Toro 07277, Workman 2110, 07277TC Operator's Manual

FormNo.3356-924RevC

Workman

ModelNo.07277—SerialNo.270000001andUp

ModelNo.07277TC—SerialNo.270000001andUp

®

2110UtilityVehicle

Registeratwww.T oro.com.OriginalInstructions(EN)

Warning

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Important:Thisengineisnotequippedwitha
sparkarrestermufer.ItisaviolationofCalifornia
PublicResourceCodeSection4442touseoroperate
theengineonanyforest-covered,brush-covered,or
grass-coveredland.Otherstatesorfederalareas
mayhavesimilarlaws.

ThissparkignitionsystemcomplieswithCanadian
ICES-002.

Theenclosed

Engine Owner’ s Man ual

issupplied
forinformationregardingtheUSEnvironmental
ProtectionAgency(EPA)andtheCalifornia
EmissionControlRegulationofemissionsystems,
maintenance,andwarranty.Replacementsmaybe
orderedthroughtheenginemanufacturer.

Introduction

Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.

YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.

Wheneveryouneedservice,genuineToroparts,
oradditionalinformation,contactanAuthorized
ServiceDealerorToroCustomerServiceandhave
themodelandserialnumbersofyourproductready .
Figure1identiesthelocationofthemodelandserial
numbersontheproduct.Writethenumbersinthe
spaceprovided.

©2007—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420

Contactusatwww.Toro.com.

2

PrintedintheUSA.

AllRightsReserved

Contents

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

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

SafeOperatingPractices.......................................4

BeforeOperating.................................................4

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

Maintenance.........................................................7

SoundPressure.....................................................7

Vibration..............................................................7

SafetyandInstructionalDecals.............................8

Setup..........................................................................10

1InstallingtheWheels........................................10

2InstallingtheSteeringWheel............................11

3InstallingtheBumper.......................................11

4InstallingtheSeats...........................................11

5InstallingtheHitch..........................................12

6InstallingtheCargoBox...................................12

7ActivatingtheBattery......................................13

8AdjustingtheFrontWheelToe-in.....................14

9ReadingtheManualandViewingtheSafety

Video.............................................................14

ProductOverview......................................................16

Controls.............................................................16

Specications.....................................................19

Attachments/Accessories...................................19

Operation...................................................................19

ThinkSafetyFirst...............................................19

Pre-StartingChecks............................................19

CheckingtheEngineOil.....................................19

CheckingtheBrakeFluidLevel...........................20

CheckingtheTirePressure.................................20

AddingFuel.......................................................20

CheckingtheTransmissionOilLevel..................21

StartingtheEngine.............................................21

StoppingtheVehicle...........................................21

ParkingtheV ehicle.............................................21

OperatingtheCargoBox....................................22

BreakinginaNewVehicle..................................23

LoadingtheCargoBox.......................................23

TransportingtheVehicle.....................................23

TowingtheVehicle.............................................23

TowingaTrailer..................................................24

Maintenance...............................................................25

RecommendedMaintenanceSchedule(s)................25

DailyMaintenanceChecklist...............................25

PremaintenanceProcedures....................................27

MaintainingtheVehicleunderSpecial

OperatingConditions.....................................27

JackingtheVehicle..............................................27

Lubrication.............................................................28

AddingGrease...................................................28

EngineMaintenance...............................................28

ServicingtheAirCleaner....................................28

ServicingtheEngineOil.....................................29

ServicingtheSparkPlugs....................................30

FuelSystemMaintenance.......................................31

InspectingFuelLinesandConnections...............31

ReplacingtheFuelFilter.....................................31

ElectricalSystemMaintenance................................31

ReplacingtheFuses............................................31

ReplacingtheHeadlights....................................31

ServicingtheBattery...........................................32

DriveSystemMaintenance.....................................34

CheckingandAdjustingNeutral.........................34

InspectingtheTires............................................34

AdjustingtheFrontSuspension..........................34

AdjustingFrontWheelToe-In............................35

MaintainingthePrimaryDriveClutch.................36

ChangingtheTransaxleFluid..............................37

CoolingSystemMaintenance..................................38

CleaningtheEngineCoolingAreas.....................38

BrakeMaintenance.................................................38

InspectingtheBrakes.........................................38

CheckingtheBrakeFluidLevel...........................38

AdjustingtheParkingBrake................................38

BeltMaintenance....................................................39

ServicingtheDriveBelt......................................39

AdjustingtheStarterGeneratorBelt...................39

Cleaning.................................................................40

WashingtheV ehicle............................................40

Storage.......................................................................41

Schematics.................................................................42

3

Safety

Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalertsymbol,whichmeans
Caution,Warning,orDanger—“personalsafety
instruction.”Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.

