Toro 07390 Workman HDX-Auto User manual

FormNo.3406-489RevC
Workman®HDX-AutoUtility
Vehicle
ModelNo.07390—SerialNo.316000001andUp
ModelNo.07390H—SerialNo.316000001andUp
ModelNo.07390TC—SerialNo.316000001andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3406-489*C

ThisproductcomplieswithallrelevantEuropean
directives;fordetails,pleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.
WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemical
orchemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orreproductiveharm.
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
ItisaviolationofCaliforniaPublicResourceCode
Section4442or4443touseoroperatetheengineon
anyforest-covered,brush-covered,orgrass-covered
landunlesstheengineisequippedwithaspark
arrester,asdenedinSection4442,maintainedin
effectiveworkingorderortheengineisconstructed,
equipped,andmaintainedforthepreventionofre.
Introduction
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely.
YoumaycontactTorodirectlyatwww.Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.
g010502
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafety-alertsymbol
(Figure2),whichsignalsahazardthatmaycause
seriousinjuryordeathifyoudonotfollowthe
recommendedprecautions.
g000502
Figure2
Safety-alertsymbol
Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
©2017—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Contents
Safety.......................................................................4
SafeOperatingPractices....................................4
Supervisor’sResponsibilities..............................4
BeforeOperating................................................4
SafeHandlingofFuels........................................4
GeneralOperation..............................................5
Braking...............................................................6
OperatingonHills...............................................6
OperatingonRoughT errain................................7
LoadingandDumping.........................................7
HaulingtheMachine...........................................7
Maintenance.......................................................7
RolloverProtectionSystem(ROPS)
Safety..............................................................8
SafetyandInstructionalDecals..........................8
Setup......................................................................14
1InstallingtheSteeringWheel..........................15
2ConnectingtheBattery..................................15
3CheckingtheFluidLevelsandTire
Pressure.......................................................16
4InstallingtheRolloverProtectionSystem
(ROPS).........................................................16
5ConnectingtheCVT-IntakeDuct....................16
6BurnishingtheBrakes....................................17
ProductOverview...................................................18
Controls...........................................................18
ControlPanel................................................20
InstrumentCluster.........................................20
Specications..................................................23
Attachments/Accessories.................................23
Operation................................................................24
OperatingtheCargoBox..................................24
CheckingtheFluidLevels.................................25
CheckingtheOil-Pressure-Warning
Light..............................................................29
AddingFuel......................................................29
CheckingtheTirePressure...............................31
RemovingDebrisfromtheCooling
System..........................................................31
PerformingPre-StartChecks............................32
StartingtheEngine...........................................32
DrivingtheMachine..........................................32
StoppingtheMachine.......................................32
ShuttingOfftheEngine.....................................32
UsingtheSpeed-RangeControl......................33
UsingtheDifferentialLock................................33
BreakinginaNewMachine..............................34
CheckingtheSafety-InterlockSystem..............34
TransportingtheMachine.................................35
TowingtheMachine..........................................35
TowingaTrailerwiththeMachine.....................35
UsingtheHydraulicControl..............................36
Maintenance...........................................................38
RecommendedMaintenanceSchedule(s)...........38
OperatinginAdverseConditions......................39
Pre-MaintenanceProcedures..............................40
UsingtheBedSupport......................................40
RemovingtheFullBed......................................41
InstallingtheFullBed........................................41
RaisingtheMachine.........................................42
RemovingandInstallingtheHood....................43
Lubrication..........................................................44
GreasingtheBearingsandthe
Bushings.......................................................44
EngineMaintenance...........................................45
ServicingtheAirFilter.......................................45
ChangingtheEngineOilandFilter....................46
ReplacingtheSparkPlug.................................47
FuelSystemMaintenance...................................48
InspectingtheCarbonCanisterAir
Filter..............................................................48
ReplacingtheFuelFilter...................................48
InspectingtheFuelLinesand
Connections..................................................48
ElectricalSystemMaintenance...........................49
ServicingtheFuses..........................................49
Jump-StartingtheMachine...............................49
ServicingtheBattery.........................................51
DriveSystemMaintenance..................................51
MaintainingtheTires,Wheels,and
Suspension...................................................51
MaintainingtheTransmission...........................53
MaintainingtheDifferentialandAxles...............56
CoolingSystemMaintenance..............................57
ChangingtheEngineCoolant...........................57
BrakeMaintenance.............................................58
AdjustingtheParkingBrake..............................58
AdjustingtheBrakePedal.................................59
ControlsSystemMaintenance.............................60
ConvertingtheSpeedometer............................60
HydraulicSystemMaintenance...........................60
ReplacingtheHydraulicFilter...........................60
ChangingtheHydraulicFluid............................61
RaisingtheBoxinanEmergency......................61
Storage...................................................................63
Troubleshooting......................................................64
3

