MB-1600 Mud Buggy

• Read the Operator's Manual and other training material. If the operator(s) or mechanic(s) cannot read or understand the information, it is the owner's responsibility to explain this material to them.

• Become familiar with the safe operation of the equipment, operator controls, and safety signs.

• All operators and mechanics should be trained. The owner is responsible for training the users.

• Never let children or untrained people operate or service the equipment. Local regulations may restrict the age of the operator.

• The owner/user can prevent and is responsible for accidents or injuries occurring to people or damage to property.

• Wear appropriate clothing including hard hat, eye protection, long pants, substantial, slip-resistant footwear, and hearing protection. Tie back long hair. Do not wear loose jewelry.

• Inspect the area where the equipment is to be used and ensure that all objects are removed from the machine before use.

• Use extreme care in handling fuel. It is flammable and its vapors are explosive.

  • Extinguish all cigarettes, cigars, pipes, and other sources of ignition.

  • Use only an approved container.

  • Do not remove the fuel cap or fill the fuel tank while the engine is running or hot.

  • Do not add or drain the fuel in an enclosed space.

  • Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance.

  • If you spill fuel, do not attempt to start the engine; avoid creating any source of ignition until the fuel vapors have dissipated.

• Ensure that the shields of the machine are attached and functioning properly. Do not operate the machine unless they are functioning properly.

• Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.

• Never run an engine in an enclosed area.

• Operate the machine only in good light, keeping away from holes and hidden hazards.

• Ensure that all drives are in neutral before starting the engine. Start the engine only from the operator's position.

• Do not operate the machine with the guards not securely in place. Ensure that all interlocks are attached, adjusted properly, and functioning properly.

• Do not change the engine governor setting or overspeed the engine.

• Stop the machine on level ground, engage the parking brake, lower the hopper, and shut off the engine before leaving the operator's position for any reason.

• Never carry passengers and keep pets and bystanders away.

• Slow down and use caution when making turns and crossing roads and sidewalks.

• Do not operate the machine while ill, tired, or under the influence of alcohol or drugs.

• Use care when loading or unloading the machine into a trailer or truck.

• Use care when approaching blind corners, shrubs, trees, or other objects that may obscure vision.

• Ensure that the area is clear of other people before operating the machine. Shut off the machine if anyone enters the area.

• Never leave a running machine unattended.

• Do not exceed the rated operating capacity, as the machine may become unstable which may result in loss of control.

• Never jerk the controls; use a steady motion.

• Watch for traffic when operating near or crossing roadways.

• Do not touch parts which may be hot from operation. Allow them to cool before attempting to maintain, adjust, or service.

• Check for overhead clearances (i.e., branches, doorways, electrical wires) before driving under any objects and do not contact them.

• Ensure that you operate the machine in areas where there are no obstacles close to you. Failure to maintain adequate distance from trees, walls, and other barriers may result in injury as the machine backs up during operation if you are not attentive to the surroundings. Operate the machine only in areas where there is sufficient clearance for you to safely maneuver the product.

• Locate the pinch point areas marked on the machine and keep hands and feet away from these areas.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

• Do not overload the hopper and always keep the load level when operating the machine.

• Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. The operator is responsible for safe slope operation. operating the machine on any slope requires extra caution. Before using the machine on a slope, you must:

  • Review and understand the slope instructions in the manual and on the machine.

  • Evaluate the site conditions of the day to determine if the slope is safe for machine operation. Always use common sense and good judgment when performing this evaluation. Changes in the terrain, such as moisture, can quickly affect the operation of the machine on a slope.

• Raising the hopper on a slope affects the stability of the machine. Keep the hopper in the lowered position when on slopes.

• When operating on a slope, fold the platform up and walk behind the machine until it is on flat ground.

• Operate up and down slopes with the heavy end of the machine uphill. Weight distribution changes with a full hopper. A full hopper makes the front of the machine the heavy end, so when on traveling up or down slopes with a full hopper, walk-behind the machine with the full hopper uphill.

