Toro 7360 User manual

FormNo.3359-770RevB
Workman®3200&4200
LiquidCooledGasUtilityVehicle
ModelNo.07360—SerialNo.280000001andUp
ModelNo.07361—SerialNo.280000001andUp
ModelNo.07361TC—SerialNo.280000001andUp
ModelNo.07365—SerialNo.280000001andUp
Registeratwww.Toro.com.OriginalInstructions(EN)

Introduction
Warning
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:Theengineinthisproductisnot
equippedwithasparkarrestermufer.Itisa
violationofCaliforniaPublicResourceCode
Section4442touseoroperatethisengineonany
forest-covered,brush-covered,orgrass-covered
landasdenedinCPRC4126.Otherstatesor
federalareasmayhavesimilarlaws.
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.
Figure2
1.Safetyalertsymbol
Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
©2007—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA.
AllRightsReserved

Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
Supervisor’sResponsibilities.................................4
BeforeOperating.................................................4
WhileOperating...................................................5
Maintenance.........................................................6
SoundPressureLevel...........................................7
VibrationLevel.....................................................7
SafetyandInstructionalDecals.............................7
Setup..........................................................................13
1InstalltheRearFenders....................................13
2InstalltheWheels............................................14
3InstalltheSteeringWheel.................................14
4InstalltheFrontFenders..................................15
5InstalltheROPS..............................................15
6ActivateandChargetheBattery........................16
7FullBedRemoval.............................................17
8Re-InstalltheFullBed......................................18
ProductOverview......................................................19
Controls.............................................................19
Specications.....................................................22
Attachments/Accessories...................................23
Operation...................................................................23
CheckCrankcaseOil..........................................23
FillFuelTank.....................................................24
CheckCoolingSystem........................................25
CheckTransaxle/HydraulicFluid......................25
CheckFrontDifferentialOil...............................26
CheckTorqueOfWheelNuts.............................26
CheckTirePressure............................................26
CheckBrakeFluid..............................................26
CheckFanBeltTension......................................27
Pre–startingChecks............................................27
StartingEngine...................................................27
DrivingVehicle..................................................28
StoppingVehicle................................................28
StoppingEngine.................................................28
NewVehicleBreak–in........................................28
CheckInterlockSystem......................................28
OperatingCharacteristics...................................29
Passengers..........................................................30
Speed.................................................................30
Turning..............................................................30
Braking..............................................................30
Tipovers.............................................................31
Hills...................................................................31
LoadingAndDumping.......................................32
UsingTheDifferentialLock...............................32
FourWheelDrive...............................................33
TransportingVehicle..........................................33
TowingVehicle...................................................33
TrailerTowing....................................................33
HydraulicControl...............................................34
Maintenance...............................................................36
RecommendedMaintenanceSchedule(s)................36
ServiceIntervalChart.........................................37
HeavyDutyOperation.......................................37
PremaintenanceProcedures....................................38
UsingBedSafetySupport...................................38
JackingVehicle...................................................39
Lubrication.............................................................39
GreasingBearingsandBushings.........................39
EngineMaintenance...............................................41
GeneralAirCleanerMaintenance
Practices.........................................................41
ServicingAirCleaner..........................................41
ChangingEngineOilAndFilter..........................41
ReplacingSparkPlugs.........................................42
FuelSystemMaintenance.......................................43
FuelSystem........................................................43
ElectricalSystemMaintenance................................43
Fuses..................................................................43
JumpStartingVehicle.........................................44
BatteryCare.......................................................44
DriveSystemMaintenance.....................................45
ChangeFrontDifferentialOil.............................45
InspectConstantVelocityBoot...........................45
AdjustingShiftCables........................................45
AdjustingHigh–lowCable..................................45
AdjustingDifferentialLockCable.......................45
InspectTires......................................................46
FrontWheelToe................................................46
CoolingSystemMaintenance..................................47
RemovingDebrisFromEngineCooling
System............................................................47
ChangingEngineCoolant...................................47
BrakeMaintenance.................................................49
InspectBrakes....................................................49
BeltMaintenance....................................................49
AdjustingBelts...................................................49
ControlsSystemMaintenance.................................50
AdjustingAcceleratorPedal................................50
AdjustingBrakePedal.........................................51
AdjustingClutchPedal.......................................51
AdjustingParkingBrake.....................................52
HydraulicSystemMaintenance...............................53
ChangingTransaxle/HydraulicFluid.................53
ReplacingHydraulicFilter...................................53
CleaningHydraulicStrainer................................54
EmergencyBoxRaising......................................54
Storage.......................................................................56
BatteryStorage...................................................56
Schematics.................................................................57
3

