplugs fromthecylinderhead.

3.Checktheconditionofthesideelectrode,center electrode,andcenterelectrodeinsulatortoensurethat thereisnodamage(Figure56).

Important:Acracked,fouled,dirty,orotherwise malfunctioningsparkplugmustbereplaced.Do notsandblast,scrape,orcleanelectrodesby usingawirebrushbecausegritmayeventually releasefromtheplugandfallintothecylinderand damagedtheengine.

Maintenance

ReplacingtheFuelFilter

ServiceInterval:Every400hours

1.Raisethebed(ifsoequipped)andinstallthebedsafety supportontotheextendedliftcylindertoholdupthe bed;refertoRaisingtheCargoBox(page19)and

UsingtheBedSafetySupport(page36).

2.Unplugthewiringharnessconnectorsfromthefuel pump(Figure57).

3.Loosenthehoseclampanddisconnectthefuelline fromthefuelpumpcap(Figure57).

Figure56

1.Sideelectrode

2.Centerelectrode4.Airgapat0.76mm(0.030

4.Settheairgap(Figure56)betweenthecenterandside electrodesat0.81mm(0.032inch).

5.Installthecorrectlygappedsparkplugandtighten themto24.5to29N-m(18to22ft-lb).

Note:Ifyoucannotuseatorquewrench,tightenthe plugrmly.

6.Installthespark-plugwire.

3.Insulator

Figure57

1.Fuelpump

2.Hoseclamp

4.Removethefuel-pumpcapbyunthreaditfromthetop

inch)

ofthefueltank(Figure57).

Important:Donotallowthefuelpumpassembly torotateduringtheremovalprocess.Ifthepump rotates,itcanresultindamagetotheoatarm assembly.

5.Removethefuelpumpassemblyandfuellterfrom thetank(Figure57.

6.Removetheclampsecuringthefuellterhosetothe fuelpumptting(Figure57).

7.Removethehosefromthetting(Figure57).

8.Insertthenewhoseclampontothenewfuellterhose.

9.Insertthehoseontothefuelpumpandsecurethe clamp.

10.Inserttheassemblyintothefueltankandtightenthe capto20to22N-m(175to200in-lb).

3.Fuelline/fuellter

Note:Note:V erifythattheoatarmdoesnotcontact thefueltankwallsatanypointthroughthefullrange ofmotion.

Page 43

11.Connectthewiresandsecurethehosewiththehose clamp.

InspectingtheCarbonCanister

ElectricalSystem Maintenance

AirFilter

ServiceInterval:Aftertherst50hours

Every200hours

1.Locatetheairlteronthebottomofthecarbon canister(Figure58).

Figure58

1.Filteropening

2.Ensurethattheopeningonthebottomofthelteris clearandopen.

ServicingtheFuses

Thefusesfortheelectricalsystemarelocatedunderthe centerofthedashpanel(Figure59andFigure60).

Figure59

1.Fuses

InspectingtheFuelLinesand Connections

ServiceInterval:Every400hours/Yearly(whichevercomes

rst)

Every1,000hours/Every2years(whichevercomes rst)

Inspectthefuellinesandconnectionsfordeterioration, damage,orlooseconnections.

Figure60

1.Powertake-off—15A5.Differentiallock—15A

2.Enginestart—10A

3.Hazards—10A7.Headlightsandrear

4.Engineignition—10A8.Horn—30A

6.Speedometer—10A

lights—15A

Page 44

Jump-StartingtheMachine

WARNING

Jump-startingcanbedangerous.T oavoidpersonal injuryordamagetoelectricalcomponentsin machine,observethefollowingwarnings:

•Neverjump-startwithavoltagesourcegreater than15voltsDC.Thiswilldamagetheelectrical system.

•Neverattempttojumpstartadischargedbattery thatisfrozen.Itcouldruptureorexplodeduring jumpstarting.

•Observeallbatterywarningswhilejumpstarting yourmachine.

•Ensurethatthemachineisnottouchingthe jumpstartmachine.

Note:ThenegativeterminalhasNEGonthe batterycover.Donotconnecttheotherendofthe jumpercabletothenegativepostofthedischarged battery—connectittotheengineorframe.

•Connectingcablestothewrongpostcould resultinpersonalinjuryand/ordamagetothe electricalsystem.

1.Squeezethebatterycovertoreleasethetabsfrom batterybase,andremovethebatterycoverfromthe batterybase(Figure61).

Figure62

1.Battery

4.Starttheengineofthemachinethatprovidesthe electricalsourceforthejumpstart.

Note:Letmachinethatprovidestheelectricalsource runafewminutes,thenstartyourengine.

5.Removethenegativejumpercablerstfromyour engine,thenthebatteryintheothervehicle.

6.Installthebatterycovertothebatterybase.

Figure61

1.Batterycover

2.Connectajumpercablebetweenthepositivepostsof the2batteries(Figure62).

Note:Thepositivepostmaybeidentiedbya+sign ontopofthebatterycover.

3.Connecttheendoftheotherjumpercabletothe negativeterminalofthebatteryintheothermachine.

Important:Donotconnectthejumpercableto thefuelsystem.

Page 45

ServicingtheBattery

DriveSystem

ServiceInterval:Every50hours—Checktheconditionof

thebattery(every30daysifthebatteryis instorage).

Every50hours—Checkthebatterycableconnections.

WARNING

CALIFORNIA

Proposition65Warning

Batteryposts,terminals,andrelated

accessoriescontainleadandleadcompounds,

chemicalsknowntotheStateofCalifornia

tocausecancerandreproductiveharm.

Washhandsafterhandling.

DANGER

Batteryelectrolytecontainssulfuricacid,whichisa deadlypoisonandcausessevereburns.

•Donotdrinkelectrolyteandavoidcontactwith skin,eyesorclothing.Wearsafetyglassesto shieldyoureyesandrubberglovestoprotect yourhands.

Maintenance

MaintainingtheTires,Wheels, andSuspension

InspectingtheTires

ServiceInterval:Every100hours

Operatingaccidents,suchashittingcurbs,candamagea tireorrimandalsodisruptwheelalignment,soinspecttire conditionafteranaccident.

Checkthetirepressurefrequentlytoensureproperination. Ifthetiresarenotinatedtothecorrectpressure,thetires willwearprematurely.

