Toro 22331, 22332, 12004TC, 20054, 20055 Operator's Manual

...

Form No. 3355-562 Rev A

Twister® 1600 Utility Vehicle

Model No. 12004TC —Serial No. 260000001 and Up

T his spark ignition system complies with Canadian ICES-002

Introduction

T his man ual uses 2 other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . Figure 1 identiﬁes the location of the model and serial n umbers on the product. W rite the n umbers in the space pro vided.

Figure 1

1. Model and serial number location

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 2 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Figure 2

1. Safety alert symbol

Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety and Instr uctional Decals . . . . . . . . . . . . 8

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

1 Installing the W heels . . . . . . . . . . . . . . . . . . . . . . . 11

2 Installing the Steering W heel . . . . . . . . . . . 11

3 Installing the Bumper . . . . . . . . . . . . . . . . . . . . . . 12

4 Installing the Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 12

5 Installing the Hitc h . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 Installing the Carg o Bo x . . . . . . . . . . . . . . . . . . 13

7 Acti v ating the Batter y . . . . . . . . . . . . . . . . . . . . . . 14

8 Adjusting the F ront W heel

T oe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9 R eading the Man ual and Viewing

the Safety Video . . . . . . . . . . . . . . . . . 16

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

T hink Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Pre-Star ting Chec ks . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chec king the Engine Oil . . . . . . . . . . . . . . . . . . . . 21

Chec king the Brak e Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 21

Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chec king the T ransmission Oil

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Star ting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Stopping the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 23

P arking the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Operating the Carg o Bo x . . . . . . . . . . . . . . . . . . . 23

Breaking in a New V ehicle . . . . . . . . . . . . . . . . . . 24

Loading the Carg o Bo x . . . . . . . . . . . . . . . . . . . . . . 25

T ranspor ting the V ehicle . . . . . . . . . . . . . . . . . . . . 25

T o wing the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

T o wing a T railer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Premaintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . 28

Maintaining the V ehicle under

Special Operating

Conditions . . . . . . . . . . . . . . . . . . . . . . . . 28

J ac king the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Adding Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 29

Ser vicing the Engine Oil . . . . . . . . . . . . . . . . . . . . 30

Ser vicing the Spark Plugs . . . . . . . . . . . . . . . . . . . 31

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Inspecting Fuel Lines and

Connections . . . . . . . . . . . . . . . . . . . . . . 31

R e placing the Fuel Filter . . . . . . . . . . . . . . . . . . . . 31

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 32

R e placing the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

R e placing the Headlights . . . . . . . . . . . . . . . . . . . 32

Ser vicing the Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 34

Chec king and Adjusting

Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Inspecting the Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Adjusting the F ront

Suspension . . . . . . . . . . . . . . . . . . . . . . . . 35

Adjusting F ront W heel T oe-In . . . . . . . . . . . 36

Maintaining the Primar y Dri v e

Clutc h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Changing the T ransaxle Fluid . . . . . . . . . . . . . 37

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 38

Cleaning the Engine Cooling

Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Inspecting the Brak es . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chec king the Brak e Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Adjusting the P arking Brak e . . . . . . . . . . . . . . . 39

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Ser vicing the Dri v e Belt . . . . . . . . . . . . . . . . . . . . . 39

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

W ashing the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Safety

clothing or jew elr y whic h could g et caught in mo ving par ts and cause personal injur y .

Improper use or maintenance b y the operator or o wner can result in injur y . T o reduce the potential for injur y , comply with these safety instr uctions and alw a ys pa y attention to the safety aler t symbol, whic h means Caution , W ar ning , or Danger —“personal safety instr uction. ” F ailure to comply with the instr uction ma y result in personal injur y or death.

T he v ehicle is an of f-highw ay v ehicle onl y and is not designed, equipped, or man uf actur ed f or use on public str eets, r oads, or highw ays.

Before Operating

• Operate the mac hine only after reading and understanding the contents of this man ual.

• Nev er allo w c hildren to operate the v ehicle . Any one who operates the v ehicle should ha v e a motor v ehicle license .

• Nev er allo w other adults to operate the v ehicle without ﬁrst reading and understanding the Operator’ s Manual . Mak e sure that all operators are ph ysically and mentally capable of operating the v ehicle .

