Toro 12004TC Twister 1600, Twister 1600, Twister 1600 Utility Vehicle User manual

Toro 12004TC Twister 1600, Twister 1600, Twister 1600 Utility Vehicle User manual
Form No. 3356-938 Rev A
Twister® 1600 Utility Vehicle
Model No. 12004TC—Serial No. 270000001 and Up
G002164
Register at www.Toro.com.
Original Instructions (EN)
This spark ignition system complies with Canadian
ICES-002.
This manual uses 2 other words to highlight information.
Important calls attention to special mechanical
information and Note emphasizes general information
worthy of special attention.
Introduction
Contents
Read this information carefully to learn how to operate
and maintain your product properly and to avoid injury
and product damage. You are responsible for operating
the product properly and safely.
Introduction................................................................. 2
Safety ........................................................................... 3
Before Operating ................................................. 3
Operation............................................................. 4
Maintenance......................................................... 6
Sound Pressure..................................................... 7
Vibration.............................................................. 7
Safety and Instructional Decals ............................. 7
Setup.......................................................................... 10
1 Installing the Wheels........................................ 11
2 Installing the Steering Wheel ............................ 11
3 Installing the Bumper....................................... 12
4 Installing the Seats ........................................... 12
5 Installing the Hitch .......................................... 13
6 Installing the Cargo Box................................... 13
7 Activating the Battery ...................................... 14
8 Adjusting the Front Wheel Toe-in..................... 14
9 Reading the Manual and Viewing the Safety
Video ............................................................. 15
Product Overview ...................................................... 17
Controls ............................................................. 17
Specifications ..................................................... 20
Attachments/Accessories................................... 20
Operation................................................................... 20
Think Safety First ............................................... 20
Pre-Starting Checks ............................................ 20
Checking the Engine Oil..................................... 20
Checking the Brake Fluid Level........................... 21
Checking the Tire Pressure ................................. 21
Adding Fuel ....................................................... 21
Checking the Transmission Oil Level .................. 22
Starting the Engine............................................. 22
Stopping the Vehicle........................................... 22
Parking the Vehicle ............................................. 23
Operating the Cargo Box .................................... 23
Breaking in a New Vehicle .................................. 24
Loading the Cargo Box....................................... 24
Transporting the Vehicle..................................... 24
Towing the Vehicle ............................................. 24
Towing a Trailer.................................................. 25
Maintenance............................................................... 26
Recommended Maintenance Schedule(s) ................ 26
Premaintenance Procedures.................................... 27
Maintaining the Vehicle under Special
Operating Conditions..................................... 27
You may contact Toro directly at www.Toro.com for
product and accessory information, help finding a
dealer, or to register your product.
Whenever you need service, genuine Toro parts,
or additional information, contact an Authorized
Service Dealer or Toro Customer Service and have
the model and serial numbers of your product ready.
Figure 1 identifies the location of the model and serial
numbers on the product. Write the numbers in the
space provided.
Figure 1
1. Model and serial number location
Model No.
Serial No.
This manual identifies potential hazards and has
safety messages identified by the safety alert symbol
(Figure 2), which signals a hazard that may cause serious
injury or death if you do not follow the recommended
precautions.
Figure 2
1. Safety alert symbol
© 2007—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
2
Contact us at www.Toro.com.
Printed in the USA.
All Rights Reserved
Safety
Jacking the Vehicle.............................................. 27
Lubrication............................................................. 28
Adding Grease ................................................... 28
Engine Maintenance............................................... 28
Servicing the Air Cleaner .................................... 28
Servicing the Engine Oil ..................................... 29
Servicing the Spark Plugs.................................... 30
Fuel System Maintenance ....................................... 31
Inspecting Fuel Lines and Connections ............... 31
Replacing the Fuel Filter ..................................... 31
Electrical System Maintenance................................ 31
Replacing the Fuses ............................................ 31
Replacing the Headlights .................................... 31
Servicing the Battery........................................... 32
Drive System Maintenance ..................................... 33
Checking and Adjusting Neutral ......................... 33
Inspecting the Tires ............................................ 34
Adjusting the Front Suspension .......................... 34
Adjusting Front Wheel Toe-In ............................ 35
Maintaining the Primary Drive Clutch ................. 36
Changing the Transaxle Fluid.............................. 36
Cooling System Maintenance .................................. 37
Cleaning the Engine Cooling Areas ..................... 37
Brake Maintenance ................................................. 37
Inspecting the Brakes ......................................... 37
Checking the Brake Fluid Level........................... 37
Adjusting the Parking Brake................................ 37
Belt Maintenance.................................................... 38
Servicing the Drive Belt ...................................... 38
Cleaning ................................................................. 39
Washing the Vehicle............................................ 39
Storage....................................................................... 39
Schematics ................................................................. 41
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.
The vehicle is an off-highway vehicle only and
is not designed, equipped, or manufactured for
use on public streets, roads, or highways.
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.
• 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.
• This vehicle is designed to carry only the operator
and one passenger in the seat provided by the
manufacturer. Never carry any other passengers on
the vehicle.
• Never operate the vehicle when under the influence
of drugs or alcohol. Even prescription drugs and
cold medicines can cause drowsiness.
• 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.
• Become familiar with the controls and know how to
stop the engine quickly.
• 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.
• 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.
• 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
3
to drive cautiously, use the headlights, and even
consider adding additional lights.
• Be extremely careful when operating around people.
Always be aware of where bystanders might be.
• 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 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.
– Use an approved gasoline container.
– Do not remove the cap from the fuel tank when
the engine is hot or running.
– Do not smoke while handling gasoline.
– Fill the fuel tank outdoors, and fill it to about
1 inch (25 mm) below the top of the tank (the
bottom of the filler neck). Do not overfill it.
– Wipe up any spilled gasoline.
– Do not fill fuel containers in the cargo box; place
fuel containers on the ground before filling.
• 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:
– Use extreme caution, reduce speed, and maintain
a safe distance around sand traps, ditches, creeks,
ramps, unfamiliar areas, or any areas that have
abrupt changes in ground conditions or elevation.
– Watch for holes or other hidden hazards.
– 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.
– Avoid sudden stops and starts. Do not go from
reverse to forward or forward to reverse without
first coming to a complete stop.
– 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.
– 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
the box, not from behind.
Operation
– Only operate the vehicle when the cargo box is
down and latched.
– Before backing up, look to the rear and ensure
that no one is behind you. Back up slowly.
Engine exhaust contains carbon monoxide,
which is an odorless, deadly poison that can
kill you.
– Watch out for traffic when you are 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 that other people know what you plan to do.
Obey all traffic rules and regulations.
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.
• 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.
• 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.
• Always shift into neutral and apply the parking brake
before leaving an idling vehicle, or else the vehicle
may creep.
– 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.
