Toro 07266, 07266TC, 07273, 07273TC, 07279 Operator's Manual

...
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FormNo.3370-258RevA
Workman
®
MDandMDXUtility
Vehicle
ModelNo.07266—SerialNo.310000001andUp
ModelNo.07266TC—SerialNo.310000001andUp
ModelNo.07273—SerialNo.310000001andUp
ModelNo.07273TC—SerialNo.310000001andUp
ModelNo.07279—SerialNo.310000001andUp
ToregisteryourproductordownloadanOperator'sManualorPartsCatalogatnocharge,gotowww.T oro.com.OriginalInstructions(EN)
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ThisproductcomplieswithallrelevantEuropean directives,fordetailspleaseseetheseparateproduct specicDeclarationofConformity(DOC)sheet.
ontheproduct.Writethenumbersinthespace provided.
WARNING
CALIFORNIA
Proposition65Warning
Theengineexhaustfromthisproduct
containschemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
Important:Thisengineisnotequippedwitha sparkarrestermufer.ItisaviolationofCalifornia PublicResourceCodeSection4442touseoroperate theengineonanyforest-covered,brush-covered,or grass-coveredland.Otherstatesorfederalareas mayhavesimilarlaws.
ThissparkignitionsystemcomplieswithCanadian ICES-002.
Theenclosed
Engine Owner’ s Man ual
forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCalifornia EmissionControlRegulationofemissionsystems, maintenance,andwarranty.Replacementsmaybe orderedthroughtheenginemanufacturer.
issupplied
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol
Figure2),whichsignalsahazardthatmaycauseserious
( injuryordeathifyoudonotfollowtherecommended precautions.
Figure2
1.Safetyalertsymbol
Thismanualuses2otherwordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
Introduction
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoidinjury andproductdamage.Youareresponsibleforoperating theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww .Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers
©2011—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Contactusatwww.Toro.com.
2
PrintedintheUSA.
AllRightsReserved
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Contents
Introduction.................................................................2
Safety...........................................................................4
SafeOperatingPractices.......................................4
BeforeOperating.................................................4
Operation.............................................................5
Maintenance.........................................................7
Models07266/TCand07279...............................7
Model07273/TC.................................................8
SafetyandInstructionalDecals.............................8
Setup..........................................................................11
1InstallingtheSteeringWheel............................11
2ActivatingtheBattery......................................11
3ReadingtheManualandViewingtheSafety
TrainingMaterial............................................12
ProductOverview......................................................13
Controls.............................................................13
Specications.....................................................15
Attachments/Accessories...................................15
Operation...................................................................16
ThinkSafetyFirst...............................................16
Pre-StartingChecks............................................16
CheckingtheEngineOil.....................................16
CheckingtheBrakeFluidLevel...........................16
CheckingtheTirePressure.................................17
AddingFuel.......................................................17
CheckingtheTransmissionOilLevel..................18
StartingtheEngine.............................................18
StoppingtheVehicle...........................................18
ParkingtheVehicle.............................................18
OperatingtheCargoBox....................................18
BreakinginaNewV ehicle..................................19
LoadingtheCargoBox.......................................19
TransportingtheVehicle.....................................20
TowingtheVehicle.............................................20
TowingaTrailer..................................................20
Maintenance...............................................................21
RecommendedMaintenanceSchedule(s)................21
DailyMaintenanceChecklist...............................22
PremaintenanceProcedures....................................23
MaintainingtheVehicleunderSpecial
OperatingConditions.....................................23
JackingtheVehicle..............................................23
AccessingtheHood............................................23
Lubrication.............................................................24
AddingGrease...................................................24
EngineMaintenance...............................................24
ServicingtheAirCleaner....................................24
ServicingtheEngineOil(Models07266/TC
and07279only)..............................................25
ServicingtheEngineOil(Models07273/TC
only)...............................................................26
ServicingtheSparkPlug(Models07266/TC
and07279only)..............................................27
ServicingtheSparkPlugs(Models07273/TC
only)...............................................................28
FuelSystemMaintenance.......................................29
InspectingFuelLinesandConnections...............29
ReplacingtheFuelFilter.....................................29
ElectricalSystemMaintenance................................29
ReplacingtheFuses............................................29
ReplacingtheHeadlights....................................29
ServicingtheBattery...........................................30
DriveSystemMaintenance.....................................32
CheckingandAdjustingNeutral.........................32
InspectingtheTires............................................33
AdjustingtheSuspension....................................33
AdjustingFrontWheelToe-In............................33
MaintainingthePrimaryDriveClutch.................34
ChangingtheTransaxleFluid..............................34
CoolingSystemMaintenance..................................35
CleaningtheEngineCoolingAreas.....................35
BrakeMaintenance.................................................36
InspectingtheBrakes.........................................36
CheckingtheBrakeFluidLevel...........................36
AdjustingtheParkingBrake................................36
BeltMaintenance....................................................37
ServicingtheDriveBelt......................................37
AdjustingtheStarterGeneratorBelt...................37
Cleaning.................................................................38
WashingtheVehicle............................................38
Storage.......................................................................38
Schematics.................................................................40
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Safety
Improperuseormaintenancebytheoperatororowner canresultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafetyalertsymbol,whichmeans Caution,Warning,orDanger—“personalsafety instruction.”Failuretocomplywiththeinstructionmay resultinpersonalinjuryordeath.
Supervisors,operators,andservicepersonsshouldbe familiarwiththefollowingstandardsandpublications (thematerialmaybeobtainedfromtheaddressshown):
FlammableandCombustibleLiquidsCode: ANSI/NFPA30
NationalFireProtectionAssociation:
ANSI/NFPA#505;PoweredIndustrialTrucks, NationalFirePreventionAssociation,Barrymarch Park,Quincy ,Massachusetts02269U.S.A.
ANSI/ASMEB56.8PersonalBurdenCarriers
AmericanNationalStandardsInstitute,Inc.,1430 Broadway,NewYork,NewYork10018U .S.A.
SAEJ2258LightUtilityVehicle
SAEInternational,400CommonwealthDrive, Warrendale,PA15096-0001U.S.A.
ANSI/UL558;InternalCombustionEngine PoweredIndustrialTrucks
AmericanNationalStandardsInstitute,Inc.,1430 Broadway,NewYork,NewYork10018U .S.A.
or
UnderwritersLaboratories,333PngstenRoad, Northbrook,Illinois60062U.S.A.
SafeOperatingPractices
WARNING
TheWorkmanisanoff-highwayvehicleonlyandis notdesigned,equipped,ormanufacturedforuseon publicstreets,roads,orhighways.
Supervisor’sResponsibilities
Makesurethatoperatorsarethoroughlytrainedand familiarwiththeOperator’sManualandalllabelson thevehicle.
Besuretoestablishyourownspecialproceduresand workrulesforunusualoperatingconditions(e.g. slopestoosteepforvehicleoperation).
BeforeOperating
Operatethemachineonlyafterreadingand understandingthecontentsofthismanual.
Neverallowchildrentooperatethevehicle.Anyone whooperatesthevehicleshouldhaveamotor vehiclelicense.
Neverallowotheradultstooperatethevehicle withoutrstreadingandunderstandingtheOperator’s Manual.Onlytrainedandauthorizedpersonsshould operatethisvehicle.Makesurethatalloperators arephysicallyandmentallycapableofoperatingthe vehicle.
Thisvehicleisdesignedtocarryonlyyou,the operator,andonepassengerintheseatprovidedby themanufacturer.Nevercarryanyotherpassengers onthevehicle.
Neveroperatethevehiclewhenundertheinuence ofdrugsoralcohol.Evenprescriptiondrugsand coldmedicinescancausedrowsiness.
Donotdrivethevehiclewhenyouaretired.Besure totakeoccasionalbreaks.Itisveryimportantthat youstayalertatalltimes.
Becomefamiliarwiththecontrolsandknowhowto stoptheenginequickly.
Keepallshields,safetydevices,anddecalsinplace. Ifashield,safetydevice,ordecalismalfunctioning, illegible,ordamaged,repairorreplaceitbefore operatingthemachine.
Alwayswearsubstantialshoes.Donotoperate themachinewhilewearingsandals,tennisshoes orsneakers.Donotwearloosettingclothingor jewelrywhichcouldgetcaughtinmovingpartsand causepersonalinjury.
Wearingsafetyglasses,safetyshoes,longpantsanda helmetisadvisableandrequiredbysomelocalsafety andinsuranceregulations.
Avoiddrivingwhenitisdark,especiallyinunfamiliar areas.Ifyoumustdrivewhenitisdark,besure todrivecautiously,usetheheadlights,andeven consideraddingadditionallights.
Beextremelycarefulwhenoperatingaroundpeople. Alwaysbeawareofwherebystandersmightbe.
Beforeoperatingthevehicle,alwayscheckthe designatedareasofthevehiclethatarestatedinthe pre-startingsectionofthismanual.Ifsomething iswrong,donotusethevehicle.Makesurethat theproblemiscorrectedbeforethevehicleor attachmentisoperated.
Sincegasolineishighlyammable,handleitcarefully.
Useanapprovedgasolinecontainer.
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Donotremovethecapfromthefueltankwhen
theengineishotorrunning.
Donotsmokewhilehandlinggasoline.
Fillthefueltankoutdoors,andllittoabout
1inch(25mm)belowthetopofthetank(the bottomofthellerneck).Donotoverllit.
Wipeupanyspilledgasoline.
Whendumping,donotletanyonestandbehind
thevehicleanddonotdumptheloadonanyone’s feet.Releasethetailgatelatchesfromthesideof thebox,notfrombehind.
Onlyoperatethevehiclewhenthecargoboxis
downandlatched.
Beforebackingup,looktotherearandensure
thatnooneisbehindyou.Backupslowly.
Operation
WARNING
Engineexhaustcontainscarbonmonoxide,which isanodorless,deadlypoisonthatcankillyou.
Donotrunengineindoorsorinanenclosedarea.
Theoperatorandpassengershouldremainseated wheneverthevehicleisinmotion.Theoperator shouldkeepbothhandsonthesteeringwheel wheneverpossible,andthepassengershoulduse thehandholdsprovided.Keepyourarmsandlegs withinthevehiclebodyatalltimes.
Driveslowerandturnlesssharplywhenyouare carryingapassenger.Rememberyourpassengermay notbeexpectingyoutobrakeorturnandmaynot beready .
Alwayswatchoutforandavoidlowoverhangssuch astreelimbs,doorjambs,andover-headwalkways. Makesurethereisenoughroomoverheadtoeasily clearthevehicleandyourhead.
Failuretooperatethevehiclesafelymayresultinan accident,tipoverofthevehicle,andseriousinjury ordeath.Drivecarefully .Topreventtippingorloss ofcontrol:
Useextremecaution,reducespeed,andmaintain
asafedistancearoundsandtraps,ditches,creeks, ramps,unfamiliarareas,oranyareasthathave abruptchangesingroundconditionsorelevation.
Watchforholesorotherhiddenhazards.
Useextracautionwhenoperatingthevehicleon
wetsurfaces,inadverseweatherconditions,at higherspeeds,orwithafullload.Stoppingtime anddistancewillincreasewithafullload.
Avoidsuddenstopsandstarts.Donotgofrom
reversetoforwardorforwardtoreversewithout rstcomingtoacompletestop.
Slowdownbeforeturning.Donotattempt
sharpturnsorabruptmaneuversorotherunsafe drivingactionsthatmaycausealossofvehicle control.
Watchoutfortrafcwhenyouarenearor
crossingroads.Alwaysyieldtherightofway topedestriansandothervehicles.Thisvehicle isnotdesignedforuseonstreetsorhighways. Alwayssignalyourturnsorstopearlyenough sothatotherpeopleknowwhatyouplantodo. Obeyalltrafcrulesandregulations.
Theelectricalandexhaustsystemsofthevehicle
canproducesparkscapableofignitingexplosive materials.Neveroperatethevehicleinornearan areawherethereisdustorfumesintheairwhich areexplosive.
