Toro Twister 1600 Utility Vehicle User manual

Toro Twister 1600 Utility Vehicle User manual
Form No. 3327-297
Twister 1600
Utility Vehicle
Model No. 12004—Serial No. 220000001 and Up
Model No. 12004TC—Serial No. 220000001 and Up
Operator’s Manual
English (EN, GB)
Warning
Stopping the Vehicle . . . . . . . . . . . . . . . . . . . . . . .
Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . .
Cargo Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Latches . . . . . . . . . . . . . . . . . . . . . . . . . .
New Vehicle Break-In . . . . . . . . . . . . . . . . . . . . .
Transporting the Vehicle . . . . . . . . . . . . . . . . . . . .
Loading the Cargo Box . . . . . . . . . . . . . . . . . . . .
Towing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . .
Towing a Trailer . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule . . . . . . . . .
Heavy Duty Operation . . . . . . . . . . . . . . . . . . . . .
Jacking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . .
Checking and Adjusting Neutral . . . . . . . . . . . . .
Servicing the Engine Oil . . . . . . . . . . . . . . . . . . .
Cleaning the Engine Cooling Areas . . . . . . . . . . .
Servicing the Air Cleaner . . . . . . . . . . . . . . . . . . .
Greasing the Machine . . . . . . . . . . . . . . . . . . . . . .
Servicing the Brakes . . . . . . . . . . . . . . . . . . . . . . .
Inspecting the Tires . . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Front Suspension . . . . . . . . . . . . . .
Adjusting Front Wheel Toe-In . . . . . . . . . . . . . . .
Servicing the Drive Belt . . . . . . . . . . . . . . . . . . . .
Servicing the Fuel System . . . . . . . . . . . . . . . . . .
Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Transaxle Fluid . . . . . . . . . . . . . . . .
Replacing the Fuses . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Headlight Bulbs . . . . . . . . . . . . . . .
Servicing the Battery . . . . . . . . . . . . . . . . . . . . . .
Washing the Vehicle . . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . .
The Toro Total Coverage Guarantee . . . . . . . . . . . . .
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
Important The engine in this product is not equipped
with a spark arrester muffler. It is a violation of California
Public Resource Code Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126. Other states
or federal areas may have similar laws.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
The enclosed Engine Owner’s Manual is supplied for
information regarding The U.S. Environmental
Protection Agency (EPA) and the California Emission
Control Regulation of emission systems, maintenance
and warranty.
Keep this engine Owner’s Manual with your unit.
Should this engine Owner’s Manual become damaged
or illegible, replace immediately. Replacements may be
ordered through the engine manufacturer.
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Slope Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Specifications . . . . . . . . . . . . . . . . . . . . .
Optional Equipment . . . . . . . . . . . . . . . . . . . . . . .
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Crankcase Oil . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the Tire Pressure . . . . . . . . . . . . . . . . . .
Checking the Transmission Oil . . . . . . . . . . . . . .
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First . . . . . . . . . . . . . . . . . . . . . . . . .
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Starting Checks . . . . . . . . . . . . . . . . . . . . . . .
Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . .
2002 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
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Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
All Rights Reserved
Printed in the USA
2
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
Warning
This vehicle is an off-highway vehicle only and is
not designed, equipped, or manufactured for use
on public streets, roads, or highways.
1
Before Operating
• Operate the machine only after reading and
understanding the contents of this manual.
• Never allow children to operate the vehicle. Anyone
who operates the vehicle should have a motor vehicle
license.
m–6044
Figure 1
• Never allow other adults to operate the vehicle without
first reading and understanding the Operator’s Manual.
Make sure that all operators are physically and mentally
capable of operating the vehicle.
1. Location of the model and serial numbers
Write the product model and serial numbers in the space
below:
• This vehicle is designed to carry only you, the operator,
and one passenger in the seat provided by the
manufacturer. Never carry any other passengers on the
vehicle.
Model No.
• Never operate the vehicle when under the influence of
drugs or alcohol. Even prescription drugs and cold
medicines can cause drowsiness.
Serial No.
• Do not drive the vehicle when you are tired. Be sure to
take occasional breaks. It is very important that you stay
alert at all times.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
• Become familiar with the controls and know how to
stop the engine quickly.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
• Keep all shields, safety devices, and decals in place. If a
shield, safety device, or decal is malfunctioning,
illegible, or damaged, repair or replace it before
operating the machine.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
• Always wear substantial shoes. Do not operate the
machine while wearing sandals, tennis shoes, or
sneakers. Do not wear loose fitting clothing or jewelry
which could get caught in moving parts and cause
personal injury.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
• Wearing safety glasses and long pants is advisable.
• Avoid driving when it is dark, especially in unfamiliar
areas. If you must drive when it is dark, be sure to drive
cautiously, use the headlights, and even consider adding
additional lights.
Safety
• Be extremely careful when operating around people.
Always be aware of where bystanders might be.
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert
symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
• Before operating the vehicle, always check the
designated areas of the vehicle that are stated in the
pre-starting section of this manual. If something is
3
– Use extra caution when operating the vehicle on wet
surfaces, in adverse weather conditions, at higher
speeds, or with a full load. Stopping time and
distance will increase with a full load.
wrong, do not use the vehicle. Make sure that the
problem is corrected before the vehicle or attachment is
operated.
• Since gasoline is highly flammable, handle it carefully.
– Avoid sudden stops and starts. Do not go from
reverse to forward or forward to reverse without
first coming to a complete stop.
– Use an approved gasoline container.
– Do not remove the cap from the fuel tank when the
engine is hot or running.
– Slow down before turning. Do not attempt sharp
turns or abrupt maneuvers or other unsafe driving
actions that may cause a loss of vehicle control.
– Do not smoke while handling gasoline.
– Fill the fuel tank outdoors and to about 1 inch
(25 mm) below top of tank (bottom of the filler
neck). Do not overfill.
– When dumping, do not let anyone stand behind the
vehicle and do not dump the load on anyone’s feet.
Release the tailgate latches from the side of box, not
from behind.
– Wipe up any spilled gasoline.
– Only operate the vehicle when the cargo box is
down and latched.
While Operating
– Before backing up, look to the rear and ensure no
one is behind the vehicle. Back up slowly.
Warning
– Watch out for traffic when near or crossing roads.
Always yield the right of way to pedestrians and
other vehicles. This vehicle is not designed for use
on streets or highways. Always signal your turns or
stop early enough so other persons know what you
plan to do. Obey all traffic rules and regulations.
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
Do not run engine indoors or in an enclosed area.
• The operator and passenger should remain seated
whenever the vehicle is in motion. The operator should
keep both hands on the steering wheel, whenever
possible and the passenger should use the hand holds
provided. Keep your arms and legs within the vehicle
body at all times.
– The electrical and exhaust systems of the vehicle
can produce sparks capable of igniting explosive
materials. Never operate the vehicle in or near an
area where there is dust or fumes in the air which
are explosive.
• Do not touch the engine or muffler while the engine is
running or soon after it has stopped. These areas may be
hot enough to cause burns.
• Drive slower and turn less sharply when you are
carrying a passenger. Remember your passenger may
not be expecting you to brake or turn and may not be
ready.
• If the machine ever vibrates abnormally, stop
immediately, wait for all motion to stop, and inspect for
damage. Repair all damage before commencing
operation.
• Always watch out for and avoid low overhangs such as
tree limbs, door jambs, and over-head walkways. Make
sure there is enough room over head to easily clear the
vehicle and your head.
• Before getting off of the seat:
• Always shift into neutral and apply the parking brake
before leaving an idling vehicle, or else the vehicle may
creep.
