Page 1
Workman 2100
Utility Vehicle
Model No. 07253—210001473 and Up
Model No. 07253TC—210001001 and Up
Form No. 3326-661
Operator ’s Manual
English (EN)
Page 2
Warning
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
Important The engine in this product is not equipped
with a spark arrester muffler. It is a violation of California
Public Resource Code Section 4442 to use or operate this
engine on any forest-covered, brush-covered, or
grass-covered land as defined in CPRC 4126. Other states
or federal areas may have similar laws.
This spark ignition system complies with Canadian
ICES-002.
Ce système d’allumage par étincelle de véhicule est
conforme à la norme NMB-002 du Canada.
Contents
Page
Introduction 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices 3. . . . . . . . . . . . . . . . . . . .
Before Operating 3. . . . . . . . . . . . . . . . . . . . . . . . .
While Operating 4. . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound Pressure Level 7. . . . . . . . . . . . . . . . . . . . . .
Vibration Level 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
Slope Chart 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety and Instruction Decals 11. . . . . . . . . . . . . . . .
Specifications 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loose Parts 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the Rear Wheels 15. . . . . . . . . . . . . . . . . .
Installing the Front Wheels 15. . . . . . . . . . . . . . . . .
Installing the Steering Wheel 15. . . . . . . . . . . . . . . .
Installing the Bumper 16. . . . . . . . . . . . . . . . . . . . . .
Installing the Seats 16. . . . . . . . . . . . . . . . . . . . . . . .
Installing the Hitch 16. . . . . . . . . . . . . . . . . . . . . . . .
Installing the Cargo Box 16. . . . . . . . . . . . . . . . . . . .
Activating the Battery 17. . . . . . . . . . . . . . . . . . . . . .
Checking the Crankcase Oil 18. . . . . . . . . . . . . . . . .
Checking the Tire Pressure 18. . . . . . . . . . . . . . . . . .
Fuel Tank 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Think Safety First 19. . . . . . . . . . . . . . . . . . . . . . . . .
Controls 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pre-Starting Checks 21. . . . . . . . . . . . . . . . . . . . . . .
Page
Starting the Engine 21. . . . . . . . . . . . . . . . . . . . . . . .
Stopping the Vehicle 21. . . . . . . . . . . . . . . . . . . . . . .
Parking the Vehicle 21. . . . . . . . . . . . . . . . . . . . . . . .
Cargo Bed 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tailgate Latches 22. . . . . . . . . . . . . . . . . . . . . . . . . .
New Vehicle Break-In 22. . . . . . . . . . . . . . . . . . . . .
Loading the Cargo Box 22. . . . . . . . . . . . . . . . . . . .
Transporting the Vehicle 23. . . . . . . . . . . . . . . . . . . .
Towing the Vehicle 23. . . . . . . . . . . . . . . . . . . . . . . .
Towing a Trailer 23. . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recommended Maintenance Schedule 24. . . . . . . . .
Daily Maintenance Checklist 25. . . . . . . . . . . . . . . .
Heavy Duty Operation 26. . . . . . . . . . . . . . . . . . . . .
Jacking the Vehicle 26. . . . . . . . . . . . . . . . . . . . . . . .
Neutral Lock Assembly 27. . . . . . . . . . . . . . . . . . . .
Servicing the Engine Oil 27. . . . . . . . . . . . . . . . . . .
Cleaning the Engine Cooling Areas 28. . . . . . . . . . .
Servicing the Air Cleaner 28. . . . . . . . . . . . . . . . . . .
Greasing the Machine 29. . . . . . . . . . . . . . . . . . . . . .
Servicing the Brakes 30. . . . . . . . . . . . . . . . . . . . . . .
Inspecting the Tires 30. . . . . . . . . . . . . . . . . . . . . . .
Adjusting the Front Suspension 30. . . . . . . . . . . . . .
Servicing the Drive Belt 31. . . . . . . . . . . . . . . . . . . .
Adjusting the Starter Generator Belt 31. . . . . . . . . .
Adjusting Front Wheel Toe-In 32. . . . . . . . . . . . . . .
Servicing the Fuel System 32. . . . . . . . . . . . . . . . . .
Spark Plugs 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Changing the Transaxle Fluid 33. . . . . . . . . . . . . . . .
Replacing the Fuses 34. . . . . . . . . . . . . . . . . . . . . . .
Replacing the Headlights 34. . . . . . . . . . . . . . . . . . .
Servicing the Battery 34. . . . . . . . . . . . . . . . . . . . . .
Washing the Vehicle 36. . . . . . . . . . . . . . . . . . . . . . .
Electrical Schematic 37. . . . . . . . . . . . . . . . . . . . . . .
The Toro General Commercial Products Warranty 40. .
Introduction
Read this manual carefully to learn how to operate and
maintain your product properly. The information in this
manual can help you and others avoid injury and product
damage. Although Toro designs and produces safe
products, you are responsible for operating the product
properly and safely.
Whenever you need service, genuine Toro parts, or
additional information, contact an Authorized Service
Dealer or Toro Customer Service and have the model and
serial numbers of your product ready. Figure 1 illustrates
the location of the model and serial numbers on the
product.
2001 by The Toro Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
All Rights Reserved
Printed in the USA
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Figure 1
1. Location of the model and serial numbers
m–5312
Supervisors, operators, and service persons should be
familiar with the following standards and publications:
(The material may be obtained from the address shown).
• Flammable and Combustible Liquids Code:
ANSI/NFPA 30
• National Fire Protection Association:
ANSI/NFPA #505; Powered Industrial Trucks
National Fire Prevention Association
Barrymarch Park
Quincy, Massachusetts 02269 U.S.A.
• ANSI/ASME B56.8 Personal Burden Carriers
American National Standards Institute, Inc.
1430 Broadway
New York, New York 10018 U.S.A.
Write the product model and serial numbers in the space
below:
Model No.
Serial No.
This manual identifies potential hazards and has special
safety messages that help you and others avoid personal
injury and even death. Danger, Warning, and Caution are
signal words used to identify the level of hazard. However,
regardless of the hazard, be extremely careful.
Danger signals an extreme hazard that will cause serious
injury or death if you do not follow the recommended
precautions.
Warning signals a hazard that may cause serious injury or
death if you do not follow the recommended precautions.
Caution signals a hazard that may cause minor or moderate
injury if you do not follow the recommended precautions.
This manual uses two other words to highlight information.
Important calls attention to special mechanical
information and Note: emphasizes general information
worthy of special attention.
• ANSI/UL 558; Internal Combustion Engine Powered
Industrial Trucks
American National Standards Institute, Inc.
1430 Broadway
New York, New York 10018 U.S.A.
or
Underwriters Laboratories
333 Pfingsten Road
Northbrook, Illinois 60062 U.S.A.
Safe Operating Practices
Warning
The Workman is an off-highway vehicle only and
is not designed, equipped, or manufactured for use
on public streets, roads, or highways.
Supervisor ’s Responsibilities
• Make sure that operators are thoroughly trained and
familiar with the Operator’s Manual and all labels on
the vehicle.
• Be sure to establish your own special procedures and
work rules for unusual operating conditions (e.g. slopes
too steep for vehicle operation).
Safety
Improper use or maintenance by the operator or owner
can result in injury. To reduce the potential for injury,
comply with these safety instructions and always pay
attention to the safety alert symbol, which means
CAUTION, WARNING, or DANGER—“personal
safety instruction.” Failure to comply with the
instruction may result in personal injury or death.
Before Operating
• Operate the machine only after reading and
understanding the contents of this manual.
• Never allow children to operate the vehicle. Anyone
who operates the vehicle should have a motor vehicle
license.
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• Never allow other adults to operate the vehicle without
first reading and understanding the Operator’s Manual.
Only trained and authorized persons should operate this
vehicle. Make sure that all operators are physically and
mentally capable of operating the vehicle.
While Operating
Warning
• This vehicle is designed to carry only you, the operator,
and one passenger in the seat provided by the
manufacturer. Never carry any other passengers on the
vehicle.
• Never operate the vehicle when under the influence of
drugs or alcohol. Even prescription drugs and cold
medicines can cause drowsiness.
• Do not drive the vehicle when you are tired. Be sure to
take occasional breaks. It is very important that you stay
alert at all times.
• Become familiar with the controls and know how to
stop the engine quickly.
• Keep all shields, safety devices, and decals in place. If a
shield, safety device, or decal is malfunctioning,
illegible, or damaged, repair or replace it before
operating the machine.
• Always wear substantial shoes. Do not operate the
machine while wearing sandals, tennis shoes or
sneakers. Do not wear loose fitting clothing or jewelry
which could get caught in moving parts and cause
personal injury.
• Wearing safety glasses, safety shoes, long pants and a
helmet is advisable and required by some local safety
and insurance regulations.
• Avoid driving when it is dark, especially in unfamiliar
areas. If you must drive when it is dark, be sure to drive
cautiously, use the headlights, and even consider adding
additional lights.
• Be extremely careful when operating around people.
Always be aware of where bystanders might be.