Ifyouareeverunsureaboutsafeoperation,stop
workandaskyoursupervisor.
Donottouchtheengineormuferwhiletheengine isrunningorsoonafterithasstopped.Theseareas maybehotenoughtocauseburns.
Ifthemachineevervibratesabnormally,stop immediately,waitforallmotiontostop,andinspect thevehiclefordamage.Repairalldamagebefore commencingoperation.
Beforegettingoffoftheseat:
1.Stopthemovementofthemachine.
2.Settheparkingbrake.
3.TurntheignitionkeytoOff.
4.Removetheignitionkey .
Note:Ifthevehicleisonanincline,blockthe wheelsaftergettingoffofthevehicle.
Lightningcancausesevereinjuryordeath.If lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.
Braking
Slowdownbeforeyouapproachanobstacle.This givesyouextratimetostoporturnaway.Hitting anobstaclecandamagethevehicleanditscontents. Moreimportant,itcaninjureyouandyourpassenger.
GrossVehicleWeight(GVW)hasamajorimpacton yourabilitytostopand/orturn.Heavyloadsand
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attachmentsmakeavehiclehardertostoporturn. Theheaviertheload,thelongerittakestostop.
topreventitfromshiftingandtakeextracarewhen haulingloadsthatshifteasily(liquid,rock,sand,etc.).
Decreasethevehiclespeedifthecargoboxhasbeen removedandthereisnoattachmentonthevehicle. Thebrakingcharacteristicschangeandfaststops maycausetherearwheelstolockup,whichmay affectthecontrolofthevehicle.
Turfandpavementaremuchmoreslipperywhen theyarewet.Itcantake2to4timesaslongtostop onwetsurfacesasondrysurfaces.Ifyoudrive throughstandingwaterdeepenoughtogetthe brakeswet,theywillnotworkwelluntiltheyare dry.Afterdrivingthroughwater,youshouldtestthe brakestomakesuretheyworkproperly.Iftheydo not,driveslowlywhileputtinglightpressureonthe brakepedal.Thiswilldrythebrakesout.
OperatingonHills
WARNING
Operatingthevehicleonahillmaycausetipping orrollingofthevehicle,ortheenginemaystalland youcouldloseheadwayonthehill.Thiscould resultinpersonalinjury.
Donotoperatemachineonexcessivelysteep slopes.
Donotacceleratequicklyorslamonthebrakes whenbackingdownahill,especiallywithaload.
Iftheenginestallsoryouloseheadwayona hill,slowlybackstraightdownthehill.Never attempttoturnthevehiclearound.
Avoidstoppingonhills,especiallywithaload. Stoppingwhilegoingdownahillwilltakelonger thanstoppingonlevelground.Ifthevehiclemust bestopped,avoidsuddenspeedchanges,whichmay initiatetippingorrollingofthevehicle.Donotslam onthebrakeswhenrollingbackward,asthismay causethevehicletooverturn.
AnoptionalROPSKitcanbeinstalledforoperation onhillyterrain.
OperatingonRoughTerrain
Reducespeedandloadwhenoperatingonroughterrain, unevenground,andnearcurbs,holes,andothersudden changesinterrain.Loadsmayshift,causingthevehicle tobecomelessstable.
AnoptionalROPSKitcanbeinstalledforoperation onhillyterrain.
WARNING
Suddenchangesinterrainmaycauseabrupt steeringwheelmovement,possiblyresultingin handandarminjuries.
Reduceyourspeedwhenoperatingonrough terrainandnearcurbs.
Gripthesteeringwheellooselyaroundthe perimeterkeepingthumbsupandoutoftheway ofthesteeringwheelspokes.
Operatethevehicleslowlyonahillanduse caution.
Avoidturningonahill.
Reduceyourloadandthespeedofthevehicle.
Avoidstoppingonhills,especiallywithaload.
Theseextracautionsneedtobetakenwhenoperating thevehicleonahill:
Slowdownbeforestartingupordownahill.
Iftheenginestallsoryoubegintoloseheadway whileclimbingahill,graduallyapplythebrakesand slowlybackstraightdownthehill.
Turningwhiletravelingupordownhillscanbe dangerous.Ifyouhavetoturnwhileonahill,do itslowlyandcautiously.Nevermakesharporfast turns.
Heavyloadsaffectstability.Reducetheweightofthe loadandyourspeedwhenoperatingonhillsorif theloadhasahighcenterofgravity.Securetheload
LoadingandDumping
Theweightandpositionofthecargoandpassenger canchangethevehiclecenterofgravityandvehicle handling.Toavoidlossofcontrolandpersonalinjury, followtheseguidelines:
Donotcarryloadswhichexceedtheloadlimits describedonthevehicleweightlabel;referto SpecicationsintheProductOverviewsection,for vehicleweightlimits.Theloadratingisforlevel surfacesonly .
Reducetheweightoftheloadwhenoperating onhillsandroughterraintoavoidtippingor overturningofthevehicle.
Reducetheweightoftheloadifthecenterofgravity ishigh.Itemssuchasbricks,fertilizer,orlandscape timbersstackhigherinthebox.Thehigheraload isstacked,themorelikelythevehicleistotipover. Distributetheloadaslowaspossible,makingsure thattheloaddoesnotaffectrearvisibility.
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Positiontheweightoftheloadevenlyfromsideto side.Ifyoupositiontheloadtowardoneofthesides, thevehicleismorelikelytotipoverwhileturning.
Positiontheweightofaloadevenlyfromfrontto back.Ifyoupositiontheloadbehindtherearaxle, itwillreducetheweightonthefrontwheels.This mayresultinalossofsteeringcontrolorcausethe vehicletotipoveronhillsorbumpyterrain.
Useextracautioniftheloadexceedsthedimensions oftheboxandwhenhandlingoff-centerloadsthat cannotbecentered.Keeploadsbalancedandsecure topreventthemfromshifting.
Alwayssecureloadssothattheydonotshift.Ifa loadisnotsecured,oryouaretransportingaliquidin alargecontainersuchasasprayer,theloadcanshift. Thisshiftinghappensmostoftenwhileturning, goingupordownhills,suddenlychangingspeeds,or whiledrivingoverroughsurfaces.Shiftingloadscan causethevehicletotipover.
andremovethekeyfromtheignitiontoprevent someonefromaccidentallystartingtheengine.
Tomakesurethattheentiremachineisingood condition,keepallnuts,bolts,andscrewsproperly tightened.
Toreducethepotentialforre,keeptheengine areafreeofexcessivegrease,grass,leaves,and accumulationofdirt.
Neveruseanopenametocheckthelevelor leakageoffuelorbatteryelectrolyte.
Iftheenginemustberunningtoperforma maintenanceadjustment,keepyourhands,feet, clothing,andanypartsofyourbodyawayfromthe engineandanymovingparts.Keepeveryoneaway.
Donotuseopenpansoffuelorammablecleaning uidsforcleaningparts.
Ifmajorrepairsareeverneededorassistanceis required,contactanAuthorizedToroDistributor.
WARNING
Theweightoftheboxmaybeheavy.Handsor otherbodypartscouldbecrushed.
Keephandsandotherbodypartsclearwhen
loweringthebox.
Donotdumpmaterialsonbystanders.
Neverdumpaloadedcargoboxwhilethevehicleis sidewaysonahill.Thechangeinweightdistribution maycausethevehicletooverturn.
Whenoperatingwithaheavyloadinthecargobox, reduceyourspeedandallowforsufcientbraking distance.Donotsuddenlyapplythebrakes.Use extracautiononslopes.
Beawarethatheavyloadsincreaseyourstopping distanceandreduceyourabilitytoturnquickly withouttippingover.
Therearcargospaceisintendedforloadcarrying purposesonly ,notforpassengers.
Neveroverloadyourvehicle.Thedecal(locatedon therearframe)showsloadlimitsforthevehicle. NeveroverloadtheattachmentsorexceedtheGross VehicleWeight(GVW).
Tobesureofoptimumperformanceandsafety, alwayspurchasegenuineTororeplacementpartsand accessories.Replacementpartsandaccessoriesmade byothermanufacturerscouldbedangerous.Altering thisvehicleinanymannerthatmayaffectvehicle operation,performance,durability,oritsuse,may resultininjuryordeath.Suchusecouldvoidthe productwarranty.
Models07266/TCand07279
SoundPressure
Thisunithasaguaranteedsoundpowerlevelof96dBA, whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe proceduresoutlinedinENISO11094.
SoundPressure
Thisunithasasoundpressurelevelattheoperator’ s earof83dBA,whichincludesanUncertaintyValue(K) of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe proceduresoutlinedinENISO11201.
Maintenance
Onlyqualiedandauthorizedpersonnelshallbe permittedtomaintain,repair,adjust,orinspectthe vehicle.
Beforeservicingormakingadjustmentstothe machine,stoptheengine,settheparkingbrake,
Hand-ArmVibration
Measuredvibrationlevelforrighthand=1.5m/s
Measuredvibrationlevelforlefthand=1.03m/s
UncertaintyValue(K)=0.5m/s
7
2
2
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Measuredvaluesweredeterminedaccordingtothe proceduresoutlinedinEN1032.
WholeBodyVibration
Measuredvibrationlevel=0.42m/s
UncertaintyValue(K)=0.5m/s
2
2
SoundPressure
Thisunithasasoundpressurelevelattheoperator’ s earof81dBA,whichincludesanUncertaintyValue(K) of1dBA.
Soundpressurelevelwasdeterminedaccordingtothe proceduresoutlinedinENISO11201.
Measuredvaluesweredeterminedaccordingtothe proceduresoutlinedinEN1032.
Model07273/TC
SoundPressure
Thisunithasaguaranteedsoundpowerlevelof96dBA, whichincludesanUncertaintyValue(K)of1dBA.
Soundpowerlevelwasdeterminedaccordingtothe proceduresoutlinedinENISO11094.
SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof potentialdanger.Replaceanydecalthatisdamagedorlost.
Hand-ArmVibration
Measuredvibrationlevelforrighthand=1.5m/s
Measuredvibrationlevelforlefthand=1.03m/s
UncertaintyValue(K)=0.5m/s2
Measuredvaluesweredeterminedaccordingtothe proceduresoutlinedinEN1032.
WholeBodyVibration
Measuredvibrationlevel=0.42m/s
UncertaintyValue(K)=0.5m/s
Measuredvaluesweredeterminedaccordingtothe proceduresoutlinedinEN1032.
2
2
2
2
1.Warning—readtheOperator’sManual.
2.Collisionhazard—donotoperatethevehicleonpublicstreets, roads,orhighways.
3.Fallinghazard—donotcarrypassengersinthecargobed.9.Headlights
4.Fallinghazard—donotallowchildrentooperatethevehicle.
5.Tostarttheengine,sitontheoperator’sseat,releasethe parkingbrake,turnthepowerkeyon,pullthechokeleverout (ifneeded),andpresstheacceleratorpedal.
6.Tostoptheengine,releasetheacceleratorpedal,setthe parkingbrake,turnthepowerkeyoff,andremovethepower key.
117–5001
7.Horn
8.Hourmeter
10.Power—Off
11.Power—On
12.Electricalpower(powerpoint)
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104-6581
1.Warning—readtheOperator’sManual.
2.Firehazard—beforefueling,stoptheengine.
3.Warning—donotoperatethismachineunlessyouaretrained.
4.Tippinghazard—usecautionanddriveslowlywhileonslopes;driveslowlywhenturning,keepthevehiclespeedunder19MPH (31km/h)whencarryingafullorheavyloadandwhendrivingonroughterrain.
5.Fallingandarm/leginjuryhazards—donotcarrypassengersinthecargobedandkeeparmsandlegsinsideofthevehicleatall times.
99-7345
1.Warning—readtheOperator’sManual.
2.Hotsurface/burnhazard—stayasafedistancefromthe hotsurface.
3.Entanglementhazard,belt—stayawayfrommovingparts; keepallguardsinplace.
