Workman® HDX-Auto Utility Vehicle

Push the switch down to start the high-flow hydraulics and push the switch up to shut off the hydraulics (Figure 13).

Note: You must set the high-flow hydraulics switch to the OFF position to start the engine.

Push the light switch (Figure 13) to toggle the headlights on or off.

The differential-lock switch allows you to lock the rear axle for increased traction. Push the differential-lock switch (Figure 13) to toggle the differential lock on or off.

Note: You may lock and unlock the differential while the machine is in motion.

The horn button is located on the control panel (Figure 13). Press the horn button to sound the horn.

Use the key switch (Figure 13) to start and shut off the engine. To shut off the engine, rotate the key switch counterclockwise to the OFF position.

The key switch has 3 positions: OFF, RUN, and START. Rotate the key switch clockwise to the START position to engage the starter motor. Release the key switch when the engine starts. The key switch moves automatically to the ON position.

Use the power point (Figure 13) to power optional 12 V electrical accessories.

The tachometer displays the speed of the engine (Figure 14).

Note: The white triangle indicates the desired engine speed for 540 rpm PTO operation.

Figure 15

1. Engine speed (rpm)
2. 3,300 rpm for 540 rpm PTO operation

The hour meter indicates the total hours of machine operation. The hour meter (Figure 14) starts to function whenever you rotate the key switch to the ON position or if the engine is running.

The speedometer registers the ground speed of the machine (Figure 14). The speedometer is in mph, but you can easily convert it to km/h; refer to Converting the Speedometer.

The check-engine light (Figure 14) illuminates to notify the operator of an engine malfunction.

Contact your authorized Toro distributor.

The oil-pressure-warning light (Figure 14) illuminates if the engine-oil pressure drops below a safe level while the engine is running.

Important: If the light flickers or remains on, stop the machine, shut off the engine, and check the oil level. If the oil level is low, but adding oil does not cause the light to go out when the engine is started, shut off the engine immediately, and contact your Authorized Service Dealer for assistance.

Check the operation of the warning lights as follows:

1. Engage the parking brake.

2. Turn the key switch to the ON/PREHEAT position, but do not start the engine.

   Note: The oil-pressure light should glow red. If the light does not function, either a bulb is burned out or there is a malfunction in the system that you must repair.

   Note: If engine was just shut off, it may take 1 to 2 minutes for the light to come on.

The coolant-temperature gauge and light registers the coolant temperature in the engine and operates only when the key switch is in ON position (Figure 14). The indicator light blinks red if the engine overheats.

The fuel gauge shows the amount of fuel in the tank. It displays only when key switch is in the ON position (Figure 14). The red segment of the display indicates a low-fuel level and the flashing red light indicates that the fuel in the tank is near empty.

Before starting the machine each day, perform the Each Use/Daily procedures listed in .

Front tires air pressure specification: 220 kPa (32 psi)

Tear tires air pressure specification: 124 kPa (18 psi)

Important: Check the tire pressure frequently to ensure proper inflation. If the tires are not inflated to the correct pressure, the tires will wear prematurely and may cause the 4-wheel drive to bind.

Figure 18 shows an example of tire wear caused by under-inflation.

Figure 18

1. Under-inflated tire

Figure 19 shows an example of tire wear caused by over-inflation.

Figure 19

1. Over-inflated tire

• For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an cetane rating of 87 or higher ((R+M)/2 rating method).

• Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use. Never use gasoline that contains more than 10% ethanol by volume, such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains up to 85% ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.

• Do not use gasoline containing methanol.

• Do not store fuel either in the fuel tank or fuel containers over the winter unless you use a fuel stabilizer.

• Do not add oil to gasoline.

Perform the following to provide proper performance for the machine:

• Ensure that the brakes are burnished; refer to Burnishing the Brakes.

• Check the fluid and engine-oil levels regularly. Remain alert for signs that the machine or its components are overheating.

• After starting a cold engine, let it warm up for about 15 seconds before using the machine.

  Note: Allow more time for the engine to warm up when operating in cold temperatures.

• Vary the machine speed during operation. Avoid fast starts and quick stops.

• A break-in oil for the engine is not required. Original engine oil is the same type specified for regular oil changes.

• Refer to for any special, low-hour checks.