• T his v ehicle is designed to car r y onl y the operator and one passenger in the seat

pro vided b y the man ufacturer . Nev er car r y any other passeng ers on the v ehicle .

• Nev er operate the v ehicle when under the inﬂuence of dr ugs or alcohol. Ev en prescription dr ugs and cold medicines can cause dro wsiness .

• Do not dri v e the v ehicle when y ou are tired. Be sure to tak e occasional breaks . It is v er y impor tant that y ou sta y aler t at all times .

• Become familiar with the controls and kno w ho w to stop the engine quic kly .

• K ee p all shields , safety devices , and decals in place . If a shield, safety device , or decal is malfunctioning, illegible , or damag ed, re pair or re place it before operating the mac hine .

• Alw a ys w ear substantial shoes . Do not operate the mac hine while w earing sandals , tennis shoes , or sneak ers . Do not w ear loose ﬁtting

• W earing safety glasses and long pants is advisable .

• A v oid dri ving when it is dark, especially in unfamiliar areas . If y ou m ust dri v e when it is dark, be sure to dri v e cautiously , use the headlights , and ev en consider adding additional lights .

• Be extremely careful when operating around people . Alw a ys be a w are of where b ystanders might be .

• Before operating the v ehicle , alw a ys c hec k the designated areas of the v ehicle that are stated in the pre-star ting section of this man ual. If something is wrong, do not use the v ehicle . Mak e sure that the problem is cor rected before the v ehicle or attac hment is operated.

• Since g asoline is highly ﬂammable , handle it carefully .

– Use an appro v ed g asoline container .

– Do not remo v e the cap from the fuel tank

when the engine is hot or r unning .

– Do not smok e while handling g asoline .

– Fill the fuel tank outdoors , and ﬁll it to

about 1 inc h (25 mm) belo w the top of the tank (the bottom of the ﬁller nec k). Do not o v erﬁll it.

– Wipe up any spilled g asoline .

– Do not ﬁll fuel containers in the carg o bo x;

place fuel containers on the g round before ﬁlling .

Operation

Engine exhaust contains carbon mono xide, which is an odor less, deadl y poison that can kill y ou.

Do not r un engine indoor s or in an enclosed ar ea.

• T he operator and passeng er should remain

seated whenev er the v ehicle is in motion. T he operator should k ee p both hands on the steering wheel whenev er possible , and the passeng er should use the hand holds pro vided.

K ee p y our ar ms and legs within the v ehicle body at all times .

• Dri v e slo w er and tur n less shar ply when y ou are car r ying a passeng er . R emember y our passeng er ma y not be expecting y ou to brak e or tur n and ma y not be ready .

• Alw a ys w atc h out for and a v oid lo w o v erhangs suc h as tree limbs , door jambs , and o v er -head w alkw a ys . Mak e sure there is enough room o v er head to easily clear the v ehicle and y our head.

• Alw a ys shift into neutral and apply the parking brak e before lea ving an idling v ehicle , or else the v ehicle ma y cree p .

• F ailure to operate the v ehicle safely ma y result in an accident, tip o v er of the v ehicle , and serious injur y or death. Dri v e carefully . T o prev ent tipping or loss of control:

– Use extreme caution, reduce speed, and

maintain a safe distance around sand traps , ditc hes , creeks , ramps , unfamiliar areas , or any areas that ha v e abr upt c hang es in g round conditions or elev ation.

– W atc h for holes or other hidden hazards .

– Use extra caution when operating the

v ehicle on w et surfaces , in adv erse w eather conditions , at higher speeds , or with a full load. Stopping time and distance will increase with a full load.

– W atc h out for trafﬁc when y ou are near or

crossing roads . Alw a ys yield the right of w a y to pedestrians and other v ehicles . T his v ehicle is not designed for use on streets or highw a ys . Alw a ys signal y our tur ns or stop early enough so that other people kno w what y ou plan to do . Obey all trafﬁc r ules and regulations .

– T he electrical and exhaust systems of the

v ehicle can produce sparks capable of igniting explosi v e materials . Nev er operate the v ehicle in or near an area where there is dust or fumes in the air whic h are explosi v e .

• Do not touc h the engine or m ufﬂer while the engine is r unning or soon after it has stopped. T hese areas ma y be hot enough to cause bur ns .

