Toro 07264, 07264TC, Workman 1110 Operator's Manual

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Form No. 3356-911 Rev B

Workman® 1110 Utility Vehicle

Model No. 07264 —Serial No. 270000001 and Up Model No. 07264TC —Serial No. 270000001 and Up

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Warning

CALIFORNIA

Pr oposition 65 W ar ning

T he engine exhaust fr om this pr oduct contains chemicals kno wn to the State of Calif or nia to cause cancer , bir th defects, or other r epr oducti v e har m.

Important: T his engine is not equipped with a spar k ar r ester muf ﬂer . It is a violation of Calif or nia Public R esource Code Section 4442 to use or operate the engine on an y f or est-co v er ed, br ush-co v er ed, or g rass-co v er ed land. Other states or federal ar eas may ha v e similar la ws.

T his spark ignition system complies with Canadian ICES-002

T he enclosed Engine Owner’ s Man ual is supplied f or inf or mation r egarding the US En vir onmental Pr otection Agency (EP A) and the Calif or nia Emission Contr ol R egulation of emission systems, maintenance, and w ar ranty . R eplacements may be order ed thr ough the engine man uf actur er .

Introduction

R ead this infor mation carefully to lear n ho w to operate and maintain y our product properly and to a v oid injur y and product damag e . Y ou are responsible for operating the product properly and safely .

Figure 1

1. Model and serial number location

Model No.

Serial No.

T his man ual identiﬁes potential hazards and has safety messag es identiﬁed b y the safety aler t symbol ( Figure 2 ), whic h signals a hazard that ma y cause serious injur y or death if y ou do not follo w the recommended precautions .

Figure 2

1. Safety alert symbol

T his man ual uses 2 other w ords to highlight infor mation. Impor tant calls attention to special mec hanical infor mation and Note emphasizes g eneral infor mation w or th y of special attention.

Y ou ma y contact T oro directly at www .T oro .com for product and accessor y infor mation, help ﬁnding a dealer , or to register y our product.

W henev er y ou need ser vice , g en uine T oro par ts , or additional infor mation, contact an A uthorized Ser vice Dealer or T oro Customer Ser vice and ha v e the model and serial n umbers of y our product ready . Figure 1 identiﬁes the location of the model and serial n umbers on the product. W rite the n umbers in the space pro vided.

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Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safe Operating Practices . . . . . . . . . . . . . . . . . . . . . . 4

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Vibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Safety and Instr uctional Decals . . . . . . . . . . . . 9

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

1 Installing the W heels . . . . . . . . . . . . . . . . . . . . . . . 11

2 Installing the Steering W heel . . . . . . . . . . . 12

3 Installing the Bumper . . . . . . . . . . . . . . . . . . . . . . 12

4 Installing the Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 13

5 Installing the Hitc h . . . . . . . . . . . . . . . . . . . . . . . . . 13

6 Installing the Carg o Bo x . . . . . . . . . . . . . . . . . . 14

7 Acti v ating the Batter y . . . . . . . . . . . . . . . . . . . . . . 15

8 Adjusting the F ront W heel

T oe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9 R eading the Man ual and Viewing

the Safety Video . . . . . . . . . . . . . . . . . 16

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

T hink Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pre-Star ting Chec ks . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chec king the Engine Oil . . . . . . . . . . . . . . . . . . . . 22

Chec king the Brak e Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 22

Adding Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Chec king the T ransmission Oil

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Star ting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Stopping the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 24

P arking the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Operating the Carg o Bo x . . . . . . . . . . . . . . . . . . . 24

Breaking in a New V ehicle . . . . . . . . . . . . . . . . . . 25

Loading the Carg o Bo x . . . . . . . . . . . . . . . . . . . . . . 26

T ranspor ting the V ehicle . . . . . . . . . . . . . . . . . . . . 26

T o wing the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

T o wing a T railer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Daily Maintenance Chec klist . . . . . . . . . . . . . . 29

Premaintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . 30

Maintaining the V ehicle under

Special Operating

Conditions . . . . . . . . . . . . . . . . . . . . . . . . 30

J ac king the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Adding Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Ser vicing the Air Cleaner . . . . . . . . . . . . . . . . . . . 31

Ser vicing the Engine Oil . . . . . . . . . . . . . . . . . . . . 32

Ser vicing the Spark Plug . . . . . . . . . . . . . . . . . . . . 33

Fuel System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Inspecting Fuel Lines and

Connections . . . . . . . . . . . . . . . . . . . . . . 33

R e placing the Fuel Filter . . . . . . . . . . . . . . . . . . . . 33

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 34

R e placing the Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

R e placing the Headlights . . . . . . . . . . . . . . . . . . . 34

Ser vicing the Batter y . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 36

Chec king and Adjusting

Neutral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Inspecting the Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Adjusting the F ront

Suspension . . . . . . . . . . . . . . . . . . . . . . . . 37

Adjusting F ront W heel T oe-In . . . . . . . . . . . 38

Maintaining the Primar y Dri v e

Clutc h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Changing the T ransaxle Fluid . . . . . . . . . . . . . 40

Cooling System Maintenance . . . . . . . . . . . . . . . . . . . . . 40

Cleaning the Engine Cooling

Areas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Inspecting the Brak es . . . . . . . . . . . . . . . . . . . . . . . . . 41

Chec king the Brak e Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Adjusting the P arking Brak e . . . . . . . . . . . . . . . 41

Belt Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Ser vicing the Dri v e Belt . . . . . . . . . . . . . . . . . . . . . 41

Adjusting the Star ter Generator

Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

W ashing the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

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Safety

Improper use or maintenance b y the operator or o wner can result in injur y . T o reduce the potential for injur y , comply with these safety instr uctions and alw a ys pa y attention to the safety aler t symbol, whic h means Caution , W ar ning , or Danger —“personal safety instr uction. ” F ailure to comply with the instr uction ma y result in personal injur y or death.

Super visors , operators , and ser vice persons should be familiar with the follo wing standards and publications (the material ma y be obtained from the address sho wn):

• Flammable and Combustible Liquids Code: ANSI/NFP A 30

• National Fire Protection Association:

ANSI/NFP A #505; P o w ered Industrial T r uc ks , National Fire Prev ention Association, Bar r ymarc h P ark, Quincy , Massac husetts 02269 U .S .A.

• ANSI/ASME B56.8 P ersonal Burden Car riers

American National Standards Institute , Inc ., 1430 Broadw a y , New Y ork, New Y ork 10018 U .S .A.

Supervisor’s Responsibilities

• Mak e sure that operators are thoroughly trained and familiar with the Operator’ s Manual and all labels on the v ehicle .

• Be sure to establish y our o wn special procedures and w ork r ules for un usual operating conditions (e .g . slopes too stee p for v ehicle operation).

Before Operating

• Operate the mac hine only after reading and understanding the contents of this man ual.

• Nev er allo w c hildren to operate the v ehicle . Any one who operates the v ehicle should ha v e a motor v ehicle license .

• Nev er allo w other adults to operate the v ehicle without ﬁrst reading and understanding the Operator’ s Manual . Only trained and authorized persons should operate this v ehicle . Mak e sure that all operators are ph ysically and mentally capable of operating the v ehicle .

• T his v ehicle is designed to car r y only y ou, the operator , and one passeng er in the seat pro vided b y the man ufacturer . Nev er car r y any other passeng ers on the v ehicle .

• SAE J2258 Light Utility V ehicle

SAE Inter national, 400 Commonw ealth Dri v e , W ar rendale , P A 15096-0001 U .S .A.

• ANSI/UL 558; Inter nal Combustion Engine P o w ered Industrial T r uc ks

American National Standards Institute , Inc ., 1430 Broadw a y , New Y ork, New Y ork 10018 U .S .A.

Underwriters Laboratories , 333 Pﬁngsten R oad, Nor thbrook, Illinois 60062 U .S .A.

Safe Operating Practices

T he W or kman is an of f-highw ay v ehicle onl y and is not designed, equipped, or man uf actur ed f or use on public str eets, r oads, or highw ays.

• Nev er operate the v ehicle when under

the inﬂuence of dr ugs or alcohol. Ev en prescription dr ugs and cold medicines can cause dro wsiness .

• Do not dri v e the v ehicle when y ou are tired. Be sure to tak e occasional breaks . It is v er y impor tant that y ou sta y aler t at all times .

• Become familiar with the controls and kno w ho w to stop the engine quic kly .

• K ee p all shields , safety devices , and decals in place . If a shield, safety device , or decal is malfunctioning, illegible , or damag ed, re pair or re place it before operating the mac hine .

• Alw a ys w ear substantial shoes . Do not operate the mac hine while w earing sandals , tennis shoes or sneak ers . Do not w ear loose ﬁtting clothing or jew elr y whic h could g et caught in mo ving par ts and cause personal injur y .

• W earing safety glasses , safety shoes , long pants and a helmet is advisable and required b y some local safety and insurance regulations .

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• A v oid dri ving when it is dark, especially in unfamiliar areas . If y ou m ust dri v e when it is dark, be sure to dri v e cautiously , use the headlights , and ev en consider adding additional lights .

• Be extremely careful when operating around people . Alw a ys be a w are of where b ystanders might be .

• Before operating the v ehicle , alw a ys c hec k the designated areas of the v ehicle that are stated in the pre-star ting section of this man ual. If something is wrong, do not use the v ehicle . Mak e sure that the problem is cor rected before the v ehicle or attac hment is operated.

• Since g asoline is highly ﬂammable , handle it carefully .

– Use an appro v ed g asoline container . – Do not remo v e the cap from the fuel tank

when the engine is hot or r unning . – Do not smok e while handling g asoline . – Fill the fuel tank outdoors , and ﬁll it to

about 1 inc h (25 mm) belo w the top of the

tank (the bottom of the ﬁller nec k). Do

not o v erﬁll it. – Wipe up any spilled g asoline .

Operation

Engine exhaust contains carbon mono xide, which is an odor less, deadl y poison that can kill y ou.

Do not r un engine indoor s or in an enclosed ar ea.

• T he operator and passeng er should remain

seated whenev er the v ehicle is in motion. T he operator should k ee p both hands on the steering wheel whenev er possible , and the passeng er should use the hand holds pro vided. K ee p y our ar ms and legs within the v ehicle body at all times .

• Dri v e slo w er and tur n less shar ply when y ou are car r ying a passeng er . R emember y our passeng er ma y not be expecting y ou to brak e or tur n and ma y not be ready .

• Alw a ys w atc h out for and a v oid lo w o v erhangs suc h as tree limbs , door jambs , and o v er -head

w alkw a ys . Mak e sure there is enough room o v er head to easily clear the v ehicle and y our head.

• Alw a ys shift into neutral and apply the parking brak e before lea ving an idling v ehicle , or else the v ehicle ma y cree p .