Figure63showsanexampleoftirewearcausedbyunder

ination.

•Fillthebatterywherecleanwaterisalways availableforushingtheskin.

•Keepthetopofthebatterycleanbywashingitperiodically

withabrushdippedinammoniaorbicarbonateofsoda solution.Flushthetopsurfacewithwateraftercleaning. Donotremovethellcapwhilecleaning.

•Ensurethatthebatterycablesarekepttightonthe

terminalstoprovidegoodelectricalcontact.

•Ifcorrosionoccursatterminals,removethebattery

cover,disconnectthecables(negative(–)cablerst),and scrapetheclampsandterminalsseparately.Connectthe cables(positive(+)cablerst)andcoattheterminals withpetroleumjelly.

•Ifyoustorethemachineinalocationwheretemperatures

areextremelyhigh,thebatterywillrundownmore rapidlythanifthemachineisstoredinalocationwhere temperaturesarecool.

Figure63

1.Underinatedtire

Figure64showsanexampleoftirewearcausedbyover

ination.

Figure64

1.Overinatedtire

Page 46

CheckingtheTorqueoftheWheelNuts

ServiceInterval:Aftertherst2hours

Aftertherst10hours

Every200hours

WARNING

Failuretomaintainpropertorqueofthewheelnuts couldresultinfailureorlossofawheelandmay resultinpersonalinjury.

Torquethefrontandrearwheelnutsto109to122 N-m(80to90ft-lb)after1to4hoursofoperation andagainafter10hoursofoperation.Torquethe wheelnutsevery200hoursthereafter.

CheckingtheFrontWheelAlignment

ServiceInterval:Every400hours/Yearly(whichevercomes

rst)

1.Makesurethatthetiresarefacingstraightahead.

2.Measurethecenter-to-centerdistance(ataxleheight)at thefrontandrearofthesteeringtires(Figure65).

Note:Themeasurementmustbewithin0±3mm (0±0.12inch)atthefrontofthetirethenattherear ofthetire.

Important:Checkthemeasurementsatconsistent locationsonthetire.Thevehicleshouldbeona atsurfacewiththetiresfacingstraightahead.

Figure66

1.Tierods2.Jamnuts

B.Rotatethetierodtomovethefrontofthetire

inwardoroutwardtoachievethecentertocenter distancesfromfronttoback.

C.Tightenthetierodjamnutwhentheadjustment

iscorrect.

D.Checktoensurethatthetiresturnanequal

amounttotherightandtotheleft.

Note:Ifthetiresdonotturnequally,referto theWorkmanServiceManualfortheadjustment procedure.

Figure65

1.Frontofvehicle3.Centertocenterdistance

2.0±3mm(0±0.12inch) fronttorearoftire

3.Rotatethetire90degreesandcheckthemeasurements again.

Note:Themeasurementmustbewithin0±3mm (0±0.12inch)atthefrontofthetirethenattherear ofthetire.

4.Adjustthecenter-to-centerdistanceasfollows:

A.Loosenthejamnutatthecenterofthetierod

(Figure66).

Page 47

MaintainingtheTransmission

CheckingtheTransmission-uidLevel

ServiceInterval:Aftertherst50hours

Every400hours

TransmissionFluidType:DexronVI

1.Locatethellplugattheatthelower-inboardareaat thebackofthetransmission(Figure67).

ChangingtheTransmissionFluid

TransmissionFluidT ype:DexronVI

TransmissionFluidCapacity:700ml(23.7oz)

1.Movethemachinetoalevelsurface.

2.Locatethellplugatthebackinboardareaofthe transmissioncaseandthelocatethedrainplugatthe frontoutboardsideofthetransmission(Figure68and

Figure69).

Figure67

1.Fillport(transmission)

2.Fillplug

2.Alignadrainpanbelowthellplug.

3.Rotatetheplugcounterclockwiseandremovetheplug fromthellportinthetransmission(Figure67).

Note:Whenthetransmissionuidleveliscorrect,the uidshouldbelevelwiththebottomofthethreads inthellport.

4.Ifthetransmission-uidlevelislow,addtransmission uidofthespeciedtypeintothetransmissionthrough thellportuntiltheuidlevelisushwiththebottom ofthethreadsintheport(Figure67).

Note:Useafunnelwithaexiblehosewhenlling thetransmission.

5.ChecktheconditionoftheO-ringatthellplug.

Note:ReplacetheO-ringifitiswarnordamaged.

6.Installthellplugintothetransmissionandtighten ithandtight(Figure67).

Figure68

1.Fillplug3.Forward

2.Transmissioncase(back inboardlocation)

Figure69

1.Forward2.Drainplug

3.Removethellplugfromthellportbyrotating theplugcounterclockwiseandremovingitfromthe transmission(Figure68).

4.Alignadrainpanbelowthedrainplug(Figure69).

Page 48

5.Removethedrainplugfromthedrainportbyrotating theplugcounterclockwiseandremovingitfromthe transmission(Figure69).

Note:Allowthetransmissionuidtodraincompletely .

6.Installthedrainplug(Figure69).

7.Add700ml(23.7oz)ofDexronVItransmissionuid intothetransmissionthroughthellport(Figure68).

Note:Useafunnelwithaexiblehosewhenlling thetransmission.

Note:Whenthetransmissionuidleveliscorrect,the uidshouldbelevelwiththebottomofthethreads inthellport.

8.Installthellplug(Figure68).

ServicingtheReservoirofthe Speed-controlCylinder

ServiceInterval:Every200hours

ReservoirFluidType:DOT3brakeuid

1.Removetheknobsfromthehydraulic-liftleverandthe speed-rangelever(Figure70).

Figure71

1.Cap3.Minmark(reservoir)

2.Maxmark(reservoir)4.DOT3brakeuid

5.Iftheuidlevelislow,performthefollowing:

A.Wipecleantheareaaroundthecapforthe

reservoir(Figure71).

B.Removethecapfromthereservoir(Figure71).

C.Addthespecieduidtoraisethelevelmidway

betweentheMinandMaxmarksonthesideof thereservoir(Figure71).

Figure70

1.Knob(speed-rangelever)4.Rod(hydraulic-liftlever)

2.Rod(speed-rangelever)5.Control-coverplate

3.Knob(hydraulic-liftlever)6.Hex-washerscrews(#10 x3/4inch

2.Removethe6hex-washerscrews(#10x3/4inch)that securethecontrol-coverplatetotheseatbase,and removethecoverplate(Figure70).