• If the machine ever vibrates abnormally, stop
immediately, wait for all motion to stop, and inspect
the vehicle for damage. Repair all damage before
commencing operation.
• Before getting off of the seat:
1. Stop the movement of the machine.
4
Operating on Hills
2. Set the parking brake.
3. Turn the ignition key to Off.
4. Remove the ignition key.
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.
Note: If the vehicle is on an incline, block the
wheels after getting off of the vehicle.
Braking
• Do not accelerate quickly or slam on the
brakes when backing down a hill, especially
with a load.
• 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.
• If the engine stalls or you lose headway on
a hill, slowly back straight down the hill.
Never attempt to turn the vehicle around.
• 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.
• Operate the vehicle slowly on a hill and use
caution.
• Avoid turning on a hill.
• 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.
• Reduce your load and the speed of the
vehicle.
• Avoid stopping on hills, especially with a
load.
• Turf and pavement are much more slippery 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.
These extra cautions need to be taken when operating
the vehicle on a hill:
• 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.
• 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.
• 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 and take extra care when
hauling loads that shift easily (liquid, rock, sand, etc.).
• 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.
• We strongly recommend installing the optional
ROPS Kit when operating on hilly terrain.
5
Operating on Rough Terrain
cannot be centered. Keep loads balanced and secure
to prevent them from shifting.
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.
• 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.
We strongly recommend installing the optional ROPS
Kit when operating on rough terrain.
Sudden changes in terrain may cause abrupt
steering wheel movement, possibly resulting in
hand and arm injuries.
The weight of the box may be heavy. Hands or
other body parts could be crushed.
• Reduce your speed when operating on rough
terrain and near curbs.
– Keep hands and other body parts clear when
lowering the box.
• Grip the steering wheel loosely around the
perimeter. Keep your hands clear of the
steering wheel spokes.
– 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.
Loading and Dumping
• 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.
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:
• Be aware that heavy loads increase your stopping
distance and reduce your ability to turn quickly
without tipping over.
• Do not carry loads which exceed the load limits
described on the vehicle weight label; refer to
Specifications in Product Overview , page 17, for
vehicle weight limits. The load rating is for level
surfaces only.
• The rear cargo space is intended for load carrying
purposes only, not for passengers.
• Never overload your vehicle. The decal (located on
the rear frame) shows load limits for the vehicle.
Never overload the attachments or exceed the Gross
Vehicle Weight (GVW).
• Reduce the weight of the load when operating
on hills and rough terrain to avoid tipping or
overturning of the vehicle.
• 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
• 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.
• 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 that the entire machine is in good
condition, keep all nuts, bolts, and screws properly
tightened.
• 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.
• To reduce the potential for fire, keep the engine
area free of excessive grease, grass, leaves, and
accumulation of dirt.
• Use extra caution if the load exceeds the dimensions
of the box and when handling off-center loads that
• Never use an open flame to check the level or
leakage of fuel or battery electrolyte.
6
Sound Pressure
• If the engine must be running to perform a
maintenance adjustment, keep your hands, feet,
clothing, and any parts of your body away from the
engine and any moving parts. Keep everyone away.
This unit has a maximum sound pressure level at the
operator’s ear of 80 dBA, based on measurements of
identical machines per EN 11094.
• Do not use open pans of fuel or flammable cleaning
fluids for cleaning parts.
Vibration
• If major repairs are ever needed or assistance is
required, contact an Authorized Toro Distributor.
This unit does not exceed a hand/arm vibration level of
2.5 m/s2, based on measurements of identical machines
per EN 1033.
• 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 that may affect vehicle
operation, performance, durability, or its use, may
result in injury or death. Such use could void the
product warranty.
This unit does not exceed a whole body vibration
level of 0.5 m/s2, based on measurements of identical
machines per EN 1032.
Safety and Instructional 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.
107–0704
8. Ignition—Run
1. Warning—read the Operator’s Manual.
2. Collision hazard—do not operate the vehicle on public streets, 9. Ignition—Start
roads, or highways.
3. Falling hazard—do not carry passengers in the cargo bed.
10. 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.
4. Falling hazard—do not allow children to operate the vehicle. 11. To stop the engine, release the accelerator pedal, set the
parking brake, turn the ignition key off, and remove the
ignition key.
5. Hour meter
12. Electrical power (power point)
6. Headlights
13. Horn
7. Ignition—Off
7
104–6581
1. Warning—read the Operator’s Manual.
2. Fire hazard—before fueling, stop the engine.
3. Tipping hazard—receive training before operating the machine, use caution and drive slowly while on slopes; drive slowly when
turning, keep the vehicle speed under 19 MPH (31 km/h) when carrying a full or heavy load and when driving on rough terrain .
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.
99–7345
1. Warning—read the Operator’s Manual.
2. Hot surface/burn hazard—stay a safe distance from the
hot surface.
3. Entanglement hazard, belt—stay away from moving parts
4. Crushing hazard, cargo box—use the prop rod to support
the cargo bed
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.
99–7350
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
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).
8
4. The base weight of the
vehicle is 1100 lb (500 kg).
5. The maximum gross
vehicle weight is 2700 lb
(1225 kg).
99–7958
1. Read the Operator’s
Manual for information on
fuses.
2. 10 amp. fuse for the
optional Road Light Kit
3. 15 amp. fuse for the
optional Rear Lift Kit
4. 10 amp. fuse-open
5. 15 amp. fuse for the
optional Electric Bed Lift
Kit
6. 10 amp. fuse for the low
oil light and the hour meter
7. 10 amp. fuse for the
headlights
8. 25 amp. fuse for the
charge circuit
9
Setup
Loose Parts
Use the chart below to verify that all parts have been shipped.
Procedure
1
2
3
4
5
6
7
8
9
Description
Use
Qty.
Wheel assembly
4
Install the wheels.
Steering wheel
1
Install the steering wheel.
Bumper
1
Install the bumper.
Seat
2
Install the seats.
Hitch
1
Install the hitch.
Cargo box
Right-hand pivot bracket
Left-hand pivot bracket
Flange head screw (3/8 x 1 inch)
Bolt (5/16 x 3/4 inch)
Flange nut (5/16 inch)
1
1
1
4
1
1
Install the cargo box.
No parts required
–
Activate the battery.
No parts required
–
Adjust the front wheel toe-in.
Operator’s Manual
Engine Operator’s Manual
Parts Catalog
Safety Video
Registration Card
Predelivery Inspection Form
Key
1
1
1
1
1
1
2
Read the Operator’s Manual and watch
the video before operating the machine.
Note: Determine the left and right sides of the machine
from the normal operating position.
10
1
2
Installing the Wheels
Installing the Steering Wheel
Parts needed for this procedure:
Parts needed for this procedure:
4
Wheel assembly
1
Steering wheel
Procedure
Procedure
1. Remove the fasteners securing the wheels.
1. Remove the nut and washer from the steering shaft.
2. Remove the shipping bracket secured to the wheel
studs.