Safety
TheTOROWORKMANmeetstherequirementsof
SAEJ2258.
Supervisors,operatorsandservicepersonsshouldbe
familiarwiththefollowingstandardsandpublications:
(Thematerialmaybeobtainedfromtheaddressshown).
•FlammableandCombustibleLiquidsCode:
ANSI/NFPA30
•NationalFireProtectionAssociation:
ANSI/NFPA#505;PoweredIndustrialTrucks
ADDRESS:
NationalFirePreventionAssociation
BarrymarchPark
Quincy,Massachusetts02269U.S.A
•ANSI/ASMEB56.8PersonalBurdenCarriers
ADDRESS:
AmericanNationalStandardsInstitute,Inc.
1430Broadway
NewYork,NewYork10018U.S.A.
•ANSI/UL558;InternalCombustionEngine
PoweredIndustrialTrucks
TrucksADDRESS:
AmericanNationalStandardsInstitute,Inc.
1430Broadway
NewYork,NewYork10018U.S.A.
OR
UnderwritersLaboratories
333PngstenRoad
Northbrook,Illinois60062U.S.A.
SafeOperatingPractices
TheWorkmanisanoff–highwayvehicleonly,
andisnotdesigned,equipped,ormanufactured
foruseonpublicstreets,roadsorhighways.
TheWorkmanwasdesignedandtestedtooffersafe
servicewhenoperatedandmaintainedproperly.
Althoughhazardcontrolandaccidentprevention
partiallyaredependentuponthedesignand
congurationofthemachine,thesefactorsarealso
dependentupontheawareness,concern,andproper
trainingofthepersonnelinvolvedintheoperation,
maintenanceandstorageofthemachine.Improperuse
ormaintenanceofthemachinecanresultininjuryor
death.
Thisisaspecializedutilityvehicledesignedforoff–road
useonly.itsrideandhandlingwillhaveadifferent
feelthanwhatdriversexperiencewithpassengercars
ortrucks.Sotaketimetobecomefamiliarwithyour
Workman.
NotalloftheattachmentsthatadapttotheWorkman
arecoveredinthismanual.SeethespecicOperator’s
Manualprovidedwithattachmentforadditionalsafety
instructions.Readthesemanuals.
Toreducethepotentialforinjuryordeath,comply
withthefollowingsafetyinstructions:
Supervisor’sResponsibilities
•Makesureoperatorsarethoroughlytrainedand
familiarwiththeOperator’sManualandalllabels
onthevehicle.
•Besuretoestablishyourownspecialproceduresand
workrulesforunusualoperatingconditions(e.g.
slopestoosteepforvehicleoperation).Usethe3rd
HighLockoutswitchifhighspeedcouldresultina
safetyorvehicleabusesituation.
BeforeOperating
•Operatethemachineonlyafterreadingand
understandingthecontentsofthismanual.A
replacementmanualisavailablebysendingcomplete
modelandserialnumberto:TheToro®Company,
8111LyndaleAvenueSouth,Minneapolis,Minnesota
55420.
•Neverallowchildrentooperatethevehicle.Never
allowadultstooperateitwithoutproperinstructions.
Onlytrainedandauthorizedpersonsshouldoperate
thisvehicle.Makesurealloperatorsarephysically
andmentallycapableofoperatingthevehicle.
•Thisvehicleisdesignedtocarryonlyyou,the
operator,andonepassengerintheseatprovidedby
themanufacturer.Nevercarryanyotherpassengers
onthevehicle.
•Neveroperatethevehiclewhenundertheinuence
ofdrugsoralcohol.
•Becomefamiliarwiththecontrolsandknowhowto
stoptheenginequickly.
•Keepallshields,safetydevicesanddecalsinplace.
Ifashield,safetydeviceordecalismalfunctioning,
4