• If the mac hine ev er vibrates abnor mally , stop immediately , w ait for all motion to stop , and inspect the v ehicle for damag e . R e pair all damag e before commencing operation.

• Before g etting off of the seat:

1. Stop the mo v ement of the mac hine .

2. Set the parking brak e .

3. T ur n the ignition k ey to Off .

4. R emo v e the ignition k ey .

Note: If the v ehicle is on an incline , bloc k the wheels after g etting off of the v ehicle .

– A v oid sudden stops and star ts . Do not

g o from rev erse to forw ard or forw ard to rev erse without ﬁrst coming to a complete stop .

– Slo w do wn before tur ning . Do not attempt

shar p tur ns or abr upt maneuv ers or other unsafe dri ving actions that ma y cause a loss of v ehicle control.

– W hen dumping, do not let any one stand

behind the v ehicle and do not dump the load on any one’ s feet. R elease the tailg ate latc hes from the side of the bo x, not from behind.

– Only operate the v ehicle when the carg o

bo x is do wn and latc hed.

– Before bac king up , look to the rear and

ensure that no one is behind y ou. Bac k up slo wly .

Braking

• Slo w do wn before y ou approac h an obstacle . T his gi v es y ou extra time to stop or tur n a w a y . Hitting an obstacle can damag e the v ehicle and its contents . More impor tant, it can injure y ou and y our passeng er .

• Gross V ehicle W eight (GVW) has a major impact on y our ability to stop and/or tur n. Hea vy loads and attac hments mak e a v ehicle harder to stop or tur n. T he hea vier the load, the long er it tak es to stop .

• Decrease the v ehicle speed if the carg o bo x has been remo v ed and there is no attac hment on the v ehicle . T he braking c haracteristics c hang e and fast stops ma y cause the rear wheels to loc k up , whic h ma y affect the control of the v ehicle .

• T urf and pa v ement are m uc h more slipper y when they are w et. It can tak e 2 to 4 times

as long to stop on w et surfaces as on dr y surfaces . If y ou dri v e through standing w ater dee p enough to g et the brak es w et, they will not w ork w ell until they are dr y . After dri ving through w ater , y ou should test the brak es to mak e sure they w ork properly . If they do not, dri v e slo wly while putting light pressure on the brak e pedal. T his will dr y the brak es out.

• A v oid stopping on hills , especially with a load. Stopping while g oing do wn a hill will tak e long er than stopping on lev el g round. If the v ehicle m ust be stopped, a v oid sudden speed c hang es , whic h ma y initiate tipping or rolling of the v ehicle . Do not slam on the brak es when rolling bac kw ard, as this ma y cause the v ehicle to o v er tur n.

Operating on Hills

Operating the v ehicle on a hill may cause tipping or r olling of the v ehicle, or the engine may stall and y ou could lose head w ay on the hill. T his could r esult in per sonal injur y .

• Do not accelerate quickl y or slam on the brak es when backing do wn a hill, especiall y with a load.

• If the engine stalls or y ou lose head w ay on a hill, slo wl y back straight do wn the hill. Nev er attempt to tur n the v ehicle ar ound.

• Operate the v ehicle slo wl y on a hill and use caution.

• A v oid tur ning on a hill.

• R educe y our load and the speed of the v ehicle.

• A v oid stopping on hills, especiall y with a load.

• W e strongly recommend installing the optional

R OPS Kit when operating on hilly ter rain.

Operating on Rough Terrain

R educe speed and load when operating on rough ter rain, unev en g round, and near curbs , holes , and other sudden c hang es in ter rain. Loads ma y shift, causing the v ehicle to become unstable .

W e strongly recommend installing the optional R OPS Kit when operating on rough ter rain.

Sudden changes in ter rain may cause a br upt steering wheel mo v ement, possibl y r esulting in hand and ar m injuries.

• R educe y our speed when operating on r ough ter rain and near curbs.

• Grip the steering wheel loosel y ar ound the perimeter . K eep y our hands clear of the steering wheel spok es.

Loading and Dumping

T hese extra cautions need to be tak en when operating the v ehicle on a hill:

• Slo w do wn before star ting up or do wn a hill.

• If the engine stalls or y ou begin to lose headw a y

while climbing a hill, g radually apply the brak es and slo wly bac k straight do wn the hill.