3.Movethespeed-rangelevertothetransportposition; refertoUsingtheSpeed-rangeControl(page27).

4.Checktheuidlevelinthereservoirforthespeed controlcylinder(Figure71).

Note:ThenormaluidlevelisbetweentheMinand Maxmarksonthesideofthereservoir.

D.Installthecaphandtight(Figure71).

6.Aligntheholesinthecontrol-coverplatetotheholes intheseatbase(Figure70).

7.Securetheplatetothebasewiththe6hex-washer screws(Figure70)thatyouremovedinstep2.

8.Threadtheknobsontotherodsforthehydraulic-lift leverandthespeed-rangelever(Figure70).

AdjustingtheSpeedControl

Important:Theminimumcontrolledspeedforthe

machineis4.0kph(2.5mph)atfullenginespeed. Controllingthemachinespeedslowerthat4.0kph(2.5 mph)willresultinexcessivebeltandclutchwear.

1.DrivethemachineinspeedrangeA(lowrange),B (mid-lowrange),C(mid-highrange),orD(highrange) inordertodeterminewhichspeedrangeincludesthe maximum-groundspeedthatyouwanttoset;referto.

Note:Usethespeedometertodeterminethespeed thatthemachineistraveling.

2.Removetheknobsfromthehydraulic-liftleverandthe speed-rangelever(Figure70).

3.Removethe6hex-washerscrews(#10x3/4inch)that securethecontrol-coverplatetotheseatbase,and removethecoverplate(Figure70).

4.Movethespeed-rangelevertotheT(transport) position(Figure72).

Page 49

5.Loosenthe2hex-socketscrews(5/16x3/4inch)that securethedetentplatetothelever-supportbracket (Figure72).

Figure72

1.Lever-supportbracket3.Detentplate

2.Hex-socketscrews

CheckingtheDriveBelt

ServiceInterval:Every400hours

1.Removethe9hex-washerbolts(1/4x1inch)that securethetransmissioncovertothemountingplateof thetransmission(Figure73).

6.Movethedetentplateinoneofthefollowingdirections:

•Movethedetentplateforwardtoincreasethe

maximumgroundspeedlimit(Figure72).

•Movethedetentplaterearwardtodecreasethe

maximumgroundspeedlimit(Figure72).

7.Tightenthe2hex-socketscrews(5/16x3/4inch)to 1978to2542N-cm(175to225in-lb).

8.Drivethemachinewiththespeedcontrolsettospeed rangeforwhichyouaresettingthemaximumground speedlimit.Ifthemaximumgroundspeedlimitistoo fastortooslow,repeatsteps1through8untilthe correctmaximumgroundspeedlimitisattained.

9.Aligntheholesinthecontrol-coverplatetotheholes intheseatbase(Figure70).

10.Securetheplatetothebasewiththe6hex-washer screws(Figure70)thatyouremovedinstep3.

11.Threadtheknobsontotherodsforthehydraulic-lift leverandthespeed-rangelever(Figure70).

Figure73

1.Hex-washerbolts(1/4x1 inch)

2.Transmissioncover

3.Drivebelt6.Beltwidth—replaceat

4.Mountingplate

5.T aperedfaces(primary clutch)

29.5mm(1.16inch)or less

2.Movethecoverforwarduntilyoucanseethedrivebelt (Figure73).

3.Checkthetaperedfacesoftheprimaryclutchforsigns ifdamage(Figure73).

Note:Ifthefacesoftheprimaryclutcharedamaged, replacetheprimaryclutch;contactyourAuthorized ServiceDealerorAuthorizedDistributor.

4.Checkthedrivebeltformissingordamagedcogs (Figure73).

Note:Ifthecogsofthedrivebeltaremissingor damaged,replacethedrivebelt.

5.Measureacrossthebeltandrecordthebeltwidth (.Figure73).

Note:Ifthewidthofthebeltis29.5mm(1.16inch) orless,replacethebelt(Figure73).

6.Aligntheholesinthetransmissioncoverwiththeholes inthemountingplate(Figure73).

7.Securethecovertothemountingplate(Figure73)with the9hex-washerbolts(1/4x1inch)thatyouremoved

Page 50

instep1,andtorquetheboltsto10.2to12.4N-m(90 to110in-lb).

CleaningtheClutches

ServiceInterval:Every400hours

1.Removethe9hex-washerbolts(1/4x1inch)that securethetransmissioncovertothemountingplateof thetransmission(Figure74).

MaintainingtheDifferential andAxles

ChangingtheDifferentialOil

Oiltype:80W90APIGL-5

Oilcapacity:550ml(18.6oz)

1.Alignadrainpanunderthedrainplug(Figure75).

Figure74

1.Hex-washerbolts(1/4x1 inch)

2.Transmissioncover

3.Primaryclutch

2.Attheprimaryandsecondaryclutches,Removedirt andmudbuildupwithwateranddryimmediatelywith compressedairtoremoveexcesswateranddebris.

3.Removeanyremainingdebrisusingafast-drying contactcleanerorbrakecleaner.

Note:Note:Removethedebrisinandaroundmoving parts.

4.Ifdebrisorbuildupexistsaroundthebeltoralongthe clutchshaft,useaneabrasivepadorasimilarproduct toremoveit.

5.Aligntheholesinthetransmissioncoverwiththeholes inthemountingplate(Figure74).

4.Mountingplate

5.Secondaryclutch

Figure75

1.Fillplug3.Drainport

2.Fillport4.Drainplug

2.Removethellplugfromthellportandthedrain plugfromthedrainportofthedifferential(Figure75).

Note:Allowthedifferentialtocompletelydrain.

3.ChecktheconditionoftheO-ringsontheplugs.

Note:ReplacedamagedorwornO-rings.

4.Installthedrainplugintothedrainport(Figure75), andtighttheplugto14to19N-m(10to14ft-lb).

Note:Thedrainplugismagnetic.Itisnormalto seesmallamountsofferrous-metalparticlesaround magnet—expectmoreparticlesaroundthemagnet afterinitialbreak-in.

5.Add550ml(18.6oz)ofthespeciedoilintothell portofthedifferential(Figure75).

Note:Useafunnelwithaexiblehosetoaddoilto thedifferential.

