Toro Twister 1600 Utility Vehicle User manual

Toro Twister 1600 Utility Vehicle User manual
Form No. 3355-562 Rev A
Twister® 1600 Utility Vehicle
Model No. 12004TC—Serial No. 260000001 and Up
Register your product 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 .................................................................. 4
Before Operating................................. 4
Operation............................................ 4
Maintenance........................................ 7
Sound Pressure.................................... 8
Vibration............................................. 8
Safety and Instructional Decals ............ 8
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 ............................... 15
9 Reading the Manual and Viewing
the Safety Video................. 16
Product Overview ............................................. 17
Controls ........................................... 17
Specifications ................................... 20
Operation.......................................................... 21
Think Safety First .............................. 21
Pre-Starting Checks ........................... 21
Checking the Engine Oil .................... 21
Checking the Brake Fluid
Level ................................. 21
Checking the Tire Pressure................. 21
Adding Fuel ...................................... 22
Checking the Transmission Oil
Level ................................. 23
Starting the Engine ............................ 23
Stopping the Vehicle.......................... 23
Parking the Vehicle ............................ 23
Operating the Cargo Box ................... 23
Breaking in a New Vehicle.................. 24
Loading the Cargo Box ...................... 25
Transporting the Vehicle.................... 25
Towing the Vehicle ............................ 25
Towing a Trailer................................. 26
Maintenance...................................................... 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
© 2005—The Toro® Company
8111 Lyndale Avenue South
Bloomington, MN 55420
2
Contact us at www.Toro.com.
Printed in the USA.
All Rights Reserved
Recommended Maintenance
Schedule(s) ............................... 27
Premaintenance Procedures....................... 28
Maintaining the Vehicle under
Special Operating
Conditions ........................ 28
Jacking the Vehicle............................. 28
Lubrication................................................ 28
Adding Grease .................................. 28
Engine Maintenance.................................. 29
Servicing the Air Cleaner ................... 29
Servicing the Engine Oil .................... 30
Servicing the Spark Plugs ................... 31
Fuel System Maintenance .......................... 31
Inspecting Fuel Lines and
Connections...................... 31
Replacing the Fuel Filter .................... 31
Electrical System Maintenance................... 32
Replacing the Fuses ........................... 32
Replacing the Headlights ................... 32
Servicing the Battery.......................... 33
Drive System Maintenance......................... 34
Checking and Adjusting
Neutral.............................. 34
Inspecting the Tires ........................... 35
Adjusting the Front
Suspension ........................ 35
Adjusting Front Wheel Toe-In ........... 36
Maintaining the Primary Drive
Clutch ............................... 37
Changing the Transaxle Fluid ............. 37
Cooling System Maintenance ..................... 38
Cleaning the Engine Cooling
Areas................................. 38
Brake Maintenance .................................... 38
Inspecting the Brakes......................... 38
Checking the Brake Fluid
Level ................................. 38
Adjusting the Parking Brake ............... 39
Belt Maintenance....................................... 39
Servicing the Drive Belt ..................... 39
Cleaning .................................................... 39
Washing the Vehicle........................... 39
Storage.............................................................. 40
Schematics ........................................................ 41
3
Safety
•
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 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.
Operation
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.
4
Keep your arms and legs within the vehicle
body at all times.
– 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.
• 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.
– 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.
• Always shift into neutral and apply the parking
brake before leaving an idling vehicle, or else
the vehicle may creep.
• 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.
• 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:
• 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.
– 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.
• Before getting off of the seat:
1. Stop the movement of the machine.
2. Set the parking brake.
– Watch for holes or other hidden hazards.
3. Turn the ignition key to Off.
– 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.
4. Remove the ignition key.
Note: If the vehicle is on an incline, block
the wheels after getting off of the vehicle.
Braking
– 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 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.
– 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.
• 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.
– 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.
• 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.
– 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.
• Turf and pavement are much more slippery
when they are wet. It can take 2 to 4 times
5
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.
• 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.
Operating on Hills
Operating on Rough Terrain
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.