4.Crushinghazard,cargobox—usetheproprodtosupport thecargobed
1.Choke
2.Reverse4.Forward
99-7952
3.Neutral
115-2412
1.Warning—readtheOperator’sManual;nostorage.
112-3325
1.ReadtheOperator’s Manualforfuse
information.
2.Lift/gate,30A5.Machinefuse,20A
3.Horn/powerpoint,10A
4.Headlights,15A
115–7739
1.Fallinghazard—donotcarrypassengersinthecargobed.
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99-7350
1.Maximumtongueweightis50lb(23kg);maximumtrailer weightis400lb(181kg).
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Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
1
2
3
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
Steeringwheel
Nopartsrequired
Operator’sManual EngineOperator’sManual PartsCatalog SafetyTrainingmaterial RegistrationCard PredeliveryInspectionForm1 CerticateofQuality Key2
1
Qty.
Use
1
1 1 1 1 1
1
Installthesteeringwheel(Model 07266TCand07273TConly).
Activatethebattery(Model07266TC and07273TConly).
ReadtheOperator’sManualandview thetrainingmaterialbeforeoperating themachine.
InstallingtheSteeringWheel
Partsneededforthisprocedure:
1
Steeringwheel
Procedure
Note:ThisprocedureisonlyneededforModelNo.
07266TCand07273TC.
1.Releasethetabsonthebackofthesteeringwheel thatholdthecentercoverinplace.Removethecover
2.Removethenutandwasherfromthesteeringshaft.
3.Slidethesteeringwheelandwasherontotheshaft. Positionthesteeringwheelontheshaftsothatthe crossbeamishorizontalwhenthetiresarepointed straightaheadandthethickerspokeofthesteering wheelisdownward.
4.Securethesteeringwheeltotheshaftwiththenut (Figure3).Torquethenutto18-22ft-lb(24-29N-m)
Figure3
1.Steeringshaft
2.Foamseal6.Nut
3.Steeringwheel7.Cover
4.Tabslotsinwheel8.Tabsincover
5.Snapthecentercoverinplace.
5.Washer
2
ActivatingtheBattery
NoPartsRequired
Procedure
None
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Note:Thisprocedureisonlynecessaryforbatteriesin ModelNo.07266TCand07273TC.
Ifthebatteryisnotlledwithelectrolyteoractivated,it mustberemovedfromthevehicle,lledwithelectrolyte, andcharged.Bulkelectrolytewith1.260specicgravity mustbepurchasedfromalocalbatterysupplyoutlet.
1.Locatethebatteryontherightsideofthemachine, behindthepassengerseat.Removethebatterycover.
2.Removethebatteryhold-downandliftthebattery outofthebatterybase.
DANGER
Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.
Donotdrinkelectrolyteorallowittocontact yourskin,eyesorclothing.Wearsafety glassestoshieldyoureyesandrubbergloves toprotectyourhands.
Fillthebatterywherecleanwaterisalways availableforushingtheskin.
3.Removethellercapsfromthebatteryandslowly lleachcelluntilelectrolyteisjustabovetheplates.
4.Replacethellercapsandconnecta3to4amp batterychargertothebatteryposts.Chargethe batteryatarateof3to4ampfor4to8hours (12volts).Donotoverchargethebattery.
3
ReadingtheManualand ViewingtheSafetyTraining Material
Partsneededforthisprocedure:
1
Operator’sManual
1
EngineOperator’sManual
1
PartsCatalog
1
SafetyTrainingmaterial
1
RegistrationCard
1PredeliveryInspectionForm
1
CerticateofQuality
2Key
Procedure
ReadtheOperator’ sManualandEngineOperator’ s Manual.
Viewthesafetytrainingmaterial.
Fillouttheregistrationcard.
CompletethePredeliveryInspectionForm.
WARNING
Chargingthebatteryproducesgassesthatcan explode.
Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.
5.Whenthebatteryischarged,disconnectthecharger fromtheelectricaloutletandbatteryposts.
6.Removethellercaps.Slowlyaddelectrolyteto eachcelluntilelectrolyteisuptothellline.Install thellercaps.
Important:Donotoverllthebattery. Electrolytewilloverowontootherpartsofthe vehicleandseverecorrosionanddeterioration willresult.
7.Installthebattery;refertoInstallingtheBattery intheElectricalSystemMaintenancesectionin Maintenance.
ReviewtheCerticateofQuality.
12
Page 13
ProductOverview
G014967
1
2
3
4
5
6
7
1.Hoodstrap
2.Parkingbrake
Figure4
3.Cargobox
4.Cargoboxreleaselever6.Gearshiftselector
5.Fuelcap7.Towingtongue
Controls
Figure5
1.Brakepedal5.Passengerhandhold
2.Parkingbrake,center console
3.Steeringwheel
4.Cupholder
AcceleratorPedal
6.Operator’sManualtube
7.Acceleratorpedal
thevehicleandtheenginewillstoprunning.Maximum forwardspeedis16mph(26km/h).
BrakePedal
Thebrakepedalisusedtostoporslowthevehicle (Figure5).
CAUTION
Brakescanbecomewornorcanbeincorrectly adjustedresultinginpersonalinjury.
Ifbrakepedaltravelstowithin1inch(25mm)of thevehicleoorboard,thebrakesmustbeadjusted orrepaired.
ParkingBrake
Theparkingbrakeisbetweentheseats(Figure5). Whenevertheengineisshutoff,theparkingbrake mustbeengagedtopreventaccidentalmovementof thevehicle.Toengagetheparkingbrake,pullbackon thelever.Todisengage,pushtheleverforward.Ifthe vehicleisparkedonasteepgrade,makesurethatthe parkingbrakeisapplied.
Theacceleratorpedal(Figure5)givestheoperatorthe abilitytovarygroundspeedofthevehicle.Pressing thepedalstartstheengine.Pressingthepedalfarther increasesgroundspeed.Releasingthepedalwillslow
ChokeControl
Thechokecontrolislocatedbelowandtotherightof theoperator’sseat.Tostartacoldengine,pullthechoke
13
Page 14
controloutward(Figure6).Aftertheenginestarts,
G009192
1 2
3
4
5
6
regulatethechoketokeeptheenginerunningsmoothly. Assoonaspossible,pushthecontrolintotheOff position.Awarmenginerequireslittleornochoking.
HourMeter
Thehourmeter(Figure7)indicatesthetotalnumber ofhourstheenginehasrun.Thehourmeterstartsto functionwhenevertheacceleratorispressed.
OilLight
Theoillightwarnstheoperatoriftheengineoillevel dropsbelowasafelevel(Figure7).Ifthelightcomeson andremainslit,theoillevelshouldbecheckedandoil addedifnecessary;refertoCheckingtheEngineOil inOperation.
Figure6
1.Choke2.Gearshiftselector
GearShiftSelector
Thegearshiftselectorhasthreepositions:forward, reverse,andneutral(Figure6).Theenginewillstartand runinanyofthethreepositions.
Note:IfthegearshiftselectorisinReversewhenthe ignitionisturnedon,abuzzerwillsoundtowarnthe operator.
Important:Alwaysstopthevehiclebefore changinggears.
IgnitionSwitch
Theignitionswitch(Figure7),usedtostartandstopthe engine,hastwopositions:OffandOn.Rotatethekey clockwisetotheOnpositiontoallowoperation.When thevehicleisstopped,rotatethekeycounterclockwise totheOffposition.Removethekeyfromtheignition whenleavingthevehicle.
Note:Theoillightmayicker.Thisisnormalandno actionneedstobetaken.
LightSwitch
Toggletheswitchtoactivatetheheadlights.Pushto turnthelightson(Figure7).
PowerPoint
Usethepowerpointtopower12voltoptionalelectrical accessories(
Figure7).
HornButton(TCModelsOnly)
Pressthehornbuttontosoundthehorn(Figure7).
FuelGauge
Thefuelgauge(Figure8)isonthefueltanknexttothe llercapontheoperator’ssideofthevehicle.Thegauge displaystheamountoffuelinthetank.
Figure7
1.HornButton(TCModels Only)
2.Hourmeter5.PowerPoint
3.Lightswitch
4.Ignitionswitch
6.Oillight
Figure8
1.Empty4.Fuelgauge
2.Full5.Fueltankcap
3.Needle
14
Page 15
PassengerHandHolds
G009193
1
2
Thepassengerhandholdsarelocatedontherightsideof thedashpanelandattheoutsideofeachseat(Figure9).
Figure9
1.Hiprestraint2.Passengerhandhold
Specications
Note:Specicationsanddesignaresubjecttochangewithoutnotice.
MDMDX
Baseweight
Ratedcapacity(onlevelground)1250lb(567kg)total,including200lb(90.7kg)
Maximumgrossvehicleweight (GVW)(onlevelground)
Maximumcargocapacity(onlevel ground)
Towcapacity:
StandardHitchTongueweight50lb(23kg)Maximumtrailerweight400lb(182kg)
HeavyDutyHitch
Overallwidth59inches(150cm)
Overalllength117.75inches(299cm)
Groundclearance10inches(25.4cm)atthefrontwithnoloadoroperator,7inches(18cm)attherearwith
Wheelbase
Wheeltread(centerlinetocenter line)
Cargoboxlength46inches(1 16.8cm)inside,52-1/4inches(132.7cm)outside
Cargoboxwidth49inches(124.5cm)inside,59inches(150cm)atoutsideofthemoldedfenders
Cargoboxheight10inches(25.4cm)inside
Dry1200lb(544kg)
operatorand200lb(90.7kg)passenger,load, trailertongueweight,grosstrailerweight, accessories,andattachments
2450lb(1 11 1kg)total,includingallofthe weightslistedabove
850lb(385kg)total,includingtrailertongue weightandgrosstrailerweight
Tongueweight100lb(45kg)Maximumtrailerweight800lb(363kg)
noloadoroperator
81inches(205.7cm)
49inches(124.5cm)inthefront,46-1/2inches (118cm)intherear
1650lb(749kg)total,including200lb(90.7kg) operatorand200lb(90.7kg)passenger,load, trailertongueweight,grosstrailerweight, accessories,andattachments
2850lb(1292kg)total,includingallofthe weightslistedabove
1250lb(567kg)total,includingtrailertongue weightandgrosstrailerweight
49inches(124.5cm)inthefront,47-1/4inches (120cm)intherear
Attachments/Accessories
AselectionofToroapprovedattachmentsandaccessoriesareavailableforusewiththemachinetoenhanceand expanditscapabilities.ContactyourAuthorizedServiceDealerorDistributororgotowww .Toro.comforalistof allapprovedattachmentsandaccessories.
15
Page 16
Operation
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
ThinkSafetyFirst
Pleasecarefullyreadallofthesafetyinstructionsand decalsinthesafetysection.Knowingthisinformation couldhelpyouorbystandersavoidinjury.
Pre-StartingChecks
Checkthefollowingitemseachtimeyoubeginusing thevehiclefortheday:
Checkthetirepressure.
Note:Thesetiresaredifferentthancartires;they requirelesspressuretominimizeturfcompaction anddamage.
Checkalluidlevelsandaddtheappropriate amountofspecieduids,ifanyarefoundtobe low .
Checkthebrakepedaloperation.
Ensurethatthelightsareworking.
Turnthesteeringwheeltotheleftandrightto checksteeringresponse.
Checkforoilleaks,looseparts,andanyother noticeablemalfunctions.Makesuretheengineisoff andallmovingpartshavestoppedbeforechecking foroilleaks,looseparts,andothermalfunctions.
Ifanyoftheaboveitemsarenotcorrect,notify yourmechanicorcheckwithyoursupervisorbefore takingthevehicleoutfortheday.Yoursupervisor maywantyoutocheckotheritemsonadailybasis, soaskwhatyourresponsibilitiesare.
CheckingtheEngineOil
ServiceInterval:Beforeeachuseordaily
Figure10
Modelnumbers07266/TC
1.Oildipstickandllspout
Figure11
Modelnumbers07273/TC
1.Oildipstick(loopdown)
3.Removetheoildipstickandwipetheendclean.