Supervisors,operators,andservicepersonsshouldbe
familiarwiththefollowingstandardsandpublications
(thematerialmaybeobtainedfromtheaddressshown):

•FlammableandCombustibleLiquidsCode:
ANSI/NFPA30

•NationalFireProtectionAssociation:

ANSI/NFPA#505;PoweredIndustrialTrucks,
NationalFirePreventionAssociation,Barrymarch
Park,Quincy ,Massachusetts02269U.S.A.

•ANSI/ASMEB56.8PersonalBurdenCarriers

AmericanNationalStandardsInstitute,Inc.,1430
Broadway,NewYork,NewYork10018U.S.A.

•SAEJ2258LightUtilityVehicle

SAEInternational,400CommonwealthDrive,
Warrendale,PA15096-0001U .S.A.

•ANSI/UL558;InternalCombustionEngine
PoweredIndustrialTrucks

AmericanNationalStandardsInstitute,Inc.,1430
Broadway,NewYork,NewYork10018U.S.A.

or

UnderwritersLaboratories,333PngstenRoad,
Northbrook,Illinois60062U .S.A.

BeforeOperating

•Operatethemachineonlyafterreadingand
understandingthecontentsofthismanual.

•Neverallowchildrentooperatethevehicle.Anyone
whooperatesthevehicleshouldhaveamotor
vehiclelicense.

•Neverallowotheradultstooperatethevehicle
withoutrstreadingandunderstandingtheOperator’ s
Manual.Onlytrainedandauthorizedpersonsshould
operatethisvehicle.Makesurethatalloperators
arephysicallyandmentallycapableofoperatingthe
vehicle.

•Thisvehicleisdesignedtocarryonlyyou,the
operator,andonepassengerintheseatprovidedby
themanufacturer.Nevercarryanyotherpassengers
onthevehicle.

•Neveroperatethevehiclewhenundertheinuence
ofdrugsoralcohol.Evenprescriptiondrugsand
coldmedicinescancausedrowsiness.

•Donotdrivethevehiclewhenyouaretired.Besure
totakeoccasionalbreaks.Itisveryimportantthat
youstayalertatalltimes.

•Becomefamiliarwiththecontrolsandknowhowto
stoptheenginequickly.

•Keepallshields,safetydevices,anddecalsinplace.
Ifashield,safetydevice,ordecalismalfunctioning,
illegible,ordamaged,repairorreplaceitbefore
operatingthemachine.

•Alwayswearsubstantialshoes.Donotoperate
themachinewhilewearingsandals,tennisshoes
orsneakers.Donotwearloosettingclothingor
jewelrywhichcouldgetcaughtinmovingpartsand
causepersonalinjury.

SafeOperatingPractices

TheWorkmanisanoff-highwayvehicleonly
andisnotdesigned,equipped,ormanufactured
foruseonpublicstreets,roads,orhighways.

Supervisor’sResponsibilities

•Makesurethatoperatorsarethoroughlytrainedand
familiarwiththeOperator’sManualandalllabelson
thevehicle.

•Besuretoestablishyourownspecialproceduresand
workrulesforunusualoperatingconditions(e.g.
slopestoosteepforvehicleoperation).

•Wearingsafetyglasses,safetyshoes,longpantsanda
helmetisadvisableandrequiredbysomelocalsafety
andinsuranceregulations.

•Avoiddrivingwhenitisdark,especiallyinunfamiliar
areas.Ifyoumustdrivewhenitisdark,besure
todrivecautiously,usetheheadlights,andeven
consideraddingadditionallights.

