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Workhorse ST480 Owner's Manual
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Workhorse ST480 Owner's Manual

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OWNER'S MANUAL & SERVICE GUIDE
Starting Model Year 2003
ST 480
R

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Summary of Contents for Workhorse ST480

  • Page 1 OWNER'S MANUAL & SERVICE GUIDE Starting Model Year 2003 ST 480...

  • Page 2: Manual Information

    MANUAL INFORMATION For any questions on material contained in this manual, contact a representative Please observe these notes, cautions, and warnings; be aware that servicing a for clarification. vehicle requires mechanical skill and a regard for conditions that could be haz- ardous.
  • Page 3 Textron Golf, Turf & Specialty Products is not liable for errors in this manual or for incidental or consequential damage that result from the use of material in this manual. CUSTOMER SERVICE DEPARTMENT IN USA PHONE: 1-800-241-5855 FAX: 1-800-448-8124 OUTSIDE USA PHONE: 010-1-706-798-4311 FAX: 010-1-706-771-4609 TEXTRON GOLF, TURF &...

  • Page 4: Notes

    NOTES To obtain a copy of the limited warranty applicable to the vehicle, call or write a local Distributor, authorized Branch or the Warranty Department with vehicle serial number and manufacture date code. The use of non Original Equipment Manufacturer (OEM) approved parts may void the warranty. Tampering with or adjusting the governor to permit vehicle to operate at above factory specifications will void the vehicle warranty.

  • Page 5: Table Of Contents

    TABLE OF CONTENTS TITLE PAGE TITLE PAGE MANUAL INFORMATION......Inside Front Cover SERVICE BRAKE PEDAL ..............3-10 PARK BRAKE ..................3-10 NOTES ..................i HORN ....................3-10 DIFFERENTIAL LOCK ................. 3-10 SAFETY INFORMATION ............2-1 LOAD BED ....................3-11 ELECTRIC LIFT BED OPERATION ............ 3-11 OPERATION AND SERVICE INFORMATION .....3-1 Fig.
  • Page 6 TABLE OF CONTENTS TITLE PAGE TITLE PAGE TOWING ....................3-22 SPARK PLUGS ................... 3-37 NEUTRAL LOCK ................. 3-22 BRAKES ....................3-37 Fig. 20 Neutral Lock ..............3-23 Daily Brake Test ................3-37 HAULING ..................... 3-22 PROLONGED STORAGE ..............3-38 HARDWARE ..................3-38 SERVICE AND MAINTENANCE ..............

  • Page 7: Safety Information

    • Textron Golf, Turf & Specialty Products is not liable for errors in this manual • Follow all safety rules established in the area where the vehicle is being or for incidental or consequential damages that result from the use of the operated.
  • Page 8 SAFETY INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings MAINTENANCE • Be aware that a vehicle that is not performing as designed is a potential hazard and must not be operated until inspected and repaired. The following information is very important in the maintenance of the vehicle.

  • Page 9: Operation And Service Information

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Service Parts Manuals, Technician’s Repair and Service Manuals and engine Repair Manuals are available from a local Distributor, an autho- rized Branch or the Service Parts Department.

  • Page 10: Terrain

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings tration of hydrogen gas is explosive and could Check for oil or fuel leaks that could have developed in shipment from cause severe injury or death.

  • Page 11: Modifications To Vehicle

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Remember that volume of your load can be misleading. Loading the When driving at full speed on a dirt road, loose surfaces or wet grass, vehicle to its rated capacity with dry sand, fertilizer, sod, etc.

  • Page 12: Environmental Concerns

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings model, but is a starting battery. Multiple deep cycling of the battery will Danger of fire when vehicle is operated over dry combustible organic material.

  • Page 13: Winch Applications

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings drum. Leave at least five turns of cable on drum. Re-engage drum by Winch shown mounted at front of vehicle turning clutch knob 90°, returning it to original position (Ref Fig.
  • Page 14 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings It is impossible to predict all conditions that the winch could be used, To prevent severe injury or death, read and understand therefore the following warnings should not be considered as complete.

  • Page 15: Five Turns Around Drum

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Fig. 5 Never Operate Winch with Less Than Five Turns Around Drum release the tension and operate clutch. Pull out Fig.

  • Page 16: Controls And Indicators

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings in view. Correct Never release the free spool clutch while the cable is under load. Never work around the winch drum or the winch cable while it is under tension.

