Toro 68038, 68038G Operator's Manual

FormNo.3421-173RevB

MB-1600MudBuggy

ModelNo.68038—SerialNo.402350000andUp ModelNo.68038G—SerialNo.402350000andUp

Registeratwww.T oro.com. OriginalInstructions(EN)

*3421-173*B

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemical

orchemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orreproductiveharm.

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Becauseinsomeareastherearelocal,state,or federalregulationsrequiringthatasparkarresterbe usedontheengineofthismachine,asparkarresteris availableasanoption.Ifyourequireasparkarrester, contactyourAuthorizedServiceDealer.

GenuineT orosparkarrestersareapprovedbythe USDAForestryService.

ItisaviolationofCaliforniaPublicResourceCode Section4442touseoroperatetheengineonany forest-covered,brush-covered,orgrass-covered landwithoutasparkarrestermufermaintainedin workingorder,ortheengineconstricted,equipped, andmaintainedforthepreventionofre.Otherstates orfederalareasmayhavesimilarlaws.

Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.

Important:Withyourmobiledevice,youcan

scantheQRcodeontheserialnumberdecal(if equipped)toaccesswarranty,parts,andother productinformation.

Theenclosedengineowner'smanualissupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCaliforniaEmission ControlRegulationofemissionsystems,maintenance, andwarranty.Replacementsmaybeorderedthrough theenginemanufacturer.

Introduction

Thismachineisintendedtobeusedbyprofessional, hiredoperatorsincommercialapplications.This machineisastable,reliable,andproductivemachine forcarryingandmovingmaterialsforanyjobsite.Itis primarilydesignedtomoveconcrete,mortar,gravel, dirt,ordebrisaroundjobsites.

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoid injuryandproductdamage.Youareresponsiblefor operatingtheproductproperlyandsafely .

YoumaycontactTorodirectlyatwww.Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.

g241971

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Contactusatwww.Toro.com.

PrintedintheUSA

AllRightsReserved

Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafetyalertsymbol (Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.

Figure2

1.Safety-alertsymbol

Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

Contents

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

SafeOperatingPractices....................................4

SafetyandInstructionalDecals..........................7

ProductOverview...................................................10

Controls...........................................................10

g000502

Specications..................................................12

Operation................................................................12

AddingFuel......................................................12

CheckingtheMachine-FluidLevels..................14

StartingtheEngine...........................................14

ShuttingOfftheEngine.....................................14

OperatingtheMachine.....................................14

ParkingtheMachine.........................................16

MovingtheMachinewithoutEngine

Power............................................................16

TransportingtheMachine.................................17

LiftingtheMachine...........................................17

UsingtheQuick-ReleaseTireHubs..................18

Maintenance...........................................................19

RecommendedMaintenanceSchedule(s)...........19

Pre-MaintenanceProcedures..............................20

RemovingtheCowl...........................................20

Lubrication..........................................................21

GreasingtheMachine.......................................21

EngineMaintenance...........................................22

CheckingtheEngine-OilLevel..........................22

ServicingtheAirCleaner..................................22

ChangingtheEngineOil...................................24

ReplacingtheSparkPlug.................................24

FuelSystemMaintenance...................................25

CleaningtheSedimentCup..............................25

ChangingtheFuelFilter....................................26

DrainingtheFuelT ank......................................27

DriveSystemMaintenance..................................27

AdjustingtheTransmissionReturntoNeutral

Position.........................................................27

CheckingtheTiresandLugNuts......................28

ControlsSystemMaintenance.............................28

BrakeMaintenance...........................................28

HydraulicSystemMaintenance...........................30

CheckingtheHydraulic-FluidLevel...................30

ReplacingtheHydraulicFilter...........................31

ChangingtheHydraulicFluid............................32

CheckingtheHydraulicLines...........................33

Cleaning..............................................................33

RemovingDebrisfromtheMachine..................33

Storage...................................................................34

Safety

Improperuseormaintenanceofthemachinecan resultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafetyalertsymbol Caution,Warning,orDanger—personalsafety instruction.Failuretocomplywiththeinstructionmay resultinpersonalinjuryordeath.

,whichmeans:

–Donotstorethemachineorfuelcontainer

wherethereisanopename,spark,orpilot light,suchasonawaterheaterorother appliance.

–Ifyouspillfuel,donotattempttostartthe

engine;avoidcreatinganysourceofignition untilthefuelvaporshavedissipated.

•Ensurethattheshieldsofthemachineare

attachedandfunctioningproperly.Donotoperate themachineunlesstheyarefunctioningproperly .

SafeOperatingPractices

WARNING

Engineexhaustcontainscarbonmonoxide, anodorlessfuelthatislethalifinhaled.