A. Stop the movement of the machine.
• Failure to operate the vehicle safely may result in an
accident, tip over of the vehicle, and serious injury or
death. Drive carefully. To prevent tipping or loss of
control:
C. Turn the ignition key to OFF.
B. Set the parking brake.
D. Remove the key from the ignition.
Note: If the vehicle is on an incline, block the wheels after
getting off of the vehicle.
– Use extreme caution and reduce speed around
unfamiliar areas or any areas that have abrupt
changes in ground conditions or elevation.
– Watch for holes or other hidden hazards.
4
• Turning while traveling up or down hills can be
dangerous. If you have to turn while on a hill, do it
slowly and cautiously. Never make sharp or fast turns.
Braking
• Slow down before you approach an obstacle. This gives
you extra time to stop or turn away. Hitting an obstacle
can damage the vehicle and its contents. More
important, it can injure you and your passenger.
• Heavy loads affect stability. Reduce the weight of the
load and your speed when operating on hills or if the
load has a high center of gravity. Secure the load to
prevent it from shifting.
• Gross Vehicle Weight (GVW) has a major impact on
your ability to stop and/or turn. Heavy loads and
attachments make a vehicle harder to stop or turn. The
heavier the load, the longer it takes to stop.
• Avoid stopping on hills, especially with a load.
Stopping while going down a hill will take longer than
stopping on level ground. If the vehicle must be
stopped, avoid sudden speed changes, which may
initiate tipping or rolling of the vehicle. Do not slam on
the brakes when rolling backward, as this may cause the
vehicle to overturn.
• Decrease the vehicle speed if the cargo box has been
removed and there is no attachment on the vehicle. The
braking characteristics change and fast stops may cause
the rear wheels to lock up, which may affect the control
of the vehicle.
• Travel straight up and down slopes whenever possible.
• Turf and pavement are much slipperier when they are
wet. It can take 2 to 4 times as long to stop on wet
surfaces as on dry surfaces. If you drive through
standing water deep enough to get the brakes wet, they
will not work well until they are dry. After driving
through water, you should test the brakes to make sure
they work properly. If they do not, drive slowly while
putting light pressure on the brake pedal. This will dry
the brakes out.
• We strongly recommend installing the optional ROPS
Kit when operating on hilly terrain.
Operating on Rough Terrain
Reduce speed and load when operating on rough terrain,
uneven ground, and near curbs, holes, and other sudden
changes in terrain. Loads may shift, causing the vehicle to
become unstable.
Operating on Hills
We strongly recommend installing the optional ROPS Kit
when operating on rough terrain.
Warning
Warning
Operating the vehicle on a hill may cause tipping
or rolling of the vehicle, or the engine may stall
and you could lose headway on the hill. This could
result in personal injury.
Sudden changes in terrain may cause abrupt
steering wheel movement, possibly resulting in
hand and arm injuries.
• Do not exceed slopes greater than 12.
• Do not accelerate quickly or slam on the brakes
when backing down a hill, especially with a load.
• If the engine stalls or you lose headway on a hill,
slowly back straight down the hill. Never
attempt to turn the vehicle around.
• Never drive across a steep hill; always drive
straight up or down or go around the hill.
• Avoid turning on a hill.
• Reduce your load and the speed of the vehicle.
• Avoid stopping on hills, especially with a load.
• Reduce your speed when operating on rough
terrain and near curbs.
• Grip the steering wheel loosely around the
perimeter. Keep your hands clear of the steering
wheel spokes.
Loading and Dumping
The weight and position of the cargo and passenger can
change the vehicle center of gravity and vehicle handling.
To avoid loss of control and personal injury, follow these
guidelines:
These extra cautions need to be taken when operating the
vehicle on a hill:
• Do not carry loads which exceed the load limits
described on the vehicle weight label; refer to
Specifications, page 11, for vehicle weight limits. The
load rating is for level surfaces only.
• Slow down before starting up or down a hill.
• If the engine stalls or you begin to lose headway while
climbing a hill, gradually apply the brakes and slowly
back straight down the hill.
• Reduce the weight of the load when operating on hills
and rough terrain to avoid tipping or overturning of the
vehicle.
5
• Reduce the weight of the load if the center of gravity is
high. Items such as bricks, fertilizer, or landscape
timbers stack higher in the box. The higher a load is
stacked, the more likely the vehicle is to tip over.
Distribute the load as low as possible, making sure that
the load does not affect rear visibility.
Maintenance
• Position the weight of the load evenly from side to side.
If you position the load toward one of the sides, the
vehicle is more likely to tip over while turning.
• To make sure the entire machine is in good condition,
keep all nuts, bolts, and screws properly tightened.
• Before servicing or making adjustments to the machine,
stop the engine, set the parking brake, and remove the
key from the ignition to prevent someone from
accidentally starting the engine.
• To reduce potential fire hazard, keep the engine area
free of excessive grease, grass, leaves, and
accumulation of dirt.
• Position the weight of a load evenly from front to back.
If you position the load behind the rear axle, it will
reduce the weight on the front wheels. This may result
in a loss of steering control or cause the vehicle to tip
over on hills or bumpy terrain.
• Never use an open flame to check the level or leakage
of fuel or battery electrolyte.
• Use extra caution if the load exceeds the dimensions of
the box and when handling off-center loads that cannot
be centered. Keep loads balanced and secure to prevent
them from shifting.
• If the engine must be running to perform a maintenance
adjustment, keep hands, feet, clothing, and any parts of
the body away from the engine and any moving parts.
Keep everyone away.
• Always secure loads so that they do not shift. If a load
is not secured, or you are transporting a liquid in a large
container such as a sprayer, the load can shift. This
shifting happens most often while turning, going up or
down hills, suddenly changing speeds, or while driving
over rough surfaces. Shifting loads can cause the
vehicle to tip over.
• Do not use open pans of fuel or flammable cleaning
fluids for cleaning parts.
• If repairs are ever needed or assistance is required,
contact an Authorized Toro Dealer.
• To be sure of optimum performance and safety, always
purchase genuine Toro replacement parts and
accessories. Replacement parts and accessories made by
other manufacturers could be dangerous. Altering this
vehicle in any manner may affect vehicle operation,
performance, or durability. This may result in injury or
death. Such use could void the product warranty.
Warning
The weight of the box may be heavy. Hands or
other body parts could be crushed.
• Keep hands and other body parts clear when
lowering the box.
• Do not dump materials on bystanders.
• Never dump a loaded cargo box while the vehicle is
sideways on a hill. The change in weight distribution
may cause the vehicle to overturn.
• When operating with a heavy load in the cargo box,
reduce your speed and allow for sufficient braking
distance. Do not suddenly apply the brakes. Use extra
caution on slopes.
• Be aware that heavy loads increase your stopping
distance and reduce your ability to turn quickly without
tipping over.
• The rear cargo space is intended for load carrying
purposes only, not for passengers.
• Never overload your vehicle. The name plate (located
under dash on center column) shows load limits for the
vehicle. Never overload the attachments or exceed the
Gross Vehicle Weight (GVW).
6
Slope Chart
ALIGN THIS EDGE WITH A VERTICAL SURFACE
(TREE, BUILDING, FENCEPOST, POLE, ETC.)
FOLD ALONG APPROPRIATE LINE.
EXAMPLE: COMPARE
SLOPE WITH FOLDED
EDGE.
7
8
Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
99-7350
1. Maximum tongue weight is 50 lb. (23 kg); maximum trailer
weight is 400 lb. (181 kg).
