Toro Workman GTX, 07041, 07043, 07131TC, 07139 Operator's Manual

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FormNo.3416-503RevC
Workman
®
GTXElectricUtility
Vehicle
ModelNo.07041—SerialNo.401061654andUp ModelNo.07043—SerialNo.401160341andUp ModelNo.07131TC—SerialNo.400000000andUp ModelNo.07139—SerialNo.400000000andUp ModelNo.07139TC—SerialNo.400000000andUp
*3416-503*C
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WARNING
CALIFORNIA
Proposition65Warning
Thisproductcontainsachemical
orchemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orreproductiveharm.
Useofthisproductmaycauseexposure
tochemicalsknowntotheStateof
Californiatocausecancer,birthdefects,
orotherreproductiveharm.
ThisproductcomplieswithallrelevantEuropean directives;fordetails,pleaseseetheseparateproduct specicDeclarationofConformity(DOC)sheet.
Introduction
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafety-alertsymbol (Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.
g000502
Figure2
Safety-alertsymbol
Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.
Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoid injuryandproductdamage.Youareresponsiblefor operatingtheproductproperlyandsafely .
YoumaycontactT orodirectlyatwww.Toro.comfor productandaccessoryinformation,helpndinga dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DealerorToroCustomerServiceandhavethemodel andserialnumbersofyourproductready.Figure1 identiesthelocationofthemodelandserialnumbers ontheproduct.Writethenumbersinthespace provided.
BottomofSeatAssemblyShown
1.Modelandserial-numberlocation
©2017—TheToro®Company 8111LyndaleAvenueSouth Bloomington,MN55420
Figure1
g034086
Contactusatwww.Toro.com.
2
PrintedintheUSA
AllRightsReserved
Page 3
Contents
Safety.......................................................................4
GeneralSafety...................................................4
BeforeOperationSafety.....................................4
DuringOperationSafety.....................................4
Multi-PassengerSafety......................................5
SlopeSafety.......................................................5
LoadingandDumpingSafety..............................6
AfterOperationSafety........................................6
SafetyandInstructionalDecals..........................7
Setup......................................................................10
1InstallingtheSteeringWheel(International
ModelsOnly).................................................10
2CheckingtheFluidLevelsandTire
Pressure.......................................................10
3BurnishingtheBrakes.....................................11
4ReadingtheManualandViewingthe
SetupMaterial................................................11
ProductOverview...................................................12
Controls...........................................................13
Specications..................................................16
Attachments/Accessories.................................16
Operation................................................................17
ThinkSafetyFirst..............................................17
OperatingtheCargoBed..................................17
UsingtheRearCargoBedAccessory
Mount............................................................20
PerformingDailyMaintenance..........................20
CheckingtheTirePressure...............................20
UnderstandingandUsingtheBattery
System..........................................................21
StoppingtheMachine.......................................23
BreakinginaNewMachine..............................23
LoadingtheCargoBed.....................................23
TransportingtheMachine.................................24
TowingtheMachine..........................................25
TowingaTrailer................................................25
Maintenance...........................................................26
RecommendedMaintenanceSchedule(s)...........26
DailyMaintenanceChecklist.............................27
MaintainingtheMachineunderSpecial
OperatingConditions....................................27
Pre-MaintenanceProcedures..............................28
MaintenanceSafety..........................................28
PreparingtheMachineforMaintenance............28
LiftingtheMachine...........................................29
AccessingtheHood..........................................30
RaisingandLoweringtheSeat
Assembly......................................................30
RemovingtheSeatAssembly...........................31
InstallingtheSeatAssembly.............................31
Lubrication..........................................................31
GreasingtheMachine.......................................31
GreasingtheFrontWheelBearings..................32
ElectricalSystemMaintenance...........................35
ElectricalSystemSafety...................................35
BatterySafety...................................................35
MaintainingtheBatteries..................................36
ReplacingtheFuses.........................................40
MaintainingtheHeadlights...............................40
DriveSystemMaintenance..................................42
MaintainingtheTires........................................42
AdjustingtheFrontWheelAlignment................42
CheckingtheTransaxle-FluidLevel..................43
ChangingtheTransaxleFluid...........................43
BrakeMaintenance.............................................44
CheckingtheParkingBrake.............................44
AdjustingtheParkingBrake..............................44
CheckingtheBrake-FluidLevel........................44
InspectingtheBrakes.......................................45
ReplacingtheServiceandParking-Brake
Pads..............................................................45
ChangingtheBrakeFluid.................................45
ChassisMaintenance...........................................46
AdjustingtheCargo-BedLatches.....................46
Cleaning..............................................................46
WashingtheMachine.......................................46
Storage...................................................................47
BatteryStorage................................................47
Troubleshooting......................................................48
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Safety
motorquickly.
Knowhowtostopthemachineandshutoffthe
Improperuseormaintenancebytheoperatoror ownercanresultininjury.T oreducethepotential forinjury,complywiththesesafetyinstructions andalwayspayattentiontothesafety-alert symbol(Figure2),whichmeansCaution,Warning, orDanger—personalsafetyinstruction.Failureto complywiththeinstructionmayresultinpersonal injuryordeath.
ThismachinemeetstherequirementsofSAEJ2258.

GeneralSafety

Thisproductiscapableofcausingpersonalinjury. Alwaysfollowallsafetyinstructionstoavoidserious personalinjury.
Usingthisproductforpurposesotherthanitsintended usecouldprovedangeroustoyouandbystanders.
Readandunderstandthecontentsofthis
Operator’sManualbeforeyoustarttheengine. Ensurethateveryoneusingthisproductknows howtouseitandunderstandsthewarnings.
Donotputyourhandsorfeetnearmoving
componentsofthemachine.
Donotoperatethemachinewithoutallguards
andothersafetyprotectivedevicesinplaceand workingonthemachine.
Keepthemachineasafedistanceawayfrom
bystanderswhileitismoving.
Keepchildrenoutoftheoperatingarea.Never
allowchildrentooperatethemachine.
Stopthemachineandshutofftheenginebefore
servicing,fueling,oruncloggingthemachine.
Improperlyusingormaintainingthismachinecan resultininjury.Toreducethepotentialforinjury, complywiththesesafetyinstructionsandalwayspay attentiontothesafety-alertsymbol,whichmeans Caution,Warning,orDanger—personalsafety instruction.Failuretocomplywiththeseinstructions mayresultinpersonalinjuryordeath.
Youcanndadditionalsafetyinformationwhere neededthroughoutthismanual.
Checkthatallsafetydevicesanddecalsarein
place.Repairorreplaceallsafetydevicesand replaceallillegibleormissingdecals.Donot operatethemachineunlesstheyarepresentand functioningproperly.

DuringOperationSafety

Theowner/operatorcanpreventandisresponsible
foraccidentsthatmaycausepersonalinjuryor propertydamage.
Passengersshouldsitinthedesignatedseating
positionsonly.Donotcarrypassengersinthe cargobed.Keepbystandersandpetsawayfrom themachineduringoperation.
Wearappropriateclothing,includingeye
protection;longpants;substantial,slip-resistant footwear;andhearingprotection.Tiebacklong hairanddonotwearjewelry.
Donotoperatethemachinewhileill,tired,or
undertheinuenceofalcoholordrugs.
Operatethemachineoutdoorsorina
well-ventilatedareaonly.
Donotexceedthemaximumgrossvehicleweight
(GVW)ofthemachine.
Useextracautionwhenoperatingthemachine
withaheavyloadinthecargobed.Theheavier theload,themoredifcultitistoturnorstop.
Carryingoversizedloadsinthecargobedreduces
thestabilityofthemachine.
Carryingmaterialthatcannotbeboundtothe
machine,suchasalargetankofliquid,adversely affectsthesteering,braking,andstabilityofthe machine.
Beforeyoustartthemotor,ensurethatthe
transmissionisinneutral,theparkingbrakeis engaged,andyouareintheoperatingposition.
Youandyourpassengersshouldremainseated
wheneverthemachineismoving.Keepyour handsonthesteeringwheel;yourpassengers shouldusethehandholdsprovided.Keepyour armsandlegswithinthemachinebodyatalltimes.

BeforeOperationSafety

Neverallowchildrenoruntrainedpeopleto
operateorservicethemachine.Localregulations mayrestricttheageoftheoperator.Theowner isresponsiblefortrainingalloperatorsand mechanics.
Becomefamiliarwiththesafeoperationofthe
equipment,operatorcontrols,andsafetysigns.
Operatethemachineonlyingoodvisibility.
Watchforholes,ruts,bumps,rocks,orother hiddenobjects.Uneventerraincouldoverturnthe machine.Tallgrasscanhideobstacles.Usecare whenapproachingblindcorners,shrubs,trees,or otherobjectsthatmayobscureyourvision.
Alwayswatchoutforandavoidlowoverhangs
suchastreelimbs,doorjambs,overhead walkways,etc.
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Lookbehindanddownbeforereversingthe
machinetobesureofaclearpath.
Donotdrivethemachineneardrop-offs,ditches,
orembankments.Themachinecouldsuddenly rolloverifawheelgoesovertheedgeorifthe edgegivesway.
Whenusingthemachineonpublicroads,follow
alltrafcregulationsanduseanyadditional accessoriesthatmayberequiredbylaw,suchas lights,turnsignals,slow-movingvehicle(SMV) signs,andothersasrequired.
Ifthemachineevervibratesabnormally,stopthe
machineimmediately,shutoffthemotor,waitfor allmovementtostop,andinspectfordamage. Repairalldamagetothemachinebeforeresuming operation.

Multi-PassengerSafety

Youmustaccountfortheextrapassengers
contributingtotheoverallgrossvehicleweight (GVW)ofthemachine.
Ifyouhavealoadinthecargobed,ensurethat
youdonotexceedthecapacityofthemachineby havingtoomanypassengers.
Passengersshouldsitinthedesignatedseating
positionsonly.Donotallowpassengerstositin thecargobed.
Youandyourpassengersshouldremainseated
wheneverthemachineisinmotion.
Theadditionalmachinelengthresultsinalarger
turnradius,soallowmorespacetomaneuverthe machine.
Carryareducedloadandreducetheground
speedofthemachinewhenoperatingonrough, uneventerrain,andnearcurbs,holes,andother suddenchangesinterrain.Loadsmayshift, causingthemachinetobecomeunstable.
Itcantakelongertostopthemachineonwet
surfacesthanondrysurfaces.T odryoutwet brakes,driveslowlyonlevelgroundwhileputting lightpressureonthebrakepedal.
Suddenchangesinterrainmaymovethesteering
wheelunexpectedly,whichcouldresultinhand andarminjuries.Reduceyourspeedandgrip thesteeringwheellooselyaroundtheperimeter, keepingyourthumbsoutofthewayofthesteering wheelspokes.
Reducethespeedwhenyouoperatethemachine
withthecargobedremoved.Operatingthe machineathighspeedandthenquicklystopping maycausetherearwheelstolockup,which impairsyourcontrolofthemachine.
Donottouchthemotor,transmission,mufer,or
mufermanifoldwhilethemotorisrunning,or soonafteryouturnoffthemotor,becausethese areasmaybehotenoughtocauseburns.
Donotleavearunningmachineunattended.
Beforeleavingtheoperatingposition,dothe
following:
–Parkthemachineonlevelground.
–Engagetheparkingbrake.
–Lowerthecargobed.
–Shutoffthemotorandremovethekey .
Donotoperatethemachinewhenthereistherisk
oflightning.
Useaccessoriesandattachmentsapprovedby
TheT oro®Companyonly.