6.Securethecovertothemountingplate(Figure74)with the9hex-washerbolts(1/4x1inch)thatyouremoved instep1,andtorquetheboltsto10.2to12.4N-m(90 to110in-lb).

6.Installthellplugintothellport(Figure75),and tightentheplugto14to19N-m(10to14ft-lb).

Page 51

CheckingtheConstantVelocityBoots

ServiceInterval:Every100hours

1.Jackupthebackendofthemachineandsupportit withjackstands;refertoJackingtheMachine(page37).

2.ChecktheCV(constantvelocity)bootsattherearaxles fordamageandleakinglubricant(Figure76).

Note:ReplaceanydamagedorleakingCVboot beforeoperatingthemachine.

CoolingSystem Maintenance

ChangingtheEngineCoolant

ServiceInterval:Every1,000hours/Every2years

(whichevercomesrst)

Coolingsystemcapacity:3.7L(4qt)

Coolanttype:a50/50solutionofwaterandpermanent

ethyleneglycolantifreeze

1.Parkthemachineonalevelsurface.

2.Raisethebed(ifsoequipped)andinstallthebedsafety supportontheextendedliftcylindertoholdupthe bed;refertoRaisingtheCargoBox(page19)and

UsingtheBedSafetySupport(page36).

Figure76

3.Removethejackstandsandlowerthemachinetothe ground.

CAUTION

Iftheenginehasbeenrunning,thecooling systemwillpressurizewithhotcoolantthat canescapeandcauseburns.

•Donotopentheradiatorcapwhenthe engineisrunning.

•Allowtheenginetocoolforatleast15 minutesoruntiltheradiatorcapiscool enoughtotouchwithoutburningyour hand.

•Usearagtoopentheradiatorcap.Open thecapslowlytoallowthesteamtoescape.

3.Removetheradiatorcap(Figure77).

Figure77

1.Radiatorcap

4.Removethecapfromthecoolantreservetank(Figure

77).

Page 52

G021229

Figure78

1.Cap(coolant-reservetank)

5.Disconnectthelowerradiatorhoseandallowthe coolanttoowintoadrainpan.

Note:Whenthecoolantstopsowing,connectthe lowerradiatorhose.

6.Slowlylltheradiatorwitha50/50mixtureofwater andpermanentethyleneglycolanti–freeze

7.Topofftheradiatorandinstallthecap(Figure77).

8.Slowlyllthecoolant-reservetankuntillevelreaches thebottomofthellerneck(Figure78).

9.Installthecaponthecoolant-reservetank(Figure78).

BrakeMaintenance

AdjustingtheParkingBrake

ServiceInterval:Aftertherst10hours

Every200hours

1.Removetherubbergripfromtheparking-brakelever (Figure79).

Figure79

1.Parking-brakelever

2.Loosenthesetscrewsecuringtheknobtothe parking-brakelever(Figure80).

2.Grip

10.Starttheengineandoperateituntilitiswarm.

11.Stoptheengine,checkthecoolantlevel,andreplenish thecoolantifrequired.

Figure80

1.Parking-brakelever

2.Knob

3.Setscrew

3.Rotatetheknob(Figure80)untilaforceof20to22kg (45to50lb)isrequiredtoactuatethelever.

4.Tightenthesetscrewwhennished(Figure80).

Note:Ifyoucannolongermakeaparking-brake adjustmentbyadjustingparking-thebrakelever,loosen thehandletothemiddleoftheadjustmentandadjust thecableattherear,thenrepeatstep3.

5.Installtherubbergripontotheparking-brakelever

(Figure79).

Page 53

AdjustingtheBrakePedal

ServiceInterval:Every200hours

1.Removethehood;refertoRemovingtheHood(page

38).

2.Removethecotterpinandclevispinsecuringthe master-cylinderyoketothebrakepedalpivot(Figure

81).

Figure81

7.Tightenthejamnutsecuringtheyoketothemaster cylindershaft(Figure81).

Note:Thebrake-mastercylindermustrelievethe pressurefromtheservicebrakewhenitisproperly adjusted.

8.Installthehood;refertoRemovingtheHood(page38).

1.Cotterpin

2.Brakepedalpivot5.Jamnut

3.Clevispin

4.Master-cylinderyoke

3.Liftuponthebrakepedal(Figure82)untilitcontacts theframe.

Figure82

1.Brakepedal2.Acceleratorpedal

4.Loosenthejamnutssecuringtheyoketothemaster cylindershaft(Figure81).

5.Adjusttheyokeuntilitsholesalignwiththeholeinthe brakepedalpivot(Figure81).

6.Securetheyoketothepedalpivotwiththeclevispin andcotterpin(Figure81).

Page 54

ControlsSystem Maintenance

ConvertingtheSpeedometer

Youcanconvertthespeedometerfrommphtokpmorkph tomph.

1.Positionthemachineonalevelsurface,stopthe engine,engagetheparkingbrake,andremovethekey fromtheignitionswitch.

2.Removethehood;refertoRemovingtheHood(page

38).

3.Locatethe2loosewiresnexttothespeedometer (Figure83).

AdjustingtheAccelerator Pedal

AdjustingtheSlowIdlefortheEngine

1.Starttheengineandrunituntiltheengineisatnormal operatingtemperature(approximately5–10minutes).

2.Ensurethatthethrottleissettoslowidleandcheck thetachometertoseeiftheenginerunningat1100 rpm(lowidle).

Note:Iftheslow-engineidlespeedis1100rpm,skip toAdjustingtheFastIdlefortheEngine(page54).

3.Iftheenginelow-idlerpmisfasterorslower than1100rpm,rotatetheidlescrewclockwiseor counterclockwiseatthethrottlebodyfortheengine untiltheengineidlespeedis1100rpm(Figure84).

Note:Thefanmustnotrunwhilesettingtheengine idlespeed.

Figure83

1.Speedometer(forward face)

2.Plug

4.Removetheconnectorplugfromtheharnesswireand connectthewirestogether(Figure83).

Note:Thespeedometerwillswitchfrommphtokph. Retainthepluginordertoconvertthespeedometer tomph.

5.Installthehood;refertoInstallingtheHood(page38).

3.Speedometerwires

Figure84

1.Idlescrew2.Throttlebody

AdjustingtheFastIdlefortheEngine

1.Starttheengineandrunituntiltheengineisatnormal operatingtemperature(approximately5–10minutes).