99-7952
1. Choke
2. Reverse
3. Neutral
4. Forward
99-7954
1. Warning—read the Operator’s Manual.
2. Falling hazard—do not carry passengers in the cargo bed.
3. Explosion hazard, static discharge into fuel container—do not
fill fuel containers in the cargo bed; place fuel containers on the
ground before filling.
99-7349
1. Unlock the cargo bed
2. Lock the cargo bed
99-7345
1. Warning—read the
Operator’s Manual.
2. Hot surface/burn
hazard—stay a safe
distance from the hot
surface.
99-7958
1.
2.
3.
4.
5.
6.
7.
8.
Read the Operator’s Manual for information on fuses.
10 amp. fuse for the optional Road Light Kit
15 amp. fuse for the optional Rear Lift Kit
10 amp. fuse—open
25 amp. fuse for the charge circuit
10 amp. fuse for the headlights
10 amp. fuse for the low oil light and the hour meter
15 amp. fuse for the optional Electric Bed Lift Kit
9
3. Entanglement hazard,
belt—stay away from
moving parts.
4. Crushing hazard, cargo
box—use the prop rod to
support the cargo bed.
99-7951
Warning—read the Operator’s Manual.
Collision hazard—do not operate the vehicle on public streets, roads, or highways.
Falling hazard—do not carry passengers in the cargo bed.
Falling hazard—do not allow children to operate the vehicle.
Hour meter
Headlights
Engine—stop
Engine—run
Engine—start
To start the engine, sit on the operator’s seat, put the gear selector in Neutral, turn the ignition key on, pull the choke lever out (if needed),
and press the accelerator pedal.
11. To stop the engine, release the accelerator pedal, set the parking brake, turn the ignition key off, and remove the ignition key.
12. Electrical power (power point)
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
104-6581
1. Warning—read the Operator’s Manual.
2. Fire hazard—before fueling, stop the engine.
3. Tipping hazard—do not drive the vehicle across or up a slope greater than 12 degrees; drive slowly when turning, when carrying a full or
heavy load, and when driving on rough terrain; keep the vehicle speed under 18 MPH (29 km/h).
4. Falling and arm/leg injury hazards—do not carry passengers in the cargo bed and keep arms and legs inside of the vehicle at all times.
10
104-6592
1. Read the Operator’s Manual.
2. The maximum combined operator and passenger weight is
400 lb. (181 kg.).
3. The maximum cargo weight is 1200 lb. (544 kg).
4. The base weight of the vehicle is 1100 lb. (500 kg).
5. The maximum gross vehicle weight is 2700 lb. (1225 kg).
Specifications
Note: Specifications and design are subject to change without notice.
General Specifications
Base weight
Dry 1050 lb. (476 kg)
Rated capacity
(on level ground)
1600 lb. (726 kg) total, including 200 lb. (91 kg) operator and 200 lb. (91 kg)
passenger, load, trailer tongue weight, gross trailer weight, accessories, and
attachments
Maximum gross vehicle
weight (GVW)
(on level ground)
2650 lb. (1202 kg) total, including all of the weights listed above
Maximum cargo capacity
(on level ground)
1200 lb. (544 kg) total, including trailer tongue weight and gross trailer weight
Tow capacity:
Standard Hitch
Tongue weight 50 lb. (23 kg) Maximum trailer weight 400 lb. (181 kg)
Heavy Duty Hitch
Tongue weight 100 lb. (45 kg) Maximum trailer weight 800 lb. (363 kg)
Overall width
59 in. (150 cm)
Overall length
115 in. (292 cm)
Ground clearance
9-1/4 in. (23.5 cm) at the front with no load or operator
7 in. (18 cm) at the rear with no load or operator
Wheel base
79 in. (200.7 cm)
Wheel tread
(center line to center line)
49 in. (124.5 cm) in the front
48-1/4 in. (122.6 cm) in the rear
Cargo box length
46 in. (116.8 cm) inside
51 in. (129.5 cm) outside
Cargo box width
49 in. (124.5 cm) inside
54 in. (137.2 cm) outside
Cargo box height
10 in. (25.4 cm) inside
11
Optional Equipment
Heavy Duty Bumper
Model No. 19050
Camouflage Box Cover
Model No. 19060
Brush Guard/Bumper
Model No. 19062
Camouflage Full Cover
Model No. 19059
Operator Shield Guard
Model No. 19052
Camouflage Seat Cover
Model No. 19058
Electric Winch
Model No. 19053
Camouflage Glove Box and Trash
Bag
Horn Kit
Model No. 19056
Electric Box Lift
Heavy Duty Hitch
Model No. 07259R
Model No. 07275
Part No. 104-6663
ROPS/Seat Belt Kit
Model No. 07276R
Vinyl Enclosure (Soft Cab)
Model No. 79979R
Stake Side Kit
Model No. 07290R
Soft Bed Cover
Model No. 79980R
Canopy
Model No. 07297R
Rear Receiver Hitch
Model No. 07278R
Folding Windshield*
Model No. 07293R
Rubber Floor Mat Kit
Model No. 07295R
Solid Windshield*
Model No. 07294R
Snow Plow
Model No. 07292R
Model No. 07291R
Electrical Harness Kit
Part No. 99-7924
Cab
Spark Arrestor
Part No. 98-9099
Brake/Taillight Kit
Part No. 104-6697
Gun Boot Kit
Model No. 19054
Signal Light Kit
Part No. 104-6953
Gun Boot Bracket Kit
Model No. 19055
Camouflage Hood Cover
Model No. 19061
* Requires Model No. 07297R
Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
Description
Qty.
Use
Key
2
Use in ignition.
Operator’s Manual
1
Read before operating the machine.
Engine Operator’s Manual
1
Read before operating the machine.
Operator Video
1
Watch before operating the machine.
Registration Card
1
Complete and return to Toro.
12
Checking the Crankcase Oil
Fuel Tank
The engine is shipped with oil in the crankcase; however,
the level of the oil must be checked before and after the
engine is first started.
Recommended Gasoline
Use fresh, clean, unleaded regular gasoline suitable for
automotive use (87 pump octane minimum). Leaded
gasoline may be used if unleaded regular is not available.
1. Position the machine on a level surface.
2. Clean around the oil dipstick (Fig. 2) so dirt cannot fall
into the hole and damage the engine.
Important Never use gasoline containing methanol,
gasoline containing more than 10% ethanol, gasoline
additives, or white gas because engine fuel system damage
could result.
3. Unscrew the oil dipstick and wipe the metal end clean.
4. Slide the oil dipstick fully into the filler tube, but do not
thread it onto the tube. Pull the dipstick out and look at
the metal end. If the oil level is low, remove the filler
cap from the valve cover (Fig. 2) and pour oil into the
opening until the oil level is up to the “FULL” mark on
the dipstick; refer to Servicing the Engine Oil, page 22,
for the proper oil type and viscosity. Add the oil slowly
and check the level often during this process. Do not
overfill.
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is to 1 in.
(25 mm) below the bottom of the filler neck.
This empty space in the tank allows gasoline to
expand.
• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground
away from your vehicle before filling.
• Do not fill gasoline containers inside a vehicle or
on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gas-powered equipment
from the truck or trailer and refuel the
equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline dispenser
nozzle.
• If a gasoline dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.
2
1
Figure 2
1. Oil dipstick
2. Filler cap
5. Install the oil dipstick.
13
Filling the Fuel Tank
Checking the Transmission Oil
The fuel tank capacity is approximately 7 gallons (26.5 l).
The transaxle fluid level should be at the bottom of the
level indicator hole (Fig. 4). If it is not, fill the reservoir
with the appropriate fluid; refer to Changing the Transaxle
Fluid, page 28, steps 3 and 4.
