Form No. 3421-173 Rev B MB-1600 Mud Buggy Model No. 68038—Serial No. 402350000 and Up Model No. 68038G—Serial No. 402350000 and Up Register at www.Toro.com.
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. WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm.
Contents 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. Safety ....................................................................... 4 Safe Operating Practices.................................... 4 Safety and Instructional Decals .......................... 7 Product Overview ...................................................
Safety Improper use or maintenance of the machine 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.
• Do not touch parts which may be hot from • • • • • operation. Allow them to cool before attempting to maintain, adjust, or service. Check for overhead clearances (i.e., branches, doorways, electrical wires) before driving under any objects and do not contact them. Ensure that you operate the machine in areas where there are no obstacles close to you.
• Use the cylinder lock to secure the hopper in the raised position. • Keep nuts and bolts tight. Keep equipment in good condition. • Never tamper with safety devices. • Use only genuine Toro replacement parts to ensure that original standards are maintained. • Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery. • Battery gases can explode. Keep cigarettes, sparks, and flames away from the battery.
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 missing. 125-4961 125-4960 decal125-4961 decal125-4960 125–4961 125–4960 1. Reverse 1. Forward decal125-4964 125–4964 1. Read the Operator’s Manual for oil information. decal125-4962 125–4962 1. Engage the parking brake decal125-4959 125–4959 1. Crushing hazard—never place your head under the dump trailer.
decal125-6694 decal125-4967 125–6694 125–4967 1. Tie down location 1. Lift point decal127-2855 127–2855 5. Tipping hazard—do not raise the dump trailer while moving; move forward slowly; raise the dump trailer slowly. 1. Warning—read the Operator’s Manual; wear hearing protection. 2. Warning—do not operate the machine without proper training. 6. Carbon monoxide poison hazard—do not run the engine indoors. 3. Warning—stay away from moving parts; keep all guards and 7.
decal130-2844 130-2844 1. Raise the pedal to lower the hopper. decal125-8190 2. Lower the pedal to raise the hopper. 125–8190 1. Press down on the pedal to apply the service brake 2. Release the pedal to release the service brake decal133-5619 decal125-4963 133-5619 125–4963 1. Warning—keep hands away from hot surfaces decal125-4958 125–4958 2.
Product Overview g019617 Figure 3 1. Operator platform 4. Drive tires 7. Dump handle/pedal 2. Steer tires 3. Reverse-speed-control lever 5. Handle bars 6. Forward-speed-control lever 8. Fuel tank 9. Parking brake Controls 10. Brake pedal To release the parking brake, press the button on the end of the brake handle and lower the lever. Become familiar with all the controls (Figure 3) before you start the engine and operate the machine.
g025707 Figure 4 g020538 1. Forward Figure 5 2. Shutoff-valve lever for the fuel tank (OFF position) 1. Recoil starter 2. Fuel shut-off valve 3. Choke lever 4. Throttle lever 5. On/Off switch Engine Controls Oil Alert System Throttle Lever The oil alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase.
Operation Fuel-Shutoff Valve The fuel-shutoff valve (Figure 5) controls the flow of fuel from the fuel tank to the carburetor. The valve is located underneath the choke lever. Move the shutoff valve to the On position before attempting to start the engine. Once you have finished using the machine and you have turned the engine off, move the fuel-shutoff valve to the Off position. Note: Determine the left and right sides of the machine from the normal operating position.
DANGER DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. • Always place fuel containers on the ground away from your vehicle before filling.
varnish deposits in the fuel system, use fuel stabilizer at all times. 6. Move the throttle lever away from the MIN position, about 1/3 of the way toward the MAX position; refer to Throttle Lever (page 11). Filling the Fuel Tank 7. Turn the engine On/Off switch to the ON position; refer to On/Off Switch (page 12). 8. Pull the recoil starter handle out until positive engagement results, then pull it vigorously to start the engine ( Recoil Starter Handle (page 12)). Fuel tank capacity: 21.6 L (5.