•Beextremelycarefulwhenoperatingaroundpeople.
Alwaysbeawareofwherebystandersmightbe.

•Beforeoperatingthevehicle,alwayscheckthe
designatedareasofthevehiclethatarestatedinthe
pre-startingsectionofthismanual.Ifsomething
iswrong,donotusethevehicle.Makesurethat
theproblemiscorrectedbeforethevehicleor
attachmentisoperated.

•Sincegasolineishighlyammable,handleitcarefully.

4

–Useanapprovedgasolinecontainer.

–Donotremovethecapfromthefueltankwhen

theengineishotorrunning.

–Donotsmokewhilehandlinggasoline.

–Fillthefueltankoutdoors,andllittoabout

1inch(25mm)belowthetopofthetank(the
bottomofthellerneck).Donotoverllit.

–Wipeupanyspilledgasoline.

Operation

Engineexhaustcontainscarbonmonoxide,
whichisanodorless,deadlypoisonthatcan
killyou.

Donotrunengineindoorsorinanenclosed
area.

•Theoperatorandpassengershouldremainseated
wheneverthevehicleisinmotion.Theoperator
shouldkeepbothhandsonthesteeringwheel
wheneverpossible,andthepassengershoulduse
thehandholdsprovided.Keepyourarmsandlegs
withinthevehiclebodyatalltimes.

•Driveslowerandturnlesssharplywhenyouare
carryingapassenger.Rememberyourpassengermay
notbeexpectingyoutobrakeorturnandmaynot
beready .

•Alwayswatchoutforandavoidlowoverhangssuch
astreelimbs,doorjambs,andover-headwalkways.
Makesurethereisenoughroomoverheadtoeasily
clearthevehicleandyourhead.

•Failuretooperatethevehiclesafelymayresultinan
accident,tipoverofthevehicle,andseriousinjury
ordeath.Drivecarefully .Topreventtippingorloss
ofcontrol:

–Useextremecaution,reducespeed,andmaintain

asafedistancearoundsandtraps,ditches,creeks,
ramps,unfamiliarareas,oranyareasthathave
abruptchangesingroundconditionsorelevation.

–Watchforholesorotherhiddenhazards.

–Useextracautionwhenoperatingthevehicleon

wetsurfaces,inadverseweatherconditions,at
higherspeeds,orwithafullload.Stoppingtime
anddistancewillincreasewithafullload.

–Avoidsuddenstopsandstarts.Donotgofrom

reversetoforwardorforwardtoreversewithout
rstcomingtoacompletestop.

–Slowdownbeforeturning.Donotattempt

sharpturnsorabruptmaneuversorotherunsafe
drivingactionsthatmaycausealossofvehicle
control.

–Whendumping,donotletanyonestandbehind

thevehicleanddonotdumptheloadonanyone’s
feet.Releasethetailgatelatchesfromthesideof
thebox,notfrombehind.

–Onlyoperatethevehiclewhenthecargoboxis

downandlatched.

–Beforebackingup,looktotherearandensure

thatnooneisbehindyou.Backupslowly.

–Watchoutfortrafcwhenyouarenearor

crossingroads.Alwaysyieldtherightofway
topedestriansandothervehicles.Thisvehicle
isnotdesignedforuseonstreetsorhighways.
Alwayssignalyourturnsorstopearlyenough
sothatotherpeopleknowwhatyouplantodo.
Obeyalltrafcrulesandregulations.

–Theelectricalandexhaustsystemsofthevehicle

canproducesparkscapableofignitingexplosive
materials.Neveroperatethevehicleinornearan
areawherethereisdustorfumesintheairwhich
areexplosive.

–Ifyouareeverunsureaboutsafeoperation,stop

workandaskyoursupervisor.

•Donottouchtheengineormuferwhiletheengine
isrunningorsoonafterithasstopped.Theseareas
maybehotenoughtocauseburns.

•Ifthemachineevervibratesabnormally,stop
immediately,waitforallmotiontostop,andinspect
thevehiclefordamage.Repairalldamagebefore
commencingoperation.

•Beforegettingoffoftheseat:

1.Stopthemovementofthemachine.