4.Slidetheoildipstickintothellertubefullyseating it.Pullthedipstickoutandlookattheend.
Iftheoillevelislow,removethellercapand addoilofthepropertypetoraisethelevelto,but notover,theFullmarkonthedipstick.Referto ServicingtheEngineOilintheEngineMaintenance sectioninMaintenance,fortheproperoiltypeand viscosity.Addtheoilslowlyandcheckthelevel oftenduringthisprocess.Donotoverll.
2.Fillcap
Note:Theengineisshippedwithoilinthecrankcase; however,theleveloftheoilmustbecheckedbefore andaftertheengineisrststarted.
Checktheengineoillevelbeforestartingtheengine eachday.
1.Positionthemachineonalevelsurface.
2.Cleanaroundtheoildipstick(Figure10formodel numbers07266/TCandFigure11formodel numbers07273/TC)sodirtcannotfallintothe holeanddamagetheengine.
5.Installtheoildipstickrmlyinplace.
Important:Makesuretheloopendoftheoil dipstickispointingdownon07273/TCmodels.
CheckingtheBrakeFluid Level
Checkthebrakeuidlevelbeforetheengineisrst started;refertoCheckingtheBrakeFluidLevelinthe BrakeMaintenancesectioninMaintenance.
16
Page 17
CheckingtheTirePressure
DANGER
ServiceInterval:Beforeeachuseordaily
Checkthetirepressureevery8hoursordailytoensure properlevels.
Theairpressurerangeinthefrontandreartiresis 8–22psi(55–103kPa).
Theairpressureneededisdeterminedbythepayload carried.Thelowertheairpressure,thelessthe compaction,smoothertheride,andtiremarksare minimized.Lowerpressureshouldnotbeusedfor heavypayloadsathighspeeds.
Higherpressuresshouldbeusedforheavierpayloadsat higherspeeds.Donotexceedthemaximumpressure.
AddingFuel
Usefresh,clean,unleadedregulargasolinesuitablefor automotiveuse(87pumpoctaneminimum).Leaded gasolinemaybeusedifunleadedregularisnotavailable.
Important:Neverusegasolinecontaining methanol,gasolinecontainingmorethan10% ethanol,gasolineadditives,orwhitegasbecause enginefuelsystemdamagecouldresult.
Incertainconditionsduringfueling,static electricitycanbereleasedcausingasparkwhich canignitethegasolinevapors.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
Alwaysplacegasolinecontainersontheground awayfromyourvehiclebeforelling.
Donotllgasolinecontainersinsideavehicle oronatruckortrailerbedbecauseinterior carpetsorplastictruckbedlinersmayinsulate thecontainerandslowthelossofanystatic charge.
Whenpractical,removegas-powered equipmentfromthetruckortrailerandrefuel theequipmentwithitswheelsontheground.
Ifthisisnotpossible,thenrefuelsuch equipmentonatruckortrailerfromaportable container,ratherthanfromagasolinedispenser nozzle.
Ifagasolinedispensernozzlemustbeused, keepthenozzleincontactwiththerimofthe fueltankorcontaineropeningatalltimesuntil fuelingiscomplete.
FillingtheFuelTank
DANGER
Incertainconditions,gasolineisextremely ammableandhighlyexplosive.Areorexplosion fromgasolinecanburnyouandothersandcan damageproperty.
Fillthefueltankoutdoors,inanopenarea, whentheengineiscold.Wipeupanygasoline thatspills.
Neverllthefueltankinsideanenclosedtrailer.
Donotllthefueltankcompletelyfull.Add gasolinetothefueltankuntilthelevelis1/4to 1/2inch(6to13mm)belowthebottomofthe llerneck.Thisemptyspaceinthetankallows gasolinetoexpand.
Neversmokewhenhandlinggasoline,andstay awayfromanopenameorwheregasoline fumesmaybeignitedbyaspark.
Storegasolineinanapprovedcontainerand keepitoutofthereachofchildren.Neverbuy morethana30-daysupplyofgasoline.
Donotoperatewithoutentireexhaustsystem inplaceandinproperworkingcondition.
Thefueltankcapacityisapproximately7gallons (26.5l).
1.Shuttheengineoffandsettheparkingbrake.
2.Cleantheareaaroundthefueltankcap(Figure12).
Figure12
1.Empty4.Fuelgauge
2.Full5.Fueltankcap
3.Needle
3.Removethefueltankcap.
17
Page 18
4.Fillthetanktoabout1inch(25mm)belowthetop
g014860
1
2
3
oftank,(bottomofthellerneck).Thisspacein thetankallowsgasolinetoexpand.Donotoverll.
Note:Stoppingdistancemayvarydependingonthe vehicleloadandspeed.
5.Installthefueltankcapsecurely .Wipeupanyfuel thatmayhavespilled.
CheckingtheTransmission OilLevel
ServiceInterval:Beforeeachuseordaily
Thetransaxleuidlevelshouldbeatthebottomof thelevelindicatorhole(Figure13).Ifitisnot,llthe reservoirwiththeappropriateuid;refertoChanging theTransaxleFluidintheDriveSystemMaintenance sectioninMaintenance.
Figure13
1.Levelindicatorhole
ParkingtheVehicle
1.Engagetheparkingbrakeandrotatetheignition keytoOff.
2.Removethekeyfromtheignitionswitchtoprevent accidentalstarting.
OperatingtheCargoBox
RaisingtheBox
WARNING
Drivingthevehiclewiththecargoboxraisedmay causethevehicletotiporrolleasier.Thebox structuremaybecomedamagedifyouoperatethe vehiclewiththeboxraised.
Onlyoperatethevehiclewhenthecargobox isdown.
Afterdumpingaload,lowerthecargobox.
1.Removethereceiverhitchdrawbar.
StartingtheEngine
1.Sitintheoperator’ sseat,insertthekeyintothe ignitionswitch,androtatethekeyclockwisetothe Onposition.
Note:Ifthebackupalarmisinstalledandthegear shiftselectorisinReverse,thebuzzerwillsoundto warntheoperator.
2.Movethegearshiftselectortothedesiredposition.
3.Releasetheparkingbrake.
4.Slowlystepontheacceleratorpedal.
Note:Iftheengineiscold,pressandholdthe acceleratorpedalabouthalf-waydown,andpull thechokeknobouttotheOnposition.Returnthe chokeknobtoOffaftertheenginewarmsup.
Important:Donotattempttopushortowthe vehicletogetitstarted.
2.Lifttheleveroneithersideoftheboxandliftthe boxup(Figure14).
Figure14
1.Lever3.Detentslot
2.Proprod
StoppingtheVehicle
Tostopthevehicle,removeyourfootfromthe acceleratorpedalandslowlypressthebrakepedal.
3.Pulltheproprodintothedetentslot,securingthe box(Figure14).
18
Page 19
LoweringtheBox
WARNING
Theweightoftheboxmaybeheavy.Handsor otherbodypartscouldbecrushed.
Keephandsandotherbodypartsclearwhen loweringthebox.
Pulltheproprodoutofthedetentslotandlowerthe boxuntilitlatchesintoplace.
AdjustingtheBoxLatches
Iftheboxlatchdoesnotlatchtightly,vibratingupand downasyoudrivethevehicle,youcanadjustthelatch poststomakethelatchestsnugly.
1.Loosenthenutontheendofthelatchpost Figure15).
(
Figure15
1.Latch3.Latchpost
2.Nut
2.Turnthelatchpostclockwiseuntilitissnugagainst
thelatchandthentightenthenut(Figure15).
3.Repeatthisprocedureforthelatchontheother
sideofthevehicle.
OperatingtheTailgateLatches
Toopenthetailgate,pulloutwardandliftthelatch up,thenslowlylowerthetailgate(Figure16).
Figure16
1.Tailgatelatch
Toclosethetailgate,liftthetailgateupwardand pushitcloseduntilitlocksinplace.
BreakinginaNewVehicle
Toprovideproperperformanceandlongvehiclelife, followtheseguidelinesfortherst100operatinghours:
Checktheuidandengineoillevelsregularly andbealertforindicationsofoverheatinginany componentofthevehicle.
Afterstartingacoldengine,letitwarmupforabout 15secondsbeforeaccelerating.
Avoidhardbrakingsituationsfortherstseveral hoursofnewvehiclebreak-inoperation.New brakeliningsmaynotbeatoptimumperformance untilseveralhoursofusehascausedthebrakesto becomeburnished(broken-in).
Varythevehiclespeedduringoperation.Avoidfast startsandquickstops.
Abreak-inoilforengineisnotrequired.Original engineoilisthesametypespeciedforregularoil changes.
RefertotheMaintenancesectionforanyspecial lowhourchecks.
Checkthefrontsuspensionpositioningand adjustitifnecessary;refertoAdjustingtheFront SuspensionintheDriveSystemMaintenance sectioninMaintenance.
LoadingtheCargoBox
Thecapacityofthecargoboxis13ft amount(volume)ofmaterialthatcanbeplacedinthe boxwithoutexceedingthevehicleloadratingscan varygreatlydependingonthedensityofthematerial. Forexample,alevelboxofwetsandweighs1500lb (680kg),whichexceedstheloadratingby250lb
19
3
(0.37m
3
).The
Page 20
(113kg).Butalevelboxofwoodweighs650lb (295kg),whichisundertheloadrating.
Seethetablebelowforloadvolumelimitswithvarious materials:
MaterialMax.cargoboxcapacity
Gravel,dry3/4full(approx.)
Gravel,wet1/2full(approx.)
Sand,dry3/4full
Sand,wet1/2full
WoodFull
BarkFull
Earth,packed
(onlevelground)
3/4full(approx.)
TransportingtheVehicle
Towingthevehicleisatwopersonjob.Ifthemachine mustbemovedaconsiderabledistance,transportiton atruckortrailer;refertoTransportingtheVehicle.
1.Removethedrivebelt;refertoReplacingtheDrive BeltintheBeltMaintenancesectioninMaintenance.
2.Afxatowlinetothetongueonthefrontofthe frame(
Figure18).
3.Putthevehicleinneutralandreleasetheparking brake.
Formovingthevehiclelongdistances,atrailershould beused.Makesurethatthevehicleissecuredtothe trailer.RefertoFigure17andFigure18forthelocation ofthetie-downpoints.
CAUTION
Looseseatsmayfalloffofthevehicleandtrailer whentransportingandlandonanothervehicleor becomeanobstructionontheroad.
Removetheseatsormakesurethattheseatsare securelyfastenedinthedetents.
Figure17
1.Tiedownpoints
Figure18
1.Towingtongueandtiedownpoint
TowingaTrailer
Thevehicleiscapableofpullingtrailers.Twotypesof towhitchesareavailableforthevehicle,depending onyourapplication.ContactyourAuthorizedToro Distributorfordetails.
Whenhaulingcargoortowingatrailer,donotoverload yourvehicleortrailer.Overloadingcancausepoor performanceordamagetothebrakes,axle,engine, transaxle,steering,suspension,bodystructure,ortires. Alwaysloadatrailerwith60%ofthecargoweightin thefrontofthetrailer.Thisplacesapproximately10% oftheGrossTrailerW eight(GTW)onthetowhitchof thevehicle.
Themaximumcargoloadshallnotexceed1250lb (567kg),includingtheGTW.Forexample,iftheGTW =400lb(181.5kg)thenthemaximumcargoload= 850lb(386kg)
TowingtheVehicle
Incaseofanemergency,thevehiclecanbetowedfor ashortdistance.However,wedonotrecommendthis asastandardprocedure.
WARNING
Towingatexcessivespeedscouldcausealossof steeringcontrol,resultinginpersonalinjury.
Nevertowthevehiclefasterthan5mph(8km/h).
Toprovideadequatebrakingandtraction,alwaysload thecargoboxwhentrailering.DonotexceedtheGTW orGVWlimits.