The purpose of the safety-interlock system is to prevent the engine from cranking or starting, unless you press the clutch pedal.

Note: Refer to the attachment Operator’s Manual for procedures on checking the attachment interlock system.

Important: Do not attempt to push or tow the machine to get it started. Damage to the drive train could result.

1. Sit on the operator seat and engage the parking brake.

2. Disengage the PTO and the high-flow hydraulics (if equipped) and move the hand-throttle lever to the OFF position (if equipped).

3. Move the transmission lever to the (PARK) position.

4. Ensure that the hydraulic-lift lever is in the OFF position (center).

5. Press the brake pedal.

   Note: Keep your foot off the accelerator pedal.

6. Insert the key into the key switch and rotate it clockwise to start the engine.

   Note: Release the key switch when the engine starts.

   Note: The oil-pressure warning light should turn off.

   Important: To prevent overheating of the starter motor, do not engage starter longer than 15 seconds. After 15 seconds of continuous cranking, wait 60 seconds before engaging starter motor again.

1. Press the brake pedal.

2. Disengage the parking brake.

3. Move the transmission lever to the desired gear.

4. Release the service brake and gradually press in the accelerator pedal.

   Important: Always stop the machine before shifting to reverse a forward gear or to a forward gear from reverse.

   Use the chart below to determine the ground speed of each gear when operating the machine with the speed-range control in the (TRANSPORT) position.

   Gear	Speed (km/h)	Speed (mph)
   (REVERSE)	0 to 21	0 to 13
   (LOW FORWARD)	0 to 18	0 to 11
   (DRIVE)	0 to 32	0 to 20

   Note: Avoid idling the engine for long periods of time.

   Note: Leaving the key switch in the ON position for long periods of time without starting the engine discharges the battery.

To stop the machine, remove your foot from the accelerator pedal, then press the brake pedal.

1. Stop the machine.

2. Move the transmission lever to the (PARK) position.

3. Engage the parking brake.

4. Rotate the key switch to the OFF position and remove the key.

Use the lever of the speed-range control to limit the maximum ground speed of the machine for operations that require a constant speed like spraying and top dressing. The speed-range lever (Figure 23) is used to select 1 of the 4 work-speed ranges that are used to limit maximum ground speed or a transport-speed range that is used when you move the machine between job sites.

Note: You must release the accelerator pedal in order to shift between speed ranges, but you do not need to stop the machine in order to shift.

• Move the speed-range lever into the detent for speed ranges A, B, C, and D when precise control of maximum-ground speed is desired.

• Move the speed-range lever to the T (TRANSPORT) position by moving the speed-range lever out of the detent for range A, B, C, or D, then forward to the T (TRANSPORT) position.

Note: Use the speed-range control to limit the maximum ground speed in each range by 4 to 18 km/h (2.5 to 11 mph) with the transmission lever in the (LOW FORWARD) position or 8 to 32 km/h (5 to 20 mph) with the transmission lever in the in the (DRIVE) position.

Figure 23

1. Speed-range lever
2. T (transport range)
3. D (high range)
4. C (mid-high range)
5. B (mid-low range)
6. A (low range)

The differential lock increases the traction of the machine by locking the rear wheels so that a wheel does not spin out. This can help when you have heavy loads to haul, on wet turf or slippery areas, going up hills, and on sandy surfaces. It is important to remember that this extra traction is only for temporary, limited use. Its use does not replace the safe operation already discussed concerning steep hills and heavy loads.

The differential lock causes the rear wheels to spin at the same speed. When using the differential lock, your ability to make sharp turns is somewhat restricted and may scuff the turf. Use the differential lock only when needed and at slower speeds.

Note: Machine motion plus a slight turn is required to engage or disengage differential lock.

• Press the differential-lock switch up to lock the differential (Figure 24).

  Note: The light in the differential-lock switch illuminates when the switch is in the lock position.

• Press the differential-lock switch up to unlock the differential (Figure 24).

Figure 24

1. Lock position (differential-lock switch)
2. Unlock position (differential-lock switch)

The hydraulic control supplies hydraulic power from the machine pump whenever the engine runs. You can use the power through the quick couplers at the rear of the machine.

Important: If multiple machines use the same attachment, cross-contamination of the transmission fluid may occur. Change the transmission fluid more frequently.