Safety
Improperuseormaintenancebytheoperatoror
ownercanresultininjury.Toreducethepotential
forinjury,complywiththesesafetyinstructions
andalwayspayattentiontothesafety-alert
symbol(Figure2),whichmeansCaution,Warning,
orDanger—personalsafetyinstruction.Failureto
complywiththeinstructionmayresultinpersonal
injuryordeath.
ThemachinemeetstherequirementsofSAEJ2258.
SafeOperatingPractices
Important:Thismachineisdesignedprimarily
asanoff-roadmachineandisnotintendedfor
extensiveuseonpublicroads.
Whenusingthemachineonpublicroads,follow
alltrafcregulationsanduseanyadditional
accessoriesthatmayberequiredbylaw,suchas
lights,turnsignals,slow-movingvehicle(SMV)
signs,andothersasrequired.
Thismachinewasdesignedandtestedtooffersafe
servicewhenoperatedandmaintainedproperly.
Althoughhazardcontrolandaccidentpreventionare
dependentuponthedesignandcongurationofthe
machine,thesefactorsarealsodependentupon
theawareness,concern,andpropertrainingofthe
operator,maintenance,andstorageofthemachine.
Improperuseormaintenanceofthemachinecan
resultininjuryordeath.
Thismachinehasadifferentfeelthanwhatdrivers
experiencewithpassengercarsortrucks.Sotake
timetobecomefamiliarwithyourmachine.
Notalltheattachmentsthatadapttothemachineare
coveredinthismanual.SeethespecicOperator’s
Manualprovidedwitheachattachmentforadditional
safetyinstructions.
Toreducethepotentialforinjuryordeath,comply
withthefollowingsafetyinstructions:
Supervisor’s
Responsibilities
Ensurethattheoperatorsarethoroughlytrainedand
familiarwiththeOperator’sManualandalllabelson
themachine.
BeforeOperating
•Thismachineisdesignedtocarrytheoperator
and1passengerintheseatprovidedbythe
manufacturer.Donotcarryanyotherpassengers
onthemachine.
•Becomefamiliarwiththecontrolsandknowhow
toshutoffthemachinequickly.
•Donotoperatethemachinewhileill,tired,or
undertheinuenceofalcoholordrugs.
•Wearappropriateclothing,includingeye
protection;substantial,slip-resistantfootwear;and
hearingprotection.Tiebacklonghairanddonot
wearjewelry.
•Donotallowchildrentooperatethemachine.
Donotallowadultstooperateitwithoutproper
instructions.Onlytrainedandauthorizedpersons
shouldoperatethismachine.Ensurethatall
operatorsarephysicallyandmentallycapableof
operatingthemachine.
•Keepallbystandersasafedistanceawayfrom
themachine.
•Keepallshields,safetydevices,anddecals
inplace.Ifashield,safetydevice,ordecalis
malfunctioning,illegible,ordamaged,repairor
replaceitbeforeoperatingthemachine.
•Avoiddrivingwhenitisdark,especiallyin
unfamiliarareas.Ifyoumustdrivewhenitisdark,
drivecautiouslyandusetheheadlights.
•Beforeoperatingthemachine,alwayscheckall
partsofthemachineandanyattachments.If
somethingiswrong,stopusingthemachine.
Ensurethatyoucorrecttheproblembefore
operatingthemachineorattachmentagain.
•Onlyoperatethemachineoutdoorsorina
well-ventilatedarea.
SafeHandlingofFuels
•Toavoidpersonalinjuryorpropertydamage,
useextremecarewhenhandlingfuel.Fuelis
extremelyammableandthevaporsareexplosive.
•Donotsmokenearthemachine.
•Useonlyanapprovednon-metal,portablefuel
container.
•Donotllcontainersinsideamachineoronatruck
ortrailerbedwithaplasticliner.Placeitonthe
groundandawayfromthemachinebeforelling.
•Keepthenozzleincontactwiththerimofthefuel
tankorcontainer.Removetheequipmentfromthe
bedofthemachinebeforefuelingit.Donotuse
anozzle-lock-opendevice.Ifthisisnotpossible,
thenrefuelsuchequipmentwithaportable
containerratherthanfromafuel-dispensernozzle.
4