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.
• Do not accelerate quickly or slam on
the brakes when backing down a hill,
especially with a load.
We strongly recommend installing the optional
ROPS Kit when operating on rough terrain.
• If the engine stalls or you lose headway
on a hill, slowly back straight down the
hill. Never attempt to turn the vehicle
around.
Sudden changes in terrain may cause abrupt
steering wheel movement, possibly resulting
in hand and arm injuries.
• Operate the vehicle slowly on a hill and
use caution.
• Reduce your speed when operating on
rough terrain and near curbs.
• Avoid turning on a hill.
• Grip the steering wheel loosely around
the perimeter. Keep your hands clear of
the steering wheel spokes.
• Reduce your load and the speed of the
vehicle.
• Avoid stopping on hills, especially with
a load.
Loading and Dumping
These extra cautions need to be taken when
operating the vehicle on a hill:
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:
• 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.
• 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.
• 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.
• Reduce the weight of the load when operating
on hills and rough terrain to avoid tipping or
overturning of the vehicle.
• 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.).
• 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
6
the vehicle is to tip over. Distribute the load as
low as possible, making sure that the load does
not affect rear visibility.
• 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).
• 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.
Maintenance
• 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.
• 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.
• 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.
• To make sure that the entire machine is in
good condition, keep all nuts, bolts, and screws
properly tightened.
• To reduce the potential for fire, keep the engine
area free of excessive grease, grass, leaves, and
accumulation of dirt.
• 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.
• Never use an open flame to check the level or
leakage of fuel or battery electrolyte.
• 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.
• Do not use open pans of fuel or flammable
cleaning fluids for cleaning parts.
The weight of the box may be heavy.
Hands or other body parts could be
crushed.
• If major repairs are ever needed or assistance
is required, contact an Authorized Toro
Distributor.
– Keep hands and other body parts
clear when lowering the box.
• 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.
– 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.
7
Sound Pressure
This unit does not exceed a whole body vibration
level of 0.5 m/s2, based on measurements of
identical machines per EN 1032.
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.
Safety and Instructional
Decals
Vibration
This unit does not exceed a hand/arm vibration
level of 2.5 m/s2, based on measurements of
identical machines per EN 1033.
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
7. Ignition—Off
1. Warning—read the Operator’s Manual.
2. Collision hazard—do not operate the vehicle on public streets, 8. Ignition—On
roads, or highways.
3. Falling hazard—do not carry passengers in the cargo bed.
9. 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. 10. 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
11. Electrical power (power point)
12. Horn
6. Headlights
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.
8
99–7345
99–7350
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
1.
Maximum tongue weight is 50 lb (23 kg); maximum trailer
weight is 400 lb (181 kg).
104–6592
1.
2.
3.
4.
Read the Operator’s
Manual.
The maximum combined
5.
operator and passenger
weight is 400 lb (181 kg).
The maximum cargo
weight is 1200 lb (544 kg).
The base weight of the
vehicle is 1100 lb (500 kg).
The maximum gross
vehicle weight is 2700 lb
(1225 kg).
99–7952
1. Choke
2. Reverse
3.
4.
Neutral
Forward
99–7958
1.
2.
3.
4.
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 ll fuel containers in the cargo bed; place fuel containers
on the ground before lling.
9
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
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
Setup
Loose Parts
Use the chart below to verify that all parts have been shipped.
Step
1
2
3
4
5
6
7
8
9
Qty.
Description
Use
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
Step
Step
1
2
Installing the Wheels
Installing the Steering
Wheel
Parts needed for this step:
4
Parts needed for this step:
Wheel assembly
1
Steering wheel
Procedure
1. Remove the fasteners securing the wheels.
Procedure
2. Remove the shipping bracket secured to the
wheel studs.
1. Remove the nut and lock washer from the
steering shaft.
3. Mount the wheels with the previously removed
fasteners (Figure 3) and torque to 45-65 ft-lb
(61-88 N⋅m).
