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

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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 .

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om batter y .

4. W hen the batter y is c harg ed, disconnect the c harg er from the electrical outlet and batter y posts .

5. R emo v e the ﬁller caps . Slo wly add electrolyte to eac h cell until electrolyte is up to the ﬁll line . Install the ﬁller caps .

Important: Do not o v erﬁll the batter y . Electr ol yte will o v erﬂo w onto other par ts of the v ehicle and sev er e cor r osion and deterioration will r esult.

6. Install the batter y; refer to Installing the Batter y , Electrical System Maintenance , pag e 32 .

If the v ehicle will be r un with medium to hea vy loads most of the time , set the toe-in on the high side of the recommended amount. If it is g oing to be r un with a light load most of the time , set the toe-in on the lo w side of the recommended amount.

1. Measure the distance betw een both of the front tires at the axle height at both the front and rear of the front tires ( Figure 11 ). A ﬁxture or alignment g aug e is needed for the rear measurement of the front tires at axle height. Use the same ﬁxture or alignment g aug e to accurately measure the front of the front tires at axle height ( Figure 11 ).

Step

Adjusting the Front Wheel Toe-in

No Parts Required

Procedure

T he toe-in should be 1/8-5/8 inc h (3-16 mm) with the follo wing parameters:

• T he tire pressure should be at 12 psi (83 kP a).

• T he ride height should be cor rect before

setting the toe-in; refer to the Adjusting the F ront Suspension procedure in Maintenance , pag e 27 .

• T he v ehicle should be dri v en bac k and for th a few times to relax the A-ar ms .

Figure 11

1. Tire center line-back

2. Tire center line-front 5. Axle center line distance

3. Axle center line

2. If the measurement does not fall within the speciﬁed rang e (refer to the dimensions and parameters at the beginning of this procedure), loosen the jam n uts at both ends of the tie rods ( Figure 45 ).

4. Fixture

6. 6 inches (15 cm) ruler

• Measure the toe-in with the wheels facing straight ahead and a 175-225 lb (79-102 kg) operator in the dri v er’ s seat.

Note: T he dri v er should dri v e up to the measurement area and sta y seated in the v ehicle while the measurement is being tak en.

Figure 12

1. Jam nut

2. Tie rod

3. R otate both tie rods to mo v e the front of the tire inw ard or outw ard.

4. Tighten the tie rod jam n uts when the adjustment is cor rect.

5. Ensure that there is full tra v el of the steering wheel in both directions .

Step

Reading the Manual and Viewing the Safety Video

Parts needed for this step:

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Safety Video

Registration Card

Predelivery Inspection Form

2 Key

Procedure

• R ead the Operator’ s Manual and Engine Operator’ s Manual .

• View the safety video .

• Fill out the registration card.

• Complete the Pr edeli ver y Inspection F or m and ﬁle

it in y our customer histor y por tfolio .

Product Overview

Figure 13

1. Steering wheel 3. Parking brake 5. Cargo box 7. Cargo box release lever

2. Gear shift selector 4. Fuel cap

6. Towing tounge

Controls

Accelerator Pedal

T he accelerator pedal ( Figure 14 ) gi v es the operator the ability to v ar y g round speed of the v ehicle . Pressing the pedal increases g round speed. R eleasing the pedal will slo w the v ehicle . Maxim um forw ard speed is 18 mph (26 km/h).

Figure 14

1. Accelerator pedal 2. Brake pedal

Brake Pedal

T he brak e pedal is used to stop or slo w the v ehicle ( Figure 14 ).

Brak es can become w or n or can be misadjusted r esulting in per sonal injur y .

If brak e pedal tra v els to within 1 inch (25 mm) of the v ehicle ﬂoor board, the brak es must be adjusted or r epair ed.

Parking Brake

T he parking brak e is betw een the seats ( Figure 15 ). W henev er the engine is shut off , the parking brak e m ust be eng ag ed to prev ent accidental mo v ement of the v ehicle . T o eng ag e the parking brak e , pull bac k on the lev er . T o diseng ag e , push the lev er forw ard. If the v ehicle is park ed on a stee p g rade , mak e sure that the parking brak e is applied. Place bloc ks at the do wnhill side of the wheels .

Figure 15

1. Parking brake lever

Choke Control

T he c hok e control is located belo w and to the right of the operator’ s seat. T o star t a cold engine , pull the c hok e control outw ard ( Figure 16 ). After the engine star ts , regulate the c hok e to k ee p the engine r unning smoothly . As soon as possible , push the control in to the Off position. A w ar m engine requires little or no c hoking .

to star t the engine . W hen the engine star ts , release the k ey . W hen the v ehicle is stopped, rotate the k ey countercloc kwise to the Off position to stop the engine . R emo v e the k ey from the ignition.

Figure 17

1. Ignition switch 4. Oil light

2. Hour meter

3. Light switch

5. Power Point

6. Horn Button

Hour Meter

Figure 16

1. Choke 2. Gear shift selector

Gear Shift Selector

T he g ear shift selector has three positions: F orw ard, R ev erse , and Neutral ( Figure 16 ). T he g ear shift selector m ust be in Neutral to star t the engine .

Note: If the g ear shift selector is in R ev erse when the ignition is tur ned on, a buzzer will sound to w ar n the operator .

Important: Al w ays stop the v ehicle bef or e changing gear s.

Ignition Switch

T he ignition switc h ( Figure 17 ), used to star t and stop the engine , has three positions: On, Off , and Star t. R otate the k ey cloc kwise to the Star t position

T he hour meter ( Figure 17 ) indicates the total n umber of hours the engine has r un.

Oil Light

T he oil light w ar ns the operator if the engine oil lev el drops belo w a safe lev el ( Figure 17 ). If the light comes on and remains lit, the oil lev el should be c hec k ed and oil added if necessar y; refer to Chec king the Engine Oil in Operation , pag e 21 .

Note: T he oil light ma y ﬂic k er . T his is nor mal and no action needs to be tak en.

Light Switch

T og gle the switc h to acti v ate the headlights . Push to tur n the lights on ( Figure 17 ).

Power Point

Use the po w er point to po w er 12 v olt optional electrical accessories ( Figure 17 ).

Horn Button

Press the hor n button to sound the hor n ( Figure 17 ).

Fuel Gauge

T he fuel g aug e ( Figure 18 ) sho ws the amount of fuel in the tank.

Figure 18

1. Fuel gauge

Passenger Hand Holds

T he passeng er hand holds are located on the right side of the dash panel and at the outside of eac h seat ( Figure 19 ).

