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  3. Fuel Tank Service Kit, MB-1600 Mud Buggy

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

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FormNo.3379-751RevB
FuelTankServiceKit
MB-1600MudBuggy
ModelNo.130-2100
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato
causecancer,birthdefects,orreproductiveharm.
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
Qty.
Use
1
Nopartsrequired
–
Removetheenginecowl.
2
Nopartsrequired
–
Drainthefueltank.
3
Nopartsrequired
–
Removethefueltank.
Tank1
Fuelhose1
Hoseclamp2
4
Fuelcap/gauge
1
Preparethefueltank.
5
Nopartsrequired
–
Installthefueltank.
6
Nopartsrequired
–
Installthefuelhose.
Venthose1
Hoseclamp2
7
Cabletie
1
Replacetheventhose.
8
Nopartsrequired
–
Checkthefuelsystem.
9
Nopartsrequired
–
Installtheenginecowl.
©2013—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.T oro.com.
OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved
*3379-751*B
1
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).
2
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
1
Figure3
1.Spark-plugwire
5.Removethehoseclampandhosefromthebarbed
ttingatthetopoftheengineswitch(Figure2).
2
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.
3
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.
3
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
4
PreparingtheFuelTank
Partsneededforthisprocedure:
1Tank
1Fuelhose
2Hoseclamp
1
Fuelcap/gauge
InstallingtheShutoffValve
1.Atthebottomoftheoriginalfueltank,removethefuel
hosefromthettingoftheshutoffvalve(Figure9).
Note:Discardtheoriginalfuelhoseandtheoriginal
hoseclamps.
4
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).
5
InstallingtheFuelTank
NoPartsRequired
Procedure
1.Wipethesurfaceofthespacersclean(Figure8).
2.Aligntheslotsinthespacerstothemountingholesfor
thefueltankthatareinthetank–supportplate(Figure
8).
5
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).
6
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.
6
7
ReplacingtheVentHosefor
theFuelTank
Partsneededforthisprocedure:
1Venthose
2Hoseclamp
1
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
7
5.Usingthe2holes9.5mm(3/8inch)inthetopofthe
fueltank,securethehosetothetankwiththecable
tieasshowninFigure16.
8
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.
9
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.
8
/