Contents
Introduction................................................................. 2
Safety ........................................................................... 4
Safe Operating Practices ....................................... 4
Supervisor’s Responsibilities ................................. 5
Before Operating ................................................. 5
While Operating................................................... 5
Maintenance......................................................... 7
Sound Pressure Level ........................................... 7
Vibration Level..................................................... 7
Safety and Instructional Decals ............................. 8
Setup.......................................................................... 13
1 Install the Steering Wheel(TC Models
Only).............................................................. 13
2 Install ROPS(TC Models Only) ........................ 13
3 Activate and Charge the Battery(TC Models
Only).............................................................. 14
4 Checking Fluid Levels ...................................... 15
Product Overview ...................................................... 16
Controls ............................................................. 16
Specifications ..................................................... 20
Attachments/Accessories................................... 20
Operation................................................................... 20
Checking the Engine Oil Level............................ 20
Adding Fuel ....................................................... 21
Checking the Coolant Level ................................ 23
Checking the Transaxle/Hydraulic Fluid
Level .............................................................. 23
Checking the High Flow Hydraulic Fluid (TC
models only)................................................... 23
Checking the Front Differential Oil Level
(Four Wheel Drive Models Only) .................... 24
Checking the Torque of the Wheel
Nuts............................................................... 24
Checking the Tire Pressure ................................. 25
Checking the Brake Fluid.................................... 25
Pre–starting Checks............................................ 25
Starting the Engine ............................................. 26
Driving the Vehicle............................................. 26
Stopping the Vehicle........................................... 26
Stopping the Engine ........................................... 26
New Vehicle Break–in ........................................ 27
Checking the Interlock System............................ 27
Operating Characteristics ................................... 27
Passengers.......................................................... 28
Speed ................................................................. 28
Turning .............................................................. 29
Braking .............................................................. 29
Tip Overs........................................................... 29
Hills ................................................................... 29
Loading and Dumping........................................ 30
Using The Differential Lock ............................... 30
Four Wheel Drive (Four Wheel Drive Models
Only).............................................................. 31
Transporting Vehicle .......................................... 31
Towing the Vehicle ............................................. 32
Towing a Trailer with the Vehicle......................... 32
Hydraulic Control............................................... 32
Maintenance............................................................... 34
Recommended Maintenance Schedule(s) ................ 34
Service Interval Chart......................................... 35
Heavy Duty Operation ....................................... 36
Premaintenance Procedures.................................... 36
Using the Bed Safety Support.............................. 36
Removing the Full Bed ....................................... 37
Installing the Full Bed......................................... 37
Jacking the Vehicle.............................................. 38
Removing the Hood ........................................... 39
Lubrication............................................................. 40
Greasing Bearings and Bushings ......................... 40
Engine Maintenance............................................... 42
Servicing the Air Cleaner .................................... 42
Changing the Engine Oil And Filter .................... 42
Fuel System Maintenance ....................................... 43
Fuel Lines and Connections................................ 43
Servicing the Water Separator/Fuel
Filter .............................................................. 43
Electrical System Maintenance................................ 44
Fuses.................................................................. 44
Jump Starting the Vehicle.................................... 45
Servicing the Battery........................................... 45
Drive System Maintenance ..................................... 46
Changing the Front Differential Oil (Four
Wheel Drive Models Only) ............................. 46
Inspecting the Constant Velocity Boot (Four
Wheel Drive Models Only) ............................. 46
Adjusting the Shift Cables................................... 47
Adjusting the High–Low Cable ........................... 47
Adjusting Differential Lock Cable....................... 47
Inspecting the Tires ............................................ 47
Checking the Front Wheel Alignment ................. 48
Cooling System Maintenance .................................. 49
Removing Debris from the Cooling
System............................................................ 49
Changing Engine Coolant................................... 49
Brake Maintenance ................................................. 50
Adjusting the Parking Brake................................ 50
Adjusting the Brake Pedal ................................... 51
Belt Maintenance.................................................... 51
Adjusting Belts ................................................... 51
Controls System Maintenance................................. 52
Adjusting the Accelerator Pedal .......................... 52
Adjusting the Clutch Pedal.................................. 52
Converting the Speedometer .............................. 53
Hydraulic System Maintenance ............................... 53
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