Figure 19

1. Passenger hand hold

2. Hip restraint

Specications

Note: Speciﬁcations and design are subject to c hang e without notice .

Base weight Rated capacity (on level ground) 1600 lb (726 kg) total, including 200 lb (90.7 kg) operator and 200 lb (90.7 kg)

Maximum gross vehicle weight (GVW) (on level ground)

Maximum cargo capacity (on level ground)

Tow capacity: Standard Hitch Heavy Duty Hitch Overall width Overall length Ground clearance

Wheel base Wheel tread (center line to center

line) Cargo box length Cargo box width Cargo box height

Dry 1050 lb (476 kg)

passenger, load, trailer tongue weight, gross trailer weight, accessories, and attachments

2700 lb (1225 kg) total, including all of the weights listed above

1200 lb (544 kg) total, including trailer tongue weight and gross trailer weight

Tongue weight 50 lb (23 kg) Maximum trailer weight 400 lb (182 kg) Tongue weight 100 lb (45 kg) Maximum trailer weight 800 lb (363 kg) 59 inches (150 cm) 115 inches (292 cm) 9-1/4 inches (23.5 cm) at the front with no load or operator, 7 inches (18 cm) at

the rear with no load or operator 79 inches (200.7 cm) 49 inches (124.5 cm) in the front, 48-1/4 inches (122.6 cm) in the rear

46 inches (116.8 cm) inside, 51 inches (129.5 cm) outside 49 inches (124.5 cm) inside, 54 inches (137.2 cm) outside 10 inches (25.4 cm) inside

Attachments/Accessories

A selection of T oro appro v ed attac hments and accessories are a v ailable for use with the mac hine to enhance and expand its capabilities . Contact y our A uthorized Ser vice Dealer or Distributor or g o to www .T oro .com for a list of all appro v ed attac hments and accessories .

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Think Safety First

Please carefully read all of the safety instr uctions and decals in the safety section. Kno wing this infor mation could help y ou or b ystanders a v oid injur y .

Figure 20

1. Oil dipstick

Pre-Starting Checks

Chec k the follo wing items eac h time y ou begin using the v ehicle for the da y:

• Chec k the tire pressure .

Note: T hese tires are different than car tires; they require less pressure to minimize turf compaction and damag e .

• Chec k all ﬂuid lev els and add the appropriate amount of speciﬁed ﬂuids , if any are found to be lo w .

• Chec k the brak e pedal operation.

• Ensure that the lights are w orking .

• T ur n the steering wheel to the left and right to

c hec k steering response .

• Chec k for oil leaks , loose par ts , and any other noticeable malfunctions . Mak e sure the engine is off and all mo ving par ts ha v e stopped before c hec king for oil leaks , loose par ts , and other malfunctions .

3. R emo v e the oil dipstic k and wipe the end clean.

4. Slide the oil dipstic k into the ﬁller tube fully seating it. Pull the dipstic k out and look at the end.

If the oil lev el is lo w , remo v e the ﬁller cap and add oil of the proper type to raise the lev el to , but not o v er , the Full mark on the dipstic k. R efer to Ser vicing the Engine Oil in Engine Maintenance , pag e 29 , for the proper oil type and viscosity . Add the oil slo wly and c hec k the lev el often during this process . Do not o v erﬁll .

5. Install the oil dipstic k ﬁr mly in place .

Checking the Brake Fluid Level

Chec k the brak e ﬂuid lev el before the engine is ﬁrst star ted; refer to Chec king the Brak e Fluid Lev el in Brak e Maintenance , pag e 38 .

If any of the abo v e items are not cor rect and y ou are not able to cor rect the problem, contact y our A uthorized Ser vice Dealer .

Checking the Engine Oil

Note: T he engine is shipped with oil in the

crankcase; ho w ev er , the lev el of the oil m ust be c hec k ed before and after the engine is ﬁrst star ted.

Chec k the engine oil lev el before star ting the engine eac h da y .

1. P osition the mac hine on a lev el surface .

2. Clean around the oil dipstic k ( Figure 20 ) so dir t cannot fall into the hole and damag e the engine .

Checking the Tire Pressure

Chec k the tire pressure ev er y 8 hours or daily to ensure proper lev els .

T he air pressure rang e in the front and rear tires is 8–22 psi (55–103 kP a).

T he air pressure needed is deter mined b y the pa yload car ried. T he lo w er the air pressure , the less the compaction, smoother the ride , and tire marks are minimized. Lo w er pressure should not be used for hea vy pa yloads at high speeds .

Higher pressures should be used for hea vier pa yloads at higher speeds . Do not ex ceed the maxim um pressure .

Adding Fuel

Use fresh, clean, unleaded regular g asoline suitable for automoti v e use (87 pump octane minim um). Leaded g asoline ma y be used if unleaded regular is not a v ailable .

Important: Nev er use gasoline containing methanol, gasoline containing mor e than 10% ethanol, gasoline additi v es, or white gas because engine fuel system dama ge could r esult.

In cer tain conditions, gasoline is extr emel y ﬂamma ble and highl y explosi v e. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Fill the fuel tank outdoor s, in an open ar ea, when the engine is cold. W ipe up an y gasoline that spills.

• Nev er ﬁll the fuel tank inside an enclosed trailer .

• Do not ﬁll the fuel tank completel y full. Add gasoline to the fuel tank until the lev el is 1/4 to 1/2 inch (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws gasoline to expand.

In cer tain conditions during fueling , static electricity can be r eleased causing a spar k which can ignite the gasoline v apor s. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Al w ays place gasoline container s on the g r ound a w ay fr om y our v ehicle bef or e ﬁlling .

• Do not ﬁll gasoline container s inside a v ehicle or on a tr uck or trailer bed because interior car pets or plastic tr uck bed liner s may insulate the container and slo w the loss of an y static charge.

• W hen practical, r emo v e gas-po w er ed equipment fr om the tr uck or trailer and r efuel the equipment with its wheels on the g r ound.

• If this is not possible, then r efuel such equipment on a tr uck or trailer fr om a por ta ble container , rather than fr om a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, k eep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

• Nev er smok e when handling gasoline, and stay a w ay fr om an open ﬂame or wher e gasoline fumes may be ignited by a spar k.

• Stor e gasoline in an appr o v ed container and k eep it out of the r each of childr en. Nev er buy mor e than a 30-day suppl y of gasoline.

• Do not operate without entir e exhaust system in place and in pr oper w or king condition.

Filling the Fuel Tank

T he fuel tank capacity is appro ximately 7 g allons (26.5 l).