• Identify hazards at the base of the slope. Do not operate the machine near drop-offs, ditches, embankments, water or other hazards. The machine could suddenly roll over if a wheel or track goes over the edge or the edge collapses. Keep a safe distance (twice the width of the machine) between the machine and any hazard.

• Avoid starting, stopping, or turning the machine on a slope. Avoid making sudden changes in speed or direction; turn slowly and gradually.

• Keep all movements on slopes slow and gradual. Do not make sudden changes in speed or direction.

• Do not operate the machine under any conditions where traction, steering, or stability is in question. Be aware that operating the machine on wet grass, across slopes or downhill may cause the machine to lose traction. Loss of traction to the wheels or tracks may result in sliding and a loss of braking and steering. The machine can slide even if the wheels or tracks are stopped.

• Remove or mark obstacles such as ditches, holes, ruts, bumps, rocks or other hidden hazards. Tall grass can hide obstacles. Uneven terrain could overturn the machine.

• If you lose control of the machine, step off and away from the direction of travel of the machine.

• Let the engine cool before storing and do not store the machine near an open flame.

• Engage the parking brake, shut off the engine, and wait for all movement to stop before adjusting, cleaning, or repairing the machine.

• Clean debris from drives, mufflers, and the engine to help prevent fires. Clean up oil or fuel spills.

• Do not store fuel near flames or drain indoors.

• Park the machine on level ground. Never allow untrained personnel to service the machine.

• Use jack stands to support components when required.

• Carefully release pressure from components with stored energy.

• Disconnect the battery, negative terminal first and positive terminal last, before making any repairs. Connect the battery positive terminal first and negative terminal last.

• Keep your hands and feet away from moving parts. If possible, do not make adjustments with the engine running.

• Charge batteries in an open, well-ventilated area, away from spark and flames. Unplug the charger before connecting or disconnecting it from the battery. Wear protective clothing and use insulated tools.

• Keep all parts in good working condition and all hardware tightened. Replace all worn or damaged decals.

• Use the cylinder lock to secure the hopper in the raised position.

• Keep nuts and bolts tight. Keep equipment in good condition.

• Never tamper with safety devices.

• Use only genuine Toro replacement parts to ensure that original standards are maintained.

• Battery acid is poisonous and can cause burns. Avoid contact with skin, eyes, and clothing. Protect your face, eyes, and clothing when working with a battery.

• Battery gases can explode. Keep cigarettes, sparks, and flames away from the battery.

• Keep your body and hands away from pinhole leaks or nozzles that eject high-pressure hydraulic fluid. Use cardboard or paper to find hydraulic leaks; never use your hands. Hydraulic fluid escaping under pressure can penetrate skin and cause injury, requiring surgery within a few hours by a qualified surgeon; otherwise, gangrene may result.

Apply the foot-operated brake pedal to stop the machine (Figure 3).

Squeeze the forward-speed-control lever (Figure 3) to move the machine forward. The more you squeeze the handle, the faster the machine will travel.

Squeeze the reverse-speed-control lever (Figure 3) to reverse the movement of the machine. The more you squeeze the handle, the faster the machine will travel.

Pull the dump handle backward and/or press on the front of the pedal to dump the hopper (Figure 3). Push the dump handle forward and/or press on the rear of the pedal to lower the hopper.

To engage the parking brake, pull up on the lever. (Figure 3).

To release the parking brake, press the button on the end of the brake handle and lower the lever.

The fuel gauge is part of the fuel-tank cap, and the gauge indicates the amount of fuel in the fuel tank (Figure 3).

The oil alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase can fall below a safe limit, the oil alert system will automatically shut off the engine (the engine switch will remain in the ON position). If the engine stops and will not restart, check the engine-oil level before troubleshooting in other areas

The choke lever (Figure 5) is required when starting a cold engine. Before pulling on the recoil start handle, move the choke lever to the CLOSED position. Once the engine is running, move the choke lever to the OPEN position. Do not use the choke if the engine is already warmed up or the air temperature is high.