2. Slide the steering wheel and washer onto the shaft.
Position the steering wheel on the shaft so that the
cross beam is horizontal when the tires are pointed
straight ahead and the thicker spoke of the steering
wheel is downward.
3. Mount the wheels with the previously removed
fasteners (Figure 3) and torque to 45-65 ft-lb
(61-88 N-m).
3. Secure the steering wheel to the shaft with the nut
(Figure 4). Torque the nut to 18-22 ft-lb (24-29 N-m)
Figure 3
1. Wheel assembly
3. Wheel stud (rear wheel
hub shown)
2. Wheel nut
Figure 4
1. Steering wheel
2. Nut
11
3. Washer
4. Foam seal
3
4
Installing the Bumper
Installing the Seats
Parts needed for this procedure:
Parts needed for this procedure:
1
Bumper
2
Seat
Procedure
Procedure
1. Remove the 4 bolts and lock nuts secured to the
front of the frame.
Insert the seat bracket into the seat base opening and
pivot the seat downward (Figure 6).
2. Align the mounting holes and secure the bumper
to the frame with the fasteners previously removed
(Figure 5).
Figure 6
1. Seat bracket
Figure 5
1. Bumper
2. Bolt
3. Frame
4. Lock nut
12
2. Seat base
5
6
Installing the Hitch
Installing the Cargo Box
Parts needed for this procedure:
Parts needed for this procedure:
1
Hitch
Procedure
1. Remove the 4 bolts and nuts from the inside rear
of the frame.
2. Align the hitch with the mounting holes on the
frame. Secure the hitch with the screws and nuts
(Figure 7).
1
Cargo box
1
Right-hand pivot bracket
1
Left-hand pivot bracket
4
Flange head screw (3/8 x 1 inch)
1
Bolt (5/16 x 3/4 inch)
1
Flange nut (5/16 inch)
Procedure
1. Position the cargo box onto the frame. The cargo
box must lay flat and be centered.
2. Mount the left hand pivot bracket to the left rear
corner of the frame with 2 flange head screws (3/8 x
1 inch). Position the bracket as shown in Figure 8.
Figure 7
1. Hitch
Figure 8
1. Pivot bracket
3. Slide the cargo box mounting hole onto the pivot
bracket (Figure 9).
13
Note: This procedure is only needed for Model No.
07277TC.
If the battery is not filled with electrolyte or activated, it
must be removed from the vehicle, filled with electrolyte,
and charged. Bulk electrolyte with 1.260 specific gravity
must be purchased from a local battery supply outlet.
1. Remove the battery hold-down and lift the battery
out of the battery base.
Battery electrolyte contains sulfuric acid which
is a deadly poison and causes severe burns.
Figure 9
1. Cargo box
2. Pivot bracket
3. Cargo box mounting hole
• Do not drink electrolyte or allow it to contact
your skin, eyes or clothing. Wear safety
glasses to shield your eyes and rubber gloves
to protect your hands.
4. Insert the right hand pivot bracket into the mounting
hole in the cargo box and then mount it to the frame.
5. Have another person help to raise the cargo box.
6. Loosen the bolt securing the prop rod clip to the
frame until you can slide the J-hook end of the prop
rod under the clip (Figure 10).
• Fill the battery where clean water is always
available for flushing the skin.
2. Remove the filler caps from the battery and slowly
fill each cell until electrolyte is just above the plates.
3. Replace the filler caps and 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.
Charging the battery produces gasses that can
explode.
Figure 10
1. Prop rod
2. Prop rod clip
Never smoke near the battery and keep sparks
and flames away from battery.
3. Bolt (5/16 x 3/4 inch)
4. Flange nut (5/16 inch)
4. When the battery is charged, disconnect the charger
from the electrical outlet and battery posts.
7. Tighten the bolt and secure the other side of the clip
with a new bolt (5/16 x 3/4 inch) and flange nut
(5/16 inch) (Figure 10).
8. Lower the cargo box.
5. Remove the filler caps. Slowly add electrolyte to
each cell until electrolyte is up to the fill line. Install
the filler caps.
7
Important: Do not overfill the battery.
Electrolyte will overflow onto other parts of the
vehicle and severe corrosion and deterioration
will result.
Activating the Battery
6. Install the battery; refer to Installing the Battery,
Electrical System Maintenance , page 31.
No Parts Required
Procedure
None
14
8
Adjusting the Front Wheel
Toe-in
No Parts Required
Procedure
The toe-in should be 1/8-5/8 inch (3-16 mm) with the
following parameters:
• The tire pressure should be at 12 psi (83 kPa).
• The ride height should be correct before setting the
toe-in; refer to the Adjusting the Front Suspension
procedure in Maintenance , page 26.
• 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.
Figure 11
1. Tire center line-back
2. Tire center line-front
3. Axle center line
4. Fixture
5. Axle center line distance
6. 6 inches (15 cm) ruler
2. 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 (Figure 45).
Note: The driver should drive up to the
measurement area and stay seated in the vehicle
while the measurement is being taken.
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. Measure the distance between both of the front tires
at the axle height at both the front and rear of the
front tires (Figure 11). A fixture or alignment gauge
is needed for the rear measurement of the front tires
at axle height. Use the same fixture or alignment
gauge to accurately measure the front of the front
tires at axle height (Figure 11).
Figure 12
1. Jam nut
2. Tie rod
3. Rotate both tie rods to move the front of the tire
inward or outward.
4. Tighten the tie rod jam nuts when the adjustment is
correct.
5. Ensure that there is full travel of the steering wheel
in both directions.
15
9
Reading the Manual and
Viewing the Safety Video
Parts needed for this procedure:
1
Operator’s Manual
1
Engine Operator’s Manual
1
Parts Catalog
1
Safety Video
1
Registration Card
1
Predelivery Inspection Form
2
Key
Procedure
• Read the Operator’s Manual and Engine Operator’s
Manual.
• View the safety video.
• Fill out the registration card.
• Complete the Predelivery Inspection Form and file it in
your customer history portfolio.
16
Product Overview
1
3
5
G002180
6
2
4
7
Figure 13
3. Parking brake
4. Fuel cap
1. Steering wheel
2. Gear shift selector
5. Cargo box
6. Towing tounge
7. Cargo box release lever
Controls
Brakes can become worn or can be misadjusted
resulting in personal injury.
Accelerator Pedal
The accelerator pedal (Figure 14) gives the operator the
ability to vary ground speed of the vehicle. Pressing the
pedal increases ground speed. Releasing the pedal will
slow the vehicle. Maximum forward speed is 18 mph
(26 km/h).
If brake pedal travels to within 1 inch (25 mm)
of the vehicle floor board, the brakes must be
adjusted or repaired.
Parking Brake
The parking brake is between the seats (Figure 15).
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.