• F ailure to operate the v ehicle safely ma y result in an accident, tip o v er of the v ehicle , and serious injur y or death. Dri v e carefully . T o prev ent tipping or loss of control:

– Use extreme caution, reduce speed, and

maintain a safe distance around sand traps , ditc hes , creeks , ramps , unfamiliar areas , or any areas that ha v e abr upt c hang es in

g round conditions or elev ation. – W atc h for holes or other hidden hazards . – Use extra caution when operating the

v ehicle on w et surfaces , in adv erse w eather

conditions , at higher speeds , or with a

full load. Stopping time and distance will

increase with a full load. – A v oid sudden stops and star ts . Do not

g o from rev erse to forw ard or forw ard to

rev erse without ﬁrst coming to a complete

stop . – Slo w do wn before tur ning . Do not attempt

shar p tur ns or abr upt maneuv ers or other

unsafe dri ving actions that ma y cause a loss

of v ehicle control. – W hen dumping, do not let any one stand

behind the v ehicle and do not dump the

load on any one’ s feet. R elease the tailg ate

latc hes from the side of the bo x, not from

behind. – Only operate the v ehicle when the carg o

bo x is do wn and latc hed. – Before bac king up , look to the rear and

ensure that no one is behind y ou. Bac k up

slo wly . – W atc h out for trafﬁc when y ou are near or

crossing roads . Alw a ys yield the right of

w a y to pedestrians and other v ehicles . T his

v ehicle is not designed for use on streets or

highw a ys . Alw a ys signal y our tur ns or stop

early enough so that other people kno w

what y ou plan to do . Obey all trafﬁc r ules

and regulations . – T he electrical and exhaust systems of the

v ehicle can produce sparks capable of

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igniting explosi v e materials . Nev er operate the v ehicle in or near an area where there is dust or fumes in the air whic h are explosi v e .

Operating on Hills

– If y ou are ev er unsure about safe operation,

stop w ork and ask y our super visor .

• Do not touc h the engine or m ufﬂer while the engine is r unning or soon after it has stopped. T hese areas ma y be hot enough to cause bur ns .

• If the mac hine ev er vibrates abnor mally , stop immediately , w ait for all motion to stop , and inspect the v ehicle for damag e . R e pair all damag e before commencing operation.

• Before g etting off of the seat:

1. Stop the mo v ement of the mac hine .

2. Set the parking brak e .

3. T ur n the ignition k ey to Off .

4. R emo v e the ignition k ey .

Note: If the v ehicle is on an incline , bloc k the wheels after g etting off of the v ehicle .

Braking

• Slo w do wn before y ou approac h an obstacle . T his gi v es y ou extra time to stop or tur n a w a y . Hitting an obstacle can damag e the v ehicle and its contents . More impor tant, it can injure y ou and y our passeng er .

• Gross V ehicle W eight (GVW) has a major impact on y our ability to stop and/or tur n. Hea vy loads and attac hments mak e a v ehicle harder to stop or tur n. T he hea vier the load, the long er it tak es to stop .

• Decrease the v ehicle speed if the carg o bo x has been remo v ed and there is no attac hment on the v ehicle . T he braking c haracteristics c hang e and fast stops ma y cause the rear wheels to loc k up , whic h ma y affect the control of the v ehicle .

• T urf and pa v ement are m uc h more slipper y when they are w et. It can tak e 2 to 4 times as long to stop on w et surfaces as on dr y surfaces . If y ou dri v e through standing w ater dee p enough to g et the brak es w et, they will not w ork w ell until they are dr y . After dri ving through w ater , y ou should test the brak es to mak e sure they w ork properly . If they do not, dri v e slo wly while putting light pressure on the brak e pedal. T his will dr y the brak es out.

Operating the v ehicle on a hill may cause tipping or r olling of the v ehicle, or the engine may stall and y ou could lose head w ay on the hill. T his could r esult in per sonal injur y .

• Do not accelerate quickl y or slam on the brak es when backing do wn a hill, especiall y with a load.

• If the engine stalls or y ou lose head w ay on a hill, slo wl y back straight do wn the hill. Nev er attempt to tur n the v ehicle ar ound.

• Operate the v ehicle slo wl y on a hill and use caution.

• A v oid tur ning on a hill.

• R educe y our load and the speed of the v ehicle.

• A v oid stopping on hills, especiall y with a load.

T hese extra cautions need to be tak en when operating the v ehicle on a hill:

• Slo w do wn before star ting up or do wn a hill.

• If the engine stalls or y ou begin to lose headw a y

while climbing a hill, g radually apply the brak es and slo wly bac k straight do wn the hill.

• T ur ning while tra v eling up or do wn hills can be dang erous . If y ou ha v e to tur n while on a hill, do it slo wly and cautiously . Nev er mak e shar p or fast tur ns .

• Hea vy loads affect stability . R educe the w eight of the load and y our speed when operating on hills or if the load has a high center of g ra vity . Secure the load to prev ent it from shifting and tak e extra care when hauling loads that shift easily (liquid, roc k, sand, etc .).

• A v oid stopping on hills , especially with a load. Stopping while g oing do wn a hill will tak e long er than stopping on lev el g round. If the v ehicle m ust be stopped, a v oid sudden speed c hang es , whic h ma y initiate tipping or rolling of the v ehicle . Do not slam on the brak es

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when rolling bac kw ard, as this ma y cause the v ehicle to o v er tur n.

• W e strongly recommend installing the optional R OPS Kit when operating on hilly ter rain.

Operating on Rough Terrain

R educe speed and load when operating on rough ter rain, unev en g round, and near curbs , holes , and other sudden c hang es in ter rain. Loads ma y shift, causing the v ehicle to become unstable .

W e strongly recommend installing the optional R OPS Kit when operating on rough ter rain.

Sudden changes in ter rain may cause a br upt steering wheel mo v ement, possibl y r esulting in hand and ar m injuries.

• R educe y our speed when operating on r ough ter rain and near curbs.

• Grip the steering wheel loosel y ar ound the perimeter . K eep y our hands clear of the steering wheel spok es.

• P osition the w eight of a load ev enly from front

to bac k. If y ou position the load behind the rear axle , it will reduce the w eight on the front wheels . T his ma y result in a loss of steering control or cause the v ehicle to tip o v er on hills or bumpy ter rain.

• Use extra caution if the load ex ceeds the dimensions of the bo x and when handling off-center loads that cannot be centered. K ee p loads balanced and secure to prev ent them from shifting .

• Alw a ys secure loads so that they do not shift. If a load is not secured, or y ou are transpor ting a liquid in a larg e container suc h as a spra yer , the load can shift. T his shifting happens most often while tur ning, g oing up or do wn hills , suddenly c hanging speeds , or while dri ving o v er rough surfaces . Shifting loads can cause the v ehicle to tip o v er .

T he w eight of the bo x may be hea vy . Hands or other body par ts could be cr ushed.

Loading and Dumping

T he w eight and position of the carg o and passeng er can c hang e the v ehicle center of g ra vity and v ehicle handling . T o a v oid loss of control and personal injur y , follo w these guidelines:

• Do not car r y loads whic h ex ceed the load limits described on the v ehicle w eight label; refer to Speciﬁcations in Product Ov er view , pag e 18 , for v ehicle w eight limits . T he load rating is for lev el surfaces only .

• R educe the w eight of the load when operating on hills and rough ter rain to a v oid tipping or o v er tur ning of the v ehicle .

• R educe the w eight of the load if the center of g ra vity is high. Items suc h as bric ks , fer tilizer , or landscape timbers stac k higher in the bo x. T he higher a load is stac k ed, the more lik ely the v ehicle is to tip o v er . Distribute the load as lo w as possible , making sure that the load does not affect rear visibility .

• P osition the w eight of the load ev enly from side to side . If y ou position the load to w ard one of the sides , the v ehicle is more lik ely to tip o v er while tur ning .

– K eep hands and other body par ts

clear when lo w ering the bo x.

– Do not dump materials on bystander s.

• Nev er dump a loaded carg o bo x while the

v ehicle is sidew a ys on a hill. T he c hang e in w eight distribution ma y cause the v ehicle to o v er tur n.

• W hen operating with a hea vy load in the carg o bo x, reduce y our speed and allo w for sufﬁcient braking distance . Do not suddenly apply the brak es . Use extra caution on slopes .

• Be a w are that hea vy loads increase y our stopping distance and reduce y our ability to tur n quic kly without tipping o v er .

• T he rear carg o space is intended for load car r ying pur poses only , not for passeng ers .

• Nev er o v erload y our v ehicle . T he decal (located on the rear frame) sho ws load limits for the v ehicle . Nev er o v erload the attac hments or ex ceed the Gross V ehicle W eight (GVW).

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Maintenance

Vibration

• Only qualiﬁed and authorized personnel shall be per mitted to maintain, re pair , adjust, or inspect the v ehicle .

• Before ser vicing or making adjustments to the mac hine , stop the engine , set the parking brak e , and remo v e the k ey from the ignition to prev ent someone from accidentally star ting the engine .

• T o mak e sure that the entire mac hine is in g ood condition, k ee p all n uts , bolts , and screws properly tightened.

• T o reduce the potential for ﬁre , k ee p the engine area free of ex cessi v e g rease , g rass , lea v es , and accum ulation of dir t.

• Nev er use an open ﬂame to c hec k the lev el or leakag e of fuel or batter y electrolyte .

• If the engine m ust be r unning to perfor m a maintenance adjustment, k ee p y our hands , feet, clothing, and any par ts of y our body a w a y from the engine and any mo ving par ts . K ee p ev er y one a w a y .

T his unit does not ex ceed a hand/ar m vibration lev el of 2.5 m/s identical mac hines per EN 1033.

T his unit does not ex ceed a whole body vibration lev el of 0.5 m/s identical mac hines per EN 1032.

, based on measurements of

• Do not use open pans of fuel or ﬂammable cleaning ﬂuids for cleaning par ts .

• Do not adjust the g round speed g o v er nor . T o ensure safety and accuracy , ha v e an A uthorized T oro Distributor c hec k the g round speed.

• If major re pairs are ev er needed or assistance is required, contact an A uthorized T oro Distributor .

• T o be sure of optim um perfor mance and safety , alw a ys purc hase g en uine T oro re placement par ts and accessories . R e placement par ts and accessories made b y other man ufacturers could be dang erous . Altering this v ehicle in any manner that ma y affect v ehicle operation, perfor mance , durability , or its use , ma y result in injur y or death. Suc h use could v oid the product w ar ranty .

Sound Pressure

T his unit has a maxim um sound pressure lev el at the operator’ s ear of 78 dB A, based on measurements of identical mac hines per EN

11094.

Page 9

Safety and Instructional Decals

Safety decals and instr uctions are easily visible to the operator and are located near any area of potential dang er . R e place any decal that is damag ed or lost.

107–0699

1. Warning—read the Operator’s Manual .

2. Collision hazard—do not operate the vehicle on public streets, roads, or highways.

3. Falling hazard—do not carry passengers in the cargo bed.

4. Falling hazard—do not allow children to operate the vehicle. 10. To stop the engine, release the accelerator pedal, set the

5. Hour meter

6. Headlights

7. Ignition—Off

8. Ignition—On

9. To start the engine, sit on the operator’s seat, release the parking brake, turn the ignition key on, pull the choke lever out (if needed), and press the accelerator pedal.

parking brake, turn the ignition key off, and remove the ignition key.