Donotruntheengineindoorsorinan enclosedarea.

Training

•ReadtheOperator'sManualandothertraining

material.Iftheoperator(s)ormechanic(s)cannot readorunderstandtheinformation,itisthe owner'sresponsibilitytoexplainthismaterialto them.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Alloperatorsandmechanicsshouldbetrained.

Theownerisresponsiblefortrainingtheusers.

•Neverletchildrenoruntrainedpeopleoperateor

servicetheequipment.Localregulationsmay restricttheageoftheoperator.

•Theowner/usercanpreventandisresponsible

foraccidentsorinjuriesoccurringtopeopleor damagetoproperty.

Preparation

•Wearappropriateclothingincludinghardhat,eye

protection,longpants,substantial,slip-resistant footwear,andhearingprotection.Tiebacklong hair.Donotwearloosejewelry.

•Inspecttheareawheretheequipmentistobe

usedandensurethatallobjectsareremovedfrom themachinebeforeuse.

•Useextremecareinhandlingfuel.Itisammable

anditsvaporsareexplosive.

–Extinguishallcigarettes,cigars,pipes,and

othersourcesofignition. –Useonlyanapprovedcontainer. –Donotremovethefuelcaporllthefueltank

whiletheengineisrunningorhot. –Donotaddordrainthefuelinanenclosed

space.

Operation

•Useyourfullattentionwhileoperatingthe

machine.Donotengageinanyactivitythat causesdistractions;otherwise,injuryorproperty damagemayoccur.

•Neverrunanengineinanenclosedarea.

•Operatethemachineonlyingoodlight,keeping

awayfromholesandhiddenhazards.

•Ensurethatalldrivesareinneutralbefore

startingtheengine.Starttheengineonlyfromthe operator'sposition.

•Donotoperatethemachinewiththeguards

notsecurelyinplace.Ensurethatallinterlocks areattached,adjustedproperly,andfunctioning properly.

•Donotchangetheenginegovernorsettingor

overspeedtheengine.

•Stopthemachineonlevelground,engagethe

parkingbrake,lowerthehopper,andshutoffthe enginebeforeleavingtheoperator'spositionfor anyreason.

•Nevercarrypassengersandkeeppetsand

bystandersaway.

•Slowdownandusecautionwhenmakingturns

andcrossingroadsandsidewalks.

•Donotoperatethemachinewhileill,tired,or

undertheinuenceofalcoholordrugs.

•Usecarewhenloadingorunloadingthemachine

intoatrailerortruck.

•Usecarewhenapproachingblindcorners,shrubs,

trees,orotherobjectsthatmayobscurevision.

•Ensurethattheareaisclearofotherpeoplebefore

operatingthemachine.Shutoffthemachineif anyoneentersthearea.

•Neverleavearunningmachineunattended.

•Donotexceedtheratedoperatingcapacity,asthe

machinemaybecomeunstablewhichmayresult inlossofcontrol.

•Neverjerkthecontrols;useasteadymotion.

•Watchfortrafcwhenoperatingnearorcrossing

roadways.

•Donottouchpartswhichmaybehotfrom

operation.Allowthemtocoolbeforeattemptingto maintain,adjust,orservice.

•Checkforoverheadclearances(i.e.,branches,

doorways,electricalwires)beforedrivingunder anyobjectsanddonotcontactthem.

•Ensurethatyouoperatethemachineinareas

wheretherearenoobstaclesclosetoyou.Failure tomaintainadequatedistancefromtrees,walls, andotherbarriersmayresultininjuryasthe machinebacksupduringoperationifyouare notattentivetothesurroundings.Operatethe machineonlyinareaswherethereissufcient clearanceforyoutosafelymaneuvertheproduct.

•Locatethepinchpointareasmarkedonthe

machineandkeephandsandfeetawayfrom theseareas.

•Lightningcancausesevereinjuryordeath.If

lightningisseenorthunderisheardinthearea,do notoperatethemachine;seekshelter.

•Donotoverloadthehopperandalwayskeepthe

loadlevelwhenoperatingthemachine.

goesovertheedgeortheedgecollapses.Keep asafedistance(twicethewidthofthemachine) betweenthemachineandanyhazard.

•Avoidstarting,stopping,orturningthemachineon

aslope.Avoidmakingsuddenchangesinspeed ordirection;turnslowlyandgradually.

•Keepallmovementsonslopesslowandgradual.

Donotmakesuddenchangesinspeedor direction.