• Before operating the vehicle, always check the
designated areas of the vehicle that are stated in the
pre-starting section of this manual. If something is
wrong, do not use the vehicle. Make sure that the
problem is corrected before the vehicle or attachment is
operated.
• Since gasoline is highly flammable, handle it carefully.
– Use an approved gasoline container.
– Do not remove the cap from the fuel tank when the
engine is hot or running.
– Do not smoke while handling gasoline.
– Fill the fuel tank outdoors, and fill it to about 1 in.
(25 mm) below the top of the tank (the bottom of
the filler neck). Do not overfill it.
– Wipe up any spilled gasoline.
Engine exhaust contains carbon monoxide, which
is an odorless, deadly poison that can kill you.
Do not run engine indoors or in an enclosed area.
• The operator and passenger should remain seated
whenever the vehicle is in motion. The operator should
keep both hands on the steering wheel whenever
possible, and the passenger should use the hand holds
provided. Keep your arms and legs within the vehicle
body at all times.
• Drive slower and turn less sharply when you are
carrying a passenger. Remember your passenger may
not be expecting you to brake or turn and may not be
ready.
• Always watch out for and avoid low overhangs such as
tree limbs, door jambs, and over-head walkways. Make
sure there is enough room over head to easily clear the
vehicle and your head.
• Always shift into neutral and apply the parking brake
before leaving an idling vehicle, or else the vehicle may
creep.
• Failure to operate the vehicle safely may result in an
accident, tip over of the vehicle, and serious injury or
death. Drive carefully. To prevent tipping or loss of
control:
– Use extreme caution, reduce speed, and maintain a
safe distance around sand traps, ditches, creeks,
ramps, unfamiliar areas, or any areas that have
abrupt changes in ground conditions or elevation.
– Watch for holes or other hidden hazards.
– Use extra caution when operating the vehicle on wet
surfaces, in adverse weather conditions, at higher
speeds, or with a full load. Stopping time and
distance will increase with a full load.
– Avoid sudden stops and starts. Do not go from
reverse to forward or forward to reverse without
first coming to a complete stop.
– Slow down before turning. Do not attempt sharp
turns or abrupt maneuvers or other unsafe driving
actions that may cause a loss of vehicle control.
– When dumping, do not let anyone stand behind the
vehicle and do not dump the load on anyone’s feet.
Release the tailgate latches from the side of the box,
not from behind.
– Only operate the vehicle when the cargo box is
down and latched.
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– Before backing up, look to the rear and ensure that
no one is behind you. Back up slowly.
– Watch out for traffic when you are near or crossing
roads. Always yield the right of way to pedestrians
and other vehicles. This vehicle is not designed for
use on streets or highways. Always signal your turns
or stop early enough so that other people know what
you plan to do. Obey all traffic rules and
regulations.
standing water deep enough to get the brakes wet, they
will not work well until they are dry. After driving
through water, you should test the brakes to make sure
they work properly. If they do not, drive slowly while
putting light pressure on the brake pedal. This will dry
the brakes out.
Operating on Hills
– The electrical and exhaust systems of the vehicle
can produce sparks capable of igniting explosive
materials. Never operate the vehicle in or near an
area where there is dust or fumes in the air which
are explosive.
– If you are ever unsure about safe operation, stop
work and ask your supervisor.
• Do not touch the engine or muffler while the engine is
running or soon after it has stopped. These areas may be
hot enough to cause burns.
• If the machine ever vibrates abnormally, stop
immediately, wait for all motion to stop, and inspect the
vehicle for damage. Repair all damage before
commencing operation.
• Before getting off of the seat:
A. Stop the movement of the machine.
B. Set the parking brake.
C. Turn the ignition key to Off.
D. Remove the ignition key.
Note: If the vehicle is on an incline, block the wheels after
getting off of the vehicle.
Warning
Operating the vehicle on a hill may cause tipping
or rolling of the vehicle, or the engine may stall
and you could lose headway on the hill. This could
result in personal injury.
• Do not exceed slopes greater than 12.
• Do not accelerate quickly or slam on the brakes
when backing down a hill, especially with a load.
• If the engine stalls or you lose headway on a hill,
slowly back straight down the hill. Never
attempt to turn the vehicle around.
• Never drive across a steep hill; always drive
straight up or down or go around the hill.
• Avoid turning on a hill.
• Reduce your load and the speed of the vehicle.
• Avoid stopping on hills, especially with a load.
These extra cautions need to be taken when operating the
vehicle on a hill:
• Slow down before starting up or down a hill.
• If the engine stalls or you begin to lose headway while
climbing a hill, gradually apply the brakes and slowly
back straight down the hill.
Braking
• Slow down before you approach an obstacle. This gives
you extra time to stop or turn away. Hitting an obstacle
can damage the vehicle and its contents. More
important, it can injure you and your passenger.
• Gross Vehicle Weight (GVW) has a major impact on
your ability to stop and/or turn. Heavy loads and
attachments make a vehicle harder to stop or turn. The
heavier the load, the longer it takes to stop.
• Decrease the vehicle speed if the cargo box has been
removed and there is no attachment on the vehicle. The
braking characteristics change and fast stops may cause
the rear wheels to lock up, which may affect the control
of the vehicle.
• Turf and pavement are much slipperier when they are
wet. It can take 2 to 4 times as long to stop on wet
surfaces as on dry surfaces. If you drive through
• Turning while traveling up or down hills can be
dangerous. If you have to turn while on a hill, do it
slowly and cautiously. Never make sharp or fast turns.
• Heavy loads affect stability. Reduce the weight of the
load and your speed when operating on hills or if the
load has a high center of gravity. Secure the load to
prevent it from shifting.
• Avoid stopping on hills, especially with a load.
Stopping while going down a hill will take longer than
stopping on level ground. If the vehicle must be
stopped, avoid sudden speed changes, which may
initiate tipping or rolling of the vehicle. Do not slam on
the brakes when rolling backward, as this may cause the
vehicle to overturn.
• Travel straight up and down slopes whenever possible.
• We strongly recommend installing the optional ROPS
Kit when operating on hilly terrain.
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Operating on Rough Terrain
Reduce speed and load when operating on rough terrain,
uneven ground, and near curbs, holes, and other sudden
changes in terrain. Loads may shift, causing the vehicle to
become unstable.
We strongly recommend installing the optional ROPS Kit
when operating on rough terrain.
Warning
Sudden changes in terrain may cause abrupt
steering wheel movement, possibly resulting in
hand and arm injuries.
• Reduce your speed when operating on rough
terrain and near curbs.
• Grip the steering wheel loosely around the
perimeter. Keep your hands clear of the steering
wheel spokes.
Loading and Dumping
The weight and position of the cargo and passenger can
change the vehicle center of gravity and vehicle handling.
To avoid loss of control and personal injury, follow these
guidelines:
• Always secure loads so that they do not shift. If a load
is not secured, or you are transporting a liquid in a large
container such as a sprayer, the load can shift. This
shifting happens most often while turning, going up or
down hills, suddenly changing speeds, or while driving
over rough surfaces. Shifting loads can cause the
vehicle to tip over.
Warning
The weight of the box may be heavy. Hands or
other body parts could be crushed.
• Keep hands and other body parts clear when
lowering the box.
• Do not dump materials on bystanders.
• Never dump a loaded cargo box while the vehicle is
sideways on a hill. The change in weight distribution
may cause the vehicle to overturn.
• When operating with a heavy load in the cargo box,
reduce your speed and allow for sufficient braking
distance. Do not suddenly apply the brakes. Use extra
caution on slopes.
• Be aware that heavy loads increase your stopping
distance and reduce your ability to turn quickly without
tipping over.
• Do not carry loads which exceed the load limits
described on the vehicle weight label; refer to
Specifications, page 13, for vehicle weight limits. The
load rating is for level surfaces only.
• Reduce the weight of the load when operating on hills
and rough terrain to avoid tipping or overturning of the
vehicle.
• Reduce the weight of the load if the center of gravity is
high. Items such as bricks, fertilizer, or landscape
timbers stack higher in the box. The higher a load is
stacked, the more likely the vehicle is to tip over.
Distribute the load as low as possible, making sure that
the load does not affect rear visibility.
• Position the weight of the load evenly from side to side.
If you position the load toward one of the sides, the
vehicle is more likely to tip over while turning.
• Position the weight of a load evenly from front to back.
If you position the load behind the rear axle, it will
reduce the weight on the front wheels. This may result
in a loss of steering control or cause the vehicle to tip
over on hills or bumpy terrain.
• Use extra caution if the load exceeds the dimensions of
the box and when handling off-center loads that cannot
be centered. Keep loads balanced and secure to prevent
them from shifting.
• The rear cargo space is intended for load carrying
purposes only, not for passengers.
• Never overload your vehicle. The name plate (located
under dash on center column) shows load limits for the
vehicle. Never overload the attachments or exceed the
Gross Vehicle Weight (GVW).
Maintenance
• Only qualified and authorized personnel shall be
permitted to maintain, repair, adjust, or inspect the
vehicle.
• Before servicing or making adjustments to the machine,
stop the engine, set the parking brake, and remove the
key from the ignition to prevent someone from
accidentally starting the engine.
