Workman® HDX Utility Vehicle

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

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

Rear 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 11 shows an example of tire wear caused by under-inflation.

Figure 11

1. Under-inflated tire

Figure 12 shows an example of tire wear caused by over-inflation.

Figure 12

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.

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

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

3. Move the shift lever to the NEUTRAL position and press the clutch pedal.

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

5. Keep your foot off the accelerator pedal.

6. Rotate the key switch clockwise to start the engine.

   Note: Release the key switch when the engine starts.

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

To enable automatic 4-Wheel Drive, press the top of the rocker switch into the 4X4 AUTO position (Figure 16).

Figure 16

1. 4x4 auto enable—on
2. 4x4 auto enable—off

When the 4WD switch is on, the machine automatically engages the 4-wheel drive if the sensor detects the back wheels spinning freely. When the 4-wheel drive is engaged, the 4WD switch light turns on.

Important: When in reverse, the machine does not automatically engage the 4-wheel drive. In reverse, you must manually engage the 4-wheel drive using the 4WD button.

To engage the 4-wheel drive manually, press and hold the 4WD button on the center console while the vehicle is in motion and the 4-wheel drive engages.

Note: The 4-wheel drive remains engaged only as long as you hold the button; the 4WD switch does not need to be in the AUTO position to manually engage the 4-wheel drive.

1. Disengage the parking brake.

2. Fully press the clutch pedal.

3. Move the gear-shift lever to first gear.

4. Release the clutch pedal smoothly while pressing the accelerator pedal.

5. When the machine gains enough speed, remove your foot from the accelerator pedal, fully press the clutch pedal, move the gear-shift lever to the next gear, and release the clutch pedal while pressing the accelerator pedal.

6. Repeat the procedure until the desired speed is attained.

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

   Note: Avoid long periods of engine idling.

   Use the chart below to determine the ground speed of the machine at 3,600 rpm.

   Gear	Range	Ratio	Speed (kmh)	Speed (mph)
   1	L	82.83 : 1	4.7	2.9
   2	L	54.52 : 1	7.2	4.5
   3	L	31.56 : 1	12.5	7.7
   1	H	32.31 : 1	12.2	7.6
   2	H	21.27 : 1	18.5	11.5
   3	H	12.31 : 1	31.9	19.8
   R	L	86.94 : 1	4.5	2.8
   R	H	33.91 : 1	11.6	7.1

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

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

1. Park the machine on a level surface.

2. Engage the parking brake.

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

The differential lock increases the machine traction 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, or on sandy surfaces. It is important to remember, however, that this extra traction is for temporary limited use only. Its use does not replace the safe operation.

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 necessary, at slower speeds, and only in first or second gear.

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 18 and Figure 19 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 18

1. Eye hole in the frame (each side)

Figure 19

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 18).

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

4. Shut off the engine and remove the key.

5. Allow the machine to cool before performing maintenance.

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 20).

   

   Figure 20

   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 21).

   

   Figure 21

   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 22).

   

   Figure 22

   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 22).

5. Remove the lynch pins and clevis pins securing the pivot brackets to the frame channels (Figure 22).

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 23).

Figure 23

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 24) are installed with the carriage-bolt heads positioned inside the machine.

Figure 24

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 24).

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 24).

   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 25).

Figure 25

1. Front jacking points

The jacking point at the rear of the machine is located under the axle (Figure 26).

Figure 26

1. Rear jacking points

Grease Type: No. 2 lithium grease

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.

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

The grease fitting locations and quantities are as follows:

• Ball joints (4); refer to Figure 28

• Tie rods (2); refer to Figure 28

• Pivot mounts (2); refer to Figure 28

• Steering cylinder (2); refer to Figure 28

  

  Figure 28

• Spring tower (2); refer to Figure 29

  

  Figure 29

• Clutch (1); refer to Figure 30

• Brake (1); refer to Figure 30

  

  Figure 30

• U-joint (18); refer to Figure 31

• 4-wheel drive shaft (3); refer to Figure 31

  

  Figure 31

Inspect the air cleaner and hoses periodically to maintain maximum engine protection and to ensure maximum service life. Check the air-cleaner body for damage that could possibly cause an air leak. Replace a damaged air-cleaner body.

1. Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body (Figure 32).

   

   Figure 32

   1. Air-cleaner cover
   2. Filter

2. Squeeze the dust cap sides to open it and knock the dust out.

3. Gently slide the filter out of the air-cleaner body (Figure 32).

   Note: Avoid knocking the filter into the side of the body.

   Note: Do not attempt to clean the filter.

4. Inspect the new filter for damage by looking into the filter while shining a bright light on the outside of the filter.

   Note: Holes in the filter appear as bright spots. Inspect the element for tears, an oily film, or damage to the rubber seal. If the filter is damaged, do not use it.

   Note: To prevent engine damage, always operate the engine with the air filter and cover installed.

5. Carefully slide the filter over the body tube (Figure 32).

   Note: Ensure that it is fully seated by pushing on the outer rim of the filter while installing it.

6. Install the air-cleaner cover with the side facing up, and secure the latches (Figure 32).

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: 3.2 L (3.4 US qt) when the filter is changed

Viscosity: See the table below.

Figure 33

Type: NGK-R BKR5E (or equivalent)

Air Gap: 0.81 mm (0.032 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.

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 37).

   

   Figure 37

   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 0.81 mm (0.032 inch) as shown in Figure 37.

6. Install the spark plug into the cylinder head, and torque the plug to 24.5 to 29 N∙m (18 to 22 ft-lb).

7. Install the spark-plug wire.

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

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 38).

3. Loosen the hose clamp and disconnect the fuel line from the fuel-pump cap (Figure 38).

   

   Figure 38

   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 38).

   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 38).

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

7. Remove the hose from the fitting (Figure 38).

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 39 and Figure 40).

Figure 39

1. Fuses

Figure 40

1. Power outlet (10 A)
2. Switched power (10 A)
3. Fuel pump, supervisor switch (10 A)
4. Horn, power point (15 A)
5. Lights, brake (15 A)
6. Hazard (10 A)
7. 4WD, transmission (10 A)

1. Squeeze the battery cover to release the tabs from the battery base and remove the battery cover from the battery base (Figure 41).

   

   Figure 41

   1. Battery cover

2. Connect a jumper cable between the positive posts of the 2 batteries (Figure 42).

   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 42

   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.

• 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.

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 fill/check plug on side of the differential (Figure 43).

   

   Figure 43

   1. Fill/check plug
   2. Drain plug

5. Remove the fill/check plug and check the level of the oil.

   Note: The oil should be up to hole.

6. If the oil is low, add specified oil.

7. Install the fill/check plug.

Differential oil specification: Mobil 424 hydraulic fluid

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 drain plug on the side of the differential (Figure 43).

5. Place a drain pan under the drain plug.

6. Remove the drain plug and let the oil flow into the drain pan.

7. Install and tighten the plug when the oil stops draining.

8. Clean the area around the fill/check plug on the bottom of the differential.

9. Remove the fill/check plug and add specified oil until the oil level is up to the hole.

10. Install the fill/check plug.

Inspect the constant-velocity boot for cracks, holes, or a loose clamp. Contact your Authorized Service Dealer for repair if you find any damage.

1. Move the shift lever to the NEUTRAL position.

2. Remove the clevis pins securing the shift cables to the transaxle-shift arms (Figure 44).

   

   Figure 44

   1. Shift arm (High to Low)
   2. Shift arm (Second to Third)
   3. Shift arm (First to Reverse)
   4. Clevis pin

3. Loosen the clevis jam nuts and adjust each clevis, so that the cable free play is equal forward and backward relative to the hole in the transaxle-shift arm (with the transaxle lever free play taken up in the same direction).

4. Install the clevis pins and tighten the jam nuts when finished.

1. Remove the clevis pin securing the high-low cable to the transaxle (Figure 44).

2. Loosen the clevis jam nut and adjust the clevis so that the clevis hole aligns with the hole in the transaxle bracket.