• Use care when loading or unloading the machine into a trailer or a truck.

• Use full-width ramps for loading the machine into a trailer or a truck.

• Tie the machine down securely.

Refer to Figure 26 and Figure 27 for the tie-down locations on the machine.

Note: Load the machine on the trailer with the front of the machine facing forward. If that is not possible, secure the machine hood to the frame with a strap, or remove the hood and transport and secure it separately; otherwise, the hood may blow off during transport.

Figure 26

1. Eye hole in the frame (each side)

Figure 27

1. Axle
2. Hitch plate

In case of an emergency, you can tow the machine for a short distance; however, this is not the standard operating procedure.

Note: The power steering does not function, making it difficult to steer.

Towing the machine is a 2-person job. If you must move the machine a considerable distance, transport it on a truck or trailer.

1. Affix a tow line to the tongue at the front of the frame of the machine (Figure 26).

2. Move the transmission to the NEUTRAL position and disengage the parking brake.

The machine is capable of pulling trailers and attachments of greater weight than the machine itself. Several types of tow hitches are available for the machine, depending on your application. Contact your Authorized Service Dealer for details.

When equipped with a tow hitch bolted onto the rear axle tube, your machine can tow trailers or attachments with a maximum gross trailer weight (GTW) up to 1587 kg (3,500 lb).

Always load a trailer with 60% of the cargo weight in the front of the trailer. This places approximately 10% (272 kg (600 lb) maximum) of the gross trailer weight (GTW) on the tow hitch of the machine.

When hauling cargo or towing a trailer (attachment), do not overload the machine or trailer. Overloading can cause poor performance or damage to the brakes, axle, engine, transaxle, steering, suspension, body structure, or tires.

Important: To reduce potential for drive line damage, use low range.

When towing fifth-wheel attachments, like a fairway aerator, always install the wheel bar (included with the fifth wheel kit) to prevent the front wheels from lifting off the ground if the towed attachments movement is suddenly impaired.

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Empty and raise the cargo bed; refer to Raising the Cargo Bed.

Important: Always install or remove the bed support from the outside of the bed.

1. Raise the bed until the lift cylinders are fully extended.

2. Remove the bed support from the storage brackets on the back of the ROPS panel (Figure 28).

   

   Figure 28

   1. Bed support

3. Push the bed support onto the cylinder rod, and ensure that the support-end tabs rest on the end of the cylinder barrel and cylinder-rod end (Figure 29).

   

   Figure 29

   1. Bed support
   2. Cylinder barrel
   3. Bed

4. Remove the bed support from the cylinder, and insert it into the brackets on the back of the ROPS panel.

   Important: Do not try to lower the bed with the bed-safety support on the cylinder.

1. Start the engine, engage the hydraulic-lift lever, and lower the bed until the cylinders are loose in the slots.

2. Release the lift lever and shut off the engine.

3. Remove the lynch pins from the outer ends of the cylinder rod clevis pins (Figure 30).

   

   Figure 30

   1. Cylinder rod end
   2. Bed-mounting plate
   3. Clevis pin
   4. Lynch pin
   5. Rear slots (full bed)
   6. Front slots (2/3 full bed)

4. Remove the clevis pins securing the cylinder rod ends to the bed-mounting plates by pushing the pins toward the inside (Figure 30).

5. Remove the lynch pins and clevis pins securing the pivot brackets to the frame channels (Figure 30).

6. Lift the bed off the machine.

   Caution

   The full bed weighs approximately 148 kg (325 lb), so do not try to install or remove it by yourself.

   Use an overhead hoist or get the help of 2 or 3 other people.

7. Store the cylinders in the storage clips.

8. Engage the hydraulic lift-lock lever on the machine to prevent accidental extension of the lift cylinders.

Note: If you are installing the bed sides on the flat bed, it is easier to install them before installing the bed on the machine.

Ensure that the rear pivot plates are bolted to the bed frame/channel so that the lower end angles to the rear (Figure 31).

Figure 31

1. Left, rear corner of bed
2. Machine frame channel
3. Pivot plate
4. Clevis pin
5. Lynch pin

Ensure that the spacer brackets and wear blocks (Figure 32) are installed with the carriage-bolt heads positioned inside the machine.