• T ur ning while tra v eling up or do wn hills can be dang erous . If y ou ha v e to tur n while on a hill, do it slo wly and cautiously . Nev er mak e shar p or fast tur ns .

• Hea vy loads affect stability . R educe the w eight of the load and y our speed when operating on hills or if the load has a high center of g ra vity . Secure the load to prev ent it from shifting and tak e extra care when hauling loads that shift easily (liquid, roc k, sand, etc .).

T he w eight and position of the carg o and passeng er can c hang e the v ehicle center of g ra vity and v ehicle handling . T o a v oid loss of control and personal injur y , follo w these guidelines:

• Do not car r y loads whic h ex ceed the load limits described on the v ehicle w eight label; refer to Speciﬁcations in Product Ov er view , pag e 17 , for v ehicle w eight limits . T he load rating is for lev el surf aces onl y .

• R educe the w eight of the load when operating on hills and rough ter rain to a v oid tipping or o v er tur ning of the v ehicle .

• R educe the w eight of the load if the center of g ra vity is high. Items suc h as bric ks , fer tilizer , or landscape timbers stac k higher in the bo x. T he higher a load is stac k ed, the more lik ely

the v ehicle is to tip o v er . Distribute the load as lo w as possible , making sure that the load does not affect rear visibility .

• P osition the w eight of the load ev enly from side to side . If y ou position the load to w ard one of the sides , the v ehicle is more lik ely to tip o v er while tur ning .

• T he rear carg o space is intended for load car r ying pur poses only , not for passeng ers .

• Nev er o v erload y our v ehicle . T he decal (located on the rear frame) sho ws load limits for the v ehicle . Nev er o v erload the attac hments or ex ceed the Gross V ehicle W eight (GVW).

• P osition the w eight of a load ev enly from front to bac k. If y ou position the load behind the rear axle , it will reduce the w eight on the front wheels . T his ma y result in a loss of steering control or cause the v ehicle to tip o v er on hills or bumpy ter rain.

• Use extra caution if the load ex ceeds the dimensions of the bo x and when handling off-center loads that cannot be centered. K ee p loads balanced and secure to prev ent them from shifting .

• Alw a ys secure loads so that they do not shift. If a load is not secured, or y ou are transpor ting a liquid in a larg e container suc h as a spra yer , the load can shift. T his shifting happens most often while tur ning, g oing up or do wn hills , suddenly c hanging speeds , or while dri ving o v er rough surfaces . Shifting loads can cause the v ehicle to tip o v er .

T he w eight of the bo x may be hea vy . Hands or other body par ts could be cr ushed.

– K eep hands and other body par ts

clear when lo w ering the bo x.

– Do not dump materials on bystander s.

• Nev er dump a loaded carg o bo x while the

v ehicle is sidew a ys on a hill. T he c hang e in w eight distribution ma y cause the v ehicle to o v er tur n.

• W hen operating with a hea vy load in the carg o bo x, reduce y our speed and allo w for sufﬁcient braking distance . Do not suddenly apply the brak es . Use extra caution on slopes .

Maintenance

• Before ser vicing or making adjustments to the mac hine , stop the engine , set the parking brak e , and remo v e the k ey from the ignition to prev ent someone from accidentally star ting the engine .

• T o mak e sure that the entire mac hine is in g ood condition, k ee p all n uts , bolts , and screws properly tightened.

• T o reduce the potential for ﬁre , k ee p the engine area free of ex cessi v e g rease , g rass , lea v es , and accum ulation of dir t.

• Nev er use an open ﬂame to c hec k the lev el or leakag e of fuel or batter y electrolyte .

• If the engine m ust be r unning to perfor m a maintenance adjustment, k ee p y our hands , feet, clothing, and any par ts of y our body a w a y from the engine and any mo ving par ts . K ee p ev er y one a w a y .

• Do not use open pans of fuel or ﬂammable cleaning ﬂuids for cleaning par ts .

• If major re pairs are ev er needed or assistance is required, contact an A uthorized T oro Distributor .

• T o be sure of optim um perfor mance and safety , alw a ys purc hase g en uine T oro re placement par ts and accessories . R e placement par ts and accessories made b y other man ufacturers could be dang erous . Altering this v ehicle in any manner that ma y affect v ehicle operation, perfor mance , durability , or its use , ma y result in injur y or death. Suc h use could v oid the product w ar ranty .