•Donotoperatethemachineunderanyconditions

wheretraction,steering,orstabilityisinquestion. Beawarethatoperatingthemachineonwetgrass, acrossslopesordownhillmaycausethemachine tolosetraction.Lossoftractiontothewheelsor tracksmayresultinslidingandalossofbraking andsteering.Themachinecanslideevenifthe wheelsortracksarestopped.

•Removeormarkobstaclessuchasditches,holes,

ruts,bumps,rocksorotherhiddenhazards.T all grasscanhideobstacles.Uneventerraincould overturnthemachine.

•Ifyoulosecontrolofthemachine,stepoffand

awayfromthedirectionoftravelofthemachine.

SlopeOperation

•Slopesareamajorfactorrelatedtoloss-of-control

andtip-overaccidents,whichcanresultinsevere injuryordeath.Theoperatorisresponsiblefor safeslopeoperation.operatingthemachineon anysloperequiresextracaution.Beforeusingthe machineonaslope,youmust:

–Reviewandunderstandtheslopeinstructions

inthemanualandonthemachine. –Evaluatethesiteconditionsofthedayto

determineiftheslopeissafeformachine

operation.Alwaysusecommonsense

andgoodjudgmentwhenperformingthis

evaluation.Changesintheterrain,suchas

moisture,canquicklyaffecttheoperationof

themachineonaslope.

•Raisingthehopperonaslopeaffectsthestability

ofthemachine.Keepthehopperinthelowered positionwhenonslopes.

•Whenoperatingonaslope,foldtheplatformup

andwalkbehindthemachineuntilitisonat ground.

•Operateupanddownslopeswiththeheavy

endofthemachineuphill.Weightdistribution changeswithafullhopper.Afullhoppermakes thefrontofthemachinetheheavyend,sowhen ontravelingupordownslopeswithafullhopper, walk-behindthemachinewiththefullhopperuphill.

•Identifyhazardsatthebaseoftheslope.Do

notoperatethemachineneardrop-offs,ditches, embankments,waterorotherhazards.The machinecouldsuddenlyrolloverifawheelortrack

MaintenanceandStorage

•Lettheenginecoolbeforestoringanddonotstore

themachinenearanopename.

•Engagetheparkingbrake,shutofftheengine,

andwaitforallmovementtostopbeforeadjusting, cleaning,orrepairingthemachine.

•Cleandebrisfromdrives,mufers,andtheengine

tohelppreventres.Cleanupoilorfuelspills.

•Donotstorefuelnearamesordrainindoors.

•Parkthemachineonlevelground.Neverallow

untrainedpersonneltoservicethemachine.

•Usejackstandstosupportcomponentswhen

required.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Disconnectthebattery,negativeterminalrstand

positiveterminallast,beforemakinganyrepairs. Connectthebatterypositiveterminalrstand negativeterminallast.

•Keepyourhandsandfeetawayfrommoving

parts.Ifpossible,donotmakeadjustmentswith theenginerunning.

•Chargebatteriesinanopen,well-ventilatedarea,

awayfromsparkandames.Unplugthecharger beforeconnectingordisconnectingitfromthe battery.Wearprotectiveclothinganduseinsulated tools.

•Keepallpartsingoodworkingconditionandall

hardwaretightened.Replaceallwornordamaged decals.

•Usethecylinderlocktosecurethehopperinthe

raisedposition.

•Keepnutsandboltstight.Keepequipmentin

goodcondition.

•Nevertamperwithsafetydevices.

•UseonlygenuineT ororeplacementpartsto

ensurethatoriginalstandardsaremaintained.

•Batteryacidispoisonousandcancauseburns.

Avoidcontactwithskin,eyes,andclothing.Protect yourface,eyes,andclothingwhenworkingwitha battery.

•Batterygasescanexplode.Keepcigarettes,

sparks,andamesawayfromthebattery.

•Keepyourbodyandhandsawayfrompinhole

leaksornozzlesthatejecthigh-pressurehydraulic uid.Usecardboardorpapertondhydraulic leaks;neveruseyourhands.Hydraulicuid escapingunderpressurecanpenetrateskinand causeinjury,requiringsurgerywithinafewhours byaqualiedsurgeon;otherwise,gangrenemay result.

SafetyandInstructionalDecals

125-4961

125-4960

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedormissing.

1.Reverse

1.ReadtheOperator’sManualforoilinformation.

decal125-4961

125–4961

1.Forward

decal125-4964

125–4960

decal125-4960

125–4964

decal125-4962

125–4962

1.Engagetheparkingbrake2.Disengagetheparking brake

125–4959

1.Crushinghazard—neverplaceyourheadunderthedump trailer.

decal125-4959

1.Liftpoint

decal125-4967

125–4967

125–6694

decal125-6694

1.Tiedownlocation

decal127-2855

127–2855

1.Warning—readtheOperator’sManual;wearhearing protection.