2.Settheparkingbrake.

3.TurntheignitionkeytoOff.

4.Removetheignitionkey.

Note:Ifthevehicleisonanincline,blockthe
wheelsaftergettingoffofthevehicle.

Braking

•Slowdownbeforeyouapproachanobstacle.This
givesyouextratimetostoporturnaway.Hitting
anobstaclecandamagethevehicleanditscontents.
Moreimportant,itcaninjureyouandyourpassenger.

•GrossVehicleWeight(GVW)hasamajorimpacton
yourabilitytostopand/orturn.Heavyloadsand
attachmentsmakeavehiclehardertostoporturn.
Theheaviertheload,thelongerittakestostop.

5

•Decreasethevehiclespeedifthecargoboxhasbeen
removedandthereisnoattachmentonthevehicle.
Thebrakingcharacteristicschangeandfaststops
maycausetherearwheelstolockup,whichmay
affectthecontrolofthevehicle.

•Turfandpavementaremuchmoreslipperywhen
theyarewet.Itcantake2to4timesaslongtostop
onwetsurfacesasondrysurfaces.Ifyoudrive
throughstandingwaterdeepenoughtogetthe
brakeswet,theywillnotworkwelluntiltheyare
dry.Afterdrivingthroughwater,youshouldtestthe
brakestomakesuretheyworkproperly .Iftheydo
not,driveslowlywhileputtinglightpressureonthe
brakepedal.Thiswilldrythebrakesout.

topreventitfromshiftingandtakeextracarewhen
haulingloadsthatshifteasily(liquid,rock,sand,etc.).

•Avoidstoppingonhills,especiallywithaload.
Stoppingwhilegoingdownahillwilltakelonger
thanstoppingonlevelground.Ifthevehiclemust
bestopped,avoidsuddenspeedchanges,whichmay
initiatetippingorrollingofthevehicle.Donotslam
onthebrakeswhenrollingbackward,asthismay
causethevehicletooverturn.

•Westronglyrecommendinstallingtheoptional
ROPSKitwhenoperatingonhillyterrain.

OperatingonRoughTerrain

OperatingonHills

Operatingthevehicleonahillmaycause
tippingorrollingofthevehicle,ortheengine
maystallandyoucouldloseheadwayonthe
hill.Thiscouldresultinpersonalinjury.

•Donotacceleratequicklyorslamonthe
brakeswhenbackingdownahill,especially
withaload.

•Iftheenginestallsoryouloseheadwayon
ahill,slowlybackstraightdownthehill.
Neverattempttoturnthevehiclearound.

•Operatethevehicleslowlyonahillanduse
caution.

•Avoidturningonahill.

•Reduceyourloadandthespeedofthe
vehicle.

•Avoidstoppingonhills,especiallywitha
load.

Theseextracautionsneedtobetakenwhenoperating
thevehicleonahill:

•Slowdownbeforestartingupordownahill.

•Iftheenginestallsoryoubegintoloseheadway
whileclimbingahill,graduallyapplythebrakesand
slowlybackstraightdownthehill.

•Turningwhiletravelingupordownhillscanbe
dangerous.Ifyouhavetoturnwhileonahill,do
itslowlyandcautiously.Nevermakesharporfast
turns.

•Heavyloadsaffectstability.Reducetheweightofthe
loadandyourspeedwhenoperatingonhillsorif
theloadhasahighcenterofgravity.Securetheload

Reducespeedandloadwhenoperatingonroughterrain,
unevenground,andnearcurbs,holes,andothersudden
changesinterrain.Loadsmayshift,causingthevehicle
tobecomeunstable.

WestronglyrecommendinstallingtheoptionalROPS
Kitwhenoperatingonroughterrain.

Suddenchangesinterrainmaycauseabrupt
steeringwheelmovement,possiblyresultingin
handandarminjuries.

•Reduceyourspeedwhenoperatingonrough
terrainandnearcurbs.

•Gripthesteeringwheellooselyaroundthe
perimeter.Keepyourhandsclearofthe
steeringwheelspokes.

