Toro Fuel Tank Service Kit, MB-1600 Mud Buggy Installation guide

Brand: Toro

Model: Fuel Tank Service Kit, MB-1600 Mud Buggy

Type: Installation guide

Toro Fuel Tank Service Kit, MB-1600 Mud Buggy empowers users with the means to restore and maintain their machines' fuel systems. This kit provides all the necessary components to replace the fuel tank, fuel hose, hose clamps, fuel cap, and vent hose, ensuring a comprehensive fuel system overhaul. By following the detailed instructions included, users can confidently undertake the repair process, giving their machines a renewed lease on life.

FormNo.3379-751RevB

FuelTankServiceKit

MB-1600MudBuggy

ModelNo.130-2100

InstallationInstructions

WARNING

CALIFORNIA

Proposition65Warning

ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato

causecancer,birthdefects,orreproductiveharm.

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Qty.

Use

Nopartsrequired

–

Removetheenginecowl.

Nopartsrequired

–

Drainthefueltank.

Nopartsrequired

–

Removethefueltank.

Tank1

Fuelhose1

Hoseclamp2

Fuelcap/gauge

Preparethefueltank.

Nopartsrequired

–

Installthefueltank.

Nopartsrequired

–

Installthefuelhose.

Venthose1

Hoseclamp2

Cabletie

Replacetheventhose.

Nopartsrequired

–

Checkthefuelsystem.

Nopartsrequired

–

Installtheenginecowl.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.T oro.com.

OriginalInstructions(EN)

PrintedintheUSA

AllRightsReserved

*3379-751*B

RemovingtheEngineCowl

NoPartsRequired

Procedure

1.Movethemachinetoalevelsurfaceandsettheparking

brake;refertotheOperator’sManualforthemachine.

2.Positionthehopperinthedumpposition;refertothe

Operator’sManualforthemachine.

3.Shutofftheengine;refertotheOperator’sManualfor

themachine.

4.Removethe4latchesthatsecuretheenginecowltothe

machineatthe4latchposts(Figure1).

Figure1

1.Enginecowl3.Latch

2.Latchpost

5.Lifttheenginecowlupandremoveitfromthemachine

(Figure1).

DrainingtheFuelTank

NoPartsRequired

Procedure

1.Rotatetheleverforthetank-shutoffvalveforwardand

uptotheOffposition(Figure2).

Figure2

1.Forward

3.Engine-switchlever(Stop

position)

2.Shutoff-valveleverforthe

fueltank(Offposition)

2.Starttheengineandrunthemachineuntiltheengine

stops.

3.Rotatetheleverfortheengineswitchclockwisetothe

Stopposition,andallowtheenginetocool(Figure2).

4.Carefullyremovethespark-plugwirefromtheterminal

ofthesparkplug.(Figure3).

G019281

Figure3

1.Spark-plugwire

5.Removethehoseclampandhosefromthebarbed

ttingatthetopoftheengineswitch(Figure2).

6.Alignthehoseintoanapprovedfuelcontainerwitha

26.5L(7USgallon)capacity(Figure4).

Figure4

1.Fuelhose2.Fuelcontainer

7.Rotatetheshutoffvalveforthefueltankbackand

downtotheOnposition(Figure2).

Note:Allowthefueltanktodraincompletely.

8.Installthehoseandhoseclampontothebarbedtting

atthetopoftheengineswitch(

Figure2).

Note:Ensurethatthebarbedttingisfullyinserted

intotheendofthefuelhoseandthattheclampis

centeredoverthebarbedareaofthetting.

RemovingtheFuelTank

NoPartsRequired

Procedure

1.Removethehoseclampandtheventhosethatare

attachedtotheventvalveinthefueltank(Figure5).

Figure5

1.Hoseclamp3.Ventvalve

2.Venthose

2.Removethehoseclampthatsecuresthefuelhoseto

thebarbedttinginthefuellter,andremovethehose

(Figure6).

Figure6

1.Fuellter

3.Fuelhose

2.Hoseclamp

4.Tank-shutoffvalve

3.Removethe4ange-headboltsthatsecurethefuel

tanktothemachine,andremovethetankfromthe

machine(Figure7).

Note:Becarefulwhenliftingthetankuptoensure

thattheshutoffvalveforthefueltankandthefuel

hosearecenteredwhilepassingthroughtheholeinthe

tank-supportplatefortheshutoffvalve.

Figure7

1.Flangebolts

Note:Retaintheangeboltsfortheinstallationofthe

fueltankfromthefuel-tankservicekit.