Avoidparkingavehiclewithatraileronahill.Ifyou mustparkonahill,engagetheparkingbrakeandblock thetrailertires.
20
Page 21
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst8hours
Aftertherst25hours
Aftertherst50hours
Beforeeachuseordaily
Every50hours
Every100hours
MaintenanceProcedure
•Changetheengineoil.(07273/TC)
•Checktheconditionofthedrivebelt.
•Checkthetensionofthestartergeneratorbelt.
•Changetheengineoil(07266/TC).
•Inspectopeningonlter.
•Checktheengineoil.
•Checkthetirepressure.
•Checkthetransmissionoillevel.
•Checkgearshiftoperation.
•Checkthebrakeuidlevel.
•Changetheengineoil(07273/TC).(twiceasofteninspecialoperatingconditions; refertoMaintainingtheVehicleunderSpecialOperatingConditions)
•Checkthebatterycableconnectionsforwearordamage.
•Checkthebatteryelectrolytelevel.
•Greasethebearingsandbushings.
•Inspectandcleantheairlterelement(twiceasofteninspecialoperatingconditions; refertoMaintainingtheVehicleunderSpecialOperatingConditions).
•Changetheengineoil(07266/TC).(twiceasofteninspecialoperatingconditions; refertoMaintainingtheVehicleunderSpecialOperatingConditions)
•Changetheoillter(07273/TC).(twiceasofteninspecialoperatingconditions;refer toMaintainingtheVehicleunderSpecialOperatingConditions)
•Checkthesparkplug(07266/TC).
•ChecktheoperationoftheNeutralgearshiftposition.
•Inspecttheconditionandwearofthetires.
•Torquethewheellugnutsto45-65ft-lb(61-88N-m).
•Checkthefrontwheeltoe-inandfrontsuspension.
•Cleantheenginecoolingareas(twiceasofteninspecialoperatingconditions;refer toMaintainingtheVehicleunderSpecialOperatingConditions).
•Inspectthebrakes.
Every200hours
Every400hours
Every800hours
Yearly
Important:Refertoyour
•Replacetheairlterelement.
•Inspectopeningonlter.
•Checktheparkingbrakeoperation.
•Checktheconditionandtensionofthedrivebelt.
•Checkthetensionofthestartergeneratorbelt.
•Inspectthefuellinesandconnections.
•Cleantheprimarydriveclutch.
•Replacethesparkplugs(07273/TC).
•Replacethefuellter.
•Changethetransaxleuid.
•CompleteallyearlymaintenanceproceduresspeciedintheEngineOperator’s Manual.
Engine Operator’ s Man ual
foradditionalmaintenanceprocedures.
21
Page 22
DailyMaintenanceChecklist
Duplicatethispageforroutineuse.
Fortheweekof: MaintenanceCheckItem
Mon.Tues.Wed.Thurs.Fri.
Checkbrakeandparking brakeoperation.
Checkgearshift/neutral operation.
Checkfuellevel.
Checkengineoillevel.
Checktransaxleoillevel.
Inspectairlter.
Inspectenginecoolingns.
Checkunusualengine noises.
Checkunusualoperating noises.
Checktirepressure.
Checkuidleaks.
Checkinstrument operation.
Checkaccelerator operation.
Lubricateallgrease ttings.
Touchupdamagedpaint.
Sat.Sun.
CAUTION
Ifyouleavethekeyintheignitionswitch,someonecouldaccidentlystarttheengineandseriouslyinjure youorotherbystanders.
Removethekeyfromtheignitionanddisconnectthewirefromthesparkplugbeforeyoudoany maintenance.Setthewireasidesothatitdoesnotaccidentallycontactthesparkplug.
WARNING
Thebedmustberaisedtoperformsomeroutinemaintenance.
Araisedbedcanfallandinjurepersonsthatareunderneathit.
Alwaysusetheproprodtoholdthebedupbeforeworkingunderit.
Removeanyloadmaterialfromthebedbeforeworkingunderit.
22
Page 23
Premaintenance Procedures
MaintainingtheVehicleunder SpecialOperatingConditions
Ifthevehicleissubjectedtoanyoftheconditions listedbelow,maintenanceshouldbeperformedtwice asfrequently .
Desertoperation
Coldclimateoperation(below50°F[10degreesC])
Trailertowing
Drivingtimetypicallylessthan5minutes
Frequentoperationindustyconditions
Constructionwork
Afterextendedoperationinmud,sand,water,or similardirtyconditions,haveyourbrakesinspected andcleanedassoonaspossible.Thiswillprevent anyabrasivematerialfromcausingexcessivewear.
Underfrequentheavydutyoperatingconditions, lubricateallgreasettingsandinspectaircleaner dailytopreventexcessivewear.
JackingtheVehicle
Figure19
1.Frontjackingpoint
Figure20
1.Rearjackingpoints
AccessingtheHood
1.Releasetherubberstrapsonbothsidesofthehood (Figure21).
Whenevertheengineisrunforroutinemaintenance and/orenginediagnostics,therearwheelsofthevehicle shouldbe1inch(25mm)offthegroundwiththerear axlesupportedonjackstands.
DANGER
Thevehiclemaybeunstablewhenusingajack.It couldslipoffthejack,injuringanyonebeneathit.
Donotstarttheenginewhilethevehicleisona jack.
Alwaysremovethekeyfromtheignitionbefore gettingoffofthevehicle.
Blockthetireswhenthevehicleisonajack.
Thejackingpointatthefrontofthevehicleisonthe frontoftheframebehindthetowingtongue(Figure19) Thejackingpointattherearofthevehicleisunderthe axletubes(
Figure20).
Figure21
2.Raisethehood.
3.Lowerthehoodtocloseanduserubberretaining strapstosecurethehood.
23
Page 24
Lubrication
Lubricateallofthebearingsandbushingsevery100 hoursoronceayear,whicheveroccursrst.Grease themmorefrequentlywhenusingthevehiclefor heavy-dutyoperations.
GreaseType:Number2GeneralPurposeLithiumBase Grease
AddingGrease
ServiceInterval:Every100hours
1.Wipethegreasettingcleansoforeignmatter cannotbeforcedintothebearingorbushing.
2.Pumpgreaseintothebearingorbushing.
EngineMaintenance
ServicingtheAirCleaner
Checktheaircleanerbodyfordamagewhichcould possiblycauseanairleak.Replaceadamagedaircleaner body.
Ensurethecoverissealingaroundtheaircleanerbody .
AirCleanerFilter:Inspectafterevery100operating hours;replaceafterevery200hoursorsoonerifdirty ordamaged.
Note:Servicetheaircleanermorefrequently(every fewhours)ifoperatingconditionsareextremelydusty orsandy .
3.Wipeoffexcessgrease.
Thegreasettingsarelocatedatthefourtierodends
Figure22)andthetwokingpins(Figure23).
(
Figure22
Leftsideshown
1.Greasetting
2.Tierod
RemovingtheFilterElement
1.Parkthemachineonalevelsurface,settheparking brake,turntheignitionoff,andremovethekey.
2.Raisethebedandsecureitwiththeproprod.
3.Releasethelatchessecuringtheaircleanercover totheaircleanerbody.Separatethecoverfrom thebody.Cleantheinsideoftheaircleanercover
Figure24).
(
4.Gentlyslidethelteroutoftheaircleanerbodyto reducetheamountofdustdislodged(Figure24). Avoidknockingthelteragainsttheaircleanerbody .
1.Greasetting
Leftsideshown
Figure23
Figure24
1.Aircleanerlatches3.Filter
2.Cover
5.Inspectthelteranddiscarditifitisdamaged.
CleaningtheFilterElement
ServiceInterval:Every100hours
Important:Donotwashorreuseadamagedlter.
Washingmethod:
24
Page 25
1.Prepareasolutionofltercleanerandwater
1
G016517
andsoakthelterelementforabout15minutes. Refertothedirectionsontheltercleanercarton forcompleteinformation.
2.Aftersoakingthelterfor15minutes,rinseit withclearwater.Rinsethelterfromtheclean sidetothedirtyside.
Important:Topreventdamagetothelter element,themaximumwaterpressuremust notexceed40psi.(276kPa).
3.Drythelterelementusingwarm,owingairat 160degreesF(71degreesC)maximum,orallow theelementtoair-dry.
Important:Donotusealightbulbtodrythe lterelementbecausedamagecouldresult.
Compressedairmethod:
1.Blowcompressedairfromtheinsidetothe outsideofthedrylterelement.Keeptheair hosenozzleatleast2inches(51mm)fromthe lterandmovethenozzleupanddownwhile rotatingthelterelement.
Important:Topreventdamagetothelter element,donotexceed100psi(689kPa)air pressure.
2.Inspectthelterelementforholesandtearsby lookingthroughtheltertowardabrightlight.
1.Locatetheairlteronthebottomofthecarbon canister(Figure25).
Figure25
1.Filteropening
2.Ensurethattheopeningonthebottomofthelter isclearandopen.
ServicingtheEngineOil (Models07266/TCand07279
InstallingtheFilterElement
ServiceInterval:Every200hours
Important:Topreventenginedamage,always operatetheenginewiththecompleteaircleaner assemblyinstalled.
1.Inspectthenewlterforshippingdamage.Check thesealingendofthelter.
Important:Donotinstalladamagedlter.
2.Insertthenewlterintoaircleanerbody.Ensure thelterissealedproperlybyapplyingpressureto theouterrimofthelterwheninstallingit.Donot pressontheexiblecenterofthelter.
3.Installthecoverandsecurethelatches.
InspectingtheCarbonCanisterAir Filter
ServiceInterval:Aftertherst50hours
Every200hours
only)
Checktheoillevelbeforeeachuse.
Changetheoilaftertherst25operatinghoursand every100operatinghoursthereafter.Changetheoil twiceasofteninspecialoperatingconditions;refer toMaintainingtheVehicleunderSpecialOperating Conditions.
Note:Changetheoilmorefrequentlywhenoperating conditionsareextremelydustyorsandy.
OilType:Detergentoil(APIserviceSJ,SK,SL,SM, orhigher)
Viscosity:Seethefollowingtable.
25
Page 26
G016516
Figure26
Note:Disposeoftheusedoilatacertiedrecycling
center.
6.Cleanaroundtheoildipstickandunscrewthecap.
7.Slowlypourapproximately80%ofthespecied amountofoilintothellertubeandcheckthe oillevel;refertoCheckingtheCrankcaseOilin Operation.Slowlyaddoiltobringtheleveltothe Fmarkonthedipstick.
8.Installthedipstick.
ServicingtheEngineOil (Models07273/TConly)
Checktheoillevelbeforeeachuse.
CheckingtheOilLevel
Tochecktheoillevel,refertoCheckingtheEngineOil inOperation.
ChangingtheOil
ServiceInterval:Aftertherst25hours
Every100hours(twiceasoftenin specialoperatingconditions;referto MaintainingtheVehicleunderSpecial OperatingConditions)
1.Startthevehicleandletitrunforafewminutesto warmtheoil.
2.Parkthemachineonalevelsurface,settheparking brake,turntheignitionoff,andremovethekey.
3.Raisethebedandsecureitwiththeproprod.
4.Disconnectthesparkplugwiresandbatterycables.
5.Removethedrainplug( owintoadrainpan.Whentheoilhasdrained completely,installthedrainplugandtorqueitto 13ft-lb(17.6N-m).
Figure27)andlettheoil
Changetheoilaftertherst8operatinghoursandevery 50hoursthereafter.Changetheoiltwiceasoftenin specialoperatingconditions;refertoMaintainingthe VehicleunderSpecialOperatingConditions.
Replacetheoillterevery100hours.
Note:Changetheoilandoilltermorefrequently whenoperatingconditionsareextremelydustyorsandy.