•Donotremovethefuelcaporaddfuelwiththe
enginerunning.
•Allowtheenginetocoolbeforerefueling.
•Donotrefuelthemachineindoors.
•Donotstorethemachineorfuelcontainerwhere
thereisanopename,spark,orpilotlight,such
asonawaterheateroronotherappliances.
•Ifyouspillfuelonyourclothing,changeyour
clothingimmediately.
•Donotoverllthefueltank.Replacethefuelcap
andtightenitsecurely.
GeneralOperation
•Theoperatorandpassengershouldremainseated
wheneverthemachineisinmotion.Theoperator
shouldkeepbothhandsonthesteeringwheel,
wheneverpossible,andthepassengershoulduse
thehandholdsprovided.Keepyourarmsandlegs
withinthemachinebodyatalltimes.
•Driveslowerandturnlesssharplywhenyou
arecarryingapassenger.Rememberthatyour
passengermaynotbeexpectingyoutobrake
orturn,andmaynotbeready.Donotcarry
passengersinthecargobedoronattachments.
•Donotoverloadthemachine.Thenameplate
(locatedundertheseatassembly)showsthe
loadlimitsforthemachine.Donotoverllthe
attachmentsorexceedthemachinemaximum
grossvehicleweight(GVW).
•Whenstartingtheengine,dothefollowing:
1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.DisengagethePTO(ifequipped)andreturn
thehand-throttlelevertotheOFFposition(if
equipped).
4.Ensurethatthehydraulic-liftleverisinthe
centerposition.
5.Pressinthebrakepedal.
6.Keepyourfootofftheacceleratorpedal.
7.TurnthekeyswitchtotheSTARTposition.
•Failuretooperatethemachinesafelymayresultin
anaccident,tip-overofthemachine,andserious
injuryordeath.Drivecarefully.T opreventtipping
orlossofcontrol,takethefollowingprecautions:
–Useextremecaution,reducethespeedof
themachine,andmaintainasafedistance
aroundsandtraps,ditches,creeks,ramps,any
unfamiliarareas,orotherhazards.
–Watchforholesorotherhiddenhazards.
–Usecautionwhenoperatingthemachineon
asteepslope.Normally,travelstraightup
anddownslopes.Reducethespeedofthe
machinewhenmakingsharpturnsorwhen
turningonhillsides.Avoidturningonhillsides
wheneverpossible.
–Useextracautionwhenoperatingthemachine
onwetsurfaces,athigherspeeds,orwithafull
load.Stoppingtimeincreaseswithafullload.
–Avoidsuddenstopsandstarts.Donotgo
fromreversetoforwardorforwardtoreverse
withoutrstcomingtoacompletestop.
–Donotattemptsharpturnsorabrupt
maneuversorotherunsafedrivingactionsthat
maycausealossofcontrolofthemachine.
–Whendumping,donotletanyonestandbehind
themachineanddonotdumptheloadon
anyone’sfeet.
–Keepallbystandersasafedisawayfromthe
machine.Beforebackingup,looktotherear
andensurethatnooneisbehindthemachine.
Backupslowly.
–Watchoutfortrafcwhennearorcrossing
roads.Alwaysyieldtherightofwayto
pedestriansandothermachines.Always
signalyourturnsorstopearlyenoughsothat
otherpersonsknowwhatyouplantodo.Obey
alltrafcrulesandregulations.
–Donotoperatethemachineinornearan
areainwhichthereisdustorfumesintheair
thatareexplosive.Theelectricalandexhaust
systemsofthemachinecanproducesparks
capableofignitingexplosivematerials.
–Alwayswatchoutforandavoidlowoverhangs
suchastreelimbs,doorjambs,overhead
walkways,etc.Ensurethatthereisenough
roomoverheadtoeasilyclearthemachineand
yourhead.
–Ifyouareeverunsureaboutthesafeoperation
ofthemachine,stopyourwork,andaskyour
supervisor.
•Beforegettingofftheseat,dothefollowing:
1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Lowerthecargobed.
4.Shutofftheengineandremovethekey.
Note:Ifthemachineisonanincline,blockthe
wheelsaftergettingoffthemachine.
•Donottouchtheengine,transmission,mufer,or
mufermanifoldwhiletheengineisrunning,or
soonafteryoustopthemachine,becausethese
areasmaybehotenoughtocauseburns.
•Ifthemachineevervibratesabnormally,stopthe
machineimmediately,shutofftheengine,waitfor
allmovementtostop,andinspectfordamage.
5