1. Shut the engine off and set the parking brak e .

2. Clean the area around the fuel tank cap ( Figure 21 ).

Figure 21

1. Fuel tank cap

3. R emo v e the fuel tank cap .

4. Fill the tank to about 1 inc h (25 mm) belo w the top of tank, (bottom of the ﬁller nec k). T his

space in the tank allo ws g asoline to expand. Do not o v erﬁll .

5. Install the fuel tank cap securely . Wipe up any fuel that ma y ha v e spilled.

Checking the Transmission

Stopping the Vehicle

T o stop the v ehicle , remo v e y our foot from the accelerator pedal and slo wly press the brak e pedal.

Note: Stopping distance ma y v ar y de pending on the v ehicle load and speed.

Oil Level

T he transaxle ﬂuid lev el should be at the bottom of the lev el indicator hole ( Figure 22 ). If it is not, ﬁll the reser v oir with the appropriate ﬂuid; refer to Changing the T ransaxle Fluid in Dri v e System Maintenance , pag e 34 .

Figure 22

1. Level indicator hole

Starting the Engine

Important: Do not attempt to push or to w

the v ehicle to get it star ted.

Parking the Vehicle

1. Eng ag e the parking brak e and rotate the ignition k ey to Off .

2. R emo v e the k ey from the ignition switc h to prev ent accidental star ting .

Operating the Cargo Box

Raising the Box

Dri ving the v ehicle with the cargo bo x raised may cause the v ehicle to tip or r oll easier . T he bo x str uctur e may become dama ged if y ou operate the v ehicle with the bo x raised.

• Onl y operate the v ehicle when the cargo bo x is do wn.

• After dumping a load, lo w er the cargo bo x.

1. Sit in the operator’ s seat.

2. Put the g ear shift selector in Neutral.

Note: T he engine will only star t in Neutral.

3. Inser t the k ey into the ignition switc h, tur n it to the Star t position, and pull the c hok e out. W hen the engine star ts , release the k ey .

Note: An engine that has been r unning and is w ar m ma y not require pulling the c hok e out.

4. After the engine star ts and w ar ms up , slo wly push the c hok e in to the Off position. If the engine stalls or hesitates , pull the c hok e out for a few more seconds before pushing it to Off .

5. R elease the parking brak e .

6. Mo v e the g ear shift selector to the desired position.

7. T o dri v e the v ehicle , mo v e the g ear shift selector to the desired position and slo wly ste p on the accelerator pedal.

1. Lift the lev er on either side of the bo x and lift the bo x up ( Figure 23 ).

Figure 23

1. Lever

2. Pull the prop rod into the detent slot, securing the bo x ( Figure 24 ).

2. T ur n the latc h post cloc kwise until it is sn ug ag ainst the latc h and then tighten the n ut ( Figure 25 ).

3. R e peat this procedure for the latc h on the other side of the v ehicle .

Operating the Tailgate Latches

Figure 24

1. Prop rod

Lowering the Box

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.

Pull the prop rod out of the detent slot and lo w er the bo x until it latc hes into place .

Adjusting the Box Latches

If the bo x latc h does not latc h tightly , vibrating up and do wn as y ou dri v e the v ehicle , y ou can adjust the latc h posts to mak e the latc hes ﬁt sn ugly .

1. Loosen the n ut on the end of the latc h post ( Figure 25 ).

1. T o open the tailg ate latc hes , lift the latc h handles up ( Figure 26 ). T he latc hes will spring out to w ard the center of the tailg ate . Slo wly lo w er the tailg ate .

Note: Y ou ma y need to push the end of the tailg ate in (especially if there is a load ag ainst the tailg ate) before the latc hes will spring to w ard the center of the tailg ate and release .

Figure 26

1. Tailgate latch

2. T o close the tailg ate latc hes , lift the handles upw ard and slide them to w ard the outside of the v ehicle .

3. Push the latc h handles do wnw ard to secure the latc h and tailg ate .

Figure 25

1. Latch 3. Latch post

2. Nut

Breaking in a New Vehicle

T o pro vide proper perfor mance and long v ehicle life , follo w these guidelines for the ﬁrst 100 operating hours:

• Chec k the ﬂuid and engine oil lev els regularly and be aler t for indications of o v erheating in any component of the v ehicle .

• After star ting a cold engine , let it w ar m up for about 15 seconds before accelerating .

• A v oid hard braking situations for the ﬁrst sev eral hours of new v ehicle break-in operation. New brak e linings ma y not be at optim um perfor mance until sev eral hours of use has caused the brak es to become bur nished (brok en-in).

• V ar y the v ehicle speed during operation. A v oid fast star ts and quic k stops .

• A break-in oil for engine is not required. Original engine oil is the same type speciﬁed for regular oil c hang es .

• R efer to the Maintenance section for any special lo w hour c hec ks .

• Chec k the front suspension positioning and adjust it if necessar y; refer to Adjusting the F ront Suspension in Dri v e System Maintenance , pag e 34 .

Loading the Cargo Box

Loose seats may f all of f of the v ehicle and trailer when transpor ting and land on another v ehicle or become an obstr uction on the r oad.

R emo v e the seats or mak e sur e that the seats ar e secur el y f astened in the detents.

T he capacity of the carg o bo x is 13 ft

(0.37 m T he amount (v olume) of material that can be placed in the bo x without ex ceeding the v ehicle load ratings can v ar y g reatly de pending on the density of the material. F or example , a lev el bo x of w et sand w eighs 1500 lb (680 kg), whic h ex ceeds the load rating b y 300 lb (136 kg). But a lev el bo x of w ood w eighs 650 lb (295 kg), whic h is under the load rating .

See the table belo w for load v olume limits with v arious materials:

Material Max. cargo box capacity

Gravel, dry Gravel, wet Sand, dry 3/4 full Sand, wet 1/2 full Wood Full Bark Full Earth, packed

(on level ground)

3/4 full (approx.) 1/2 full (approx.)

3/4 full (approx.)

Figure 27

1. Tie down points

Towing the Vehicle

In case of an emerg ency , the v ehicle can be to w ed for a shor t distance . Ho w ev er , w e do not recommend this as a standard procedure .

T o wing at ex cessi v e speeds could cause a loss of steering contr ol, r esulting in per sonal injur y .

Nev er to w the v ehicle f aster than 5 mph (8 km/h).

Transporting the Vehicle

F or mo ving the v ehicle long distances , a trailer should be used. Mak e sure that the v ehicle is secured to the trailer . R efer to Figure 27 and Figure 28 for the location of the tie-do wn points .