• To make sure that the entire machine is in good
condition, keep all nuts, bolts, and screws properly
tightened.
• To reduce the potential for fire, keep the engine area
free of excessive grease, grass, leaves, and
accumulation of dirt.
• Never use an open flame to check the level or leakage
of fuel or battery electrolyte.
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• If the engine must be running to perform a maintenance
adjustment, keep your hands, feet, clothing, and any
parts of your body away from the engine and any
moving parts. Keep everyone away.
• Do not use open pans of fuel or flammable cleaning
fluids for cleaning parts.
• Do not adjust the ground speed governor. To ensure
safety and accuracy, have an Authorized Toro
Distributor check the ground speed.
• If major repairs are ever needed or assistance is
required, contact an Authorized Toro Distributor.
• To be sure of optimum performance and safety, always
purchase genuine Toro replacement parts and
accessories. Replacement parts and accessories made by
other manufacturers could be dangerous. Altering this
vehicle in any manner that may affect vehicle operation,
performance, durability, or its use, may result in injury
or death. Such use could void the product warranty.
Sound Pressure Level
This unit has an equivalent continuous A-weighted sound
pressure at the operator ear of 80 dB(A) based on
measurements of identical machines per SAE J1174-MAR
85 procedures.
Vibration Level
This unit does not exceed a vibration level of 2.5 m/s2 at
the hands based on measurements of identical machines per
ISO 5349 procedures.
This unit does not exceed a vibration level of 0.5 m/s2 at
the posterior based on measurements of identical machines
per ISO 2631 procedures.
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Slope Chart
ALIGN THIS EDGE WITH A VERTICAL SURFACE
(TREE, BUILDING, FENCEPOST, POLE, ETC.)
FOLD ALONG APPROPRIATE LINE.
EXAMPLE: COMPARE
SLOPE WITH FOLDED
EDGE.
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Safety and Instruction Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or lost.
99-7350
1. Maximum tongue weight
is 50 lb. (23 kg)
2. Maximum trailer weight is
400 lb. (181 kg)
99-7348
1. Read the operator’s manual for further instructions.
2. The maximum combined operator and passenger weight
should not exceed 400 lb. (181 kg).
3. The maximum cargo weight should not exceed 1250 lb.
(567 kg).
4. The base weight of the vehicle is 1000 lb. (454 kg).
5. The maximum gross vehicle weight should not exceed 2650 lb.
(1202 kg).
1. Parking brake
2. Parking brake on
1. Choke
2. Reverse
99-7346
3. Parking brake off
99-7347
3. Forward
99-7349
1. Unlock cargo bed 2. Lock cargo bed
99-7954
1. Danger—read the operator’s manual.
2. Do not carry passengers in the cargo bed. They may fall out.
3. Explosive hazard—remove fuel containers from the cargo bed
before filling.
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99-7343
1. Warning—read the operator’s manual.
2. Only drive this vehicle off-highway. This vehicle is not made for use on public streets, roads, or highways.
3. Do not carry passengers in the cargo bed. They may fall out of the vehicle.
4. Do not allow children to operate this vehicle.
5. Hour meter
6. Headlights
7. Ignition off
8. Ignition on
9. To start the vehicle, sit in the operator’s seat. Release the parking brake. Turn the ignition on. Pull the choke lever out (if needed). Depress
the accelerator.
10. To stop the vehicle, disengage the accelerator and engage the parking brake. Turn the ignition off and remove the key.
11. Power point
99-7344
1. Danger—read the operator’s manual.
2. Fuel is flammable. Stop the engine before adding fuel.
3. Tipping hazard—do not drive across slopes that are greater than 15 degrees or up slopes greater than 12 degrees. Reduce speed when
turning, carrying heavy loads, or driving on rough terrain. Keep the engine speed under 16 MPH (26 km/h).
4. Passengers are at risk of falling from the vehicle. Do not carry passengers in the cargo bed. Keep arms and legs inside of the vehicle at all
times.
99-7345
1. Danger—read the operator’s manual.
2. Hot surface hazard—keep hands away.
3. Entanglement hazard—stay away from moving parts.
4. Crushing hazard—use the prop rod to support the cargo bed.
26-7390
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99-7352
1. Read the operator’s
manual for information on
fuses.
2. 10 amp. fuse for optional
Road Light Kit
3. 15 amp. fuse for optional
Rear Lift Kit
4. 10 amp. fuse—open
5. 10 amp. fuse for
headlights
6. 10 amp. fuse for ignition
system
7. 15 amp. fuse for optional
Electric Bed Lift Kit
Specifications
Note: Specifications and design are subject to change without notice.
Base weight Dry 1000 lb. (454 kg)
Rated capacity
(on level ground)
Maximum gross vehicle
1650 lb. (749 kg) total, including 200 lb. (90.7 kg) operator and 200 lb. (90.7 kg)
passenger, load, trailer tongue weight, gross trailer weight, accessories, and
attachments
2650 lb. (1203 kg) total, including all of the weights listed above
weight (GVW)
(on level ground)
Maximum cargo capacity
1250 lb. (567 kg) total, including trailer tongue weight and gross trailer weight
(on level ground)
Tow capacity:
Standard Hitch Tongue weight 50 lbs. (23 kg) Maximum trailer weight 400 lbs. (182 kg)
Heavy Duty Hitch Tongue weight 100 lbs. (45 kg) Maximum trailer weight 800 lbs. (363 kg)
Overall width 60 in. (152.4 cm)
Overall length 117 in. (297.2 cm)
Ground clearance
9-1/4 in. (23.5 cm) at the front with no load or operator
6-1/2 in. (16.5 cm) at the rear with no load or operator
Wheel base 79 in. (200.7 cm)
Wheel tread
(center line to center line)
Cargo box length
Cargo box width
49 in. (124.5 cm) in the front
48-1/4 in. (122.6 cm) in the rear
46 in. (116.8 cm) inside
51 in. (129.5 cm) outside
49 in. (124.5 cm) inside
54 in. (137.2 cm) outside
Cargo box height 10 in. (25.4 cm) inside
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Setup
Note: Determine the left and right sides of the machine from the normal operating position.
Loose Parts
Note: Use the chart below to verify that all parts have been shipped.
Description Qty. Use
Wheel assembly 2 Installing the rear wheels (Model No. 07253TC)
Wheel assembly
Washer
Dust cap
Steering wheel 1 Installing the steering wheel (Model No. 07253TC)
Bumper 1 Installing the bumper (Model No. 07253TC)
Hitch 1 Installing the hitch (Model No. 07253TC)
Seat 2 Installing the seats (Model No. 07253TC)
Cargo box
Right-hand pivot bracket
Left-hand pivot bracket
Prop rod clip
Flange head screw, 3/8 x 1 in.
Screw, 5/16 x 3/4 in.
Key 2 Use in the ignition switch.
Operator’s Manual
Engine Operator’s Manual
Operator Video 1 Watch before operating the machine.
2
2
2
1
1
1
1
4
2
1
1
Installing the front wheels (Model No. 07253TC)
Installing the cargo box (Model No. 07253TC)
Read before operating the machine.
Parts Catalog 1 Use for ordering replacement parts.
Registration Card 1 Complete and return to Toro.
Predelivery Inspection Form 1 Complete and file in your customer history portfolio.
14
Page 15
Installing the Rear Wheels
1
Note: This procedure is only needed for Model No.
07253TC.
1. Remove the fasteners securing the wheels.
2. Remove the shipping bracket secured to the wheel
studs.
3. Mount the wheels with the previously removed
fasteners (Fig. 2) and torque to 45–65 ft.-lb.
(61–88 N⋅m).
3
Figure 2
1. Wheel assembly
2. Wheel nut
3. Wheel stud
Installing the Front Wheels
Note: This procedure is only needed for Model No.
07253TC.
1. Remove the fasteners securing the wheels.
3
4
2
5
6
Figure 3
1
1. Tire and wheel assembly
2. Spindle
3. Small washer
4. Large washer
5. Screw
6. Dust cap
2
Installing the Steering Wheel
Note: This procedure is only needed for Model No.
07253TC.
1. Remove the nut and lock washer from the steering
shaft.
2. Slide the steering wheel and washer onto the shaft.
Position the steering wheel on the shaft so that the cross
beam is horizontal when the tires are pointed straight
ahead and the thicker spoke of the steering wheel is
downward.
3. Secure the steering wheel to the shaft with the nut
(Fig. 4).
2
2. Remove the shipping bracket from the spindles.
3. Apply Loctite (blue) to the screw threads.
4. Mount the wheels with the previously removed
fasteners (Fig. 3) and torque the bolts to 135–165 ft.-lb.
(183–224 N⋅m)
1. Steering wheel
2. Nut
15
1
3
4
Figure 4
3. Washer
4. Foam seal
Page 16
Installing the Bumper
Installing the Hitch
Note: This procedure is only needed for Model No.
07253TC.
1. Remove the 2 bolts, washers, and nuts secured to the
front of the frame.
2. Align the mounting holes and secure the bumper to the
frame with the fasteners previously removed (Fig. 5).
