Form No.
Maintenance Daily Maintenance Checklist Heavy-Duty Operation Jacking the Vehicle Neutral Lock Assembly Servicing the Engine Oil Cleaning the Engine Cooling Areas Servicing the Air Cleaner Greasing the Machine Servicing the Brakes Inspecting Tires Adjusting the Front Suspension Servicing the Drive Belt Adjusting the Starter Generator Belt Adjusting Front Wheel Toe-in Servicing the Fuel System Spark Plugs Changing Transaxle Fluid Fuses Replacing the Headlights Servicing the Battery Washing the Vehicle WARNIN
serious injury or death if you do not follow the recommended precautions. Introduction Warning signals a hazard that may cause serious injury or death if the recommended precautions are not followed. Read this manual carefully to learn how to operate and maintain your product correctly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely.
New York, New York 10018 U. S. A. or Underwriters Laboratories 333 Pfingsten Road Northbrook, Illinois 60062 U.S.A. • 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.
bottom of the filler neck). Do not overfill it. – – 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.
Note: If the vehicle is on an incline, block the wheels after getting off of the vehicle. Operating on Hills WARNING Braking • • • • 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. 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.
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. not slam on the brakes when rolling backward, as this may cause the vehicle to overturn. • Travel straight up and down slopes whenever possible.
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. purposes only, not for passengers. • Never overload your vehicle. The name plate (located under dash on center column) shows load limits for the vehicle. Never overload the attachments or exceed the gross vehicle weight.
Slope Chart Align this edge with a vertical surface (tree, building, fence post, pole, etc. This is a 1 5° Sl ope Th i s i s a 12° Slope T h is is a 10° S lope This is a 5° S lope Fold along appropriate line Example: Compare slope with folded edge.
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 1 2 1 2 3 99-7346 99-7350 1 Parking brake 2. Parking brake on 3. Parking brake off 1. Maximum tongue weight is 23 kg (50 lbs.) 2. Maximum trailer weight is 181 kg (400 lbs.) 2 1 3 4 2 1 5 99-7348 3 1. Read the operator’s manual for further instructions. 2.
7 6 5 8 9 1 2 3 10 4 11 99-7343 1. 2. 3. 4. 5. 6. 7. 8. 9. Warning—read the operator’s manual. Only drive this vehicle off- highway. This vehicle is not made for use on public streets, roads, or highways. Do not carry passengers in the cargo bed. They may fall out of the vehicle. Do not allow children to operate this vehicle. Hour meter Headlights Ignition off Ignition on To start the vehicle, sit in the operator’s seat. Release the parking brake. Turn the ignition on.
2 3 1 7 6 5 4 99-7352 1. 2. 3. 4. 5. 6. 7. Read the operator’s manual for information on fuses. 10-amp. fuse for optional road light kit 15-amp. fuse for optional rear lift kit 10-amp. fuse—open 10-amp. fuse for headlights 10-amp. fuse for ignition system 15-amp. fuse for optional electric bed lift kit Specifications Note: specifications and design are subject to change without notice. Base weight Dry 454kg (1000 lbs.) Rated capacity (on level ground) 749 kg (1650 lbs.) total, including 90.
Before Operating Checking the Crankcase Oil pressure. The engine is shipped with oil in the crankcase; however, the oil level must be checked before and after the engine is first started. Fuel Tank DANGER 1. Position the machine on a level surface. 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. 2. Remove the dipstick and wipe it with a clean cloth (Fig. 2).
suitable for automotive use (85 pump octan minimum). Leaded gasoline may be used if unleaded regular is not available. Operation Note: Determine the left and right sides of the machine from the normal operating position. Important Never use gasoline containing methanol, gasoline containing more than 10% ethanol, gasoline additives, or white gas because engine fuel system damage could result. Think Safety First Please carefully read all the safety instructions and symbols in the safety section.
vehicle will start in either direction. on a steep grade, make sure the parking brake is applied. Place blocks at the downhill side of the wheels. Note: If the gear shift selector is in reverse when the ignition is turned on, a buzzer will sound to warn the operator.the Important : The vehicle should always be stopped before changing the gear selection and direction. Ignition Switch The ignition switch (Fig. 6), used to start and stop the engine, has two positions: OFF and ON.
Figure 6 1. 2. 3. 4. 5. Ignition switch Hour meter Light switch Oil light Power point Figure 8 Passenger hand hold 2. Hip restraint 1. Pre-Starting Checks Fuel Gauge Safe operation begins before taking the vehicle out for a day’s work. You should check these items each time: The fuel gauge (Fig. 7) shows amount of fuel in the tank. • Check tire pressure. Note: These tires are different than car tires, they require less pressure to minimize turf compaction and damage.
Starting the Engine 1. Sit in the operator’s seat, insert the key into the ignition switch, and turn the key clockwise to the On position. Note: If the gear shift selector is in reverse, the buzzer will sound to warn the operator. 2. Move gear shift selector to the desired position. Figure 9 4. Slowly step on the accelerator pedal. 1. Latch Note:The parking brake will automatically disengage when the accelerator pedal is depressed. 2.
until several hours of use has caused the brakes to become burnished (broke-in). Tailgate Latches 1. To open the tailgate latches, lift the latch handles up (Fig. 11). 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. • Vary vehicle speeds during operation.