Figure 5

1. Recoil starter
2. Fuel shut-off valve
3. Choke lever
4. Throttle lever
5. On/Off switch

The throttle lever (Figure 5) controls the speed (rpm) of the engine. It is located next to the choke lever. It sets the engine rpm and therefore can increase and decrease the speed of the machine. For best performance, set the throttle lever to the FAST position.

The fuel-shutoff valve (Figure 5) controls the flow of fuel from the fuel tank to the carburetor. The valve is located underneath the choke lever. Move the shutoff valve to the On position before attempting to start the engine. Once you have finished using the machine and you have turned the engine off, move the fuel-shutoff valve to the Off position.

The On/Off switch (Figure 5) allows the engine to start and also stops the engine. This switch is located on the front of the engine. The On/Off switch is marked as follows:

• l (On)—the ignition system is on.

• O (Off)—the ignition system is off.

Note: To start the machine, you must first move this control to the ON position. When you want to shut off the engine, move this switch to the OFF position.

To start the engine, pull on the recoil starter handle (Figure 5) quickly to turn the engine over. The engine controls described in Figure 5 must all be set correctly for the engine to start.

Use Toro fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps fuel fresh during storage of 90 days or less. Drain the fuel tank for periods of longer storage.

• Eliminates gum-like varnish buildup in the fuel system, which causes hard starting

Important: Do not use fuel additives containing methanol or ethanol.

Add the correct amount of fuel stabilizer/conditioner to the fuel.

Note: A fuel stabilizer/conditioner is most effective when mixed with fresh fuel. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

Fuel tank capacity: 21.6 L (5.7 US gal).

1. Park the machine on a level surface and shut off the engine. Allow the engine to cool.

2. Clean around the fuel tank cap and remove it.

3. Add fuel to the fuel tank until the level is just below the bottom of the filler neck.

   Important: This space in the tank allows fuel to expand. Do not fill the fuel tank completely full.

4. Install the fuel tank cap securely, turning it until it clicks.

5. Wipe up any fuel that may have spilled.

Know the load capacities of your machine and never exceed them. The machine is normally operated on uneven, unpaved, bumpy, and/or inclined surfaces. Adjust your load accordingly.

1. Position the machine in the area where you intend to dump the load.

2. Dump the hopper by pushing forward the dump handle or pressing down on the forward part of the dump pedal (Figure 6).

   

   Figure 6

   1. Dump handle
   2. Dump pedal
   3. Hopper dump position
   4. Hopper upright position

3. Move the hopper to the upright position by pulling back the dump handle or pressing down on the rear part of the dump pedal (Figure 6).

Parking the machine on a grade should be avoided if possible. If the machine must be parked on a grade, park it at a right angle to the slope, engage the parking brake and block the wheels, if necessary.

1. Park the machine out of main traffic areas and engage the parking brake.

2. When the machine will be out of use for a long period of time, tilt the hopper up so water, snow, and debris will not collect inside.

3. Cover the dump cylinder shaft to prevent corrosion.

Note: You must dump the hopper before you remove the cowl. You can do this using either the hydraulics or by removing the pin in the hydraulic cylinder and the hopper base.

1. Before removing the cowl (Figure 14), shut off the engine and allow the engine to cool.

   

   Figure 14

   1. Cowl

2. Unhook the cowl latches (Figure 15) and remove the cowl.

   

   Figure 15

   1. Cowl latch

3. Install the cowl and secure the latches upon completion of the task.

If you operate the machine under normal conditions, lubricate all grease fittings for the bearings and bushings after every 50 hours of operation with No. 2 lithium grease. Lubricate bearings and bushings immediately after every washing, regardless of the interval listed. Also, apply a light coating of oil onto the control cables.

The grease fitting locations and quantities are as follows:

Note: Remove the blue protection caps before greasing and replace when finished.

• Hopper pivot points (Quantity 2)—Figure 16

  

  Figure 16

• Cylinder pivots (Quantity 2)—Figure 17

  

  Figure 17

Oil type: API classification SJ or later.