T o wing the v ehicle is a tw o person job . If the mac hine m ust be mo v ed a considerable distance , transpor t it on a tr uc k or trailer; refer to T ranspor ting the V ehicle .

1. R emo v e the dri v e belt; refer to R e placing the Dri v e Belt in Belt Maintenance , pag e 39 .

2. Afﬁx a to w line to the tongue on the front of the frame ( Figure 28 ).

3. Put the v ehicle in neutral and release the parking brak e .

Figure 28

1. Towing tongue and tie down point

Towing a Trailer

T he v ehicle is capable of pulling trailers . T w o types of to w hitc hes are a v ailable for the v ehicle , de pending on y our application. Contact y our A uthorized T oro Distributor for details .

W hen hauling carg o or to wing a trailer , do not o v erload y our v ehicle or trailer . Ov erloading can cause poor perfor mance or damag e to the brak es , axle , engine , transaxle , steering, suspension, body str ucture , or tires . Alw a ys load a trailer with 60% of the carg o w eight in the front of the trailer . T his places appro ximately 10% of the Gross T railer W eight (GTW) on the to w hitc h of the v ehicle .

T he maxim um carg o load shall not ex ceed 1200 lb (544 kg), including the GTW and tongue w eight. F or example , if the GTW = 400 lb (181.5 kg) and tongue w eight = 50 lb (23 kg), then the maxim um carg o load = 750 lb (340 kg)

T o pro vide adequate braking and traction, alw a ys load the carg o bo x when trailering . Do not ex ceed the GTW limits .

A v oid parking a v ehicle with a trailer on a hill. If y ou m ust park on a hill, eng ag e the parking brak e and bloc k the trailer tires .

Maintenance

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst 8 operating

hours

After the rst 25

operating hours

Before each use or daily

Every 50 hours

Every 100 hours

Maintenance Procedure

• Change the engine oil.

• Check the condition and tension of the drive belt.

• Check the front wheel toe-in and front suspension.

• Check the engine oil.

• Check the tire pressure.

• Check the transmission oil level.

• Check the brake uid level.

• Change the engine oil (twice as often in special operating conditions; refer to Maintaining the Vehicle under Special Operating Conditions).

• Check the battery cable connections for wear or damage.

• Grease the bearings and bushings.

• Inspect and clean the air lter element (twice as often in special operating conditions; refer to Maintaining the Vehicle under Special Operating Conditions).

• Change the oil lter (twice as often in special operating conditions; refer to Maintaining the Vehicle under Special Operating Conditions).

• Check the operation of the Neutral gear shift position.

• Inspect the condition and wear of the tires.

•

Torque the wheel lug nuts to 45-65 ft-lb (61-88 N ⋅ m).

• Check the front wheel toe-in and front suspension.

• Clean the engine cooling areas (twice as often in special operating conditions; refer to Maintaining the Vehicle under Special Operating Conditions).

• Inspect the brakes.

• Replace the air lter element.

Every 200 hours

Every 400 hours

Every 800 hours

Yearly

• Adjust the parking brake.

• Check the condition and tension of the drive belt.

• Inspect the fuel lines and connections.

• Clean and lubricate the primary drive clutch.

• Replace the spark plugs.

• Replace the fuel lter.

• Change the transaxle uid.

• Complete all yearly maintenance procedures specied in the Engine Operator’s Manual.

Important: R efer to y our Engine Operator’ s Man ual f or additional maintenance pr ocedur es.

Premaintenance Procedures

Maintaining the Vehicle under Special Operating Conditions

If the v ehicle is subjected to any of the conditions listed belo w , maintenance should be perfor med twice as frequently .

• Deser t operation

• Cold climate operation (belo w 50° F [10° C])

• T railer to wing

• Dri ving time typically less than 5 min utes

• F requent operation in dusty conditions

• Constr uction w ork

• After extended operation in m ud, sand, w ater ,

or similar dir ty conditions , ha v e y our brak es inspected and cleaned as soon as possible . T his will prev ent any abrasi v e material from causing ex cessi v e w ear .

• Under frequent hea vy duty operating conditions , lubricate all g rease ﬁttings and inspect air cleaner daily to prev ent ex cessi v e w ear .

( Figure 29 ) T he jac king point at the rear of the v ehicle is under the axle tubes ( Figure 30 ).

Figure 29

1. Front jacking point

Figure 30

1. Rear jacking points

Jacking the Vehicle

W henev er the engine is r un for routine maintenance and/or engine diagnostics , the rear wheels of the v ehicle should be 1 inc h (25 mm) off the g round with the rear axle suppor ted on jac k stands .

T he v ehicle may be unsta ble when using a jack. It could slip of f the jack, injuring an y one beneath it.

• Do not star t the engine while the v ehicle is on a jack.

• Al w ays r emo v e the k ey fr om the ignition bef or e getting of f of the v ehicle.

• Block the tir es when the v ehicle is on a jack.

T he jac king point at the front of the v ehicle is on the front of the frame behind the to wing tongue

Lubrication

Lubricate all of the bearings and bushings ev er y 100 hours or once a year , whic hev er occurs ﬁrst. Grease them more frequently when using the v ehicle for hea vy-duty operations .

Grease T ype: Number 2 General Pur pose Lithium Base Grease

Adding Grease

1. Wipe the g rease ﬁtting clean so foreign matter cannot be forced into the bearing or bushing .

2. Pump g rease into the bearing or bushing .

3. Wipe off ex cess g rease .

T he g rease ﬁttings are located at the four tie rod ends ( Figure 31 and the tw o king pins ( Figure 32 ).

Figure 31

Figure 32

4. Gently slide the ﬁlter out of the air cleaner body to reduce the amount of dust dislodg ed ( Figure 33 ). A v oid knoc king the ﬁlter ag ainst the air cleaner body .

Figure 33

1. Air cleaner latches 3. Filter

2. Cover

5. Inspect the ﬁlter and discard it if it is damag ed.

Engine Maintenance

Servicing the Air Cleaner

Chec k the air cleaner body for damag e whic h could possibly cause an air leak. R e place a damag ed air cleaner body .

Ensure the co v er is sealing around the air cleaner body .

Air Cleaner Filter : Inspect after ev er y 100 operating hours; re place after ev er y 200 hours or sooner if dir ty or damag ed.

Note: Ser vice the air cleaner more frequently (ev er y few hours) if operating conditions are extremely dusty or sandy .

Removing the Filter Element

1. P ark the mac hine on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. Raise the bed and secure it with the prop rod.