• Be a w are that hea vy loads increase y our stopping distance and reduce y our ability to tur n quic kly without tipping o v er .

Sound Pressure

T his unit has a maxim um sound pressure lev el at the operator’ s ear of 80 dB A, based on measurements of identical mac hines per EN

11094.

Vibration

T his unit does not ex ceed a hand/ar m vibration lev el of 2.5 m/s identical mac hines per EN 1033.

, based on measurements of

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

T his unit does not ex ceed a whole body vibration lev el of 0.5 m/s

, based on measurements of

identical mac hines per EN 1032.

Safety and Instructional Decals

107–0704

1. Warning—read the Operator’s Manual.

2. Collision hazard—do not operate the vehicle on public streets, roads, or highways.

3. Falling hazard—do not carry passengers in the cargo bed.

4. Falling hazard—do not allow children to operate the vehicle. 10. To stop the engine, release the accelerator pedal, set the

5. Hour meter

6. Headlights

104–6581

1. Warning—read the Operator’s Manual .

2. Fire hazard—before fueling, stop the engine.

3. Tipping hazard—receive training before operating the machine, use caution and drive slowly while on slopes; drive slowly when turning, keep the vehicle speed under 19 MPH (31 km/h) when carrying a full or heavy load and when driving on rough terrain .

4. Falling and arm/leg injury hazards—do not carry passengers in the cargo bed and keep arms and legs inside of the vehicle at all times.

7. Ignition—Off

8. Ignition—On

9. To start the engine, sit on the operator’s seat, put the gear selector in Neutral, turn the ignition key on, pull the choke lever out (if needed), and press the accelerator pedal.

parking brake, turn the ignition key off, and remove the ignition key.

11. Electrical power (power point)

12. Horn

99–7345

1. Warning—read the Operator’s Manual .

2. Hot surface/burn hazard—stay a safe distance from the hot surface.

3. Entanglement hazard, belt—stay away from moving parts

4. Crushing hazard, cargo box—use the prop rod to support the cargo bed

99–7952

1. Choke 3. Neutral

2. Reverse

4. Forward

99–7350

1. Maximum tongue weight is 50 lb (23 kg); maximum trailer weight is 400 lb (181 kg).

104–6592

1. Read the Operator’s Manual.

2. The maximum combined operator and passenger weight is 400 lb (181 kg).

3. The maximum cargo weight is 1200 lb (544 kg).

4. The base weight of the vehicle is 1100 lb (500 kg).

5. The maximum gross vehicle weight is 2700 lb (1225 kg).

99–7954

1. Warning—read the Operator’s Manual .

2. Falling hazard—do not carry passengers in the cargo bed.

3. Explosion hazard, static discharge into fuel container—do not ll fuel containers in the cargo bed; place fuel containers on the ground before lling.

99–7958

1. Read the Operator’s Manual for information on fuses.

2. 10 amp. fuse for the optional Road Light Kit

3. 15 amp. fuse for the optional Rear Lift Kit

4. 10 amp. fuse-open 8. 25 amp. fuse for the charge

5. 15 amp. fuse for the optional Electric Bed Lift Kit

6. 10 amp. fuse for the low oil light and the hour meter

7. 10 amp. fuse for the headlights

circuit

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Step

1 2 3 4 5

7 8

Wheel assembly

Steering wheel

Bumper 1

Seat 2

Hitch

Cargo box Right-hand pivot bracket Left-hand pivot bracket Flange head screw (3/8 x 1 inch) Bolt (5/16 x 3/4 inch) Flange nut (5/16 inch)

No parts required

Operator’s Manual Engine Operator’s Manual Parts Catalog Safety Video Registration Card Predelivery Inspection Form Key 2

Description

Qty.

1 1 1 4 1 1

–

1 1 1 1 1 1

Install the wheels.

Install the steering wheel.

Install the bumper.

Install the seats.

Install the hitch.

Install the cargo box.

Activate the battery.

Adjust the front wheel toe-in.

Read the Operator’s Manual and watch the video before operating the machine.