1. Shut the engine off and set the parking brake.
2. Clean the area around the fuel tank cap (Fig. 3).
1
1
m–4849
Figure 4
Figure 3
1. Level indicator hole
1. Fuel tank cap
3. Remove the fuel tank cap.
Operation
4. Fill the tank to about one inch (25 mm) below the top of
tank, (bottom of the filler neck). This space in the tank
allows gasoline to expand. Do not overfill.
Note: Determine the left and right sides of the machine
from the normal operating position.
5. Install the fuel tank cap securely. Wipe up any fuel that
may have spilled.
Think Safety First
Checking the Brake Fluid Level
Please carefully read all of the safety instructions and
symbols in the safety section. Knowing this information
could help you or bystanders avoid injury.
Check the brake fluid level before the engine is first started;
refer to Servicing the Brakes, page 24.
Controls
Accelerator Pedal
Checking the Tire Pressure
The accelerator pedal (Fig. 5) gives the operator the ability
to vary the engine and ground speed of the vehicle.
Depressing the pedal increases the engine RPM and ground
speed. Releasing the pedal decreases the engine RPM and
ground speed. Maximum forward speed is 18 MPH
(26 km/h).
Check the tire pressure every 8 hours or daily to ensure
proper levels.
The air pressure range for the front and rear tires is
8–22 psi (55–103 kPa).
The air pressure needed is determined by the payload
carried. The lower the air pressure, the less the compaction,
smoother the ride, and tire marks are minimized. Lower
pressure should not be used for heavy payloads at high
speeds.
Higher pressures should be used for heavier payloads at
higher speeds. Do not exceed the maximum pressure.
14
Brake Pedal
Choke Control
The brake pedal is used to stop or slow the vehicle (Fig. 5).
The choke control is located below and to the right of the
operator’s seat. To start a cold engine, close the carburetor
choke (Fig. 7) by pulling the choke control outward to the
ON position. After the engine starts, regulate the choke to
keep the engine running smoothly. As soon as possible,
open the choke by pushing the control in to the OFF
position. A warm engine requires little or no choking.
Caution
Brakes can become worn or can be misadjusted
resulting in personal injury.
If brake pedal travels to within 1 in. (25 mm) of
the vehicle floor board, the brakes must be
adjusted or repaired.
1
2
2
m–5371
Figure 7
1. Choke
1
2. Gear shift selector
m–5908
Figure 5
1. Accelerator pedal
Gear Shift Selector
2. Brake pedal
The gear shift selector has three positions: forward, reverse,
and neutral (Fig. 7). The gear shift selector must be in
neutral to start the engine.
Parking Brake
Important The vehicle should always be stopped
before changing the gear selection and direction.
The parking brake is between the seats (Fig. 6). Whenever
the engine is shut off, the parking brake must be engaged to
prevent accidental movement of the vehicle. To engage the
parking brake, pull back on the lever. To disengage, push
the lever forward. If the vehicle is parked on a steep grade,
make sure that the parking brake is applied. Place blocks at
the downhill side of the wheels.
Ignition Switch
The ignition switch (Fig. 8), used to start and stop the
engine, has three positions: On, Off, and Start. Rotate the
key clockwise to the Start position to start the vehicle.
When the engine starts, release the key. When the vehicle is
stopped, rotate the key counterclockwise to the Off position
to shut the engine off. Remove the key from the ignition.
1
Hour Meter
The hour meter (Fig. 8) indicates the total number of hours
that the engine has run.
Oil Light
The oil light warns the operator if the engine oil pressure
drops below a safe level (Fig. 8). If the light comes on and
remains lit, the oil level should be checked and oil added if
necessary; see Servicing the Engine Oil, page 22.
m–5909
Figure 6
1. Parking brake lever
Note: The oil light may flicker. This is normal and no
action needs to be taken.
15
Light Switch
Passenger Hand Holds
Toggle the switch to activate the headlights. Push to turn
the lights on (Fig. 8).
The passenger hand holds are located on the right side of
the dash panel and at the outside of each seat (Fig. 10).
2
1
Power Point
The power point is used to power 12 volt, optional
electrical accessories (Fig. 8).
3
4
m–4887
Figure 10
1. Passenger hand hold
2
1
5
Pre-Starting Checks
m–4885
Safe operation begins before taking the vehicle out for a
day’s work. You should check these items each time:
Figure 8
1. Ignition switch
2. Hour meter
3. Light switch
2. Hip restraint
4. Oil light
5. Power point
• Check the tire pressure.
Note: These tires are different than car tires; they require
less pressure to minimize turf compaction and damage.
Fuel Gauge
• Check all fluid levels and add the appropriate amount of
Toro specified fluids, if any are found to be low.
The fuel gauge (Fig. 9) shows the amount of fuel in the
tank.
• Check the brake pedal operation.
• Ensure that the lights are working.
• Turn the steering wheel to the left and right to check
steering response.
1
• Check for oil leaks, loose parts, and any other
noticeable malfunctions. Make sure the engine is off
and all moving parts have stopped before checking for
oil leaks, loose parts, and other malfunctions.
If any of the above items are not correct and you are not
able to correct the problem, contact an Authorized Service
Dealer.
Figure 9
1. Fuel gauge
16
Starting the Engine
Cargo Bed
1. Sit in the operator’s seat.
Raising the Bed
2. Put the gear shift selector in Neutral.
1. Slide the latch upward toward the top of the cutout in
the bed frame (Fig. 11).
Note: The engine will only start in Neutral.
2. Lift up on the latch with one hand while raising the bed
with the other hand.
3. Insert the key into the ignition switch, turn it clockwise
to the Start position, and pull the choke out. When the
engine starts, release the key.
Note: An engine that has been running and is warm may
not require pulling the choke out.
1
4. After the engine starts and warms up, slowly return the
choke knob to the Off position. If the engine stalls or
hesitates, pull the Choke out for a few seconds. Then
move it back to Off.
5. Disengage the parking brake.
6. Slowly step on the accelerator pedal.
m–4850
Figure 11
Important Do not attempt to push or tow the vehicle to
get it started.
1. Latch
Stopping the Vehicle
3. Raise the bed to its full height; then lower it slightly to
engage the prop rod (Fig. 12).
To stop the vehicle, remove your foot from the accelerator
pedal and slowly depress the brake pedal.
Note: Stopping distance may vary depending on the vehicle
load and speed.
1
Parking the Vehicle
1. Engage the parking brake and rotate the ignition key to
Off.
2. Remove the key from the switch to prevent accidental
starting.
m–4865
Figure 12
1. Prop rod
Lowering the Bed
1. Lift up the bed slightly with one hand while pressing
down on the prop rod.
2. Lower the bed until the latch engages.
3. To secure the bed tightly to the bed frame, move the
latch to the lower section of the cutout (Fig. 11).
17
Tailgate Latches
Transporting the Vehicle
1. To open the tailgate latches, lift the latch handles up
(Fig. 13). The latches will spring out toward the center
of the tailgate. Slowly lower the tailgate.
For moving the vehicle long distances, a trailer should be
used. Make sure that the vehicle is secured to the trailer.
Refer to Figures 14 and 15 for the location of tie-down
points.
Note: You may need to push the end of the tailgate in
(especially if there is a load against the tailgate) before the
latches will spring toward the center of the tailgate and
release.
Caution
Loose seats may fall off of the vehicle and trailer
when transporting and land on another vehicle or
become an obstruction on the road.