SlopeSafety

Note:A2-postRolloverProtectionSystem(ROPS)
isavailableforthismachineasanaccessory.Usea ROPSifyouwillworknexttodrop-offs,nearwater, inroughterrain,oronaslope,whichcouldresultin arollover.ContactanauthorizedTorodistributorfor moreinformation.
Slopesareamajorfactorrelatedtoloss-of-control andtip-overaccidents,whichcanresultinsevere injuryordeath.
Surveythesitetodeterminewhichslopesare
safeforoperatingthemachineandestablishyour ownproceduresandrulesforoperatingonthose slopes.Alwaysusecommonsenseandgood judgmentwhenperformingthissurvey.
Ifyoufeeluneasyoperatingthemachineona
slope,donotdoit.
Keepallmovementonslopesslowandgradual.
Donotsuddenlychangethespeedordirectionof themachine.
Avoidoperatingthemachineonwetterrain.Tires
maylosetractionregardlessifthebrakesare availableandfunctioning.Arollovercanoccur beforethetireslosetraction.
Avoidstarting,stopping,orturningthemachine
onaslope.
Travelstraightupanddownaslope.
Ifyoubegintolosemomentumwhileclimbinga
slope,graduallyengagethebrakesandslowly reversethemachinestraightdowntheslope.
Turningwhilegoingupordownaslopecanbe
dangerous.Ifyoumustturnonaslope,doitslowly andcautiously.
Heavyloadsaffectstabilityonaslope.Carrya
reducedloadandreduceyourgroundspeedwhen operatingonaslopeoriftheloadhasahigh centerofgravity.Securetheloadtothecargobed
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ofthemachinetopreventtheloadfromshifting. Takeextracarewhenhaulingloadsthatshifteasily (e.g.,liquids,rock,sand,etc.).
Avoidstoppingonaslope,especiallywitha
load.Stoppingwhilegoingdownaslopetakes longerthanstoppingonlevelground.Ifyoumust stopthemachine,avoidsuddenspeedchanges, whichcancausethemachinetotiporrollover. Donotengagethebrakessuddenlywhenrolling rearward,asthismaycausethemachineto overturn.

LoadingandDumping Safety

Donotexceedthegrossvehicleweight(GVW)
ofthemachinewhenoperatingitwithaloadin thecargobedand/ortowingatrailer;referto
Specications(page16).
Distributetheloadinthecargobedevenlyto
improvethestabilityandcontrolofthemachine.
Beforedumping,ensurethatthereisnoone
behindthemachine.
Donotdumpaloadedcargobedwhilethe
machineissidewaysonaslope.Thechange inweightdistributionmaycausethemachineto overturn.

AfterOperationSafety

Allowtheenginetocoolbeforestoringthemachine
inanyenclosure.
Shutoffthefuelbeforestoringortransportingthe
machine.
Donotstorethemachineorfuelcontainerwhere
thereisanopename,spark,orpilotlight,such asonawaterheaterorotherappliance.
Keepallpartsofthemachineingoodworking
conditionandallhardwaretightened.
Replaceallworn,damaged,ormissingdecals.
Usecarewhenloadingorunloadingthemachine
intoatraileroratruck.
Usefull-widthrampsforloadingthemachineinto
atraileroratruck.
Tiethemachinedownsecurely.
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SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decal115-7739
115-7739
99-7345
1.Warning—readtheOperator'sManual.
2.Hotsurface/burnhazard—stayasafedistanceawayfrom thehotsurface.
3.Entanglementhazard,belt—stayawayfrommovingparts; keepallguardsinplace.
4.Crushinghazard,cargobed—usetheproprodtosupport thecargobed.
115-2047
1.Warning—donottouchthehotsurface.
decal99-7345
1.Falling,crushinghazard,bystanders—noridersonmachine
decal120-9570
120-9570
1.Warning—stayawayfrommovingparts;keepallguards andshieldsinplace.
decal115-2047
131-8411
1.Headlight—on3.Raisethebed.
2.Headlight—off
4.Lowerthebed.
7
decal131-8411
Page 8
decal131-8412
131-8414
decal131-8414
131-8412
1.Warning—readthe
1.Horn
2.Forward
3.Neutral
5.Off
6.On
7.Turningon—1)Sitinthe
Operator'sManual.
driver'sseat;2)Disengage theparkingbrake;3)Turn thekeyswitchtothestart position;4)Pushdownon thepedal.
4.Reverse
8.Turningoff—1)Release
2.Warning—receiveproper trainingbeforeoperating themachine.
thepedal;2)Engagethe parkingbrake;3)Turn thekeyswitchtothestop position;4)Removethe keyfromthekeyswitch.
3.Tippinghazard—drive slowlyacrossorupslopes; taketurnsslowly;donot exceedspeedsof25kph (16mph);driveslowly whenhaulingcargo;drive slowlyonuneventerrain.
4.Fallinghazard;severing hazardoflimbs—donot carrypassengersinthe bed;donotcarryextra passengersinbetween theseats;donotputyour armsorlegsoutsideofthe machinewhileoperating.
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decal131-8527
131-8527
131-8495
1.Thebatteryisempty .3.Thebatteryischarged.
2.Thebatteryisalmost charged.
4.Chargerfault;refertothe chargermanualforthe faultcodes.
131-8506
1.Solidlight—unitis preparedforoperation.
2.Flashinglight—refertothe chargermanualforthe faultcodes.
1.Performancemode
decal131-8495
2.Ecomode
decal131-8551
131-8551
1.ReadtheOperator’s Manualforfuse
information.
2.Horn(30A)4.Mainpower(10A)
decal131-8506
3.Optionalliftkit(15A)
decal131-8598
131-8598
1.Maximumbedweight91 kg(200lb)
2.Maximumtrailerweight 454kg(1,000lb)
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Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescription
Steeringwheel Steeringwheelcover
1
2 3
4
Washer(1/2inch) Dustcover1
Nopartsrequired
Nopartsrequired
Operator'sManual Engineowner'smanual1 Registrationcard1 PredeliveryInspectionForm1 CerticateofQuality Key2
Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
1
Qty.
1 1 1
1
1
4.Securethesteeringwheeltotheshaftwiththe locknut(1/2inch)andtightenitto18to30N∙m (13to22ft-lb).
5.Installthecoveronthesteeringwheel(Figure3).
Installthesteeringwheel(International modelsonly).
Checktheuidlevelsandtirepressure.
Burnish(break-in)thebrakes.
ReadtheOperator'sManualandview thesetupmaterialbeforeoperatingthe machine.
Use

InstallingtheSteering Wheel(InternationalModels Only)

Partsneededforthisprocedure:
1
Steeringwheel
1
Steeringwheelcover
1
Washer(1/2inch)
1Dustcover
Procedure
1.Ifthecoverisinstalled,removeitfromthehub ofthesteeringwheel(Figure3).
2.Removethelocknut(1/2inch)fromthesteering shaft(Figure3).
3.Slidethesteeringwheel,dustcover,andwasher (1/2inch)ontothesteeringshaft(Figure3).
Note:Withthefrontwheelsstraight,orientthe
steeringwheelsothatthesmallerspokeonthe steeringwheelisvertical.
Figure3
1.Steeringwheelcover4.Steeringwheel
2.Locknut(1/2inch)
3.Washer(1/2inch)6.Steeringshaft
5.Dustcover
g198932
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2
4
CheckingtheFluidLevels andTirePressure
NoPartsRequired
Procedure
1.Checkthewaterlevelinthebatteriesbefore youoperatethemachine;refertoCheckingthe
WaterLeveloftheBatteries(page38).
2.Ensurethatthebatteriesarecharged;referto
ChargingtheBatteries(page36).
3.Checkthebrake-uidlevelbeforeyouoperate themachine;refertoCheckingtheBrake-Fluid
Level(page44).
4.Checktheairpressureinthetires;referto
CheckingtheTirePressure(page20).
3

ReadingtheManualand ViewingtheSetupMaterial

Partsneededforthisprocedure:
1
Operator'sManual
1Engineowner'smanual
1Registrationcard
1PredeliveryInspectionForm
1
CerticateofQuality
2Key
Procedure
ReadtheOperator'sManualandtheengine
owners'smanual.
Fillouttheregistrationcard.
CompletethePredeliveryInspectionForm.
ReviewtheCerticateofQuality.

BurnishingtheBrakes

NoPartsRequired
Procedure
Toensureoptimumperformanceofthebrakesystem, burnish(break-in)thebrakesbeforeuse.
1.Bringthemachineuptofullspeed,applythe brakestorapidlystopthemachinewithout lockingupthetires.
2.Repeatthisprocedure10times,waiting1minute betweenstops,toavoidoverheatingthebrakes.
Important:Thisprocedureismosteffective
ifthemachineisloadedwith227kg(500lb).
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ProductOverview
g034154
Figure4
1.Hoodlatch
2.Steeringwheel
3.Cargobed
4.Towingtongue
5.Batterycharger
6.Cargo-bedlever
g034544
Figure5
1.Passengerhandhold3.Rearcargo-bed-accessorymount
2.Parking-brakelever4.Trailerhitch
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Controls
ControlPanel
Figure6
1.Lightswitch7.Parking-brakelever
2.Hourmeter8.Brakepedal
3.Battery-dischargeindicator9.Acceleratorpedal
4.Hornbutton(Internationalmodelsonly)10.USBpowerpoint
5.Gear-shiftselector11.Status-indicatorlight
6.Keyswitch
AcceleratorPedal
Usetheacceleratorpedal(Figure6)tovaryground speedofthemachine.Pressingdowntheaccelerator pedalstartsthemachine.Pressingthepedalfarther increasesgroundspeed.Releasingthepedalslows themachine,andthemachineshutsoff.
BrakePedal
Usethebrakepedaltostoporslowthemachine (Figure6).
CAUTION
Operatingamachinewithwornorincorrectly
Themaximumforwardspeedinperformancemodeis 26km/h(16mph)asshowninFigure9.
Themaximumforwardspeedineconomymodeis19 km/h(12mph)asshowninFigure9.
adjustedbrakescanmayresultinpersonal injury.
Ifthebrakepedaltravelstowithin25mm(1 inch)ofthemachineoorboard,adjustor repairthebrakes.
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Parking-BrakeLever
DirectionSelector
Theparking-brakeleverislocatedonthecontrol panel(Figure7).
Wheneveryoushutofftheengine,engagetheparking braketopreventthemachinefromaccidentally moving.Ifthemachineisparkedonasteepgrade, ensurethatyouengagetheparkingbrake.
Toengagetheparkingbrake,pulltheparking-brake levertowardyou(Figure7).
Figure7
Thedirectionselectorislocatedtotheleftofthe parking-brakelever.Thedirectionselectorhas3 positions:FORWARD,REVERSE,andNEUTRAL(Figure
6).
Note:Themachinecanbeoninanyofthe3
positions,butonlymovesintheFORWARDand REVERSEpositions.
Important:Alwaysstopthemachinebefore
changingdirection.
HornButton
InternationalModelsOnly
Thehornbuttonislocatedonthecontrolpanel(Figure
6).Pressthehornbuttontosoundthehorn.
LightSwitch
Usethelightswitch(Figure6)toilluminatethe headlights.Pushthelightswitchuptoturnonthe
g033923
headlights.Pushthelightswitchdowntoturnoffthe lights.
1.Parking-brakelever
Todisengagetheparkingbrake,pushdownthe buttonontopoftheparking-brakelever,pullthe parking-brakelevertowardyoutoreleasepressure, andthenpushtheparking-brakeleverforward(Figure
8).
Figure8
1.Parking-brakelever
Battery-DischargeIndicator
Thebattery-dischargeindicatorislocatedto theleftofthesteeringcolumn(Figure6).The battery-dischargeindicatorindicatestheremaining chargeinthebatteries.Whenthebatteriesarefully charged,10indicatorbarsextendfromthe0tothe1 position.Asyouusethecharge,theindicatorbars disappear,startingattherightsideofthemeter.For detailedinformationonthebatterymeter,referto
UnderstandingandUsingtheBatterySystem(page
21).
HourMeter
Thehourmeterislocatedtotherightofthelight switch(Figure6).Usethehourmetertondoutthe totalnumberofoperatinghours.Thehourmeter startstofunctionwheneveryouturnthekeyswitchto theONpositionorifthemachineisrunning.
g033924
Note:Whenthemachineisrunning,thehourmeter
blinkscontinuously,recordingusage.
USBPowerPoint
TheUSBpowerpointislocatedtotheleftofthe parking-brakelever(Figure6).Usethepowerpoint topowermobiledevices.
Important:WhenyouarenotusingtheUSB
powerpoint,inserttherubberplugtoprevent damagetothepowerpoint.
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Page 15
KeySwitch
Status-IndicatorLight
Usethekeyswitch(Figure6),torunandshutoffthe machine.
Thekeyswitchhas2positions:ONandOFF.Rotate thekeyclockwisetotheONpositiontooperatethe machine.Whenyoustopthemachine,rotatethekey counterclockwisetotheOFFpositiontoshutoffthe machine.Removethekeywheneveryouleavethe machine.
SupervisorSpeed-LimitSwitch
Thesupervisorspeed-limitswitch,locatedunder theseatassembly,has2positions:PERFORMANCE andECONOMY.Rotatetheswitchclockwisetothe ECONOMYpositiontolimitthemaximummachine speedto19km/h(12mph).Rotatetheswitch counterclockwisetothePERFORMANCEpositionto restorethemaximumspeedofthemachineto26km/h (16mph)asshowninFigure9.
Thestatus-indicatorlightislocatedtotherightofthe parking-brakeleveronthecontrolpanel(Figure6).
Whenthemachineisturnedon,thegreen status-indicatorlightilluminateseithersolidorblinking.
Ifthelightissolid,thisindicatesthatthemachineis readyfornormaloperation.Ifthelightisblinking, thereisanissuethatneedstoberesolvedbefore continuingwithnormaloperationofthemachine.
Ifthestatus-indicatorlightblinks2times,this indicatesthattheparkingbrakeisengagedwhilein theFORWARDorREVERSEpositiononthedirection selector.Disengagetheparkingbraketoshutoffthe status-indicatorlight.
RefertoTroubleshooting(page48)ifthe status-indicatorlightblinksmorethan2times.
PassengerHandholds
Thepassengerhandholdsarelocatedontheoutside ofeachseat(Figure10).
1.PERFORMANCEposition
2.ECONOMYposition
Figure9
3.Supervisorspeed-limit
g033955
g034167
switch
1.Passengerhandhold
15
Figure10
PassengerSideShown
Page 16
Specications
Note:Specicationsanddesignaresubjecttochangewithoutnotice.
Baseweight
Ratedcapacity(onlevelground)
Maximumgrossvehicleweight(GVW)—onlevelground1177kg(2,595lb)total,includingalloftheweightslistedabove
Maximumcargocapacity(onlevelground)363kg(800lb)total,includingrear-mountedaccessories
Maximumrearcargobedaccessorymountcapacity
Towcapacity
Overallwidth119cm(47inches)
Overalllength302cm(119inches)
Overallheight127.5cm(50.2inches)
Groundclearance
Wheelbase
Wheeltread(centerlinetocenterline)
Cargobedlength
Cargobedwidth
Cargobedheight28cm(11inches)inside
Dry633kg(1,395lb)
544kg(1,200lb)total,including91kg(200lb)operatorand91kg (200lb)passenger,load,accessories,andattachments
45kg(100lb)total
Tongueweight:91kg(200lb)
Maximumtrailerweight:454kg(1,000lb)
21.6cm(8.5inches)atthefrontwithnoloadoroperator
14cm(5.5inch)attherearwithnoloadoroperator
220cm(86.6inches)
Front:119cm(47inches)
Rear:119cm(47inches)
Inside:102cm(40inches)
Outside:1 14.3cm(45inches)
Inside:98cm(38.5inches)
Outsideofthemoldedfenders:107.3cm(42.3inches)
*SpecicationslistedarewithTrojanT-125batteries.**Installingnon-standardbatteriesmayreducethe
cargo-bedcapacity.