11. Electrical power (power point)

12. Horn

104–6581

1. Warning—read the Operator’s Manual .

2. Fire hazard—before fueling, stop the engine.

3. Tipping hazard—receive training before operating the machine, use caution and drive slowly while on slopes; drive slowly when turning, keep the vehicle speed under 19 MPH (31 km/h) when carrying a full or heavy load and when driving on rough terrain .

4. Falling and arm/leg injury hazards—do not carry passengers in the cargo bed and keep arms and legs inside of the vehicle at all times.

26-7390

Page 10

99–7345

1. Warning—read the Operator’s Manual .

2. Hot surface/burn hazard—stay a safe distance from the hot surface.

3. Entanglement hazard, belt—stay away from moving parts

4. Crushing hazard, cargo box—use the prop rod to support the cargo bed

110–2620

1. Read the Operator’s Manual .

2. The maximum combined operator and passenger weight is 400 lb (181 kg).

3. The maximum cargo weight is 850 lb (386 kg).

4. The base weight of the vehicle is 1100 lb (499 kg).

5. The maximum gross vehicle weight is 2350 lb (1066 kg).

99–7352

1. Read the Operator’s Manual for information on fuses.

2. 10 amp. fuse for the optional Road Light Kit

3. 15 amp. fuse for the optional Rear Lift Kit

4. 10 amp. fuse—open

5. 10 amp. fuse for the headlights

6. 10 amp. fuse for the ignition system

7. 15 amp. fuse for the optional Electric Bed Lift Kit

99–7954

1. Warning—read the Operator’s Manual .

2. Falling hazard—do not carry passengers in the cargo bed.

3. Explosion hazard, static discharge into fuel container—do not ll fuel containers in the cargo bed; place fuel containers on the ground before lling.

99–7952

1. Choke 3. Neutral

2. Reverse

99–7350

1. Maximum tongue weight is 50 lb (23 kg); maximum trailer weight is 400 lb (181 kg).

4. Forward

Page 11

Setup

Loose Parts

Use the chart below to verify that all parts have been shipped.

Step

1 2 3 4 5

7 8

Wheel assembly

Steering wheel

Bumper 1

Seat 2

Hitch

Cargo box Right-hand pivot bracket Left-hand pivot bracket Flange head screw (3/8 x 1 inch) Bolt (5/16 x 3/4 inch) Flange nut (5/16 inch)

No parts required

Operator’s Manual Engine Operator’s Manual Parts Catalog Safety Video Registration Card Predelivery Inspection Form Key 2

Description

Qty.

1 1 1 4 1 1

–

1 1 1 1 1 1

Install the wheels (Model 07264TC only).

Install the steering wheel (Model 07264TC only).

Install the bumper (Model 07264TC only).

Install the seats (Model 07264TC only).

Install the hitch (Model 07264TC only).

Install the cargo box (Model 07264TC only).

Activate the battery (Model 07264TC only).

Adjust the front wheel toe-in.

Read the Operator’s Manual and watch the video before operating the machine.

Use

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Page 12

Step

Installing the Wheels

Parts needed for this step:

Wheel assembly

Procedure Note: T his procedure is only needed for Model

No . 07264TC .

1. R emo v e the fasteners securing the wheels .

2. R emo v e the shipping brac k et secured to the wheel studs .

3. Mount the wheels with the previously remo v ed fasteners ( Figure 3 ) and tor que to 45-65 ft-lb (61-88 N ⋅ m).

Installing the Steering Wheel

Parts needed for this step:

Steering wheel

Procedure Note: T his procedure is only needed for Model

No . 07264TC .

1. R emo v e the n ut and w asher from the steering shaft.

2. Slide the steering wheel and w asher onto the shaft. P osition the steering wheel on the shaft so that the cross beam is horizontal when the tires are pointed straight ahead and the thic k er spok e of the steering wheel is do wnw ard.

3. Secure the steering wheel to the shaft with the n ut ( Figure 4 ). T or que the n ut to 18-22 ft-lb (24-29 N ⋅ m)

1. Wheel assembly

2. Wheel nut

Figure 3

3. Wheel stud (rear wheel hub shown)

1. Steering wheel 3. Washer

2. Nut

Figure 4

4. Foam seal

Page 13

Step

Installing the Bumper

Parts needed for this step:

1 Bumper

Procedure Note: T his procedure is only needed for Model

No . 07264TC .

1. R emo v e the 2 bolts , w ashers , and n uts secured to the front of the frame .

2. Align the mounting holes and secure the bumper to the frame with the fasteners previously remo v ed ( Figure 5 ).

Inser t the seat brac k et into the seat base opening and pi v ot the seat do wnw ard ( Figure 6 ).

Figure 6

1. Seat bracket 2. Seat base

1. Bumper

Step

Installing the Seats

Parts needed for this step:

2 Seat

Figure 5

Step

Installing the Hitch

Parts needed for this step:

Hitch

Procedure Note: T his procedure is only needed for Model

No . 07264TC .

1. R emo v e the 4 bolts and n uts from the inside rear of the frame .

2. Align the hitc h with the mounting holes on the frame . Secure the hitc h with the screws and n uts ( Figure 7 ).

Procedure Note: T his procedure is only needed for Model

No . 07264TC .

Page 14

Figure 7

1. Hitch

Step

Installing the Cargo Box

Parts needed for this step:

Cargo box

Right-hand pivot bracket

Left-hand pivot bracket

Flange head screw (3/8 x 1 inch)

Bolt (5/16 x 3/4 inch)

Flange nut (5/16 inch)

Procedure

Figure 8

1. Pivot bracket

3. Slide the carg o bo x mounting hole onto the pi v ot brac k et ( Figure 9 ).

Figure 9

1. Cargo box 3. Cargo box mounting hole

2. Pivot bracket

Note: T his procedure is only needed for Model No . 07264TC .

1. P osition the carg o bo x onto the frame . T he carg o bo x m ust la y ﬂat and be centered.

2. Mount the left hand pi v ot brac k et to the left rear cor ner of the frame with 2 ﬂang e head screws (3/8 x 1 inc h). P osition the brac k et as sho wn in Figure 8 .

4. Inser t the right hand pi v ot brac k et into the mounting hole in the carg o bo x and then mount it to the frame .

5. Ha v e another person help to raise the carg o bo x.

6. Loosen the bolt securing the prop rod clip to the frame until y ou can slide the J-hook end of the prop rod under the clip ( Figure 10 ).

Page 15

1. Prop rod

2. Prop rod clip

Figure 10

3. Bolt (5/16 x 3/4 inch)

4. Flange nut (5/16 inch)

Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

• Do not drink electr ol yte or allo w it to contact y our skin, ey es or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

• Fill the batter y wher e clean w ater is al w ays a v aila ble f or ﬂushing the skin.

7. Tighten the bolt and secure the other side of the clip with a new bolt (5/16 x 3/4 inc h) and ﬂang e n ut (5/16 inc h) ( Figure 10 ).

8. Lo w er the carg o bo x.

Step

Activating the Battery

No Parts Required

Procedure

None Note: T his procedure is only needed for Model

No . 07264TC .

If the batter y is not ﬁlled with electrolyte or acti v ated, it m ust be remo v ed from the v ehicle , ﬁlled with electrolyte , and c harg ed. Bulk electrolyte with 1.260 speciﬁc g ra vity m ust be purc hased from a local batter y supply outlet.

1. R emo v e the batter y hold-do wn and lift the batter y out of the batter y base .

2. R emo v e the ﬁller caps from the batter y and slo wly ﬁll eac h cell until electrolyte is just abo v e the plates .

3. R e place the ﬁller caps and connect a 3 to 4 amp . batter y c harg er to the batter y posts . Charg e the batter y at a rate of 3 to 4 amperes for 4 to 8 hours (12 v olts). Do not o v erc harg e the batter y .

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om batter y .

4. W hen the batter y is c harg ed, disconnect the c harg er from the electrical outlet and batter y posts .

5. R emo v e the ﬁller caps . Slo wly add electrolyte to eac h cell until electrolyte is up to the ﬁll line . Install the ﬁller caps .

Important: Do not o v erﬁll the batter y . Electr ol yte will o v erﬂo w onto other par ts of the v ehicle and sev er e cor r osion and deterioration will r esult.

6. Install the batter y; refer to Installing the Batter y , Electrical System Maintenance , pag e 34 .

Page 16

Step

Adjusting the Front Wheel Toe-in

No Parts Required

Procedure

T he toe-in should be 1/8-5/8 inc h (3-16 mm) with the follo wing parameters:

• T he tire pressure should be at 12 psi (83 kP a).

Figure 11

1. Tire center line-back

2. Tire center line-front 5. Axle center line distance

3. Axle center line

4. Fixture

6. 6 inches (15 cm) ruler

• T he ride height should be cor rect before setting the toe-in; refer to the Adjusting the F ront Suspension procedure in Maintenance , pag e 28 .

• T he v ehicle should be dri v en bac k and for th a few times to relax the A-ar ms .

• Measure the toe-in with the wheels facing straight ahead and a 175-225 lb (79-102 kg) operator in the dri v er’ s seat.

Note: T he dri v er should dri v e up to the measurement area and sta y seated in the v ehicle while the measurement is being tak en.

If the v ehicle will be r un with medium to hea vy loads most of the time , set the toe-in on the high side of the recommended amount. If it is g oing to be r un with a light load most of the time , set the toe-in on the lo w side of the recommended amount.

1. Measure the distance betw een both of the front tires at the axle height at both the front and rear of the front tires ( Figure 11 ). A ﬁxture or alignment g aug e is needed for the rear measurement of the front tires at axle height. Use the same ﬁxture or alignment g aug e to accurately measure the front of the front tires at axle height ( Figure 11 ).

2. If the measurement does not fall within the speciﬁed rang e (refer to the dimensions and parameters at the beginning of this procedure), loosen the jam n uts at both ends of the tie rods ( Figure 12 ).

Figure 12

1. Jam nut

3. R otate both tie rods to mo v e the front of the tire inw ard or outw ard.

4. Tighten the tie rod jam n uts when the adjustment is cor rect.

5. Ensure that there is full tra v el of the steering wheel in both directions .

2. Tie rod

Page 17

Step

Reading the Manual and Viewing the Safety Video

Parts needed for this step:

Operator’s Manual

Engine Operator’s Manual

Parts Catalog

Safety Video

Registration Card

Predelivery Inspection Form

2 Key

Procedure

• R ead the Operator’ s Manual and Engine Operator’ s Manual .

• View the safety video .

• Fill out the registration card.

• Complete the Pr edeli ver y Inspection F or m and ﬁle

it in y our customer histor y por tfolio .