Figure 14
1. Accelerator pedal
2. Brake pedal
Brake Pedal
Figure 15
The brake pedal is used to stop or slow the vehicle
(Figure 14).
1. Parking brake lever
17
Choke Control
The choke control is located below and to the right of
the operator’s seat. To start a cold engine, pull the choke
control outward (Figure 16). After the engine starts,
regulate the choke to keep the engine running smoothly.
As soon as possible, push the control in to the Off
position. A warm engine requires little or no choking.
Figure 17
1. Ignition switch
2. Hour meter
3. Light switch
Hour Meter
Figure 16
1. Choke
4. Oil light
5. Power Point
6. Horn Button
2. Gear shift selector
The hour meter (Figure 17) indicates the total number
of hours the engine has run.
Gear Shift Selector
Oil Light
The gear shift selector has three positions: Forward,
Reverse, and Neutral (Figure 16). The gear shift selector
must be in Neutral to start the engine.
The oil light warns the operator if the engine oil level
drops below a safe level (Figure 17). If the light comes
on and remains lit, the oil level should be checked and
oil added if necessary; refer to Checking the Engine Oil
in Operation , page 20.
Note: If the gear shift selector is in Reverse when the
ignition is turned on, a buzzer will sound to warn the
operator.
Note: The oil light may flicker. This is normal and no
action needs to be taken.
Important: Always stop the vehicle before
changing gears.
Light Switch
Ignition Switch
Toggle the switch to activate the headlights. Push to
turn the lights on (Figure 17).
The ignition switch (Figure 17), 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
engine. When the engine starts, release the key. When
the vehicle is stopped, rotate the key counterclockwise
to the Off position to stop the engine. Remove the key
from the ignition.
Power Point
Use the power point to power 12 volt optional electrical
accessories (Figure 17).
Horn Button
Press the horn button to sound the horn (Figure 17).
Fuel Gauge
The fuel gauge (Figure 18) shows the amount of fuel
in the tank.
18
Figure 18
1. Fuel gauge
Passenger Hand Holds
The passenger hand holds are located on the right side of
the dash panel and at the outside of each seat (Figure 19).
Figure 19
1. Passenger hand hold
2. Hip restraint
19
Specifications
Note: Specifications and design are subject to change without notice.
Base weight
Dry 1050 lb (476 kg)
Rated capacity (on level ground)
1600 lb (726 kg) total, including 200 lb (90.7 kg) operator and 200 lb (90.7 kg) passenger, load,
trailer tongue weight, gross trailer weight, accessories, and attachments
Maximum gross vehicle weight
(GVW) (on level ground)
2700 lb (1225 kg) total, including all of the weights listed above
Maximum cargo capacity (on level 1200 lb (544 kg) total, including trailer tongue weight and gross trailer weight
ground)
Tow capacity:
Standard Hitch
Tongue weight 50 lb (23 kg) Maximum trailer weight 400 lb (182 kg)
Heavy Duty Hitch
Tongue weight 100 lb (45 kg) Maximum trailer weight 800 lb (363 kg)
Overall width
59 inches (150 cm)
Overall length
115 inches (292 cm)
Ground clearance
9-1/4 inches (23.5 cm) at the front with no load or operator, 7 inches (18 cm) at the rear with
no load or operator
Wheel base
79 inches (200.7 cm)
Wheel tread (center line to center
line)
49 inches (124.5 cm) in the front, 48-1/4 inches (122.6 cm) in the rear
Cargo box length
46 inches (116.8 cm) inside, 51 inches (129.5 cm) outside
Cargo box width
49 inches (124.5 cm) inside, 54 inches (137.2 cm) outside
Cargo box height
10 inches (25.4 cm) inside
Attachments/Accessories
A selection of Toro approved attachments and accessories are available for use with the machine to enhance and
expand its capabilities. Contact your Authorized Service Dealer or Distributor or go to www.Toro.com for a list of
all approved attachments and accessories.
Operation
• Check the brake pedal operation.
• Ensure that the lights are working.
Note: Determine the left and right sides of the machine
from the normal operating position.
• Turn the steering wheel to the left and right to check
steering response.
Think Safety First
• 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.
Please carefully read all of the safety instructions and
decals in the safety section. Knowing this information
could help you or bystanders avoid injury.
If any of the above items are not correct and you
are not able to correct the problem, contact your
Authorized Service Dealer.
Pre-Starting Checks
Check the following items each time you begin using the
vehicle for the day:
• Check the tire pressure.
Checking the Engine Oil
Note: 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.
Note: These tires are different than car tires; they
require less pressure to minimize turf compaction
and damage.
• Check all fluid levels and add the appropriate amount
of specified fluids, if any are found to be low.
Check the engine oil level before starting the engine
each day.
20
1. Position the machine on a level surface.
Adding Fuel
2. Clean around the oil dipstick (Figure 20) so dirt
cannot fall into the hole and damage the engine.
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.
Important: Never use gasoline containing
methanol, gasoline containing more than 10%
ethanol, gasoline additives, or white gas because
engine fuel system damage could result.
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.
Figure 20
1. Oil dipstick
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any
gasoline that spills.
3. Remove the oil dipstick and wipe the end clean.
4. Slide the oil dipstick into the filler tube fully seating
it. Pull the dipstick out and look at the end.
• Never fill the fuel tank inside an enclosed
trailer.
If the oil level is low, remove the filler cap and add oil
of the proper type to raise the level to, but not over,
the Full mark on the dipstick. Refer to Servicing the
Engine Oil in Engine Maintenance , page 28, for the
proper oil type and viscosity. Add the oil slowly and
check the level often during this process. Do not
overfill.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1/4
to 1/2 inch (6 to 13 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.
5. Install the oil dipstick firmly in place.
Checking the Brake Fluid
Level
• 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.
Check the brake fluid level before the engine is first
started; refer to Checking the Brake Fluid Level in Brake
Maintenance , page 37.
• Do not operate without entire exhaust
system in place and in proper working
condition.
Checking the Tire Pressure
Check the tire pressure every 8 hours or daily to ensure
proper levels.
The air pressure range in 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.
21
Checking the Transmission Oil
Level
In certain conditions during fueling, static
electricity can be released causing a spark
which can ignite the gasoline vapors. A fire
or explosion from gasoline can burn you and
others and can damage property.
The transaxle fluid level should be at the bottom of
the level indicator hole (Figure 22). If it is not, fill the
reservoir with the appropriate fluid; refer to Changing
the Transaxle Fluid in Drive System Maintenance ,
page 33.
• 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.
Figure 22
1. Level indicator hole
• 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.
Starting the Engine
Important: Do not attempt to push or tow the
vehicle to get it started.
• 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.
1. Sit in the operator’s seat.
2. Put the gear shift selector in Neutral.
Note: The engine will only start in Neutral.
3. Insert the key into the ignition switch, turn it to the
Start position, and pull the choke out. When the
engine starts, release the key.