Attachments/Accessories

AselectionofToroapprovedattachmentsandaccessoriesisavailableforusewiththemachinetoenhance andexpanditscapabilities.ContactyourAuthorizedServiceDealerorDistributororgotowww.Toro.comfora listofallapprovedattachmentsandaccessories.
16
Page 17
Operation

OperatingtheCargoBed

Note:Determinetheleftandrightsidesofthe
machinefromthenormaloperatingposition.
CAUTION
Araisedbedfullofmaterialwithouttheproper safetysupportmaylowerunexpectedly. Workingunderanunsupportedraisedbed couldinjureyouorothers.
Beforeservicingormakingadjustmentsto themachine,parkthemachineonalevel surface,engagetheparkingbrake,shutoff theengine,andremovethekey.
Removeanyloadmaterialfromthebed orotherattachment,andinsertthesafety supportonafully-extendedcylinderrod beforeworkingunderaraisedbed.

ThinkSafetyFirst

Carefullyreadallthesafetyinstructionsandsymbols inthesafetysection.Knowingthisinformationcould helpyouorbystandersavoidinjury.
DANGER

RaisingtheCargoBedtothe DumpPosition

WARNING
Araisedbedcouldfallandinjurepersonsthat areworkingbeneathit.
Alwaysusetheproprodtoholdthebedup beforeworkingunderthebed.
Removeanyloadmaterialfromthebed beforeraisingit.
WARNING
Drivingthemachinewiththecargobedraised couldcausethemachinetotiporrolleasier. Youcoulddamagethestructureofthecargo bedifyouoperatethemachinewiththebed raised.
Operatethemachinewhenthecargobed isdown.
Afteremptyingthecargobed,lowerit.
Operatingonwetgrassorslopescancause slidingandlossofcontrol.
Wheelsdroppingoveredgescancause rollovers,whichmayresultinseriousinjury, death,ordrowning.
Toavoidlossofcontrolandpossibilityof rollover:
Donotoperateneardropoffsornearwater.
Reducespeedanduseextremecautionon slopes.
Avoidsuddenturnsorrapidspeed changes.
CAUTION
Ifaloadisconcentratednearthebackofthe cargobedwhenyoureleasethelatches,the bedmayunexpectedlytipopen,injuringyou orbystanders.
Centerloadsinthecargobed,ifpossible.
Holdthecargobeddownandensurethat nooneisleaningoverthebedorstanding behinditwhenreleasingthelatches.
Removeallcargofromthebedbefore liftingthebeduptoservicethemachine.
1.Pulltheleveronleft,insideofthecargobed towardyouandliftthecargobedup(Figure11).
17
Page 18

RaisingtheCargoBedtothe ServicePosition

1.Pulltheleveronleft,insideofthecargobed towardyouandliftthecargobedup(Figure11).
2.Pullproprodintotheservicepositiondetentslot tosecurethebedformaintenance(Figure12).

LoweringtheCargoBed

Figure11
1.Cargo-bedlever
2.Pulltheproprodintothedumppositiondetent slottosecurethebedfordumping(Figure12).
Figure12
1.Servicepositiondetent
slot
2.Proprod
3.Dumppositiondetentslot
g034019
WARNING
Theweightofthebedmaybeheavy.Hands orotherbodypartscouldbecrushed.
Keepyourhandsandotherbodypartsaway whenloweringthebed.
1.Raisethecargobedslightlybyliftinguponthe latchlever(Figure11).
2.Pulltheproprodoutofthedetentslot(Figure
12).
3.Lowerthebeduntilitlatchessecurely.
g034021
18
Page 19

OpeningtheTailgate

ClosingtheTailgate

1.Ensurethatthecargobedisdownandlatched.
2.Usingbothhands,raisethetailgateusingthe ridgenearthetopofthetailgate(Figure13).
3.Lowerthetailgateuntilitisushwiththebottom ofthecargobed(Figure13).
Ifyouunloadedloosematerialsuchassand, landscapingrock,orwoodchipsfromthecargobedof themachine,someofthematerialthatyouunloaded mayhavelodgedinthehingeareaofthetailgate. Performthefollowingstepsbeforeclosingthetailgate.
1.Useyourhandstoremoveasmuchofthe materialfromthehingeareaaspossible.
2.Rotatethetailgatetoapproximatelythe45° position(Figure14).
g034023
Figure14
Figure13
1.Rotatethetailgateback
andforthseveraltimes.
2.Rotatethetailgateto
g034022
approximatelythe45° position.
3.Hingearea
3.Useashort,shakingmotiontorotatethetailgate backandforthseveraltimes(Figure14).
Note:Thisactionhelpsmovematerialaway
fromthehingearea.
4.Lowerthetailgateandcheckformaterial remaininginthehingearea.
5.Repeatsteps1through4untilthematerialis removedfromthehingearea.
6.Rotatethetailgateupandliftthetailgateintothe notchesinthecargobed.
19
Page 20
UsingtheRearCargoBed
PerformingDaily
AccessoryMount
Usetherearcargobedaccessorymounttoattach accessoriestotherearofthemachine.
Capacity:45kg(100lb)
1.Loosenthe“T”handlebyrotatingitclockwise (Figure15).
Figure15
1.Receiver
2.Insertyouraccessoryintothereceiveruntilthe holesalign(Figure15).
3.Securetheassembledaccessorytothereceiver tubeusingtheclevispinandhairpincotter suppliedwiththeaccessory .
2.“T”handle
Maintenance
Beforestartingthemachineeachday,perform theEachUse/DailyprocedureslistedinDaily
MaintenanceChecklist(page27).

CheckingtheTirePressure

ServiceInterval:Beforeeachuseordaily
Frontandreartiresairpressurespecication:165
to207kPa(24to30psi)
Important:Donotexceedthemaximumair
pressureindicatedonthesidewallofthetire.
Note:Theairpressureneededinthetiresis
determinedbythepayloadthatyouintendtocarry.
1.Checktheairpressureinthetires.
g034545
Uselowerairpressureinthetiresforlighter
payloads,forlesssoilcompaction,fora smootherride,andtominimizetiremarkson theground.
Usehigherairpressureinthetiresfor
carryingheavierpayloadsathigherspeeds.
2.Ifnecessary ,adjusttheairpressureinthetires byaddingorremovingairinthetires.
4.Tightenthe“T”handlebyrotatingit counterclockwise(Figure16).
Figure16
1.“T”handle
g001055
Figure17
g034546
20
Page 21

UnderstandingandUsing theBatterySystem

UnderstandingDeep-Cycle Batteries

Themachinecontains8deep-cycle,lead-acid batteriesthatsupplypowertothemotorand accessories.Adeep-cyclebatteryisnotthesame asanautomobilebattery .Anautomobilebattery isdesignedtoprovideasurgeofpowertostart themachineandmoderatepowertorunthelights andaccessorieswhenthemotorifofforidling. Thealternatorthencontinuouslychargesasthe automobileruns.Assuch,anautomobilebattery seldomdropsbelow90%ofthemaximumcharge level.
Adeep-cyclebatteryisdesignedtobeaprimarypower sourcetoprovideasustainedoutput.Deep-cycle batteriesaretypicallydischargedaslowas20to30% ofthemaximumchargelevel.Adischargethislowis consideredadeepdischarge.
Important:Repeateddeep-dischargecycles
reducesthebatterylife.
Lead-acidbatteriesproduceelectricitythrougha chemicalreactionbetweenleadplatesandsulfuric acid.Chargingabatteryreversesthechemical reaction,allowingthebatterytoonceagainproduce electricity.
Abatteryisaperishableitemthathasalimited lifetime(Figure18).Whenabatteryisnew,itrequires abreak-inperiodtoestablishefcientelectrical production.Thisbreakinperiodusuallyrequires100 to150discharge/chargecycles.
Afterthebreak-inperiod,thebatterymaintainsahigh capacityformanycycles.Thenumberofcyclesthata batteryperformsdependsonthefollowing:
Batterymaintenance—impropermaintenance
severelyreducesthelifeofthebatteries.
Depthofdischargebetweenchargecycles—the
deeperthebatteriesaredischargedona regularbasisbetweencharges,theshorterthe servicelifethebatterieswillhave.
Chargefrequency—fullychargethebatteries
wheneverpossible.
Important:Fullydischargingthebatteries
damagesthemandreducestheirlife.
Lowwaterlevels—iftheleadplatesbecome
exposed,itmaypermanentlydamagethe batteries.Performthefollowingtomaintainthe
electrolytelevel:
Afterfullychargingthebatteries,llthe batterieswithdistilledordeionizedwater;referto
CheckingtheWaterLeveloftheBatteries(page
38)andAddingDistilledorDeionizedWatertothe Batteries(page38).
Important:Fullychargethebatteriesbefore
addingthewatertothebatteries.While charging,theelectrolyteincreasesinvolume, andllingalowbatterybeforefullycharging thebatteriescancausetheelectrolyteto overowandleakoutofthevent.
Attheendofthebatterylife,thebatteriesgradually loseelectriccapacity.
Figure18
Battery-LifetimeT able
1.Batterycapacity
2.Discharge/chargecycles5.Endofthebatterylife
3.Break-inperiod(100to
150cycles)
4.Primebatterylife
g004049
21
Page 22