1
Remove the seats or make sure that the seats are
securely fastened in the detents.
m–5334
Figure 13
1. Tailgate latch
2. To close the tailgate latches, lift the handles upward and
slide them toward the outside of the vehicle.
3. Push the latch handles downward to secure the latch and
tailgate.
1
1
Figure 14
New Vehicle Break-In
1. Tie down points
To provide proper performance and long vehicle life,
follow these guidelines for the first 100 operating hours.
• Check the fluid and engine oil levels regularly and be
alert for indications of overheating in any component of
the vehicle.
• After starting a cold engine, let it warm up for about 15
seconds before accelerating.
• Avoid hard braking situations for the first several hours
of new vehicle break-in operation. New brake linings
may not be at optimum performance until several hours
of use has caused the brakes to become burnished
(broken-in).
• Vary the vehicle speed during operation. Avoid fast
starts and quick stops.
• A break-in oil for engine is not required. Original
engine oil is the same type specified for regular oil
changes.
• Refer to the Maintenance section for any special low
hour checks.
• Check the front suspension positioning and adjust it if
necessary; refer to Adjusting the Front Suspension,
page 25.
18
Loading the Cargo Box
The capacity of the cargo box is 13 ft.3 (0.37 m3). The
amount (volume) of material that can be placed in the box
without exceeding the vehicle load ratings can vary greatly
depending on the density of the material. For example, a
level box of wet sand weighs 1500 lb. (680 kg), which
exceeds the load rating by 500 lb. (227 kg). But a level box
of wood weighs 650 lb. (295 kg), which is under the load
rating.
1
See the table below for load volume limits with various
materials:
Density
(lb./ft.3)
Max. cargo box
capacity (on level
ground)
Dry
95
3/4 full (approx.)
Wet
120
1/2 full (approx.)
Dry
90
3/4 full
Wet
120
1/2 full
Wood
45
Full
Bark
<45
Full
Earth, packed
100
3/4 full (approx.)
Material
Figure 15
1. Towing tongue and tie down point
Gravel
Towing a Trailer
The vehicle is capable of pulling trailers. Two types of tow
hitches are available for the vehicle, depending on your
application. Contact your Authorized Toro Dealer for
details.
Sand
When hauling cargo or towing a trailer, do not overload
your vehicle or trailer. Overloading can cause poor
performance or damage to the brakes, axle, engine,
transaxle, steering, suspension, body structure, or tires.
Always load a trailer with 60% of the cargo weight in the
front of the trailer. This places approximately 10% of the
Gross Trailer Weight (GTW) on the tow hitch of the
vehicle.
Towing the Vehicle
The maximum cargo load shall not exceed 1200 lb.
(544 kg), including the GTW and tongue weight. For
example, if the GTW = 400 lb. (181 kg) and tongue weight
= 50 lb. (23 kg), then the maximum cargo load = 750 lb.
(340 kg).
In case of an emergency, the vehicle can be towed for a
short distance. However, we do not recommend this as a
standard procedure.
To provide adequate braking and traction, always load the
cargo box when trailering. Do not exceed the GTW limits.
Warning
Avoid parking a vehicle with a trailer on a hill. If you must
park on a hill, engage the parking brake and block the
trailer tires.
Towing at excessive speeds could cause a loss of
steering control, resulting in personal injury.
Never tow the vehicle faster than 5 MPH (8 km/h).
Towing the vehicle is a two person job. If the machine must
be moved a considerable distance, transport it on a truck or
trailer; refer to Transporting the Vehicle, page 18.
1. Remove the drive belt; refer to Replacing the Drive
Belt, page 27, steps 1 and 2.
2. Affix a tow line to the tongue on the front of the frame
(Fig. 15).
3. Put the vehicle in neutral and release the parking brake.
19
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule
Maintenance Service
Interval
After first 8 hours
Every 8 hours
After first 20 hours
Maintenance Procedure
• Change the engine oil.
• Check the drive belt tension.
• Check the engine oil.
• Check the tire pressure.
• Check the front wheel toe-in at the proper ride height.
Every 50 hours
• Check the battery fluid level.
• Check the battery cable connections.
• Change the engine oil (includes synthetic oil).1
Every 100 hours
•
•
•
•
•
•
•
•
•
Every 200 hours
• Replace the air cleaner filter.
• Check the parking brake cable adjustments.
• Inspect the drive belt.
Lubricate all grease fittings.
Clean the engine rotating screen.2
Inspect the air cleaner filter.2
Replace the engine oil filter.
Inspect the brake and parking brake.
Inspect the condition and wear of the tires.
Torque the wheel lug nuts.
Check the front suspension toe-in and ride height.
Check the operation of the Neutral gear shift position.
Every 400 hours or
yearly
• Inspect the fuel lines.
Every 800 hours or
yearly
• Replace the fuel filter.
• Change the transaxle oil.
• Replace the spark plugs.
1More
2More
often when operating under heavy load or high temperatures
often in dusty, dirty conditions
Important
Refer to your engine operator’s manual for additional maintenance procedures.
Caution
If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.
Remove the key from the ignition and disconnect the wire(s) from the spark plug(s) before you
do any maintenance. Set the wire(s) aside so that it does not accidentally contact the spark
plug(s).
20
Warning
The bed must be raised to perform some routine
maintenance. The bed could fall and injure
persons that are underneath it.
• Always use prop rod to hold bed up before
working under raised bed.
• Remove any load material from bed before
working under raised bed.
1
Figure 16
Heavy Duty Operation
1. Front jacking point
Important If vehicle is subjected to conditions listed
below, maintenance should be performed twice as
frequently.
• Desert operation
• Cold climate operation (below 32° F [0° C])
• Trailer towing
• Frequent operation on dusty roads
• Construction work
• After extended operation in mud, sand, water, or similar
dirty conditions, have your brakes inspected and
cleaned as soon as possible. This will prevent any
abrasive material from causing excessive wear.
1
1
Figure 17
• Under frequent heavy duty operating conditions,
lubricate all grease fittings and inspect air cleaner daily
to prevent excessive wear.
1. Rear jacking points
Checking and Adjusting
Neutral
Jacking the Vehicle
Whenever the engine is run for routine maintenance and/or
engine diagnostics, the rear wheels of the vehicle should be
1 in. (25 mm) off of the ground with the rear axle supported
on jack stands.
When performing routine maintenance and/or engine
diagnostics, the transaxle must be shifted into neutral
(Fig. 18). The vehicle has a neutral position on the shift
lever, which controls the neutral in the transaxle. The
following steps should be taken to make sure that the
neutral shift lever operates the transaxle neutral correctly:
Danger
1. Set the shift lever into the Neutral position.
A vehicle on a jack may be unstable and slip off of
the jack, injuring anyone beneath it.
2. Set the neutral bracket on the transaxle to the neutral
position (level), turn the drive clutch, and check to see
if the vehicle rolls back and forth (Fig. 18).
• Do not start the engine while the vehicle is on a
jack.
• Always remove the key from the ignition before
getting off of the vehicle.
• Block the tires when the vehicle is on a jack.
3. Tighten one of the locknuts (Fig. 18) just enough to take
the slack out of the shift cable.
Note: You must hold the threaded shaft below the bracket
to tighten the locknut on top.
The jacking point at the front of the vehicle is on the front
of the frame behind the towing tongue (Fig. 16) The
jacking point at the rear of the vehicle is under the axle
tubes (Fig. 17).
4. Tighten the other locknut just enough to take the slack
out of the other shift cable.
