Table of Contents
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Contents
Safety ....................................................................... 4
General Safety ................................................... 4
Safety and Instructional Decals .......................... 5
Setup .......................................................................11
1 Installing the Roll Bar ......................................11
Pressure ....................................................... 12
3 Burnishing the Brakes.................................... 12
Product Overview ................................................... 13
Controls ........................................................... 13
Specifications .................................................. 19
Attachments/Accessories ................................. 19
Before Operation ................................................. 20
Before Operation Safety ................................... 20
Performing Daily Maintenance.......................... 20
Checking the Tire Pressure............................... 20
Adding Fuel ...................................................... 21
Breaking in a New Machine .............................. 21
Checking the Safety-Interlock System .............. 22
During Operation ................................................. 22
During Operation Safety ................................... 22
Operating the Cargo Bed .................................. 24
Starting the Engine ........................................... 25
Engaging the 4-Wheel Drive ............................. 25
Driving the Machine .......................................... 25
Stopping the Machine ....................................... 26
Shutting Off the Engine..................................... 26
Using the Differential Lock ................................ 26
Using the Hydraulic Control .............................. 26
After Operation .................................................... 28
After Operation Safety ...................................... 28
Hauling the Machine ......................................... 29
Towing the Machine .......................................... 29
Towing a Trailer ................................................ 29
Maintenance ........................................................... 30
Maintenance Safety.......................................... 30
Recommended Maintenance Schedule(s) ........... 31
Operating Conditions .................................... 33
Pre-Maintenance Procedures .............................. 33
Preparing the Machine for Maintenance............ 33
Using the Bed Support...................................... 33
Removing the Full Bed...................................... 34
Installing the Full Bed........................................ 35
Raising the Machine ......................................... 36
Removing and Installing the Hood .................... 36
Lubrication .......................................................... 37
Greasing the Bearings and Bushings ................ 37
Engine Maintenance ........................................... 39
Engine Safety ................................................... 39
Servicing the Air Cleaner .................................. 39
Servicing the Engine Oil.................................... 40
Replacing the Spark Plugs................................ 42
Fuel System Maintenance ................................... 43
Replacing the Fuel Filter ................................... 43
Inspecting Fuel Lines and Connections............. 43
Electrical System Maintenance ........................... 44
Electrical System Safety ................................... 44
Servicing the Fuses .......................................... 44
Jump-Starting the Machine............................... 44
Servicing the Battery......................................... 45
Drive System Maintenance .................................. 46
Level ............................................................. 46
Changing the Front Differential Oil .................... 46
Inspecting the Constant-Velocity Boot .............. 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
Torquing the Wheel Lug Nuts ............................ 49
Cooling System Maintenance .............................. 50
Cooling System Safety ..................................... 50
Checking the Engine-Coolant Level.................. 50
System.......................................................... 51
Changing the Engine Coolant ........................... 51
Brake Maintenance ............................................. 52
Checking the Brake-Fluid Level ........................ 52
Adjusting the Parking Brake.............................. 52
Adjusting the Brake Pedal................................. 53
Belt Maintenance ................................................ 54
Adjusting the Alternator Belt ............................. 54
Controls System Maintenance ............................. 55
Adjusting the Clutch Pedal................................ 55
Adjusting the Accelerator Pedal ........................ 56
Hydraulic System Maintenance ........................... 56
Hydraulic System Safety................................... 56
System.......................................................... 56
System.......................................................... 59
Raising the Cargo Bed in an Emergency ........... 60
Cleaning .............................................................. 62
Washing the Machine ....................................... 62
Storage ................................................................... 63
Storage Safety.................................................. 63
Storing the Machine.......................................... 63
Troubleshooting ...................................................... 64
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