UsingtheBatterySystem

Whenyourbatteriesarefullycharged,thetenth bar(farright)illuminatesonthebattery-discharge indicator(Figure19).
Figure19
Ifyoucontinuetousethemachinewithonly2bars remaining,bars1and2alternatelyash.
Important:Whenonlythesecondbarfromthe
leftremainsonthebattery-dischargeindicator, themachinemayenterareduced-speedmode; thismodeaidsinprotectingthebatteries,but prolongedoperationinthismodecandamage thebatteriesand/orthemachine.Avoiddraining yourbatteriesdowntothesecondbarfromthe lefttopreventthisissue.Chargethebatteries immediately.
Ifthebatteriesbecomefullydischarged,the machineshutsdown.Donotallowthebatteriesto
becomefullydischarged.
Important:Toobtainmaximumbatterylife,
alwayschargethebatteriesbeforethecharge reachesthesecondbarfromtheleftonthe screen.Regularlydepletingthebatteriestolower thanthesecondbarfromtheleftreducesthelife
g192308
ofthebatteries.
1.Battery-discharge
indicator
2.Charge-indicatorbars
Asyouusethemachine,thebarsdisappearasthe electricalcapacityofthebatteriesisused.
Whenonlythesecondbarfromtheleftremainson thebattery-dischargeindicator,itisagoodtimeto charge(Figure20).
Figure20
1.The2leftbarsalternatelyblinkuntilyouchargethe
batteries.
g192309
22
Page 23

StoppingtheMachine

LoadingtheCargoBed

Important:Whenstoppingthemachineon
anincline,usetheservicebrakestostopthe machineandengagetheparkingbraketoholdthe machineinplace.Usingtheacceleratortostall themachineonthehillcanoverheatthemotoror drainthebatteries.
1.Removeyourfootfromtheacceleratorpedal.
2.Slowlypressthebrakepedaltoapplytheservice brakesuntilthemachinecomestoacomplete stop.
Note:Thestoppingdistancemayvary
dependingonthemachineloadandspeed.

BreakinginaNewMachine

ServiceInterval:Aftertherst100hours—Perform
thebreakinginanewmachine guidelines.
Performthebreakinginanewmachineguidelines toprovideproperperformanceandlonglifeforthe machine.
Checkthebrakeuidandthewaterlevelinthe
batteriesregularly.
Avoidhardbrakingsituationsfortherstseveral
hoursofnewmachinebreak-inoperation.New brakeliningsmaynotbeatoptimumperformance untilseveralhoursofusehascausedthebrakes tobecomeburnished(broken-in).
RefertoMaintenance(page26)foranyspecial
lowhourchecks.
Checkthefrontsuspensionpositioningandadjust
itifnecessary.
Usethefollowingguidelineswhenloadingthecargo bedandoperatingthemachine:
Observetheweightcapacityofthemachineand
limittheweightoftheloadthatyoucarryinthe cargobedasdescribedinSpecications(page
16)andonthegrossvehicleweighttagofthe
machine.
Note:Theloadratingisspeciedformachine
operationonalevelsurfaceonly.
Reducetheweightoftheloadthatyoucarryinthe
cargobedwhenoperatingthemachineonhills androughterrain.
Reducetheweightoftheloadthatyoucarrywhen
thematerialsaretall(andhaveahighcenterof gravity),suchasastackofbricks,landscaping timbers,orfertilizerbags.Distributetheloadas lowaspossibletoensurethattheloaddoesnot reduceyourabilitytoseebehindthemachine whenoperatingit.
Keeploadscenteredbyloadingthecargobedas
follows:
–Evenlypositiontheweightinthecargobed
fromsidetoside.
Important:Tippingoverismorelikelyto
occurifthecargobedisloadedto1side.
–Evenlypositiontheweightinthecargobed
fromfronttoback.
Important:Lossofsteeringcontrolorthe
machinemaytipoverifyoupositionthe loadbehindtherearaxleandthetraction onthefronttiresisreduced.
Useextracautionwhentransportingoversized
loadsinthecargobed,particularlywhenyou cannotcenterthewightoftheoversizeloadtothe cargobed.
Wheneverpossible,securetheloadbybindingit
tothecargobedsothatitdoesnotshift.
Whentransportingliquidinalargetank(such
asasprayertank),usecautionwhendriving themachineuphillordownhill,whensuddenly changingspeedorstopping,orwhendrivingover toughsurfaces.
Thecapacityofthecargobedis0.28m Theamount(volume)ofmaterialthatyoucanplace inthebedwithoutexceedingtheloadratingsofthe machinecanvarygreatlydependingonthedensity ofthematerial.
23
3
(10ft3).
Page 24
Refertothefollowingtableforloadvolumelimitswith variousmaterials:
MaterialDensity
Gravel,dry1522kg/m
Gravel,wet1922kg/m
Sand,dry1442kg/m
Sand,wet1922kg/m
Wood
Bark
Earth,packed
721kg/m
3
(95
3
lb/ft
)
3
(120
3
lb/ft
)
3
(90
3
lb/ft
)
3
(120
3
lb/ft
)
3
(45lb/ft
<721kg/m
1602kg/m
3
(<45
3
lb/ft
)
3
(100
3
lb/ft
)
MaximumCargo
BedCapacity
(onlevelground)
Full
3/4Full
Full
3/4full
3
)
Full
Full
3/4Full
(approximately)

TransportingtheMachine

Useatrailerwithfull-widthrampstomovethe machinealongdistance.Ensurethatyousecurethe machinetothetrailer.RefertoFigure21andFigure
22forthetie-downlocationsonthemachine.
g034029
Figure21
1.Towingtongueandtie-downpoint(frontofthemachine)
Note:Loadthemachineonthetrailerwiththefront
ofthemachinefacingforward.Ifthatisnotpossible, securethemachinehoodtotheframewithastrap, orremovethehoodandtransportandsecureit separatelyorthehoodmayblowoffduringtransport.
CAUTION
Looseseatsmayfalloffthemachineand trailerwhentransportingthemachine,and theseatsmaylandonanothermachineor obstructtheroadway.
Removetheseatsormakesurethattheseats aresecurelyfastenedtothecouplinginthe seatshroud.
g034273
Figure22
1.Reartie-downpoints
24
Page 25

TowingtheMachine

TowingaTrailer

Incaseofanemergency,youcantowthemachine forashortdistance;however,thisshouldnotbea standardoperatingprocedure.
WARNING
Towingatexcessivespeedscouldcausea lossofsteeringcontrol,resultinginpersonal injury.
Nevertowthemachineatfasterthan8km/h (5mph).
Towingthemachineisa2-personjob.Ifyoumust movethemachineaconsiderabledistance,transport itonatruckortrailer;refertoT owingaTrailer(page
25).
1.Shutoffthemachineandremovethekey.
Important:Ifyoutowthemachinewiththe
keyintheONposition,theelectricalsystem maybedamaged.
2.Afxatowlinetothetongueatthefrontofthe machine’sframe(Figure21).
3.Disengagetheparkingbrake.
Themachineiscapableofpullingtrailers.2typesof towhitchesareavailableforthemachine,depending onyourapplication.ContactyourAuthorizedT oro Distributorfordetails.
Whenhaulingcargoortowingatrailer,donot overloadyourmachineortrailer.Overloadingeither themachineorthetrailercancausepoorperformance ordamagetothebrakes,axle,motor,transaxle, steering,suspension,bodystructure,ortires.
Alwaysloadatrailerwith60%ofthecargoweightin thefrontofthetrailer.Thisplacesapproximately10% ofthegrosstrailerweight(GTW)onthetowhitchof themachine.
Themaximumcargoloadshouldnotexceed454kg (1,000lb),includingtheGTW.Forexample,ifthe GTWis181.5kg(400lb)thenthemaximumcargo loadis544kg(1,200lb)includingoperator(s).
Toprovideadequatebrakingandtraction,alwaysload thecargobedwhenusingatrailer.Donotexceed theGTWorGVWlimits.
Avoidparkingamachinewithatraileronahill.Ifyou mustparkonahill,engagetheparkingbrakeand blockthetiresofthetrailer.
25
Page 26
Maintenance
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
Note:Downloadacopyoftheelectricalschematicbyvisitingwww.T oro.comandsearchingforyourmachine
fromtheManualslink.
WARNING
Failuretoproperlymaintainthemachinecouldresultinprematurefailureofmachinesystems causingpossibleharmtoyouorbystanders.
Keepthemachinewellmaintainedandingoodworkingorderasindicatedintheseinstructions.
RecommendedMaintenanceSchedule(s)
MaintenanceService
Interval
Aftertherst100hours
Beforeeachuseordaily
Every25hours
Every100hours
Every300hours
Every400hours
Every800hours
Every1,000hours
MaintenanceProcedure
•Performthebreakinginanewmachineguidelines.
•Checkthetirepressure.
•Chargethebatteries.
•Checkthewaterlevelofthebatteries.
•Checkthebrake-uidlevel.
•Cleanthebatteries.
•Checkthewaterlevelofthebatteriesandadddistilledordeionizedwatertothe batteries(ifnecessary).
•Greasethebearingsandbushings.
•Checktheconditionofthetiresandrims.
•Torquethewheel-lugnuts.
•Checkthefrontwheelcamberandtoe-in.
•Checkthetransaxle-uidlevel.
•Checkthetransaxleforleaks.
•Inspectthebrakes.
•Greasethefrontwheelbearings.
•Replacetheserviceandparking-brakepads.
•Changethetransaxleuid.
•Changethebrakeuid.
26
Page 27

DailyMaintenanceChecklist

Duplicatethispageforroutineuse.
Fortheweekof: MaintenanceCheckItem
Checkbrakeandparking brakeoperation.
Checkgearshift/neutral operation.
Checkthewaterlevelof thebatteries.
Checkbrake-uidlevel.
Checkunusualoperating noises.
Checktirepressure.
Checkuidleaks.
Checkinstrument operation.
Checkaccelerator operation.
Lubricateallgrease ttings.
Touchupanydamaged paint.
MondayTuesdayWednesdayThursdayFriday
SaturdaySunday

MaintainingtheMachineunderSpecialOperating Conditions

Important:Ifthemachineissubjectedtoanyoftheconditionslistedbelow,performmaintenance
twiceasfrequently:
Desertoperation
Coldclimateoperation—below10°C(50°F)
Trailertowing
Frequentoperationindustyconditions
Constructionwork
Afterextendedoperationinmud,sand,water,orsimilardirtyconditions,haveyourbrakesinspectedand
cleanedassoonaspossible.Thispreventsanyabrasivematerialfromcausingexcessivewear.
27
Page 28
Pre-Maintenance Procedures
WARNING
Raisethecargobedbeforeperforming maintenance.Araisedcargobedcanfalland injurepersonsthatareunderneathit.
Alwaysusetheproprodtoholdthecargo bedupbeforeworkingunderneathit.
Removeanyloadmaterialfromthecargo bedbeforeworkingunderneathit.

MaintenanceSafety

Donotallowuntrainedpersonneltoservicethe
machine.
Beforeservicingormakinganyadjustmentstothe
machine,parkthemachineonalevelsurface, engagetheparkingbrake,shutoffthemotor,and removethekeytopreventaccidentalstartingof themachine.
Usejackstandstosupportthemachineor
componentswhenrequired.
Donotworkunderaraisedbedwithouttheproper
bedsafetysupportinplace.
Ensurethatallhydraulic-lineconnectorsaretight
andthatallthehydraulichosesandlinesarein goodconditionbeforeapplyingpressuretothe system.
Beforedisconnectingorperforminganyworkon
thehydraulicsystem,relieveallpressureinthe systembyshuttingoffthemotor,cyclingthedump valvefromraisetolower,and/orloweringthecargo bedandattachments.Placetheremotehydraulics
leverintheoatposition.Ifthebedmustbein raisedposition,secureitwiththesafetysupport.
Carefullyreleasepressurefromcomponentswith
storedenergy.
Toensurethattheentiremachineisingood
condition,keepallthenuts,bolts,andscrews properlytightened.
Toreducethepotentialrehazard,keepthemotor
areafreeofexcessivegrease,grass,leaves,and accumulationofdirt.
Ifpossible,donotperformmaintenancewhilethe
motorisrunning.Keepawayfrommovingparts.
Ifyoumustrunthemotortoperformamaintenance
adjustment,keepyourhands,feet,clothing,and anypartsofthebodyawayfromthemotorand anymovingparts.Keepbystandersawayfrom themachine.
Checktheparkingbrakeoperationfrequently.
Adjustandserviceasrequired.
Keepallpartsingoodworkingconditionandall
hardwaretightened.Replaceallwornordamaged decals.
Neverinterferewiththeintendedfunctionofa
safetydeviceorreducetheprotectionprovided byasafetydevice.Checktheirproperoperation regularly.
Ifmajorrepairsareevernecessaryorassistance
isrequired,contactanauthorizedT orodistributor.
Toensureoptimumperformanceandsafety,
alwayspurchasegenuineTororeplacement partsandaccessories.Replacementpartsand accessoriesmadebyothermanufacturerscould bedangerous.Alteringthismachineinany mannermayaffecttheoperationofthemachine, performance,durability,oritsusemayresultin injuryordeath.Suchusecouldvoidtheproduct warrantyofTheToro®Company.