Page 18

Product Overview

Figure 13

1. Steering wheel 3. Parking brake 5. Cargo box 7. Cargo box release lever

2. Gear shift selector 4. Fuel cap

6. Towing tongue

Controls

Accelerator Pedal

T he accelerator pedal ( Figure 14 ) gi v es the operator the ability to v ar y g round speed of the v ehicle . Pressing the pedal star ts the engine . Pressing the pedal far ther increases g round speed. R eleasing the pedal will slo w the v ehicle and the engine will stop r unning . Maxim um forw ard speed is 14 mph (22 km/h).

Figure 14

1. Accelerator pedal 2. Brake pedal

Brake Pedal

T he brak e pedal is used to stop or slo w the v ehicle ( Figure 14 ).

Brak es can become w or n or can be misadjusted r esulting in per sonal injur y .

If brak e pedal tra v els to within 1 inch (25 mm) of the v ehicle ﬂoor board, the brak es must be adjusted or r epair ed.

Parking Brake

T he parking brak e is betw een the seats ( Figure 15 ). W henev er the engine is shut off , the parking brak e m ust be eng ag ed to prev ent accidental mo v ement of the v ehicle . T o eng ag e the parking brak e , pull bac k on the lev er . T o diseng ag e , push the lev er forw ard. If the v ehicle is park ed on a stee p g rade , mak e sure that the parking brak e is applied. Place bloc ks at the do wnhill side of the wheels .

Page 19

Figure 15

1. Parking brake lever

Choke Control

T he c hok e control is located belo w and to the right of the operator’ s seat. T o star t a cold engine , pull the c hok e control outw ard ( Figure 16 ). After the engine star ts , regulate the c hok e to k ee p the engine r unning smoothly . As soon as possible , push the control in to the Off position. A w ar m engine requires little or no c hoking .

stopped, rotate the k ey countercloc kwise to the Off position. R emo v e the k ey from the ignition.

Figure 17

1. Ignition switch 4. Oil light

2. Hour meter

3. Light switch

5. Power Point

6. Horn Button

Hour Meter

T he hour meter ( Figure 17 ) indicates the total n umber of hours the engine has r un. T he hour meter star ts to function whenev er the accelerator is pressed.

Figure 16

1. Choke 2. Gear shift selector

Gear Shift Selector

T he g ear shift selector has three positions: forw ard, rev erse , and neutral ( Figure 16 ). T he engine will star t and r un in any of the three positions .

Note: If the g ear shift selector is in R ev erse when the ignition is tur ned on, a buzzer will sound to w ar n the operator .

Important: Al w ays stop the v ehicle bef or e changing gear s.

Ignition Switch

Oil Light

T he oil light w ar ns the operator if the engine oil lev el drops belo w a safe lev el ( Figure 17 ). If the light comes on and remains lit, the oil lev el should be c hec k ed and oil added if necessar y; refer to Chec king the Engine Oil in Operation , pag e 22 .

Note: T he oil light ma y ﬂic k er . T his is nor mal and no action needs to be tak en.

Light Switch

T og gle the switc h to acti v ate the headlights . Push to tur n the lights on ( Figure 17 ).

Power Point

Use the po w er point to po w er 12 v olt optional electrical accessories ( Figure 17 ).

Horn Button

Press the hor n button to sound the hor n ( Figure 17 ).

T he ignition switc h ( Figure 17 ), used to star t and stop the engine , has tw o positions: Off and On. R otate the k ey cloc kwise to the On position to allo w operation. W hen the v ehicle is

Fuel Gauge

T he fuel g aug e ( Figure 18 ) sho ws the amount of fuel in the tank.

Page 20

Figure 18

1. Fuel gauge

Passenger Hand Holds

T he passeng er hand holds are located on the right side of the dash panel and at the outside of eac h seat ( Figure 19 ).

Figure 19

1. Passenger hand hold

2. Hip restraint

Page 21

Specications

Note: Speciﬁcations and design are subject to c hang e without notice .

Base weight Rated capacity (on level ground) 1250 lb (567 kg) total, including 200 lb (90.7 kg) operator and 200 lb (90.7 kg)

Maximum gross vehicle weight (GVW) (on level ground)

Maximum cargo capacity (on level ground)

Tow capacity: Standard Hitch Heavy Duty Hitch Overall width Overall length Ground clearance

Wheel base Wheel tread (center line to center

line) Cargo box length Cargo box width Cargo box height

Dry 1050 lb (476 kg)

passenger, load, trailer tongue weight, gross trailer weight, accessories, and attachments

2350 lb (1066 kg) total, including all of the weights listed above

850 lb (386 kg) total, including trailer tongue weight and gross trailer weight

Tongue weight 50 lb (23 kg) Maximum trailer weight 400 lb (182 kg) Tongue weight 100 lb (45 kg) Maximum trailer weight 800 lb (363 kg) 60 inches (152.4 cm) 117 inches (297.2 cm) 9-1/4 inches (23.5 cm) at the front with no load or operator, 6-1/2 inches (19.7 cm)

at the rear with no load or operator 79 inches (200.7 cm) 49 inches (124.5 cm) in the front, 48-1/4 inches (122.6 cm) in the rear

46 inches (116.8 cm) inside, 51 inches (129.5 cm) outside 49 inches (124.5 cm) inside, 54 inches (137.2 cm) outside 10 inches (25.4 cm) inside

Attachments/Accessories

A selection of T oro appro v ed attac hments and accessories are a v ailable for use with the mac hine to enhance and expand its capabilities . Contact y our A uthorized Ser vice Dealer or Distributor or g o to www .T oro .com for a list of all appro v ed attac hments and accessories .

Page 22

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

Think Safety First

Please carefully read all of the safety instr uctions and decals in the safety section. Kno wing this infor mation could help y ou or b ystanders a v oid injur y .

Pre-Starting Checks

Chec k the follo wing items eac h time y ou begin using the v ehicle for the da y:

2. Clean around the oil dipstic k ( Figure 20 ) so dir t cannot fall into the hole and damag e the engine .

• Chec k the tire pressure .

Note: T hese tires are different than car tires; they require less pressure to minimize turf compaction and damag e .

• Chec k all ﬂuid lev els and add the appropriate amount of speciﬁed ﬂuids , if any are found to be lo w .

• Chec k the brak e pedal operation.

• Ensure that the lights are w orking .

• T ur n the steering wheel to the left and right to

c hec k steering response .

• Chec k for oil leaks , loose par ts , and any other noticeable malfunctions . Mak e sure the engine is off and all mo ving par ts ha v e stopped before c hec king for oil leaks , loose par ts , and other malfunctions .

If any of the abo v e items are not cor rect, notify y our mec hanic or c hec k with y our super visor before taking the v ehicle out for the da y . Y our super visor ma y w ant y ou to c hec k other items on a daily basis , so ask what y our responsibilities are .

Figure 20

1. Oil dipstick

3. R emo v e the oil dipstic k and wipe the metal end clean.

4. Slide the oil dipstic k fully into the ﬁller tube . Pull the dipstic k out and look at the metal end.

If the oil lev el is lo w , add oil of the proper type to raise the lev el to , but not o v er , the F mark on the dipstic k. R efer to Ser vicing the Engine Oil in Engine Maintenance , pag e 31 , for the proper oil type and viscosity . Add the oil slo wly and c hec k the lev el often during this process . Do not o v erﬁll.

5. Install the oil dipstic k.

Checking the Brake Fluid Level

Chec k the brak e ﬂuid lev el before the engine is ﬁrst star ted; refer to Chec king the Brak e Fluid Lev el in Brak e Maintenance , pag e 41 .

Checking the Engine Oil

Note: T he engine is shipped with oil in the

crankcase; ho w ev er , the lev el of the oil m ust be c hec k ed before and after the engine is ﬁrst star ted.

Chec k the engine oil lev el before star ting the engine eac h da y .

1. P osition the mac hine on a lev el surface .

Checking the Tire Pressure

Chec k the tire pressure ev er y 8 hours or daily to ensure proper lev els .

T he air pressure rang e in the front and rear tires is 8–22 psi (55–103 kP a).

T he air pressure needed is deter mined b y the pa yload car ried. T he lo w er the air pressure , the

Page 23

less the compaction, smoother the ride , and tire marks are minimized. Lo w er pressure should not be used for hea vy pa yloads at high speeds .

Higher pressures should be used for hea vier pa yloads at higher speeds . Do not ex ceed the maxim um pressure .

In cer tain conditions during fueling , static electricity can be r eleased causing a spar k which can ignite the gasoline v apor s. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

Adding Fuel

Use fresh, clean, unleaded regular g asoline suitable for automoti v e use (87 pump octane minim um). Leaded g asoline ma y be used if unleaded regular is not a v ailable .

Important: Nev er use gasoline containing methanol, gasoline containing mor e than 10% ethanol, gasoline additi v es, or white gas because engine fuel system dama ge could r esult.

In cer tain conditions, gasoline is extr emel y ﬂamma ble and highl y explosi v e. A ﬁr e or explosion fr om gasoline can bur n y ou and other s and can dama ge pr oper ty .

• Fill the fuel tank outdoor s, in an open ar ea, when the engine is cold. W ipe up an y gasoline that spills.

• Al w ays place gasoline container s on the g r ound a w ay fr om y our v ehicle bef or e ﬁlling .

• Do not ﬁll gasoline container s inside a v ehicle or on a tr uck or trailer bed because interior car pets or plastic tr uck bed liner s may insulate the container and slo w the loss of an y static charge.

• W hen practical, r emo v e gas-po w er ed equipment fr om the tr uck or trailer and r efuel the equipment with its wheels on the g r ound.

• If this is not possible, then r efuel such equipment on a tr uck or trailer fr om a por ta ble container , rather than fr om a gasoline dispenser nozzle.

• If a gasoline dispenser nozzle must be used, k eep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete.

• Nev er ﬁll the fuel tank inside an enclosed trailer .

• Do not ﬁll the fuel tank completel y full. Add gasoline to the fuel tank until the lev el is 1/4 to 1/2 inch (6 to 13 mm) belo w the bottom of the ﬁller neck. T his empty space in the tank allo ws gasoline to expand.

• Nev er smok e when handling gasoline, and stay a w ay fr om an open ﬂame or wher e gasoline fumes may be ignited by a spar k.

• Stor e gasoline in an appr o v ed container and k eep it out of the r each of childr en. Nev er buy mor e than a 30-day suppl y of gasoline.

• Do not operate without entir e exhaust system in place and in pr oper w or king condition.

Filling the Fuel Tank

T he fuel tank capacity is appro ximately 7 g allons (26.5 l).

1. Shut the engine off and set the parking brak e .

2. Clean the area around the fuel tank cap ( Figure 21 ).

Figure 21

1. Fuel tank cap

3. R emo v e the fuel tank cap .

4. Fill the tank to about 1 inc h (25 mm) belo w the top of tank, (bottom of the ﬁller nec k). T his

Page 24

space in the tank allo ws g asoline to expand. Do not o v erﬁll.