Repairalldamagetothemachinebeforeyoustart
operationagain.
•Lightningcancausesevereinjuryordeath.Ifyou
seelightning,donotoperatethemachine;seek
shelter.
Braking
•Slowdownthemachinebeforeyouapproachan
obstacle.Thisgivesyouextratimetostoporturn
away.Hittinganobstaclecaninjureyouandyour
passenger.Inaddition,itcandamagethemachine
anditscontents.
•Grossvehicleweight(GVW)hasamajorimpact
onyourabilitytostopand/orturn.Heavyloads
andattachmentsmakethemachinehardertostop
orturn.Theheaviertheload,thelongerittakes
tostop.
•Decreasethespeedofthemachineifthe
cargobeenisremovedandthereisno
attachmentinstalledonthemachine.Thebraking
characteristicschangeandfaststopsmaycause
therearwheelstolockup,whichaffectsthe
controlofthemachine.
•Turfandpavementaremuchmoreslipperywhen
theyarewet.Itcantake2to4timeslongertostop
themachineonwetsurfacesthanondrysurfaces.
Ifyoudrivethroughdeep-standingwaterandget
thebrakeswet,theywillnotworkwelluntilthey
aredry.Afterdrivingthroughwater,youshould
testthebrakestoensurethattheyworkproperly.
Iftheydonot,driveslowlyonlevelgroundwhile
puttinglightpressureonthebrakepedal.This
driesoutthebrakes.
OperatingonHills
WARNING
Operatingthemachineonahillmaycause
tippingorrollingofthemachine,ortheengine
maystallandyoucouldloseheadwayonthe
hill.Thiscouldresultinpersonalinjury.
•Donotoperatethemachineonexcessively
steepslopes.
•Donotacceleratequicklyorslam
thebrakeswhenbackingdownahill,
especiallywithaload.
•Iftheenginestallsoryouloseheadwayon
ahill,slowlybackstraightdownthehill.
Donotattempttoturnthemachinearound.
•Operatethemachineslowlyonahilland
usecaution.
•Avoidturningonahill.
•Reduceyourloadandthespeedofthe
machine.
•Avoidstoppingonhills,especiallywitha
load.
Taketheseprecautionswhenoperatingthemachine
onahill:
•Slowthemachinedownbeforestartingupordown
ahill.
•Iftheenginestallsoryoubegintolosemomentum
whileclimbingahill,graduallyapplythebrakes
andslowlybackthemachinestraightdownthehill.
•Turningwhiletravelingupordownhillscanbe
dangerous.Ifyouhavetoturnwhileonahill,do
itslowlyandcautiously.Donotmakesharpor
fastturns.
•Heavyloadsaffectstability.Reducetheweightof
theloadandyourgroundspeedwhenoperating
onhillsoriftheloadhasahighcenterofgravity.
Securetheloadtothecargobedofthemachine
topreventtheloadfromshifting.Takeextracare
whenhaulingloadsthatshifteasily(liquid,rock,
sand,etc.).
•Avoidstoppingonhills,especiallywithaload.
Stoppingwhilegoingdownahilltakeslongerthan
stoppingonlevelground.Ifyoumuststopthe
machine,avoidsuddenspeedchanges,which
mayinitiatetippingorrollingofthemachine.Do
notslamonthebrakeswhenrollingbackward,as
thismaycausethemachinetooverturn.
6

OperatingonRoughTerrain
Reducethegroundspeedofthemachineandthe
loadcarriedinthemachinewhenoperatingonrough
terrain,unevenground,andnearcurbs,holes,and
othersuddenchangesinterrain.Loadsmayshift,
causingthemachinetobecomeunstable.
WARNING
Suddenchangesinterrainmaycauseabrupt
steeringwheelmovement,possiblyresulting
inhandandarminjuries.
•Reduceyourspeedwhenoperatingon
roughterrainandnearcurbs.
•Gripthesteeringwheellooselyaroundthe
perimeterkeepingthumbsupandoutof
thewayofthesteeringwheelspokes.
LoadingandDumping
•Donotexceedtheratedweightcapacityofthe
machinewhenoperatingitwithaloadinthe
cargobox,whentowingatrailer,orboth;referto
Specications(page23).
•Usecautionwhenoperatingthemachineona
hillsideoronroughterrain,particularlywithaload
inthecargoboxorwhentowingatrailerorboth.
•Beawarethatthestabilityandcontrolofthe
machinearereducedwhentheloadinthecargo
boxispoorlydistributed.
•Carryingoversizedloadsinthecargoboxchanges
thestabilityofthemachine.
•Thesteering,braking,andstabilityofthemachine
areaffectedwhencarryingaloadwheretheweight
ofthematerialcannotbeboundtothemachine,
suchastheliquidinalargetank.
WARNING
Theweightoftheboxmaybeheavy.Hands
orotherbodypartscouldbecrushed.
–Keepyourhandsandotherbodyparts
awaywhenloweringthebox.
–Donotdumpmaterialsonbystanders.
•Donotdumpaloadedcargoboxwhilethemachine
issidewaysonahill.Thechangeinweight
distributionmaycausethemachinetooverturn.
•Whenoperatingwithaheavyloadinthecargo
box,reduceyourspeedandallowforsufcient
brakingdistance.Donotsuddenlyapplythe
brakes.Useextracautiononslopes.
•Beawarethatheavyloadsincreaseyourstopping
distanceandreduceyourabilitytoturnquickly
withouttippingover.
•Therearcargospaceisintendedforloadcarrying
purposesonly,notforpassengers.
•Donotoverloadyourmachine.Thenameplate
(locatedunderthemiddleofthedash)shows
theloadlimitsforthemachine.Donotoverload
attachmentsorexceedthemachinemaximum
grossvehicleweight(GVW).
HaulingtheMachine
•Usecarewhenloadingorunloadingthemachine
intoatraileroratruck.
•Usefull-widthrampsforloadingthemachineinto
atraileroratruck.
•Tiethemachinedownsecurely.
Maintenance
WARNING
Hydraulicuidescapingunderpressurecan
havesufcientforcetopenetrateskinanddo
seriousdamage.Ifuidisinjectedintothe
skin,itmustbesurgicallyremovedwithina
fewhoursbyadoctorfamiliarwiththisform
ofinjury;otherwisegangrenemayresult.
Keepyourbodyandhandsawayfrompinhole
leaksornozzlesthatejecthydraulicuid
underhighpressure.Usepaperorcardboard,
notyourhands,tosearchforleaks.
•Beforeservicingormakinganyadjustmentstothe
machine,parkthemachineonalevelsurface,
engagetheparkingbrake,shutofftheengine,and
removethekeytopreventaccidentalstartingof
themachine.
•Donotworkunderaraisedbedwithoutplacingthe
bedsafetysupportonthefully-extendedcylinder
rod.
•Ensurethatallhydraulic-lineconnectorsaretight
andthatallthehydraulichosesandlinesarein
goodconditionbeforeapplyingpressuretothe
system.
•Beforedisconnectingorperforminganyworkon
thehydraulicsystem,relieveallpressureinthe
systembyshuttingofftheengine,cyclingthe
dumpvalvefromraisetolower,and/orloweringthe
boxandattachments.Placetheremotehydraulics
leverintheoatposition.Iftheboxmustbein
raisedposition,secureitwiththesafetysupport.
•Toensurethattheentiremachineisingood
condition,keepallthenuts,bolts,andscrews
properlytightened.
7