PreparingtheMachineforMaintenance

1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Shutofftheengineandremovethekey .
g038447
Figure23
28
Page 29

LiftingtheMachine

DANGER
Themachinemaybeunstablewhenusing ajack.Themachinecouldslipoffthejack, injuringanyonebeneathit.
Donotstartthemachinewhilethemachine isonajack.
Alwaysremovethekeyfromthekeyswitch beforegettingoffthemachine.
Blockthetireswhenthemachineis supportedbyliftingequipment.
Usejackstandstosupportthemachine onceyouhaveliftedit.
Important:Wheneveryourunthemachinefor
routinemaintenanceand/ordiagnostics,ensure thattherearwheelsofthemachineare25mm(1 inch)offtheground,withtherearaxlesupported onjackstands.
g034407
Figure25
1.Rearliftingpoints
Theliftingpointatthefrontofthemachineis
locatedatthefrontoftheframe,behindthetowing tongue(Figure24).
Figure24
1.Frontliftingpoint
Theliftingpointattherearofthemachineis
locatedundertheaxletubes(Figure25).
g034043
29
Page 30

AccessingtheHood

RaisingtheHood
1.Liftupthehandleoftherubberlatchesoneach sideofthehood(Figure26).
Figure26

RaisingandLoweringthe SeatAssembly

Toraisetheseatassembly,pushtheseatassembly forwarduntilitrestsonthesteeringwheel(Figure27).
Tolowertheseatassembly,pushtheseatassembly rearwarduntilitseatsbackintotheoriginalposition (Figure27).
g008402
2.Raisethehood.
ClosingtheHood
1.Gentlylowerthehood.
2.Securethehoodbyaligningtherubberlatches ontothelatchanchorsoneachsideofthehood (Figure26).
g190066
Figure27
30
Page 31

RemovingtheSeat Assembly

Lubrication
1.Pushtheseatassemblyforwardtotheraised position(Figure27).
2.Slidetheseatassemblytothesideoutofthe pins,andlifttheseatassemblyupward(Figure
28).
Figure28
1.Pins

GreasingtheMachine

ServiceInterval:Every100hours/Yearly(whichever
comesrst)—Greasethebearings andbushings.Greasethemachine morefrequentlywhenusingitfor heavy-dutyoperations.
GreaseType:No.2lithiumgrease
1.Usearagtowipethegreasettingcleansothat foreignmattercannotbeforcedintothebearing orbushing.
2.Withagreasegun,apply1or2pumpsofgrease intothegreasettingsonthemachine.
3.Wipetheexcessgreaseoffthemachine.
Thegreasettingsarelocatedattheinnerendofthe controlarms,thetie-rodballjoint,andtheouterend ofthecontrolarms(Figure30andFigure31).
g190187

InstallingtheSeat Assembly

Slidetheseatassemblyontothepinsandlowerthe seatassembly(Figure29).
Figure29
1.Pins
g034057
Figure30
g034058
Figure31
g190186
31
Page 32

GreasingtheFrontWheel Bearings

ServiceInterval:Every300hours
Greasespecication:MobilgreaseXHP™-222
RemovingtheHubandRotor
1.Liftthefrontofthemachineandsupportitwith jackstands.
2.Removethe4lugnutsthatsecurethewheel tothehub(Figure32).
g033047
Figure33
Figure32
1.Hub3.Lugnut
2.Wheel
3.Removetheange-headbolts(3/8x3/4inch) thatsecurethebracketforthebrakeassembly tothespindleandseparatethebrakefromthe spindle(Figure33).
Note:Supportthebrakeassemblybefore
proceedingtothenextstep.
1.Flange-headbolts(3/8x 3/4inch)
2.Spindle
3.Caliperbracket(brake assembly)
4.Removethedustcapfromthehub(Figure34).
g033046
g192346
Figure34
1.Cotterpin4.Spindlenut
2.Spindle
3.Tabwasher6.Dustcap
5.Nutretainer
5.Removethecotterpinandnutretainerfromthe spindleandspindlenut(Figure34).
6.Removethespindlenutfromthespindle,and separatethehubandrotorassemblyfromthe spindle(Figure34andFigure35).
32
Page 33
Figure35
GreasingtheWheelBearings
1.Removetheoutboardbearingandbearingrace fromthehub(Figure36).
g192347
1.Spindle
2.Hubandrotorassembly
7.Wipecleanthespindlewitharag.
8.Repeatsteps1through7tothehubandrotorat theothersideofthemachine.
Figure36
1.Seal4.Bearingcavity(hub)
2.Inboardbearing
3.Inboard-bearingrace
5.Outboard-bearingrace
6.Outboardbearing
2.Removetheseal,inboardbearingfromthehub (Figure36).
3.Wipecleanthesealandcheckforwearand damage.
Note:Donotusecleaningsolventtocleanthe
seal.Replacethesealifitiswornordamaged.
4.Cleanthebearingsandraces,andcheckthese partsforwearanddamage.
Note:Replaceallwornordamagedparts.
Ensurethatthebearingsandracesareclean anddry.
5.Cleanthecavityofthehubofallgrease,dirt, anddebris(Figure36).
g033050
6.Packthebearingswiththespeciedgrease.
7.Fillthecavityofhub50to80%fullofthe speciedgrease(Figure36).
8.Assembletheinboardbearingontotheraceat theinboardsideofthehubandinstalltheseal (Figure36).
9.Repeatsteps1through8tothebearingsforthe otherhub.
33
Page 34
InstallingtheHubandRotor
1.Applyalightcoatofthespeciedgreasetothe spindle(Figure37).
Figure37
1.Nutretainer
2.Spindlenut
3.Tabwasher
2.Assemblethehubandrotorontothespindle withtherotorinboard(Figure37).
3.Assembletheoutboardbearingontothespindle andseatthebearingtotheoutboardrace (Figure37).
4.Assemblethetabwasherontothespindle (Figure37).
5.Threadthespindlenutontothespindleand tightenthenutwhilerotatingthehub(Figure37).
Note:Tightenthenutandrotatethespindle
untilthebearingsarefullyseatedandthehub hasnolinear-endmovement.
6.Loosenthespindlenutuntilthehubrotates freely.
7.Torquethespindlenutto170N∙cm(15in-lb) whilerotatingthehub.
8.Installtheretaineroverthenutandcheckthe alignmentoftheslotintheretainerandthehole inthespindleforthecotterpin(Figure38).
Note:Iftheslotintheretainerandtheholein
thespindlearenotaligned,tightenthespindle nuttoaligntheslotandholetoamaximum torqueof226N∙cm(20in-lb)onthenut.
4.Outerbearing
5.Hub,rotor,innerbearing, race,andseal
6.Spindle
g192345
g192344
1.Cotterpin
2.Nutretainer
Figure38
3.Dustcap
9.Installthecotterpinandbendeachlegsaround theretainer(Figure38).
10.Installthedustcapontothehub(Figure38).
11.Repeatsteps1through10forthehubandrotor attheothersideofthemachine.
InstallingtheBrakesandWheels
1.Cleanthe2ange-headbolts(3/8x3/4inch) andapplyacoatofanti-seizecompoundtothe threadsofthebolts.
2.Alignthebrakepadstoeithersideoftherotor (Figure33)andtheholesinthecaliperbracket withtheholesinthebrakemountofthespindle frame(Figure36).
3.Assemblethecaliperbrackettothespindle frame(Figure33)withthe2ange-headbolts (3/8x3/4inch),andtorquetheboltsto47to54 N∙m(35to40ft-lb).
4.Aligntheholesinthewheeltothestudsofthe hubandassemblethewheeltothehubwiththe valvestemoutward(Figure32).
Note:Ensurethatthemountingsurfaceofthe
wheelisushwiththehub.
5.Securethewheeltothehubwiththelugnuts (Figure32),andtorquethenutsto108to122 N∙m(80to90ft-lb).
6.Repeatsteps1through5forthebrakeand wheelattheothersideofthemachine.
34
Page 35
ElectricalSystem
–Donotuseanopenametocheckthelevelor
leakageofbatteryelectrolyte.
Maintenance

ElectricalSystemSafety

WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandlead
compounds,chemicalsknownto
theStateofCaliforniatocause
cancerandreproductiveharm.Wash
handsafterhandling.
Disconnectthebatterybeforerepairingthe
machine.Disconnectthenegativeterminalrst andthepositivelast.Connectthepositiveterminal rstandthenegativelast.
Chargethebatteryinanopen,well-ventilated
area,awayfromsparksandames.Unplugthe chargerbeforeconnectingordisconnectingthe battery.Wearprotectiveclothinganduseinsulated tools.
–Wearpropereye,hand,andfaceprotection.
–Donotleanoverthebatteriesatanytime.
–Avoidbreathinginbatteryfumes.
–Fillthebatterieswherecleanwaterisalways
availableforushingtheskin.
–Ifyougetelectrolyteonyourskinoreyes,
ushtheaffectedareafor20minuteswith cleanwater.Removeaffectedclothing.Seek medicalattentionimmediately .
–Keepchildrenandpetsawayfromthebatteries
andelectrolyte.
Electrolyteispoisonous.
–Donotdrinktheelectrolyte.
–Ifelectrolytehasbeenswallowed,havethem
drinklargequantitiesofwaterimmediatelyto dilutetheelectrolyte,ifpossible.
–Donotattempttomakethemvomit.
–Callapoisoncontrolcenterandgetmedical
attentionimmediately.
Whennotllingthebatteries,keepthebattery
ventcapstightonthebatteries.Donotoperate themachineifanyoftheventcapsaremissingor damaged.

BatterySafety

Toreducethepotentialforre,keepthebatteries
andmotorareafreeofexcessivegrease,grass, leaves,andaccumulationofdirt.
Removealljewelryandwatchesbeforeservicing
thebatteries.
Donotchargethebatterieswhileservicingthe
machine.
Alwaysdisconnectallthebatterycablesbefore
servicinganyelectricalcomponents;referto
DisconnectingtheBatteries(page39).
Note:Disconnectingallthebatterycables
isolatespowerfromtheelectricalsystem.
Batteryelectrolytecontainssulfuricacid,which
produceshydrogen,agasthatisexplosivein certainconditions.Sulfuricacidcanburnskinand damageclothing;whenemittedingasform,itcan damageyourlungs.
–Alwaysservice,store,andchargethemachine
inawell-ventilatedarea.
–Keepsparksandopenamesawayfromthe
batteries.
–Donotsmokenearthebatteries.
Whenremovingorinstallingthebatteries,donot
allowthebatteryterminalstotouchanymetal partsofthemachine.
Donotallowmetaltoolstoshortbetweenthe
batteryterminalsandmetalpartsofthemachine.
Donotcheckabatterychargebyplacingametal
objectacrosstheposts.Thiscausessparks, whichcancauseanexplosion.
Alwayskeepthebatteryretainersinplaceto
protectandsecurethebatteries.
Readandunderstandthecharginginstructions
beforechargingthebatteries;refertoCharging
theBatteries(page36).Also,takethefollowing
precautionswhenchargingthebatteries:
–TurnthemachinekeyswitchtoOFFbefore
connectingthechargertoapowersource.
–Useonlythebatterychargersuppliedwiththe
machinetochargethebatteries.
–Donotchargeadamagedorfrozenbattery.
–AlwaysunplugtheACpowercordfromthe
poweroutletbeforeunpluggingitfromthe machinechargingreceptacletoavoidsparks.
–Ifabatterygetshotwhilecharging,begins
emittinglargeamountsofgasses,orspews
35
Page 36
electrolyte,immediatelydisconnectthecharger powercordfromthepoweroutlet.Have themachineservicedbyanauthorizedToro distributorbeforeusingitagain.