  • Page 17: Key/Light Switch

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings • accelerator pedal DIRECTION SELECTOR • brake pedal T o r e d u c e t h e p o s s i b i l i t y o f component damage, the vehicle •...

  • Page 18: Choke

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CHOKE cause the vehicle to move which could result in severe injury or death. The choke is used to aid cold starting (Ref Fig. 10 on page 3-9). With the key switch ‘ON’, depressing the accelerator pedal starts the See ‘Cold Starting’...

  • Page 19: Differential Lock

    Danger label affixed to the front of the load bed. ential. With the differential unlocked, if one drive wheel looses traction, The electric lift bed is the standard bed for the ST480. all available power is transferred to that wheel until it regains traction.

  • Page 20: Electric Lift Bed Operation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ment of distance or an unstable surface could result in the vehicle fall- ing backwards. Before operating load bed, check to ensure no one is behind the vehi- cle.
  • Page 21 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ing down an incline. A sudden stop or change highways. It is not designed to comply with any of direction may result in loss of control.

  • Page 22: Run-In

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings A motorcycle helmet and protective clothing are Check the oil level per the Periodic Service Schedule. Add oil if the recommended for operator and passenger at all level on the dipstick indicates that oil is in the add oil range (Ref Fig.

  • Page 23: Starting And Driving

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings attempt, turn the key switch off, set the park brake and STARTING THE VEHICLE ON A HILL determine the cause of the problem.

  • Page 24: Fuel

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings FUEL alcohol or ether. To reduce the possibility of Do not overfill the fuel tank. Allow adequate space for severe injury or death from the expansion of gasoline.

  • Page 25: Labels And Pictograms

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The generator is capable of supplying 35 amps; therefore, operation of all accessories could result in the discharge of the battery even though 12 VOLT POWER OUTLET the engine is running and the generator operating.

  • Page 26: Vehicle Cleaning And Care

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The range of motion of the trailer is limited by the ball and hitch. The Normal cleaning of vinyl seats and plastic or rubber trim requires the trailer should not be used on rough trails or over objects such as logs, use of a mild soap solution applied with a sponge or soft brush and large rocks, holes, etc.

  • Page 27: Repair

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings 28432-G** for solid colors; 75831-G** for camouflage colors) REPAIR • Battery Protectant formulated to form a long-term, flexible, non- LIFTING THE VEHICLE tacky, dry coating that will not crack, peel or flake over a wide tem- Tool List...

  • Page 28: Fig. 16 Lifting The Vehicle

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings If only front or rear of vehicle is to be raised, place the chocks in front and behind each wheel not being raised in order to stabilize the vehicle.

  • Page 29: Wheel Installation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings surize tire with small amount of air applied only impact sockets. Regular sockets are not designed for intermittently to seat beads.

  • Page 30: Fig. 17 Wheel Installation

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings With the valve stem to the outside, mount the wheel onto the hub with Turn Signal Lens Inside lug nuts.

  • Page 31: Transporting Vehicle

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings TRANSPORTING VEHICLE Roll Rubber TOWING Bezel Away Tail/Brake From Body This vehicle is not designed Light to be towed.

  • Page 32: Service And Maintenance

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings If the vehicle is to be transported at highway speeds, the sun top must be removed. When transporting vehicle below highway speeds, check for tightness of hardware and cracks in sun top at mounting points.
  • Page 33 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings It is in the best interest of both vehicle owner and service technician, to carefully follow the procedures recommended in this manual. Preven- To reduce the possibility of causing an electri- tative maintenance, applied at recommended intervals, is the best cal arc, which could result in a battery explo-...

  • Page 34: Serial Number Plate Location

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Be sure that no loose clothing or hair can con- operate a vehicle in an environment that does tact moving parts.
  • Page 35 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings To access powertrain for routine maintenance, lift seats. Additional access may be obtained by raising or removing the load bed. For major repair, refer to appropriate Technician’s Repair and Service Manual.

  • Page 36: Periodic Service Schedule

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings PERIODIC SERVICE SCHEDULE ✓ ♦ ▲ Replace Check Clean, Adjust, etc. To perform service that is listed in this schedule but not described in this manual, contact a local Service Representative or see the Repair and Service Manual for this vehicle.
  • Page 37 OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ✓ STEERING ASSEMBLY Check for abnormal play, tightness of all hardware ✓ TIE RODS/LINKAGES Check for excessive play, bent components or loose connections ✓...

  • Page 38: Tire Inspection

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ♦ RACK END BALL JOINT Lubricate, use wheel bearing grease ✓ REAR AXLE Check for unusual noise and loose or missing mounting hardware ✓...