OilType:Detergentoil(APIserviceSF ,SG,SH,SJ,or higher)
CrankcaseCapacity:48oz./1-1/2qt.(1.4liters)when thelterischanged
Viscosity:Seethetablebelow
Figure27
1.Engineoildrainplug3.Primarydriveclutch
2.Engine
Figure28
CheckingtheOilLevel
Tochecktheoillevel,refertoCheckingtheEngineOil inOperation.
ChangingtheOil
ServiceInterval:Aftertherst8hours
26
Page 27
Every50hours(twiceasoftenin specialoperatingconditions;referto MaintainingtheVehicleunderSpecial OperatingConditions)
1.Startthevehicleandletitrunforafewminutesto warmtheoil.
2.Parkthemachineonalevelsurface,settheparking brake,turntheignitionoff,andremovethekey.
3.Raisethebedandsecureitwiththeproprod.
4.Disconnectthesparkplugwiresandbatterycables.
5.Removethedrainplug( owintoadrainpan.Whentheoilstops,installthe drainplug.
Figure29)andlettheoil
5.Fillthecrankcasewiththepropertypeofnewoil.
6.Startandruntheenginetocheckforleaks.
7.Stoptheengineandchecktheoillevel.Addoilif necessary.
ServicingtheSparkPlug (Models07266/TCand07279 only)
Checkthesparkplugafterevery100operatinghoursor yearly,whicheveroccursrst.Replaceifnecessary.
Type:ChampionRN14YC(orequivalent)
Note:Disposeoftheusedoilatacertiedrecycling center.
Figure29
1.Engineoildrainplug
6.Pouroilintothellopeninguntiltheoillevelisup totheFullmarkonthedipstick.Addtheoilslowly andchecktheleveloftenduringthisprocess.Do notoverll.
7.Installtheoilllcapanddipstickrmlyinplace.
2.Engineoillter
ChangingtheOilFilter
ServiceInterval:Every100hours(twiceasoftenin
specialoperatingconditions;referto MaintainingtheVehicleunderSpecial OperatingConditions)
AirGap:0.030inch(0.762mm)
CheckingandReplacingtheSparkPlug
ServiceInterval:Every100hours
Note:Thesparkplugusuallylastsalongtime;however, theplugshouldberemovedandcheckedwheneverthe enginemalfunctions.
1.Cleantheareaaroundthesparkplugssothatforeign mattercannotfallintothecylinderwhenthespark plugisremoved.
2.Pullthewiresoffofthesparkplugsandremovethe plugsfromthecylinderhead.
3.Checktheconditionofthesideelectrode,center electrode,andcenterelectrodeinsulatortoensure thatthereisnodamage(
Important:Acracked,fouled,dirty,or malfunctioningsparkplugmustbereplaced. Donotsand-blast,scrape,orcleanelectrodesby usingawirebrushbecausegritmayeventually releasefromtheplugandfallintothecylinder. Theresultisusuallyadamagedengine.
Figure30).
Replacetheoillterevery100operatinghoursoryearly, whicheveroccursrst.
1.Draintheoilfromtheengine;refertoChanging theOil.
2.Removetheexistingoillter(
3.Applyalightcoatofcleanoiltothenewltergasket.
4.Screwthenewlteronuntilthegasketcontactsthe mountingplate,thentightenthelteranadditional 1/2to3/4turnfurther.Donotovertighten.
Figure29).
27
Page 28
Figure30
1.Centerelectrodeinsulator3.Airgap(nottoscale)
2.Sideelectrode
Figure31
1.Centerelectrodeinsulator3.Airgap(nottoscale)
2.Sideelectrode
4.Settheairgapbetweenthecenterandsideofthe electrodesat0.030inch(0.762mm)(Figure30). Installthecorrectlygappedsparkplugandtighten theplugto14ft-lb(20N-m).
5.Installthesparkplugwires.
ServicingtheSparkPlugs (Models07273/TConly)
ServiceInterval:Every800hours
Replacethesparkplugsafterevery800operatinghours oryearly,whicheveroccursrst,toensureproperengine performanceandreducetheexhaustemissionlevel.
Type:ChampionRC14YC(orequivalent)
AirGap:0.030inch(0.762mm)
Note:Thesparkplugsusuallylastalongtime;however, theplugsshouldberemovedandcheckedwheneverthe enginemalfunctions.
Important:Acracked,fouled,dirty,or malfunctioningsparkplugmustbereplaced.Do notsand-blast,scrape,orcleantheelectrodesby usingawirebrushbecausegritmayeventually releasefromtheplugandfallintothecylinder. Theresultisusuallyadamagedengine.
4.Settheairgapbetweenthecenterandsideelectrodes at0.030inch(0.762mm)(
Figure30).
5.Installthecorrectlygappedsparkplugandtighten theplugto18-22ft-lb(24-30N-m).Ifatorque wrenchisnotused,tightentheplugrmly.
6.Installthesparkplugwires.
1.Cleantheareaaroundthesparkplugssothatforeign mattercannotfallintothecylinderwhenthespark plugisremoved.
2.Pullthesparkplugwiresoffofthesparkplugsand removetheplugsfromthecylinderhead.
3.Checktheconditionofthesideelectrode,center electrode,andcenterelectrodeinsulatortoensure thatthereisnodamage(
Figure30).
28
Page 29
FuelSystem
ElectricalSystem
Maintenance
InspectingFuelLinesand Connections
ServiceInterval:Every400hours
Checkthefuellinesandconnectionsevery400operating hoursoryearly ,whicheveroccursrst.Inspectthemfor deterioration,damage,orlooseconnections.
ReplacingtheFuelFilter
ServiceInterval:Every800hours
Replacethefuellterevery800operatinghoursor yearly,whicheveroccursrst.
1.Raisetheboxandsupportitwiththeproprod.
2.Placeacleancontainerunderthefuellter.
3.Removetheclampssecuringthefuelltertothefuel
Figure32).
lines(
Maintenance
ReplacingtheFuses
Thereare3fusesintheelectricalsystem.Theyare locatedbeneaththedashonthedriver’sside(Figure33).
Auxillary(Open)
IgnitionSystem/Horn
Headlights15A
PowerPoint20A
30A
10A
Figure32
1.Fuellter
4.Installthereplacementltertothefuellineswiththe clampspreviouslyremoved.
Mounttheltersothatthearrowpointstowardthe carburetor.
Figure33
1.Fuseblock3.Pedalassembly
2.Groundblock
ReplacingtheHeadlights
Beforeperforminganymaintenancesettheparking brake,turntheignitionoff,andremovethekey .
Releasetheretainingstrapsonthehoodandraisethe hoodtoaccesstheheadlights.
ReplacingtheBulbs
CAUTION
Thehalogenbulbsbecomeextremelyhotwhenin operation.Handlingahotbulbcancausesevere burnsandpersonalinjury.
Alwaysallenoughtimetoforthebulbstocool beforereplacingthem.Usecarewheneverhandling thebulb.
29
Page 30
CAUTION
G009198
1
2
3
4
5
6
Anysurfacecontaminationcandamagethe headlightbulbandleadingtoitsfailureorexplosion creatingaserioussafetyhazard.
Headlightlampsshouldbehandledwithout touchingtheclearquartz,eitherbyusingaclean papertowelorcarefullyholdingthebase.
Specication:SeeyourPartsCatalog.
1.Disconnecttheelectricalharnessfromthebulb housingonthebackofthelamp.
2.Removethebulbassemblybyturningit1/4turn counterclockwiseandmovingitrearward,outofthe lamphousing.
3.Removethebulbfromthebasetakingcarenotto touchthehalogenquartz.
4.Installanewbulbonthebase.Useapapertowel tograspthenewbulbwithhandlingittoavoid contaminatingthesurface.
5.Insertthenewbulbandassemblyintotheheadlight housingandsecurebyturningit1/4turnclockwise tolockitinplace.
6.Connecttheelectricalharness.
3.Installthenewheadlightthroughtheopeninginthe bumper(Figure34).Ensuretheadjustmentposts arelinedupwiththeholesinthemountingbracket inthebumper.
4.Securetheheadlightassemblywiththewashersand speedclipsremovedpreviously .
5.Attachtheheadlighttothewireharnessremoved previously.
6.Adjusttheheadlightstodirectthebeamstothe desiredposition.
AdjustingtheHeadlights
Usethefollowingproceduretoadjusttheheadlight beampositionwheneveraheadlightassemblyisreplaced orremoved.
1.TurntheignitionkeytotheOnpositionandturnon theheadlights.
2.Attheheadlightassembly,usethefastenerstopivot theheadlightassemblyandaffectthecastbeam position.
ServicingtheBattery
ReplacingtheHeadlight
Whenremovingorreplacingtheheadlightassembly, disconnectthewiringharnesstothebulbassemblyifthe bulbistoberemovedwiththelamp.
1.Removethespeedclipsandwasherssecuringthe headlightinplace.Retainallparts.
2.Removetheheadlightassemblybymovingitforward throughtheopeninginthefrontbumper(
Figure34).
Batteryposts,terminals,andrelated
accessoriescontainleadandleadcompounds,
chemicalsknowntotheStateofCalifornia
tocausecancerandreproductiveharm.
Washhandsafterhandling.
WARNING
CALIFORNIA
Proposition65Warning
Important:Donotjumpstartthevehicle.
Alwayskeepthebatterycleanandfullycharged.Use apapertoweltocleanthebatteryandbatterybox.If thebatteryterminalsarecorroded,cleanthemwitha solutionoffourpartswaterandonepartbakingsoda. Applyalightcoatingofgreasetothebatteryterminals topreventcorrosion.
Voltage:12voltwith280coldcrankingAmps@0
Figure34
1.Headlight4.Headlightbulbharness
2.Openinginfrontend5.Speedclip
3.Headlightbulbassembly6.Flatwasher
connection
degreesF(-18degreesC).
RemovingtheBattery
1.Positionthevehicleonalevelsurface,settheparking brake,turntheignitionoff,andremovethekey.
2.Locatethebatteryontherightsideofthemachine, behindthepassengerseat.Removethebatterycover.
30
Page 31
3.Disconnectthenegative(black)groundcablefrom thebatterypost.
CheckingtheElectrolyteLevel
ServiceInterval:Every50hours
WARNING
Incorrectbatterycableroutingcoulddamage thevehicleandcables,causingsparks.Sparks cancausethebatterygassestoexplode, resultinginpersonalinjury.
Alwaysdisconnectthenegative(black) batterycablebeforedisconnectingthe positive(red)cable.
Alwaysreconnectthepositive(red)battery cablebeforereconnectingthenegative (black)cable.
Alwayskeepthebatterystrapinplaceto protectandsecurethebattery.
WARNING
Batteryterminalsormetaltoolscouldshort againstmetalvehiclecomponents,causing sparks.Sparkscancausethebatterygassesto explode,resultinginpersonalinjury.
Whenremovingorinstallingthebattery,do notallowthebatteryterminalstotouchany metalpartsofthevehicle.
Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe vehicle.
4.Disconnectthepositive(red)cablefromthebattery post.
5.Removethefastenerssecuringthebatteryhold down.Removetheholddownandretainallparts.
6.Removethebatteryfromtheholderbox.
Note:Thisprocedureisonlynecessaryforbatteriesin ModelNo.07266TCand07273TC.
Checktheelectrolytelevelevery50operatinghoursor, ifthemachineisinstorage,every30days.
1.Locatethebatteryontherightsideofthemachine, behindthepassengerseat.Removethebatterycover.
2.Removethellercaps.Iftheelectrolyteisnotup tothellline,addtherequiredamountofdistilled water;refertoAddingWatertotheBattery.
DANGER
Batteryelectrolytecontainssulfuricacidwhich isadeadlypoisonandcausessevereburns.
Donotdrinkelectrolyteorallowittocontact yourskin,eyesorclothing.Wearsafety glassestoshieldyoureyesandrubbergloves toprotectyourhands.
Fillthebatterywherecleanwaterisalways availableforushingtheskin.
AddingWatertotheBattery
Note:Thisprocedureisonlynecessaryforbatteriesin
ModelNo.07266TCand07273TC.