MaintainingtheBatteries

Raisetheseatassemblyandraisethecargobed beforemaintainingthebatteries;refertoRaisingand
LoweringtheSeatAssembly(page30)andRaising theCargoBedtotheDumpPosition(page17).
WARNING
CALIFORNIA
Proposition65Warning
Batteryposts,terminals,andrelated
accessoriescontainleadandlead
compounds,chemicalsknownto
theStateofCaliforniatocause
cancerandreproductiveharm.Wash
handsafterhandling.
WARNING
Batteryterminalsormetaltoolscouldshort againstmetalcomponentscausingsparks. Sparkscancausethebatterygasesto explode,resultinginpersonalinjury.
Whenremovingorinstallingthebattery, donotallowthebatteryterminalstotouch anymetalpartsofthemachine.
CleaningtheBatteries
ServiceInterval:Every25hours
1.Ensurethatallthebatterycapsaretight.
2.Useapapertoweltocleanthebatteries.
3.Ifthebatteryterminalsarecorroded,cleanthem withasolutionof4partswaterand1partbaking soda.Also,cleanthepostsandcableclamps withapostandclampcleaner.
Note:Thepostsandclampsshouldhavea
bright,metallicshine.
4.ApplyalightcoatingofT orobattery-terminal protector.
ChargingtheBatteries
ServiceInterval:Beforeeachuseordaily
Thechargerforthismachineislocatedinsidethe machineundertheoperator’sseat.Formaximum batterylife,chargethebatterieswheneveryouarenot usingthemachine.Dependingonhowdischarged thebatteriesareandtheambienttemperatureofthe batteries,itmaytakeupto16hourstochargethe batteriestofullcapacity.
Note:Normalchargetimeisapproximately8to10
hours.
Important:Lead-acidbatteriesdonotdevelop
achargememoryanddonotneedtobe fullydischargedbeforechargingthem.Fully
dischargingthebatteriesmaydamagethem.
Chargethebatteriesanytimethemachineisnot inuse.
Donotallowmetaltoolstoshortbetween thebatteryterminalsandmetalpartsofthe machine.
Useinsulatedtoolswhenmaintainingthe batteries.
Alwayskeepthebatteryretainersinplace toprotectandsecurethebatteries.
DANGER
Donottouchanyelectricalcomponentsor contactsonthemotor.
Touchinganyofthesecomponentsor contactscouldseriouslyinjureyouorcause death.
WARNING
Chargingthebatteryproducesgasesthatcan explode.
Neversmokenearthebatteriesandkeep sparksandamesawayfromthem.
1.Positionthemachineinawell-ventilatedarea nearasuitablepoweroutlet.
2.Checktheelectrolytelevelofthebatteries.
Note:Afterfullychargingthebatteries,ll
thebatterieswithdistilledordeionizedwater; refertoAddingDistilledorDeionizedWaterto
theBatteries(page38).
Important:Fullychargethebatteries
beforeaddingthewatertothebatteries. Whilecharging,theelectrolyteincreases involume,andllingalowbatterybefore fullychargingthebatteriescancausethe electrolytetooverowandleakoutofthe vent.
36
Page 37
3.Connecta16gauge(orlargerdiameter),
2.5m(8.2ft)orshorterchargercordtothe chargingreceptacleonthemachine(Figure39).
RefertothefollowingtableandFigure39for informationonthemeaningsofthevaryingcolorsof thecharger-statuslight.
Note:Ensurethatthecharger-voltagesetting
matchesthevoltageatthepoweroutletbeing used.
Note:Inhigh-ambienttemperature
environments,removetheseatassemblyfor optimalchargingtime;refertoRemovingthe
SeatAssembly(page31).Ifthebatterycharger
istoohot,itmaynotchargeproperly.Incold temperatures,itmaytakealongerforthe batteriestocharge.
Charger-StatusLightT able
Charger-Status
LightColor
GreenSolidChargingcomplete
Green
AmberFlashingReduced-power
RedFlashing
Solid/Flashing
Flashing
Meaning
Shortash—less than80%charge Long ash—greaterthan 80%charge
mode—lowAC voltageorhigh internalcharger temperature; chargeimmediately
Charger error—resetthe chargerpower Ifthiserrorpersists, refertotheblink codesinthe chargermanual
Figure39
1.Charger-statuslight
2.Chargingreceptacle
3.Thebatteryisnearempty.
4.Thebatteryisalmost charged.
5.Thebatteryischarged.
6.Chargerfault;refertothe chargermanualforthe faultcodes.
4.Plugthechargerpowercordintothepower outlet.
Note:Whilethebatteriesarecharging,the
greenlightonthechargerblinksonandoff. Whenthebatteriesarefullycharged,thegreen lightstopsblinkingandstayson.
5.Disconnectthecordfromthepoweroutlet.
6.Disconnectthechargerfromthemachine.
g034217
37
Page 38
CheckingtheWaterLevelofthe Batteries
ServiceInterval:Beforeeachuseordaily
1.Parkthemachineonalevelsurface,engagethe parkingbrake,shutoffthemachine,removethe key,andraisecargobed;RaisingtheCargoBed
totheDumpPosition(page17).
2.Raisetheseatassemblytoaccessthebatteries; refertoRaisingandLoweringtheSeatAssembly
(page30).
3.Checktheeyeletsoneachofthebatteriesto seeiftheyareeitherblackorwhite(Figure40).
Note:Blackeyeletsindicatethatthebatteries
arefullofwater.Whiteeyeletsindicatethat waterisneededforthebatteries.
key,andraisecargobed;RaisingtheCargoBed
totheDumpPosition(page17).
2.Chargethebatteriesuntilafullchargeis achieved;refertoChargingtheBatteries(page
36).
3.Raisetheseatassemblytoaccessthebatteries; refertoRaisingandLoweringtheSeatAssembly
(page30).
4.ConnectyourT orowaterhandpumptothe water-llport(Figure41).
Figure40
1.Batteryeyelet
4.Iftheeyeletsarewhite,youmustadddistilledor deionizedwatertothebatteries;refertoAdding
DistilledorDeionizedWatertotheBatteries (page38).
AddingDistilledorDeionized WatertotheBatteries
ServiceInterval:Every25hours/Every2weeks
(whichevercomesrst)
Important:Fullychargethebatteriesbefore
addingthewatertothebatteries.Whilecharging, theelectrolyteincreasesinvolume,andllinga lowbatterybeforefullychargingthebatteriescan causetheelectrolytetooverowandleakoutof thevent.
Important:Useonlyclean,distilledordeionized
watertollthebatteries.Usingtapwatermay damageandreducethelifeofthebatteries.
1.Parkthemachineonalevelsurface,engagethe parkingbrake,shutoffthemachine,removethe
g034218
Figure41
1.Water-llport
2.Hand-pumpconnector
5.Pumpwaterintothewaterintobatteriesuntilall oftheeyeletsontopofthebatteriesareblack, indicatingthattheyarelledwithwater.
3.Waterhandpump
g034255
Important:Donotoverllthebattery.
Electrolytewilloverowontootherparts ofthemachineandseverecorrosionand deteriorationmayresult.Also,overllingthe batterymayreducethelifeofthebattery.
ChangingtheBatteries
Whenthemachinebeginstoloseoperatingrange orwhenthelengthoftimetodischargeorcharge thebatteryissignicantlyreduced,thebatteriesare probablywearingandlosingtheirabilitytoholda charge.T akethemachinetoanAuthorizedService Dealerandhavethemtestthebatteriestodetermine whetherthebatteriesneedtobereplaced.Thedealer canthenreplacethebatteriesforyou.Ifyouwish toreplacethebatteriesyourself,usethefollowing procedures:
38
Page 39
DisconnectingtheBatteries
ConnectingtheBatteries
1.Raisethecargobed,turnthekeyswitchtothe OFFposition,andremovethekey.
2.Disconnectthemainnegative-batterycable (black)thatconnectsthebankofbatteriestothe groundpointofthemachine(Figure42).
Note:Themainbatterycablesarelongwhen
comparedtobattery-interconnectcables.
1.Ensurethatthebatteryterminalsarecleanand freeofoxidation.
2.Connectthemainpositive-batterycable(red) betweenthebankofbatteriesandthemachine (Figure42).
3.Connectthemainnegative-batterycable(black) betweenthebankofbatteriesandthemachine (Figure42).
4.T orquethenutssecuringallofthebatterycables untiltheretainersecurelygripsthebattery.
5.CoatthebatteryterminalswithT oro battery-terminalprotector.
6.Ensurethattherubberbootsoneachbattery cablearesecurelyseatedoverthebattery terminals.
7.Insertthekeyintothekeyswitchandrotatethe switchtotheONposition.
8.Lowerthecargobed,rotatethekeyswitchto theOFFposition,andremovethekey.
Figure42
3.Disconnectthemainpositive-batterycable(red) thatconnectsthebankofbatteriestothemain contactorofthemachine(Figure42).
ReplacingtheBatteries
1.Removeallofthebattery-interconnectcables fromthebatteries.
2.Removethebatteryretainerslocatedbetween thebatteries.
3.Removeallofthebatteriesandrecyclethem accordingtoyourlocalcodes.
4.Assemblenewbatteriesintothemachineatthe locationsfromwhereyouremovedbatteriesin step3.
Note:Payattentiontothebatterypolaritywhen
installingthenewbatteries(Figure42).
StoringtheBatteries
g034412
Chargethebatteriesfullybeforeplacingthemachine intostorage.Plugthechargerintoawalloutletwhile themachineandbatteriesareinstorage.Leave thechargerpluggedintoawalloutletandcharging receptacleduringstoragetoensurethatthebatteries staychargedanddonotfreeze;otherwise,chargethe batteriesatleastonceamonth.
Important:Ifthemachinecannotbeplugged
induringstorage,fullychargethebatteriesat leastonceamonth.Thebatteriesself-discharge overlongperiodsoftime,whichmaydamagethe batteriestothepointofbeingunusable,evenif thebatteriesarenew.
5.Installthebatteryretainersandtightenthenuts untiltheretainersecurelygripsthebatteries.
6.Connectthebatteriestogetherasshownin
Figure42withthebattery-interconnectcables
thatyouremovedinstep1.
39
Page 40

ReplacingtheFuses

Thereis1fuseintheelectricalsystem;theotherslots areopenforoptions.Theyarelocatedundertheseat assemblybehindabatteryontherightsideofthe machine(Figure43).