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. Secure the steering wheel to the shaft with the
nut (Figure 4).
Figure 3
1. Wheel assembly
2. Wheel nut
3.
Wheel stud (rear wheel hub
shown)
Figure 4
1.
2.
11
Steering wheel
Nut
3.
4.
Washer
Foam seal
Step
Step
3
4
Installing the Bumper
Installing the Seats
Parts needed for this step:
Parts needed for this step:
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.
4.
Frame
Lock nut
12
2.
Seat base
Step
Step
5
6
Installing the Hitch
Installing the Cargo Box
Parts needed for this step:
Parts needed for this step:
1
1
1
1
4
1
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).
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)
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
Step
7
Activating the Battery
No Parts Required
Procedure
None
Figure 9
1. Cargo box
2. Pivot bracket
3.
Note: This procedure is only needed for Model
No. 07277TC.
Cargo box mounting hole
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.
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.
1. Remove the battery hold-down and lift the
battery out of the battery base.
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).
Battery electrolyte contains sulfuric acid
which is a deadly poison and causes
severe burns.
• 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.
• Fill the battery where clean water is
always available for flushing the skin.
Figure 10
1. Prop rod
2. Prop rod clip
3.
4.
Bolt (5/16 x 3/4 inch)
Flange nut (5/16 inch)
2. Remove the filler caps from the battery and
slowly fill each cell until electrolyte is just above
the plates.
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).
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.
8. Lower the cargo box.
14
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.
Charging the battery produces gasses
that can explode.
Never smoke near the battery and keep
sparks and flames away from battery.
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).
4. When the battery is charged, disconnect the
charger from the electrical outlet and battery
posts.
5. Remove the filler caps. Slowly add electrolyte
to each cell until electrolyte is up to the fill line.
Install 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.
6. Install the battery; refer to Installing the
Battery, Electrical System Maintenance,
page 32.
Step
8
Adjusting the Front Wheel
Toe-in
Figure 11
1.
2.
3.
No Parts Required
Tire center line-back
Tire center line-front
Axle center line
4.
5.
6.
Fixture
Axle center line distance
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).
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 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.
Note: The driver should drive up to the
measurement area and stay seated in the vehicle
while the measurement is being taken.
15
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.
Step
9
Reading the Manual and
Viewing the Safety Video
Parts needed for this step:
1
1
1
1
1
1
2
Operator’s Manual
Engine Operator’s Manual
Parts Catalog
Safety Video
Registration Card
Predelivery Inspection Form
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
Figure 13
1. Steering wheel
2. Gear shift selector
3.
4.
Parking brake
Fuel cap
5. Cargo box
6. Towing tounge
7. Cargo box release lever
Controls
Brake Pedal
Accelerator Pedal
The brake pedal is used to stop or slow the vehicle
(Figure 14).
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).
Brakes can become worn or can be
misadjusted resulting in personal injury.
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
17
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.
Figure 15
1. Parking brake lever
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
4.
5.
6.
Oil light
Power Point
Horn Button
Hour Meter
The hour meter (Figure 17) indicates the total
number of hours the engine has run.
Oil Light
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 21.
Figure 16
1. Choke
2.
Gear shift selector
Note: The oil light may flicker. This is normal
and no action needs to be taken.
Gear Shift Selector
Light Switch
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.
Toggle the switch to activate the headlights. Push
to turn the lights on (Figure 17).
Power Point
Note: If the gear shift selector is in Reverse when
the ignition is turned on, a buzzer will sound to
warn the operator.
Use the power point to power 12 volt optional
electrical accessories (Figure 17).
Horn Button
Important: Always stop the vehicle before
changing gears.
Press the horn button to sound the horn
(Figure 17).
Ignition Switch
Fuel Gauge
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
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
Specications
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 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 (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.
20
Operation
Note: Determine the left and right sides of the
machine from the normal operating position.
Think Safety First
Please carefully read all of the safety instructions
and decals in the safety section. Knowing this
information could help you or bystanders avoid
injury.
Figure 20
1.