Figure 32

1. Wear block
2. Spacer bracket
3. Carriage bolt

1. Ensure that the lift cylinders are fully retracted.

2. Carefully set the bed onto the machine frame, aligning the rear bed pivot-plate holes with the holes in the rear frame channel, and install the 2 clevis pins and lynch pins (Figure 32).

3. With the bed lowered, secure each cylinder rod end to the appropriate slots in the bed-mounting plates with a clevis pin and lynch pin.

4. Insert the clevis pin from outside of the bed with the lynch pin oriented toward the outside (Figure 32).

   Note: The rear slots are for a full bed installation; the front slots are for a 2/3-full bed installation.

   Note: You may need to start the engine to extend or retract the cylinders for alignment with the holes.

   Note: You can plug the unused slot with a bolt and nut to prevent assembly errors.

5. Start the engine and engage the hydraulic-lift lever to raise the bed.

6. Release the lift lever and shut off the engine.

7. Install the bed-safety support to prevent accidentally lowering the bed; refer to Using the Bed Support.

8. Install the lynch pins to the inside ends of the clevis pins.

   Note: If the automatic tailgate release is installed on the bed, ensure that the front dump link rod is placed on the inside of the left clevis pin before you install the lynch pin.

When jacking up the front of the machine, always place a wooden block (or similar material) between the jack and the machine frame.

The jacking point at the front of the machine is located under the front, center frame support (Figure 33).

Figure 33

1. Front jacking points

The jacking point at the rear of the machine is located under the axle (Figure 34).

Figure 34

1. Rear jacking points

Grease Type: No. 2 lithium grease

Important: When greasing the drive shaft universal shaft bearing crosses, pump grease until it comes out of all 4 cups at each cross.

1. Use a rag to wipe the grease fitting clean so that foreign matter cannot be forced into the bearing or bushing.

2. With a grease gun, apply grease into the grease fittings on the machine.

3. Wipe any excess grease off the machine.

The grease fitting locations and quantities are as follows:

• Ball joints (4); refer to Figure 36

• Pivot mounts (2); refer to Figure 36

• Steering cylinder (2); refer to Figure 36

• Tie rods (2); refer to Figure 36

  

  Figure 36

• Spring tower (2); refer to Figure 37

  

  Figure 37

• Brake (1); refer to Figure 38

• Throttle (1); refer to Figure 38

  

  Figure 38

• Drive shaft U-joints (2); refer to Figure 39

• Sliding yolk (1); refer to Figure 39

  

  Figure 39

Inspect the air filter and hoses periodically to maintain maximum engine protection and to ensure maximum service life. Check the air-filter cover and housing for damage, which could cause an air leak. Replace any damaged air-filter components.

1. Pull the latch outward and rotate the air-filter cover counterclockwise (Figure 40).

   

   Figure 40

   1. Latch
   2. Air-filter cover
   3. Air filter
   4. Dust valve
   5. Air-filter housing

2. Before removing the filter, use low-pressure air (40 psi, clean and dry) to remove large accumulations of debris packed between the outside of the air filter and the air-filter housing.

   Important: Avoid using high-pressure air, which could force dirt through the filter into the intake tract. This cleaning process prevents debris from migrating into the intake when the primary filter is removed.

3. Remove the air filter from the housing (Figure 40).

   Note: Do not clean a used filter element because you may damage the filter media.

4. Wipe clean the interior of the air-filter cover and housing (Figure 40).

5. Remove the rubber dust valve from the cover (Figure 40).

6. Clean the dirt-ejection port located in the air-cleaner cover, the dust-valve cavity, and replace the dust valve (Figure 40).

7. Inspect the new air filter for shipping damage, checking the sealing end of the filter and the body.

   Important: Do not use a damaged element.

8. Insert the new air filter by applying light pressure to the outer rim of the filter to seat it in the air-filter housing (Figure 40).

9. Align the air-filter cover with the dust valve at the 6 o’clock position when viewed from the left end of the cover (Figure 40).

10. Secure the latch of the air-filter cover (Figure 40).

    Note: Reset the indicator if it shows red (if equipped).

Note: Change the oil more frequently when operating conditions are extremely dusty or sandy.