•Toreducethepotentialrehazard,keepthe
engineareafreeofexcessivegrease,grass,
leaves,andaccumulationofdirt.
•Ifyoumustruntheenginetoperforma
maintenanceadjustment,keepyourhands,feet,
clothing,andanypartsofthebodyawayfromthe
engineandanymovingparts.Keepbystanders
awayfromthemachine.
•Donotoverspeedtheenginebychangingthe
governorsettings.Themaximumenginespeed
is3,650rpm.Toensuresafetyandaccuracy,
haveanAuthorizedT oroDistributortocheckthe
maximumenginespeedwithatachometer.
•Ifmajorrepairsareevernecessaryorassistance
isrequired,contactanAuthorizedToroDistributor.
•Toensureoptimumperformanceandsafety,
alwayspurchasegenuineTororeplacement
partsandaccessories.Replacementpartsand
accessoriesmadebyothermanufacturerscould
bedangerous.Alteringthismachineinany
mannermayaffecttheoperationofthemachine,
performance,durability,oritsusemayresultin
injuryordeath.Suchusecouldvoidtheproduct
warrantyofTheT oro®Company.
RolloverProtectionSystem
(ROPS)Safety
•DonotremovetheROPSfromthemachine.
•Ensurethattheseatbeltisattachedandthatyou
canreleaseitquicklyinanemergency.
•Checkcarefullyforoverheadobstructionsanddo
notcontactthem.
•KeeptheROPSinsafeoperatingconditionby
thoroughlyinspectingitperiodicallyfordamage
andkeepingallthemountingfastenerstight.
•ReplaceadamagedROPS.Donotrepairoralter
it.
•TheROPSisanintegralsafetydevice.
•Alwayswearyourseatbelt.
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decal93-9850
93-9850
1.Donotrepairorrevise—readtheOperator'sManual.
decal93-9852
93-9852
1.Warning—readtheOperator’sManual.2.Crushinghazard—installthecylinderlock.
8

decal93-9868
93–9868
1.Crushinghazardofhand—readtheOperator’sManual.
decal93-9879
93-9879
1.Storedenergyhazard—readtheOperator'sManual.
93-9899
decal93-9899
93-9899
1.Crushinghazard—installthecylinderlock.
decal105-4215
105-4215
1.Warning—avoidpinchpoints.
decal105-7977
105–7977
1.Tank2.Pressure
decal106-2353
106-2353
1.Electricalpowerpoint
decal106-6755
106-6755
1.Enginecoolantunder
pressure.
3.Warning—donottouchthe
hotsurface.
2.Explosionhazard—read
theOperator'sManual.
4.Warning—readthe
Operator'sManual.
9