3. R elease the latc hes securing the air cleaner co v er to the air cleaner body . Se parate the co v er from the body . Clean the inside of the air cleaner co v er ( Figure 33 ).

Cleaning the Filter Element Important: Do not w ash or r euse a dama ged

ﬁlter .

• W ashing method:

1. Pre pare a solution of ﬁlter cleaner and w ater and soak the ﬁlter element for about 15 min utes . R efer to the directions on the ﬁlter cleaner car ton for complete infor mation.

2. After soaking the ﬁlter for 15 min utes , rinse it with clear w ater . Rinse the ﬁlter from the clean side to the dir ty side .

Important: T o pr ev ent dama ge to the ﬁlter element, the maximum w ater pr essur e must not ex ceed 40 psi. (276 kP a).

3. Dr y the ﬁlter element using w ar m, ﬂo wing air at 160°F (71°C) maxim um, or allo w the element to air -dr y .

Important: Do not use a light bulb to dr y the ﬁlter element because dama ge could r esult.

• Compr essed air method:

1. Blo w compressed air from the inside to the outside of the dr y ﬁlter element. K ee p the air hose nozzle at least 2 inc hes (51 mm) from the ﬁlter and mo v e the nozzle up and do wn while rotating the ﬁlter element.

Important: T o pr ev ent dama ge to the ﬁlter element, do not ex ceed 100 psi (689 kP a) air pr essur e.

2. Inspect the ﬁlter element for holes and tears b y looking through the ﬁlter to w ard a bright light.

Installing the Filter Element Important: T o pr ev ent engine dama ge,

al w ays operate the engine with the complete air cleaner assembl y installed.

1. Inspect the new ﬁlter for shipping damag e . Chec k the sealing end of the ﬁlter .

Important: Do not install a dama ged ﬁlter .

2. Inser t the new ﬁlter into air cleaner body . Ensure the ﬁlter is sealed properly b y applying pressure to the outer rim of the ﬁlter when installing it. Do not press on the ﬂexible center of the ﬁlter .

3. Install the co v er and secure the latc hes .

Servicing the Engine Oil

Chec k the oil lev el before eac h use .

Chang e the oil after the ﬁrst 8 operating hours and ev er y 50 hours thereafter . Chang e the oil twice as often in special operating conditions; refer to Maintaining the V ehicle under Special Operating Conditions .

Viscosity: See the table belo w

Figure 34

Checking the Oil Level

T o c hec k the oil lev el, refer to Chec king the Engine Oil in Operation , pag e 21 .

Changing the Oil

1. Star t the v ehicle and let it r un for a few min utes to w ar m the oil.

2. P ark the mac hine on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

3. Raise the bed and secure it with the prop rod.

4. Disconnect the spark plug wires and batter y cables .

5. R emo v e the drain plug ( Figure 35 ) and let the oil ﬂo w into a drain pan. W hen the oil stops , install the drain plug .

Note: Dispose of the used oil at a cer tiﬁed recycling center .

R e place the oil ﬁlter ev er y 100 hours . Note: Chang e the oil and oil ﬁlter more

frequently when operating conditions are extremely dusty or sandy .

Oil T ype: Deterg ent oil (API ser vice SF , SG , SH, SJ , or higher)

Crankcase Capacity: 48 oz./1-1/2 qt. (1.4 liters) when the ﬁlter is c hang ed

Figure 35

1. Engine oil drain plug 2. Engine oil lter

6. P our oil into the ﬁll opening until the oil lev el is up to the Full mark on the dipstic k. Add the oil slo wly and c hec k the lev el often during this process . Do not o v erﬁll .

7. Install the oil ﬁll cap and dipstic k ﬁr mly in place .

8. Connect the spark plug wires and batter y cables .

Changing the Oil Filter

R e place the oil ﬁlter ev er y 100 operating hours or yearly , whic hev er occurs ﬁrst.

1. Drain the oil from the engine; refer to Changing the Oil.

2. R emo v e the existing oil ﬁlter ( Figure 35 ).

3. Apply a light coat of clean oil to the new ﬁlter g ask et.

4. Screw the new ﬁlter on until the g ask et contacts the mounting plate , then tighten the ﬁlter an additional 1/2 to 3/4 tur n fur ther . Do not o v er tighten .

5. Fill the crankcase with the proper type of new oil.

6. Star t and r un the engine to c hec k for leaks .

7. Stop the engine and c hec k the oil lev el. Add oil if necessar y .

Servicing the Spark Plugs

R e place the spark plugs after ev er y 800 operating hours or yearly , whic hev er occurs ﬁrst, to ensure proper engine perfor mance and reduce the exhaust emission lev el.

Figure 36

1. Center electrode insulator

2. Side electrode

Important: A crack ed, f ouled, dir ty , or malfunctioning spar k plug must be r eplaced. Do not sandblast, scrape, or clean the electr odes by using a wir e br ush because g rit may ev entuall y r elease fr om the plug and f all into the cylinder . T he r esult is usuall y a dama ged engine.

4. Set the air g ap betw een the center and side electrodes at 0.030 inc h (0.762 mm) ( Figure 36 ).

5. Install the cor rectly g apped spark plug and tighten the plug to 18-22 ft-lb (24-30 N ⋅ m). If a tor que wrenc h is not used, tighten the plug ﬁr mly .

6. Install the spark plug wires .

3. Air gap (not to scale)

Fuel System Maintenance

T ype: Champion R C 14Y C (or equi v alent)

Air Gap: 0.030 inc h (0.762 mm) Note: T he spark plugs usually lasts a long

time; ho w ev er , the plugs should be remo v ed and c hec k ed whenev er the engine malfunctions .

1. Clean the area around the spark plugs so that foreign matter cannot fall into the cylinder when the spark plug is remo v ed.

2. Pull the spark plug wires off of the spark plugs and remo v e the plugs from the cylinder head.

3. Chec k the condition of the side electrode , center electrode , and center electrode insulator to ensure that there is no damag e ( Figure 36 ).

Inspecting Fuel Lines and Connections

Chec k the fuel lines and connections ev er y 400 operating hours or yearly , whic hev er occurs ﬁrst. Inspect them for deterioration, damag e , or loose connections .

Replacing the Fuel Filter

R e place the fuel ﬁlter ev er y 800 operating hours or yearly , whic hev er occurs ﬁrst.

1. Raise the bo x and suppor t it with the prop rod.

2. Place a clean container under the fuel ﬁlter .

3. R emo v e the clamps securing the fuel ﬁlter to the fuel lines ( Figure 37 ), as follo ws:

A. Squeeze the clamp tabs tog ether and slide

the clamps up the hose off of the ﬁlter hose ﬁttings .