Note: Dispose of the used engine oil and oil filter at a certified recycling center.

Engine-Oil Specifications

Oil Type: Detergent engine oil (API SJ or higher)

Crankcase Capacity: 2.0 L (2.1 US qt) when the filter is changed

Viscosity: See the table below.

Figure 41

Note: If you just shut off the engine, it may take 1 to 2 minutes for the light to come on.

1. Engage the parking brake.

2. Turn the key switch to the ON position, but do not start the engine.

   Note: The oil-pressure light should glow red.

   Note: If the light does not function, either a bulb is burned out, or there is a malfunction in the system that you must repair.

Type: Champion RN14YC (or equivalent)

Air Gap: 0.762 mm (0.03 inch)

Important: A cracked, fouled, dirty, or malfunctioning spark plug must be replaced. Do not sand-blast, scrape, or clean electrodes by using a wire brush because grit may eventually release from the plug and fall into the cylinder. The result is usually a damaged engine.

Note: The plug should be removed and checked whenever the engine malfunctions.

1. Clean the area around the spark plug so that foreign matter cannot fall into the cylinder when you remove the spark plug.

2. Pull the wire off the terminal of the spark plug.

3. Remove the plug from the cylinder head.

4. Check the condition of the side electrode, center electrode, and center electrode insulator to ensure that there is no damage (Figure 46).

   Note: Do not use a damaged or worn spark plug. Replace it with a new spark plug of the specified type.

   

   Figure 46

   1. Side electrode
   2. Center electrode insulator
   3. Air gap (not to scale)

5. Set the air gap between the center and side of the electrodes at 0.762 mm (0.030 inch) as shown in Figure 46.

6. Install the spark plug into the cylinder head, and torque the plug to 20 N∙m (14.7 ft-lb).

7. Install the spark-plug wire.

8. Repeat steps 1 through 7 for the other spark plug.

1. Locate the air filter on the bottom of the carbon canister (Figure 47).

   

   Figure 47

   1. Filter opening

2. Ensure that the opening on the bottom of the filter is clear and open.

3. Remove and install the new filter (if necessary).

1. Raise the bed and place the safety support on the extended-lift cylinder to hold up the bed.

2. Unplug the wire-harness connectors from the fuel pump (Figure 48).

3. Loosen the hose clamp and disconnect the fuel line from the fuel-pump cap (Figure 48).

   

   Figure 48

   1. Fuel pump
   2. Hose clamp
   3. Fuel line/fuel filter

4. Remove the fuel-pump cap from the top of the fuel tank (Figure 48).

   Important: Do not allow the fuel-pump assembly to rotate in the tank while removing the fuel pump. Damage to the float assembly can occur if the fuel pump rotates inside the fuel tank.

5. Remove the fuel-pump assembly and the fuel filter from the tank (Figure 48).

6. Remove the clamp securing the fuel filter hose to the fuel-pump fitting.

7. Remove the hose from the fitting (Figure 48).

8. Insert the new hose clamp onto the new fuel-filter hose.

9. Insert the hose onto the fuel pump and secure the clamp.

10. Insert the assembly into the fuel tank, and tighten the cap to 20 to 22 N∙m (175 to 200 in-lb).

11. Connect the wires and secure the hose with the hose clamp.

Inspect the fuel lines, fittings, and clamps for signs of leaking, deterioration, damage, or loose connections.

Note: Repair any damaged or leaking fuel system component before using the machine.

The fuses for the electrical system are located under the center of the dash panel (Figure 49 and Figure 50).

Figure 49

1. Fuses

Figure 50

1. Power takeoff (15 A)
2. Engine start (10 A)
3. Hazards (10 A)
4. Engine ignition (10 A)
5. Differential lock (15 A)
6. Speedometer (10 A)
7. Headlights and rear lights (15 A)
8. Horn (30 A)

1. Squeeze the battery cover to release the tabs from the battery base and remove the battery cover from the battery base (Figure 51).

   

   Figure 51

   1. Battery cover

2. Connect a jumper cable between the positive posts of the 2 batteries (Figure 52).

   Note: The positive post may be identified by a + sign on top of the battery cover.

3. Connect 1 end of the other jumper cable to the negative terminal of the battery in the other machine.

   Note: The negative terminal has “NEG” on the battery cover.