2.Withyourhand,movethebellcrankforthethrottle againstthefast-idlestop(Figure85).

Note:Theenginespeeddisplayedonthetachometer shouldread3600rpm.

Note:Ifthefast-engineidlespeedis3600rpm,skip toAdjustingtheAcceleratorPedalPosition(page55).

Page 55

Figure85

1.Bellcrank3.Jamnut

2.Fast-idlestop

3.Ifthefast-idlespeedfortheengineisfasterorslower than3600rpm,performthefollowing:

A.Loosenthejamnutthatsecuresthefast-idlestop

(Figure85).

B.Rotatethestopinthefollowingdirections:

•Clockwisetodecreasetheenginerpm(Figure

85).

•Counterclockwisetoincreasetheenginerpm

(Figure85).

C.Tightenthejamnut(Figure85).

D.Movethebellcrankagainstthefast-idlestop

(Figure85).

E.Iftheenginehighidlerpmisfasterorslower3600

rpm,repeatstepsAthroughDuntilthefast-idle speedis3600rpm.

Figure86

1.Floor

2.Acceleratorpedal

3.6.35mm(1/4inch)gap

3.Ifthegapbetweentheacceleratorpedalandtheoor (Figure86)islargerthanorsmallerthan6.35mm (1/4inch),performthefollowingwhileholdingthe bellcrankagainstthefast-idlestop(Figure85):

•Loosentheinboard-jamnutforthethrottlecable

andtightentheoutboardjamnuttodecreasethe gap(Figure87).

•Loosentheoutboard-jamnutforthethrottlecable

andtightentheinboardjamnuttoincreasethegap (Figure87).

4.Shutofftheengineandremovethekeyfromthe ignitionswitch.

AdjustingtheAcceleratorPedal Position

Useanotherpersontohelpadjusttheacceleratorpedal.

1.Movethebellcrankagainstthefast-idlestopandhold itagainstthestop(Figure85).

2.Measurethegapbetweentheacceleratorpedalandthe oorbeneaththepedal(Figure86).

Note:Thegapbetweentheacceleratorpedalandthe oorshouldmeasure6.35mm(1/4inch).

Note:Ifthegapbetweentheacceleratorpedaland theooris6.35mm(1/4inch),skiptoAdjustingthe

AcceleratorPedalUpstop(page56).

Figure87

1.Bellcrank3.Throttlebracket

2.Fast-idlestop4.Jamnut

4.Ensurethatthejamnutsforthethrottlecablearetight (Figure87).

5.Holdthebellcrankagainstthefast-idlestopandcheck thegapbetweentheacceleratorpedalandtheoor.If thegapislargerthanorsmallerthan6.35mm(1/4

Page 56

inch),repeatsteps3and4untilyoumeasurea6.35mm (1/4inch)gapbetweenthepedalandtheoor.

AdjustingtheAcceleratorPedalUpstop

1.Withtheacceleratorpedalup,measurethe distancefromtherearward-bottomcornerofthe accelerator-pedalarmtotheoor(Figure88).

Note:Writedownthismeasurement(measurement

1).

Figure89

Figure88

1.Accelerator-pedalarm3.Measurement2

2.Measurement1

2.Gentlymovethethrottlepedaldownuntilthefreeplay isremovedfrombetweentheacceleratorpedalandthe throttlecable(Figure88).

3.Whileholdingthepedalinpositiontoremovethefree play,measurethedistancefromtherearwardbottom corneroftheaccelerator-pedalarmtotheoor(Figure

88).

Note:Writedownthismeasurement(measurement

2).

4.Subtractmeasurement2frommeasurement1;the resultisthepedal-freetravel.

1.Accelerator-pedalstop

2.Jamnut

C.Tightenthejamnut(Figure89).

D.Repeatsteps1through4tomeasurethepedal-free

travel(Figure89).

Note:Thepedal-freetravelshouldmeasure3 mm(0.125inch).

E.RepeatstepsAthroughDuntilthepedal-free

travelis3mm(0.125inch).

3.Flangeofthe accelerator-pedalarm

Note:Thepedal-freetravelshouldmeasure3mm (0.125inch).

5.Ifthepedal-freetravelislargerthanorsmallerthan3 mm(0.125inch),performthefollowing:

A.Loosenthejamnutthatsecuresthe

accelerator-pedalstop(Figure89).

B.Rotatetheaccelerator-pedalstopinthefollowing

directions:

•Clockwisetoincreasethepedal-freetravel

(Figure89).

•Counterclockwisetodecreasethepedal-free

travel(Figure89).

Page 57

HydraulicSystem Maintenance

ChangingtheHydraulicFluid

ServiceInterval:Every800hours

HydraulicFluidType:MobilM15

ReplacingtheHydraulicFilter

ServiceInterval:Aftertherst10hours

Every800hours

Important:Useofanyotherltermayvoidthewarranty onsomecomponents.

1.Positionthevehicleonalevelsurface,stoptheengine, engagetheparkingbrake,andremovethekeyfrom ignitionswitch.

2.Cleantheareaaroundltermountingarea(Figure90).

HydraulicFluidCapacity:(Non-TCmodel):7.5L(2US gallons)

HydraulicFluidCapacity:(Non-TCmodelwiththeHigh FlowHydraulicKit(option)orTCmodel):15.1L(4US gallons)

1.Positionthevehicleonalevelsurface,stoptheengine, engagetheparkingbrake,andremovethekeyfrom theignitionswitch.

2.Raisethecargobox,refertoRaisingtheCargoBox

(page19).

3.Removethecapanddipstickfromthellerneckof thereservoir(Figure91).

Figure90

1.Filteradapter

3.Placeadrainpanunderthelter(Figure90).

4.Removethelterbyrotatingitcounterclockwise (Figure90).

5.Cleanthelter-seatingsurfaceofthelteradapter (Figure90).

6.Lubricatethegasketonthenewlterwiththespecied MobilM15hydraulicuid.

7.Threadthelterontothelteradapteruntilthegasket oftheltercontactstheseatingsurfaceoftheadapter (Figure90),andthentightenthelteranadditional 1/2turn(Figure90).

8.Starttheengineandletitrunforabout2minutesto purgeairfromthesystem.