Transporting the Vehicle 2. Affix a tow line to tongue on front frame member (Fig. 13). For moving the vehicle long distances, a trailer should be used. Make sure the vehicle is secured to the trailer. Refer to Figures 12 and 13 for location of tie down points. 3. Put the vehicle in neutral (see Neutral Lock Assembly, page 23) and release the parking brake. CAUTION Loose seats may fall off of the vehicle and trailer when transporting and land on another vehicle or become an obstruction on the road.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After First 8 hours • Check the engine oil. • Check the drive belt tension. • Check the starter belt tension. Every 8 Hours • Check the engine oil. • Check the tire pressure. After First 20 Hours • Check the front wheel toe-in at the proper ride height. Every 50 Hours • Check the battery fluid level.
Daily Maintenance Checklist Duplicate this page for routine use. Note: Check proper section of the operator’s manual for fluid specifications.
CAUTION If you leave the key in the ignition switch, someone could accidentally start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire(s) from the spark plug(s) before you do any maintenance. Set the wire(s) aside so it does not accidentally contact the spark plug(s).
1 1 1 Figure 15 1. Rear jacking points Figure 17 1. Secondary clutch Neutral Lock Assembly Servicing the Engine Oil When performing routine maintenance and/or engine diagnostics, the transaxle must be shifted into a neutral position. The vehicle does not have a neutral position on the shift lever, so the following steps must be performed: Service Interval/Specification Check the oil level before each use. 1.
Checking the Oil Level Changing the Oil Filter To check the oil level, refer to Checking the Crankcase Oil, page 13. Replace the oil filter every 100 operating hours or yearly, whichever occurs first. Changing and Draining the Oil 1. Drain the oil from the engine; refer to Changing and Draining the Oil, page 24. 1. Start the vehicle and let it run for a few minutes to warm the oil. 2. Remove the existing oil filter ( Fig. 27). Apply a light coat of clean oil to the new filter gasket. 2.
Ensure the cover is sealing around the air cleaner body. Cleaning the Filter Element Important Do not wash or reuse a damaged filter. Air Cleaner Filter: Inspect after every 100 operating hours; replace after every 200 hours or sooner if dirty or damaged. 1. Washing method: A. Prepare a solution of filter cleaner and water and soak the filter element about 15 minutes. Refer to directions of the filter cleaner carton for complete information.
2. Insert the new filter properly into the air cleaner body. Ensure the filter is sealed properly by applying pressure to outer rim of the filter when installing. Do not press on the flexible center of the filter. 3. Reinstall the cover and secure the latches. Greasing the Machine Figure 21 Service Interval/Specification Lubricate all bearings and bushings after every 100 hours or once a year, whichever occurs first. Grease them more frequently when using for heavy-duty vehicle operations.
1. Turn the ignition to OFF and remove the key. (Fig. 24). 2. Raise the vehicle off the ground; see Jacking the Vehicle page 22. 5. Rotate the front “A” frame to desired position (Fig. 24). The distance from the bottom side of the front hitch to the ground should be 9 to 9-3⁄4 in. (22.9 to 24.8 cm) with the tires inflated to 12 psi (83 kPa). 3. Tighten the cable adjusting screw, located beneath the floor panel, until the cables are snug in the brake equalizer (Fig. 23). 6.
Assembly, page 23. 4 4. Rotate and inspect the belt for excessive wear or damage. Replace as necessary. 3 1 3 Figure 26 1. 2. 3. 4. 2 Figure 25 1. Drive belt 2. Primary clutch 3. Secondary clutch Generator pivot bolt Jam nut 14 N•m 6mm (1⁄4 in.) 3. Adjust the jam nut on the starter rod (Fig. 26) until the belt flexes 6mm (1⁄4 in.) with 14 N•m (10 lbs..) of force. Replacing the Drive Belt 4. Tighten the starter generator pivot bolt (Fig. 26). 1.
yearly, whichever occurs first. Inspect for deterioration, damage, or loose connections. 1 Replacing the Fuel Filter 2 Replace the fuel filter after every 800 operating hours or yearly, whichever occurs first. 1. Raise the bed and support it with the prop rod. 3 Figure 27 2. Place a clean container under the fuel filter. 1. Center-to-center distance (rear of tires) 2. Forward 3. Center-to-center distance (front of tires) 3. Remove the clamps securing the fuel filter to the fuel lines. 1 1 3.
(Fig. 31) and let fluid flow into drain pan. Reinstall and tighten the plug when fluid stops draining. Replacing the Spark Plug 1. Clean the area around the spark plugs so foreign matter cannot fall into the cylinder when the spark plug is removed. 2. Pull the spark plug wires off 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 assure there is no damage. 0.76mm Figure 31 1. Drain plug 3.
Fuses There are three fuses in the machine’s electrical system. They are located beneath the bed in a box on the right hand side of the frame (Fig. 33). Fuses: Ignition System—10 amp. Lights—10 amp. Power Point—10 amp. (15 amp. max.) 2 Figure 34 1. Rubber seal 2. Inside notch—align with notch on headlight 3. Outside notch align with notch in hood 4. Headlight 2 6. Attach the headlight to the wire harness using the previously removed screws. 3 Figure 33 1. 2. 3. 4.
Voltage: 12 volts with 280 cold-cranking Amps @ –17.8°C (0°F). battery post. 6. Remove the battery from the chassis. Removing the Battery Installing the Battery 1. Position the vehicle on a level surface, set the parking brake, turn the ignition off and remove the key. 1. Set the battery on the battery base so the battery posts are toward the rear of the vehicle. 2.
Charging the Battery Washing the Vehicle Important Always keep the battery fully charged 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. (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 0°C (32°F). Important Pressurized water is not recommended 1. Remove the battery from the chassis; refer to Removing the Battery, page 32.