3. Install the clevis pin and tighten the jam nut when finished.

1. Move the differential-lock lever to the OFF position.

2. Loosen the jam nuts securing the differential-lock cable to the bracket on the transaxle (Figure 45).

   

   Figure 45

   1. Differential-lock cable
   2. Transaxle bracket
   3. Spring
   4. 0.25 to 1.5 mm (0.01 to 0.06 inch) gap

3. Adjust the jam nuts to obtain a 0.25 to 1.5 mm (0.01 to 0.06 inch) gap between the spring hook and the OD of the hole in the transaxle lever.

4. Tighten the jam nuts when finished.

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

Figure 46

1. Under-inflated tire

Figure 47 is an example of tire wear caused by over-inflation.

Figure 47

1. Over-inflated tire

1. Ensure that the tire pressures are correct before checking the front wheel alignment; refer to Checking the Tire Pressure.

2. Either have an operator in the operator’s seat or add weight to the driver’s seat equal to the average operator of the vehicle.

   The operator or weight must remain on the seat for the duration of the front wheel alignment procedure.

3. On a level surface, roll the machine straight back 2 to 3 m (6 to 10 ft) and then straight forward to the original starting position.

   This allows the machine suspension to settle into the normal operating position.

4. Ensure that the tires are facing straight ahead.

5. Measure the distance between the front tires at axle height at both the front and rear of the tires (Figure 48).

   The front wheel toe-in should be 0 ± 6 mm (0 ± 1/4 inch).

   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 48

   1. Front of the machine
   2. 0 ± 6 mm (0 ± 1/4 inch) front to rear of the tire
   3. Center-to-center distance

6. If the front wheel toe-in is incorrect, adjust it as follows:

   1. Loosen the jam nut at the center of the tie rod (Figure 49).

      

      Figure 49

      1. Tie rods
      2. Jam nuts

   2. Rotate both tie rods equally to move the front of the tires inward or outward.

   3. Tighten the tie rod jam nuts when the toe-in adjustment is correct.

      Torque the tie rod jam nuts to 62 to 74 N∙m (45 to 55 ft-lb).

7. After completing the toe-in adjustment, ensure that there is full steering travel in both directions.

   There should be no contact between any machine components as you move the wheels from lock to lock. If necessary, adjust any components.

Wheel lug nut torque specification: 109 to 122 N∙m (80 to 90 ft-lb)

Torque the lug nuts at the front and rear wheels in a crossing pattern as shown in Figure 50 to the specified torque.

Figure 50

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. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Check the coolant level inside the reserve tank (Figure 51).

   Note: The coolant should be up to the bottom of the filler neck when the engine is cold.

   

   Figure 51

   1. Reserve-tank cap
   2. Reserve tank

5. If the 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 the reserve tank with coolant.

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 52).

   

   Figure 52

   1. Radiator screen
   2. Latch

6. If equipped, rotate the latches and pivot the oil cooler away from the radiator (Figure 53).

   

   Figure 53

   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 54).

   

   Figure 54

   1. Radiator cap

4. Remove the reserve-tank cap (Figure 54).

   

   Figure 55

   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 54).

8. Slowly fill the coolant-reserve tank until level reaches the bottom of the filler neck (Figure 55).

9. Install the reserve-tank cap (Figure 55).

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

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Raise the hood to access to the master brake cylinder and reservoir (Figure 56).

   

   Figure 56

   1. Brake-fluid reservoir

5. Ensure that the fluid level is up to the Full line on the reservoir (Figure 57).

   

   Figure 57

   1. Brake-fluid reservoir

6. If the fluid level is low, clean the area around the cap, remove the reservoir cap, and fill the reservoir to the proper level with the specified brake fluid (Figure 57).

   Note: Do not overfill the reservoir with brake fluid.

1. Remove the rubber grip from the parking-brake lever (Figure 58).

   

   Figure 58

   1. Grip
   2. Parking-brake lever

2. Loosen the set screw securing the knob to the parking-brake lever (Figure 59).

   

   Figure 59

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

3. Rotate the knob (Figure 59) 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 59).

   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 58).