Filling the Fuel Tank
The fuel tank capacity is approximately 7 gallons (26.5 l).
Note: An engine that has been running and is warm
may not require pulling the choke out.
1. Shut the engine off and set the parking brake.
2. Clean the area around the fuel tank cap (Figure 21).
4. After the engine starts and warms up, slowly push
the choke in to the Off position. If the engine
stalls or hesitates, pull the choke out for a few more
seconds before pushing it to Off.
5. Release the parking brake.
6. Move the gear shift selector to the desired position.
Figure 21
7. To drive the vehicle, move the gear shift selector
to the desired position and slowly step on the
accelerator pedal.
1. Fuel tank cap
3. Remove the fuel tank cap.
4. Fill the tank to about 1 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.
Stopping the Vehicle
To stop the vehicle, remove your foot from the
accelerator pedal and slowly press the brake pedal.
5. Install the fuel tank cap securely. Wipe up any fuel
that may have spilled.
Note: Stopping distance may vary depending on the
vehicle load and speed.
22
Parking the Vehicle
Lowering the Box
1. Engage the parking brake and rotate the ignition
key to Off.
2. Remove the key from the ignition switch to prevent
accidental starting.
The weight of the box may be heavy. Hands or
other body parts could be crushed.
Operating the Cargo Box
Keep hands and other body parts clear when
lowering the box.
Raising the Box
Pull the prop rod out of the detent slot and lower the
box until it latches into place.
Adjusting the Box Latches
Driving the vehicle with the cargo box raised
may cause the vehicle to tip or roll easier. The
box structure may become damaged if you
operate the vehicle with the box raised.
If the box latch does not latch tightly, vibrating up and
down as you drive the vehicle, you can adjust the latch
posts to make the latches fit snugly.
• Only operate the vehicle when the cargo box
is down.
1. Loosen the nut on the end of the latch post
(Figure 25).
• After dumping a load, lower the cargo box.
1. Lift the lever on either side of the box and lift the
box up (Figure 23).
Figure 25
1. Latch
2. Nut
3. Latch post
Figure 23
1. Lever
2. Turn the latch post clockwise until it is snug against
the latch and then tighten the nut (Figure 25).
2. Pull the prop rod into the detent slot, securing the
box (Figure 24).
3. Repeat this procedure for the latch on the other side
of the vehicle.
Operating the Tailgate Latches
1. To open the tailgate latches, lift the latch handles up
(Figure 26). The latches will spring out toward the
center of the tailgate. Slowly lower the tailgate.
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.
Figure 24
1. Prop rod
23
See the table below for load volume limits with various
materials:
Material
Figure 26
1. Tailgate latch
2. To close the tailgate latches, lift the handles upward
and slide them toward the outside of the vehicle.
Max. cargo box capacity
(on level ground)
Gravel, dry
3/4 full (approx.)
Gravel, wet
1/2 full (approx.)
Sand, dry
3/4 full
Sand, wet
1/2 full
Wood
Full
Bark
Full
Earth, packed
3. Push the latch handles downward to secure the latch
and tailgate.
3/4 full (approx.)
Transporting the Vehicle
Breaking in a New Vehicle
For moving the vehicle long distances, a trailer should
be used. Make sure that the vehicle is secured to the
trailer. Refer to Figure 27 and Figure 28 for the location
of the 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.
Loose seats may fall off of the vehicle and trailer
when transporting and land on another vehicle
or become an obstruction on the road.
• 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).
Remove the seats or make sure that the seats
are securely fastened in the detents.
• 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.
Figure 27
• Check the front suspension positioning and adjust it
if necessary; refer to Adjusting the Front Suspension
in Drive System Maintenance , page 33.
1. Tie down points
Loading the Cargo Box
Towing the Vehicle
The capacity of the cargo box is 13 ft3 (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 300 lb (136 kg). But
a level box of wood weighs 650 lb (295 kg), which is
under the load rating.
In case of an emergency, the vehicle can be towed for a
short distance. However, we do not recommend this as
a standard procedure.
24
To provide adequate braking and traction, always load
the cargo box when trailering. Do not exceed the GTW
limits.
Towing at excessive speeds could cause a loss
of steering control, resulting in personal injury.
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.
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.
1. Remove the drive belt; refer to Replacing the Drive
Belt in Belt Maintenance , page 38.
2. Affix a tow line to the tongue on the front of the
frame (Figure 28).
3. Put the vehicle in neutral and release the parking
brake.
Figure 28
1. Towing tongue and tie down point
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
Distributor for details.
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.
The maximum cargo load shall not exceed 1200 lb
(544 kg), including the GTW and tongue weight. For
example, if the GTW = 400 lb (181.5 kg) and tongue
weight = 50 lb (23 kg), then the maximum cargo load =
750 lb (340 kg)
25
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule(s)
Maintenance Service
Interval
Maintenance Procedure
After the first 8 operating
hours
• Change the engine oil.
• Check the condition and tension of the drive belt.
After the first 25 operating
hours
• Check the front wheel toe-in and front suspension.
Before each use or daily
•
•
•
•
Check
Check
Check
Check
the
the
the
the
engine oil.
tire pressure.
transmission oil level.
brake fluid level.
Every 50 hours
• Change the engine oil (twice as often in special operating conditions; refer to
Maintaining the Vehicle under Special Operating Conditions).
• Check the battery cable connections for wear or damage.
Every 100 hours
• Grease the bearings and bushings.
• Inspect and clean the air filter element (twice as often in special operating conditions;
refer to Maintaining the Vehicle under Special Operating Conditions).
• Change the oil filter (twice as often in special operating conditions; refer to
Maintaining the Vehicle under Special Operating Conditions).
• Check the operation of the Neutral gear shift position.
• Inspect the condition and wear of the tires.
• Torque the wheel lug nuts to 45-65 ft-lb (61-88 N-m).
• Check the front wheel toe-in and front suspension.
• Clean the engine cooling areas (twice as often in special operating conditions; refer
to Maintaining the Vehicle under Special Operating Conditions).
• Inspect the brakes.
Every 200 hours
• Replace the air filter element.
• Adjust the parking brake.
• Check the condition and tension of the drive belt.
Every 400 hours
• Inspect the fuel lines and connections.
• Clean and lubricate the primary drive clutch.
Every 800 hours
• Replace the spark plugs.
• Replace the fuel filter.
• Change the transaxle fluid.
Yearly
• Complete all yearly maintenance procedures specified in the Engine Operator’s
Manual.
Important: Refer to your Engine Operator’s Manual for additional maintenance procedures.
26
Premaintenance
Procedures
Maintaining the Vehicle under
Special Operating Conditions
If the vehicle is subjected to any of the conditions
listed below, maintenance should be performed twice
as frequently.