Oil dipstick
Pre-Starting Checks
3. Remove the oil dipstick and wipe the end clean.
Check the following items each time you begin
using the vehicle for the day:
4. Slide the oil dipstick into the filler tube fully
seating it. Pull the dipstick out and look at the
end.
• Check the tire pressure.
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 29, for the proper
oil type and viscosity. Add the oil slowly and
check the level often during this process. Do
not overfill.
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 brake pedal operation.
5. Install the oil dipstick firmly in place.
• Ensure that the lights are working.
Checking the Brake Fluid
Level
• Turn the steering wheel to the left and right to
check steering response.
• 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.
Check the brake fluid level before the engine is
first started; refer to Checking the Brake Fluid
Level in Brake Maintenance, page 38.
Checking the Tire Pressure
If any of the above items are not correct
and you are not able to correct the problem,
contact your Authorized Service Dealer.
Check the tire pressure every 8 hours or daily to
ensure proper levels.
Checking the Engine Oil
The air pressure range in the front and rear tires is
8–22 psi (55–103 kPa).
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.
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.
Check the engine oil level before starting the
engine each day.
1. Position the machine on a level surface.
Higher pressures should be used for heavier
payloads at higher speeds. Do not exceed the
maximum pressure.
2. Clean around the oil dipstick (Figure 20) so
dirt cannot fall into the hole and damage the
engine.
21
Adding Fuel
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.
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.
Important: Never use gasoline containing
methanol, gasoline containing more than
10% ethanol, gasoline additives, or white gas
because engine fuel system damage could
result.
• 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.
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.
• When practical, remove gas-powered
equipment from the truck or trailer and
refuel the equipment with its wheels on
the ground.
• Fill the fuel tank outdoors, in an open
area, when the engine is cold. Wipe up
any gasoline that spills.
• 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.
• Never fill the fuel tank inside an enclosed
trailer.
• 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.
• 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.
• Never smoke when handling gasoline,
and stay away from an open flame or
where gasoline fumes may be ignited by
a spark.
Filling the Fuel Tank
• 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.
1. Shut the engine off and set the parking brake.
The fuel tank capacity is approximately 7 gallons
(26.5 l).
2. Clean the area around the fuel tank cap
(Figure 21).
• Do not operate without entire exhaust
system in place and in proper working
condition.
Figure 21
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
22
Stopping the Vehicle
space in the tank allows gasoline to expand.
Do not overfill.
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.
Checking the Transmission
Oil Level
Parking the Vehicle
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 34.
1. Engage the parking brake and rotate the
ignition key to Off.
2. Remove the key from the ignition switch to
prevent accidental starting.
Operating the Cargo Box
Raising the Box
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.
Figure 22
1. Level indicator hole
Starting the Engine
• Only operate the vehicle when the cargo
box is down.
Important: Do not attempt to push or tow
the vehicle to get it started.
• After dumping a load, lower the cargo
box.
1. Sit in the operator’s seat.
1. Lift the lever on either side of the box and lift
the box up (Figure 23).
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.
Note: An engine that has been running and
is warm may not require pulling the choke out.
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.
Figure 23
1.
Lever
5. Release the parking brake.
2. Pull the prop rod into the detent slot, securing
the box (Figure 24).
6. Move the gear shift selector to the desired
position.
7. To drive the vehicle, move the gear shift
selector to the desired position and slowly step
on the accelerator pedal.
23
2. Turn the latch post clockwise until it is snug
against the latch and then tighten the nut
(Figure 25).
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.
Figure 24
1. Prop rod
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.
Lowering the Box
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.
Pull the prop rod out of the detent slot and lower
the box until it latches into place.
Figure 26
Adjusting the Box Latches
1. Tailgate latch
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.
2. To close the tailgate latches, lift the handles
upward and slide them toward the outside of
the vehicle.
1. Loosen the nut on the end of the latch post
(Figure 25).
3. Push the latch handles downward to secure the
latch and tailgate.
Breaking in a New Vehicle
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.
Figure 25
1. Latch
2. Nut
3.