9.Stoptheengineandcheckthehydraulicoillevelinthe reservoirandthelterareaforleaks.

2.Hydrauliclter

Figure91

1.Cap4.Siphonequipment

2.Dipstick

3.Fillerneck(hydraulic reservoir)

4.Routetheintakehoseofthesiphoningequipment throughthellerneckofthehydraulicreservoirandto thebottomofthereservoir(Figure91).

5.Directthedischargehoseofthesiphoningequipment intoacollectioncontainer(Figure91)witha11.4L(3 USgallon)capacity—Non-TCmodelor18.9L(5US gallon)capacity—Non-TCmodelwiththeHighFlow HydraulicKit(option)orTCmodel.

5.Collectioncontainer

6.Siphonthehydraulicuidfromthereservoir.

Page 58

7.Removethesiphoningequipmentfromthereservoir (Figure91).

8.Add7.5L(2USgallons)—Non-TCmodelor15.1L (4USgallons)—Non-TCmodelwiththeHighFlow HydraulicKit(option)orTCmodelofthespecied hydraulicuidintothehydraulicreservoir(Figure91).

Important:Useonlythehydraulicuids specied.Otheruidscouldcausesystem damage.

9.Installthedipstickandcaptothellerneckofthe hydraulicreservoir(Figure91).

10.Starttheengineandoperatethevehicletollthe hydraulicsystem.Checkthehydraulicoilleveland replenishit,ifrequired.

RaisingtheBoxinan Emergency

Figure92

1.QuickcouplerhoseA

2.QuickcouplerhoseB

Youcanraisetheboxinanemergencywithoutstartingthe enginebycrankingstarterorbyjumpinghydraulicsystem.

RaisingtheBoxUsingtheStarter

Note:Iftheenginewillnotcrank,youmustremovetheload

andbox(attachment)inordertoservicetheengine.

1.EnsurethatthetransmissionleverisintheP(park) position;refertoTransmissionLever(page15).

2.Crankthestarterwhileholdingtheliftleverinthe Raiseposition.

Note:Runthestarterfor15secondsthenwait60 secondsbeforeengagingthestarteragain.

RaisingtheBoxbyJumpingthe HydraulicSystem

Note:Thisprocedurerequires2hydraulichoses,eachwith

amaleandafemalequickcoupler,thattsthecouplerson thevehicle.

1.Backanothervehicleuptotherearofthedisabled vehicle.

Important:ThehydraulicsystemusesMobil M15.Toavoidsystemcontamination,makesure thatthevehicleyouusetojumpthehydraulic systemusesanequivalentuid.

3.Onthedisabledvehicle,connectthe2jumperhosesto thehosesthatweredisconnected(Figure93).

Note:Captheunusedttings.

Figure93

1.Disconnectedhoses2.Jumperhoses

4.Ontheothervehicle,connectthe2hosestothe couplerstillinthecouplerbracket(connectthetop hosetothetopcouplerandthebottomhosetothe bottomcoupler)(Figure94).

Note:Captheunusedttings.

2.Onbothvehicles,disconnectthe2quickcouplerhoses fromthehosessecuredtothecouplerbracket(Figure

92).

Page 59

Figure94

1.Jumperhoses

5.Keepallbystandersawayfromthevehicles.

6.Startthesecondvehicleandmovetheliftlevertothe raisepositionwhichwillraisethedisabledbox.

7.Movethehydraulicliftlevertotheneutralpositionand setthehydraulic-liftlock;refertoHydraulicLiftLever

(page16).

8.Installthebedsafetysupportontotheextendedlift cylinder;refertoUsingtheBedSafetySupport(page

36).

Note:Withboththevehiclesturnedoff,movethelift leverbackandforthtoremovethesystempressureand easethedisconnectionofthequickcouplers.

9.Aftercompletingtheoperation,removethejumper hosesandconnectthehydraulichosestobothvehicles.

Important:Checkthehydraulicuidlevelsin bothvehiclesbeforeresumingoperation.

Storage

1.Positionthemachineonalevelsurface,settheparking brake,stoptheengine,andremovetheignitionkey.

2.Cleandirtandgrimefromtheentiremachine,including theoutsideoftheenginecylinderheadnsandblower housing.

Important:Youcanwashthemachinewithmild detergentandwater.Donotusehigh-pressure watertowashthemachine.Pressurewashing themachinemaydamagetheelectricalsystem orwashawaynecessarygreaseatfrictionpoints. Avoidexcessiveuseofwater,especiallynearthe controlpanel,lights,engine,andbattery.

3.Inspectthebrakes;refertoCheckingtheBrakeFluid

(page24).

4.Servicetheaircleaner;refertoServicingtheAirFilter

(page40).

5.Greasethemachine.

6.Changetheengineoil;refertoChangingtheEngine

OilandFilter(page41).

7.Checkthetirepressure;refertoCheckingtheTire

Pressure(page26).

8.Forstorageover30days,preparethefuelsystemas follows:

A.Addapetroleumbasedstabilizer/conditionerto

thefuelinthetank.

Followmixinginstructionsfromthestabilizer manufacturer.(1ozperUSgallon).Donotuse analcoholbasedstabilizer(ethanolormethanol).

Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshgasolineandthe stabilizer/conditionerisusedatalltimes.

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystemfor5minutes.

C.Stoptheengine,allowittocool,anddrainthe

fueltank.

D.Starttheengineandrunituntilitstops.

E.Startandruntheengineagainuntilitwillnot

startagain.

F.Disposeofdrainedfuelproperly.Recycleasper

localcodes.

Important:Donotstore stabilizer/conditionedgasolineforover 90days.

9.Removethesparkplugsandchecktheircondition; refertoReplacingtheSparkPlug(page42).

10.Withthesparkplugsremovedfromtheengine,pour2 tablespoonsofengineoilintothesparkplughole.

11.Usethestartertocranktheengineanddistributethe oilinsidethecylinder.

Page 60

12.Installthesparkplugsandtighteneachonetothe recommendedtorque;refertoReplacingtheSpark

Plug(page42).

Note:Donotinstallthespark-plugwiresonthespark plugs.

13.Checktheantifreezeprotectionandadda50/50 solutionofwaterandantifreezeasneededforexpected minimumtemperatureinyourarea.

14.Removethebatteryfromthechassis,andchargeit fully;refertoServicingtheBattery(page45).