5. Torque the first locknut to 8–10 in.-lb. (1 N⋅m).
21
6. Torque the second locknut to 8–10 in.-lb. (1 N⋅m).
Checking the Oil Level
7. Start the engine and shift into Forward, Reverse, and
Neutral several times to ensure that the neutral bracket
is operating properly.
To check the oil level, refer to Checking the Crankcase Oil,
page 13.
Changing and Draining the Oil
1. Start the vehicle and let it run for a few minutes to
warm the oil.
2
2. Park the machine on a level surface, set the parking
brake, turn the ignition off, and remove the key.
1
3. Raise the bed and secure it with the prop rod.
4. Disconnect the spark plug wires and battery cables.
5. Remove the drain plug (Fig. 19) and let the oil flow into
a drain pan. When the oil drains completely, install the
drain plug.
Note: Dispose of the used oil at a certified recycling center.
Figure 18
1. Neutral bracket
2. Locknuts
Servicing the Engine Oil
1
Check the oil level before each use.
Change the oil after the first 8 operating hours and every 50
hours thereafter.
2
Figure 19
Replace the oil filter every 100 hours.
1. Engine oil drain plug
2. Engine oil filter
Note: Change the oil and oil filter more frequently when
operating conditions are extremely dusty or sandy.
6. Pour oil into fill opening until the oil level is up to the
“FULL” mark on the dipstick. Add the oil slowly and
check the level often during this process. Do not
overfill.
Oil Type: Detergent oil (API service SF, SG, SH, SJ, or
higher)
Crankcase Capacity: 48 oz./1-1/2 qt. (1.4 liters) when the
filter is changed
7. Reinstall the oil fill cap and dipstick firmly in place.
Viscosity: See the table below
Changing the Oil Filter
USE THESE SAE VISCOSITY OILS
Replace the oil filter every 100 operating hours or yearly,
whichever occurs first.
1. Drain the oil from the engine; refer to Changing and
Draining the Oil, page 22.
2. Remove the existing oil filter (Fig. 19). Apply a light
coat of clean oil to the new filter gasket.
–20
°F
0
–30
°C
–20
20
–10
40
0
60
10
80
20
3. Screw the filter on until gasket contacts mounting plate,
then tighten filter an additional 1/2 to 3/4 turn further.
Do not overtighten.
100
30
40
4. Fill the crankcase with the proper type of new oil; refer
to Servicing the Engine Oil, page 22.
22
5. Start and run the engine to check for leaks.
6. Stop the engine and recheck the oil level. Add oil if
necessary.
Cleaning the Engine Cooling
Areas
ÎÎÎ
ÎÎÎ
3
Clean the rotating screen, cooling fins, and external
surfaces of the engine every 100 hours of operation or more
often under extremely dusty and dirty conditions.
Important Operating the engine with a blocked
rotating screen, dirty or plugged cooling fins or cooling
shrouds removed, will cause engine damage due to
overheating.
2
1
Figure 20
Important Never clean the engine with pressurized
water because water could contaminate the fuel system.
1. Air cleaner latches
2. Cover
3. Filter
Servicing the Air Cleaner
Check the air cleaner body for damage which could
possibly cause an air leak. Replace a damaged air cleaner
body.
Cleaning the Filter Element
Ensure that the cover is sealing around the air cleaner body.
1. Washing method:
Important
Air Cleaner Filter: Inspect after every 100 operating hours;
replace after every 200 hours or sooner if dirty or damaged.
Do not wash or reuse a damaged filter.
A. Prepare a solution of filter cleaner and water and
soak the filter element about 15 minutes; refer to the
directions on the filter cleaner carton for complete
information.
Note: Service the air cleaner more frequently (every few
hours) if operating conditions are extremely dusty or sandy.
B. After soaking the filter for 15 minutes, rinse it with
clear water. Rinse the filter from the clean side to
the dirty side.
Removing the Filter Element
1. Park the machine on a level surface, set the parking
brake, turn the ignition off, and remove the key.
2. Raise the bed and secure it with the prop rod.
Important To prevent damage to the filter element,
maximum water pressure must not exceed 40 psi
(276 kPa).
3. Release the latches securing the air cleaner cover to the
air cleaner body. Separate the cover from the body.
Clean the inside of the air cleaner cover (Fig. 20).
C. Dry the filter element using warm, flowing air at
160°F (71°C) maximum, or allow the element to
air-dry.
4. Gently slide the filter out of the air cleaner body to
reduce the amount of dust dislodged (Fig. 20). Avoid
knocking the filter against the air cleaner body.
Important Do not use a light bulb to dry the filter
element because damage could result.
2. Compressed air method:
5. Inspect the filter and discard it if it is damaged.
A. Blow compressed air from the inside to the outside
of the dry filter element. Keep the air hose nozzle at
least 2 inches (51 mm) from the filter and move the
nozzle up and down while rotating the filter
element.
Important To prevent damage to the filter element,
do not exceed 100 psi (689 kPa) air pressure.
B. Inspect the filter element for holes and tears by
looking through the filter toward a bright light.
23
Installing the Filter Element
Important To prevent engine damage, always operate
the engine with the complete air cleaner assembly installed.
1. Inspect the new filter for shipping damage. Check the
sealing end of the filter.
Important
Do not install a damaged filter.
2. Insert the new filter properly into the air cleaner body.
Ensure that the filter is sealed properly by applying
pressure to the outer rim of the filter when installing it.
Do not press on the flexible center of the filter.
m–5324
3. Install the cover and secure the latches.
Figure 22
Greasing the Machine
Servicing the Brakes
Lubricate all bearings and bushings after every 100 hours
or once a year, whichever occurs first. Grease more
frequently when using for heavy-duty vehicle operations.
Inspecting the Brakes
Brakes are a critical safety component of the vehicle. As
with all safety components, they should be closely
inspected at regular intervals to ensure optimum
performance and safety. The following inspections should
be done every 100 hours:
Grease Type: No. 2 General Purpose Lithium Base Grease
Where to Add Grease
The grease fitting locations are at the tie rod ends (4)
(Fig. 21) and the king pins (2) (Fig. 22).
• Inspect the brake shoes for wear or damage. If the
lining (brake pad) thickness is less than 1/16 in.
(1.6 mm), the brake shoes should be replaced.
1. Wipe grease fitting clean so foreign matter cannot be
forced into the bearing or bushing.
• Inspect the backing plate and other components for
signs of excessive wear or deformation. If any
deformation is found, the appropriate components must
be replaced.
2. Pump grease into the bearing or bushing.
3. Wipe off excess grease.
• Check the brake fluid level; refer to Checking the Brake
Fluid Level, page 24.
Checking the Brake Fluid Level
The brake fluid reservoir is filled and shipped from the
factory with DOT 3 brake fluid. Check the level before the
engine is first started and every 8 hours or daily, thereafter.
1. Park the machine on a level surface, set the parking
brake, turn the ignition off, and remove the key.
2. Look at the side of the reservoir. The level should be
above the Minimum line (Fig. 23). If the fluid level is
low, clean the area around the cap, remove the cap, and
fill the reservoir to above the Minimum line. Do not
overfill.
m–5320
Figure 21
24
1
2
2
m–5910
Figure 23
1. Brake fluid reservoir
3
2. Minimum line
2
1
Figure 24
Inspecting the Tires
1. Travel limiting bolt
2. Centering bolt
Check tire condition at least every 100 hours of operation.
Operating accidents, such as hitting curbs, can damage a
tire or rim and also disrupt wheel alignment, so inspect tire
condition after an accident.
3. Ride height adjustment
bolt
5. Rotate the front A-arm to the desired position (refer to
the note below) and replace the ride height adjustment
bolt (Fig. 24).