MaintainingtheHeadlights

ReplacingtheBulbs
CAUTION
Optionalliftkit—open
Mainpower10A
Horn—optional(standardon Internationalmodelsonly)
Figure43
1.Fuseblock
15A
30A
Ifyouinstallahigherwattagebulbthanthe systemisdesignedfor,youmaydamagethe 12Vpowersupply,orataminimum,blowthe fuse.
AlwaysusethespeciedToroLEDbulbto preventthisissue.
CAUTION
Thebulbsbecomeextremelyhotwhenin operation.Handlingahotbulbcancause severeburnsandpersonalinjury.
Alwaysallowenoughtimeforthebulbs tocoolbeforereplacingthem.Usecare wheneverhandlingthebulb.
Specication:SeeyourPartsCatalog.
1.Disconnectthebatteries;refertoDisconnecting
theBatteries(page39).
2.Openthehood;refertoRaisingtheHood(page
g036964
30).
3.Disconnecttheelectricalconnectorforthe harnessfromtheconnectorofthelamp assemblyatthebackoftheheadlighthousing (Figure44).
Figure44
1.Headlighthousing3.Harness-electrical
2.Lampassembly
4.Rotatethelampassembly1/4turn counterclockwiseandmovingitrearward, outoftheheadlighthousing(Figure44).
5.Insertthenewlampassemblyandheadlight housingandalignthetabsinthelampassembly
40
g035852
connector
Page 41
withtheslotsintheheadlighthousing(Figure
44).
6.Securelampassemblybyturningit1/4turn clockwise(Figure44).
7.Connecttheelectricalconnectorfortheharness totheconnectorofthenewlampassembly (Figure44).
8.Connectthebatteriesandclosethehood;refer toClosingtheHood(page30).
ReplacingtheHeadlight
Note:Ensuretheadjustmentpostsarelinedup
withtheholesinthemountingbracketbehind thebumper.
7.Securetheheadlightassemblywiththespeed clipsthatyouremovedinstep4.
8.Connecttheelectricalconnectorfortheharness totheconnectorofthelampassembly(Figure
45).
9.Adjusttheheadlightstodirectthebeamsto thedesiredposition,refertoAdjustingthe
Headlights(page41).
1.Disconnectthebatteries;refertoDisconnecting
theBatteries(page39).
2.Openthehood;refertoRaisingtheHood(page
30).
3.Disconnecttheelectricalconnectorforthe harnessfromtheconnectorofthelamp assembly(Figure45).
AdjustingtheHeadlights
Usethefollowingproceduretoadjusttheheadlight beampositionwheneveraheadlightassemblyis replacedorremoved.
1.TurnthekeyswitchtotheONposition,andturn ontheheadlights.
2.Atthebackoftheheadlightassembly,rotate adjustmentscrews(Figure45)topivotthe headlightassemblyandalignthepositionofthe castbeam.
3.Connectthebatteryandclosethehood;referto
ClosingtheHood(page30).
Figure45
1.Speedclip
2.Openinginthebumper
3.Adjustmentscrew6.Harness-electrical
4.Headlight
5.Lampassembly
connector
4.Removethespeedclipsthatsecurethe headlighttotheheadlightbracket(Figure45).
Note:Retainallpartsforinstallationofthenew
headlight.
5.Removetheheadlightassemblybymovingit forwardthroughtheopeninginthefrontbumper (Figure45).
6.Installthenewheadlightthroughtheopeningin thebumper(Figure45).
g035853
41
Page 42
DriveSystem Maintenance

MaintainingtheTires

ServiceInterval:Every100hours—Checkthe
conditionofthetiresandrims.
Every100hours—Torquethewheel-lugnuts.
1.Inspectthetiresanrimsforsignsofwearand damage.
Note:Operatingaccidents,suchashitting
curbs,candamageatireorrimandalsodisrupt wheelalignment,soinspecttireconditionafter anaccident.
2.T orquethewheel-lugnutsto108to122N∙m(80 to90ft-lb).

AdjustingtheFrontWheel Alignment

ServiceInterval:Every100hours/Yearly(whichever
comesrst)—Checkthefrontwheel camberandtoe-in.
PreparingtoAdjustCamberor Toe-in
1.Checkthetirepressuretoensurethatthefront tiresareinatedto82kPa(12psi).
2.Eitheraddweighttothedriver'sseatequalto theaverageoperatorwhowillrunthemachine, orhaveanoperatorsitontheseat.Theweight oroperatormustremainontheseatforthe durationoftheadjustmentprocedure.
3.Onalevelsurface,rollthemachinestraightback 2to3m(6to10ft)andthenstraightforward totheoriginalstartingposition.Thisallowsthe suspensiontosettleintotheoperatingposition.
AdjustingtheCamber
2.Ifthewheelcamberisoutofalignment,usethe spannerwrenchtorotatethecollarontheshock absorbertoalignthewheel(Figure46).
g033218
Figure46
1.Shock-absorberspring3.Springlength
2.Collar
AdjustingtheFrontWheelToe-in
Important:Beforeadjustingtoe-in,ensurethat
thecamberadjustmentisasclosetoneutralas possible;refertoAdjustingtheCamber(page42).
1.Measurethedistancebetweenbothofthefront tiresattheaxleheightatboththefrontandrear ofthefronttires(Figure47).
g009235
Figure47
1.Tirecenterline—back3.Axlecenterline
2.Tirecenterline—front
Ownerprovidedtools:spannerwrench,ToroPart No.132-5069;refertoyourauthorizedT orodistributor.
Important:Makethecamberadjustmentsonly
ifyouareusingafrontattachmentorifthereis uneventirewear.
1.Checkthecamberalignmentateachwheel;the alignmentshouldbeasclosetoneutral(zero) aspossible.
Note:Thetiresshouldbealignedwiththetread
evenlyonthegroundtoreduceunevenwear.
2.Ifthemeasurementdoesnotfallwithin0to 6mm(0to1/4inch),loosenthejamnutsatthe outerendofthetierods(Figure48).
42
Page 43

ChangingtheTransaxle Fluid

ServiceInterval:Every100hours—Checkthe
transaxleforleaks.
Every800hours/Y early(whichevercomes rst)—Changethetransaxleuid.
FluidType:SAE10W-30(APIserviceSJorhigher)
Figure48
1.Tierod2.Jamnut
3.Rotatebothtierodstomovethefrontofthetire inwardoroutward.
4.Tightenthetierodjamnutswhentheadjustment iscorrect.
5.Ensurethatthereisfulltravelofthesteering wheelinbothdirections.

Checkingthe Transaxle-FluidLevel

ServiceInterval:Every100hours—Checkthe
transaxle-uidlevel.
1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Shutoffthemotorandremovethekey.
4.Removethellplugonthetransaxle(Figure49).
Note:Theuidlevelshouldbeevenwiththe
bottomofthellplug.
g033219
FluidCapacity:0.66L(0.7USqt)
1.Alignadrainpanunderthetransaxlecover (Figure50).
g217834
Figure50
1.Transaxlecover2.Bolts
2.Removetheboltsfromthetransaxlecoverand draintheuidcompletely(Figure50).
Note:Retainthetransaxlecoverandbolt.
3.Installthetransaxlecoverusingthepreviously removedbolts,andtorquetheboltsto22to32 N∙m(16to24ft-lb).
4.Removethellplugonthetransaxleandllthe transaxlewiththespecieduiduntilitrunsout ofthellhole(Figure49).
Figure49
1.Fillplug
5.Iftheuidlevelislow,removethellplugand addthespecieduiduntilitrunsoutofthehole (Figure49).
6.Installthellplugandtorqueitto20to27N∙m (15to20ft-lb).
5.Installthellplugandtorqueitto20to27N∙m (15to20ft-lb).
g217835
43
Page 44
BrakeMaintenance
8.Verifythattheparkingbrakeisadjustedtothe propertension;refertoCheckingtheParking
Brake(page44).

CheckingtheParkingBrake

1.Engagetheparkingbrakebypullingthe parking-brakelevertowardyou,untilyoufeel tension.
2.Ifyoudonotfeeltensionwhenpullingthe parking-braketowardyouwithin11.4to16.5cm (4-1/2to6-1/2inches)fromthe“P”symbolon thedash,thenyouneedtoadjusttheparking brake;refertoAdjustingtheParkingBrake
(page44).

AdjustingtheParking Brake

1.Ensurethattheparkingbrakeisdisengaged.
2.Usingjackstands,lifttherearofthemachine; refertoLiftingtheMachine(page29).
3.Using2wrenches,holdtheadjustingpostonthe caliperinplacewith1wrench,andloosenthe jamnut1/4turnwiththeotherwrench(Figure
51).
Note:Ifyoucannotadjusttheparkingbrake
totherequiredtension,thebrakepadsmay bewornandneedtobereplace.Contactyour AuthorizedT oroServiceDealerforassistance.

CheckingtheBrake-Fluid Level

ServiceInterval:BeforeeachuseordailyCheckthe
brake-uidlevelbeforethemotoris rstused.
BrakeFluidType:DOT3
1.Parkthemachineonalevelsurface,engagethe parkingbrake,shutoffthemachine,andremove thekey.
2.Raisethehoodtogainaccesstothe master-brakecylinderandreservoir(Figure52).
Figure51
1.Adjustingpost
2.Jamnut
4.Whileholdingtheadjustingpostandthejam nutinplace,turntheadjustingpostintotighten (Figure51).
3.Caliper
Note:Performthisstepuntilyoufeeldragon
thewheel.
5.Whileholdingtheadjustingpostandthejamnut inplace,backoff1/4turn(Figure51).
6.Whileholdingtheadjustingpostandthejamnut inplace,tightenthejamnut(Figure51).
7.Performsteps1through6totheotherside.
g034434
Figure52
1.Fillerneck(reservoir)3.DOT3brakeuid
2.Reservoircap
3.Lookattheoutlineoftheuidlevelatthesideof thereservoir(Figure53).
g034314
Note:ThelevelshouldbeabovetheMinimum
line.
44
Page 45

ReplacingtheServiceand Parking-BrakePads

ServiceInterval:Every400hours
ContactyourauthorizedAuthorizedT oroService Dealertoinspectandpossiblyreplacetheserviceand parking-brakepads.
Figure53
1.Brake-uidreservoir
4.Iftheuidlevelislow,performthefollowing:
A.Cleantheareaaroundthereservoircap
andremovethecap(Figure52).
B.AddDOT3brakeuidtothereservoiruntil
theuidlevelisabovetheMinimumline (Figure53).
2.Minimumline
Note:Donotoverllthereservoirwith
brakeuid.
C.Installthereservoircap(Figure52).
5.Closethehoodofthemachine.

InspectingtheBrakes

ServiceInterval:Every100hours
Brakesareacriticalsafetycomponentofthemachine. Aswithallsafetycomponents,theyshouldbeclosely inspectedatregularintervalstoensureoptimum performanceandsafety.
g002136

ChangingtheBrakeFluid

ServiceInterval:Every1,000hours
ContactyourauthorizedAuthorizedT oroService Dealer.
Inspectthebrakeshoesforwearordamage.Ifthe
lining(brakepad)thicknessislessthan1.6mm (1/16inch),thebrakeshoesshouldbereplaced.
Inspectthebackingplateandothercomponents
forsignsofexcessivewearordeformation.Ifany deformationisfound,theappropriatecomponents mustbereplaced.
Checkthebrake-uidlevel;refertoCheckingthe
Brake-FluidLevel(page44).
45
Page 46

ChassisMaintenance

Cleaning

AdjustingtheCargo-Bed Latches

Ifthecargo-bedlatchisoutofadjustment,thecargo bedvibratesupanddownasyoudrivethemachine. Youcanadjustthelatchpoststomakethelatches holdthecargobedsnuglytothechassis.
1.Verifythatthecargobedislatching.
Note:Ifthecargobeddoesnotlatch,the
bed-latchstrikerislikelytoolow.Ifthecargo bedlatches,butvibratesupanddownasyou drive,thebed-latchstrikerislikelytoohigh.
2.Raisethecargobed;RaisingtheCargoBedto
theDumpPosition(page17).
3.Loosenthe2boltsonthebed-latchstrikerand movethestrikerupordown,dependingonifthe strikeristoohighortoolow(Figure54).

WashingtheMachine

Washthemachineasneeded.Usewateraloneor withamilddetergent.Youmayusearagwhen washingthemachine;however,thehoodwilllose someofitsluster.
Important:Pressurizedwaterisnot
recommendedwhenwashingthemachine.Itmay damagetheelectricalsystem,loosenimportant decals,orwashawaynecessarygreaseatfriction points.Avoidexcessiveuseofwater,especially nearthecontrolpanel,motor,motorcontroller, charger,backofthedashboard,andbatteries.
Figure54
1.Bolts2.Bed-latchstriker
4.Tightenthe2boltsonthebed-latchstriker (Figure54).
5.Verifythattheadjustmentiscorrectbylatching thecargobedseveraltimes.
g034451
46
Page 47
Storage
1.Parkthemachineonalevelsurface,engagethe parkingbrake,shutoffthemachine,andremove thekey.
2.Cleandirtandgrimefromtheentiremachine, includingtheoutsideofthemotorhousing.
Important:Youcanwashthemachine
withmilddetergentandwater.Donotuse highpressurewatertowashthemachine. Pressurewashingmaydamagetheelectrical systemorwashawaynecessarygreaseat frictionpoints.Avoidexcessiveuseofwater, especiallynearthecontrolpanel,lights, motor,andthebattery.
3.Inspectthebrakes;refertoInspectingthe
Brakes(page45).
4.Greasethemachine;refertoGreasingthe
Machine(page31).
5.Checkthetirepressure;refertoCheckingthe
TirePressure(page20).
6.Checkandtightenallbolts,nuts,andscrews. Repairorreplaceanypartthatisdamaged.