2.Warning—donotoperatethemachinewithoutpropertraining.

3.Warning—stayawayfrommovingparts;keepallguardsand shieldsinplace.

4.Warning—keepbystandersawaywhileoperatingthe machine;checkbehindyouwhenmovinginreverse.

5.Tippinghazard—donotraisethedumptrailerwhilemoving; moveforwardslowly;raisethedumptrailerslowly.

6.Carbonmonoxidepoisonhazard—donotruntheengine indoors.

7.Explosionhazard—shutofftheengineandextinguishall amesbeforerefueling.

1.Raisethepedaltolower thehopper.

130-2844

2.Lowerthepedaltoraise thehopper.

decal130-2844

decal125-8190

125–8190

1.Pressdownonthepedal toapplytheservicebrake

2.Releasethepedalto releasetheservicebrake

125–4963

1.Warning—keephandsawayfromhotsurfaces

1.ReadtheOperator’sManualforinformationonstartingthe engine—1)Engagetheparkingbrake;2)Setthedriveto neutral;3)Openthechoke;4)Turntheengineswitchon;5) Engagethefuelswitch;6)Pulltherecoilstarterandsetthe throttletofast;7)Closethechoke.

decal125-4963

133-5619

decal133-5619

decal125-4958

125–4958

2.ReadtheOperator’sManualforinformationonshuttingoff theengine—1)Setthethrottletoslow;2)Engagetheparking brake;3)Setthedrivetoneutral;4)Turntheengineswitchto stop;5)Disengagethefuelswitch.

ProductOverview

g019617

Figure3

1.Operatorplatform

2.Steertires

3.Reverse-speed-control lever

4.Drivetires

5.Handlebars8.Fueltank

6.Forward-speed-control lever

Controls

Becomefamiliarwithallthecontrols(Figure3)before youstarttheengineandoperatethemachine.

BrakePedal

Applythefoot-operatedbrakepedaltostopthe machine(Figure3).

Forward-Speed-ControlLever

Squeezetheforward-speed-controllever(Figure3)to movethemachineforward.Themoreyousqueeze thehandle,thefasterthemachinewilltravel.

Reverse-Speed-ControlLever

Squeezethereverse-speed-controllever(Figure3)to reversethemovementofthemachine.Themoreyou squeezethehandle,thefasterthemachinewilltravel.

7.Dumphandle/pedal

9.Parkingbrake

10.Brakepedal

Toreleasetheparkingbrake,pressthebuttononthe endofthebrakehandleandlowerthelever.

FuelGauge

Thefuelgaugeispartofthefuel-tankcap,andthe gaugeindicatestheamountoffuelinthefueltank (Figure3).

Fuel-TankShutoffValve

Thefuel-tankshutoffvalveislocatedatthebottomof thefueltank.Theshutoffvalveisusedtocontrolthe owoffuelfromthetankwhenyouareperforming maintenanceorstoringthemachine(Figure4).

DumpHandle/Pedal

Pullthedumphandlebackwardand/orpressonthe frontofthepedaltodumpthehopper(Figure3).Push thedumphandleforwardand/orpressontherearof thepedaltolowerthehopper.

ParkingBrakeLever

Toengagetheparkingbrake,pulluponthelever. (Figure3).

g025707

Figure4

1.Forward

2.Shutoff-valveleverforthe fueltank(OFFposition)

Figure5

1.Recoilstarter4.Throttlelever

2.Fuelshut-offvalve5.On/Offswitch

3.Chokelever

g020538

EngineControls

OilAlertSystem

Theoilalertsystemisdesignedtopreventengine damagecausedbyaninsufcientamountofoilin thecrankcase.Beforetheoillevelinthecrankcase canfallbelowasafelimit,theoilalertsystemwill automaticallyshutofftheengine(theengineswitch willremainintheONposition).Iftheenginestops andwillnotrestart,checktheengine-oillevelbefore troubleshootinginotherareas

ChokeLever

Thechokelever(Figure5)isrequiredwhenstartinga coldengine.Beforepullingontherecoilstarthandle, movethechokelevertotheCLOSEDposition.Once theengineisrunning,movethechokelevertothe OPENposition.Donotusethechokeiftheengineis alreadywarmeduportheairtemperatureishigh.

ThrottleLever

Thethrottlelever(Figure5)controlsthespeed(rpm) oftheengine.Itislocatednexttothechokelever. Itsetstheenginerpmandthereforecanincrease anddecreasethespeedofthemachine.Forbest performance,setthethrottlelevertotheFASTposition.

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