1
Figure 5
1. Bumper
Installing the Seats
Note: This procedure is only needed for Model No.
07253TC.
1. Remove the 4 bolts and nuts from the inside rear of the
frame.
2. Align the hitch with the mounting holes on the frame.
Secure the hitch with the screws and nuts (Fig. 7).
1
Figure 7
1. Hitch
Note: This procedure is only needed for Model No.
07253TC.
Insert the seat bracket into the seat base opening and pivot
the seat downward (Fig. 6).
1
2
Figure 6
1. Seat bracket 2. Seat base
Installing the Cargo Box
Note: This procedure is only needed for Model No.
07253TC.
1. Position the cargo box onto the frame. The cargo box
must lay flat and be centered.
2. Mount the left hand pivot bracket to the left rear corner
of the frame with 2 flange head screws (3/8 x 1 in.).
Position the bracket as shown in Figure 8.
1
Figure 8
1. Pivot bracket
3. Slide the cargo box mounting hole onto the pivot
bracket (Fig. 9).
16
Page 17
Activating the Battery
Note: This procedure is only needed for Model No.
07253TC.
If the battery is not filled with electrolyte or activated, it
must be removed from the vehicle, filled with electrolyte,
and charged. Bulk electrolyte with 1.260 specific gravity
must be purchased from a local battery supply outlet.
1. Remove the rubber strap securing the battery to the
3
1
battery base. Lift the battery out of the battery base.
Danger
2
Figure 9
1. Cargo box
2. Pivot bracket
4. Insert the right hand pivot bracket into the mounting
hole in the cargo box and then mount it to the frame.
5. Have another person help to raise the cargo box until
the “J” hook end of the prop rod is positioned between
the 2 holes on the left frame rail (Fig. 10).
2
3. Cargo box mounting hole
1
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
2. Remove the filler caps from the battery and slowly fill
each cell until electrolyte is just above the plates.
3. Replace the filler caps and connect a 3 to 4 amp. battery
charger to the battery posts. Charge the battery at a rate
of 3 to 4 amperes for 4 to 8 hours (12 volts). Do not
overcharge the battery.
Warning
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks and
flames away from battery.
Figure 10
1. Prop rod 2. Prop rod clip
6. Secure the prop rod to the frame rail with the prop rod
clip and 2 screws (5/16 x 3/4 in.) (Fig. 10).
7. Lower the cargo box.
4. When the battery is charged, disconnect the charger
from the electrical outlet and battery posts.
5. Remove the filler caps. Slowly add electrolyte to each
cell until electrolyte is up to the fill line. Install the filler
caps.
Important Do not overfill the battery. Electrolyte will
overflow onto other parts of the vehicle and severe
corrosion and deterioration will result.
6. Install the battery; refer to Installing the Battery,
page 35.
17
Page 18
Checking the Crankcase Oil
Fuel Tank
The engine is shipped with oil in the crankcase; however,
the level of oil must be checked before and after the engine
is first started.
1. Position the machine on a level surface.
2. Remove the dipstick and wipe it with a clean rag
(Fig. 11). Insert the dipstick into the tube and make sure
it is seated fully. Remove the dipstick and check the oil
level.
2
1
Figure 11
1. Dipstick 2. Filler cap
3. If the oil level is low, remove the filler cap from the
valve cover (Fig. 11) and pour oil into the opening until
the oil level is up to the Full mark on the dipstick; refer
to Engine Oil, page 27, for the proper oil type and
viscosity. Add the oil slowly and check the level often
during this process. Do not overfill.
4. Install the dipstick firmly in place.
Checking the Tire Pressure
Check the tire pressure every 8 hours or daily to ensure
proper levels.
The air pressure range in the front and rear tires is 8–22 psi
(55–152 kPa).
The air pressure needed is determined by the payload
carried. The lower the air pressure, the less the compaction
and tire marks are minimized. Lower pressure should not
be used for heavy payloads at high speeds.
Recommended Gasoline
Use fresh, clean, unleaded regular gasoline suitable for
automotive use (85 pump octane minimum). Leaded
gasoline may be used if unleaded regular is not available.
Important Never use gasoline containing methanol,
gasoline containing more than 10% ethanol, gasoline
additives, or white gas because engine fuel system damage
could result.
Danger
In certain conditions, gasoline is extremely
flammable and highly explosive. A fire or
explosion from gasoline can burn you and others
and can damage property.
• Fill the fuel tank outdoors, in an open area,
when the engine is cold. Wipe up any gasoline
that spills.
• Do not fill the fuel tank completely full. Add
gasoline to the fuel tank until the level is 1 in.
(25 mm) below the bottom of the filler neck.
This empty space in the tank allows gasoline to
expand.
• Never smoke when handling gasoline, and stay
away from an open flame or where gasoline
fumes may be ignited by a spark.
• Store gasoline in an approved container and
keep it out of the reach of children. Never buy
more than a 30-day supply of gasoline.
• Always place gasoline containers on the ground
away from your vehicle before filling.
• Do not fill gasoline containers inside a vehicle or
on a truck or trailer bed because interior
carpets or plastic truck bed liners may insulate
the container and slow the loss of any static
charge.
• When practical, remove gas-powered equipment
from the truck or trailer and refuel the
equipment with its wheels on the ground.
• If this is not possible, then refuel such
equipment on a truck or trailer from a portable
container, rather than from a gasoline dispenser
nozzle.
• If a gasoline dispenser nozzle must be used, keep
the nozzle in contact with the rim of the fuel
tank or container opening at all times until
fueling is complete.
Higher pressures should be used for heavier payloads at
higher speeds. Do not exceed the maximum pressure.
18
Page 19
Filling the Fuel Tank
Brake Pedal
Fuel tank capacity is approximately 7 gallons.
1. Shut the engine off and set the parking brake.
2. Clean the area around the fuel tank cap (Fig. 12).
1
Figure 12
1. Fuel tank cap
3. Remove the fuel tank cap.
4. Fill the tank to about one inch below the top of the tank,
(bottom of the filler neck). This space in the tank allows
gasoline to expand. Do not overfill.
The brake pedal is used to stop or slow the vehicle
(Fig. 13).
Caution
Brakes can become worn or can be misadjusted
resulting in personal injury.
If brake pedal travels to within 1 of the vehicle
floor board, the brakes must be adjusted or
repaired.
Parking Brake
The parking brake is a small plate at the top of the brake
pedal (Fig. 13). Whenever the engine is shut off, the
parking brake must be engaged to prevent accidental
movement of the vehicle. To engage the parking brake, step
on the brake pedal firmly and roll forward with the top of
your foot. To disengage, depress the accelerator pedal. If
the vehicle is parked on a steep grade, make sure that the
parking brake is applied. Place blocks at the downhill side
of the wheels.
3
5. Install the fuel tank cap securely. Wipe up any fuel that
may have spilled.
Operation
Note: Determine the left and right sides of the machine
from the normal operating position.
Think Safety First
Please carefully read all of the safety instructions and
decals in the safety section. Knowing this information
could help you or bystanders avoid injury.
Controls
Accelerator Pedal
The accelerator pedal (Fig. 13) gives the operator the
ability to vary ground speed of the vehicle. Depressing the
pedal starts the engine. Depressing the pedal farther
increases ground speed. Releasing the pedal will slow the
vehicle and the engine will stop running. Maximum
forward speed is 16 MPH (26 km/h).
2
1
m–5313
Figure 13
1. Accelerator pedal
2. Brake pedal
3. Parking brake
Choke Control
The choke control is located below and to the right of the
operator’s seat. To start a cold engine, close the carburetor
choke (Fig. 14) by pulling the choke control outward to the
On position. After the engine starts, regulate the choke to
keep the engine running smoothly. As soon as possible,
open the choke by pushing the control in to the Off
position. A warm engine requires little or no choking.
19
Page 20
Light Switch
Toggle the switch to activate the headlights. Push it to turn
the lights on (Fig. 15).
Power Point
1
The power point is used to power optional electrical
accessories (Fig. 15).
2
Figure 14
1. Choke 2. Gear shift selector
Gear Shift Selector
The gear shift selector moves the vehicle in the desired
direction—forward or reverse (Fig. 14). The vehicle will
start in either direction.
Note: If the gear shift selector is in Reverse when the
ignition is turned on, a buzzer will sound to warn the
operator.
Important The vehicle should always be stopped
before changing the gear selection and direction.
Ignition Switch
The ignition switch (Fig. 15), used to start and stop the
engine, has two positions: Off and On. Rotate the key
clockwise to the On position to allow operation. When the
vehicle is stopped, rotate the key counterclockwise to the
Off position. Remove the key from the ignition.
3
1. Ignition switch
2. Hour meter
3. Light switch
12
Figure 15
4. Oil light
5. Power Point
4
5 m–4885
Fuel Gauge
The fuel gauge (Fig. 16) shows the amount of fuel in the
tank.
1
Hour Meter
The hour meter (Fig. 15) indicates the total number of
hours the engine is running. The hour meter starts to
function whenever the accelerator is depressed.