illegible,ordamaged,repairorreplaceitbefore
operatingthemachine.
•Alwayswearsubstantialshoes.Donotoperate
machinewhilewearingsandals,tennisshoesor
sneakers.Donotwearloosettingclothingor
jewelrywhichcouldgetcaughtinmovingpartsand
causepersonalinjury.
•Wearingsafetyglasses,safetyshoes,longpantsanda
helmetisadvisableandrequiredbysomelocalsafety
andinsuranceregulations.
•Keepeveryone,especiallychildrenandpets,away
fromtheareasofoperation.
•Beforeoperatingthevehicle,alwayscheckallparts
ofthevehicleandanyattachments.Ifsomethingis
wrong,stopusingvehicle.Makesureproblemis
correctedbeforevehicleorattachmentisoperated
again.
•Sincegasolineishighlyammable,handleitcarefully.
–Useanapprovedfuelcontainer.
–Donotremovecapfromfueltankwhenengine
ishotorrunning.
–Donotsmokewhilehandlingfuel.
–Fillfueltankoutdoorsandtoaboutoneinch
belowtopoftank(bottomofllerneck).Do
notoverll.
–Wipeupanyspilledfuel.
•Operatevehicleonlyoutdoorsorinawellventilated
area.
•Useonlyanapprovednon–metal,portablefuel
container.Staticelectricdischargecanignitefuel
vaporsinaungroundedfuelcontainer.Removethe
fuelcontainerfromthebedofthevehicleandplace
onthegroundawayfromthevehiclebeforelling.
Keepnozzleincontactwithcontainerwhilelling.
Removeequipmentfromvehiclebedbeforelling.
•Checkthesafetyinterlocksystemdailyforproper
operation.Ifaswitchshouldmalfunction,replace
theswitchbeforeoperatingmachine.Afterevery
twoyears,replacetheinterlockswitchesinthesafety
system,whethertheyareworkingproperlyornot.
WhileOperating
•Operatorandpassengershoulduseseatbeltsand
remainseatedwheneverthevehicleisinmotion.
Operatorshouldkeepbothhandsonsteeringwheel,
wheneverpossibleandpassengershouldusehand
holdsprovided.Keeparmsandlegswithinthe
vehiclebodyatalltimes.Nevercarrypassengers
intheboxoronattachments.Rememberyour
passengermaynotbeexpectingyoutobrakeorturn
andmaynotbeready.
•Neveroverloadyourvehicle.Nameplate(located
undermiddleofdash)showsloadlimitsforvehicle.
Neveroverllattachmentsorexceedthevehicle
maximumGVW .
•Whenstartingtheengine:
–Sitonoperator’sseatandensureparkingbrake
isengaged.
–DisengagePTO(ifsoequipped)andreturnhand
throttlelevertoOFFposition(ifsoequipped).
–Makesurethehydraulicliftleverisinthecenter
position.
–MoveshiftlevertoNEUTRALanddepress
clutchpedal.
–Keepfootoffacceleratorpedal.
–TurnignitionkeytoSTART.
•Usingthemachinedemandsattention.Failureto
operatevehiclesafelymayresultinanaccident,tip
overofvehicleandseriousinjuryordeath.Drive
carefully.Topreventtippingorlossofcontrol:
–Useextremecaution,reducespeedandmaintain
asafedistancearoundsandtraps,ditches,creeks,
ramps,anyunfamiliarareasorotherhazards.
–Watchforholesorotherhiddenhazards.
–Usecautionwhenoperatingvehicleonasteep
slope.Normallytravelstraightupanddown
slopes.Reducespeedwhenmakingsharpturns
orwhenturningonhillsides.Avoidturningon
hillsideswheneverpossible.
–Useextracautionwhenoperatingvehicleonwet
surfaces,athigherspeedsorwithafullload.
Stoppingtimewillincreasewithafullload.Shift
intoalowergearbeforestartingupordowna
hill.
–Whenloadingbed,distributeloadevenly.Use
extracautioniftheloadexceedsthedimensions
ofthevehicle/bed.Operatevehiclewithextra
cautionwhenhandlingoff–centerloadsthat
cannotbecentered.Keeploadsbalancedand
securetopreventthemfromshifting.
–Avoidsuddenstopsandstarts.Donotgofrom
reversetoforwardorforwardtoreversewithout
rstcomingtoacompletestop.
–Donotattemptsharpturnsorabruptmaneuvers
orotherunsafedrivingactionsthatmaycausea
lossofvehiclecontrol.
–Donotpassanothervehicletravelinginthesame
directionatintersections,blindspots,oratother
dangerouslocations.
5

