Table of Contents
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Contents
Introduction .................................................................. 2
Safety ........................................................................... 4
Safe Operating Practices........................................... 4
Sound Pressure ....................................................... 7
Vibration................................................................ 7
Safety and Instructional Decals ................................. 8
Setup ...........................................................................13
only) .................................................................13
(ROPS)-TC models only ...................................13
3 Checking the Fluid Levels .....................................14
Product Overview .........................................................15
Controls ...............................................................15
Specifications ........................................................18
Attachments/Accessories........................................18
Operation ....................................................................19
Operating the Cargo Box.........................................19
Checking the Engine-oil Level..................................20
Responding to a Check-engine Light .........................21
Adding Fuel...........................................................21
Checking the Coolant Level .....................................22
Level.................................................................23
models only) ......................................................24
drive models only)...............................................24
Checking the Torque of the Wheel Nuts.....................25
Checking the Tire Pressure ......................................25
Checking the Brake-fluid Level .................................25
Starting the Engine .................................................26
Driving the Machine ...............................................26
Stopping the Machine .............................................27
Stopping the Engine ...............................................27
Breaking in a New Machine......................................27
Checking the Safety-interlock System ........................27
Ensuring Passenger Safety .......................................28
Ensuring Proper Speed ...........................................28
Ensuring Proper Turning.........................................28
Ensuring Proper Braking .........................................28
Preventing Tip Overs..............................................29
Operating on Hills..................................................29
Loading and Dumping ............................................29
Using the Differential Lock......................................30
only) .................................................................30
Transporting the Machine........................................30
Towing the Machine ...............................................31
Towing a Trailer with the Machine.............................31
Using the Hydraulic Control ....................................31
Maintenance .................................................................34
Recommended Maintenance Schedule(s) ......................34
Operating in Adverse Conditions..............................35
Premaintenance Procedures ........................................36
Using the Bed Support ............................................36
Removing the Full Bed............................................37
Installing the Full Bed .............................................37
Raising the Machine................................................38
Removing the Hood ...............................................39
Installing the Hood.................................................39
Lubrication ...............................................................40
Greasing the Bearings and Bushings ..........................40
Engine Maintenance ..................................................42
Inspecting the Carbon Canister Air Filter ...................42
Servicing the Air Cleaner .........................................42
Changing the Engine Oil and Filter ...........................43
Replacing the Spark Plug .........................................43
Fuel System Maintenance ...........................................44
Replacing the Fuel Filter..........................................44
Inspecting the Fuel Lines and Connections.................44
Electrical System Maintenance ....................................45
Servicing the Fuses .................................................45
Jump Starting the Machine.......................................45
Servicing the Battery...............................................46
Drive System Maintenance .........................................47
models only) ......................................................47
drive models only)...............................................47
Adjusting the Shift Cables........................................47
Adjusting the High-Low Cable ................................47
Adjusting Differential-lock Cable..............................47
Inspecting the Tires ................................................48
Checking the Front-wheel Alignment ........................48
Cooling System Maintenance ......................................49
Removing Debris from the Cooling System ................49
Changing the Engine Coolant...................................50
Brake Maintenance ....................................................51
Adjusting the Parking Brake .....................................51
Adjusting the Brake Pedal ........................................51
Belt Maintenance ......................................................52
Adjusting the Alternator Belt ...................................52
Controls System Maintenance .....................................53
Adjusting the Clutch Pedal.......................................53
Converting the Speedometer....................................53
Hydraulic System Maintenance ....................................54
Strainer..............................................................54
Replacing the Hydraulic Filter ..................................54
(TC models only) ................................................55
Raising the Cargo Box in an Emergency .....................55
Cleaning ...................................................................57
Washing the Machine ..............................................57
Storage ........................................................................57
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