Thebesttimetoadddistilledwatertothebatteryisjust beforeyouoperatethemachine.Thisletsthewatermix thoroughlywiththeelectrolytesolution.
1.Cleanthetopofthebatterywithapapertowel.
2.Removethellercapsfromthebatteryandslowly lleachcellwithdistilledwateruntilthelevelisup tothellline.Replacethellercaps.
InstallingtheBattery
ServiceInterval:Every50hours
1.Setthebatteryintothebatteryholderboxsothe batterypostsareawayfromthevehicleframe.
2.Installthebatteryholddownandsecureitwith fastenersremovedpreviously.
Important:Alwayskeepthebatteryhold-down inplacetoprotectandsecurethebattery.
3.Connectthepositive(red)cabletothepositive(+) batterypostandthenegative(black)cabletothe negative(-)batterypostusingtheboltsandwing nuts.Slidetherubberbootoverthepositivebattery post.
4.Installthebatterycover.
Important:Donotoverllthebattery. Electrolytewilloverowontootherpartsofthe vehicleandseverecorrosionanddeterioration willresult.
ChargingtheBattery
Important:Alwayskeepthebatteryfullycharged
(1.260specicgravity).Thisisespeciallyimportant topreventbatterydamagewhenthetemperatureis below32degreesF(0degreesC).
1.Removethebatteryfromthemachine;referto RemovingtheBattery.
2.Connecta3to4ampbatterychargertothebattery posts.Chargethebatteryatarateof3to4ampfor4 to8hours(12volts).Donotoverchargethebattery.
31
Page 32
WARNING
Chargingthebatteryproducesgassesthatcan explode.
DriveSystem Maintenance
Neversmokenearthebatteryandkeepsparks andamesawayfrombattery.
3.Installthebatteryinthechassis;refertoInstalling theBattery.
StoringtheBattery
Ifthemachinewillbestoredformorethan30days, removethebatteryandchargeitfully.Eitherstore itontheshelforonthemachine.Leavethecables disconnectedifitisstoredonthemachine.Storethe batteryinacoolatmospheretoavoidquickdeterioration ofthechargeinthebattery.T opreventthebatteryfrom freezing,makesureitisfullycharged.
CheckingandAdjusting Neutral
ServiceInterval:Every100hours
Whenperformingroutinemaintenanceand/orengine diagnostics,thetransaxlemustbeshiftedintoneutral
Figure35).Thevehiclehasaneutralpositiononthe
( shiftlever,whichcontrolstheneutralinthetransaxle. Thefollowingstepsshouldbetakentomakesurethat theneutralshiftleveroperatesthetransaxleneutral correctly:
1.SettheshiftleverintotheNeutralposition.
2.Ensurethattheneutralbracketisintheneutral position(leveltothecablemountingbracketlocated belowtheshiftbracket)byturningthedrivenclutch
Figure35).Thevehicleshouldnotrollbackand
( forth.Ifitdoes,manuallymovetheneutralbracket totheneutralposition.
Figure35
1.Neutralbracket2.Locknuts
3.Tightenoneofthelocknuts(Figure35)toachieve agapof0.03-0.06inch.
Note:Youmustholdthethreadedshaftbelowthe brackettotightenthelocknutontop.
4.Tightentheotherlocknuttoachieveagapof
0.03-0.06inch.
5.Pulluponeachshiftcableanensurethatthereisa
0.03-0.06inchgapbetweenthenut/washerandthe neutralbracket( adjustthenutstoachieveagapof0.03-0.06inch.
32
Figure36).Ifthereisanotagap
Page 33
Figure36
1.Neutralbracket4.0.03-0.06inchgap
2.Pullup5.Wrong,adjusttoachieve agapof0.03-0.06inch
3.Cableboot
AdjustingtheSuspension
6.StarttheengineandshiftintoForward,Reverse, andNeutralseveraltimestoensurethattheneutral bracketisoperatingproperly.
InspectingtheTires
ServiceInterval:Every100hours
Every100hours
Checkthetireconditionatleastevery100hours ofoperation.Operatingaccidents,suchashitting curbs,candamageatireorrimandalsodisruptwheel alignment,soinspecttireconditionafteranaccident.
Checkthewheelstoensurethattheyaremounted securely.T orquethelugnutsto45-65ft-lb(61-88N-m).
Figure37
1.Shockabsorber2.Collar
Thespringovercoilshockabsorbersemployacollar thatcanbeadjustedateachwheeltoachieveadesired suspensionperformanceorridefeel.Toadjustthe shockabsorbers,consultthemachine’ sServiceManual fortheproperproceduresandtoolsusedtoperform theadjustmentsorcontactyourlocalAuthorizedToro Dealerforservice.
AdjustingFrontWheelToe-In
ServiceInterval:Every100hours
Checkthefrontwheeltoe-inafterevery100operating hours,orannually,whicheveroccursrst.
Thetoe-inshouldbe0-1/4inch(0-6mm)withthe followingparameters:
Thevehicleshouldbedrivenbackandforthafew timestorelaxtheA-arms.
Measurethetoe-inwiththewheelsfacingstraight aheadanda175-225lb(79-102kg)operatorinthe driver’sseat.
Note:Thedrivershoulddriveuptothe measurementareaandstayseatedinthevehicle whilethemeasurementisbeingtaken.
1.Measurethedistancebetweenbothofthefronttires attheaxleheightatboththefrontandrearofthe fronttires(
33
Figure38).
Page 34
G009235
1
2
3
Figure38
1
2
1.Tirecenterline-back3.Axlecenterline
2.Tirecenterline-front
2.Ifthemeasurementdoesnotfallwithinthespecied range(refertothedimensionsandparametersatthe beginningofthisprocedure),loosenthejamnutsat bothendsofthetierods(Figure39).
Figure39
1.Jamnut2.Tierod
3.Rotatebothtierodstomovethefrontofthetire inwardoroutward.
Figure40
1.Cover
2.Bolts
4.Thoroughlycleantheinsideofthecoverandthe innerworkingsoftheclutchusingcompressedair.
CAUTION
Thedustintheclutchwillbecomeairborneand coulddamageyoureyesoryoucouldinhaleit causingbreathingdifculties.
Wearsafetygogglesandadustmaskorother eyeandrespiratoryprotectionwhenperforming thisprocedure.
5.Installtheclutchcoverandsecureitwiththe3bolts removedpreviously.
4.Tightenthetierodjamnutswhentheadjustmentis correct.
5.Ensurethatthereisfulltravelofthesteeringwheel inbothdirections.
MaintainingthePrimaryDrive Clutch
ServiceInterval:Every400hours
Afterevery400operatinghoursoryearly ,cleanthe clutchasfollows:
1.Stoptheengine,removethekey,andsettheparking brake.
2.Raiseandlatchthecargobox.
3.Removethe3boltssecuringthecovertotheclutch andremovethecover(
Figure40).
ChangingtheTransaxleFluid
ServiceInterval:Every800hours
Changethetransaxleuidevery800operatinghoursor yearly,whicheveroccursrst.
1.Positionthevehicleonalevelsurface,settheparking brake,turntheignitionoff,andremovethekey.
2.Removethedrainplugfromtherightsideofthe reservoir(Figure41)andlettheuidowintoa drainpan.Installandtightentheplugwhentheuid stopsdraining.
Note:Disposeoftheusedoilatacertiedrecycling center.
34
Page 35
CoolingSystem Maintenance
CleaningtheEngineCooling Areas
Figure41
1.Drainplug2.Levelindicatorhole
3.Fillthereservoir(Figure42)withapproximately 1-1/2qt.(1.4liters)ofSAE10W30motoroil oruntiltheoillevelisatthebottomofthelevel indicatorhole(
1.Oilll
4.Starttheengineandoperateittollthesystem. Rechecktheoillevelandreplenishit,ifrequired.
Figure41).
Figure42
ServiceInterval:Every100hours
Cleantherotatingscreen,coolingns,andexternal surfacesoftheengineevery100operatinghoursor moreoftenunderextremelydustyanddirtyconditions.
Important:Operatingtheenginewithablocked rotatingscreen,dirtyorpluggedcoolingns,or coolingshroudsremovedwillcauseenginedamage duetooverheating.
Important:Nevercleantheenginewith pressurizedwaterbecausewatercouldcontaminate thefuelsystem.
35
Page 36
BrakeMaintenance
InspectingtheBrakes
ServiceInterval:Every100hours
Brakesareacriticalsafetycomponentofthevehicle. Aswithallsafetycomponents,theyshouldbeclosely inspectedatregularintervalstoensureoptimum performanceandsafety .Thefollowinginspections shouldbedoneevery100hours:
Inspectthebrakeshoesforwearordamage.Ifthe lining(brakepad)thicknessislessthan1/16inch (1.6mm),thebrakeshoesshouldbereplaced.
1.Brakeuidreservoir
Figure43
2.Minimumline
Inspectthebackingplateandothercomponents forsignsofexcessivewearordeformation.Ifany deformationisfound,theappropriatecomponents mustbereplaced.
Checkthebrakeuidlevel;refertoCheckingthe BrakeFluidLevel.
CheckingtheBrakeFluid Level
ServiceInterval:Beforeeachuseordaily
Thebrakeuidreservoirislledandshippedfromthe factorywithDOT3brakeuid.Checkthelevelbefore theengineisrststartedandevery8hoursordaily, thereafter.
1.Parkthemachineonalevelsurface,settheparking brake,turntheignitionoff,andremovethekey.
2.Removetherubberpluginthecenterandontopof thedashtogainaccesstothemasterbrakecylinder andreservoir.
3.Lookatthesideofthereservoir.Thelevelshould beabovetheMinimumline( levelislow ,cleantheareaaroundthecap,remove thecap,andllthereservoirtoabovetheMinimum line.Donotoverll.
Figure43).Iftheuid
AdjustingtheParkingBrake
Checktheparkingbrakeadjustmentevery200hours.
1.Prytherubbercoveroffoftheparkingbrake.
2.Loosenthesetscrewsecuringtheknobtothe parkingbrakelever(
1.Parkingbrakelever
2.Knob
3.Rotatetheknobuntilaforceof30-35lb(133-156N) isrequiredtoactuatethelever.
4.Tightenthesetscrewandinstalltherubbercover.
Figure44).
Figure44
3.Setscrew
36
Page 37
BeltMaintenance
G011948
1
2
3
ServicingtheDriveBelt
CheckingtheDriveBelt
ServiceInterval:Aftertherst8hours
Every200hours
Checktheconditionandtensionofthedrivebeltafter therstdayofoperationandevery200operatinghours thereafter.
1.Parkthemachineonalevelsurface,shiftinto Neutral,settheparkingbrake,turntheignitionoff, andremovethekey.
2.Raisethebedandsecureitwiththeproprod.
3.Rotateandinspectthebelt( wearordamage.Replacethebeltifnecessary.
Figure45)forexcessive
Figure46
1.Primarydriveclutch housing
2.Drivebelts
3.Startergenerator6.Generatorpivotnut
4.Startergeneratorbelt
5.Generatorpivotbracket
3.Wedgeaprybarbetweentheenginemountand starter..
4.Tiltthestarterintheslotuntilthebeltexes1/4inch (6mm)with10lb(44N)offorce(
Figure46).
Figure45
1.Drivebelt
2.Primaryclutch
3.Secondaryclutch
ReplacingtheDriveBelt
1.Rotateandroutethebeltoverthesecondaryclutch (Figure45).
2.Removethebeltfromtheprimaryclutch(
3.Toreplacethebelt,reversetheprocedure.
Figure45).
5.Tightenthestartergeneratornutandremovethe prybar(Figure46).Torquethenutto65-85ft-lb (88-115N-m).
AdjustingtheStarter GeneratorBelt
ServiceInterval:Aftertherst8hours
Every200hours
1.Parkthemachineonalevelsurface,settheparking brake,turntheignitionoff,andremovethekey.
2.Loosenthestartergeneratorpivotnut(Figure46).