Oil Light
The oil light warns the operator if the engine oil pressure
drops below a safe level (Fig. 15). If the light comes on and
remains lit, the oil level should be checked and oil added if
necessary; see Engine Oil, page 27.
Note: The oil light may flicker. This is normal and no
action needs to be taken.
Figure 16
1. Fuel gauge
20
Page 21
Passenger Hand Holds
The passenger hand holds are located on the right side of
the dash panel and at the outside of each seat (Fig. 17).
2
1
2. Move the gear shift selector to the desired position.
3. Slowly step on the accelerator pedal.
Note: The parking brake will automatically disengage
when the accelerator pedal is depressed.
Note: If the engine is cold, depress and hold the accelerator
pedal about half-way down and pull the choke knob out to
the On position. Return the choke knob to Off after the
engine warms up.
Important Do not attempt to push or tow the vehicle to
get it started.
m–4887
Figure 17
1. Passenger hand hold 2. Hip restraint
Pre-Starting Checks
Check the following items each time you begin using the
vehicle for the day:
• Check the tire pressure.
Note: These tires are different than car tires; they
require less pressure to minimize turf compaction and
damage.
• Check all fluid levels and add the appropriate amount of
specified fluids, if any are found to be low.
• Check the brake pedal operation.
• Check to see that the lights are working.
• Turn the steering wheel to the left and right to check
steering response.
• Check for oil leaks, loose parts, and any other
noticeable malfunctions. Make sure the engine is off
and all moving parts have stopped before checking for
oil leaks, loose parts, and other malfunctions.
Stopping the Vehicle
To stop the vehicle, remove your foot from the accelerator
pedal and slowly depress the brake pedal.
Note: Stopping distance may vary depending on the vehicle
load and speed.
Parking the Vehicle
1. Engage the parking brake and rotate the ignition key to
Off.
2. Remove the key from the switch to prevent accidental
starting.
Cargo Bed
Raising the Bed
1. Slide the latch upward toward the top of the cutout in
the bed frame (Fig. 18).
1
If any of the above items are not correct, notify your
mechanic or check with your supervisor before taking the
vehicle out for the day. Your supervisor may want you to
check other items on a daily basis, so ask what your
responsibilities are.
Starting the Engine
1. Sit in the operator’s seat, insert the key into the ignition
switch, and rotate the key clockwise to the On position.
Note: If the gear shift selector is in Reverse, the buzzer will
sound to warn the operator.
m–4850
Figure 18
1. Latch
2. Lift up on the latch with one hand while raising the bed
with the other hand.
3. Raise the bed to its full height; then lower it slightly to
engage the prop rod (Fig. 19).
21
Page 22
1
m–4865
Figure 19
1. Prop rod
Lowering the Bed
1. Lift up the bed slightly with one hand while pressing
down on the prop rod.
2. Lower the bed until the latch engages.
3. To secure the bed tightly to the bed frame, move the
latch to the lower section of the cutout (Fig. 18).
New Vehicle Break-In
To provide proper performance and long vehicle life,
follow these guidelines for the first 100 operating hours:
• Check the fluid and engine oil levels regularly and be
alert for indications of overheating in any component of
the vehicle.
• After starting a cold engine, let it warm up for about 15
seconds before accelerating.
• Avoid hard braking situations for the first several hours
of new vehicle break-in operation. New brake linings
may not be at optimum performance until several hours
of use has caused the brakes to become burnished
(broken-in).
• Vary the vehicle speed during operation. Avoid fast
starts and quick stops.
• A break-in oil for engine is not required. Original
engine oil is the same type specified for regular oil
changes.
• Refer to the Maintenance section for any special low
hour checks.
• Check the front suspension positioning and adjust it if
necessary; refer to Adjusting the Front Suspension,
page 30.
Tailgate Latches
1. To open the tailgate latches, lift the latch handles up
(Fig. 20). The latches will spring out toward the center
of the tailgate. Slowly lower the tailgate.
Note: You may need to push the end of the tailgate in
(especially if there is a load against the tailgate) before the
latches will spring toward the center of the tailgate and
release.
1
m–5334
Figure 20
1. Tailgate latch
2. To close the tailgate latches, lift the handles upward and
slide them toward the outside of the vehicle.
3. Push the latch handles downward to secure the latch and
tailgate.
Loading the Cargo Box
The capacity of the cargo box is 13 ft.3 (.37 m3). The
amount (volume) of material that can be placed in the box
without exceeding the vehicle load ratings can vary greatly
depending on the density of the material. For example, a
level box of wet sand weighs 1500 lb. (680 kg), which
exceeds the load rating by 250 lb. (113 kg). But a level box
of wood weighs 650 lb. (295 kg), which is under the load
rating.
See the table below for load volume limits with various
materials:
Material
Gravel
Dry
Wet
Sand
Dry
Wet
Wood 45 Full
Bark <45 Full
Earth, packed 100 3/4 full (approx.)
Density
(lb./ft.3)
95
120
90
120
Max. cargo box
capacity (on level
ground)
3/4 full (approx.)
1/2 full (approx.)
3/4 full
1/2 full
22
Page 23
Transporting the Vehicle
For moving the vehicle long distances, a trailer should be
used. Make sure that the vehicle is secured to the trailer.
Refer to Figures 21 and 22 for the location of the tie down
points.
Caution
Loose seats may fall off of the vehicle and trailer
when transporting and land on another vehicle or
become an obstruction on the road.
Remove the seats or make sure that the seats are
securely fastened in the detents.
3. Put the vehicle in neutral (see Neutral Lock Assembly,
page 27) and release the parking brake.
1
Figure 22
1. Towing tongue and tie down point
Towing a Trailer
The vehicle is capable of pulling trailers. Two types of tow
hitches are available for the vehicle, depending on your
application. Contact your Authorized Toro Distributor for
details.
1 1
Figure 21
1. Tie down points
Towing the Vehicle
In case of an emergency, the vehicle can be towed for a
short distance. However, we do not recommend this as a
standard procedure.
Warning
Towing at excessive speeds could cause a loss of
steering control, resulting in personal injury.
Never tow the vehicle faster than 5 MPH.
Towing the vehicle is a two person job. If the machine must
be moved a considerable distance, transport it on a truck or
trailer; refer to Transporting the Vehicle, page 23.
When hauling cargo or towing a trailer, do not overload
your vehicle or trailer. Overloading can cause poor
performance or damage to the brakes, axle, engine,
transaxle, steering, suspension, body structure, or tires.
Always load a trailer with 60% of the cargo weight in the
front of the trailer. This places approximately 10% of the
Gross Trailer Weight (GTW) on the tow hitch of the
vehicle.
The maximum cargo load shall not exceed 1250 lb.
(567 kg), including the GTW and tongue weight. For
example, if the GTW = 400 lb. and tongue weight = 50 lb.,
then the maximum cargo load = 800 lb.
To provide adequate braking and traction, always load the
cargo box when trailering. Do not exceed the GTW limits.
Avoid parking a vehicle with a trailer on a hill. If you must
park on a hill, engage the parking brake and block the
trailer tires.
1. Remove the drive belt; refer to Replacing the Drive
Belt, page 31, steps 1 and 2.
2. Affix a tow line to the tongue on the front frame
member (Fig. 22).
23
Page 24
Maintenance
Note: Determine the left and right sides of the machine from the normal operating position.
Recommended Maintenance Schedule
Maintenance Service
Interval
After first 8 hours
Every 8 hours
After first 20 hours • Check the front wheel toe-in at the proper ride height.
Every 50 hours
Every 100 hours
Every 200 hours
Maintenance Procedure
• Change the engine oil.
• Check the drive belt tension.
• Check the starter belt tension.
• Check the engine oil.
• Check the tire pressure.
• Check the battery fluid level.
• Check the battery cable connections.
• Change the engine oil (includes synthetic oil).
• Lubricate all grease fittings.
• Clean the engine rotating screen.
• Inspect the air cleaner filter.
• Replace the engine oil filter.
• Inspect the brake and parking brake.
• Inspect the condition and wear of the tires.
• Torque the wheel lug nuts.
• Check the front suspension toe-in and ride height.
• Replace the air cleaner filter.
• Check the brake cable adjustments.
• Inspect the drive belt.
• Inspect and adjust the starter belt.
2
2
1
Every 400 hours or
yearly
Every 800 hours or
yearly
1
More often when operating under heavy load or high temperatures
2
More often in dusty, dirty conditions
Important Refer to your engine operator’s manual for additional maintenance procedures.
• Inspect the fuel lines.
• Replace the fuel filter.
• Change the transaxle oil.
• Replace the spark plugs.
24
Page 25
Daily Maintenance Checklist
Duplicate this page for routine use.
For the week of:
Maintenance Check Item
Check the brake and parking brake
operation.
Check the gear shift operation.
Check the fuel level.
Check the engine oil level.
Check the transaxle oil level.
Inspect the air filter.
Inspect the engine cooling fins.
Check any unusual engine noises.
Check any unusual operating noises.
Check the tire pressure.
Check for fluid leaks.
Check the instrument operation.
Check the accelerator operation.
Check ride height and toe-in.
Lubricate all grease fittings.