LoadingandDumping

Theweightandpositionofthecargoandpassenger
canchangethevehiclecenterofgravityandvehicle
handling.T oavoidlossofcontrolandpersonalinjury,
followtheseguidelines:

•Donotcarryloadswhichexceedtheloadlimits
describedonthevehicleweightlabel;referto
SpecicationsinProductOverview,page16,for
vehicleweightlimits.Theloadratingisforlevel
surfacesonly .

•Reducetheweightoftheloadwhenoperating
onhillsandroughterraintoavoidtippingor
overturningofthevehicle.

•Reducetheweightoftheloadifthecenterofgravity
ishigh.Itemssuchasbricks,fertilizer,orlandscape
timbersstackhigherinthebox.Thehigheraload
isstacked,themorelikelythevehicleistotipover.

6

Distributetheloadaslowaspossible,makingsure
thattheloaddoesnotaffectrearvisibility.

•Positiontheweightoftheloadevenlyfromsideto
side.Ifyoupositiontheloadtowardoneofthesides,
thevehicleismorelikelytotipoverwhileturning.

•Positiontheweightofaloadevenlyfromfrontto
back.Ifyoupositiontheloadbehindtherearaxle,
itwillreducetheweightonthefrontwheels.This
mayresultinalossofsteeringcontrolorcausethe
vehicletotipoveronhillsorbumpyterrain.

•Useextracautioniftheloadexceedsthedimensions
oftheboxandwhenhandlingoff-centerloadsthat
cannotbecentered.Keeploadsbalancedandsecure
topreventthemfromshifting.

•Alwayssecureloadssothattheydonotshift.Ifa
loadisnotsecured,oryouaretransportingaliquidin
alargecontainersuchasasprayer,theloadcanshift.
Thisshiftinghappensmostoftenwhileturning,
goingupordownhills,suddenlychangingspeeds,or
whiledrivingoverroughsurfaces.Shiftingloadscan
causethevehicletotipover.

Maintenance

•Onlyqualiedandauthorizedpersonnelshallbe
permittedtomaintain,repair,adjust,orinspectthe
vehicle.

•Beforeservicingormakingadjustmentstothe
machine,stoptheengine,settheparkingbrake,
andremovethekeyfromtheignitiontoprevent
someonefromaccidentallystartingtheengine.

•Tomakesurethattheentiremachineisingood
condition,keepallnuts,bolts,andscrewsproperly
tightened.

•Toreducethepotentialforre,keeptheengine
areafreeofexcessivegrease,grass,leaves,and
accumulationofdirt.

•Neveruseanopenametocheckthelevelor
leakageoffuelorbatteryelectrolyte.

•Iftheenginemustberunningtoperforma
maintenanceadjustment,keepyourhands,feet,
clothing,andanypartsofyourbodyawayfromthe
engineandanymovingparts.Keepeveryoneaway.

Theweightoftheboxmaybeheavy.Handsor
otherbodypartscouldbecrushed.

–Keephandsandotherbodypartsclearwhen

loweringthebox.

–Donotdumpmaterialsonbystanders.

•Neverdumpaloadedcargoboxwhilethevehicleis
sidewaysonahill.Thechangeinweightdistribution
maycausethevehicletooverturn.

•Whenoperatingwithaheavyloadinthecargobox,
reduceyourspeedandallowforsufcientbraking
distance.Donotsuddenlyapplythebrakes.Use
extracautiononslopes.

•Beawarethatheavyloadsincreaseyourstopping
distanceandreduceyourabilitytoturnquickly
withouttippingover.

•Therearcargospaceisintendedforloadcarrying
purposesonly ,notforpassengers.

•Neveroverloadyourvehicle.Thedecal(locatedon
therearframe)showsloadlimitsforthevehicle.
NeveroverloadtheattachmentsorexceedtheGross
VehicleWeight(GVW).

•Donotuseopenpansoffuelorammablecleaning
uidsforcleaningparts.

•Ifmajorrepairsareeverneededorassistanceis
required,contactanAuthorizedToroDistributor.