decal106-7767
106-7767
1.Warning—readtheOperator'sManual;avoidtippingthe
machine;weartheseatbelt;leanawayfromthedirection
themachineistipping.
decal115-2047
115-2047
1.Warning—donottouchthehotsurface.
decal115-2282
115-2282
1.Warning—readtheOperator'sManual.
2.Warning—stayawayfrommovingparts,keepallguardsandshieldsinplace.
3.Crushing/dismembermenthazardofbystanders—keepbystandersasafedistanceawayfromthemachine,donotcarry
passengersinthecargobed,keeparmsandlegsinsideofthemachineatalltimes,anduseseatbeltsandhandholds.
10

decal115-7723
115-7723
1.Warning—thehydraulic-uidpressureis124bar(1,800psi).
2.CouplerA
3.CouplerB
decal115-7739
115-7739
1.Falling,crushinghazard,bystanders—noridersonmachine
decal115-7756
115-7756
1.High-owhydraulics—engaged
decal121-9776
121-9776
1.Warning—readtheOperator’sManualandreceiveproper
trainingbeforeoperatingthemachine.
4.Warning—engagetheparkingbrake,shutofftheengine,and
removethekeyfromthekeyswitchbeforewalkingawayfrom
themachine.
2.Warning—wearhearingprotection.5.Tippinghazard—taketurnsslowly;driveslowlyupandacross
cliffs;withnoload,donotexceed32kph(20mph);while
carryingaloadorwhendrivingonuneventerrain,driveslowly.
3.Firehazard—shutofftheenginebeforerefuelingthemachine.
11

decal121-9890
121-9890
1.Parkingbrake4.Cylinderretract7.Fast
2.Hydraulicsystem—unlock5.Cylinderextend8.Slow
3.Hydraulicsystem—lock6.Transport
decal127-8620
127-8620
1.Headlights4.Horn7.Engine—start
2.Differentiallock—lock5.Engine—shutoff8.Brake
3.Differentiallock—unlock6.Engine—run
12

decal127-8626a
127-8626
1.Powertakeoff(15A)5.Differentiallock(15A)
2.Startengine(10A)6.Speedometer(10A)
3.Hazardlights(10A)7.Headlightsandrearlights
(15A)
4.Engineignition(10A)8.Horn(30A)
decal127-8760
127–8760
1.Park4.Lowgear
2.Reverse5.Drive
3.Neutral
decal136-1163
136-1163
1.Donotexceedatransport
loadof1591kg(3,500lb).
2.Donotexceedatowing
weightof273kg(600lb).
13

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
Steeringwheel1
Cover1
1Washer(5/8inch)1
Installthesteeringwheel(TCandH
modelsonly).
2Nopartsrequired–Connectthebattery(TCandHmodels
only).
3Nopartsrequired–Checktheuidlevelsandtirepressure.
ROPSframe1
4Flange-headbolt(1/2x1-1/4inches)6
MounttheRolloverProtectionSystem
(ROPS).
5Nopartsrequired–Connectthecontinuously-variable
transmissionintakeduct.
6Nopartsrequired–Burnish(break-in)thebrakes.
MediaandAdditionalParts
DescriptionQty.Use
Operator'sManual1Readbeforeoperatingthemachine.
OperatorTrainingMaterial1Viewbeforeoperatingthemachine.
CVTKit121-98531ConnecttheCVTIntakeDuct(TCandHModelsOnly)
CVTAdapter127-87501ConnecttheCVTIntakeDuct(TCandHModelsOnly)
Note:Determinetheleftandrightsideofthemachinefromthenormaloperatingposition.
14

1
InstallingtheSteering
Wheel
TCandHModelsOnly
Partsneededforthisprocedure:
1Steeringwheel
1Cover
1Washer(5/8inch)
Procedure
1.Ifthecoverisinstalled,removeitfromthehub
ofthesteeringwheel(Figure3).
2.Removethenutfromthesteeringshaft(Figure
3).
3.Slidethesteeringwheelandwasherontothe
steeringshaft(Figure3).
4.Securethesteeringwheeltotheshaftwiththe
nutandtightenitto27to34N∙m(20to25ft-lb).
5.Installthecoveronthesteeringwheel(Figure3).
g024240
Figure3
1.Cover4.Steeringwheel
2.Nut5.Steeringshaft
3.Washer(5/8inch)
2
ConnectingtheBattery
TCandHModelsOnly
NoPartsRequired
Procedure
WARNING
Incorrectlyroutingthebatterycablecould
damagethemachineandcables,causing
sparks.Sparkscancausethebatterygasses
toexplode,resultinginpersonalinjury.
•Alwaysdisconnectthenegativebattery
cable(black)beforedisconnectingthe
positivebatterycable(red).
•Alwaysconnectthepositivebatterycable
(red)rst.
1.Squeezethebatterycovertoreleasethetabs
fromthebatterybase(Figure4).
g010326
Figure4
1.Batterycover
2.Removethebatterycoverfromthebatterybase
(Figure4).
3.Connectthepositivebatterycable(red)tothe
positive(+)terminalofthebatteryandsecure
thecablewiththeboltsandnuts(Figure5).
15