–Whendumping,donotletanyonestandbehind
vehicleanddonotdumploadonanyone’sfeet.
Releasetailgatelatchesfromsideofbox,not
frombehind.
–Keepallbystandersaway.Beforebackingup,
looktotherearandassurenooneisbehindthe
vehicle.Backupslowly.
–Watchoutfortrafcwhennearorcrossingroads.
Alwaysyieldtherightofwaytopedestriansand
othervehicles.Thisvehicleisnotdesignedfor
useonstreetsorhighways.Alwayssignalyour
turnsorstopearlyenoughsootherpersons
knowwhatyouplantodo.Obeyalltrafcrules
andregulations.
–Neveroperatevehicleinornearanareawhere
thereisdustorfumesintheairwhichare
explosive.Theelectricalandexhaustsystems
ofthevehiclecanproducesparkscapableof
ignitingexplosivematerials.
–Alwayswatchoutforandavoidlowoverhangs
suchastreelimbs,doorjambs,overhead
walkways,etc.Makesurethereisenoughroom
overheadtoeasilyclearthevehicleandyour
head.
–Ifeverunsureaboutsafeoperation,STOP
WORKandaskyoursupervisor.
•Donottouchengine,transaxle,radiator,muferor
mufermanifoldwhileengineisrunningorsoon
afterithasstoppedbecausetheseareasmaybehot
enoughtocauseburns.
•Ifthemachineevervibratesabnormally,stop
immediately,turnengineoff,waitforallmotion
tostopandinspectfordamage.Repairalldamage
beforeresumingoperation.
•Beforegettingofftheseat:
–Stopmovementofthemachine.
–Lowerbed.
–Shutengineoffandwaitforallmovementto
stop.
–Setparkingbrake.
–Removekeyfromignition.
Maintenance
•Beforeservicingormakingadjustmentstothe
machine,stopengine,setparkingbrakeandremove
keyfromignitiontopreventaccidentalstartingof
theengine.
•Neverworkunderaraisedbedwithoutplacingbed
safetysupportonfullyextendedcylinderrod.
•Makesureallhydrauliclineconnectorsaretight,and
allhydraulichosesandlinesareingoodcondition
beforeapplyingpressuretothesystem.
•Keepbodyandhandsawayfrompinholeleaksor
nozzlesthatejecthydraulicuidunderhighpressure.
Usepaperorcardboard,nothands,tosearchfor
leaks.Hydraulicuidescapingunderpressurecan
havesufcientforcetopenetrateskinanddoserious
damage.Ifuidisinjectedintotheskinitmustbe
surgicallyremovedwithinafewhoursbyadoctor
familiarwiththisformofinjuryorgangrenemay
result.
•Beforedisconnectingorperforminganyworkon
thehydraulicsystem,allpressureinsystemmust
berelievedbystoppingengine,cyclingdump
valvefromraisetolowerand/orloweringboxand
attachments.Placetheremotehydraulicsleverin
theoatposition.Ifboxmustbeinraisedposition,
securewithsafetysupport.
•Tomakesureentiremachineisingoodcondition,
keepallnuts,boltsandscrewsproperlytightened.
•Toreducepotentialrehazard,keeptheengine
areafreeofexcessivegrease,grass,leavesand
accumulationofdirt.
•Iftheenginemustberunningtoperforma
maintenanceadjustment,keephands,feet,clothing,
andanypartsofthebodyawayfromtheengineand
anymovingparts.Keepeveryoneaway.
•Donotoverspeedenginebychanginggovernor
settings.Maximumenginespeedis3650rpm.To
assuresafetyandaccuracy,haveanAuthorizedToro
Distributorcheckmaximumenginespeedwitha
tachometer.
•Ifmajorrepairsareeverneededorassistanceis
required,contactanAuthorizedToroDistributor.
•Tobesureofoptimumperformanceandsafety,
alwayspurchasegenuineTororeplacementpartsand
accessories.Replacementpartsandaccessoriesmade
byothermanufacturerscouldbedangerous.Altering
thisvehicleinanymannermayaffectthevehicle’s
operation,performance,durabilityoritsusemay
resultininjuryordeath.Suchusecouldvoidthe
productwarrantyofTheToro®Company.
•Thisvehicleshouldnotbemodiedwithout
TheToro®Company’sauthorization.Directany
inquiriestoTheToro®Company,Commercial
Division,VehicleEngineeringDept.,8111Lyndale
Ave.So.,Bloomington,Minnesota55420–1196.
USA
6