Check the wheels to ensure that they are mounted securely.
Torque the front bolts to 135–165 ft.-lb. (183–224 kPa) and
the rear lug nuts to 45–65 ft.-lb. (61–88 kPa).
Note: The A-arms are made with rubber and have different
spring rates. Because of the different spring rates, the
A-arms come adjusted from the factory based on that
spring rate. Generally the adjustment bolts will be installed
in hole number 2, 3, or 4 (Fig. 25) and it may be different
from the left side (driver side) to the right side (passenger
side). If the A-arms look like they are sagging, then they
should be adjusted to the next higher number (Fig. 25).
Each hole equals about 3/4 in. (19 mm) of adjustment at the
wheel. You will also need to do this if you are adding heavy
attachments or carrying heavy loads often.
Adjusting the Front
Suspension
The ride height of each side of the vehicle can be adjusted
separately. The ride height should be 8-3/4 to 9-1/2 in.
(22.2–24.1 cm) with the following parameters:
• The tire pressure should be at 12 psi (83 kPa).
• The vehicle should be driven back and forth a few times
to relax the A-arms.
• Measure the ride height with the wheels facing straight
ahead and a 175–225 lb. (79–102 kg) operator in the
driver’s seat.
Note: The driver should drive up to the measurement
area and stay seated in the vehicle while the
measurement is being taken.
• Measure the ride height on a flat surface, from the
bottom of the front tongue to the ground.
1. Jack the front end of the vehicle off of the ground; refer
to Jacking the Vehicle, page 21.
1
2. Remove the travel limiting bolt (Fig. 24).
m–5640
3. Loosen the centering bolts in the front A-arm (Fig. 24).
Figure 25
4. Remove the ride height adjustment bolt (Fig. 24).
1. Left-hand A-arm
25
height. Use the same fixture or alignment gauge to
accurately measure the front of the front tires at axle
height (Fig. 26).
6. Torque the ride height adjustment bolt to 135–165 ft.-lb.
(183–224 N⋅m).
7. Replace the travel limiting bolt (Fig. 24).
Note: The vehicle may need to be lowered to the ground on
that side to install the bolt.
6
1
8. Tighten and torque the centering bolts to
240–290 ft.-lbs. (325–393 N⋅m).
5
9. Check the ride height at the front tongue per the
dimensions and parameters given at the beginning of
this procedure.
4
Adjusting Front Wheel Toe-In
52 in.
(132 cm)
2
3
5
Check the front wheel toe-in after every 100 operating
hours, or annually, whichever occurs first.
m–5639
The toe-in should be 1/8–5/8 in. (3–16 mm) with the
following parameters:
Figure 26
1. Tire center line—back
2. Tire center line—front
3. Axle center line
• The tire pressure should be at 12 psi (83 kPa).
• The ride height should be correct before setting the
toe-in; refer to Adjusting the Front Suspension, page 25.
4. Fixture
5. Axle center line distance
6. 6 in. (15 cm) ruler
3. If the measurement does not fall within the specified
range (refer to the dimensions and parameters at the
beginning of this procedure), loosen the jam nuts at
both ends of the tie rods (Fig. 27).
• The vehicle should be driven back and forth a few times
to relax the A-arms.
• Measure the toe-in with the wheels facing straight
ahead and a 175–225 lb. (79–102 kg) operator in the
driver’s seat.
1
2
Note: The driver should drive up to the measurement
area and stay seated in the vehicle while the
measurement is being taken.
1
If the vehicle will be run with medium to heavy loads most
of the time, set the toe-in on the high side of the
recommended amount. If it is going to be run with a light
load most of the time, set the toe-in on the low side of the
recommended amount.
1. Ensure that the front suspension is adjusted properly;
refer to Adjusting the Front Suspension, page 25.
Adjust if necessary.
m–5320
Figure 27
1. Jam nut
2. Measure the distance between both of the front tires at
the axle height at both the front and rear of the front
tires (Fig. 26). A fixture or alignment gauge is needed
for the rear measurement of the front tires at axle
2. Tie rod
4. Rotate both tie rods to move the front of the tire inward
or outward.
5. Tighten the tie rod jam nuts when the adjustment is
correct.
6. Ensure that there is full travel of the steering wheel in
both directions.
26
Servicing the Drive Belt
Servicing the Fuel System
Check condition and tension of drive belt after first day of
operation and every 200 operating hours thereafter.
Fuel Lines and Connections
Check lines and connections every 400 hours or yearly,
whichever occurs first. Inspect for deterioration, damage, or
loose connections.
1. Park the machine on a level surface, shift into Neutral,
set the parking brake, turn the ignition off, and remove
the key.
2. Raise bed and secure with prop rod.
Replacing the Fuel Filter
3. Rotate and inspect belt for excessive wear or damage.
Replace as necessary.
Replace the fuel filter after every 800 operating hours or
yearly, whichever occurs first.
1. Raise the bed and support it with the prop rod.
1
2. Place a clean container under the fuel filter.
3. Remove the clamps securing the fuel filter to the fuel
lines.
1
3
2
Figure 28
1. Drive belt
2. Primary clutch
3. Secondary clutch
m–5322
Figure 29
Replacing the Drive Belt
1. Fuel filter
1. Rotate and route the belt over the secondary clutch
(Fig. 28).
4. Install the replacement fuel filter to the fuel lines with
the clamps previously removed. Mount the filter so that
the arrow points toward the carburetor.
2. Remove the belt from the primary clutch (Fig. 28).
3. To replace the belt, reverse the procedure.
Spark Plugs
Replace the spark plugs after every 800 operating hours or
yearly, whichever occurs first, to ensure proper engine
performance and reduce the exhaust emission level.
Type: Champion RC 12YC (or equivalent)
Air Gap: 0.030 in. (0.76 mm)
Note: The spark plug usually lasts a long time; however,
the plug should be removed and checked whenever the
engine malfunctions.
Checking and Replacing the Spark Plug
1. Clean the area around the spark plugs so that foreign
matter cannot fall into the cylinder when the spark plug
is removed.
2. Pull the spark plug wires off of the spark plugs and
remove the plugs from the cylinder head.
27
3. Check the condition of the side electrode, center
electrode, and center electrode insulator to ensure that
there is no damage.
3. Fill the reservoir (Fig. 32) with approximately 1-1/2 qt.
(1.4 liters) of SAE 10W30 motor oil or until the oil
level is at the bottom of the level indicator hole
(Fig. 31).
0.030 in.
(0.76 mm)
1
Figure 30
Important A cracked, fouled, dirty or malfunctioning
spark plug must be replaced. Do not sand blast, scrape, or
clean the 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.
Figure 32
4. Set the air gap between the center and side electrodes at
0.030 in. (0.76 mm). Install the correctly gapped spark
plug and tighten the plug to 18–22 ft.-lb. (24–30 N⋅m).
If a torque wrench is not used, tighten the plug firmly.
1. Oil fill
4. Start engine and operate to fill system. Recheck oil
level and replenish, if required.
5. Install the spark plug wires.
Replacing the Fuses
Changing the Transaxle Fluid
There are 4 fuses in the electrical system. They are located
beneath the bed in a box on the right hand side of the frame
(Fig. 33).
Change transaxle fluid every 800 operating hours or yearly,
whichever occurs first.
1. Position the vehicle on a level surface, set the parking
brake, turn the ignition off, and remove the key.
2. Remove the drain plug from the right side of the
reservoir (Fig. 31) and let the fluid flow into a drain
pan. Install and tighten the plug when the fluid stops
draining.
Low oil light, hour meter
10 amp.