1
Mon. Tues. Wed. Thurs. Fri. Sat. Sun.
Touch up and damaged paint.
1
Immediately after every washing, regardless of the interval listed
Notation for Areas of Concern
Inspection performed by:
Item Date Information
1
2
3
4
5
6
7
8
9
10
11
12
13
25
Page 26
Caution
If you leave the key in the ignition switch, someone could accidently start the engine and
seriously injure you or other bystanders.
Remove the key from the ignition and disconnect the wire(s) from the spark plug(s) before you
do any maintenance. Set the wire(s) aside so that it does not accidentally contact the spark
plug(s).
Warning
The bed must be raised to perform some routine
maintenance. The bed could fall and injure
persons that are underneath it.
• Always use prop rod to hold bed up before
working under raised bed.
• Remove any load material from bed before
working under raised bed.
Heavy Duty Operation
Important If the vehicle is subjected to any of the
conditions listed below, maintenance should be performed
twice as frequently:
• Desert operation
• Cold climate operation (below 32 degrees F)
• Trailer towing
• Frequent operation on dusty roads
• Construction work
Jacking the Vehicle
Whenever the engine is run for routine maintenance and/or
engine diagnostics, the rear wheels of the vehicle should be
1 in. (25 mm) off of the ground with the rear axle supported
on jack stands.
Danger
A vehicle on a jack may be unstable and slip off of
the jack, injuring anyone beneath it.
• Do not start the engine while the vehicle is on a
jack.
• Always remove the key from the ignition before
getting off of the vehicle.
• Block the tires when the vehicle is on a jack.
The jacking point at the front of the vehicle is on the front
of the frame behind the towing tongue (Fig. 23) The
jacking point at the rear of the vehicle is under the axle
tubes (Fig. 24).
• After extended operation in mud, sand, water, or similar
dirty conditions, have your brakes inspected and
cleaned as soon as possible. This will prevent any
abrasive material from causing excessive wear.
• Under frequent heavy duty operating conditions,
lubricate all grease fittings and inspect the air cleaner
daily to prevent excessive wear.
1
Figure 23
1. Front jacking point
26
Page 27
1 1
Figure 24
1. Rear jacking points
Neutral Lock Assembly
When performing routine maintenance and/or engine
diagnostics, the transaxle must be shifted into a neutral
position. The vehicle does not have a neutral position on
the shift lever. The following steps must be performed to
put the vehicle in neutral:
1. To lock the transaxle in neutral, rotate the locking pin
180 degrees on the shift block (Fig. 25).
1
Figure 26
1. Secondary clutch
Servicing the Engine Oil
Service Interval/Specification
Check the oil level before each use.
Change the oil after the first 8 operating hours and every 50
hours thereafter.
1
Figure 25
1. Locking pin
2. Shift the gear selector into Reverse and then into
Forward. Leave the gear shift selector in the Forward
position.
3. Ensure that the transaxle is locked in neutral by rotating
the secondary clutch (Fig. 26). The tires should not
rotate. If tire rotation does occur, repeat step 2 until the
tires no longer rotate.
Replace the oil filter every 100 hours.
Note: Change the oil and oil filter more frequently when
operating conditions are extremely dusty or sandy.
Oil Type: Detergent oil (API service SF, SG, SH, SJ, or
higher)
Crankcase Capacity: 48 oz./1-1/2 qt. (1.4 liters) when the
filter is changed
Viscosity: See the table below
USE THESE SAE VISCOSITY OILS
–20 0 20 40 60 80 100
°
F
–30°–20 –10 0 10 20 30 40
C
Checking the Oil Level
To check the oil level, refer to Checking the Crankcase Oil,
page 18.
27
Page 28
Changing and Draining the Oil
1. Start the vehicle and let it run for a few minutes to
warm the oil.
2. Park the machine on a level surface, set the parking
brake, turn the ignition off, and remove the key.
3. Raise the bed and secure it with the prop rod.
4. Disconnect the spark plug wires and battery cables.
5. Remove the drain plug (Fig. 27) and let the oil flow into
a drain pan. When the oil stops, install the drain plug.
Note: Dispose of the used oil at a certified recycling center.
1
Cleaning the Engine Cooling
Areas
Clean the rotating screen, cooling fins, and external
surfaces of the engine every 100 hours of operation or more
often under extremely dusty and dirty conditions.
Important Operating the engine with a blocked
rotating screen, dirty or plugged cooling fins, or cooling
shrouds removed, will cause engine damage due to
overheating.
Important Never clean the engine with pressurized
water because water could contaminate the fuel system.
Servicing the Air Cleaner
Service Interval/Specification
Check the air cleaner body for damage which could
possibly cause an air leak. Replace a damaged air cleaner
body.
Ensure that the cover is sealing around the air cleaner body.
2
Figure 27
1. Engine oil drain plug 2. Engine oil filter
6. Pour oil into the fill opening until the oil level is up to
the Full mark on the dipstick. Add the oil slowly and
check the level often during this process. Do not
overfill.
7. Install the oil fill cap and dipstick firmly in place.
Changing the Oil Filter
Replace the oil filter every 100 operating hours or yearly,
whichever occurs first.
1. Drain the oil from the engine; refer to Changing and
Draining the Oil, page 28.
2. Remove the existing oil filter (Fig. 27). Apply a light
coat of clean oil to the new filter gasket.
3. Screw the new filter on until the gasket contacts the
mounting plate, then tighten the filter an additional 1/2
to 3/4 turn further. Do not overtighten.
Air Cleaner Filter: Inspect after every 100 operating hours;
replace after every 200 hours or sooner if it is dirty or
damaged.
Note: Service the air cleaner more frequently (every few
hours) if operating conditions are extremely dusty or sandy.
Removing the Filter Element
1. Park the machine on a level surface, set the parking
brake, turn the ignition off, and remove the key.
2. Raise the bed and secure it with the prop rod.
3. Release the latches securing the air cleaner cover to the
air cleaner body. Separate the cover from the body.
Clean the inside of the air cleaner cover (Fig. 28).
3
4. Fill the crankcase with the proper type of new oil; refer
to Engine Oil, page 27.
5. Start and run the engine to check for leaks.
6. Stop the engine and check the oil level. Add oil if
necessary.
1. Air cleaner latches
2. Cover
28
2
1
Figure 28
3. Filter
Page 29
4. Gently slide the filter out of the air cleaner body to
reduce the amount of dust dislodged (Fig. 28). Avoid
knocking the filter against the air cleaner body.
5. Inspect the filter and discard it if it is damaged.
Cleaning the Filter Element
Important Do not wash or reuse a damaged filter.
1. Washing method:
A. Prepare a solution of filter cleaner and water and
soak the filter element about 15 minutes. Refer to
the directions on the filter cleaner carton for
complete information.
B. After soaking the filter for 15 minutes, rinse it with
clear water. Rinse the filter from the clean side to
the dirty side.
Important To prevent damage to the filter element,
maximum water pressure must not exceed 40 psi.
C. Dry the filter element using warm, flowing air at
160° F maximum, or allow the element to air-dry.
Important Do not use a light bulb to dry the filter
element because damage could result.
Greasing the Machine
Service Interval/Specification
Lubricate all bearings and bushings after every 100 hours
or once a year, whichever occurs first. Grease them more
frequently when using the vehicle for heavy-duty
operations.
Grease Type: No. 2 General Purpose Lithium Base Grease
Where to Add Grease
The grease fitting locations are at the four tie rod ends
(Fig. 29) and the two king pins (Fig. 30).
The two throttle and brake pedal pivots (Fig. 31) are not
greased at the factory and should only be greased when and
if the pedals begin to stick.
1. Wipe the grease fitting clean so that foreign matter
cannot be forced into the bearing or bushing.
2. Pump grease into the bearing or bushing.
3. Wipe off excess grease.
2. Compressed air method:
A. Blow compressed air from the inside to the outside
of the dry filter element. Keep the air hose nozzle at
least 2 inches from the filter and move the nozzle up
and down while rotating the filter element.
Important To prevent damage to the filter element, do
not exceed 100 psi air pressure.
B. Inspect the filter element for holes and tears by
looking through the filter toward a bright light.
Installing the Filter Element
Important To prevent engine damage, always operate
the engine with the complete air cleaner assembly installed.
1. Inspect the new filter for shipping damage. Check the
sealing end of the filter.
Important Do not install a damaged filter.
2. Insert the new filter properly into the air cleaner body.
Ensure that the filter is sealed properly by applying
pressure to the outer rim of the filter when installing it.
Do not press on the flexible center of the filter.
m–5320
Figure 29
3. Install the cover and secure the latches.
m–5324
Figure 30
29
Page 30
Figure 31
Servicing the Brakes
Inspecting the Brakes
Brakes are a critical safety component of the vehicle. As
with all safety components, they should be closely
inspected at regular intervals to ensure optimum
performance and safety. The following inspections should
be done every 100 hours:
• Inspect the brake shoes for wear or damage. If the
lining (brake pad) thickness is less than 1/16 in.
(1.6 mm), the brake shoes should be replaced.
• Inspect the backing plate and other components for
signs of excessive wear or deformation. If any
deformation is found, the appropriate components must
be replaced.