5. Install the fuel tank cap securely . Wipe up any fuel that ma y ha v e spilled.

Checking the Transmission Oil Level

T he transaxle ﬂuid lev el should be at the bottom of the lev el indicator hole ( Figure 22 ). If it is not, ﬁll the reser v oir with the appropriate ﬂuid; refer to Changing the T ransaxle Fluid in Dri v e System Maintenance , pag e 36 .

Note: Stopping distance ma y v ar y de pending on the v ehicle load and speed.

Parking the Vehicle

1. Eng ag e the parking brak e and rotate the ignition k ey to Off .

2. R emo v e the k ey from the ignition switc h to prev ent accidental star ting .

Operating the Cargo Box

Raising the Box

Dri ving the v ehicle with the cargo bo x raised may cause the v ehicle to tip or r oll easier . T he bo x str uctur e may become dama ged if y ou operate the v ehicle with the bo x raised.

Figure 22

1. Level indicator hole

Starting the Engine

1. Sit in the operator’ s seat, inser t the k ey into the ignition switc h, and rotate the k ey cloc kwise to the On position.

Note: If the g ear shift selector is in R ev erse , the buzzer will sound to w ar n the operator .

2. Mo v e the g ear shift selector to the desired position.

3. R elease the parking brak e .

4. Slo wly ste p on the accelerator pedal. Note: If the engine is cold, press and hold

the accelerator pedal about half-w a y do wn, and pull the c hok e knob out to the On position. R etur n the c hok e knob to Off after the engine w ar ms up .

Important: Do not attempt to push or to w the v ehicle to get it star ted.

• Onl y operate the v ehicle when the cargo bo x is do wn.

• After dumping a load, lo w er the cargo bo x.

1. Lift the lev er on either side of the bo x and lift the bo x up ( Figure 23 ).

Figure 23

1. Lever

2. Pull the prop rod into the detent slot, securing the bo x ( Figure 24 ).

Stopping the Vehicle

T o stop the v ehicle , remo v e y our foot from the accelerator pedal and slo wly press the brak e pedal.

Page 25

Figure 24

1. Prop rod

Lowering the Box

T he w eight of the bo x may be hea vy . Hands or other body par ts could be cr ushed.

K eep hands and other body par ts clear when lo w ering the bo x.

Operating the Tailgate Latches

1. T o open the tailg ate latc hes , lift the latc h handles up ( Figure 26 ). T he latc hes will spring out to w ard the center of the tailg ate . Slo wly lo w er the tailg ate .

Note: Y ou ma y need to push the end of the tailg ate in (especially if there is a load ag ainst the tailg ate) before the latc hes will spring to w ard the center of the tailg ate and release .

Figure 26

1. Tailgate latch

Pull the prop rod out of the detent slot and lo w er the bo x until it latc hes into place .

Adjusting the Box Latches

If the bo x latc h does not latc h tightly , vibrating up and do wn as y ou dri v e the v ehicle , y ou can adjust the latc h posts to mak e the latc hes ﬁt sn ugly .

1. Loosen the n ut on the end of the latc h post ( Figure 25 ).

Figure 25

1. Latch 3. Latch post

2. Nut

2. T o close the tailg ate latc hes , lift the handles upw ard and slide them to w ard the outside of the v ehicle .

3. Push the latc h handles do wnw ard to secure the latc h and tailg ate .

Breaking in a New Vehicle

T o pro vide proper perfor mance and long v ehicle life , follo w these guidelines for the ﬁrst 100 operating hours:

• Chec k the ﬂuid and engine oil lev els regularly and be aler t for indications of o v erheating in any component of the v ehicle .

• After star ting a cold engine , let it w ar m up for about 15 seconds before accelerating .

• A v oid hard braking situations for the ﬁrst sev eral hours of new v ehicle break-in operation. New brak e linings ma y not be at optim um perfor mance until sev eral hours of use has caused the brak es to become bur nished (brok en-in).

2. T ur n the latc h post cloc kwise until it is sn ug ag ainst the latc h and then tighten the n ut ( Figure 25 ).

3. R e peat this procedure for the latc h on the other side of the v ehicle .

• V ar y the v ehicle speed during operation. A v oid fast star ts and quic k stops .

• A break-in oil for engine is not required. Original engine oil is the same type speciﬁed for regular oil c hang es .

Page 26

• R efer to the Maintenance section for any special lo w hour c hec ks .

• Chec k the front suspension positioning and adjust it if necessar y; refer to Adjusting the F ront Suspension in Dri v e System Maintenance , pag e 36 .

Loading the Cargo Box

T he capacity of the carg o bo x is 13 ft

(0.37 m T he amount (v olume) of material that can be placed in the bo x without ex ceeding the v ehicle load ratings can v ar y g reatly de pending on the density of the material. F or example , a lev el bo x of w et sand w eighs 1500 lb (680 kg), whic h ex ceeds the load rating b y 650 lb (295 kg). But a lev el bo x of w ood w eighs 650 lb (295 kg), whic h is under the load rating .

See the table belo w for load v olume limits with v arious materials:

Max. cargo box

)

capacity (on

level ground)

2/3 full (approx.) 1/2 full (approx.)

2/3 full 1/2 full

Full Full

2/3 full (approx.)

Gravel, dry Gravel, wet Sand, dry Sand, wet Wood Bark Earth, packed

Material

Density (lb/ft

120

<45 100

Figure 27

1. Tie down points

Towing the Vehicle

In case of an emerg ency , the v ehicle can be to w ed for a shor t distance . Ho w ev er , w e do not recommend this as a standard procedure .

T o wing at ex cessi v e speeds could cause a loss of steering contr ol, r esulting in per sonal injur y .

Nev er to w the v ehicle f aster than 5 mph (8 km/h).

T o wing the v ehicle is a tw o person job . If the mac hine m ust be mo v ed a considerable distance , transpor t it on a tr uc k or trailer; refer to T ranspor ting the V ehicle .

Transporting the Vehicle

F or mo ving the v ehicle long distances , a trailer should be used. Mak e sure that the v ehicle is secured to the trailer . R efer to Figure 27 and Figure 28 for the location of the tie-do wn points .

Loose seats may f all of f of the v ehicle and trailer when transpor ting and land on another v ehicle or become an obstr uction on the r oad.

R emo v e the seats or mak e sur e that the seats ar e secur el y f astened in the detents.

1. R emo v e the dri v e belt; refer to R e placing the Dri v e Belt in Belt Maintenance , pag e 41 .

2. Afﬁx a to w line to the tongue on the front of the frame ( Figure 28 ).

3. Put the v ehicle in neutral and release the parking brak e .

Page 27

Figure 28

1. Towing tongue and tie down point

Towing a Trailer

T he v ehicle is capable of pulling trailers . T w o types of to w hitc hes are a v ailable for the v ehicle , de pending on y our application. Contact y our A uthorized T oro Distributor for details .

W hen hauling carg o or to wing a trailer , do not o v erload y our v ehicle or trailer . Ov erloading can cause poor perfor mance or damag e to the brak es , axle , engine , transaxle , steering, suspension, body str ucture , or tires . Alw a ys load a trailer with 60% of the carg o w eight in the front of the trailer . T his places appro ximately 10% of the Gross T railer W eight (GTW) on the to w hitc h of the v ehicle .

T he maxim um carg o load shall not ex ceed 850 lb (386 kg), including the GTW and tongue w eight. F or example , if the GTW = 400 lb (181.5 kg) and tongue w eight = 50 lb (23 kg), then the maxim um carg o load = 400 lb (181.5 kg)

T o pro vide adequate braking and traction, alw a ys load the carg o bo x when trailering . Do not ex ceed the GTW limits .

A v oid parking a v ehicle with a trailer on a hill. If y ou m ust park on a hill, eng ag e the parking brak e and bloc k the trailer tires .

Page 28

Maintenance

Note: Deter mine the left and right sides of the mac hine from the nor mal operating position.

Recommended Maintenance Schedule(s)

Maintenance Service

Interval

After the rst 8 operating

hours

After the rst 25

operating hours

Before each use or daily

Every 50 hours

Every 100 hours

Maintenance Procedure

• Check the engine oil.

• Check the condition and tension of the drive belt.

• Check the tension of the starter generator belt.

• Change the engine oil.

• Check the front wheel toe-in and front suspension.

• Check the engine oil.

• Check the tire pressure.

• Check the transmission oil level.

• Check the brake uid level.

• Check the battery cable connections for wear or damage.

• Check the battery electrolyte level.

• Grease the bearings and bushings.

• Inspect and clean the air lter element (twice as often in special operating conditions; refer to Maintaining the Vehicle under Special Operating Conditions).

• Change the engine oil (twice as often in special operating conditions; refer to Maintaining the Vehicle under Special Operating Conditions).

• Check the spark plug.

• Check the operation of the Neutral gear shift position.

• Inspect the condition and wear of the tires.

•

Torque the wheel lug nuts to 45-65 ft-lb (61-88 N ⋅ m).

• Check the front wheel toe-in and front suspension.

• Clean the engine cooling areas (twice as often in special operating conditions; refer to Maintaining the Vehicle under Special Operating Conditions).

• Inspect the brakes.

• Replace the air lter element.

Every 200 hours

Every 400 hours

Every 800 hours

Yearly

• Adjust the parking brake.

• Check the condition and tension of the drive belt.

• Check the tension of the starter generator belt.

• Inspect the fuel lines and connections.

• Clean and lubricate the primary drive clutch.

• Replace the fuel lter.

• Change the transaxle uid.

• Complete all yearly maintenance procedures specied in the Engine Operator’s Manual.

Important: R efer to y our Engine Operator’ s Man ual f or additional maintenance pr ocedur es.

Page 29

Daily Maintenance Checklist

Duplicate this page for routine use.

Maintenance Check Item

Check brake and parking brake operation.

Check gear shift/neutral operation.

Check fuel level. Check engine oil level. Check transaxle oil level. Inspect air lter. Inspect engine cooling

ns. Check unusual engine

noises. Check unusual operating

noises. Check tire pressure. Check uid leaks. Check instrument

operation. Check accelerator

operation. Check ride height and

toe-in. Lubricate all grease

ttings. Touch up damaged

paint.

For the week of:

Mon. Tues.

Wed. Thurs.

Fri.

Sat. Sun.

If y ou lea v e the k ey in the ignition s witch, someone could accidentl y star t the engine and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the ignition and disconnect the wir e fr om the spar k plug bef or e y ou do an y maintenance. Set the wir e aside so that it does not accidentall y contact the spar k plug .

T he bed must be raised to perf or m some r outine maintenance.

A raised bed can f all and injur e per sons that ar e under neath it.

• Al w ays use the pr op r od to hold the bed up bef or e w or king under it.

• R emo v e an y load material fr om the bed bef or e w or king under it.

Page 30

Premaintenance Procedures

Maintaining the Vehicle under Special Operating Conditions

If the v ehicle is subjected to any of the conditions listed belo w , maintenance should be perfor med twice as frequently .