•Tobesureofoptimumperformanceandsafety,
alwayspurchasegenuineTororeplacementpartsand
accessories.Replacementpartsandaccessoriesmade
byothermanufacturerscouldbedangerous.Altering
thisvehicleinanymannerthatmayaffectvehicle
operation,performance,durability,oritsuse,may
resultininjuryordeath.Suchusecouldvoidthe
productwarranty.

SoundPressure

Thisunithasamaximumsoundpressurelevelatthe
operator’searof80dBA,basedonmeasurementsof
identicalmachinesperEN11094.

Vibration

Thisunitdoesnotexceedahand/armvibrationlevelof

2.5m/s
perEN1033.

Thisunitdoesnotexceedawholebodyvibration
levelof0.5m/s
machinesperEN1032.

2

,basedonmeasurementsofidenticalmachines

2

,basedonmeasurementsofidentical

7

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.

107-0699

1.Warning—readtheOperator’sManual.7.Ignition—Off

2.Collisionhazard—donotoperatethevehicleonpublicstreets,
roads,orhighways.

3.Fallinghazard—donotcarrypassengersinthecargobed.9.Tostarttheengine,sitontheoperator’sseat,releasethe

4.Fallinghazard—donotallowchildrentooperatethevehicle.10.Tostoptheengine,releasetheacceleratorpedal,setthe

5.Hourmeter

6.Headlights12.Horn

8.Ignition—On

parkingbrake,turntheignitionkeyon,pullthechokeleverout
(ifneeded),andpresstheacceleratorpedal.

parkingbrake,turntheignitionkeyoff,andremovethe
ignitionkey.

11.Electricalpower(powerpoint)

104-6581

1.Warning—readtheOperator’sManual.

2.Firehazard—beforefueling,stoptheengine.

3.Tippinghazard—receivetrainingbeforeoperatingthemachine,usecautionanddriveslowlywhileonslopes;driveslowlywhen
turning,keepthevehiclespeedunder19MPH(31km/h)whencarryingafullorheavyloadandwhendrivingonroughterrain.

4.Fallingandarm/leginjuryhazards—donotcarrypassengersinthecargobedandkeeparmsandlegsinsideofthevehicleatall
times.

26-7390

8

99-7345

1.Warning—readtheOperator’sManual.

2.Hotsurface/burnhazard—stayasafedistancefromthe
hotsurface.

3.Entanglementhazard,belt—stayawayfrommovingparts

4.Crushinghazard,cargobox—usetheproprodtosupport
thecargobed

99-7952

1.Choke

2.Reverse4.Forward

3.Neutral

99-7954

1.Warning—readtheOperator’sManual.

2.Fallinghazard—donotcarrypassengersinthecargobed.

3.Explosionhazard,staticdischargeintofuelcontainer—do
notllfuelcontainersinthecargobed;placefuelcontainers
onthegroundbeforelling.

104–6591

1.ReadtheOperator’sManual.

2.Themaximumcombinedoperatorandpassengerweightis
400lb.(181kg).

3.Themaximumcargoweightis1250lb.(567kg).

4.Thebaseweightofthevehicleis1 100lb.(500kg).

5.Themaximumgrossvehicleweightis2750lb.(1247kg).

99-7352

1.ReadtheOperator’sManualforinformationonfuses.

2.10amp.fusefortheoptionalRoadLightKit

3.15amp.fusefortheoptionalRearLiftKit

4.10amp.fuse—open

5.10amp.fusefortheheadlights

6.10amp.fusefortheignitionsystem

7.15amp.fusefortheoptionalElectricBedLiftKit

99-7350

1.Maximumtongueweightis50lb(23kg);maximumtrailer
weightis400lb(181kg).

9

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

1

2

3

4
5

6

7

8

9

Wheelassembly4

Steeringwheel

Bumper1

Seat

Hitch1

Cargobox
Right-handpivotbracket1
Left-handpivotbracket
Flangeheadscrew(3/8x1inch)
Bolt(5/16x3/4inch)
Flangenut(5/16inch)

Nopartsrequired

Nopartsrequired

Operator’sManual
EngineOperator’sManual
PartsCatalog
SafetyVideo
RegistrationCard
PredeliveryInspectionForm1
Key2

Qty.

Use

Installthewheels(Model07277TC
only).