   Note: Do not connect the other end of the jumper cable to the negative post of the discharged battery. Connect the jumper cable to the engine or frame. Do not connect the jumper cable to the fuel system.

   

   Figure 52

   1. Battery

4. Start the engine in the machine providing the jump-start.

   Note: Let it run for a few minutes, then start your engine.

5. Remove the negative jumper cable first from your engine, then the battery in the other machine.

6. Install the battery cover to the battery base.

• Always keep the battery clean and fully charged.

• Always keep the battery clean and fully charged.

• If the battery terminals are corroded, clean them with a solution of 4 parts water and 1 part baking soda.

• Apply a light coating of grease to the battery terminals to prevent corrosion.

• Maintain the battery electrolyte level.

• Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning. Do not remove the fill cap while cleaning.

• Ensure that the battery cables are kept tight on the terminals to provide good electrical contact.

• Maintain the cell electrolyte level with distilled or demineralized water. Do not fill the cells above the bottom of the fill ring inside each cell.

• If you store the machine in a location where temperatures are extremely high, the battery runs down more rapidly than if the machine is stored in a location where temperatures are cool.

Front tires air pressure specification: 220 kPa (32 psi)

Rear tires air pressure specification: 124 kPa (18 psi)

Operating accidents, such as hitting curbs, can damage a tire or rim and also disrupt wheel alignment, so inspect the tire condition after an accident.

Important: Check the tire pressure frequently to ensure proper inflation. If the tires are not inflated to the correct pressure, the tires will wear prematurely and may cause 4-wheel drive to bind.

Figure 53 is an example of tire wear caused by under-inflation.

Figure 53

1. Under-inflated tire

Figure 54 is an example of tire wear caused by over-inflation.

Figure 54

1. Over-inflated tire

1. Ensure that the tires are facing straight ahead.

2. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires (Figure 55).

   Note: The measurement must be within 0 ± 3 mm (0 ± 0.12 inch) at the front of the tire then at the rear of the tire. Rotate the tire 90° and check the measurement.

   Important: Check the measurements at consistent locations on the tire. The machine should be on a flat surface with the tires facing straight ahead.

   

   Figure 55

   1. Front of the machine
   2. 0 ± 3 mm (0 ± 0.12 inch) front to rear of the tire
   3. Center to center distance

3. Adjust the center-to-center distance as follows:

   1. Loosen the jam nut at the center of the tie rod (Figure 56).

      

      Figure 56

      1. Tie rods
      2. Jam nuts

   2. Rotate the tie rod to move the front of the tire inward or outward to achieve the center to center distances from front to back.

   3. Tighten the tie rod jam nut when the adjustment is correct.

   4. Check to ensure that the tires turn an equal amount to the right and to the left.

      Note: If the tires do not turn equally, refer to the Service Manual for the adjustment procedure.

Coolant type: a 50/50 solution of water and permanent ethylene-glycol antifreeze

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Check the coolant level at the reserve tank (Figure 67).

   Note: The coolant should be up to the bottom of the filler neck.

   

   Figure 67

   1. Coolant-reserve tank

5. If coolant is low, remove the reserve- tank cap and add a 50/50 mixture of water and permanent ethylene-glycol antifreeze.

   Note: Do not overfill.

6. Install the reserve-tank cap.

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Clean the engine area thoroughly of all debris.

5. Unlatch and remove the radiator screen from the front of the radiator (Figure 68).

   

   Figure 68

   1. Radiator screen
   2. Latch

6. If equipped, rotate the latches and pivot the oil cooler away from the radiator (Figure 69).

   

   Figure 69

   1. Radiator housing
   2. Oil cooler
   3. Latches

7. Clean the radiator, oil cooler, and screen with compressed air.

   Note: Blow debris away from the radiator.

8. Install the cooler and screen to the radiator.

Cooling-system capacity: 3.7 L (4 US qt)

Coolant type: a 50/50 solution of water and permanent ethylene-glycol antifreeze

1. Park the machine on a level surface.

2. Raise the bed and install the bed safety support on the extended lift cylinder to secure the bed.

   Caution

   If the engine has been running, the cooling system pressurizes with hot coolant that can escape and cause burns.

   • Do not open the radiator cap when the engine is running.