Note:Donotconnectthebatterycablestothebattery postsduringstorage.

Important:Thebatterymustbefullychargedto preventitfromfreezingandbeingdamagedat temperaturesbelow0°C(32°F).Afullycharged batterymaintainsitschargeforabout50days attemperatureslowerthan4°C(40°F).Ifthe temperatureswillbeabove4°C(40°F),checkthe waterlevelinthebatteryandchargeitevery30 days.

15.Checkandtightenallthebolts,nuts,andscrews.Repair orreplaceanypartthatisdamaged.

16.Paintallthescratchedorbaremetalsurfaces.

Note:PaintisavailablefromyourAuthorizedService Distributor.

17.Storethemachineinaclean,drygarageorstoragearea.

18.Removetheignitionkeyandputitinasafeplacethat isoutofthereachofchildren.

19.Coverthemachinetoprotectitandkeepitclean.

Page 61

Troubleshooting

Problem

Thequickcouplersaredifcultto connectordisconnect.

Thepowersteeringmoveshard.

Anattachmentdoesnotfunction.

Asquealingnoiseisheard.

PossibleCauseCorrectiveAction

1.Thehydraulicpressurenotrelieved (thequickcouplerisunderpressure).

1.Thehydraulicoillevelislow.

2.Thehydraulicoilishot.

3.Thehydraulicpumpnotoperating.

1.Thettingisloose.1.Tightenthetting. Thehydraulicttingleaks.

2.Thehydraulicttingismissingan O-ring.

1.Thequickcouplersarenotfully connected.

2.Thequickcouplersareinterchanged.2.Disconnectthequickcouplings,align

1.TheHydraulic-liftleverislockedinthe Onposition(causinghydraulicoilto owoverthereliefvalve).

1.Shutofftheengine,movethe hydraulic-liftleverforwardand backwardseveraltimes,andconnect thequickcouplersforthettingsinthe auxiliaryhydraulicpanel.

1.Servicethehydraulicreservoir.

2.Checkthehydraulicoilleveland serviceifitislow.Contactyou AuthorizedServiceDealer .

3.ContactyouAuthorizedService Dealer.

2.InstallthemissingO-ring.

1.Disconnectthequickcouplings, removeanddebrisfromthecouplings, connectthecouplings.Replaceany damagedcouplings.

thecouplingstothecorrectportson theauxiliaryhydraulicpanel,connect thecouplings.

1.Setthehydraulic-liftlocktotheUnlock positionandmovethehydraulic-lift levertoNeutral.

Theenginewillnotstart.

Thetransmissionishardtoshift

Theclutchengagementisabrupt.

1.Thehydraulic-liftleverislockedinthe Onposition.

1.Theengineidlerpmissettoofast.

2.Theclutchedaredirty .

1.Theengineidleistooslow.1.Adjusttheengineslowidleto1100

2.Thebeltisnew.

3.Theacceleratorpedalfreeplayistoo large.

4.Theclutchedaredirty .

1.Setthehydraulic-liftlocktotheUnlock position,movethehydraulic-liftleverto Neutral,andstarttheengine.

1.Adjusttheengineslowidleto1100 rpm;refertoAdjustingtheSlowIdlefor theEngine.

2.Cleantheclutches;refertoCleaning theClutches.

rpm;refertoAdjustingtheSlowIdlefor theEngine.

2.Allow10hoursofnormaloperationfor thebeltbreak-inperiod.

3.Adjusttheacceleratorpedal;referto AdjustingtheAcceleratorPedal.

4.Cleantheclutches;refertoCleaning theClutches.

Page 62

Notes:

Page 63

InternationalDistributorList

Distributor:

AgrolancKft BalamaPrimaEngineeringEquip.HongKong85221552163 B-RayCorporation

CascoSalesCompany

CeresS.A.CostaRica

CSSCTurfEquipment(pvt)Ltd.SriLanka CyrilJohnston&Co. CyrilJohnston&Co.RepublicofIreland

EquiverMexico525553995444ParklandProductsLtd.NewZealand6433493760 FemcoS.A.Guatemala ForGarderOU

G.Y .K.CompanyLtd. GeomechanikiofAthensGreece GolfinternationalTurizm GuandongGoldenStarChina HakoGroundandGardenSweden

HakoGroundandGarden HayterLimited(U.K.) HydroturfInt.CoDubai HydroturfEgyptLLC IrrimacPortugal351212388260ToroEuropeNVBelgium3214562960 IrrigationProductsInt'lPvtLtd.India0091442449

JeanHeybroekb.v.Netherlands31306394611VictusEmakPoland48618238369

Country:

Hungary3627539640

Korea82325512076

PuertoRico7877888383

NorthernIreland442890813121

Estonia3723846060

Japan81726325861

Turkey902163365993Riversa

Norway4722907760 UnitedKingdom441279723444 UnitedArabEmirates97143479479T-MarktLogisticsLtd.Hungary3626525500 Egypt2025194308ToroAustraliaAustralia61395807355

PhoneNumber:Distributor:

5062391138

94112746100

442890813121

5024423277

30109350054

862087651338 4635100000

4387

Country:

MaquiverS.A.Colombia MaruyamaMfg.Co.Inc. Mountelda.s.CzechRepublic

Mountelda.s.Slovakia

MunditolS.A.

NormaGarden OslingerTurfEquipmentSA OyHakoGroundandGarden

Perfetto PratoverdeSRL.

Prochaska&Cie RTCohen2004Ltd.

LelyTurfcare SolvertS.A.S.

SpyprosStavrinidesLimitedCyprus SurgeSystemsIndiaLimited

ValtechMorocco21253766

Japan81332522285

Argentina541 14821

Russia74954116120 Ecuador59342396970 Finland35898700733

Poland48618208416 Italy390499128

Austria4312785100 Israel97298617979 Spain Denmark4566109200 France331308177

India911292299901

Phone Number:

5712364079

420255704 220 420255704 220

9999

128

34952837500

00 35722434131

3636

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374-0269RevH

Page 64

ToroGeneralCommercialProductWarranty

ATwo-YearLimitedWarranty

ConditionsandProductsCovered

TheToroCompanyanditsafliate,T oroWarrantyCompany,pursuant toanagreementbetweenthem,jointlywarrantyourT oroCommercial product(“Product”)tobefreefromdefectsinmaterialsorworkmanship fortwoyearsor1500operationalhours*,whicheveroccursrst.This warrantyisapplicabletoallproductswiththeexceptionofAerators (refertoseparatewarrantystatementsfortheseproducts).Wherea warrantableconditionexists,wewillrepairtheProductatnocosttoyou includingdiagnostics,labor,parts,andtransportation.Thiswarranty beginsonthedatetheProductisdeliveredtotheoriginalretailpurchaser . *Productequippedwithanhourmeter.