Latch post
• 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).
24
• Vary the vehicle speed during operation. Avoid
fast starts and quick stops.
Loose seats may fall off of the vehicle
and trailer when transporting and land on
another vehicle or become an obstruction
on the road.
• 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.
Remove the seats or make sure that the seats
are securely fastened in the detents.
• Check the front suspension positioning
and adjust it if necessary; refer to
Adjusting the Front Suspension in
Drive System Maintenance, page 34.
Loading the Cargo Box
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.
Figure 27
1.
Towing the Vehicle
See the table below for load volume limits with
various materials:
Material
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
In case of an emergency, the vehicle can be
towed for a short distance. However, we do not
recommend this as a standard procedure.
Max. cargo box capacity
(on level ground)
Gravel, dry
Tie down points
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).
3/4 full (approx.)
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.
Transporting the 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.
1. Remove the drive belt; refer to Replacing the
Drive Belt in Belt Maintenance, page 39.
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.
25
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)
To provide adequate braking and traction, always
load the cargo box when trailering. Do not exceed
the GTW limits.
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.
26
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 rst 8 operating
hours
• Change the engine oil.
• Check the condition and tension of the drive belt.
After the rst 25
operating hours
• Check the front wheel toe-in and front suspension.
Before each use or daily
•
•
•
•
Check the engine oil.
Check the tire pressure.
Check the transmission oil level.
Check the brake uid 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 lter element (twice as often in special operating
conditions; refer to Maintaining the Vehicle under Special Operating
Conditions).
• Change the oil lter (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 lter 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 lter.
• Change the transaxle uid.
Yearly
• Complete all yearly maintenance procedures specied in the Engine
Operator’s Manual.
Important: Refer to your Engine Operator’s Manual for additional maintenance procedures.
27
Premaintenance
Procedures
(Figure 29) The jacking point at the rear of the
vehicle is under the axle tubes (Figure 30).
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.
• Desert operation
• Cold climate operation (below 50° F [10° C])
• 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.
• Under frequent heavy duty operating
conditions, lubricate all grease fittings and
inspect air cleaner daily to prevent excessive
wear.
Figure 29
1. Front jacking point
Figure 30
1. Rear jacking points
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.
Lubrication
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.
Grease Type: Number 2 General Purpose Lithium
Base Grease
The vehicle may be unstable when using
a jack. It could slip off the jack, injuring
anyone beneath it.
Adding Grease
• Do not start the engine while the vehicle
is on a jack.
1. Wipe the grease fitting clean so foreign matter
cannot be forced into the bearing or bushing.
• Always remove the key from the ignition
before getting off of the vehicle.
2. Pump grease into the bearing or bushing.
• Block the tires when the vehicle is on a
jack.
3. Wipe off excess grease.
The grease fittings are located at the four tie rod
ends (Figure 31 and the two king pins (Figure 32).
The jacking point at the front of the vehicle is on
the front of the frame behind the towing tongue
28
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 33
1.
2.
Figure 32
Air cleaner latches
Cover
3.
Filter
5. Inspect the filter and discard it if it is damaged.
Engine Maintenance
Cleaning the Filter Element
Important: Do not wash or reuse a damaged
filter.
Servicing the Air Cleaner
• Washing method:
Check the air cleaner body for damage which could
possibly cause an air leak. Replace a damaged air
cleaner body.
1. Prepare a solution of filter cleaner and
water and soak the filter element for about
15 minutes. Refer to the directions on
the filter cleaner carton for complete
information.
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.
2. After soaking the filter for 15 minutes, rinse
it with clear water. Rinse the filter from the
clean side to the dirty side.
Note: Service the air cleaner more frequently
(every few hours) if operating conditions are
extremely dusty or sandy.
Important: To prevent damage
to the filter element, the maximum
water pressure must not exceed 40 psi.
(276 kPa).
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.
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).
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:
29
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.
Viscosity: See the table below
Important: To prevent damage to
the filter element, do not exceed 100 psi
(689 kPa) air pressure.