Oil viscosity: selected the oil viscosity according to ambient temperature in the table below.

Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it has already been run, allow the oil to drain back down to the sump for at least 10 minutes before checking.

1. Park the machine on a level surface and shut off the engine. Allow the engine to cool.

2. Unlatch and remove the cowl.

3. Clean around the oil filler cap/dipstick (Figure 18).

   

   Figure 18

   1. Filler tube
   2. Dipstick
   3. Upper limit
   4. Lower limit
   5. Oil drain bolt

4. Remove the oil filler cap/dipstick by rotating it counterclockwise (Figure 18).

5. Wipe the oil filler cap/dipstick clean and insert it into filler port.

   Note: Do not screw into port.

   Important: Do not overfill the crankcase with oil because the engine may be damaged.

6. Remove and check level of oil.

   Note: If oil level is near or below the lower limit mark on the dipstick, add only enough of the specified oil to raise level to the upper limit mark (bottom edge of the oil fill hole); refer to Figure 18.

7. Check level of oil (Figure 18).

8. Install the oil filler cap/dipstick and wipe up any spilled oil (Figure 18).

9. Install the cowl and secure the latches.

1. Disconnect the spark-plug wire.

2. Remove the wing nut that secures the air-cleaner cover to the air cleaner and remove the cover. Clean the cover thoroughly (Figure 19).

3. Remove the wing nut from the air filter and remove the filter (Figure 19).

   

   Figure 19

   1. Wing nut
   2. Air-cleaner cover
   3. Wing nut
   4. Paper element
   5. Foam element
   6. Gasket

4. Remove the foam filter from the paper filter (Figure 19).

5. Inspect both air-filter elements and replace them if they are damaged.

   Note: Always replace the paper air-filter element at the scheduled interval.

6. Clean the foam element as follows:

   1. Wash the foam element in a solution of liquid soap and warm water.

      Note: Squeeze to remove dirt, but do not twist the element because the foam may tear.

   2. Dry the element by wrapping in a clean rag. Squeeze the rag and foam element to dry, but do not twist the element because the foam may tear.

   3. Saturate the element with clean engine oil. Squeeze element to remove excess oil and to distribute oil thoroughly.

7. Cleaning the paper element: Tap the filter element several times on a hard surface to remove dirt or blow compressed air (not exceeding 2.07 bar (30 psi) through the filter element from the inside. Never try to brush off dirt; brushing will force dirt into the fibers.

8. Install the foam element, paper element, and air-cleaner cover.

   Important: Do not operate the engine without the air-cleaner element. Operating without an element causes damage to the engine.

Crankcase capacity: 1.1 L (1.16 US qt).

Oil type: API classification SJ or later.

Oil viscosity: selected the oil viscosity according to ambient temperature in the table below.

1. Start and run the engine for a few minutes to warm the engine oil; then, shut off the engine.

2. Have a funnel ready to place under the oil drain plug, then remove the plug and place the funnel under the plug to guide the oil into a container (Figure 20).

3. Install the drain plug and wipe away excess oil from the machine.

4. Fill the crankcase with the specified oil; refer to Figure 18 in Checking the Engine-Oil Level.

5. Dispose of the oil properly. Recycle the used oil according to local codes.

   

   Figure 20

   1. Oil pan
   2. Oil-drain hole
   3. Oil-fill cap

Spark plug type: NGK BPR 6ES spark plug or equivalent.

Air gap: 0.70-0.80 mm (0.028-0.031 inch).

1. Remove the spark-plug wire.

2. Clean around spark plug and remove plug from cylinder head.

   Important: Replace a cracked, fouled, or dirty spark plug. Do not sand blast, scrape, or clean electrodes because engine damaged could result from grit entering the cylinder.

3. Set the air gap at 0.70 to 0.80 mm (0.028 to 0.031 inch) (Figure 21). Install the spark plug carefully by hand to avoid cross-threading.