Figure 29
1. Front jacking point
• Desert operation
• Cold climate operation (below 50° F [10° C])
G002092
• Trailer towing
• Driving time typically less than 5 minutes
• Frequent operation in dusty conditions
• 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 30
1. Rear jacking points
• Under frequent heavy duty operating conditions,
lubricate all grease fittings and inspect air cleaner
daily to prevent excessive wear.
Jacking the Vehicle
Whenever the engine is run for routine maintenance
and/or engine diagnostics, the rear wheels of the vehicle
should be 1 inch (25 mm) off the ground with the rear
axle supported on jack stands.
The vehicle may be unstable when using a
jack. It could slip off the jack, injuring anyone
beneath it.
• 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.
The jacking point at the front of the vehicle is on the
front of the frame behind the towing tongue (Figure 29)
The jacking point at the rear of the vehicle is under the
axle tubes (Figure 30).
27
Lubrication
Engine Maintenance
Lubricate all of the bearings and bushings every 100
hours or once a year, whichever occurs first. Grease
them more frequently when using the vehicle for
heavy-duty operations.
Servicing the Air Cleaner
Check the air cleaner body for damage which could
possibly cause an air leak. Replace a damaged air cleaner
body.
Grease Type: Number 2 General Purpose Lithium Base
Grease
Ensure the cover is sealing around the air cleaner body.
Air Cleaner Filter: Inspect after every 100 operating
hours; replace after every 200 hours or sooner if dirty
or damaged.
Adding Grease
1. Wipe the grease fitting clean so foreign matter
cannot be forced into the bearing or bushing.
Note: Service the air cleaner more frequently (every
few hours) if operating conditions are extremely dusty
or sandy.
2. Pump grease into the bearing or bushing.
3. Wipe off excess grease.
Removing the Filter Element
The grease fittings are located at the four tie rod ends
(Figure 31 and the two king pins (Figure 32).
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.
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
(Figure 33).
4. Gently slide the filter out of the air cleaner body to
reduce the amount of dust dislodged (Figure 33).
Avoid knocking the filter against the air cleaner body.
Figure 31
Figure 32
Figure 33
1. Air cleaner latches
2. Cover
3. Filter
5. Inspect the filter and discard it if it is damaged.
Cleaning the Filter Element
Important: Do not wash or reuse a damaged filter.
• Washing method:
1. Prepare a solution of filter cleaner and water
and soak the filter element for about 15 minutes.
28
Note: Change the oil and oil filter more frequently
when operating conditions are extremely dusty or sandy.
Refer to the directions on the filter cleaner carton
for complete information.
2. After soaking the filter for 15 minutes, rinse it
with clear water. Rinse the filter from the clean
side to the dirty side.
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
Important: To prevent damage to the filter
element, the maximum water pressure must
not exceed 40 psi. (276 kPa).
Viscosity: See the table below
3. Dry the filter element using warm, flowing air at
160°F (71°C) maximum, or allow the element
to air-dry.
Important: Do not use a light bulb to dry the
filter element because damage could result.
• Compressed air method:
1. 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.
Figure 34
Important: To prevent damage to the filter
element, do not exceed 100 psi (689 kPa) air
pressure.
Checking the Oil Level
2. Inspect the filter element for holes and tears by
looking through the filter toward a bright light.
To check the oil level, refer to Checking the Engine Oil
in Operation , page 20.
Installing the Filter Element
Important: To prevent engine damage, always
operate the engine with the complete air cleaner
assembly installed.
Changing the Oil
1. Inspect the new filter for shipping damage. Check
the sealing end of the filter.
2. Park the machine on a level surface, set the parking
brake, turn the ignition off, and remove the key.
1. Start the vehicle and let it run for a few minutes to
warm the oil.
Important: Do not install a damaged filter.
3. Raise the bed and secure it with the prop rod.
2. Insert the new filter into air cleaner body. Ensure
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.
4. Disconnect the spark plug wires and battery cables.
5. Remove the drain plug (Figure 35) and let the oil
flow into a drain pan. When the oil stops, install the
drain plug.
3. Install the cover and secure the latches.
Note: Dispose of the used oil at a certified recycling
center.
Servicing the Engine Oil
Check the oil level before each use.
Change the oil after the first 8 operating hours and every
50 hours thereafter. Change the oil twice as often in
special operating conditions; refer to Maintaining the
Vehicle under Special Operating Conditions.
Replace the oil filter every 100 hours.
29
2. Pull the spark plug wires off of the spark plugs and
remove the plugs from the cylinder head.
3. Check the condition of the side electrode, center
electrode, and center electrode insulator to ensure
that there is no damage (Figure 36).
Figure 35
1. Engine oil drain plug
2. Engine oil filter
6. Pour oil into the 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.
7. Install the oil fill cap and dipstick firmly in place.
8. Connect the spark plug wires and battery cables.
Figure 36
1. Center electrode insulator
2. Side electrode
Changing the Oil Filter
3. Air gap (not to scale)
Important: A cracked, fouled, dirty, or
malfunctioning spark plug must be replaced. Do
not sandblast, 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.
Replace the oil filter every 100 operating hours or yearly,
whichever occurs first.
1. Drain the oil from the engine; refer to Changing
the Oil.
2. Remove the existing oil filter (Figure 35).
3. Apply a light coat of clean oil to the new filter gasket.
4. Screw the new filter on until the gasket contacts the
mounting plate, then tighten the filter an additional
1/2 to 3/4 turn further. Do not overtighten.
5. Fill the crankcase with the proper type of new oil.
6. Start and run the engine to check for leaks.
7. Stop the engine and check the oil level. Add oil if
necessary.
4. Set the air gap between the center and side electrodes
at 0.030 inch (0.762 mm) (Figure 36).
5. 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.
6. Install the spark plug wires.
Servicing the 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 14YC (or equivalent)
Air Gap: 0.030 inch (0.762 mm)
Note: The spark plugs usually lasts a long time;
however, the plugs should be removed and checked
whenever the engine malfunctions.
1. Clean the area around the spark plugs so that foreign
matter cannot fall into the cylinder when the spark
plug is removed.
30
Fuel System
Maintenance
Electrical System
Maintenance
Inspecting Fuel Lines and
Connections
Replacing the Fuses
There are 3 fuses in the electrical system. They are
located beneath the bed in a box on the right hand side
of the frame (Figure 38).
Check the fuel lines and connections every 400 operating
hours or yearly, whichever occurs first. Inspect them for
deterioration, damage, or loose connections.
Charge circuit
25 amp.
Lights
10 amp.
Power Point
Replacing the Fuel Filter
10 amp. (15 amp. max.)
Low oil light and hour meter
10 amp.
Replace the fuel filter every 800 operating hours or
yearly, whichever occurs first.
1. Raise the box and support it with the prop rod.
G002190
2. Place a clean container under the fuel filter.
3. Remove the clamps securing the fuel filter to the fuel
lines (Figure 37), as follows:
A. Squeeze the clamp tabs together and slide the
clamps up the hose off of the filter hose fittings.