• Deser t operation

• Cold climate operation (belo w 50 deg rees F

[10 deg rees C])

• T railer to wing

• Dri ving time typically less than 5 min utes

• F requent operation in dusty conditions

• Constr uction w ork

• After extended operation in m ud, sand, w ater ,

or similar dir ty conditions , ha v e y our brak es inspected and cleaned as soon as possible . T his will prev ent any abrasi v e material from causing ex cessi v e w ear .

T he jac king point at the front of the v ehicle is on the front of the frame behind the to wing tongue ( Figure 29 ) T he jac king point at the rear of the v ehicle is under the axle tubes ( Figure 30 ).

Figure 29

1. Front jacking point

• Under frequent hea vy duty operating conditions , lubricate all g rease ﬁttings and inspect air cleaner daily to prev ent ex cessi v e w ear .

Jacking the Vehicle

W henev er the engine is r un for routine maintenance and/or engine diagnostics , the rear wheels of the v ehicle should be 1 inc h (25 mm) off the g round with the rear axle suppor ted on jac k stands .

T he v ehicle may be unsta ble when using a jack. It could slip of f the jack, injuring an y one beneath it.

• Do not star t the engine while the v ehicle is on a jack.

• Al w ays r emo v e the k ey fr om the ignition bef or e getting of f of the v ehicle.

• Block the tir es when the v ehicle is on a jack.

Figure 30

1. Rear jacking points

Lubrication

Lubricate all of the bearings and bushings ev er y 100 hours or once a year , whic hev er occurs ﬁrst. Grease them more frequently when using the v ehicle for hea vy-duty operations .

Grease T ype: Number 2 General Pur pose Lithium Base Grease

Adding Grease

1. Wipe the g rease ﬁtting clean so foreign matter cannot be forced into the bearing or bushing .

2. Pump g rease into the bearing or bushing .

3. Wipe off ex cess g rease .

Page 31

T he g rease ﬁttings are located at the four tie rod ends ( Figure 31 and the tw o king pins ( Figure 32 ).

Figure 31

Figure 32

co v er from the body . Clean the inside of the air cleaner co v er ( Figure 33 ).

4. Gently slide the ﬁlter out of the air cleaner body to reduce the amount of dust dislodg ed ( Figure 33 ). A v oid knoc king the ﬁlter ag ainst the air cleaner body .

Figure 33

1. Air cleaner latches 3. Filter

2. Cover

Engine Maintenance

Servicing the Air Cleaner

Chec k the air cleaner body for damag e whic h could possibly cause an air leak. R e place a damag ed air cleaner body .

Ensure the co v er is sealing around the air cleaner body .

Air Cleaner Filter : Inspect after ev er y 100 operating hours; re place after ev er y 200 hours or sooner if dir ty or damag ed.

Note: Ser vice the air cleaner more frequently (ev er y few hours) if operating conditions are extremely dusty or sandy .

Removing the Filter Element

1. P ark the mac hine on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. Raise the bed and secure it with the prop rod.

3. R elease the latc hes securing the air cleaner co v er to the air cleaner body . Se parate the

5. Inspect the ﬁlter and discard it if it is damag ed.

Cleaning the Filter Element Important: Do not w ash or r euse a dama ged

ﬁlter .

• W ashing method:

1. Pre pare a solution of ﬁlter cleaner and w ater and soak the ﬁlter element for about 15 min utes . R efer to the directions on the ﬁlter cleaner car ton for complete infor mation.

2. After soaking the ﬁlter for 15 min utes , rinse it with clear w ater . Rinse the ﬁlter from the clean side to the dir ty side .

Important: T o pr ev ent dama ge to the ﬁlter element, the maximum w ater pr essur e must not ex ceed 40 psi. (276 kP a).

3. Dr y the ﬁlter element using w ar m, ﬂo wing air at 160 deg rees F (71 deg rees C) maxim um, or allo w the element to air -dr y .

Important: Do not use a light bulb to dr y the ﬁlter element because dama ge could r esult.

• Compr essed air method:

Page 32

1. Blo w compressed air from the inside to the outside of the dr y ﬁlter element. K ee p the air hose nozzle at least 2 inc hes (51 mm) from the ﬁlter and mo v e the nozzle up and do wn while rotating the ﬁlter element.

Important: T o pr ev ent dama ge to the ﬁlter element, do not ex ceed 100 psi (689 kP a) air pr essur e.

2. Inspect the ﬁlter element for holes and tears b y looking through the ﬁlter to w ard a bright light.

Installing the Filter Element Important: T o pr ev ent engine dama ge,

al w ays operate the engine with the complete air cleaner assembl y installed.

1. Inspect the new ﬁlter for shipping damag e . Chec k the sealing end of the ﬁlter .

Important: Do not install a dama ged ﬁlter .

2. Inser t the new ﬁlter into air cleaner body . Ensure the ﬁlter is sealed properly b y applying pressure to the outer rim of the ﬁlter when installing it. Do not press on the ﬂexible center of the ﬁlter .

3. Install the co v er and secure the latc hes .

Servicing the Engine Oil

Chec k the oil lev el before eac h use .

Chang e the oil after the ﬁrst 25 operating hours and ev er y 100 operating hours thereafter . Chang e the oil twice as often in special operating conditions; refer to Maintaining the V ehicle under Special Operating Conditions .

Figure 34

Checking the Oil Level

T o c hec k the oil lev el, refer to Chec king the Engine Oil in Operation , pag e 22 .

Changing the Oil

1. Star t the v ehicle and let it r un for a few min utes to w ar m the oil.

2. P ark the mac hine on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

3. Raise the bed and secure it with the prop rod.

4. Disconnect the spark plug wires and batter y cables .

5. R emo v e the drain plug ( Figure 35 ) and let the oil ﬂo w into a drain pan. W hen the oil has drained completely , install the drain plug and tor que it to 13 ft-lb (17.6 N ⋅ m).

Note: Chang e the oil more frequently when operating conditions are extremely dusty or sandy .

Oil T ype: Deterg ent oil (API ser vice SG , SH, SJ , or higher)

Viscosity: See the table belo w .

Page 33

Figure 35

1. Engine oil drain plug

Note: Dispose of the used oil at a cer tiﬁed recycling center .

6. Clean around the oil dipstic k and unscrew the cap .

7. Slo wly pour appro ximately 80% of the speciﬁed amount of oil into the ﬁller tube and c hec k the oil lev el; refer to Chec king the Crankcase Oil in Operation , pag e 22 . Slo wly add oil to bring the lev el to the F mark on the dipstic k.

8. Install the dipstic k.

3. Chec k the condition of the side electrode , center electrode , and center electrode insulator to ensure that there is no damag e ( Figure 36 ).

Important: A crack ed, f ouled, dir ty , or malfunctioning spar k plug must be r eplaced. Do not sand-blast, scrape, or clean electr odes by using a wir e br ush because g rit may ev entuall y r elease fr om the plug and f all into the cylinder . T he r esult is usuall y a dama ged engine.

Figure 36

1. Center electrode insulator

2. Side electrode

4. Set the air g ap betw een the center and side of the electrodes at 0.030 inc h (0.762 mm) ( Figure 36 ). Install the cor rectly g apped spark plug and tighten the plug to 14 ft-lb (20 N ⋅ m).

3. Air gap (not to scale)

Servicing the Spark Plug

Chec k the spark plug after ev er y 100 operating hours or yearly , whic hev er occurs ﬁrst. R e place if necessar y .

T ype: Champion RN14Y C (or equi v alent)

Air Gap: 0.030 inc h (0.762 mm)

Checking and Replacing the Spark Plug

Note: T he spark plug usually lasts a long time;

ho w ev er , the plug should be remo v ed and c hec k ed whenev er the engine malfunctions .

1. Clean the area around the spark plugs so that foreign matter cannot fall into the cylinder when the spark plug is remo v ed.

2. Pull the wires off of the spark plugs and remo v e the plugs from the cylinder head.

5. Install the spark plug wires .

Fuel System Maintenance

Inspecting Fuel Lines and Connections

Chec k the fuel lines and connections ev er y 400 operating hours or yearly , whic hev er occurs ﬁrst. Inspect them for deterioration, damag e , or loose connections .

Replacing the Fuel Filter

R e place the fuel ﬁlter ev er y 800 operating hours or yearly , whic hev er occurs ﬁrst.

1. Raise the bo x and suppor t it with the prop rod.

Page 34

2. Place a clean container under the fuel ﬁlter .

3. R emo v e the clamps securing the fuel ﬁlter to the fuel lines ( Figure 37 ).

Figure 37

1. Fuel lter

4. Install the re placement ﬁlter to the fuel lines with the clamps previously remo v ed.

Mount the ﬁlter so that the ar ro w points to w ard the carburetor .

Electrical System Maintenance

2. R eac h beneath the dash and push the headlight out of the hood.

3. R emo v e the screws attac hing the wire har ness to the headlight.

4. R emo v e the r ubber seal from around the headlight ( Figure 39 ). Discard the headlight.

Figure 39

1. Rubber seal 3. Outside notch-align with

2. Inside notch-align with the notch on the headlight

notch in hood

4. Headlight

Replacing the Fuses

T here are 3 fuses in the electrical system. T hey are located beneath the bed in a bo x on the right hand side of the frame ( Figure 38 ).

Ignition System Lights Power Point

Figure 38

1. Ignition system 3. Power point

2. Lights

10 amp. (15 amp. max.)

10 amp. 10 amp.

Replacing the Headlights

Speciﬁcation: GE Headlight #H7610

1. Set the parking brak e , tur n the ignition off , and remo v e the k ey .

5. Align the notc h on the inside of the seal with the notc h on the new headlight ( Figure 39 ). Slide the seal onto the headlight until the seal is ﬁr mly in place .

6. Attac h the headlight to the wire har ness using the previously remo v ed screws .

7. Align the notc h on the outside of the seal with the notc h in the hood. Push the headlight and seal into the hood until it is ﬁr mly in place .

Note: Applying soapy w ater to the outside of the seal ma y aid in sliding the seal into the hood.

Servicing the Battery

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Batter y posts, ter minals, and r elated accessories contain lead and lead compounds, chemicals kno wn to the State of Calif or nia to cause cancer and r epr oducti v e har m. W ash hands after handling .

Page 35

Important: Do not jump star t the v ehicle.

Alw a ys k ee p the batter y clean and fully c harg ed. Use a paper to w el to clean the batter y and batter y bo x. If the batter y ter minals are cor roded, clean them with a solution of four par ts w ater and one par t baking soda. Apply a light coating of g rease to the batter y ter minals to prev ent cor rosion.

V oltag e: 12 v olt with 280 cold cranking Amps @ 0 deg rees F (-18 deg rees C).

Removing the Battery

1. P osition the v ehicle on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. Raise the bed and secure it with the prop rod.