2. Inspect the filter element for holes and
tears by looking through the filter toward a
bright light.
Installing the Filter Element
Figure 34
Important: To prevent engine damage,
always operate the engine with the complete
air cleaner assembly installed.
Checking the Oil Level
1. Inspect the new filter for shipping damage.
Check the sealing end of the filter.
To check the oil level, refer to Checking the Engine
Oil in Operation, page 21.
Important: Do not install a damaged
filter.
Changing the Oil
1. Start the vehicle and let it run for a few minutes
to warm the oil.
2. Park the machine on a level surface, set the
parking brake, turn the ignition off, and
remove the key.
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 (Figure 35) and let the
oil flow into a drain pan. When the oil stops,
install the drain plug.
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.
3. Install the cover and secure the latches.
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.
Note: Dispose of the used oil at a certified
recycling center.
Replace the oil filter every 100 hours.
Note: Change the oil and oil filter more
frequently when operating conditions are
extremely dusty or sandy.
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
Figure 35
1. Engine oil drain plug
30
2.
Engine oil lter
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.
Changing the Oil Filter
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.
Figure 36
1.
2.
Center electrode insulator
Side electrode
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.
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.
Servicing the Spark Plugs
6. Install the spark plug wires.
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.
Fuel System
Maintenance
Type: Champion RC 14YC (or equivalent)
Inspecting Fuel Lines and
Connections
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.
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).
Check the fuel lines and connections every 400
operating hours or yearly, whichever occurs first.
Inspect them for deterioration, damage, or loose
connections.
Replacing the Fuel Filter
Replace the fuel filter every 800 operating hours
or yearly, whichever occurs first.
1. Raise the box and support it with the prop rod.
2. Place a clean container under the fuel filter.
31
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.
4.
Power point
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 lter
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.
Electrical System
Maintenance
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).
Charge circuit
25 amp.
Lights
10 amp.
Power Point
Low oil light and hour
meter
Figure 39
1. Lamp assembly
2. Reector
10 amp. (15 amp. max.)
3.
4.
Tabs
Slots
4. Pull the lamp assembly out of the reflector.
5. Remove the lamp assembly from the wire
harness.
6. Discard the lamp assembly.
7. Push the replacement lamp assembly onto the
wire harness.
8. Reach beneath the dash and align the three
tabs on the lamp assembly with the slots in the
reflector (Figure 39).
9. Insert the lamp assembly into the reflector and
rotate it 1/4 turn clockwise until it stops.
10 amp.
32
Servicing the Battery
Important: Do not jump start the vehicle.
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.
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.
• When removing or installing the
battery, do not allow the battery
terminals to touch any metal parts of
the vehicle.
Voltage: 12 volt with 280 cold cranking Amps @
0° F (-18° C).
• Do not allow metal tools to short
between the battery terminals and
metal parts of the vehicle.
Removing the Battery
1. Position the vehicle on a level surface, set
the parking brake, turn the ignition off, and
remove the key.
5. Disconnect the positive (red) cable from the
battery post.
2. Raise the bed and secure it with the prop rod.
6. Remove the battery from the chassis.
3. Remove the battery hold-down.
Installing the Battery
4. Disconnect the negative (black) ground cable
from the battery post.
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.
Incorrect battery cable routing could
damage the vehicle and cables, causing
sparks. Sparks can cause the battery
gasses to explode, resulting in personal
injury.
3. Replace the battery hold-down to secure the
battery to the base.
• Always disconnect the negative
(black) battery cable before
disconnecting the positive (red)
cable.
Important: Always keep the battery
hold-down in place to protect and secure
the battery.
• Always reconnect the positive (red)
battery cable before reconnecting the
negative (black) cable.
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).
• Always keep the battery strap in place
to protect and secure the battery.
1. Remove the battery from the chassis; refer to
Removing the Battery.
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.
33
Charging the battery produces gasses
that can explode.
Never smoke near the battery and keep
sparks and flames away from battery.
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.
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.