g026250
Figure5
1.Insulatorboot(positive
batterycable)
3.Negativebatterycable
(black)
2.Negativebatterypost
4.Slidetheinsulatorbootoverthepositive
terminal.
Note:Theinsulatorbootpreventsapossible
short-to-groundfromoccurring.
5.Connectthenegativebatterycable(black)tothe
negative(–)terminalofthebatteryandsecure
thecablewithboltsandnuts.
6.Alignthebatterycovertothebatterybase
(Figure4).
7.Squeezethebatterycover,alignthetabsto
thebatterybase,andreleasethebatterycover
(Figure4).
3
CheckingtheFluidLevels
andTirePressure
NoPartsRequired
Procedure
1.Checktheengine-oillevelbeforeandafter
yourststarttheengine;refertoCheckingthe
Engine-OilLevel(page25).
2.Checkthetransmission-uidlevelbeforeyou
rststarttheengine;refertoCheckingthe
Transmission-FluidLevel(page53).
3.Checktheengine-coolantlevelbeforeyou
rststarttheengine;refertoCheckingthe
Engine-CoolantLevel(page27).
4.Checkthebrake-uidlevelbeforeyourststart
theengine;refertoCheckingtheBrake-Fluid
Level(page28).
5.Checktheairpressureinthetires;referto
CheckingtheTirePressure(page31).
4
InstallingtheRollover
ProtectionSystem(ROPS)
Partsneededforthisprocedure:
1ROPSframe
6Flange-headbolt(1/2x1-1/4inches)
Procedure
1.Applymedium-grade(service-removable)
thread-lockingcompoundtothethreadsofthe6
ange-headbolts(1/2x1-1/4inches).
2.AligneachsideoftheROPSwiththemounting
holesoneachsideofthemachineframe(Figure
6).
g009812
Figure6
1.ROPSmountingbracket2.Flange-headbolt(1/2x
1-1/4inches)
3.SecuretheROPSmountingbrackettothe
machineframeusing3ange-headbolts(1/2x
1-1/4inches)oneachside(Figure6).
4.Torquetheange-headbolts(1/2x1-1/4inches)
to115N∙m(85ft-lb).
16

5
ConnectingtheCVT-Intake
Duct
NoPartsRequired
Procedure
Important:Removetheplasticbagcoveringthe
endoftheCVTductbeforestartingtheengine.
TheCVTKit(PartNo.121-9853)andAdapterKit
(PartNo.127-8750)arerequiredforthisprocedure.
1.Loosenthehoseclampsecuringtheplasticbag
attheendoftheCVT-intakehoseandremove
thebag.
2.Raisethecargobedbyperformingthefollowing:
A.Engagetheparkingbrake.
B.Starttheengine.
C.Movethehydraulic-liftleverrearwardto
raisethecargobox.
D.Shutofftheengine.
E.Removethebedsupportfromthestorage
bracketsonthebackoftheROPSpanel
andinstallthesupportontothecylinderrod
ofthebed-liftcylinder;refertoUsingthe
BedSupport(page40).
3.AligntheCVT-intakehoseontotheintake-tube
connectoratthebacksideoftheROPSpanel
andtightenthehoseclamp(Figure7).
g026251
Figure7
1.CVT-intakehose3.Intake-tubeconnector
2.Hoseclamp
4.Removethebedsupport,lowerthebed,shutoff
theengine,andremovethekey.
6
BurnishingtheBrakes
NoPartsRequired
Procedure
Toensureoptimumperformanceofthebrakesystem,
burnish(break-in)thebrakesbeforeuse.
1.Bringthemachineuptofullspeed,applythe
brakestorapidlystopthemachinewithout
lockingupthetires.
2.Repeatthisprocedure10times,waiting1minute
betweenstops,toavoidoverheatingthebrakes.
Important:Thisprocedureismosteffective
ifthemachineisloadedwith454kg(1,000
lb).
17

ProductOverview
Controls
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
AcceleratorPedal
Usetheacceleratorpedal(Figure8)tovarytheground
speedofthemachinewhenthetransmissionisin
gear.Pressingdowntheacceleratorpedalincreases
theenginespeedandgroundspeed.Releasingthe
pedaldecreasestheenginespeedandgroundspeed.
g024307
Figure8
1.Brakepedal2.Acceleratorpedal
BrakePedal
Usethebrakepedaltostoporslowthemachine
(Figure8).
CAUTION
Operatingamachinewithwornorincorrectly
adjustedbrakescanmayresultinpersonal
injury.
Ifthebrakepedaltravelstowithin25mm(1
inch)ofthemachineoorboard,adjustor
repairthebrakes.
TransmissionLever
Usethetransmissionlever(Figure9)toshiftthe
transmissionbetweenP(PARK),R(REVERSE),N
(NEUTRAL),L(LOWFORWARD),andD(DRIVE)ground
operation.
Important:Donotshiftthetransmissiontothe
REVERSE,LOW,orDRIVEgearunlessthemachine
ismotionlessandtheengineisatlowidle;
otherwise,youcoulddamagethetransmission.
g028609
Figure9
1.Transmissionlever4.N(neutral)
2.P(park)5.L(lowforward)
3.R(reverse)6.D(drive)
18