3. R emo v e the batter y hold-do wn.

4. Disconnect the neg ati v e (blac k) g round cable from the batter y post.

Incor r ect batter y ca ble r outing could dama ge the v ehicle and ca bles, causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• Al w ays disconnect the negati v e (black) batter y ca ble bef or e disconnecting the positi v e (r ed) ca ble.

• Al w ays r econnect the positi v e (r ed) batter y ca ble bef or e r econnecting the negati v e (black) ca ble.

• Al w ays k eep the batter y strap in place to pr otect and secur e the batter y .

Batter y ter minals or metal tools could shor t a gainst metal v ehicle components, causing spar ks. Spar ks can cause the batter y gasses to explode, r esulting in per sonal injur y .

• W hen r emo ving or installing the batter y , do not allo w the batter y ter minals to touch an y metal par ts of the v ehicle.

• Do not allo w metal tools to shor t betw een the batter y ter minals and metal par ts of the v ehicle.

5. Disconnect the positi v e (red) cable from the batter y post.

6. R emo v e the batter y from the c hassis .

Installing the Battery

1. Set the batter y on the batter y base so the batter y posts are to w ard the rear of the v ehicle .

2. Connect the positi v e (red) cable to the positi v e (+) batter y post and the neg ati v e (blac k) cable to the neg ati v e (-) batter y post using the bolts and wing n uts . Slide the r ubber boot o v er the positi v e batter y post.

3. R e place the batter y hold-do wn to secure the batter y to the base .

Important: Al w ays k eep the batter y hold-do wn in place to pr otect and secur e the batter y .

Checking the Electrolyte Level

Chec k the electrolyte lev el ev er y 50 operating hours or , if the mac hine is in storag e , ev er y 30 da ys .

1. Raise the bed and secure it with the prop rod.

2. R emo v e the ﬁller caps . If the electrolyte is not up to the ﬁll line , add the required amount of distilled w ater; refer to Adding W ater to the Batter y .

Page 36

Storing the Battery

Batter y electr ol yte contains sulfuric acid which is a deadl y poison and causes sev er e bur ns.

• Do not drink electr ol yte or allo w it to contact y our skin, ey es or clothing . W ear safety g lasses to shield y our ey es and r ub ber g lo v es to pr otect y our hands.

• Fill the batter y wher e clean w ater is al w ays a v aila ble f or ﬂushing the skin.

Adding Water to the Battery

T he best time to add distilled w ater to the batter y is just before y ou operate the mac hine . T his lets the w ater mix thoroughly with the electrolyte solution.

1. Clean the top of the batter y with a paper to w el.

2. R emo v e the ﬁller caps from the batter y and slo wly ﬁll eac h cell with distilled w ater until the lev el is up to the ﬁll line . R e place the ﬁller caps .

Important: Do not o v erﬁll the batter y . Electr ol yte will o v erﬂo w onto other par ts of the v ehicle and sev er e cor r osion and deterioration will r esult.

Charging the Battery Important: Al w ays k eep the batter y

full y charged (1.260 speciﬁc g ra vity). T his is especiall y impor tant to pr ev ent batter y dama ge when the temperatur e is belo w 32 deg r ees F (0 deg r ees C).

If the mac hine will be stored for more than 30 da ys , remo v e the batter y and c harg e it fully . Either store it on the shelf or on the mac hine . Lea v e the cables disconnected if it is stored on the mac hine . Store the batter y in a cool atmosphere to a v oid quic k deterioration of the c harg e in the batter y . T o prev ent the batter y from freezing, mak e sure it is fully c harg ed.

Drive System Maintenance

Checking and Adjusting Neutral

W hen perfor ming routine maintenance and/or engine diagnostics , the transaxle m ust be shifted into neutral ( Figure 40 ). T he v ehicle has a neutral position on the shift lev er , whic h controls the neutral in the transaxle . T he follo wing ste ps should be tak en to mak e sure that the neutral shift lev er operates the transaxle neutral cor rectly:

1. Set the shift lev er into the Neutral position.

2. Ensure that the neutral brac k et is in the neutral position (lev el) b y tur ning the dri v e clutc h ( Figure 40 ). T he v ehicle should not roll bac k and for th. If it does , man ually mo v e the neutral brac k et to the neutral position.

1. R emo v e the batter y from the c hassis; refer to R emo ving the Batter y .

2. Connect a 3 to 4 amp batter y c harg er to the batter y posts . Charg e the batter y at a rate of 3 to 4 amperes for 4 to 8 hours (12 v olts). Do not o v erc harg e the batter y .

Charging the batter y pr oduces gasses that can explode.

Nev er smok e near the batter y and k eep spar ks and ﬂames a w ay fr om batter y .

3. Install the batter y in the c hassis; refer to Installing the Batter y .

Page 37

Inspecting the Tires

Chec k the tire condition at least ev er y 100 hours of operation. Operating accidents , suc h as hitting curbs , can damag e a tire or rim and also disr upt wheel alignment, so inspect tire condition after an accident.

Chec k the wheels to ensure that they are mounted securely . T or que the lug n uts to 45-65 ft-lb (61-88 N ⋅ m).

Adjusting the Front Suspension

Figure 40

1. Neutral bracket 2. Locknuts

3. Tighten one of the loc kn uts ( Figure 40 ) just enough to tak e the slac k out of the shift cable .

Note: Y ou m ust hold the threaded shaft belo w the brac k et to tighten the loc kn ut on top .

4. Tighten the other loc kn ut just enough to tak e the slac k out of the other shift cable .

5. Pull up on eac h shift cable an ensure that there is no g ap betw een the n ut/w asher and the neutral brac k et ( Figure 41 ). If there is a g ap , tighten the n ut.

T he ride height of eac h side of the v ehicle can be adjusted se parately . T he ride height should be 8-3/4 to 9-1/2 inc hes (22.2 to 24 cm) with the follo wing parameters:

• T he tire pressure should be at 12 psi (83 kP a).

• T he v ehicle should be dri v en bac k and for th a

few times to relax the A-ar ms .

• Measure the ride height with the wheels facing straight ahead and a 175-225 lb (79-102 kg) operator in the dri v er’ s seat.

Note: T he dri v er should dri v e up to the measurement area and sta y seated in the v ehicle while the measurement is being tak en.

• Measure the ride height on a ﬂat surface , from the bottom of the front tongue to the g round.

1. J ac k the front end of the v ehicle off of the g round; refer to J ac king the V ehicle in Premaintenance Procedures , pag e 30 .

2. R emo v e the tra v el limiting bolt ( Figure 42 ).

Figure 41

1. Neutral bracket 4. Wrong, must tighten the nut

2. Pull up 5. Correct adjustment

3. Cable boot

6. Star t the engine and shift into F orw ard, R ev erse , and Neutral sev eral times to ensure that the neutral brac k et is operating properly .

3. Loosen the centering bolts in the front A-ar m ( Figure 42 ).

4. R emo v e the ride height adjustment bolt ( Figure 42 ).

Page 38

Figure 42

1. Travel limiting bolt 3. Ride height adjustment bolt

2. Centering bolt

5. R otate the front A-ar m to the desired position (refer to the note belo w) and re place the ride height adjustment bolt ( Figure 42 ).

Note: T he A-ar ms are made with r ubber and ha v e different spring rates . Because of the different spring rates , the A-ar ms come adjusted from the factor y based on that spring rate . Generally the adjustment bolts will be installed in hole n umber 2, 3, or 4 ( Figure 43 ) and it ma y be different from the left side (dri v er side) to the right side (passeng er side). If the A-ar ms look lik e they are sag ging, then they should be adjusted to the next higher n umber ( Figure 43 ). Eac h hole equals about 3/4 inc h (19 mm) of adjustment at the wheel. Y ou will also need to do this if y ou are adding hea vy attac hments or car r ying hea vy loads often.

Figure 43

1. Left-hand A-arm

6. T or que the ride height adjustment bolt to 135-165 ft-lb (183-224 N ⋅ m).

7. R e place the tra v el limiting bolt ( Figure 42 ). Note: T he v ehicle ma y need to be lo w ered to

the g round on that side to install the bolt.

8. Tighten and tor que the centering bolts to 240-290 ft-lb (325-393 N ⋅ m).

9. Chec k the ride height at the front tongue per the dimensions and parameters gi v en at the beginning of this procedure .

Adjusting Front Wheel Toe-In

Chec k the front wheel toe-in after ev er y 100 operating hours , or ann ually , whic hev er occurs ﬁrst.

T he toe-in should be 1/8-5/8 inc h (3-16 mm) with the follo wing parameters:

• T he tire pressure should be at 12 psi (83 kP a).

• T he ride height should be cor rect before

setting the toe-in; refer to Adjusting the F ront Suspension.

• T he v ehicle should be dri v en bac k and for th a few times to relax the A-ar ms .

• Measure the toe-in with the wheels facing straight ahead and a 175-225 lb (79-102 kg) operator in the dri v er’ s seat.

Page 39

Note: T he dri v er should dri v e up to the measurement area and sta y seated in the v ehicle while the measurement is being tak en.

1. Ensure that the front suspension is adjusted properly; refer to Adjusting the F ront Suspension. Adjust if necessar y .

2. Measure the distance betw een both of the front tires at the axle height at both the front and rear of the front tires ( Figure 44 ). A ﬁxture or alignment g aug e is needed for the rear measurement of the front tires at axle height. Use the same ﬁxture or alignment g aug e to accurately measure the front of the front tires at axle height ( Figure 44 ).

Figure 45

1. Jam nut

2. Tie rod

4. R otate both tie rods to mo v e the front of the tire inw ard or outw ard.

5. Tighten the tie rod jam n uts when the adjustment is cor rect.

6. Ensure that there is full tra v el of the steering wheel in both directions .

Maintaining the Primary Drive Clutch

Figure 44

1. Tire center line-back

2. Tire center line-front 5. Axle center line distance

3. Axle center line

4. Fixture

6. 6 inches (15 cm) ruler

3. If the measurement does not fall within the speciﬁed rang e (refer to the dimensions and parameters at the beginning of this procedure), loosen the jam n uts at both ends of the tie rods ( Figure 45 ).

After ev er y 400 operating hours or yearly , clean and lubricate the clutc h as follo ws:

1. Raise and latc h the carg o bo x.

2. Stop the engine , remo v e the k ey , and set the parking brak e .

3. R emo v e the 3 bolts securing the co v er to the clutc h and remo v e the co v er ( Figure 46 ).

Figure 46

1. Cover

2. Bolts

4. T horoughly clean the inside of the co v er and the inner w orkings of the clutc h using compressed air .

Page 40

T he dust in the clutch will become airbor ne and could dama ge y our ey es or y ou could inhale it causing br eathing dif ﬁculties.

W ear safety go g g les and a dust mask or other ey e and r espirator y pr otection when perf or ming this pr ocedur e.

5. Lubricate the mo ving par ts in the areas circled in Figure 47 using T oro Dr y Lubricant Spra y , a v ailable through y our A uthorized T oro Dealer or Distributor .