Adjusting the Brake Pedal
Adjust the brake if the parking brake does not hold, brake
pedal travel is excessive, or braking power is not sufficient
when the brake pedal is depressed. Check the adjustment
every 200 hours.
1. Turn the ignition off and remove the key.
2. Raise the vehicle off of the ground; see Jacking the
Vehicle, page 26.
3. Tighten the cable adjusting screw, located beneath the
floor panel, until the cables are snug in the brake
equalizer (Fig. 32). Do not overtighten. There should be
some free play in the brake pedal before the brake
engages.
2
Figure 32
1. Cable adjusting screw 2. Brake equalizer
1
m–4848
Inspecting the Tires
Check the tire condition at least every 100 hours of
operation. Operating accidents, such as hitting curbs, can
damage a tire or rim and also disrupt wheel alignment, so
inspect tire condition after an accident.
Check the wheels to ensure that they are mounted securely.
Torque the front bolts to 135–165 ft.-lb. (183–224 N⋅m)
and the rear lug nuts to 45–65 ft.-lb. (61–88 N⋅m).
Adjusting the Front
Suspension
The ride height of each side of the vehicle can be adjusted.
1. Jack the front end of the vehicle off of the ground; refer
to Jacking the Vehicle, page 26.
2. Remove the travel limiting bolt (Fig. 33).
3. Loosen the centering bolts in the front “A” frame
(Fig. 33).
4. Remove the ride height adjustment bolt (Fig. 33).
5. Rotate the front “A” frame to the desired position
(Fig. 33). The distance from the bottom side of the front
hitch to the ground should be 9 to 9-3/4 in. (22.9 to
24.8 cm) with the tires inflated to 12 psi (83 kPa).
6. Replace the ride height adjustment bolt and the travel
limiting bolt (Fig. 33).
7. Tighten and torque the centering bolts to
240–290 ft.-lbs. (325–393 N⋅m).
8. Tighten and torque the ride height adjustment bolt to
135–165 ft.-lbs. (183–224 N⋅m).
30
Page 31
9. Repeat the procedure on the opposite side of the
vehicle.
Replacing the Drive Belt
1. Rotate and route the belt over the secondary clutch
(Fig. 34).
2. Remove the belt from the primary clutch (Fig. 34).
3. To replace the belt, reverse the procedure.
Adjusting the Starter Generator
Belt
Check the tension of the starter generator belt after the first
day of operation and every 200 operating hours thereafter.
3
2
1. Travel limiting bolt
2. Centering bolt
1
Figure 33
3. Ride height adjustment
bolt
Servicing the Drive Belt
Service Interval/Specification
Check the condition and tension of the drive belt after the
first day of operation and every 200 operating hours
thereafter.
1. Park the machine on a level surface, set the parking
brake, turn the ignition off, and remove the key.
2. Raise the bed and secure it with the prop rod.
3. Put the vehicle in neutral; refer to Neutral Lock
Assembly, page 27.
4. Rotate and inspect the belt for excessive wear or
damage. Replace the belt if necessary.
1. Park the machine on a level surface, set the parking
brake, turn the ignition off, and remove the key.
2. Loosen the starter generator pivot bolt (Fig. 35).
2
1/4 in.
10 lb.
1
m–4956
Figure 35
1. Generator pivot bolt 2. Jam nut
3. Adjust the jam nut on the starter rod (Fig. 35) until the
belt flexes 1/4 in. with 10 lb. of force.
4. Tighten the starter generator pivot bolt (Fig. 35).
1. Drive belt
2. Primary clutch
1
2
Figure 34
3
3. Secondary clutch
31
Page 32
Adjusting Front Wheel Toe-In
Servicing the Fuel System
Check the front wheel toe-in after every 100 operating
hours, or annually, whichever occurs first.
1. Ensure that the distance from the bottom of the tongue
to the ground is 9 to 9-3/4 in. (22.9 to 24.8 cm) when
the tires are inflated to 12 psi. (83 kPa). Adjust if
necessary; refer to Adjusting the Front Suspension,
page 30.
2. Measure the distance between both of the front tires at
axle height (at the front and rear of the wheels)
(Fig. 36). The front measurement must be equal to the
rear measurement ±1/4 in. (6.4 mm).
CentertoCenter
Distance (rear of
tires)
Forward
CentertoCenter
Distance (front of tires)
Fuel Lines and Connections
Check the lines and connections every 400 hours or yearly,
whichever occurs first. Inspect them for deterioration,
damage, or loose connections.
Replacing the Fuel Filter
Replace the fuel filter after every 800 operating hours or
yearly, whichever occurs first.
1. Raise the bed and support it with the prop rod.
2. Place a clean container under the fuel filter.
3. Remove the clamps securing the fuel filter to the fuel
lines.
1
Figure 36
3. If the measurement is greater than 1/4 in. (6.4 mm),
loosen the jam nuts at both ends of the tie rods
(Fig. 37).
4. Rotate both tie rods to move the front of the tire inward
or outward.
1
2
Figure 37
1. Jam nut 2. Tie rod
1
m–5320
m–5322
Figure 38
1. Fuel filter
4. Install the replacement fuel filter to the fuel lines with
the clamps previously removed. Mount the filter so that
the arrow points toward the carburetor.
Spark Plugs
Service Interval/Specification
Replace the spark plugs after every 800 operating hours or
yearly, whichever occurs first, to ensure proper engine
performance and reduce the exhaust emission level.
Type: Champion RC 12YC (or equivalent)
Air Gap: 0.030 in. (.762 mm)
Note: The spark plug usually lasts a long time; however,
the plug should be removed and checked whenever the
engine malfunctions.
5. Tighten tie rod jam nuts when the adjustment is correct.
6. Ensure that there is full travel of the steering wheel in
both directions.
32
Page 33
Checking and Replacing the Spark Plug
1. Clean the area around the spark plugs so that foreign
matter cannot fall into the cylinder when the spark plug
is removed.
2. Pull the spark plug wires off of the spark plugs and
remove the plugs from the cylinder head.
3. Check the condition of the side electrode, center
electrode, and center electrode insulator to ensure that
there is no damage.
1
2
0.030 in.
(0.762 mm)
Figure 39
Important A cracked, fouled, dirty, or malfunctioning
spark plug must be replaced. Do not sand-blast, scrape, or
clean the electrodes by using a wire brush because grit may
eventually release from the plug and fall into the cylinder.
The result is usually a damaged engine.
4. Set the air gap between the center and side electrodes at
0.030 in. (0.762 mm). Install the correctly gapped spark
plug and tighten the plug to 18–22 ft.-lb. (24–30 N⋅m).
If a torque wrench is not used, tighten the plug firmly.
5. Install the spark plug wires.
Changing the Transaxle Fluid
Change the transaxle fluid every 800 operating hours or
yearly, whichever occurs first.
m–4849
Figure 40
1. Drain plug 2. Level indicator hole
3. Fill the reservoir (Fig. 41) with approximately 1-1/2 qt.
(1.4 liters) of SAE 10W30 motor oil or until the oil
level is at the bottom of the level indicator hole
(Fig. 40).
1
Figure 41
1. Oil fill
1. Position the vehicle on a level surface, set the parking
brake, turn the ignition off, and remove the key.
2. Remove the drain plug from the right side of the
reservoir (Fig. 40) and let the fluid flow into a drain
pan. Install and tighten the plug when the fluid stops
draining.
Note: Dispose of used oil at a certified recycling center.
4. Start the engine and operate it to fill the system.
Recheck the oil level and replenish it, if required.
33
Page 34
Replacing the Fuses
There are 3 fuses in the electrical system. They are located
beneath the bed in a box on the right hand side of the frame
(Fig. 42).
Ignition system 10 amp.
Lights 10 amp.
Power point 10 amp.
(15 amp. max.)
1
3
1. Ignition system
2. Lights
2
Figure 42
3. Power point
m–5323
Replacing the Headlights
Specification: GE Headlight #H7610
3
2
4
1. Rubber seal
2. Inside notch—align with
notch on headlight
6. Attach the headlight to the wire harness using the
previously removed screws.
7. Align the notch on the outside of the seal with the notch
in the hood. Push the headlight and seal into the hood
until it is firmly in place.
Note: Applying soapy water to the outside of the seal may
aid in sliding the seal into the hood.
1
Figure 43
3. Outside notch—align with
notch in hood
4. Headlight
Servicing the Battery
1. Set the parking brake, turn the ignition off, and remove
the key.
2. Reach beneath the dash and push the headlight out of
the hood.
3. Remove the screws attaching the wire harness to the
headlight.
4. Remove the rubber seal from around the headlight
(Fig. 43). Discard the headlight.
5. Align the notch on the inside of the seal with the notch
on the new headlight (Fig. 43). Slide the seal onto the
headlight until the seal is firmly in place.
Warning
Battery posts, terminals, and related accessories
contain lead and lead compounds, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after
handling.
Important Do not jump start the vehicle.