1

2

1

1
4
1
1

–

–

1
1
1
1
1

Installthesteeringwheel(Model
07277TConly).

Installthebumper(Model07277TC
only).

Installtheseats(Model07277TConly).

Installthehitch(Model07277TConly).

Installthecargobox(Model07277TC
only).

Activatethebattery(Model07277TC
only).

Adjustthefrontwheeltoe-in.

ReadtheOperator’sManualandwatch
thevideobeforeoperatingthemachine.

Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.

1

InstallingtheWheels

Partsneededforthisprocedure:

4Wheelassembly

Procedure

Note:ThisprocedureisonlyneededforModelNo.

07277TC.

1.Removethefastenerssecuringthewheels.

2.Removetheshippingbracketsecuredtothewheel
studs.

3.Mountthewheelswiththepreviouslyremoved
fasteners(Figure3)andtorqueto45-65ft-lb
(61-88N-m).

10

3

InstallingtheBumper

Partsneededforthisprocedure:

Figure3

1.Wheelassembly

2.Wheelnut

3.Wheelstud(rearwheel
hubshown)

2

InstallingtheSteeringWheel

Partsneededforthisprocedure:

1

Steeringwheel

Procedure

Note:ThisprocedureisonlyneededforModelNo.

07277TC.

1.Removethenutandwasherfromthesteeringshaft.

2.Slidethesteeringwheelandwasherontotheshaft.
Positionthesteeringwheelontheshaftsothatthe
crossbeamishorizontalwhenthetiresarepointed
straightaheadandthethickerspokeofthesteering
wheelisdownward.

3.Securethesteeringwheeltotheshaftwiththenut
(Figure4).Torquethenutto18-22ft-lb(24-29N-m)

1Bumper

Procedure

Note:ThisprocedureisonlyneededforModelNo.

07277TC.

1.Removethe2bolts,washers,andnutssecuredtothe
frontoftheframe.

2.Alignthemountingholesandsecurethebumper
totheframewiththefastenerspreviouslyremoved
(Figure5).

Figure5

1.Bumper

Figure4

1.Steeringwheel

2.Nut4.Foamseal

3.Washer

4

InstallingtheSeats

Partsneededforthisprocedure:

2

Seat

Procedure

Note:ThisprocedureisonlyneededforModel

No.07277TC.

Inserttheseatbracketintotheseatbaseopeningand
pivottheseatdownward(Figure6).

11

Figure6

1.Seatbracket2.Seatbase

Figure7

1.Hitch

6

InstallingtheCargoBox

Partsneededforthisprocedure:

5

InstallingtheHitch

Partsneededforthisprocedure:

1Hitch

Procedure

Note:ThisprocedureisonlyneededforModelNo.

07277TC.

1.Removethe4boltsandnutsfromtheinsiderear
oftheframe.

2.Alignthehitchwiththemountingholesonthe
frame.Securethehitchwiththescrewsandnuts
(Figure7).

1

Cargobox

1Right-handpivotbracket

1

Left-handpivotbracket

4

Flangeheadscrew(3/8x1inch)

1

Bolt(5/16x3/4inch)

1

Flangenut(5/16inch)

Procedure

Note:ThisprocedureisonlyneededforModel

No.07277TC.

1.Positionthecargoboxontotheframe.Thecargo
boxmustlayatandbecentered.

2.Mountthelefthandpivotbrackettotheleftrear
corneroftheframewith2angeheadscrews(3/8x
1inch).PositionthebracketasshowninFigure8.

12

Figure8

1.Pivotbracket

3.Slidethecargoboxmountingholeontothepivot
bracket(Figure9).

Figure10

1.Proprod

2.Proprodclip

7.Tightentheboltandsecuretheothersideoftheclip
withanewbolt(5/16x3/4inch)andangenut
(5/16inch)(Figure10).

8.Lowerthecargobox.

3.Bolt(5/16x3/4inch)

4.Flangenut(5/16inch)

7

ActivatingtheBattery

NoPartsRequired

Procedure

None

Figure9

1.Cargobox3.Cargoboxmountinghole

2.Pivotbracket

4.Inserttherighthandpivotbracketintothemounting
holeinthecargoboxandthenmountittotheframe.