   

   Figure 21

   1. 0.70 to 0.80 mm (0.028 to 0.031 inch)

4. After the spark plug is seated, tighten it with a spark plug wrench to compress the sealing washer.

5. When installing a new spark plug, tighten 1/2 turn after the spark plug seats to compress the washer.

6. When installing the original spark plug, tighten 1/8 to 1/4 turn after the spark plug seats to compress the washer.

   Note: A loose spark plug can overheat and damage the engine. Overtightening the spark plug can damage the threads in the cylinder head.

7. Connect the spark-plug wire.

1. Move the fuel valve to the OFF position, then remove the fuel sediment cup and O-ring (Figure 22).

   

   Figure 22

   1. Fuel valve
   2. O-ring
   3. Fuel sediment bowl

2. Wash the sediment cup and O-ring in nonflammable solvent, and dry them thoroughly.

3. Place the O-ring in the fuel valve, and install the sediment cup (Figure 22).

4. Tighten the sediment cup securely.

1. Shut off the engine and engage the parking brake. Allow the engine to cool.

2. Rotate the lever for the tank-shutoff valve forward and up to the OFF position (Figure 23).

   

   Figure 23

   1. Forward
   2. Lever—tank-shutoff-valve (Off position)
   3. Lever—engine switch (Stop position)

3. Start the engine and run the machine until the engine shuts off.

4. Rotate the lever for the engine switch clockwise to the STOP position, and allow the engine to cool (Figure 23).

5. Remove the spark-plug wire (Figure 24).

   

   Figure 24

   1. Spark-plug wire

6. Remove the hose clamps and hose from the barbed fitting at fuel filter (Figure 25).

   Note: Drain the fuel from the old fuel filter dispose of the fuel and filter at an authorized disposal site.

   

   Figure 25

   1. Hose (engine switch)
   2. Fuel-filter arrow
   3. Hose clamp
   4. Hose (tank-shutoff valve)

7. Align the arrow on the case of the new fuel filter to correspond with the fuel flow to the engine (Figure 25).

   Note: Ensure that the hose clamps are slipped over the hoses attached to the engine fuel-shutoff valve and the tank-shutoff valve.

8. Insert the barbed fitting of the fuel filter into the hose from the engine switch (Figure 25).

9. Insert the barbed fitting at the other end of the fuel filter into the hose attached to the tank-shutoff valve (Figure 25).

10. Align the clamps over the hoses at the barbed area of the filter, and secure the clamps to the hoses.

11. Connect the spark-plug wire (Figure 24).

12. Open the tank-shutoff valve and turn on the engine switch, and check for fuel leaks (Figure 23).

1. Shut off the engine and engage the parking brake. Allow the engine to cool.

2. Move the tank fuel-shutoff valve to the OFF position.

3. Remove the fuel sediment cup (Figure 22) and empty the fuel from it.

4. Move the tank fuel-shutoff valve (Figure 22) to the ON position, and drain the fuel from the fuel tank into a suitable container.

5. Replace the sediment cup and tighten securely (Figure 22).

6. Loosen the drain screw to drain fuel from the carburetor into a suitable container.

7. Install the drain screw when the carburetor is drained.

The hydrostatic transmission is equipped with a self-centering device that adjusts the transmission to the Neutral position, stopping the machine. If the machine creeps in one direction or the other when you release the controls, adjust the transmission. To adjust the transmission, use the following procedure:

1. Shut off the engine.

2. Remove the throttle lever cables at the transmission.

3. Lift the front wheels off the ground, and support the machine with a jack stand.

4. Start the machine. Increase the engine throttle to full speed while checking for front drive wheel rotation.

   Note: If the wheels rotate, proceed to the next step. If the wheels do not rotate, shut off the engine and install the control cables.

5. Note the directional movement of the front drive wheels. Shut off the engine.

6. Loosen the lock down screw (Figure 26) until the return arm can be rotated.

   Note: If wheels rotate forward, rotate the return arm counterclockwise. If wheels rotate backward, rotate the return arm clockwise.