4. Release the parking brake lever; refer to Parking Brake Lever (page 10). 5. To move the machine forward, squeeze the speed-control-lever on the right handle bar. To move the machine rearward, squeeze the speed-control lever on the left handle bar; refer to Forward-Speed-Control Lever (page 10) and Reverse-Speed-Control Lever (page 10). Operating the Hopper Know the load capacities of your machine and never exceed them.
Moving the Machine without Engine Power Parking the Machine Parking on a Grade The machine can be moved a short distance if the engine does not run. The transmission features a bypass valve (Figure 7). Parking the machine on a grade should be avoided if possible. If the machine must be parked on a grade, park it at a right angle to the slope, engage the parking brake and block the wheels, if necessary. • Rotate the bypass valve counterclockwise to tow the machine.
Transporting the Machine When transporting the machine on a trailer, always use the following procedure: Important: Do not operate or drive the machine on roadways. 1. Shut off the engine and engage the parking brake. 2. When transporting the machine, observe overall height for proper clearance of obstacles overhead. 3. Ensure that the hopper is lowered and latched down. 4. Secure the machine with the proper devices at the tie-down loop. g019612 Figure 9 1.
WARNING The maximum payload is reduced to 850 kg (1875 lb) when operating the machine without the dual wheels. g019606 Figure 12 1. Platform release ring Using the Quick-Release Tire Hubs The quick-release tire system allows quick removal of the outer machine tires. The quick-release system allows the machine to be converted from a 117 cm (46 inch) to a 91 cm (36 inch) wide machine without any special tools for hub removal. 1.
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 50 hours • Change the engine oil. Before each use or daily • • • • • • Check the engine oil level. Check service brake operation. Check parking brake operation. Check the hydraulic fluid level. Remove debris from the machine. Check for loose fasteners.
Pre-Maintenance Procedures Removing the Cowl Note: You must dump the hopper before you remove the cowl. You can do this using either the hydraulics or by removing the pin in the hydraulic cylinder and the hopper base. 1. Before removing the cowl (Figure 14), shut off the engine and allow the engine to cool. g019604 Figure 15 1. Cowl latch 3. g019788 Figure 14 1. Cowl 2. Unhook the cowl latches (Figure 15) and remove the cowl. 20 Install the cowl and secure the latches upon completion of the task.
Lubrication Greasing the Machine Service Interval: Every 50 hours—Grease and oil the machine. Yearly—Pack wheel bearings. If you operate the machine under normal conditions, lubricate all grease fittings for the bearings and bushings after every 50 hours of operation with No. 2 lithium grease. Lubricate bearings and bushings immediately after every washing, regardless of the interval listed. Also, apply a light coating of oil onto the control cables.
Engine Maintenance 5. Wipe the oil filler cap/dipstick clean and insert it into filler port. Note: Do not screw into port. Checking the Engine-Oil Level Important: Do not overfill the crankcase with oil because the engine may be damaged. Service Interval: Before each use or daily 6. Oil type: API classification SJ or later.
C. Saturate the element with clean engine oil. Squeeze element to remove excess oil and to distribute oil thoroughly. 7. Cleaning the paper element: Tap the filter element several times on a hard surface to remove dirt or blow compressed air (not exceeding 2.07 bar (30 psi) through the filter element from the inside. Never try to brush off dirt; brushing will force dirt into the fibers. 8. Install the foam element, paper element, and air-cleaner cover.
Changing the Engine Oil Replacing the Spark Plug Service Interval: After the first 50 hours—Change the engine oil. Every 100 hours—Change the engine oil. Service Interval: Every 100 hours—Check/adjust the spark plug. Every 300 hours—Replace the spark plug. Crankcase capacity: 1.1 L (1.16 US qt). Oil type: API classification SJ or later. Spark plug type: NGK BPR 6ES spark plug or equivalent. Oil viscosity: selected the oil viscosity according to ambient temperature in the table below. Air gap: 0.70-0.
Fuel System Maintenance Cleaning the Sediment Cup Service Interval: Every 100 hours—Clean the sediment cup. DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 25 mm (1 inch) below the bottom of the filler neck.