BatteryStorage

1.Chargethebatteriesfullybeforeplacingthe machineintostorage;refertoChargingthe
Batteries(page36).Plugthechargerintoawall
outletwhilethemachineandbatteriesarein storage.Leavethechargerpluggedintoawall outletandchargingreceptacleduringstorage toensurethatthebatteriesstaychargedand donotfreeze;otherwise,chargethebatteries monthlyataminimum.
2.Pluginthechargerduringstoragetomaintain fullbatterylife.
Important:Ifthemachinecannotbe
pluggedinduringstorage,fullychargethe batteriesatleastonceamonth.Thebatteries self-dischargeoverlongperiodsoftime, whichmaydamagethebatteriestothepoint ofbeingunusable,evenifthebatteriesare new.
3.Afterfullychargingthebatteries,llthebatteries withdistilledordeionizedwaterbeforestoring; refertoAddingDistilledorDeionizedWaterto
theBatteries(page38).
7.Paintallscratchedorbaremetalsurfaces.
Note:PaintisavailablefromyourAuthorized
ServiceDealer.
8.Storethemachineinaclean,drygarageor storagearea.
9.Removethekeyandputitinasafeplaceoutof thereachofchildren.
10.Coverthemachinetoprotectitandkeepitclean.
47
Page 48
Troubleshooting
Machine-StatusLightFlashPattern
Problem
Themachine-statuslightisalways illuminated.
Themachine-statuslightashed1time.1.Thereisacontroller-congurationfault.1.ContactyourAuthorizedToroService
Themachine-statuslightashed2times.
Themachine-statuslightashed3times.
Themachine-statuslightashed4times.1.Amain-contactorfaultoccurred.
Themachine-statuslightashed5times.
1.Thesystemisfunctioningproperly.
1.Theparkingbrakeisengagedwhilein FORWARDorREVERSEposition.
2.Adrive-switchfaultoccurred.2.Turnoffthemachineandcheckthe
1.Themotorcurrentexceededthe controller-ratedmaximum.
2.Thereisaninternal-powercomponent fault.
1.Exceededthemaximummotorspeed.
PossibleCauseCorrectiveAction
1.None
Dealer.
1.Disengagetheparkingbrake.
functionalityoftheswitches.
1.TurnthekeyswitchtotheOFFposition, waitafewseconds,andturnthekey switchtotheONposition.Checkall batteriesandhigh-currentcontroller connectionsIftheconditioncontinues, refertoyourAuthorizedService Dealer.
2.ContactyourAuthorizedToroService Dealer.
1.T estthecontactwires,coiland contactsfornormaloperation.
1.TurnthekeyswitchtotheOFFposition, waitafewseconds,turnthekeyswitch totheONposition,andcheckfor normaloperation.
Themachine-statuslightashed6times.
Themachine-statuslightashed7times.
Themachine-statuslightashed8times.
Themachine-statuslightashed10times.
1.Thethrottleispressedwhilestarting themachine.
2.Thereisawirethatisnotmakinga connection.
1.Theremainingchargeonthebatteries islow .
2.Thebatteriesarefullydischarged.
3.Theinternalcapacitorhasapre-charge oflessthan5V.
1.Thecontrollerormotorisoverheated ortoocold.
1.Acontroller-congurationfault occurred.
1.Releasethepedal,turnthekeyswitch totheOFFposition,waitafewseconds, turnthekeyswitchtotheONposition, andcheckfornormaloperation.
2.T estthewiringbetweenthecontroller andcontactor,switches,andthe status-indicatorlight.
1.Stopoperation,driveslowlytoyour nearestchargingstation,andcharge thebatteriesfully .
2.T owthemachinetoyourcharging stationandchargethebatteriesfully.
3.Fullychargethebatteries,turnthe keyswitchtotheOFFposition,waita fewseconds,turnthekeyswitchto theONposition,andcheckfornormal operation.
1.Determineifthemotororcontrolleris veryhotorverycold,thenallowthe machinetoreturntosafetemperatures beforeresumingnormaloperation.
1.ContactyourAuthorizedToroService Dealer.
48
Page 49
Problem
PossibleCauseCorrectiveAction
Themachine-statuslightashed11times.
Themachine-statuslightashed12times.1.Acontroller-congurationfault
Themachine-statuslightashed13times.1.Aninternal-softwarefaultoccurred.1.ContactyourAuthorizedToroService
Themachine-statuslightashed14times.1.Acommunicationfaultoccurred.1.ContactyourAuthorizedToroService
Themachine-statuslightisnotilluminated.1.Thereiseithernopowertothe
1.Amotor-encoderfaultoccurred.1.Checkthemotor-encoder(speed
2.Exceededthemaximummotorspeed.
occurred.
controllerorthecontrollerhasfailed.
sensor)wiring.
2.TurnthekeyswitchtotheOFFposition, waitafewseconds,turnthekeyswitch totheONposition,andcheckfor normaloperation.
1.ContactyourAuthorizedToroService Dealer.
Dealer.
Dealer.
1.ContactyourAuthorizedToroService Dealer.
49
Page 50
Notes:
Page 51
EuropeanPrivacyNotice
TheInformationToroCollects ToroWarrantyCompany(Toro)respectsyourprivacy.Inordertoprocessyourwarrantyclaimandcontactyouintheeventofaproductrecall,weaskyou tosharecertainpersonalinformationwithus,eitherdirectlyorthroughyourlocalT orocompanyordealer.
TheT orowarrantysystemishostedonserverslocatedwithintheUnitedStateswhereprivacylawmaynotprovidethesameprotectionasapplies inyourcountry.
BYSHARINGYOURPERSONALINFORMATIONWITHUS,YOUARECONSENTINGTOTHEPROCESSINGOFYOURPERSONALINFORMATION ASDESCRIBEDINTHISPRIV ACYNOTICE.
TheWayT oroUsesInformation Toromayuseyourpersonalinformationtoprocesswarrantyclaims,tocontactyouintheeventofaproductrecallandforanyotherpurposewhichwetell youabout.ToromayshareyourinformationwithT oro'safliates,dealersorotherbusinesspartnersinconnectionwithanyoftheseactivities.Wewillnot sellyourpersonalinformationtoanyothercompany.Wereservetherighttodisclosepersonalinformationinordertocomplywithapplicablelawsand withrequestsbytheappropriateauthorities,tooperateoursystemsproperlyorforourownprotectionorthatofotherusers.
RetentionofyourPersonalInformation Wewillkeepyourpersonalinformationaslongasweneeditforthepurposesforwhichitwasoriginallycollectedorforotherlegitimatepurposes (suchasregulatorycompliance),orasrequiredbyapplicablelaw .
Toro'sCommitmenttoSecurityofYourPersonalInformation Wetakereasonableprecautionsinordertoprotectthesecurityofyourpersonalinformation.Wealsotakestepstomaintaintheaccuracyandcurrent statusofpersonalinformation.
AccessandCorrectionofyourPersonalInformation Ifyouwouldliketorevieworcorrectyourpersonalinformation,pleasecontactusbyemailatlegal@toro.com.
AustralianConsumerLaw
AustraliancustomerswillnddetailsrelatingtotheAustralianConsumerLaweitherinsidetheboxoratyourlocalT oroDealer.
374-0282RevC
Page 52
TheToroWarranty
ALimitedWarranty
Electric Workman
ConditionsandProductsCovered
TheToroCompanyanditsafliate,T oroWarrantyCompany,pursuant toanagreementbetweenthem,jointlywarrantyourT oroCommercial product(“Product”)tobefreefromdefectsinmaterialsorworkmanship fortwoyearsor1500operationalhours*,whicheveroccursrst.Where awarrantableconditionexists,wewillrepairtheProductatnocostto youincludingdiagnostics,labor,parts,andtransportation.Thiswarranty beginsonthedatetheProductisdeliveredtotheoriginalretailpurchaser. *Productequippedwithanhourmeter.
InstructionsforObtainingWarrantyService
YouareresponsiblefornotifyingtheCommercialProductsDistributoror AuthorizedCommercialProductsDealerfromwhomyoupurchasedthe Productassoonasyoubelieveawarrantableconditionexists.Ifyouneed helplocatingaCommercialProductsDistributororAuthorizedDealer,or ifyouhavequestionsregardingyourwarrantyrightsorresponsibilities, youmaycontactusat:
CommercialProductsServiceDepartment ToroWarrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1196 E-mail:commercial.warranty@toro.com
OwnerResponsibilities
AstheProductowner,youareresponsibleforrequiredmaintenanceand adjustmentsstatedinyourOperator’sManual.Failuretoperformrequired maintenanceandadjustmentscanbegroundsfordisallowingawarranty claim.
ItemsandConditionsNotCovered
Notallproductfailuresormalfunctionsthatoccurduringthewarranty periodaredefectsinmaterialsorworkmanship.Thiswarrantydoesnot coverthefollowing:
Productfailureswhichresultfromtheuseofnon-Tororeplacement
parts,orfrominstallationanduseofadd-on,ormodiednon-Toro brandedaccessoriesandproducts.Aseparatewarrantymaybe providedbythemanufactureroftheseitems.
Productfailureswhichresultfromfailuretoperformrecommended
maintenanceand/oradjustments.Failuretoproperlymaintainyour ToroproductpertheRecommendedMaintenancelistedinthe Operator’sManualcanresultinclaimsforwarrantybeingdenied.
ProductfailureswhichresultfromoperatingtheProductinanabusive,
negligentorrecklessmanner.
Partssubjecttoconsumptionthroughuseunlessfoundtobedefective.
Examplesofpartswhichareconsumed,orusedup,duringnormal Productoperationinclude,butarenotlimitedto,batteries,carbon brushes,brakecomponents,tires,lters,belts,etc.
Failurescausedbyoutsideinuence.Itemsconsideredtobeoutside
inuenceinclude,butarenotlimitedto,weather,storagepractices, contamination,useofunapprovedlubricants,additives,chemicals,etc.
Normal“wearandtear”items.Normal“wearandtear”includes,butis
notlimitedto,damagetoseatsduetowearorabrasion,wornpainted surfaces,scratcheddecalsorwindows,etc.
Parts
Partsscheduledforreplacementasrequiredmaintenancearewarranted fortheperiodoftimeuptothescheduledreplacementtimeforthatpart. Partsreplacedunderthiswarrantyarecoveredforthedurationofthe originalproductwarrantyandbecomethepropertyofT oro.T orowillmake thenaldecisionwhethertorepairanyexistingpartorassemblyorreplace it.T oromayuseremanufacturedpartsforwarrantyrepairs.
NoteRegardingDeepCycleBatteryWarranty:
Deepcyclebatterieshaveaspeciedtotalnumberofkilowatt-hoursthey candeliverduringtheirlifetime.Operating,recharging,andmaintenance techniquescanextendorreducetotalbatterylife.Asthebatteriesin thisproductareconsumed,theamountofusefulworkbetweencharging intervalswillslowlydecreaseuntilthebatteryiscompletelywornout. Replacementofwornoutbatteries,duetonormalconsumption,isthe responsibilityoftheproductowner.Batteryreplacementmayberequired duringthenormalproductwarrantyperiodatowner’sexpense.
GeneralConditions
RepairbyanAuthorizedToroDistributororDealerisyoursoleremedy underthiswarranty.
NeitherTheToroCompanynorToroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheToroProductscoveredbythiswarranty,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletionof repairsunderthiswarranty.
Allimpliedwarrantiesofmerchantabilityandtnessforusearelimitedtothe durationofthisexpresswarranty .Somestatesdonotallowexclusionsof incidentalorconsequentialdamages,orlimitationsonhowlonganimplied warrantylasts,sotheaboveexclusionsandlimitationsmaynotapplytoyou.
Thiswarrantygivesyouspeciclegalrights,andyoumayalsohaveother rightswhichvaryfromstatetostate.
CountriesOtherthantheUnitedStatesorCanada
CustomerswhohavepurchasedT oroproductsexportedfromtheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtain guaranteepoliciesforyourcountry ,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtaining guaranteeinformation,contacttheT oroimporter.Ifallotherremediesfail,youmaycontactusatT oroWarrantyCompany.
374-0274RevB
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