   

   Figure 26

   1. Lock down screw
   2. Return arm

7. Tighten the lock down screw and repeat step 4.

• Inspect tires for cuts, slashes, or bulges. Tires with defects need to be replaced or repaired for proper handling and safety.

• Check weekly to make sure all lug nuts are tight. Torque the lug nuts to 122 N∙m (90 ft-lb). This is important on new machines or newly replaced wheels.

Hydraulic fluid type: Mobil 424 Hydraulic Oil or equivalent

The machine hydraulic tank is filled at the factory with approximately 28.4 L (30 US qt) of hydraulic fluid.

Important: Always use the correct hydraulic fluid. Unspecified fluids will damage the hydraulic system.

1. Park the machine on a level surface and shut off the engine. Allow the engine to cool.

2. Unlatch and remove the cowl.

3. Ensure that the hopper is down and in the level position.

4. Locate the fluid sight gauge (Figure 30) on the side of the hydraulic fluid tank.

   Note: When the fluid level is correct, the fluid level will cover 25% to 75% of the window in the sight gauge.

   

   Figure 30

   1. Sight gauge

5. If the fluid level is low, remove the breather/filler cap from the top of the hydraulic tank (Figure 31) and add enough of the specified hydraulic fluid to raise it to the proper level.

   Caution

   The hydraulic breather/filler cap is designed to pressurize the reservoir to 34 kPa (5 psi).

   Loosen the cap slowly to avoid injury whenever adding fluid or working on the hydraulic system. Use a wrench on the hex directly under the cap.

   

   Figure 31

   1. Breather/filler cap
   2. Hex

6. Install the breather/filler cap. Wipe up any spilled hydraulic fluid (Figure 31).

Important: Do not use an automotive oil filter or severe hydraulic system damage may result.

1. Park the machine on a level surface, engage the parking brake. and shut off the engine.

2. Unlatch and remove the cowl.

3. Place a drain pan under the filter (Figure 32).

   

   Figure 32

   1. Hydraulic filter

4. Remove the old filter (Figure 32) and wipe the surface of the filter adapter gasket clean.

5. Apply a thin coat hydraulic fluid to the rubber gasket on the replacement filter.

6. Install the replacement hydraulic filter onto the filter adapter (Figure 32). Tighten it clockwise until the rubber gasket contacts the filter adapter, then tighten the filter an additional 3/4 turn.

7. Clean up any spilled fluid.

8. Start the engine and let it run for 2 minutes to purge air from the system.

9. Shut off the engine and check for leaks.

10. Check the fluid level in the hydraulic tank, refer to Checking the Hydraulic-Fluid Level.

    Note: Do not over fill the hydraulic tank.

11. Install the cowl and secure the latches.

Hydraulic fluid type: Mobil 424 Hydraulic Oil or equivalent

Hydraulic fluid capacity: 28.4 L (30 US qt)

Note: For temperatures below 1°C (35°F), the fluid should be switched to thinner 15 weight hydraulic fluid.

1. Park the machine on a level surface.

2. Unlatch and remove the cowl (Figure 14 and Figure 15).

3. Allow the machine to cool completely.

4. Remove the hydraulic tank breather/filler cap (Figure 33).

   Caution

   The hydraulic breather/filler cap is designed to pressurize the reservoir to 34 kPa (5 psi).

   Loosen the cap slowly to avoid injury whenever adding oil or working on the hydraulic system. Use a wrench on the hex directly under the cap.

   

   Figure 33

   1. Hex
   2. Breather/filler cap

5. Place a large drain pan under the drain plug located at the bottom of the hydraulic tank.

6. Remove the drain plug and allow the oil to drain into the pan.

7. When finished, install and tighten the drain plug.

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

8. Fill the hydraulic tank with approximately 28.4 liters (30 US quarts) of hydraulic fluid as specified previously.

9. Start the engine and let it run for a 2 to 3 minutes.

10. Shut off the engine.

11. Check the hydraulic fluid level and add more hydraulic fluid if necessary.

12. Install the cowl and secure the latches.