Changing the Fuel Filter Note: Drain the fuel from the old fuel filter dispose of the fuel and filter at an authorized disposal site. Service Interval: Every 300 hours/Yearly (whichever comes first) 1. Shut off the engine and engage the parking brake. Allow the engine to cool. 2. Rotate the lever for the tank-shutoff valve forward and up to the OFF position (Figure 23). g025708 Figure 25 1. Hose (engine switch) 3. Hose clamp 2. Fuel-filter arrow 4. Hose (tank-shutoff valve) 7.
Draining the Fuel Tank Drive System Maintenance Service Interval: Every 1,000 hours/Yearly (whichever comes first)—Drain and flush the fuel tank. Adjusting the Transmission Return to Neutral Position DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. The hydrostatic transmission is equipped with a self-centering device that adjusts the transmission to the Neutral position, stopping the machine.
Checking the Tires and Lug Controls System Nuts Maintenance Service Interval: Every 40 hours—Check the condition of the tires. Brake Maintenance Every 40 hours—Check the lug nuts. • Inspect tires for cuts, slashes, or bulges. Tires with WARNING defects need to be replaced or repaired for proper handling and safety. If the brakes are not properly adjusted, serious injury or death may occur. • Check weekly to make sure all lug nuts are tight. Check your brakes daily.
Checking the Parking Brake Service Interval: Before each use or daily 1. Park the machine on a level surface. Note: Ensure that there is nothing in front of the machine. 2. Engage the parking brake (Figure 27). 3. Start the engine and set the throttle to fast. 4. Grasp the forward-speed-control lever. Note: The engine should stall at full engagement of speed control and the machine should not move forward. Note: If the machine moves forward, refer to Adjusting the Parking Brake (page 30).
Adjusting the Parking Brake Hydraulic System Maintenance Turning the knob on the parking brake handle adjusts the parking brake. • Loosening the parking brake:(Figure 29). WARNING 1. Ensure that engine is off. 2. Step on the service brake pedal (Figure 28). 3. Disengage the parking brake (Figure 27). 4. Rotate the parking-brake knob counterclockwise (Figure 29). Hydraulic fluid escaping under pressure can penetrate skin and cause injury.
6. Install the breather/filler cap. Wipe up any spilled hydraulic fluid (Figure 31). Replacing the Hydraulic Filter Service Interval: Every 100 hours—Replace the hydraulic filter. Important: Do not use an automotive oil filter or severe hydraulic system damage may result. 1. Park the machine on a level surface, engage the parking brake. and shut off the engine. 2. Unlatch and remove the cowl. 3. Place a drain pan under the filter (Figure 32). g019625 Figure 30 1. Sight gauge 5.
11. Install the cowl and secure the latches. 8. Fill the hydraulic tank with approximately 28.4 liters (30 US quarts) of hydraulic fluid as specified previously. 9. Start the engine and let it run for a 2 to 3 minutes. Changing the Hydraulic Fluid 10. Shut off the engine. Service Interval: Every 200 hours 11. Hydraulic fluid type: Mobil 424 Hydraulic Oil or equivalent Check the hydraulic fluid level and add more hydraulic fluid if necessary. 12. Install the cowl and secure the latches.
Checking the Hydraulic Lines Cleaning Removing Debris from the Machine Service Interval: Every 40 hours—Check the hydraulic lines for leaks, loose fittings, kinked lines, loose mounting supports, wear, and deterioration. (Make necessary repairs before operating.) Service Interval: Before each use or daily Important: Operating the engine with blocked screens, dirty or plugged cooling fins, and/or cooling shrouds removed, will result in engine damage from overheating.
Storage Note: Do not install the wire on the spark plug. 9. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 1. Shut off the engine and engage the parking brake. 2. Remove dirt and grime from the external parts of the entire machine, especially the engine. Clean dirt and chaff from the outside of the engine cylinder head fins and blower housing. 10. Paint all scratched or bare metal surfaces. Paint is available from your Authorized Service Dealer. 11.
Notes:
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