B. Pull the hose ends off of the filter hose fittings.
Figure 38
1. Charge circuit
2. Lights
3. Power point
4. Low oil light and hour
meter
Replacing the Headlights
Figure 37
Specification: GE #862
1. Set the parking brake, turn the ignition off, and
remove the key.
2. Switch the headlights off.
3. Reach beneath the dash and rotate the lamp assembly
1/4 turn counterclockwise (Figure 39).
1. Fuel filter
4. Install the replacement filter to the fuel lines with the
clamps previously removed.
Mount the filter so that the arrow points toward the
carburetor.
31
Incorrect battery cable routing could damage
the vehicle and cables, causing sparks. Sparks
can cause the battery gasses to explode,
resulting in personal injury.
• 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.
G002141
Figure 39
1. Lamp assembly
2. Reflector
• Always keep the battery strap in place to
protect and secure the battery.
3. Tabs
4. Slots
4. Pull the lamp assembly out of the reflector.
5. Remove the lamp assembly from the wire harness.
7. Push the replacement lamp assembly onto the wire
harness.
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.
8. Reach beneath the dash and align the three tabs on
the lamp assembly with the slots in the reflector
(Figure 39).
• When removing or installing the battery, do
not allow the battery terminals to touch any
metal parts of the vehicle.
9. Insert the lamp assembly into the reflector and rotate
it 1/4 turn clockwise until it stops.
• Do not allow metal tools to short between
the battery terminals and metal parts of the
vehicle.
6. Discard the lamp assembly.
Servicing the Battery
5. Disconnect the positive (red) cable from the battery
post.
6. Remove the battery from the chassis.
Important: Do not jump start the vehicle.
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.
Installing the Battery
1. Set the battery on the battery base so the battery
posts are toward the rear of 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.
3. Replace the battery hold-down to secure the battery
to the base.
Voltage: 12 volt with 280 cold cranking Amps @ 0° F
(-18° C).
Removing the Battery
1. Position the vehicle on a level surface, set the parking
brake, turn the ignition off, and remove the key.
Important: Always keep the battery hold-down
in place to protect and secure the battery.
2. Raise the bed and secure it with the prop rod.
3. Remove the battery hold-down.
Charging the Battery
4. Disconnect the negative (black) ground cable from
the battery post.
Important: Always keep the battery fully charged
(1.260 specific gravity). This is especially important
32
Drive System
Maintenance
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.
Checking and Adjusting
Neutral
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.
When performing routine maintenance and/or engine
diagnostics, the transaxle must be shifted into neutral
(Figure 40). 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:
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks
and flames away from battery.
1. Set the shift lever into the Neutral position.
2. Ensure that the neutral bracket is in the neutral
position (level) by turning the drive clutch
(Figure 40). The vehicle should not roll back and
forth. If it does, manually move the neutral bracket
to the neutral position.
3. Install the battery in the chassis; refer to Installing
the Battery.
Storing the Battery
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.
2
1
G002093
Figure 40
1. Neutral bracket
2. Locknuts
3. Tighten one of the locknuts (Figure 40) 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.
4. Tighten the other locknut just enough to take the
slack out of the other shift cable.
5. Pull up on each shift cable an ensure that there is no
gap between the nut/washer and the neutral bracket
(Figure 41). If there is a gap, tighten the nut.
33
2. Remove the travel limiting bolt (Figure 42).
3. Loosen the centering bolts in the front A-arm
(Figure 42).
4. Remove the ride height adjustment bolt (Figure 42).
Figure 41
1. Neutral bracket
2. Pull up
3. Cable boot
4. Wrong, must tighten the
nut
5. Correct adjustment
6. Start the engine and shift into Forward, Reverse,
and Neutral several times to ensure that the neutral
bracket is operating properly.
Figure 42
Inspecting the Tires
1. Travel limiting bolt
3. Ride height adjustment
bolt
2. Centering bolt
Check the 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.
5. Rotate the front A-arm to the desired position
(refer to the note below) and replace the ride height
adjustment bolt (Figure 42).
Check the wheels to ensure that they are mounted
securely. Torque the lug nuts to 45-65 ft-lb (61-88 N-m).
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
(Figure 43) 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 (Figure 43).
Each hole equals about 3/4 inch (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 inches (22.2 to 24 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 in Premaintenance
Procedures , page 27.
34
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.
Adjust if necessary.
2. Measure the distance between both of the front tires
at the axle height at both the front and rear of the
front tires (Figure 44). A fixture or alignment gauge
is needed for the rear measurement of the front tires
at axle height. Use the same fixture or alignment
gauge to accurately measure the front of the front
tires at axle height (Figure 44).
Figure 43
1. Left-hand A-arm
6. Torque the ride height adjustment bolt to
135-165 ft-lb (183-224 N-m).
7. Replace the travel limiting bolt (Figure 42).
Note: The vehicle may need to be lowered to the
ground on that side to install the bolt.
8. Tighten and torque the centering bolts to
240-290 ft-lb (325-393 N-m).
9. Check the ride height at the front tongue per the
dimensions and parameters given at the beginning of
this procedure.
Figure 44
1. Tire center line-back
2. Tire center line-front
3. Axle center line
4. Fixture
5. Axle center line distance
6. 6 inches (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 (Figure 45).
Adjusting Front Wheel Toe-In
Check the front wheel toe-in after every 100 operating
hours, or annually, whichever occurs first.
The toe-in should be 1/8-5/8 inch (3-16 mm) with the
following parameters:
• 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.
• 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.
Figure 45
1. Jam nut
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.
Note: The driver should drive up to the
measurement area and stay seated in the vehicle
while the measurement is being taken.
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
35
Maintaining the Primary Drive
Clutch
Changing the Transaxle Fluid
Change the transaxle fluid every 800 operating hours or
yearly, whichever occurs first.
After every 400 operating hours or yearly, clean and
lubricate the clutch as follows:
1. Position the vehicle on a level surface, set the parking
brake, turn the ignition off, and remove the key.
1. Raise and latch the cargo box.
2. Remove the drain plug from the right side of the
reservoir (Figure 48) and let the fluid flow into a
drain pan. Install and tighten the plug when the fluid
stops draining.
2. Stop the engine, remove the key, and set the parking
brake.
3. Remove the 3 bolts securing the cover to the clutch
and remove the cover (Figure 46).
Note: Dispose of the used oil at a certified recycling
center.
Figure 46
1. Cover
2. Bolts
Figure 48
4. Thoroughly clean the inside of the cover and the
inner workings of the clutch using compressed air.
1. Drain plug
2. Level indicator hole
3. Fill the reservoir (Figure 49) 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 (Figure 48).
The dust in the clutch will become airborne and
could damage your eyes or you could inhale it
causing breathing difficulties.