Parking-BrakeLever
Wheneveryoushutofftheengine,engagethe
parkingbrake(Figure10)topreventthemachinefrom
accidentallymoving.Ifthemachineisparkedona
steepgrade,ensurethatyouengagetheparking
brake.
•Toengagetheparkingbrake,pullbackonthe
parking-brakelever.
•Todisengagetheparkingbrake,pushthe
parking-brakeleverforward.
Note:Disengagetheparkingbrakebefore
movingthemachine.
•Ifyouparkthemachineonasteepuphillor
downhillgrade,shiftthetransmissionintoP(PARK)
andengagetheparkingbrake.Placechocksat
thedownhillsideofthewheels.
g028610
Figure10
1.Parking-brakelever
Hydraulic-LiftLever
Thehydraulicliftraisesandlowersthebed.Move
thehydraulic-liftleverrearwardtoraisethebed,and
forwardtolowerit(Figure11).
Important:Whenloweringthebed,holdthelever
intheforwardpositionfor1to2secondsafterthe
bedcontactstheframetosecureitinthelowered
position.Donotholdthehydraulicliftintheraise
orlowerpositionformorethan5seconds,once
thecylindersreachtheendoftheirtravel.
g024361
Figure11
1.Lowerthebed4.Unlocked
2.Raisethebed5.Hydraulic-liftlock
3.Locked6.Hydraulic-liftlever
Hydraulic-LiftLock
Thehydraulic-liftlocksecurestheliftlever,sothatthe
hydrauliccylindersdonotoperatewhenthemachine
isnotequippedwithabed(Figure11).Italsolocksthe
liftleverintheONpositionwhenusingthehydraulics
forattachments.
Speed-RangeLever
Usethespeed-rangelever(Figure12)toselect1of
the4work-speedrangesforprecisecontrolofthe
maximumgroundspeedoratransportspeedrange
formovingthemachinebetweenjobsites.
g024320
Figure12
1.Speed-rangelever4.C(mid-highrange)
2.T(transportrange)5.B(mid-lowrange)
3.D(highrange)6.A(lowrange)
19

ControlPanel
g024365
Figure13
1.High-owhydraulics
switch(TCmodelsonly)
6.Off
2.Lightswitch7.On
3.Differentialswitch8.Start
4.Hornbutton(TCmodels
only)
9.Powerpoint
5.Keyswitch
High-FlowHydraulicsSwitch
TCModelsOnly
Pushtheswitchdowntostartthehigh-owhydraulics
andpushtheswitchuptoshutoffthehydraulics
(Figure13).
Note:Youmustsetthehigh-owhydraulicsswitchto
theOFFpositiontostarttheengine.
LightSwitch
Pushthelightswitch(Figure13)totogglethe
headlightsonoroff.
Differential-LockSwitch
Thedifferential-lockswitchallowsyoutolocktherear
axleforincreasedtraction.Pushthedifferential-lock
switch(Figure13)totogglethedifferentiallockonor
off.
Note:Youmaylockandunlockthedifferentialwhile
themachineisinmotion.
HornButton
InternationalModelsOnly
Thehornbuttonislocatedonthecontrolpanel(Figure
13).Pressthehornbuttontosoundthehorn.
KeySwitch
Usethekeyswitch(Figure13)tostartandshutoffthe
engine.T oshutofftheengine,rotatethekeyswitch
counterclockwisetotheOFFposition.
Thekeyswitchhas3positions:OFF,RUN,and
START.RotatethekeyswitchclockwisetotheSTART
positiontoengagethestartermotor.Releasethekey
switchwhentheenginestarts.Thekeyswitchmoves
automaticallytotheONposition.
PowerPoint
Usethepowerpoint(Figure13)topoweroptional12
Velectricalaccessories.
InstrumentCluster
g024370
Figure14
1.Tachometer5.Charge-indicatorlight
2.Hourmeter6.Check-enginelight
3.Speedometer7.Low-oilpressurelight
4.Fuelgauge8.Coolant-temperature
gauge
Tachometer
Thetachometerdisplaysthespeedoftheengine
(Figure14).
Note:Thewhitetriangleindicatesthedesiredengine
speedfor540rpmPTOoperation.
20