  • Page 39: Fig. 23 Seat Prop

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings that will spill (Ref Fig. 24 on page 3-32). Remove hose coming from fuel tank first and plug. Remove filter from hose going to fuel pump and discard.

  • Page 40: Changing The Oil

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings If oil is required, remove oil fill cap and add oil slowly to bring level to the FULL mark.

  • Page 41: Fig. 27 Oil Viscosity Chart

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The oil must be high quality detergent oil classified ‘For Service SF, SG, SH, SJ’ or higher. Do not use special additives and do not mix oil with gasoline.

  • Page 42: Changing The Oil Filter

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings LUBRICATION Do not use more than three (3) Oil Filter pumps of grease in each grease fitting at any one time.

  • Page 43: Air Cleaner Inspection And Replacement

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings AIR CLEANER INSPECTION AND REPLACEMENT The air cleaner is a dual filter cleaner, equipped with a foam pre-cleaner over a conventional paper cartridge.

  • Page 44: Rear Axle

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings Unscrew the knob securing the cartridge to the air cleaner base and from the check plug hole. Install the check plug and the fill plug. In the remove plate.

  • Page 45: Fig. 32 Check Belt Tension With Gauge

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings The starter/generator belt tension should be checked after the first 15- 20 hours of operation and set to 75 - 80 lbs. (34 - 36 kg). 3/8"...

  • Page 46: Battery Cleaning

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings BATTERY CLEANING 38). In addition to the battery, special attention should be paid to metal components adjacent to the battery which should also be sprayed with To reduce the possibility of damage the sodium bicarbonate (baking soda) solution.

  • Page 47: Fig. 36 Cleaning Air Intake And Cooling Fins

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings After every off road use, allow to cool and then check for a build up of plug.

  • Page 48: Prolonged Storage

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings ing a vehicle with improperly operating brake sys- Always wear safety glasses while refueling to te m, the br ak ing s ys te m mus t be prope r ly prevent possible eye injury from gasoline or maintained.

  • Page 49: Hardware

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings HARDWARE Generally, three grades of hardware are used in the vehicle. Grade 5 hardware can be identified by the three marks on the hexagonal head Periodically, the vehicle should be inspected for loose fasteners.

  • Page 50: Capacities And Replacement Parts

    OPERATION AND SERVICE INFORMATION Read all of manual to become thoroughly familiar with this vehicle. Pay particular attention to all Notes, Cautions and Warnings CAPACITIES AND REPLACEMENT PARTS Fuel 6.0 gal (22.5 liters) 87 Octane Tank / Fuel 1 1/2 qt (1.4 liters) Engine Oil P/N 492932 Oil Filter...

  • Page 51: General Specifications

    GENERAL SPECIFICATIONS ST 480 STANDARD EQUIPMENT: BATTERY....... One 12 Volt Maintenance Free (515 CCA, 82 Minute DASH PANEL ......Scuff Resistant Glass Fiber Reinforced Plastic Reserve) (Thermoplastic Olefin) with 4 Drink Holders ENGINE........16 H.P. (11.9 kW) 29.2 ci (480 cc) Twin Cylinder, Overhead LOAD BED......

  • Page 52: Fig. 1 Vehicle Dimensions

    GENERAL SPECIFICATIONS 110.5" (281 cm) 12" (31 cm) 49" (125 cm) 34" 78" (86 cm) (198 cm) 15" (38 cm) 75" (191 cm) 77" (196 cm) 6" with Brush (15 cm) Guard Ground Clearance Cage 40" (102 cm) Front 38" (96 cm) Rear 48"...

  • Page 53: Fig. 2 Vehicle Incline Specifications

    GENERAL SPECIFICATIONS Maximum Recommended Ramp Grade Maximum Recommended Side Tilt 25% or 14˚ Max. 25% or 14˚ Max. Fig. 2 Vehicle Incline Specifications...

  • Page 54: Intersecting Aisle Clearance

    GENERAL SPECIFICATIONS 83" (211 cm) INTERSECTING AISLE CLEARANCE TURNING CLEARANCE DIAMETER Approx. 23.5 ft (7.2 m) 83" (211 cm) Fig. 3 Vehicle Turning Clearance Diameter and Intersecting Aisle Clearance...