Note: Remove the font hood to ease the adjustment procedure.

1. Remove the cotter pin and clevis pin securing the master cylinder yoke to the brake-pedal pivot (Figure 60).

   

   Figure 60

   1. Master cylinder yoke
   2. Brake-pedal pivot

2. Lift up on the brake pedal (Figure 61) until it contacts the frame.

3. Loosen the jam nuts securing the yoke to the master cylinder shaft (Figure 61).

4. Adjust the yoke until its holes align with the hole in the brake-pedal pivot.

5. Secure the yoke to the pedal pivot with the clevis pin and cotter pin.

6. Tighten the jam nuts securing the yoke to the master cylinder shaft.

   Note: The brake master cylinder must relieve pressure when properly adjusted.

   

   Figure 61

   1. Clutch pedal
   2. Brake pedal
   3. Accelerator pedal

1. Raise the bed and position the safety support on the extended lift cylinder to secure the bed.

2. Check the tension by pressing the belt at mid span between the crankshaft and alternator pulleys with 10 kg (22 lb) of force (Figure 62).

   Note: A new belt should deflect 8 to 12 mm (0.3 to 0.5 inch).

   Note: A used belt should deflect 10 to 14 mm (0.4 to 0.55 inch). If the deflection is incorrect, proceed to the next step. If correct, continue operation.

3. To adjust belt tension, perform the following:

   1. Loosen the 2 alternator-mounting bolts (Figure 62).

      

      Figure 62

      1. Alternator belt
      2. Alternator-mounting bolts

   2. Using a pry bar, rotate the alternator until the proper belt tension is attained, then tighten the mounting bolts (Figure 62).

Note: You can adjust the clutch-pedal cable at the bell housing or at the clutch-pedal pivot. You can remove the front hood to easily access to the pedal pivot.

1. Loosen the jam nuts securing the clutch cable to the bracket on the bell housing (Figure 63).

   Note: You may remove and rotate the ball joint, if additional adjustment is required.

   

   Figure 63

   1. Return spring
   2. Ball joint
   3. Jam nuts
   4. Clutch cable

2. Disconnect the return spring from the clutch lever.

3. Adjust the jam nuts or ball joint until the rear edge of the clutch pedal is 9.2 to 9.8 cm (3-5/8 to 3-7/8 inches) from the top of the floor plate diamond pattern, when you apply 1.8 kg (4 lb) of force to the pedal (Figure 64).

   

   Figure 64

   1. Clutch pedal
   2. 9.2 to 9.8 cm (3-5/8 to 3-7/8 inches)

   Note: Force is applied so that the clutch-release bearing lightly contacts the pressure-plate fingers.

4. Tighten the jam nuts after you attain the proper adjustment.

5. Check the 9.2 to 9.8 cm (3-5/8 to 3-7/8 inches) dimension after the jam nuts have been tightened to ensure proper adjustment.

   Note: Adjust again, if necessary.

6. Connect the return spring to the clutch lever.

   Important: Ensure that the rod end is positioned squarely on the ball, not twisted, and remains parallel to the clutch pedal after the jam nut is tightened (Figure 65).

   Note: The clutch free play should never be less than 19 mm (3/4 inch).

   

   Figure 65

   1. Clutch-cable rod end
   2. Clutch pedal
   3. Rod end jam nut
   4. Parallel

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

2. Adjust the ball joint on the accelerator cable (Figure 66) to allow 2.54 to 6.35 mm (0.100 to 0.250 inch) of clearance between the accelerator pedal arm and the top of the diamond tread floor plate (Figure 67), when you apply 11.3 kg (25 lb) of force to the center of the pedal.

   Note: The engine must not be running and the return spring must be attached.

3. Tighten the locknut (Figure 66).

   

   Figure 66

   1. Locknut
   2. Accelerator cable
   

   Figure 67

   1. 2.54 to 6.35 mm (0.100 to 0.250 inch) clearance

Important: The maximum high-idle speed is 3,650 rpm. Do not adjust the high-idle stop.

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

Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine.

Important: Do not use brackish or reclaimed water to clean 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.