   • Allow the engine to cool for at least 15 minutes or until the radiator cap is cool enough to touch without burning your hand.

   • Use a rag to open the radiator cap. Open the cap slowly to allow the steam to escape.

3. Remove the radiator cap (Figure 70).

   

   Figure 70

   1. Radiator cap

4. Remove the reserve-tank cap (Figure 70).

   

   Figure 71

   1. Reserve tank-cap
   2. Reserve tank

5. Disconnect the lower radiator hose and allow the coolant to flow into a drain pan.

   Note: When the coolant stops flowing, connect the lower radiator hose.

6. Slowly fill the radiator with a 50/50 mixture of water and permanent ethylene-glycol antifreeze

7. Top off the radiator and install the cap (Figure 70).

8. Slowly fill the coolant-reserve tank until level reaches the bottom of the filler neck (Figure 71).

9. Install the reserve-tank cap (Figure 71).

10. Start the engine and operate it until it is warm.

11. Shut off the engine, check the coolant level, and replenish the coolant, if necessary.

Brake-fluid type: DOT 3 brake fluid

Note: The brake-fluid reservoir ships from the factory filled with DOT 3 brake fluid.

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Remove the hood.

5. Check the fluid level in the brake-fluid reservoir (Figure 72 and Figure 73).

   Note: The fluid level should be up to the Full line on the reservoir.

   

   Figure 72

   1. Brake-fluid reservoir
   

   Figure 73

   1. Brake-fluid reservoir

6. If the fluid level is low, perform the following:

   1. Clean the area around the cap for the reservoir (Figure 73).

   2. Remove the reservoir cap (Figure 73).

   3. Add the specified brake fluid to the Full line on the reservoir (Figure 73).

      Important: Do not overfill the brake-fluid reservoir.

   4. Install the cap (Figure 73).

7. Install the hood.

1. Remove the rubber grip from the parking-brake lever (Figure 74).

   

   Figure 74

   1. Grip
   2. Parking-brake lever

2. Loosen the set screw securing the knob to the parking-brake lever (Figure 75).

   

   Figure 75

   1. Knob
   2. Set screw
   3. Parking-brake lever

3. Rotate the knob (Figure 75) until a force of 20 to 22 kg (45 to 50 lb) is required to actuate the lever.

4. Tighten the set screw when finished (Figure 75).

   Note: If you can no longer make a parking-brake adjustment by adjusting the parking-brake lever, loosen the handle to the middle of the adjustment and adjust the cable at the rear, then repeat step 3.

5. Install the rubber grip onto the parking-brake lever (Figure 74).

1. Remove the hood.

2. Remove the cotter pin and clevis pin securing the master cylinder yoke to the brake-pedal pivot (Figure 76).

   

   Figure 76

   1. Cotter pin
   2. Brake-pedal pivot
   3. Clevis pin
   4. Master cylinder yoke
   5. Jam nut

3. Lift up on the brake pedal (Figure 77) until it contacts the frame.

   

   Figure 77

   1. Brake pedal
   2. Accelerator pedal

4. Loosen the jam nuts securing the yoke to the master cylinder shaft (Figure 76).

5. Adjust the yoke until its holes align with the hole in the brake-pedal pivot (Figure 76).

6. Secure the yoke to the pedal pivot with the clevis pin and cotter pin (Figure 76).

7. Tighten the jam nut securing the yoke to the master cylinder shaft (Figure 76).

   Note: The brake master cylinder must relieve the pressure from the service brake when it is properly adjusted.

8. Install the hood.

You can convert the speedometer from mph to kpm or kph to mph.

1. Position the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Remove the hood.

3. Locate the 2 loose wires next to the meter (Figure 78).

   

   Figure 78

   1. meter (forward face)
   2. Plug
   3. Speedometer wires

4. Remove the connector plug from the harness wire and connect the wires together (Figure 78).

   Note: The meter switches from mph to kph. Retain the plug in order to convert the speedometer to mph.

5. Install the hood.

Hydraulic-fluid type: Mobil M15

Hydraulic-fluid capacity: (Non-TC model): 7.5 L (2 US gallons)

Hydraulic-fluid capacity: (Non-TC model with the High-Flow-Hydraulic Kit (optional kit) or TC Model): 15.1 L (4 US gallons)

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Clean the area around the filler neck and the cap of the hydraulic reservoir (Figure 79 and Figure 80).