Wear safety goggles and a dust mask or other
eye and respiratory protection when performing
this procedure.
5. Lubricate the moving parts in the areas circled in
Figure 47 using Toro Dry Lubricant Spray, available
through your Authorized Toro Dealer or Distributor.
Figure 49
1. Oil fill
4. Start the engine and operate it to fill the system.
Recheck the oil level and replenish it, if required.
Figure 47
6. Install the clutch cover and secure it with the 3 bolts
removed previously.
36
Cooling System
Maintenance
Brake Maintenance
Cleaning the Engine Cooling
Areas
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:
• Inspect the brake shoes for wear or damage. If the
lining (brake pad) thickness is less than 1/16 inch
(1.6 mm), the brake shoes should be replaced.
• 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.
• Check the brake fluid level; refer to Checking the
Brake Fluid Level.
Inspecting the Brakes
Clean the rotating screen, cooling fins, and external
surfaces of the engine every 100 operating hours 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.
Important: Never clean the engine with
pressurized water because water could contaminate
the fuel system.
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 (Figure 50). 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.
Figure 50
1. Brake fluid reservoir
2. Minimum line
Adjusting the Parking Brake
Check the parking brake adjustment every 200 hours.
1. Pry the rubber cover off of the parking brake.
37
Belt Maintenance
2. Loosen the set screw securing the knob to the
parking brake lever (Figure 51).
Servicing the Drive Belt
Checking the Drive Belt
Check the condition and tension of the drive belt after
the first day of operation and every 200 operating hours
thereafter.
1. Park the machine on a level surface, shift into
Neutral, set the parking brake, turn the ignition off,
and remove the key.
Figure 51
1. Parking brake lever
2. Knob
3. Set screw
2. Raise the bed and secure it with the prop rod.
3. Rotate and inspect the belt (Figure 52) for excessive
wear or damage. Replace the belt if necessary.
3. Rotate the knob until a force of 30-35 lb (133-156 N)
is required to actuate the lever.
4. Tighten the set screw and install the rubber cover.
Figure 52
1. Drive belt
2. Primary clutch
3. Secondary clutch
Replacing the Drive Belt
1. Rotate and route the belt over the secondary clutch
(Figure 52).
2. Remove the belt from the primary clutch (Figure 52).
3. To replace the belt, reverse the procedure.
38
Cleaning
Storage
Washing the Vehicle
1. Position the machine on a level surface, set the
parking brake, stop the engine, and remove the
ignition key.
2. Clean dirt and grime from the entire machine,
including the outside of the engine’s cylinder head
fins and blower housing.
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.
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.
3.
4.
5.
6.
7.
8.
Important: You can wash the machine with
mild detergent and water. Do not use high
pressure water to wash the machine. Pressure
washing may damage the electrical system or
wash away necessary grease at friction points.
Avoid excessive use of water, especially near the
control panel, lights, engine, and the battery.
Inspect the brakes; refer to Inspecting the Brakes in
Brake Maintenance , page 37.
Service the air cleaner; refer to Servicing the Air
Cleaner in Engine Maintenance , page 28.
Grease the machine; refer to Lubrication , page 28.
Change the engine oil; refer to Servicing Engine Oil
in Engine Maintenance , page 28.
Check the tire pressure; refer to Checking the Tire
Pressure in Drive System Maintenance , page 33.
For storage over 30 days, prepare the fuel system
as follows:
A. Add a petroleum based stabilizer/conditioner to
fuel in the tank.
Follow mixing instructions from stabilizer
manufacturer. (1 oz. per gallon). Do not use an
alcohol based stabilizer (ethanol or methanol).
B.
C.
D.
E.
F.
G.
Note: A fuel stabilizer/conditioner is most
effective when mixed with fresh gasoline and
used at all times.
Run the engine to distribute conditioned fuel
through the fuel system (5 minutes).
Stop the engine, allow it to cool, and drain the
fuel tank.
Restart the engine and run it until it stops.
Choke the engine.
Start and run the engine until it will not start
again.
Dispose of fuel properly. Recycle as per local
codes.
Important: Do not store
stabilizer/conditioned gasoline over 90
days
39
9. Remove the spark plugs and check their condition;
refer to Changing Spark Plugs in Engine Maintenance
, page 28.
10. With the spark plugs removed from the engine, pour
two tablespoons of engine oil into the spark plug
hole.
11. Use the electric starter to crank the engine and
distribute the oil inside the cylinder.
12. Install the spark plugs and tighten to recommended
torque; refer to Changing Spark Plugs in Engine
Maintenance , page 28.
Note: Do not install the wire on the spark plug(s).
13. Remove the battery from the chassis, check the
electrolyte level, and charge it fully; refer to Servicing
the Battery in Electrical System Maintenance ,
page 31.
Note: Do not connect the battery cables to the
battery posts during storage.
Important: The battery must be fully charged
to prevent it from freezing and being damaged
at temperatures below 32°F (0°C). A fully
charged battery maintains its charge for about
50 days at temperatures lower than 40°F (4°C).
If the temperatures will be above 40°F (4°C),
check the water level in the battery and charge it
every 30 days.
14. Check and tighten all bolts, nuts, and screws. Repair
or replace any part that is damaged.
15. Paint all scratched or bare metal surfaces.
Paint is available from your Authorized Service
Dealer.
16. Store the machine in a clean, dry garage or storage
area.
17. Remove the ignition key and put it in a safe place out
of the reach of children.
18. Cover the machine to protect it and keep it clean.
40
(-)
(+)
W/BU
BU
99-7410
LOW OIL
PRESSURE
3
OR
HEAD LIGHTS
LIGHT SWITCH
95-8999
1
BK
F8
G006342
Electrical Schematic (Rev. A)
41
ENGINE OIL
PRESSURE
P3-3
P3-1
F7
99-7428
W/BU
F6
Y
STOP ---- (-M)+(+M)
RUN ---- B+A
START --- B+A+S
FUEL
SOL.
F4
F2
BK
BK
10 A
BOX LIFT
(OPTIONAL)
A
-M
10 A
F3
S
86
30
SP ARK PLUG
66-8800
IGNITION
MODULES
25 A
F1
ENGINE GROUND
ATTACHMENT RELAY
85
87
+M
B
BU
PK
Start
SP ARK PLUG
AC
AC
RUN
S
+M
A
START
99-7429
MAG
99-741 1
BK
99-7416
FUSIBLE LINK
99-7404
REG
W BK
POWER POINT
IGNITION SWITCH
-M
B
OFF
VIO
99-7428
P3-2
P3-4
Y
99-7427
10 A
CLOSED IN NEUTRAL
1
NEUTRAL SW.
F5
2
R
3
R
FRAME GROUND
BK
94-4208
HOUR
METER
HR
BU
(-)
(+)
GY
28-4210
SOLENOID,STSP
R
BN
Schematics
4
2
6
5
Notes:
42
Notes:
43
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