B . Pull the hose ends off of the ﬁlter hose

ﬁttings .

Figure 38

1. Charge circuit

2. Lights 4. Low oil light and hour

3. Power point

meter

Replacing the Headlights

Figure 37

1. Fuel lter

4. Install the re placement ﬁlter to the fuel lines with the clamps previously remo v ed.

Mount the ﬁlter so that the ar ro w points to w ard the carburetor .

Electrical System Maintenance

Replacing the Fuses

T here are 3 fuses in the electrical system. T hey are located beneath the bed in a bo x on the right hand side of the frame ( Figure 38 ).

Charge circuit Lights Power Point Low oil light and hour

meter

10 amp. (15 amp. max.)

25 amp. 10 amp.

10 amp.

Speciﬁcation: GE #862

1. Set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. Switc h the headlights off .

3. R eac h beneath the dash and rotate the lamp assembly 1/4 tur n countercloc kwise ( Figure 39 ).

Figure 39

1. Lamp assembly 3. Tabs

2. Reector 4. Slots

4. Pull the lamp assembly out of the reﬂector .

5. R emo v e the lamp assembly from the wire har ness .

6. Discard the lamp assembly .

7. Push the re placement lamp assembly onto the wire har ness .

8. R eac h beneath the dash and align the three tabs on the lamp assembly with the slots in the reﬂector ( Figure 39 ).

9. Inser t the lamp assembly into the reﬂector and rotate it 1/4 tur n cloc kwise until it stops .

Servicing the Battery

Important: Do not jump star t the v ehicle.

Alw a ys k ee p the batter y clean and fully c harg ed. Use a paper to w el to clean the batter y and batter y bo x. If the batter y ter minals are cor roded, clean them with a solution of four par ts w ater and one par t baking soda. Apply a light coating of g rease to the batter y ter minals to prev ent cor rosion.

V oltag e: 12 v olt with 280 cold cranking Amps @ 0° F (-18° C).

Removing the Battery

1. P osition the v ehicle on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. Raise the bed and secure it with the prop rod.

3. R emo v e the batter y hold-do wn.

4. Disconnect the neg ati v e (blac k) g round cable from the batter y post.

Batter y ter minals or metal tools could shor t a gainst metal v ehicle components, causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• W hen r emo ving or installing the batter y , do not allo w the batter y ter minals to touch an y metal par ts of the v ehicle.

• Do not allo w metal tools to shor t betw een the batter y ter minals and metal par ts of the v ehicle.

5. Disconnect the positi v e (red) cable from the batter y post.

6. R emo v e the batter y from the c hassis .

Installing the Battery

1. Set the batter y on the batter y base so the batter y posts are to w ard the rear of the v ehicle .

Incor r ect batter y ca ble r outing could dama ge the v ehicle and ca bles, causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• Al w ays disconnect the negati v e (black) batter y ca ble bef or e disconnecting the positi v e (r ed) ca ble.

• Al w ays r econnect the positi v e (r ed) batter y ca ble bef or e r econnecting the negati v e (black) ca ble.

• Al w ays k eep the batter y strap in place to pr otect and secur e the batter y .

2. Connect the positi v e (red) cable to the positi v e (+) batter y post and the neg ati v e (blac k) cable to the neg ati v e (-) batter y post using the bolts and wing n uts . Slide the r ubber boot o v er the positi v e batter y post.

3. R e place the batter y hold-do wn to secure the batter y to the base .

Important: Al w ays k eep the batter y hold-do wn in place to pr otect and secur e the batter y .

Charging the Battery Important: Al w ays k eep the batter y

full y charged (1.260 speciﬁc g ra vity). T his is especiall y impor tant to pr ev ent batter y dama ge when the temperatur e is belo w 32°F (0°C).

1. R emo v e the batter y from the c hassis; refer to R emo ving the Batter y .

2. 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 .

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om batter y .

3. Install the batter y in the c hassis; refer to Installing the Batter y .

Storing the Battery

If the mac hine will be stored for more than 30 da ys , remo v e the batter y and c harg e it fully . Either store it on the shelf or on the mac hine . Lea v e the cables disconnected if it is stored on the mac hine . Store the batter y in a cool atmosphere to a v oid quic k deterioration of the c harg e in the batter y . T o prev ent the batter y from freezing, mak e sure it is fully c harg ed.

Drive System Maintenance

Figure 40

1. Neutral bracket 2. Locknuts

3. Tighten one of the loc kn uts ( Figure 40 ) just enough to tak e the slac k out of the shift cable .

Note: Y ou m ust hold the threaded shaft belo w the brac k et to tighten the loc kn ut on top .

4. Tighten the other loc kn ut just enough to tak e the slac k out of the other shift cable .

Checking and Adjusting Neutral

W hen perfor ming routine maintenance and/or engine diagnostics , the transaxle m ust be shifted into neutral ( Figure 40 ). T he v ehicle has a neutral position on the shift lev er , whic h controls the neutral in the transaxle . T he follo wing ste ps should be tak en to mak e sure that the neutral shift lev er operates the transaxle neutral cor rectly:

1. Set the shift lev er into the Neutral position.

2. Ensure that the neutral brac k et is in the neutral position (lev el) b y tur ning the dri v e clutc h ( Figure 40 ). T he v ehicle should not roll bac k and for th. If it does , man ually mo v e the neutral brac k et to the neutral position.

5. Pull up on eac h shift cable an ensure that there is no g ap betw een the n ut/w asher and the neutral brac k et ( Figure 41 ). If there is a g ap , tighten the n ut.

Figure 41

1. Neutral bracket 4. Wrong, must tighten the nut

2. Pull up 5. Correct adjustment

3. Cable boot

6. Star t the engine and shift into F orw ard, R ev erse , and Neutral sev eral times to ensure that the neutral brac k et is operating properly .

Inspecting the Tires

Chec k the tire condition at least ev er y 100 hours of operation. Operating accidents , suc h as hitting curbs , can damag e a tire or rim and also disr upt wheel alignment, so inspect tire condition after an accident.

Chec k the wheels to ensure that they are mounted securely . T or que the lug n uts to 45-65 ft-lb (61-88 N ⋅ m).

Adjusting the Front Suspension

T he ride height of eac h side of the v ehicle can be adjusted se parately . T he ride height should be 8-3/4 to 9-1/2 inc hes (22.2 to 24 cm) with the follo wing parameters:

• T he tire pressure should be at 12 psi (83 kP a).