SoundPressureLevel
ThisunithasanequivalentcontinuousA-weighted
soundpressureattheoperatorearof:88dB(A),based
onmeasurementsofidenticalmachinesperDirective
98/37/ECandamendments.
VibrationLevel
Hand-Arm
Thisunitdoesnotexceedavibrationlevelof2.5m/s2at
thehandsbasedonmeasurementsofidenticalmachines
perISO5349procedures.
WholeBody
Thisunitdoesnotexceedavibrationlevelof0.5m/s2
attheposterior,basedonmeasurementsofidentical
machinesperISO2631procedures.
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.
93-9852
1.Warning—readtheOperator’sManual.2.Crushinghazard—installthecylinderlock.
93-9448
1.Warning—whenaddingfueltothetank,leave25mm
betweenthefuelandthetopofthetank;readtheOperator’s
Manual.
93-9442
1.Maximumtongueweight
is90kg;maximumtrailer
weightis680kg.
2.Forinformationon
transmissionuid,read
theOperator’sManual.
93-9879
1.Storedenergyhazard—readtheOperator’sManual.
93-8071
1.Hotsurface/burnhazard—stayasafedistancefromthe
hotsurface.
93-9447
1.Warning—readtheOperator’sManual;removetheignition
keybeforeservicingorperformingmaintenanceonthe
engineairintakesystem.
7

93-6687
1.Donotstephere.
93-7814
1.Entanglementhazard,belt—stayawayfrommovingparts.
93-9449
1.ReadtheOperator’s
Manual.
3.Addgrease(9grease
points).
2.Greaseevery100hours.
115-2320
1.Warning—donotoperate
thevehicleonpublic
streets,roads,orhighways.
4.Engine—preheat7.Temperaturelevel10.Engine—run
2.Headlights5.Horn8.Hourmeter11.Engine—start
3.Engine—oil6.Battery9.Engine—stop
105-4215
1.Warning—avoidpinchpoints.93-9862
1.Entanglementhazard,shaft—stayawayfrommovingparts,
keepallguardsandshieldsinplace.
8

106-2353
1.Electricalpowerpoint
106-2355
1.Slow3.Transmission—thirdhigh;
nofastspeed
2.Fast
106-2377
1.Locked8.Warning—readtheOperator’sManual.
2.Differentiallock9.Entanglementhazard,shaft—keepbystander’sasafe
distancefromthevehicle.
3.Unlocked10.Retracthydraulics
4.Hydrauliclock11.Extendhydraulics
5.Engage12.Transmission—highspeed
6.Powertake-off(PTO)13.Transmission—lowspeed
7.Disengage14.Parkingbrake
9

110-2599
1.Warning—readtheOperator’sManual.
2.Firehazard—stoptheenginebeforefueling.
3.Tippinghazard—readtheOperator’sManual,donotoperatethismachineunlessyouaretrained,usecautionanddriveslowly
whendrivingonslopes,slowdownandturngradually,donotexceed20mph(32kph),anddriveslowlyoverroughterrainor
whencarryingafullorheavyload.
4.Crushing/dismembermenthazardofbystanders—keepbystandersasafedistancefromthevehicle,donotcarrypassengersin
thecargobed,andkeeparmsandlegsinsideofthevehicleatalltimes.
5.Warning—stoptheengineandremovetheignitionkeybeforeleavingthevehicle.
93-6689
1.Warning—donotcarrypassengers.
98-9335
1.Cutting/dismembermenthazard,fan—stayawayfrom
movingparts.
93–9868
1.Crushinghazardofhand—readtheOperator’sManual.
106-7894
1.Engine—start3.Headlights
2.Ignition4.Powerpoint
106-7767
1.Warning—readtheOperator’sManual;avoidtippingthe
machine;weartheseatbelt;leanawayfromthedirection
themachineistipping.
10

106-7888
1.Warning—readthe
hydraulicoilpressure
is124bar(1800psi)
3.CouplerB
2.CouplerA
93-9899
93-9899
1.Crushinghazard—installthecylinderlock.
BatterySymbols
Someorallofthesesymbolsareonyourbattery
1.Explosionhazard6.Keepbystandersasafe
distancefromthebattery.
2.Nore,opename,or
smoking.
7.Weareyeprotection;
explosivegasescan
causeblindnessandother
injuries
3.Causticliquid/chemical
burnhazard
8.Batteryacidcancause
blindnessorsevereburns.
4.Weareyeprotection9.Flusheyesimmediately
withwaterandgetmedical
helpfast.
5.ReadtheOperator’s
Manual.
10.Containslead;donot
discard.
93-9850
1.Donotrepairorrevise—readtheOperator’sManual.
11