37
Page 38
Cleaning
WashingtheVehicle
Thevehicleshouldbewashedasneeded.Usewater aloneorwithamilddetergent.Aragmaybeused, howeverthehoodwillloosesomeofitsluster.
Important:Pressurizedwaterisnotrecommended whenwashingthemachine.Itmaydamagethe electricalsystem,loosenimportantdecals,orwash awaynecessarygreaseatfrictionpoints.Avoid excessiveuseofwater,especiallynearthecontrol panel,engine,andbattery.
Storage
1.Positionthemachineonalevelsurface,setthe parkingbrake,stoptheengine,andremovethe ignitionkey .
2.Cleandirtandgrimefromtheentiremachine, includingtheoutsideoftheengine’scylinderhead nsandblowerhousing.
Important:Youcanwashthemachinewith milddetergentandwater.Donotusehigh pressurewatertowashthemachine.Pressure washingmaydamagetheelectricalsystemor washawaynecessarygreaseatfrictionpoints. Avoidexcessiveuseofwater,especiallynearthe controlpanel,lights,engine,andthebattery.
3.Inspectthebrakes;refertoInspectingtheBrakesin theBrakeMaintenancesectioninMaintenance.
4.Servicetheaircleaner;refertoServicingtheAir CleanerintheEngineMaintenancesectionin Maintenance.
5.Greasethemachine;refertoLubricationsectionin Maintenance.
6.Changetheengineoil;refertoServicingEngineOil intheEngineMaintenancesectioninMaintenance.
7.Checkthetirepressure;refertoCheckingtheTire Pressure.
8.Forstorageover30days,preparethefuelsystem asfollows:
A.Addapetroleumbasedstabilizer/conditionerto
fuelinthetank.
Followmixinginstructionsfromstabilizer manufacturer.(1oz.pergallon).Donotusean alcoholbasedstabilizer(ethanolormethanol).
Note:Afuelstabilizer/conditionerismost effectivewhenmixedwithfreshgasolineand usedatalltimes.
B.Runtheenginetodistributeconditionedfuel
throughthefuelsystem(5minutes).
C.Stoptheengine,allowittocool,anddrainthe
fueltank.
D.Restarttheengineandrunituntilitstops.
E.Choketheengine.
F.Startandruntheengineuntilitwillnotstart
again.
G.Disposeoffuelproperly.Recycleasperlocal
codes.
38
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Important:Donotstore stabilizer/conditionedgasolineover90 days
9.Removethesparkplugsandchecktheircondition; refertoChangingSparkPlugsintheEngine MaintenancesectioninMaintenance.
10.Withthesparkplugsremovedfromtheengine,pour twotablespoonsofengineoilintothesparkplug hole.
11.Usetheelectricstartertocranktheengineand distributetheoilinsidethecylinder.
12.Installthesparkplugsandtightentorecommended torque;refertoChangingSparkPlugsintheEngine MaintenancesectioninMaintenance.
Note:Donotinstallthewireonthesparkplug(s).
13.Removethebatteryfromthechassis,checkthe electrolytelevel,andchargeitfully;refertoServicing theBatteryintheElectricalSystemMaintenance sectioninMaintenance.
Note:Donotconnectthebatterycablestothe batterypostsduringstorage.
Important:Thebatterymustbefullycharged topreventitfromfreezingandbeingdamaged attemperaturesbelow32degreesF(0degreesC). Afullychargedbatterymaintainsitschargefor about50daysattemperatureslowerthan40 degreesF(4degreesC).Ifthetemperatureswill beabove40degreesF(4degreesC),checkthe waterlevelinthebatteryandchargeitevery30 days.
14.Checkandtightenallbolts,nuts,andscrews.Repair orreplaceanypartthatisdamaged.
15.Paintallscratchedorbaremetalsurfaces.
PaintisavailablefromyourAuthorizedService Dealer.
16.Storethemachineinaclean,drygarageorstorage area.
17.Removetheignitionkeyandputitinasafeplaceout ofthereachofchildren.
18.Coverthemachinetoprotectitandkeepitclean.
39
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Schematics
Y
R
Y
PK
Y
PK
GY
W
BK
Y
W/BK
BK
BK
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BU
VIO
GN
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BN/W
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(+)(-)
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(-)
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ACTUATOR
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DPDT
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95-8999
DPDT ON-NONE-ON
5
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DBC
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RUN---- A,C&F
START---A,B&C
(114-8316)
IGNITIONSWITCH(HOBBS)
DF
I
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I
C
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2
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P
15 A 20 A
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OPTIONAL
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MODULE
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F4 F2
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F1 F3
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A
A
LEFT REAR
RIGHT REAR
PILOT
NOT USED
HEADLIGHT
LIGHTSWITCH
MAG
MAG
A1
F1
J6
J5
RPM
HORN
(OPTIONAL)
P3-E
P3-D
P3-C
P3-B
P3-A
3
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H
POWER
OPTIONAL FUSES
10 A
TURNSIGNAL SWITCH
ENGINE/FRAMEGROUND
PRESSURE
ENGINE/FRAMEGROUND
ENGINEOIL
SPARKPLUG
armature
STARTER/GENERA TOR
HORNSWITCH
P3-A
P3-C
BACKUP ALARM
BRAKE
SWITCH
HAZARDSWITCH
LEFT FRONT
TURN
ANDRUNNING
FLASHER
MODULE
BRAKESWITCH
LEFT FRONT
HEADLIGHTS
ENGINEOIL
SAMECONNECTIONFORBOTHENGINES
PRESSURE
IGNITION
MODULES
fields
NEUTRAL
P3-C
P3-B
P3-D
P3-E
P3-A
ENGINECONNECTION
P3-B
P3-E
REGULA
TOR
(PEDAL NOT PUSHEDIN)
ACCELERATOR
REARFRAME
GROUND
PRESSURE
60 AMP MAXI-FUSE
BOXLIFT
30 A
AUTO
RESETTING
RIGHT FRONT
SHUTDOWN
IGNITION
MODULE
INHARNESS
NEARMAINRELAY
OPTIONAL
REARLIFT
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(INFORWARD)
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16HP
ENGINE
KEY-STARTKIT
FRONT
FRAME
GROUND
REVERSESW .
11HP ENGINE
G009199
ElectricalSchematic(Rev.A)
40
Page 41
Notes:
41
Page 42
Notes:
42
Page 43
Notes:
43
Page 44
TheToroTotalCoverageGuarantee
ALimitedWarranty
ConditionsandProductsCovered
TheT oro toanagreementbetweenthem,jointlywarrantyourT oroCommercial product(“Product”)tobefreefromdefectsinmaterialsorworkmanship fortwoyearsor1500operationalhours*,whicheveroccursrst.This warrantyisapplicabletoallproductswiththeexceptionofAerators (refertoseparatewarrantystatementsfortheseproducts).Wherea warrantableconditionexists,wewillrepairtheProductatnocosttoyou includingdiagnostics,labor,parts,andtransportation.Thiswarranty beginsonthedatetheProductisdeliveredtotheoriginalretailpurchaser. *Productequippedwithanhourmeter.
®
Companyanditsafliate,T oroWarrantyCompany,pursuant
InstructionsforObtainingWarrantyService
YouareresponsiblefornotifyingtheCommercialProductsDistributoror AuthorizedCommercialProductsDealerfromwhomyoupurchasedthe Productassoonasyoubelieveawarrantableconditionexists.Ifyouneed helplocatingaCommercialProductsDistributororAuthorizedDealer,or ifyouhavequestionsregardingyourwarrantyrightsorresponsibilities, youmaycontactusat:
CommercialProductsServiceDepartment ToroWarrantyCompany
811 1LyndaleAvenueSouth Bloomington,MN55420-1196 E-mail:commercial.warranty@toro.com
OwnerResponsibilities
AstheProductowner,youareresponsibleforrequiredmaintenance andadjustmentsstatedinyourOperator’sManual.Failuretoperform requiredmaintenanceandadjustmentscanbegroundsfordisallowinga warrantyclaim.
ItemsandConditionsNotCovered
Notallproductfailuresormalfunctionsthatoccurduringthewarranty periodaredefectsinmaterialsorworkmanship.Thiswarrantydoesnot coverthefollowing:
Productfailureswhichresultfromtheuseofnon-T ororeplacement
parts,orfrominstallationanduseofadd-on,ormodiednon-Toro brandedaccessoriesandproducts.Aseparatewarrantymaybe providedbythemanufactureroftheseitems.
Productfailureswhichresultfromfailuretoperformrecommended
maintenanceand/oradjustments.Failuretoproperlymaintainyour ToroproductpertheRecommendedMaintenancelistedinthe Operator’sManualcanresultinclaimsforwarrantybeingdenied.
ProductfailureswhichresultfromoperatingtheProductinan
abusive,negligentorrecklessmanner.
Partssubjecttoconsumptionthroughuseunlessfoundtobe
defective.Examplesofpartswhichareconsumed,orusedup,during normalProductoperationinclude,butarenotlimitedto,brakes padsandlinings,clutchlinings,blades,reels,bedknives,tines, sparkplugs,castorwheels,tires,lters,belts,andcertainsprayer componentssuchasdiaphragms,nozzles,andcheckvalves,etc.
Failurescausedbyoutsideinuence.Itemsconsideredtobeoutside
inuenceinclude,butarenotlimitedto,weather,storagepractices, contamination,useofunapprovedcoolants,lubricants,additives, fertilizers,water,orchemicals,etc.
Normalnoise,vibration,wearandtear,anddeterioration.
Normal“wearandtear”includes,butisnotlimitedto,damageto
seatsduetowearorabrasion,wornpaintedsurfaces,scratched decalsorwindows,etc.
Parts
Partsscheduledforreplacementasrequiredmaintenancearewarranted fortheperiodoftimeuptothescheduledreplacementtimeforthatpart. Partsreplacedunderthiswarrantyarecoveredforthedurationofthe originalproductwarrantyandbecomethepropertyofT oro.Torowill makethenaldecisionwhethertorepairanyexistingpartorassemblyor replaceit.T oromayuseremanufacturedpartsforwarrantyrepairs.
NoteRegardingDeepCycleBatteryWarranty:
Deepcyclebatterieshaveaspeciedtotalnumberofkilowatt-hoursthey candeliverduringtheirlifetime.Operating,recharging,andmaintenance techniquescanextendorreducetotalbatterylife.Asthebatteriesinthis productareconsumed,theamountofusefulworkbetweencharging intervalswillslowlydecreaseuntilthebatteryiscompletelywornout. Replacementofwornoutbatteries,duetonormalconsumption,isthe responsibilityoftheproductowner.Batteryreplacementmayberequired duringthenormalproductwarrantyperiodatowner’sexpense.
MaintenanceisatOwner’sExpense
Enginetune-up,lubricationcleaningandpolishing,replacementof ItemsandConditionsNotCoveredlters,coolant,andcompleting RecommendedMaintenancearesomeofthenormalservicesT oro productsrequirethatareattheowner’sexpense.
GeneralConditions
RepairbyanAuthorizedT oroDistributororDealerisyoursoleremedy underthiswarranty.
NeitherTheToroCompanynorToroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheT oroProductscoveredbythiswarranty,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.ExceptfortheEmissionswarranty referencedbelow,ifapplicable,thereisnootherexpresswarranty.
Allimpliedwarrantiesofmerchantabilityandtnessforusearelimitedto thedurationofthisexpresswarranty.Somestatesdonotallowexclusions ofincidentalorconsequentialdamages,orlimitationsonhowlongan impliedwarrantylasts,sotheaboveexclusionsandlimitationsmaynot applytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother rightswhichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomersshouldcontacttheirT oroDistributor(Dealer)toobtainguaranteepoliciesforyourcountry,province,orstate.Ifforanyreasonyouare dissatisedwithyourDistributor’sserviceorhavedifcultyobtainingguaranteeinformation,contacttheT oroimporter.Ifallotherremediesfail,you maycontactusatT oroWarrantyCompany .
374-0277RevA
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