• T he v ehicle should be dri v en bac k and for th a

few times to relax the A-ar ms .

• Measure the ride height with the wheels facing straight ahead and a 175-225 lb (79-102 kg) operator in the dri v er’ s seat.

Note: T he dri v er should dri v e up to the measurement area and sta y seated in the v ehicle while the measurement is being tak en.

• Measure the ride height on a ﬂat surface , from the bottom of the front tongue to the g round.

1. J ac k the front end of the v ehicle off of the g round; refer to J ac king the V ehicle in Premaintenance Procedures , pag e 28 .

2. R emo v e the tra v el limiting bolt ( Figure 42 ).

3. Loosen the centering bolts in the front A-ar m ( Figure 42 ).

Figure 42

1. Travel limiting bolt 3. Ride height adjustment bolt

2. Centering bolt

5. R otate the front A-ar m to the desired position (refer to the note belo w) and re place the ride height adjustment bolt ( Figure 42 ).

Note: T he A-ar ms are made with r ubber and ha v e different spring rates . Because of the different spring rates , the A-ar ms come adjusted from the factor y based on that spring rate . Generally the adjustment bolts will be installed in hole n umber 2, 3, or 4 ( Figure 43 ) and it ma y be different from the left side (dri v er side) to the right side (passeng er side). If the A-ar ms look lik e they are sag ging, then they should be adjusted to the next higher n umber ( Figure 43 ). Eac h hole equals about 3/4 inc h (19 mm) of adjustment at the wheel. Y ou will also need to do this if y ou are adding hea vy attac hments or car r ying hea vy loads often.

4. R emo v e the ride height adjustment bolt ( Figure 42 ).

Figure 43

1. Left-hand A-arm

6. T or que the ride height adjustment bolt to 135-165 ft-lb (183-224 N ⋅ m).

7. R e place the tra v el limiting bolt ( Figure 42 ).

Note: T he dri v er should dri v e up to the measurement area and sta y seated in the v ehicle while the measurement is being tak en.

1. Ensure that the front suspension is adjusted properly; refer to Adjusting the F ront Suspension. Adjust if necessar y .

2. Measure the distance betw een both of the front tires at the axle height at both the front and rear of the front tires ( Figure 44 ). A ﬁxture or alignment g aug e is needed for the rear measurement of the front tires at axle height. Use the same ﬁxture or alignment g aug e to accurately measure the front of the front tires at axle height ( Figure 44 ).

Note: T he v ehicle ma y need to be lo w ered to the g round on that side to install the bolt.

8. Tighten and tor que the centering bolts to 240-290 ft-lb (325-393 N ⋅ m).

9. Chec k the ride height at the front tongue per the dimensions and parameters gi v en at the beginning of this procedure .

Adjusting Front Wheel Toe-In

Chec k the front wheel toe-in after ev er y 100 operating hours , or ann ually , whic hev er occurs ﬁrst.

T he toe-in should be 1/8-5/8 inc h (3-16 mm) with the follo wing parameters:

• T he tire pressure should be at 12 psi (83 kP a).

• T he ride height should be cor rect before

setting the toe-in; refer to Adjusting the F ront Suspension.

Figure 44

1. Tire center line-back

2. Tire center line-front 5. Axle center line distance

3. Axle center line

4. Fixture

6. 6 inches (15 cm) ruler

3. If the measurement does not fall within the speciﬁed rang e (refer to the dimensions and parameters at the beginning of this procedure), loosen the jam n uts at both ends of the tie rods ( Figure 45 ).

• T he v ehicle should be dri v en bac k and for th a few times to relax the A-ar ms .

• Measure the toe-in with the wheels facing straight ahead and a 175-225 lb (79-102 kg) operator in the dri v er’ s seat.

Figure 45

1. Jam nut

2. Tie rod

4. R otate both tie rods to mo v e the front of the tire inw ard or outw ard.

5. Tighten the tie rod jam n uts when the adjustment is cor rect.

6. Ensure that there is full tra v el of the steering wheel in both directions .

Maintaining the Primary Drive Clutch

T he dust in the clutch will become airbor ne and could dama ge y our ey es or y ou could inhale it causing br eathing dif ﬁculties.

W ear safety go g g les and a dust mask or other ey e and r espirator y pr otection when perf or ming this pr ocedur e.

5. Lubricate the mo ving par ts in the areas circled in Figure 47 using T oro Dr y Lubricant Spra y , a v ailable through y our A uthorized T oro Dealer or Distributor .

After ev er y 400 operating hours or yearly , clean and lubricate the clutc h as follo ws:

1. Raise and latc h the carg o bo x.

2. Stop the engine , remo v e the k ey , and set the parking brak e .

3. R emo v e the 3 bolts securing the co v er to the clutc h and remo v e the co v er ( Figure 46 ).

Figure 46

1. Cover

2. Bolts

4. T horoughly clean the inside of the co v er and the inner w orkings of the clutc h using compressed air .

Figure 47

6. Install the clutc h co v er and secure it with the 3 bolts remo v ed previously .

Changing the Transaxle Fluid

Chang e the transaxle ﬂuid ev er y 800 operating hours or yearly , whic hev er occurs ﬁrst.

1. P osition the v ehicle on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. R emo v e the drain plug from the right side of the reser v oir ( Figure 48 ) and let the ﬂuid ﬂo w into a drain pan. Install and tighten the plug when the ﬂuid stops draining .

Note: Dispose of the used oil at a cer tiﬁed recycling center .

Important: Nev er clean the engine with pr essuriz ed w ater because w ater could contaminate the fuel system.

Brake Maintenance

Inspecting the Brakes

Figure 48

1. Drain plug 2. Level indicator hole

3. Fill the reser v oir ( Figure 49 ) with appro ximately 1-1/2 qt. (1.4 liters) of SAE 10W30 motor oil or until the oil lev el is at the bottom of the lev el indicator hole ( Figure 48 ).

Figure 49

1. Oil ll

4. Star t the engine and operate it to ﬁll the system. R ec hec k the oil lev el and re plenish it, if required.

Brak es are a critical safety component of the v ehicle . As with all safety components , they should be closely inspected at regular inter v als to ensure optim um perfor mance and safety . T he follo wing inspections should be done ev er y 100 hours:

• Inspect the brak e shoes for w ear or damag e . If the lining (brak e pad) thic kness is less than 1/16 inc h (1.6 mm), the brak e shoes should be re placed.