106-2384
12

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
Rearfender2
Bolts,3/8x1–1/4in10
Locknut,3/82
1Supportplate2
Mounttherearfenders.
Wheelnut10
Frontwheel2
Wheelnut10
2Rearwheel2
Mountthewheels.
Steeringwheel1
Cap1
Washer1
3Foamseal1
Installthesteeringwheel.
Frontfender2
Sockethexheadbolt,#10x3/4”in.10
Washer,.210I.D.20
4Locknut,#1010
Installthefrontfenders.
ROPSframe1
bolt,1/2x3”in.4
5Locknut,1/24
MounttheROPS(RolloverProtection
System)
MediaandAdditionalParts
DescriptionQty.Use
Operator’sManual1Readbeforeoperatingthevehicle
PartsManual1Usetoreferencepartnumbers
Note:Determinetheleftandrightsideofthemachine
fromthenormaloperatingposition.1
InstalltheRearFenders
Partsneededforthisprocedure:
2Rearfender
10Bolts,3/8x1–1/4in
2Locknut,3/8
2Supportplate
Procedure
1.Loosenthelocknutsandboltssecuringtaillight
bracketstorightandleftframebrackets(Figure3).
2.Pivottaillightbracketsrearwardandtightenbolts
andlocknuts.
13

Figure3
1.Fender
3.Securerearofeachtaillightbrackettorearof
framebracketswitha5/16x1in.bolt,.344”I.D.
atwasherandlocknut,asshowninFigure3.
Figure4
1.Fender2.Supportplate
4.Looselysecureafendertoeachsideofframewith
asupportplate,(5)3/8x1–1/4in.bolts,anda
locknutasshowninFigure4.
Note:Weldnutsareinplacetosecure(4)ofthe
bolts.
5.Tightenallfasteners.
2
InstalltheWheels
Partsneededforthisprocedure:
10Wheelnut
2Frontwheel
10Wheelnut
2Rearwheel
Procedure
1.Removelugnutssecuringwheelstowheelbrackets.
Retainlugnuts.
2.Mountwheelsandinstalllugnuts.Torquelugnuts
to45–65ft-lb.
Figure5
1.Wheel2.Wheelnut
14

3
InstalltheSteeringWheel
Partsneededforthisprocedure:
1Steeringwheel
1Cap
1Washer
1Foamseal
Procedure
1.Removethejamnutfromthesteeringshaft.Slide
thefoamseal,steeringwheelandwasheronto
steeringshaft(Figure6).
2.Securesteeringwheeltoshaftwithjamnutand
tightenitto10-15ft-lb.
3.Installcaptosteeringwheel.
Figure6
1.Steeringwheel3.Cap
2.Jamnut4.Washer
4
InstalltheFrontFenders
Partsneededforthisprocedure:
2Frontfender
10Sockethexheadbolt,#10x3/4”in.
20Washer,.210I.D.
10Locknut,#10
Procedure
1.Alignthevefendermountingholeswiththeholes
ineachsideofbody(Figure7).
2.Mountafendertoeachsideofbodywith(5)#10x
3/4in.socketheadbolts,(10)atwashersand(5)
#10locknuts.Positionawashernexttobolthead
andlocknut.
Figure7
1.Fender
15

5
InstalltheROPS
Partsneededforthisprocedure:
1ROPSframe
4bolt,1/2x3”in.
4Locknut,1/2
Procedure
1.InserteachsideofROPSintomountingbracket
oneachsideofvehicleframe,positioningROPSas
showninFigure8.
Note:TheROPScoverplatemountingboltsmay
havetobeloosenedtoinserttheROPSintothe
mountingbrackets.
2.SecureeachsideofROPStomountingbracketswith
(2)1/2–13x3”lg.boltsandlocknuts.
Figure8
1.ROPS3.Covermountingplate
2.Mountingbracket
6
ActivateandChargethe
Battery
Partsneededforthisprocedure:
Procedure
Ifbatteryisnotlledwithelectrolyteoractivated,it
mustberemovedfromvehicle,lledwithelectrolyte
andcharged.Bulkelectrolytewith1.260specicgravity
canbepurchasedfromalocalbatterysupplyoutlet.
Warning
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
Batteryelectrolytecontainssulfuricacidwhich
isadeadlypoisonandcausessevereburns.
•Donotdrinkelectrolyteandavoidcontact
withskin,eyesorclothing.Wearsafety
glassestoshieldyoureyesandrubbergloves
toprotectyourhands.
•Fillthebatterywherecleanwaterisalways
availableforushingtheskin.
1.Loosenknobssecuringbatterycovertobatterybase
andslidecoveroff.
16