Service Interval/Specification
Always keep the battery clean and fully charged. Use a
paper towel to clean the battery and battery box. If the
battery terminals are corroded, clean them with a solution
of four parts water and one part baking soda. Apply a light
coating of grease to the battery terminals to prevent
corrosion.
Voltage: 12 volt with 280 cold cranking Amps @ 0° F
34
Page 35
Removing the Battery
Installing the Battery
1. Position the vehicle on a level surface, set the parking
brake, turn the ignition off, and remove the key.
2. Raise the bed and secure it with the prop rod.
3. Unhook the battery strap.
4. Disconnect the negative (black) ground cable from the
battery post.
Warning
Incorrect battery cable routing could damage the
vehicle and cables causing sparks. Sparks can
cause the battery gasses to explode, resulting in
personal injury.
• Always disconnect the negative (black) battery
cable before disconnecting the positive (red)
cable.
• Always reconnect the positive (red) battery cable
before reconnecting the negative (black) cable.
Warning
1. Set the battery on the battery base so that the battery
posts are toward the rear of the vehicle.
2. Connect the positive (red) cable to the positive (+)
battery post and the negative (black) cable to the
negative (–) battery post using the bolts and wing nuts.
Slide the rubber boot over the positive battery post.
3. Replace the rubber strap to secure the battery to the
base.
Important Always keep the battery strap in place to
protect and secure the battery.
Checking the Electrolyte Level
Check the electrolyte level every 50 operating hours or, if
the machine is in storage, every 30 days.
1. Raise the bed and secure it with the prop rod.
2. Remove the filler caps. If the electrolyte is not up to the
fill line, add the required amount of distilled water;
refer to Adding Water to the Battery, page 35.
Danger
Battery terminals or metal tools could short
against metal vehicle components causing sparks.
Sparks can cause the battery gasses to explode,
resulting in personal injury.
• When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the vehicle.
• Do not allow metal tools to short between the
battery terminals and metal parts of the vehicle.
• Always keep the battery strap in place to protect
and secure the battery.
5. Disconnect the positive (red) cable from the battery
post.
6. Remove the battery from the chassis.
Battery electrolyte contains sulfuric acid which is a
deadly poison and causes severe burns.
• Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
• Fill the battery where clean water is always
available for flushing the skin.
Adding Water to the Battery
The best time to add distilled water to the battery is just
before you operate the machine. This lets the water mix
thoroughly with the electrolyte solution.
1. Clean the top of the battery with a paper towel.
2. Remove the filler caps from the battery and slowly fill
each cell with distilled water until the level is up to the
fill line. Replace the filler caps.
Important Do not overfill the battery. Electrolyte will
overflow onto other parts of the vehicle and severe
corrosion and deterioration will result.
35
Page 36
Charging the Battery
Important Always keep the battery fully charged
(1.260 specific gravity). This is especially important to
prevent battery damage when the temperature is below
32°F (0°C).
1. Remove the battery from the chassis; refer to Removing
the Battery, page 35.
2. Connect a 3 to 4 amp battery charger to the battery
posts. Charge the battery at a rate of 3 to 4 amperes for
4 to 8 hours (12 volts). Do not overcharge the battery.
Warning
Charging the battery produces gasses that can
explode.
Never smoke near the battery and keep sparks and
flames away from battery.
3. Install the battery in the chassis; refer to Installing the
Battery, page 35.
Washing the V ehicle
The vehicle should be washed as needed. Use water alone
or with a mild detergent. A rag may be used, however the
hood will loose some of its luster.
Important Pressurized water is not recommended when
washing the machine. It may damage the electrical system,
loosen important decals, or wash away necessary grease at
friction points. Avoid excessive use of water, especially
near the control panel, engine, and battery.
Storing the Battery
If the machine will be stored for more than 30 days, remove
the battery and charge it fully. Either store it on the shelf or
on the machine. Leave the cables disconnected if it is stored
on the machine. Store the battery in a cool atmosphere to
avoid quick deterioration of the charge in the battery. To
prevent the battery from freezing, make sure it is fully
charged.
36
Page 37
Electrical Schematic
2
GY
VIO
REVERSE SW.1(IN FORWARD)
BN
BU
R
R
POWER POINT
BK
(+)
(–)
BACKUP ALARM
BK
R
SOLENOID,STSP
(–)
(+)
BU
R
GN
HR
HOUR
BK
METER
VOLTAGE
P3–1
ENGINE / FRAME GROUND
BK
MAG
SPARK PLUGSPARK PLUG
IGNITION
99–7415
MODULES
BK
A1
F1
BK
REGULATOR
P3–4
fields
STARTER/GENERATOR
F2DFA2
BK
armature
GN
P3–2
AIR VALVE
GY
878687a
OR
30
85
SHUTDOWN MODULE
–C–B
P16
SHUTDOWN DELAY RELAY
BK
(PEDAL NOT PUSHED IN)
WBK
–A
J16
VIO
BU
3
4
VIO
2
BN/W
2
1
ACCELERATOR
BK
M+
(OFF)
M–
1
KEY–SWITCH
PK
BU
BK BN
Y
BU
F1
F2 F3
F4
LOW OIL
PRESSURE
10 A
10 A
10 A
OPTIONAL FUSES
HEAD LIGHTS
1
LIGHT SWITCH
2
3
4
5
6
OR
PRESSURE
W/BU
P3–3
(+)(–)
ENGINE OIL
37
Page 38
38
Page 39
39
Page 40
The Toro General Commercial Products Warranty
A Two-Year Limited Warranty
Conditions and Products Covered
The Toro Company and its affiliate, Toro Warranty Company,
pursuant to an agreement between them, jointly warrant your 1996
or newer Toro Commercial Product (“Product”) purchased after
January 1, 1997, to be free from defects in materials or
workmanship for two years or 1500 operational hours*, whichever
occurs first. Where a warrantable condition exists, we will repair
the Product at no cost to you including diagnosis, labor, parts, and
transportation. This warranty begins on the date the Product is
delivered to the original retail purchaser.
* Product equipped with hour meter
Instructions for Obtaining Warranty Service
You are responsible for notifying the Commercial Products
Distributor or Authorized Commercial Products Dealer from whom
you purchased the Product as soon as you believe a warrantable
condition exists.
If you need help locating a Commercial Products Distributor or
Authorized Dealer, or if you have questions regarding your
warranty rights or responsibilities, you may contact us at:
Toro Commercial Products Service Department
Toro Warranty Company
8111 Lyndale Avenue South
Bloomington, MN 55420-1196
952-888-8801 or 800-982-2740
E-mail: commercial.service@toro.com
Owner Responsibilities
As the Product owner, you are responsible for required maintenance and adjustments stated in your operator’s manual. Failure
to perform required maintenance and adjustments can be grounds
for disallowing a warranty claim.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the
warranty period are defects in materials or workmanship. This
express warranty does not cover the following:
• Product failures which result from the use of non-Toro
replacement parts, or from installation and use of add-on,
modified, or unapproved accessories
• Product failures which result from failure to perform required
maintenance and/or adjustments
• Product failures which result from operating the Product in an
abusive, negligent or reckless manner
• Parts subject to consumption through use unless found to be
defective. Examples of parts which are consumed, or used up,
during normal Product operation include, but are not limited to,
blades, reels, bedknives, tines, spark plugs, castor wheels,
tires, filters, belts, etc.
• Failures caused by outside influence. Items considered to be
outside influence include, but are not limited to, weather,
storage practices, contamination, use of unapproved coolants,
lubricants, additives, or chemicals, etc.
• Normal “wear and tear” items. Normal “wear and tear”
includes, but is not limited to, damage to seats due to wear or
abrasion, worn painted surfaces, scratched decals or windows, etc.
Parts
Parts scheduled for replacement as required maintenance are
warranted for the period of time up to the scheduled replacement
time for that part.
Parts replaced under this warranty become the property of Toro.
T oro will make the final decision whether to repair any existing part
or assembly or replace it. Toro may use factory remanufactured
parts rather than new parts for some warranty repairs.
General Conditions
Repair by an Authorized Toro Distributor or Dealer is your sole
remedy under this warranty.
Neither The Toro Company nor Toro Warranty Company is
liable for indirect, incidental or consequential damages in
connection with the use of the Toro Products covered by this
warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of
malfunction or non-use pending completion of repairs under
this warranty. Except for the Emissions warranty referenced
below, if applicable, there is no other express warranty. All
implied warranties of merchantability and fitness for use are
limited to the duration of this express warranty.
Some states do not allow exclusions of incidental or consequential
damages, or limitations on how long an implied warranty lasts, so
the above exclusions and limitations may not apply to you.
This warranty gives you specific legal rights, and you may also
have other rights which vary from state to state.
Note regarding engine warranty: The Emissions Control
System on your Product may be covered by a separate warranty
meeting requirements established by the U.S. Environmental
Protection Agency (EPA) and/or the California Air Resources
Board (CARB). The hour limitations set forth above do not apply to
the Emissions Control System Warranty. Refer to the Engine
Emission Control Warranty Statement printed in your operator’s
manual or contained in the engine manufacturer’s documentation
for details.
Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer)
to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or
have difficulty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty
Company.
Part No. 374-0031 Rev. –
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