Drive System
Maintenance
4. Tighten the other locknut just enough to take
the slack out of the other shift cable.
Checking and Adjusting
Neutral
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.
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:
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.
Figure 41
1. Neutral bracket
4.
2. Pull up
3. Cable boot
5.
Wrong, must tighten the
nut
Correct adjustment
6. Start the engine and shift into Forward,
Reverse, and Neutral several times to ensure
that the neutral bracket is operating properly.
34
Inspecting the Tires
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.
Check the wheels to ensure that they are mounted
securely. Torque the lug nuts to 45-65 ft-lb
(61-88 N⋅m).
Adjusting the Front
Suspension
Figure 42
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).
1.
Travel limiting bolt
2.
Centering bolt
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 (Figure 42).
• The vehicle should be driven back and forth a
few times to relax the A-arms.
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.
• 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 28.
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).
35
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. 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.
Adjusting Front Wheel
Toe-In
Figure 44
Check the front wheel toe-in after every
100 operating hours, or annually, whichever occurs
first.
1. Tire center line-back
2. Tire center line-front
3. Axle center line
The toe-in should be 1/8-5/8 inch (3-16 mm) with
the following parameters:
4.
5.
6.
Fixture
Axle center line distance
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).
• 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.
36
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.
Figure 45
1. Jam nut
2.
Tie rod
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.
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.
Maintaining the Primary
Drive Clutch
After every 400 operating hours or yearly, clean
and lubricate the clutch as follows:
Figure 47
1. Raise and latch the cargo box.
2. Stop the engine, remove the key, and set the
parking brake.
6. Install the clutch cover and secure it with the 3
bolts removed previously.
3. Remove the 3 bolts securing the cover to the
clutch and remove the cover (Figure 46).
Changing the Transaxle
Fluid
Change the 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 (Figure 48) and let the fluid flow
into a drain pan. Install and tighten the plug
when the fluid stops draining.
Figure 46
1. Cover
2.
Bolts
4. Thoroughly clean the inside of the cover
and the inner workings of the clutch using
compressed air.
Note: Dispose of the used oil at a certified
recycling center.
37
Important: Never clean the engine with
pressurized water because water could
contaminate the fuel system.
Brake Maintenance
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:
Figure 48
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).
• 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.
Checking the Brake Fluid
Level
Figure 49
1. Oil ll
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.
4. Start the engine and operate it to fill the
system. Recheck the oil level and replenish it,
if required.
1. Park the machine on a level surface, set the
parking brake, turn the ignition off, and
remove the key.
Cooling System
Maintenance
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.
Cleaning the Engine Cooling
Areas
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.
38
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 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.
Figure 50
1. Brake uid 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.
2. Loosen the set screw securing the knob to the
parking brake lever (Figure 51).
Figure 52
1.
2.
Drive belt
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.
Figure 51
1. Parking brake lever
2. Knob
3.
Cleaning
Set screw
Washing the Vehicle
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.
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.
Belt Maintenance
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.
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.
39
Storage
G. Dispose of fuel properly. Recycle as per
local codes.
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.
3.
4.
5.
6.
7.
8.
Important: Do not store
stabilizer/conditioned gasoline
over 90 days
9. Remove the spark plugs and check their
condition; refer to Changing Spark Plugs in
Engine Maintenance, page 29.
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 38.
Service the air cleaner; refer to Servicing the
Air Cleaner in Engine Maintenance, page 29.
Grease the machine; refer to Lubrication,
page 28.
Change the engine oil; refer to Servicing
Engine Oil in Engine Maintenance, page 29.
Check the tire pressure; refer to Checking the
Tire Pressure in Drive System Maintenance,
page 34.
For storage over 30 days, prepare the fuel
system as follows:
A. Add a petroleum based
stabilizer/conditioner to fuel in the
tank.
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 29.
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 32.
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.
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.
14. Check and tighten all bolts, nuts, and screws.
Repair or replace any part that is damaged.
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.
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
Schematics
Electrical Schematic (Rev. A)
41
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