Figure9
1.Batterycover3.Batterybase
2.Knob
2.Removebolt,washersandlocknutsecuringbattery
holddowntobatterybase.Removeholddownand
slidebatteryoutofbatterybase.
3.Removellercapsfrombatteryandslowlylleach
celluntilelectrolyteisjustabovetheplates.
4.Replacellercapsandconnecta3to4ampbattery
chargertothebatteryposts.Chargethebatteryata
rateof3to4amperesfor4to8hours.
Chargingthebatteryproducesgassesthatcan
explode.
Neversmokenearthebatteryandkeepsparks
andamesawayfrombattery.
5.Whenbatteryischarged,disconnectchargerfrom
electricaloutletandbatteryposts.
Figure10
1.Positive(+)cable
6.Removellercaps.Slowlyaddelectrolytetoeach
celluntillevelisuptollring.Installllercaps.
Important:Donotoverllbattery.Electrolyte
willoverowontootherpartsofthevehicleand
severecorrosionanddeteriorationwillresult.
7.Slidebatteryintobatterybasesobatteryterminals
aretowardtherearofthevehicle.
8.Installthepositivecable(red)tothepositive(+)
terminalandthenegativecable(black)tothe
negative(—)terminalofthebatteryandsecure
withboltsandnuts.Slidetherubberbootoverthe
positiveterminaltopreventpossibleshort–outfrom
occurring.
Incorrectbatterycableroutingcoulddamage
themachineandcablescausingsparks.Sparks
cancausethebatterygassestoexplode,
resultinginpersonalinjury.
•Alwaysdisconnectthenegative(black)
batterycablebeforedisconnectingthe
positive(red)cable.
•Alwaysconnectthepositive(red)battery
cable
9.Installbatteryholddownandsecuretobasewith
bolt,washersandlocknut.
10.Reinstallbatterycovertobatterybaseandtighten
knobs.
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7
FullBedRemoval
NoPartsRequired
Procedure
1.Startengine.Engagehydraulicliftleverandlower
beduntilcylindersarelooseinslots.Releaseliftlever
andturnoffengine.
2.Removelynchpinsfromouterendsofcylinderrod
clevispins(Figure11).
Figure11
1.Bedmountingplate4.Lynchpin
2.Cylinderrodend5.Rearslots(Fullbed)
3.Clevispin6.Frontslots(2/3bed)
3.Removeclevispinssecuringcylinderrodendsto
bedmountingplatesbypushingpinstowardsinside
(Figure11).
4.Removelynchpinsandclevispinssecuringpivot
bracketstoframechannels(Figure11).
5.Liftbedoffvehicle.
Thefullbedweighsapproximately325pounds,
sodonottrytoinstallorremoveitbyyourself.
Useanoverheadhoistorgetthehelpoftwoor
threeotherpeople.
6.Storecylindersinstorageclips.Engagehydrauliclift
lockleveronvehicletopreventaccidentalextension
ofliftcylinders.
8
Re-InstalltheFullBed
NoPartsRequired
Procedure
Note:Ifbedsideswillbeinstalledonatbed,itis
easiertoinstallthembeforebedisinstalledonvehicle.
Note:Assurerearpivotplatesareboltedtothebed
frame/channelsothatlowerendanglestotherear
(Figure12).
Figure12
1.Leftrearcornerofbed4.Clevispin
2.Vehicleframechannel5.Lynchpin
3.Pivotplate
Note:Makesurespacerbracketsandwearblocks
(Figure13)areinstalledorradiatorcovermaybe
damaged.Carriageboltsheadstobepositionedinside
themachine.
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Thefullbedweighsapproximately325pounds,
sodonottrytoinstallorremoveitbyyourself.
Useanoverheadhoistorgetthehelpoftwoor
threeotherpeople.
Figure13
1.Spacerbracket3.Carriagebolt
2.Wearblock
1.Assureliftcylindersarefullyretracted.
2.Carefullysetbedontovehicleframealigningrearbed
pivotplateholeswithholesinrearframechannel
andinstall(2)clevispinsandlynchpins(Figure12).
3.Withbedlowered,secureeachcylinderrodend,to
appropriateslotsinbedmountingplateswithclevis
pinandlynchpin.Insertclevispinfromoutsideof
bedwithlynchpintowardoutside(Figure12).Rear
slotsareforfullbedinstallationandfrontslotsare
for2/3bedinstallation.
Note:Enginemayneedtobestartedtoextend
orretractcylindersforalignmentwithholes.Keep
ngersout!
Note:Unusedslotcanbepluggedwithaboltand
nuttopreventassemblyerrors.
4.Startengineandengagehydraulicliftlevertoraise
bed.Releaseliftleverandturnoffengine.Installthe
bedsafetysupporttopreventaccidentalloweringof
thebed.RefertoUsingBedSafetySupport.
5.Installlynchpinstoinsideendsofclevispins.
Note:Ifautomatictailgatereleasehasbeen
installedonbed,makesurefrontdumplinkrodhas
beenplacedoninsideofleftsideclevispinbefore
lynchpinisinstalled.
ProductOverview
Controls
Note:Determinetheleftandrightsideofthemachine
fromthenormaloperatingposition.
AcceleratorPedal
Theacceleratorpedal(Figure14)givestheoperatorthe
abilitytovaryengineandgroundspeedofthevehicle,
whenthetransmissionisingear.Depressingthepedal
increasesengineRPMandgroundspeed.Releasing
pedalwilldecreaseengineRPMandgroundspeedof
themachine.
Figure14
1.Acceleratorpedal3.Brakepedal
2.Clutchpedal
ClutchPedal
Theclutchpedal(Figure14)mustbefullydepressed
todisengageclutchwhenstartingengineorshifting
transmissiongears.Releasepedalsmoothlywhen
transmissionisingeartopreventunnecessarywearon
transmissionandotherrelatedparts.
Important:Donotrideclutchpedalduring
operation.Clutchpedalmustbefullyoutorclutch
willslipcausingheatandwear.Neverholdthe
vehiclestoppedonahillusingtheclutchpedal.
Damagetotheclutchmayoccur.
BrakePedal
Thebrakepedal(Figure14)isusedtoapplyservice
brakestostoporslowvehicle.
19