Note:ForToroModelNo.68038—Serial

No.313000101–313000240andModelNo.

68038G—SerialNo.313000101–313000200,retainthe

spacersforinstallingofthenewfueltankfromthe

fuel-tankservicekit(Figure8).

Important:ForStoneConstructionEquipment

ModelNo.FB1000,SB1000,andSB2100,refer

totheToro

SWS Ser vice Bulletin No. 73

for

informationaboutorderingthe4bolts,4washers,

and2fueltankspacersnecessarytoinstallthenew

fueltankfromthefuel-tankservicekit.

Figure8

1.Leftspacer

3.Tankplate

2.Fuel-valvehole4.Rightspacer

PreparingtheFuelTank

Partsneededforthisprocedure:

1Tank

1Fuelhose

2Hoseclamp

Fuelcap/gauge

InstallingtheShutoffValve

1.Atthebottomoftheoriginalfueltank,removethefuel

hosefromthettingoftheshutoffvalve(Figure9).

Note:Discardtheoriginalfuelhoseandtheoriginal

hoseclamps.

Figure9

1.Fueltank(original)4.Fuelshutoffvalve

2.Coupler5.Fuelhose(original)

3.Fueltank(fuel-tankservice

kit)

6.Fuelhose(fuel-tank

servicekit)

2.Removetheshutoffvalvefromthecouplerinthe

bottomoftheoriginaltank(Figure9).

Note:Discardtheoriginalfueltank.

3.Cleanoffthethreadsoftheshutoffvalve.

4.ApplyPTFEthread-sealingtapetothethreadsofthe

shutoffvalve.

5.Inserttheshutoffvalveintothecouplerofthefuel

tankfromthefuel-tankservicekit,andthreadthevalve

intothecoupler(

Figure9).

6.Tightentheshutoffvalveandpositionthebarbed

ttingtopointtotheleftasviewedfromthebottom

ofthetank(Figure10).

Figure10

1.Forward

4.Fueltankbottom(fuel-tank

servicekit)

2.Fuelhose(fuel-tank

servicekit)

5.Fuel-shutoffvalve

3.Hoseclamp(fuel-tank

servicekit)

7.Positionaclampfromthefuel-tankservicekitover

eachendofthefuelhosefromthekit(Figure9and

Figure10).

8.Installoneendofthefuelhoseoverthebarbedtting

oftheshutoffvalveinthetank(

Figure10).

Note:Ensurethatthebarbedttingisfullyinserted

intotheendofthefuelhoseandthattheclampis

centeredoverthebarbedareaofthetting.

InstallingtheFuelCap

1.Inserttheretainerthatisattheendofthechainfor

thefuelcap/gaugeintothellerneckofthefueltank

(Figure11).

Note:Useascrewdrivertopushtheretainerintothe

cavityofthefueltank.

Figure11

1.Fuelcap/gauge

3.Retainer

2.Chain

4.Fillerneck

2.Alignthefuelcap/gaugeoverthellerneck,andfeed

thechainattheendofthegaugeintothellerneck

(Figure11).

3.Threadthecapontothellerneckofthefueltank

untilitishandtight(Figure11).

InstallingtheFuelTank

NoPartsRequired

Procedure

1.Wipethesurfaceofthespacersclean(Figure8).

2.Aligntheslotsinthespacerstothemountingholesfor

thefueltankthatareinthetank–supportplate(Figure

8).

Note:Ensurethatthecutoutintheleftspacersfor

thefuel-shutoffvalveisalignedwiththeholeinthe

tank-supportplatefortheshutoffvalve.

3.Alignthefueltank(fromthefuel-tankservicekit)to

themachine,andinsertthefuelhoseandshutoffvalve

throughthetank-supportplate(Figure12).

Note:Avoiddamagingthefuelhoseandfuel-shutoff

valvewhenloweringthetank.Ensurethatthefuel

hoseandfuel-shutoffvalvearecenteredwhilepassing

throughtheholeinthetank-supportplateforthe

shutoffvalve.

Figure12

1.Flangebolts

4.Lowerthetankandalignthemountingholesinthe

tankwiththemountingholesinthetank-supportplate.

5.Applymedium-grade(serviceremovable)

thread-lockingcompoundtothe4angeboltsthatyou

removedinstep3of3RemovingtheFuelTank(page

3).

6.Securethetanktothemachinewiththe4angebolts

(Figure12),andtorquetheboltsto23to28N-m(17

to21ft-lb).