• Inspect the bac king plate and other components for signs of ex cessi v e w ear or defor mation. If any defor mation is found, the appropriate components m ust be re placed.

• Chec k the brak e ﬂuid lev el; refer to Chec king the Brak e Fluid Lev el.

Checking the Brake Fluid Level

T he brak e ﬂuid reser v oir is ﬁlled and shipped from the factor y with DOT 3 brak e ﬂuid. Chec k the lev el before the engine is ﬁrst star ted and ev er y 8 hours or daily , thereafter .

Cooling System Maintenance

Cleaning the Engine Cooling Areas

Clean the rotating screen, cooling ﬁns , and exter nal surfaces of the engine ev er y 100 operating hours or more often under extremely dusty and dir ty conditions .

Important: Operating the engine with a block ed r otating scr een, dir ty or plug ged cooling ﬁns, or cooling shr ouds r emo v ed will cause engine dama ge due to o v erheating .

1. P ark the mac hine on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. Look at the side of the reser v oir . T he lev el should be abo v e the Minim um line ( Figure 50 ). If the ﬂuid lev el is lo w , clean the area around the cap , remo v e the cap , and ﬁll the reser v oir to abo v e the Minim um line . Do not o v erﬁll.

Figure 50

1. Brake uid reservoir 2. Minimum line

Adjusting the Parking Brake

Chec k the parking brak e adjustment ev er y 200 hours .

1. Pr y the r ubber co v er off of the parking brak e .

2. Loosen the set screw securing the knob to the parking brak e lev er ( Figure 51 ).

1. P ark the mac hine on a lev el surface , shift into Neutral, set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. Raise the bed and secure it with the prop rod.

3. R otate and inspect the belt ( Figure 52 ) for ex cessi v e w ear or damag e . R e place the belt if necessar y .

Figure 52

1. Drive belt 3. Secondary clutch

2. Primary clutch

Figure 51

1. Parking brake lever

2. Knob

3. Set screw

3. R otate the knob until a force of 30-35 lb (133-156 N) is required to actuate the lev er .

4. Tighten the set screw and install the r ubber co v er .

Belt Maintenance

Servicing the Drive Belt

Checking the Drive Belt

Chec k the condition and tension of the dri v e belt after the ﬁrst da y of operation and ev er y 200 operating hours thereafter .

Replacing the Drive Belt

1. R otate and route the belt o v er the secondar y clutc h ( Figure 52 ).

2. R emo v e the belt from the primar y clutc h ( Figure 52 ).

3. T o re place the belt, rev erse the procedure .

Cleaning

Washing the Vehicle

T he v ehicle should be w ashed as needed. Use w ater alone or with a mild deterg ent. A rag ma y be used, ho w ev er the hood will loose some of its luster .

Important: Pr essuriz ed w ater is not r ecommended when w ashing the machine. It may dama ge the electrical system, loosen impor tant decals, or w ash a w ay necessar y g r ease at friction points. A v oid ex cessi v e use of w ater , especiall y near the contr ol panel, engine, and batter y .

Storage

1. P osition the mac hine on a lev el surface , set the parking brak e , stop the engine , and remo v e the ignition k ey .

2. Clean dir t and g rime from the entire mac hine , including the outside of the engine’ s cylinder head ﬁns and blo w er housing .

Important: Y ou can w ash the machine with mild detergent and w ater . Do not use high pr essur e w ater to w ash the machine. Pr essur e w ashing may dama ge the electrical system or w ash a w ay necessar y g r ease at friction points. A v oid ex cessi v e use of w ater , especiall y near the contr ol panel, lights, engine, and the batter y .

3. Inspect the brak es; refer to Inspecting the Brak es in Brak e Maintenance , pag e 38 .

4. Ser vice the air cleaner; refer to Ser vicing the Air Cleaner in Engine Maintenance , pag e 29 .

5. Grease the mac hine; refer to Lubrication , pag e 28 .

6. Chang e the engine oil; refer to Ser vicing Engine Oil in Engine Maintenance , pag e 29 .

7. Chec k the tire pressure; refer to Chec king the Tire Pressure in Dri v e System Maintenance , pag e 34 .

8. F or storag e o v er 30 da ys , pre pare the fuel system as follo ws:

A. Add a petroleum based

stabilizer/conditioner to fuel in the tank.

F ollo w mixing instr uctions from stabilizer man ufacturer . (1 oz. per g allon). Do not use an alcohol based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effecti v e when mix ed with fresh g asoline and used at all times .

B . R un the engine to distribute conditioned

fuel through the fuel system (5 min utes).

C . Stop the engine , allo w it to cool, and drain

the fuel tank. D . R estar t the engine and r un it until it stops . E. Chok e the engine . F . Star t and r un the engine until it will not

star t ag ain.

G . Dispose of fuel properly . R ecycle as per

local codes .

Important: Do not stor e sta biliz er/conditioned gasoline o v er 90 days

9. R emo v e the spark plugs and c hec k their condition; refer to Changing Spark Plugs in Engine Maintenance , pag e 29 .

10. With the spark plugs remo v ed from the engine , pour tw o tablespoons of engine oil into the spark plug hole .

11. Use the electric star ter to crank the engine and distribute the oil inside the cylinder .

12. Install the spark plugs and tighten to recommended tor que; refer to Changing Spark Plugs in Engine Maintenance , pag e 29 .

Note: Do not install the wire on the spark plug(s).

13. R emo v e the batter y from the c hassis , c hec k the electrolyte lev el, and c harg e it fully; refer to Ser vicing the Batter y in Electrical System Maintenance , pag e 32 .

Note: Do not connect the batter y cables to the batter y posts during storag e .

Important: T he batter y must be full y charged to pr ev ent it fr om fr eezing and being dama ged at temperatur es belo w 32°F (0°C). A full y charged batter y maintains its charge f or a bout 50 days at temperatur es lo w er than 40°F (4°C). If the temperatur es will be a bo v e 40°F (4°C), check the w ater lev el in the batter y and charge it ev er y 30 days.

14. Chec k and tighten all bolts , n uts , and screws . R e pair or re place any par t that is damag ed.

15. P aint all scratc hed or bare metal surfaces .

P aint is a v ailable from y our A uthorized Ser vice Dealer .

16. Store the mac hine in a clean, dr y g arag e or storag e area.

17. R emo v e the ignition k ey and put it in a safe place out of the reac h of c hildren.

18. Co v er the mac hine to protect it and k ee p it clean.

Schematics

Electrical Schematic (Rev. A)

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

Specifications and Main Features

Frequently Asked Questions

User Manual