  • Page 55: Limited Warranty

    LIMITED WARRANTY EMISSION CONTROL SYSTEM WARRANTY STATEMENT (Owner’s Defect Warranty Rights and Obligations) ® Refer to the Briggs & Stratton Operating & Maintenance Instructions, provided with vehicle, for Emission Control System Warranty information. ENGINE OWNER WARRANTY POLICY ® Refer to the Briggs & Stratton Operating &...
  • Page 56 LIMITED WARRANTY Notes:...

  • Page 57: Declaration Of Conformity

    DECLARATION OF CONFORMITY...
  • Page 58 DECLARATION OF CONFORMITY Notes:...

  • Page 59: Labels And Pictograms

    LABELS AND PICTOGRAMS See Following Pages For Explanation Of These Pictograms: (2,3,4,6,9,36,37, 35962-G01 38,39,40,29) 35962G01 See Following Pages See Following Pages For Explanation Of For Explanation Of These Pictograms: These Pictograms: (19,43,44,45) (1,2,46,47,48) 75808-G01 75808G01 74443G01 74443G01 See Following Pages 75851G01 For Explanation Of 75851G01...
  • Page 60 LABELS AND PICTOGRAMS WARNING See Following Pages For Windshields do not provide protection Explanation Of Pictogram: (30) from golf balls or other flying objects. EGWHL14 See Following Pages For Explanation Of Pictogram: (49) WARNING 250 l b s. 114 k g Keep entire body inside car.
  • Page 61 LABELS AND PICTOGRAMS MAXIMUM CROSS HILL/RAMP WARNING ANGLE AS SPECIFIED 14˚ / 25% WARNING READ MANUAL MAXIMUM CROSS HILL/RAMP ANGLE AS SPECIFIED LOAD WITH WARNING HIGH CENTER USE CAUTION IN OF GRAVITY INCLEMENT WEATHER COULD RESULT IN TIP OVER LOAD xx in CENTER WARNING...
  • Page 62 LABELS AND PICTOGRAMS WARNING READ MANUAL FOR MAXIMUM LOAD BED CAPACITY. DANGER OF EXPLOSION MAXIMUM DO NOT FILL GAS CAN RAMP/HILL IN LOAD BED WARNING SECURE LOAD MAXIMUM AS FAR FORWARD LOAD & AS POSSIBLE. xxx lbs . CENTER OF MAXIMUM LOAD MAX LOAD MAX LOAD...
  • Page 63 LABELS AND PICTOGRAMS CLEAN UP SHORTING BATTERY GASOLINE TERMINALS MAY SPILLS WITH CAUSE EXPLOSION WATER BEFORE STARTING ENGINE TAMPERING. UNLEADED KEEP HANDS GASOLINE DO NOT SPILL FUEL WARNING ON A HOT CORROSIVE ENGINE GROUND FUEL PUMP WARNING EXPLOSIVE LOW OIL PRESSURE WARNING NEGATIVE LETHAL...
  • Page 64 LABELS AND PICTOGRAMS WEAR EYE DO NOT PROTECTION DISPOSE OF BATTERIES IN LANDFILL DO NOT DRIVE ON NO SMOKING HIGHWAY WINDSHIELDS DO NOT PROVIDE PROTECTION HOT SURFACE FROM FLYING OBJECTS BATTERIES ARE HEAVY. USE CARE LIFTING OPERATE FROM DRIVERS SIDE ONLY USE INSULATED TOOLS...
  • Page 65 LABELS AND PICTOGRAMS TO LEAVE A GASOLINE POWERED KEEP ARMS VEHICLE IN PARK: AND LEGS ✱ APPLY PARKING BRAKE WITHIN VEHICLE ✱ TURN KEY TO OFF ✱ MOVE DIRECTION SELECTOR TO FORWARD TO OPERATE VEHICLE IN FORWARD: ✱ TURN KEY TO ON ✱...
  • Page 66 LABELS AND PICTOGRAMS POSITION DIFFERENTIAL LOCKED POSITION HEADLIGHTS WARNING UNLOCKED KEEP ENTIRE BODY INSIDE CAR LOCKED Fig. 8 Pictogram Definitions (Continued) Appendix A-8...
  • Page 68 P/N 28578-G03-GB ISSUED: 07/2002 Textron Golf, Turf & Specialty Products P.O. Box 388 Augusta, Georgia 30903-0388 USA Inside USA Phone: 1-800-241-5855, FAX: 1-800-448-8124 Outside USA Phone: 010-1-706-798-4311, FAX: 010-1-706-771-4609 Copyrighted Material This manual may not be reproduced in whole or in part without the express permission of Textron Golf, Turf &...