InstallingtheFuelHose

NoPartsRequired

Procedure

1.Installthefuelhosefromtheshutoffvalvetothe

barbedttingofthefuellter(Figure13).

Figure13

1.Fuellter

3.Fuelhose

2.Hoseclamp

2.Securethefuelhosetolterthewithahoseclamp

fromthefuel-tankservicekit(Figure13).

Note:Ensurethatthebarbedttingofthefuellteris

fullyinsertedintotheendofthefuelhoseandthatthe

clampiscenteredoverthebarbedareaofthetting.

ReplacingtheVentHosefor

theFuelTank

Partsneededforthisprocedure:

1Venthose

2Hoseclamp

Cabletie

RemovingtheVentHose

1.Removethecabletiethatsecurestheventhoseforthe

fueltanktothehandlebarcolumn(Figure14).

Figure14

1.Cabletie

3.HoseFitting

2.Venthose4.Hoseclamp

2.Removetheclampthatsecurestheventhosetothe

hosettingatthebottomforwardcornerofthe

air-ltercase(Figure14).

3.Removethehosefromthettingandremovethehose

fromthemachine(

Figure14).

Note:Discardtheventhoseandclamps.

InstallingtheVentHose

1.Aligntheventhosefromthefromthefuel-tankservice

kitwiththehosettingatthebottomforwardcorner

oftheair-ltercase(Figure15).

Figure15

1.Handlebarcolumn3.Hoseclamp

2.Bearing-supportbracket

4.Venthose(fuel-tank

servicekit)

2.Securethehosewithaclampfromthekit(Figure15).

Note:Ensurethatthettingoftheair-ltercaseis

fullyinsertedintotheendoftheventhoseandthatthe

clampiscenteredoverthetting.

3.Routetheventhoseforwardofthehandlebarcolumn

abovethebearing-supportbracketandupalongthe

rightsideofthecolumnasshowninFigure15.

4.Installtheventhoseandhoseclampontothehose

ttingoftheventvalveforthefueltank(Figure16).

Note:Ensurethatthettingoftheventvalveisfully

insertedintotheendoftheventhoseandthatthe

clampiscenteredoverthetting.

Figure16

1.Holes9.5mm(3/8inch)

4.Hoseclamp

2.Cabletie5.Barbedtting(ventvalve)

3.Venthose

5.Usingthe2holes9.5mm(3/8inch)inthetopofthe

fueltank,securethehosetothetankwiththecable

tieasshowninFigure16.

CheckingtheFuelSystem

NoPartsRequired

Procedure

1.Add2L(0.5USgallon)offueltothefueltank;refer

totheOperator’sManualforthemachine.

2.Rotatethetank-shutoffvalveclockwisetotheOn

position(Figure2).

3.Checkthebottomofthetank,fuelshutoffvalve,and

fuelhoseforleaks.

Note:Ifthereisafuelleak,rotatethefuelshutoff

valvetotheOffposition,andrepairtheleaksbefore

proceedingtothenextstep.

4.RotateengineswitchcounterclockwisetotheOn

position(Figure2).

5.Checktheengineswitchandthefuelhoseforfuelleaks.

Note:Ifthereisafuelleak,rotatethefuelshutoff

valvetotheOffposition,andrepairtheleaksbefore

proceedingtothenextstep.

6.Connectthespark-plugwiretotheterminalofthe

sparkplug(Figure3).

7.Startthemachine;refertotheOperator’sManualforthe

machine.

8.Checkthefuelsystemandengineforfuelleaks.

Note:Ifthereisafuelleak,immediatelyshutoff

themachine,rotatethefuelshutoffvalvetotheOff

position,andrepairtheleaks.

9.Shutoffthemachine.

InstallingtheEngineCowl

NoPartsRequired

Procedure

1.Aligntheenginecowloverthemachine(Figure17).

Figure17

1.Hole3.Latch

2.Guidepin

4.Latchpost

2.Carefullylowerthecowlwhilealigningtheguidepins

inthechassiswiththeholesinthecowl(Figure17).

3.Securetheenginecowltothechassiswiththe4latches

onthechassistothe4latchpostsonthecowl(Figure

17).

4.Startthemachine,movethehoppertotheupright

position,andshutoffthemachine;refertothe

Operator’sManualforthemachine.

Toro Fuel Tank Service Kit, MB-1600 Mud Buggy Installation guide

Toro Fuel Tank Service Kit, MB-1600 Mud Buggy Installation guide

Toro Fuel Tank Service Kit, MB-1600 Mud Buggy Installation guide

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