Wornormisadjustedbrakesmayresultin
personalinjury.Ifbrakepedaltravelstowithin
1–1/2”ofthevehicleoorboard,thebrakes
mustbeadjustedorrepaired.
GearShiftLever
Fullydepressclutchpedalandmoveshiftlever
(Figure16)intodesiredgearselection.Adiagramofthe
shiftpatternisindicatedinFigure15.
Figure15
Important:Donotshiftthetransaxletothereverse
orforwardgearunlessthevehicleisstandingstill.
Damagetotransaxlemayoccur.
Downshiftingfromtoohighaspeedcan
causetherearwheelstoskidresultinginloss
ofvehiclecontrolaswellasclutchand/or
transmissiondamage.Shiftsmoothlytoavoid
grindinggears.
DifferentialLock
Allowsrearaxletobelockedforincreasedtraction.
Differentiallock(Figure16)maybeengagedwith
vehicleinmotion.Moveleverforwardandtotheright
toengagelock.
Note:Vehiclemotionplusaslightturnisrequiredto
engageordisengagedifferentiallock.
Turningwiththedifferentiallockoncanresult
inlossofvehiclecontrol.Donotoperatewith
differentiallockonwhenmakingsharpturnsor
athighspeeds.Refertousingthedifferential
lock.
Figure16
1.Gearshiftlever4.Hydraulicliftlock
2.Parkingbrake5.Differentiallock
3.Hydraulicbedlift6.High–lowrangeshifter
ParkingBrake
Whenevertheengineisshutoff,theparkingbrake
(Figure16)mustbeengagedtopreventaccidental
movementofthevehicle.Toengagetheparkingbrake,
pullbackonlever.Todisengage,pushleverforward.
Makesureparkingbrakeisreleasedbeforemoving
vehicle.Ifvehicleisparkedonasteepgrade,makesure
parkingbrakeisapplied.Also,shiftthetransmission
into1stgearonauphillgradeorreverseonadownhill
grade.Placechocksatthedownhillsideofwheels.
HydraulicLift
Raisesandlowersbed.Moverearwardtoraise,forward
tolower(Figure16).
Important:Whenloweringbed,holdleverin
forwardpositionfor1or2secondsafterbed
contactsframetosecureitinloweredposition.
Donotholdthehydraulicliftineithertheraiseor
lowerposition,formorethan5seconds,oncethe
cylindershavereachedtheendoftheirtravel.
HydraulicLiftLock
Locksliftleversohydrauliccylindersdonotoperate
whenvehicleisnotequippedwithabed(Figure16).
ItalsolocksliftleverinONpositionwhenusingthe
hydraulicsforattachments.
High–LowRangeShifter
Addsthreeadditionalspeedsforprecisespeedcontrol
(Figure16).
•Vehiclemustbecompletelystoppedbeforeshifting
betweenHighandLowrange.
20