Use

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Step

Installing the Wheels

Parts needed for this step:

Wheel assembly

Procedure

1. R emo v e the fasteners securing the wheels .

2. R emo v e the shipping brac k et secured to the wheel studs .

3. Mount the wheels with the previously remo v ed fasteners ( Figure 3 ) and tor que to 45-65 ft-lb (61-88 N ⋅ m).

Installing the Steering Wheel

Parts needed for this step:

Steering wheel

Procedure

1. R emo v e the n ut and loc k w asher from the steering shaft.

2. Slide the steering wheel and w asher onto the shaft. P osition the steering wheel on the shaft so that the cross beam is horizontal when the tires are pointed straight ahead and the thic k er spok e of the steering wheel is do wnw ard.

3. Secure the steering wheel to the shaft with the n ut ( Figure 4 ).

1. Wheel assembly

2. Wheel nut

Figure 3

3. Wheel stud (rear wheel hub shown)

Figure 4

1. Steering wheel 3. Washer

2. Nut

4. Foam seal

Step

Installing the Bumper

Parts needed for this step:

1 Bumper

Procedure

1. R emo v e the 4 bolts and loc k n uts secured to the front of the frame .

2. Align the mounting holes and secure the bumper to the frame with the fasteners previously remo v ed ( Figure 5 ).

Installing the Seats

Parts needed for this step:

2 Seat

Procedure

Inser t the seat brac k et into the seat base opening and pi v ot the seat do wnw ard ( Figure 6 ).

Figure 5

1. Bumper

2. Bolt 4. Lock nut

3. Frame

Figure 6

1. Seat bracket 2. Seat base

Step

Installing the Hitch

Parts needed for this step:

Hitch

Procedure

1. R emo v e the 4 bolts and n uts from the inside rear of the frame .

2. Align the hitc h with the mounting holes on the frame . Secure the hitc h with the screws and n uts ( Figure 7 ).

Installing the Cargo Box

Parts needed for this step:

Cargo box

Right-hand pivot bracket

Left-hand pivot bracket

Flange head screw (3/8 x 1 inch)

Bolt (5/16 x 3/4 inch)

Flange nut (5/16 inch)

Procedure

1. P osition the carg o bo x onto the frame . T he carg o bo x m ust la y ﬂat and be centered.

2. Mount the left hand pi v ot brac k et to the left rear cor ner of the frame with 2 ﬂang e head screws (3/8 x 1 inc h). P osition the brac k et as sho wn in Figure 8 .

Figure 7

1. Hitch

Figure 8

1. Pivot bracket

3. Slide the carg o bo x mounting hole onto the pi v ot brac k et ( Figure 9 ).

Figure 9

1. Cargo box 3. Cargo box mounting hole

2. Pivot bracket

4. Inser t the right hand pi v ot brac k et into the mounting hole in the carg o bo x and then mount it to the frame .

5. Ha v e another person help to raise the carg o bo x.

6. Loosen the bolt securing the prop rod clip to the frame until y ou can slide the J-hook end of the prop rod under the clip ( Figure 10 ).

Step

Activating the Battery

No Parts Required

Procedure

None Note: T his procedure is only needed for Model

No . 07277TC .

If the batter y is not ﬁlled with electrolyte or acti v ated, it m ust be remo v ed from the v ehicle , ﬁlled with electrolyte , and c harg ed. Bulk electrolyte with 1.260 speciﬁc g ra vity m ust be purc hased from a local batter y supply outlet.

1. R emo v e the batter y hold-do wn and lift the batter y out of the batter y base .

Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

Figure 10

1. Prop rod

2. Prop rod clip

7. Tighten the bolt and secure the other side of the clip with a new bolt (5/16 x 3/4 inc h) and ﬂang e n ut (5/16 inc h) ( Figure 10 ).

8. Lo w er the carg o bo x.

3. Bolt (5/16 x 3/4 inch)

4. Flange nut (5/16 inch)

• Do not drink electr ol yte or allo w it to contact y our skin, ey es or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

• Fill the batter y wher e clean w ater is al w ays a v aila ble f or ﬂushing the skin.

2. R emo v e the ﬁller caps from the batter y and slo wly ﬁll eac h cell until electrolyte is just abo v e the plates .

3. R e place the ﬁller caps and connect a 3 to 4 amp . batter y c harg er to the batter y posts . Charg e the batter y at a rate of 3 to 4 amperes for 4 to 8 hours (12 v olts). Do not o v erc harg e the batter y .

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