Figure 47

Figure 48

1. Drain plug 2. Level indicator hole

3. Fill the reser v oir ( Figure 49 ) with appro ximately 1-1/2 qt. (1.4 liters) of SAE 10W30 motor oil or until the oil lev el is at the bottom of the lev el indicator hole ( Figure 48 ).

6. Install the clutc h co v er and secure it with the 3 bolts remo v ed previously .

Changing the Transaxle Fluid

Chang e the transaxle ﬂuid ev er y 800 operating hours or yearly , whic hev er occurs ﬁrst.

1. P osition the v ehicle on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. R emo v e the drain plug from the right side of the reser v oir ( Figure 48 ) and let the ﬂuid ﬂo w into a drain pan. Install and tighten the plug when the ﬂuid stops draining .

Note: Dispose of the used oil at a cer tiﬁed recycling center .

Figure 49

1. Oil ll

4. Star t the engine and operate it to ﬁll the system. R ec hec k the oil lev el and re plenish it, if required.

Cooling System Maintenance

Cleaning the Engine Cooling Areas

Clean the rotating screen, cooling ﬁns , and exter nal surfaces of the engine ev er y 100 operating hours or more often under extremely dusty and dir ty conditions .

Important: Operating the engine with a block ed r otating scr een, dir ty or plug ged cooling ﬁns, or cooling shr ouds r emo v ed will cause engine dama ge due to o v erheating .

Page 41

Important: Nev er clean the engine with pr essuriz ed w ater because w ater could contaminate the fuel system.

Brake Maintenance

Inspecting the Brakes

Brak es are a critical safety component of the v ehicle . As with all safety components , they should be closely inspected at regular inter v als to ensure optim um perfor mance and safety . T he follo wing inspections should be done ev er y 100 hours:

Figure 50

1. Brake uid reservoir 2. Minimum line

• Inspect the brak e shoes for w ear or damag e . If the lining (brak e pad) thic kness is less than 1/16 inc h (1.6 mm), the brak e shoes should be re placed.

• Inspect the bac king plate and other components for signs of ex cessi v e w ear or defor mation. If any defor mation is found, the appropriate components m ust be re placed.

• Chec k the brak e ﬂuid lev el; refer to Chec king the Brak e Fluid Lev el.

Checking the Brake Fluid Level

T he brak e ﬂuid reser v oir is ﬁlled and shipped from the factor y with DOT 3 brak e ﬂuid. Chec k the lev el before the engine is ﬁrst star ted and ev er y 8 hours or daily , thereafter .

1. P ark the mac hine on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. Look at the side of the reser v oir . T he lev el should be abo v e the Minim um line ( Figure 50 ). If the ﬂuid lev el is lo w , clean the area around the cap , remo v e the cap , and ﬁll the reser v oir to abo v e the Minim um line . Do not o v erﬁll.

Adjusting the Parking Brake

Chec k the parking brak e adjustment ev er y 200 hours .

1. Pr y the r ubber co v er off of the parking brak e .

2. Loosen the set screw securing the knob to the parking brak e lev er ( Figure 51 ).

Figure 51

1. Parking brake lever

2. Knob

3. R otate the knob until a force of 30-35 lb (133-156 N) is required to actuate the lev er .

4. Tighten the set screw and install the r ubber co v er .

3. Set screw

Belt Maintenance

Servicing the Drive Belt

Checking the Drive Belt

Chec k the condition and tension of the dri v e belt after the ﬁrst da y of operation and ev er y 200 operating hours thereafter .

Page 42

1. P ark the mac hine on a lev el surface , shift into Neutral, set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. Raise the bed and secure it with the prop rod.

3. R otate and inspect the belt ( Figure 52 ) for ex cessi v e w ear or damag e . R e place the belt if necessar y .

Figure 52

1. Drive belt 3. Secondary clutch

2. Primary clutch

Replacing the Drive Belt

Figure 53

1. Generator pivot bolt 2. Adjusting carriage bolt

3. W edg e a pr y bar betw een the engine mount and star ter . Loosen the n ut on the adjusting car riag e bolt ( Figure 53 ).

4. Tilt the star ter in the slot until the belt ﬂex es 1/4 inc h (6 mm) with 10 lb (44.5 N) of force .

5. Tighten the car riag e bolt n ut and remo v e the pr y bar . Tighten the star ter g enerator pi v ot bolt ( Figure 53 ).

1. R otate and route the belt o v er the secondar y clutc h ( Figure 52 ).

2. R emo v e the belt from the primar y clutc h ( Figure 52 ).

3. T o re place the belt, rev erse the procedure .

Adjusting the Starter Generator Belt

Chec k the tension of the star ter g enerator belt after the ﬁrst da y of operation and ev er y 200 operating hours thereafter .

1. P ark the mac hine on a lev el surface , set the parking brak e , tur n the ignition off , and remo v e the k ey .

2. Loosen the star ter g enerator pi v ot bolt ( Figure 53 ).

Cleaning

Washing the Vehicle

T he v ehicle should be w ashed as needed. Use w ater alone or with a mild deterg ent. A rag ma y be used, ho w ev er the hood will loose some of its luster .

Important: Pr essuriz ed w ater is not r ecommended when w ashing the machine. It may dama ge the electrical system, loosen impor tant decals, or w ash a w ay necessar y g r ease at friction points. A v oid ex cessi v e use of w ater , especiall y near the contr ol panel, engine, and batter y .

Page 43

Storage

1. P osition the mac hine on a lev el surface , set the parking brak e , stop the engine , and remo v e the ignition k ey .

2. Clean dir t and g rime from the entire mac hine , including the outside of the engine’ s cylinder head ﬁns and blo w er housing .

Important: Y ou can w ash the machine with mild detergent and w ater . Do not use high pr essur e w ater to w ash the machine. Pr essur e w ashing may dama ge the electrical system or w ash a w ay necessar y g r ease at friction points. A v oid ex cessi v e use of w ater , especiall y near the contr ol panel, lights, engine, and the batter y .

3. Inspect the brak es; refer to Inspecting the Brak es in Brak e Maintenance , pag e 41 .

4. Ser vice the air cleaner; refer to Ser vicing the Air Cleaner in Engine Maintenance , pag e 31 .

5. Grease the mac hine; refer to Lubrication , pag e 30 .

6. Chang e the engine oil; refer to Ser vicing Engine Oil in Engine Maintenance , pag e 31 .

7. Chec k the tire pressure; refer to Chec king the Tire Pressure in Dri v e System Maintenance , pag e 36 .

8. F or storag e o v er 30 da ys , pre pare the fuel system as follo ws:

A. Add a petroleum based

stabilizer/conditioner to fuel in the tank.

F ollo w mixing instr uctions from stabilizer man ufacturer . (1 oz. per g allon). Do not use an alcohol based stabilizer (ethanol or methanol).

Note: A fuel stabilizer/conditioner is most effecti v e when mix ed with fresh g asoline and used at all times .

B . R un the engine to distribute conditioned

fuel through the fuel system (5 min utes).

C . Stop the engine , allo w it to cool, and drain

the fuel tank. D . R estar t the engine and r un it until it stops . E. Chok e the engine . F . Star t and r un the engine until it will not

star t ag ain.

G . Dispose of fuel properly . R ecycle as per

local codes .

Important: Do not stor e sta biliz er/conditioned gasoline o v er 90 days

9. R emo v e the spark plugs and c hec k their condition; refer to Changing Spark Plugs in Engine Maintenance , pag e 31 .

10. With the spark plugs remo v ed from the engine , pour tw o tablespoons of engine oil into the spark plug hole .

11. Use the electric star ter to crank the engine and distribute the oil inside the cylinder .

12. Install the spark plugs and tighten to recommended tor que; refer to Changing Spark Plugs in Engine Maintenance , pag e 31 .

Note: Do not install the wire on the spark plug(s).

13. R emo v e the batter y from the c hassis , c hec k the electrolyte lev el, and c harg e it fully; refer to Ser vicing the Batter y in Electrical System Maintenance , pag e 34 .

Note: Do not connect the batter y cables to the batter y posts during storag e .

Important: T he batter y must be full y charged to pr ev ent it fr om fr eezing and being dama ged at temperatur es belo w 32 deg r ees F (0 deg r ees C). A full y charged batter y maintains its charge f or a bout 50 days at temperatur es lo w er than 40 deg r ees F (4 deg r ees C). If the temperatur es will be a bo v e 40 deg r ees F (4 deg r ees C), check the w ater lev el in the batter y and charge it ev er y 30 days.

14. Chec k and tighten all bolts , n uts , and screws . R e pair or re place any par t that is damag ed.

15. P aint all scratc hed or bare metal surfaces .

P aint is a v ailable from y our A uthorized Ser vice Dealer .

16. Store the mac hine in a clean, dr y g arag e or storag e area.

17. R emo v e the ignition k ey and put it in a safe place out of the reac h of c hildren.

18. Co v er the mac hine to protect it and k ee p it clean.

Page 44

Schematics

10A

10A 10 A

-M

RUN

OFF

START

104-6929

OPTIONS

MAG

P3-5

REGULA

TOR

ACCELERATOR

fields

VIO

BN/W

P3-1

(+)(-)

W/BU

HEADLIGHTS

-M

99-7402

IGNITION-SWITCH

POWERPOINT

VIO

P3-2

VOLTAGE

BN/W

armature

99-7438

99-7436

BACKUPALARM

80-9330

(-)

(+)

(-)

P3-3

LOWOIL

99-7404

P3-4

104-6927

99-7416

104-6928

99-7406

(INFORWARD)

PRESSURE

ENGINEOIL

LIGHT

SWITCH

95-8999

PRESSURE

99-7410

IGNITION

MODULE

SPARKPLUG

OPTIONAL FUSES

ENGINEGROUND

99-7405

STARTER/GENERA

TOR

HOUR

METER

94-4208

99-7411

(PEDAL NOT PUSHEDIN)

99-7407

HARNESS-WIRE,ENGINE(1

1HP)

HARNESS-WIRE,MAIN2100,1100

FRAMEGROUND

99-7403

REVERSESW.

99-7408

SOLENOID,STSP

STOP ----(-M)+(+M)

RUN----B+A

START ---B+A+S

G004986

Electrical Schematic (Rev. A)

Page 45

Page 46

Page 47

Page 48

The Toro General Commercial Products Warranty

A Two-Year Limited Warranty

Conditions and Products Covered

The Toro® Company and its afliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial Product (“Product") to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs rst. 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.

* P r o d u c t e q u i p p e d w i t h h o u r m e t e r

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, modied, 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, lters, belts, and certain sprayer components such as diaphragms, nozzles, and check valves, etc.

• Failures caused by outside inuence. Items considered to be

outside inuence 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. Toro will make the nal 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 tness 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 specic 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 dissatised with your Distributor’s service or have difculty obtaining guarantee information, contact the Toro importer. If all other remedies fail, you may contact us at Toro Warranty Company.

374-0031 Rev C