Headlights
10 amp.
Charge circuit
25 amp.
Power point
10 amp.
(15 amp. max.)
Note: Dispose of the used oil at a certified recycling center.
1
2
3
4
1
m–5362
Figure 33
2
1. Charge circuit
2. Headlights
m–4849
Figure 31
1. Drain plug
2. Level indicator hole
28
3. Power point
4. Low oil light, hour meter
Replacing the Headlight Bulbs
Removing the Battery
Replacement bulb: GE #862
1. Position the vehicle on a level surface, set the parking
brake, turn the ignition off, and remove key.
1. Set the parking brake, turn the ignition off, and remove
the key. Switch the headlights off.
2. Raise the bed and secure with the prop rod.
3. Unhook the battery strap.
2. Reach beneath the dash and rotate the lamp assembly
1/4 turn counterclockwise (Fig. 34). Pull the lamp
assembly out of the reflector.
4. Disconnect the negative (black) ground cable from the
battery post.
3. Remove the lamp assembly from the wire harness.
Discard the lamp assembly.
Warning
3
4
Incorrect battery cable routing could damage the
vehicle and cables, causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
1
2
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always reconnect the positive (red) battery cable
before reconnecting the negative (black) cable.
m–4849
Figure 34
1. Lamp assembly
2. Reflector
3. Tabs
4. Slots
Warning
Battery terminals or metal tools could short
against metal vehicle components, causing sparks.
Sparks can cause the battery gasses to explode,
resulting in personal injury.
4. Push the replacement lamp assembly onto the wire
harness.
5. Reach beneath the dash and align the three tabs on the
lamp assembly with the slots in the reflector (Fig. 34).
Insert the lamp assembly into the reflector and rotate it
1/4 turn clockwise until it stops.
• When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the vehicle.
• Do not allow metal tools to short between the
battery terminals and metal parts of the vehicle.
• Always keep the battery strap in place to protect
and secure the battery.
Servicing the Battery
Warning
5. Disconnect the positive (red) cable from the battery
post.
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
Important
6. Remove the battery from the chassis.
Installing the Battery
1. Set the battery on the battery base so the battery posts
are toward the rear of the vehicle.
Do not jump start the vehicle.
2. Connect the positive (red) cable to the positive (+)
battery post and the negative (black) cable to the
negative (–) battery post using the bolts and wing nuts.
Slide the rubber boot over the positive battery post.
Always keep the battery clean and fully charged. Use a
paper towel to clean the battery and battery box. If the
battery terminals are corroded, clean them with a solution
of four parts water and one part baking soda. Apply a light
coating of grease to the battery terminals to prevent
corrosion.
3. Replace the rubber strap to secure the battery to the
base.
Voltage: 12 volt with 280 cold cranking Amps @ 0°F
(–18°C).
29
Important Always keep the battery strap in place to
protect and secure the battery.
Warning
Charging the battery produces gasses that can
explode.
Checking the Electrolyte Level
Check the electrolyte level every 50 operating hours or, if
the machine is in storage, every 30 days.
Never smoke near the battery and keep sparks and
flames away from battery.
1. Raise the bed and secure with the prop rod.
3. Install the battery in the chassis; refer to Installing the
Battery, page 29.
2. Remove the filler caps. If the electrolyte is not up to the
fill line, add the required amount of distilled water;
refer to Adding Water to the Battery, page 30.
Storing the Battery
Danger
If the machine will be stored for more than 30 days, remove
the battery and charge it fully. Either store it on the shelf or
on the machine. Leave the cables disconnected if it is stored
on the machine. Store the battery in a cool atmosphere to
avoid quick deterioration of the charge in the battery. To
prevent the battery from freezing, make sure it is fully
charged.
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
Washing the Vehicle
The vehicle should be washed as needed. Use water alone
or with a mild detergent. A rag may be used, however the
hood will loose some of its luster.
Adding Water to the Battery
Important Pressurized water is not recommended when
washing the machine. It may damage the electrical system,
loosen important decals, or wash away necessary grease at
friction points. Avoid excessive use of water, especially
near the control panel, engine, and battery.
The best time to add distilled water to the battery is just
before you operate the machine. This lets the water mix
thoroughly with the electrolyte solution.
1. Clean the top of the battery with a paper towel.
2. Remove the filler caps from the battery and slowly fill
each cell with distilled water until the level is up to the
fill line. Replace the filler caps.
Important Do not overfill the battery. Electrolyte will
overflow onto other parts of the vehicle and severe
corrosion and deterioration will result.
Charging the Battery
Important Always keep the battery fully charged
(1.260 specific gravity). This is especially important to
prevent battery damage when the temperature is below
32°F (0°C).
1. Remove the battery from the chassis; refer to Removing
the Battery, page 29.
2. Connect a 3 to 4 amp. battery charger to the battery
posts. Charge the battery at a rate of 3 to 4 amperes for
4 to 8 hours (12 volts). Do not overcharge the battery.
30
Electrical Schematic
31
The Toro Total Coverage Guarantee
Consumer
Vehicles
A One-Year Limited Warranty
Conditions and Products Covered
Items and Conditions Not Covered
The Toro Company and its affiliate, Toro Warranty Company,
pursuant to an agreement between them, jointly promise to repair
any Toro Product used for residential or commercial use if
defective in materials or workmanship for a period of one year from
the date of purchase.
This warranty covers both the cost of parts and labor, but you must
pay transportation costs.
This warranty applies to all consumer vehicles and their attachments.
There is no other express warranty except for special emission
system coverage on some products. This express warranty does
not cover:
• Cost of regular maintenance service or parts, such as filters,
fuel, lubricants, tune-up parts, brake and clutch adjustments
• Any product or part which has been altered or misused or
required replacement or repair due to normal wear, accidents,
or lack of proper maintenance
• Repairs necessary due to improper fuel, contaminants in the
fuel system, or failure to properly prepare the fuel system prior
to any period of non-use over three months
• Pickup and delivery charges
All repairs covered by this warranty must be performed by an
Authorized Toro Service Dealer using Toro approved replacement
parts.
Instructions for Obtaining Warranty Service
If you think that your Toro Product contains a defect in materials or
workmanship, follow this procedure:
1. Contact any Toro Authorized or Master Service Dealer to
arrange service at their dealership. To locate a dealer
convenient to you, refer to the Yellow Pages of your telephone
directory (look under “Lawn Mowers”) or access our website at
www.Toro.com. U.S. Customers may also call 800-421-9684
to use our 24-hour Toro dealer locator system.
2. Bring the product and your proof of purchase (sales receipt) to
the Service Dealer.
If for any reason you are dissatisfied with the Service Dealer’s
analysis or with the assistance provided, contact us at:
Customer Care Department, Consumer Division
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
800-348-2424 (U.S. customers)
877-484-9255 (Canada customers)
Owner Responsibilities
You must maintain your Toro Product by following the maintenance
procedures described in the operator’s manual. Such routine
maintenance, whether performed by a dealer or by you, is at your
expense.
General Conditions
Repair by an Authorized Toro Service Dealer is your sole remedy
under this warranty.
Neither The Toro Company nor Toro Warranty Company is liable
for indirect, incidental or consequential damages in connection
with the use of the Toro Products covered by this warranty,
including any cost or expense of providing substitute equipment or
service during reasonable periods of malfunction or non-use
pending completion of repairs under this warranty.
All implied warranties of merchantability (that the product is fit for
ordinary use) and fitness for use (that the product is fit for a
particular purpose) are limited to the duration of the express
warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer)
to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or
have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty
Company.
Part No. 374-0038 Rev. A
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