InstructionsforObtainingWarrantyService

YouareresponsiblefornotifyingtheCommercialProductsDistributoror AuthorizedCommercialProductsDealerfromwhomyoupurchasedthe Productassoonasyoubelieveawarrantableconditionexists.Ifyouneed helplocatingaCommercialProductsDistributororAuthorizedDealer,or ifyouhavequestionsregardingyourwarrantyrightsorresponsibilities, youmaycontactusat:

ToroCommercialProductsServiceDepartment ToroWarrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1196

952–888–8801or800–952–2740 E-mail:commercial.warranty@toro.com

OwnerResponsibilities

AstheProductowner,youareresponsibleforrequiredmaintenanceand adjustmentsstatedinyourOperator'sManual.Failuretoperformrequired maintenanceandadjustmentscanbegroundsfordisallowingawarranty claim.

ItemsandConditionsNotCovered

Notallproductfailuresormalfunctionsthatoccurduringthewarranty periodaredefectsinmaterialsorworkmanship.Thiswarrantydoesnot coverthefollowing:

•Productfailureswhichresultfromtheuseofnon-T ororeplacement

parts,orfrominstallationanduseofadd-on,ormodiednon-Toro brandedaccessoriesandproducts.Aseparatewarrantymaybe providedbythemanufactureroftheseitems.

•Productfailureswhichresultfromfailuretoperformrecommended

maintenanceand/oradjustments.Failuretoproperlymaintainyour ToroproductpertheRecommendedMaintenancelistedinthe Operator’sManualcanresultinclaimsforwarrantybeingdenied.

•ProductfailureswhichresultfromoperatingtheProductinanabusive,

negligent,orrecklessmanner.

•Partssubjecttoconsumptionthroughuseunlessfoundtobedefective.

Examplesofpartswhichareconsumed,orusedup,duringnormal Productoperationinclude,butarenotlimitedto,brakepadsand linings,clutchlinings,blades,reels,rollersandbearings(sealedor greasable),bedknives,sparkplugs,castorwheelsandbearings,tires, lters,belts,andcertainsprayercomponentssuchasdiaphragms, nozzles,andcheckvalves,etc.

•Failurescausedbyoutsideinuence.Conditionsconsideredtobe

outsideinuenceinclude,butarenotlimitedto,weather,storage practices,contamination,useofunapprovedfuels,coolants,lubricants, additives,fertilizers,water,orchemicals,etc.

•Failureorperformanceissuesduetotheuseoffuels(e.g.gasoline,

diesel,orbiodiesel)thatdonotconformtotheirrespectiveindustry standards.

•Normalnoise,vibration,wearandtear ,anddeterioration.

•Normal“wearandtear”includes,butisnotlimitedto,damagetoseats

duetowearorabrasion,wornpaintedsurfaces,scratcheddecalsor windows,etc.

Parts

Partsscheduledforreplacementasrequiredmaintenancearewarranted fortheperiodoftimeuptothescheduledreplacementtimeforthatpart. Partsreplacedunderthiswarrantyarecoveredforthedurationofthe originalproductwarrantyandbecomethepropertyofT oro.T orowillmake thenaldecisionwhethertorepairanyexistingpartorassemblyorreplace it.T oromayuseremanufacturedpartsforwarrantyrepairs.

DeepCycleandLithium-IonBatteryWarranty:

DeepcycleandLithium-Ionbatterieshaveaspeciedtotalnumberof kilowatt-hourstheycandeliverduringtheirlifetime.Operating,recharging, andmaintenancetechniquescanextendorreducetotalbatterylife.Asthe batteriesinthisproductareconsumed,theamountofusefulworkbetween chargingintervalswillslowlydecreaseuntilthebatteryiscompletelyworn out.Replacementofwornoutbatteries,duetonormalconsumption, istheresponsibilityoftheproductowner.Batteryreplacementmaybe requiredduringthenormalproductwarrantyperiodatowner’sexpense. Note:(Lithium-Ionbatteryonly):ALithium-Ionbatteryhasapartonly proratedwarrantybeginningyear3throughyear5basedonthetime inserviceandkilowatthoursused.RefertotheOperator'sManualfor additionalinformation.

MaintenanceisatOwner’sExpense

Enginetune-up,lubrication,cleaningandpolishing,replacementoflters, coolant,andcompletingrecommendedmaintenancearesomeofthe normalservicesT oroproductsrequirethatareattheowner’sexpense.

GeneralConditions

RepairbyanAuthorizedToroDistributororDealerisyoursoleremedy underthiswarranty.

NeitherTheToroCompanynorToroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheToroProductscoveredbythiswarranty,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.ExceptfortheEmissionswarranty referencedbelow,ifapplicable,thereisnootherexpresswarranty.All impliedwarrantiesofmerchantabilityandtnessforusearelimitedto thedurationofthisexpresswarranty.

Somestatesdonotallowexclusionsofincidentalorconsequential damages,orlimitationsonhowlonganimpliedwarrantylasts,sotheabove exclusionsandlimitationsmaynotapplytoyou.Thiswarrantygivesyou speciclegalrights,andyoumayalsohaveotherrightswhichvaryfrom statetostate.

Noteregardingenginewarranty:

TheEmissionsControlSystemonyourProductmaybecoveredby aseparatewarrantymeetingrequirementsestablishedbytheU.S. EnvironmentalProtectionAgency(EP A)and/ortheCaliforniaAirResources Board(CARB).Thehourlimitationssetforthabovedonotapplytothe EmissionsControlSystemWarranty.RefertotheEngineEmissionControl WarrantyStatementsuppliedwithyourproductorcontainedintheengine manufacturer’sdocumentationfordetails

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedT oroproductsexportedfromtheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtain guaranteepoliciesforyourcountry ,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtaining guaranteeinformation,contacttheT oroimporter.

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