5.Haveanotherpersonhelptoraisethecargobox.

6.Loosentheboltsecuringtheproprodcliptothe
frameuntilyoucanslidetheJ-hookendoftheprop
rodundertheclip(Figure10).

Note:ThisprocedureisonlyneededforModelNo.
07277TC.

Ifthebatteryisnotlledwithelectrolyteoractivated,it
mustberemovedfromthevehicle,lledwithelectrolyte,
andcharged.Bulkelectrolytewith1.260specicgravity
mustbepurchasedfromalocalbatterysupplyoutlet.

1.Removethebatteryhold-downandliftthebattery
outofthebatterybase.

Batteryelectrolytecontainssulfuricacidwhich
isadeadlypoisonandcausessevereburns.

•Donotdrinkelectrolyteorallowittocontact
yourskin,eyesorclothing.Wearsafety
glassestoshieldyoureyesandrubbergloves
toprotectyourhands.

•Fillthebatterywherecleanwaterisalways
availableforushingtheskin.

2.Removethellercapsfromthebatteryandslowly
lleachcelluntilelectrolyteisjustabovetheplates.

13

3.Replacethellercapsandconnecta3to4amp.
batterychargertothebatteryposts.Chargethe
batteryatarateof3to4amperesfor4to8hours
(12volts).Donotoverchargethebattery.

Chargingthebatteryproducesgassesthatcan
explode.

Neversmokenearthebatteryandkeepsparks
andamesawayfrombattery.

4.Whenthebatteryischarged,disconnectthecharger
fromtheelectricaloutletandbatteryposts.

5.Removethellercaps.Slowlyaddelectrolyteto
eachcelluntilelectrolyteisuptothellline.Install
thellercaps.

Important:Donotoverllthebattery.
Electrolytewilloverowontootherpartsofthe
vehicleandseverecorrosionanddeterioration
willresult.

Ifthevehiclewillberunwithmediumtoheavyloads
mostofthetime,setthetoe-inonthehighsideof
therecommendedamount.Ifitisgoingtoberun
withalightloadmostofthetime,setthetoe-inon
thelowsideoftherecommendedamount.

1.Measurethedistancebetweenbothofthefronttires
attheaxleheightatboththefrontandrearofthe
fronttires(Figure11).Axtureoralignmentgauge
isneededfortherearmeasurementofthefronttires
ataxleheight.Usethesamextureoralignment
gaugetoaccuratelymeasurethefrontofthefront
tiresataxleheight(Figure11).

6.Installthebattery;refertoInstallingtheBattery,
ElectricalSystemMaintenance,page31.

8

AdjustingtheFrontWheel
Toe-in

NoPartsRequired

Procedure

Thetoe-inshouldbe1/8-5/8inch(3-16mm)withthe
followingparameters:

•Thetirepressureshouldbeat12psi(83kPa).

•Therideheightshouldbecorrectbeforesettingthe
toe-in;refertotheAdjustingtheFrontSuspension
procedureinMaintenance,page25.

•Thevehicleshouldbedrivenbackandforthafew
timestorelaxtheA-arms.

•Measurethetoe-inwiththewheelsfacingstraight
aheadanda175-225lb(79-102kg)operatorinthe
driver’sseat.

Note:Thedrivershoulddriveuptothe
measurementareaandstayseatedinthevehicle
whilethemeasurementisbeingtaken.

Figure11

1.Tirecenterline-back4.Fixture

2.Tirecenterline-front

3.Axlecenterline

2.Ifthemeasurementdoesnotfallwithinthespecied
range(refertothedimensionsandparametersatthe
beginningofthisprocedure),loosenthejamnutsat
bothendsofthetierods(Figure12).

1.Jamnut2.Tierod

3.Rotatebothtierodstomovethefrontofthetire
inwardoroutward.

4.Tightenthetierodjamnutswhentheadjustmentis
correct.

5.Ensurethatthereisfulltravelofthesteeringwheel
inbothdirections.

5.Axlecenterlinedistance

6.6inches(15cm)ruler

Figure12

14