   

   Figure 79

   Hydraulic-fluid level (non-TC models)

   1. Cap
   2. Dipstick
   3. Filler neck
   

   Figure 80

   Hydraulic-fluid level (non-TC model with the High Flow Hydraulic Kit (optional kit) or TC model)

   1. Cap
   2. Dipstick
   3. Filler neck

5. Remove the cap and dipstick from the filler neck of the reservoir and wipe the dipstick clean with a rag (Figure 79 and Figure 80).

6. Insert the dipstick into the filler neck; then remove it and check the fluid level (Figure 79 and Figure 80).

   • Non-TC model: The hydraulic-fluid level should be between the lower indented area on the dipstick.

   • Non-TC model with the High-Flow-Hydraulic Kit (option) or TC model: The hydraulic-fluid level should be between the upper indented area on the dipstick.

7. If the level is low, add the specified hydraulic fluid into the reservoir to raise the level to the middle of the indented area on the dipstick (Figure 79 and Figure 80).

8. Install the dipstick and cap to the filler neck of the reservoir (Figure 79 and Figure 80).

Important: Use of any other filter may void the warranty on some components.

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Clean the area around filter-mounting area (Figure 81).

   

   Figure 81

   1. Filter adapter
   2. Hydraulic filter

3. Place a drain pan under the filter (Figure 81).

4. Remove the filter by rotating it counterclockwise (Figure 81).

5. Clean the filter-seating surface of the filter adapter (Figure 81).

6. Lubricate the gasket on the new filter with the specified Mobil M15 hydraulic fluid.

7. Thread the filter onto the filter adapter until the gasket of the filter contacts the seating surface of the adapter (Figure 81), and then tighten the filter an additional 1/2 turn (Figure 81).

8. Start the engine and let it run for about 2 minutes to purge air from the system.

9. Shut off the engine and check the hydraulic-fluid level in the hydraulic tank and the filter area for leaks.

Hydraulic-fluid type: Mobil M15

Hydraulic-fluid capacity: (Non-TC model): 7.5 L (2 US gallons)

Hydraulic-fluid capacity: (Non-TC model with the High Flow Hydraulic Kit (option) or TC model): 15.1 L (4 US gallons)

1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.

2. Raise the cargo bed.

3. Remove the cap and dipstick from the filler neck of the hydraulic tank (Figure 82).

   

   Figure 82

   1. Cap
   2. Dipstick
   3. Filler neck (hydraulic tank)
   4. Siphon equipment
   5. Collection container

4. Route the intake hose of the siphoning equipment through the filler neck of the hydraulic tank and to the bottom of the tank (Figure 82).

5. Direct the discharge hose of the siphoning equipment into a collection container (Figure 82) with a 11.4 L (3 US gallon) capacity—Non-TC model or 18.9 L (5 US gallon) capacity—Non-TC model with the High Flow Hydraulic Kit (option) or TC model.

6. Siphon the hydraulic fluid from the hydraulic tank.

7. Remove the siphoning equipment from the hydraulic tank (Figure 82).

8. Add 7.5 L (2 US gallons)—Non-TC model or 15.1 L (4 US gallons)—Non-TC model with the High Flow Hydraulic Kit (option) or TC model of the specified hydraulic fluid into the hydraulic tank (Figure 82).

   Important: Use only the hydraulic fluids specified. Other fluids could cause system damage.

9. Install the dipstick and cap to the filler neck of the hydraulic tank (Figure 82).

10. Start the engine and operate the machine to fill the hydraulic system.

11. Check the hydraulic-fluid level and replenish it, if required.

The cargo bed can be raised in an emergency without starting the engine by cranking starter or by jumping the hydraulic system.

The machine should be washed as needed. Use water alone or with a mild detergent. A rag may be used when washing the machine.

Important: Do not use power washing equipment to wash the machine. Power washing equipment may damage the electrical system, loosen important decals, or wash away necessary grease at friction points. Avoid excessive use of water near the control panel, engine, and battery.

Important: Do not wash the machine with the engine running. Washing the machine with the engine running may result in internal engine damage.