Toro 07287TC, 07288TC, Workman e2060, Workman e2065, 07280 Operator's Manual

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Form No. 3356-406 Rev A

G004117

Workman® e2060 and e2065 Utility Vehicles

Model No. 07287TC —Serial No. 270000001 and Up Model No. 07288TC —Serial No. 270000001 and Up

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 .

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.

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.

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

Contents

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

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

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

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Handling and Ser vicing

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

1 Installing the R ear W heels . . . . . . . . . . . . . . . 12

2 Installing the F ront W heels . . . . . . . . . . . . . . 13

3 Installing the Steering W heel . . . . . . . . . . . 13

4 Installing the Bumper . . . . . . . . . . . . . . . . . . . . . . 14

5 Installing the Seats . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6 Installing the Hitc h . . . . . . . . . . . . . . . . . . . . . . . . . 14

7 Installing the Batteries . . . . . . . . . . . . . . . . . . . . . 15

8 Installing the Carg o Bo x . . . . . . . . . . . . . . . . . . 17

9 Chec king the Tire Pressure . . . . . . . . . . . . . . 17

10 Setting the Charg er V oltag e . . . . . . . . . . . 18

11 Adjusting the F ront W heel

T oe-in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

12 R eading the Man ual and Viewing

the Safety Video . . . . . . . . . . . . . . . . . 19

Product Ov er view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Speciﬁcations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

T hink Safety First . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Pre-Star ting Chec ks . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Chec king the Tire Pressure . . . . . . . . . . . . . . . . . 24

Operating the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . 24

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

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

Understanding and Using the

Batter y System . . . . . . . . . . . . . . . . . . . 24

Operating the Carg o Bo x . . . . . . . . . . . . . . . . . . . 26

Breaking in a New V ehicle . . . . . . . . . . . . . . . . . . 27

Loading the Carg o Bo x . . . . . . . . . . . . . . . . . . . . . . 27

T ranspor ting the V ehicle . . . . . . . . . . . . . . . . . . . . 27

T o wing the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

T o wing a T railer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

R ecommended Maintenance

Sc hedule(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Daily Maintenance Chec klist . . . . . . . . . . . . . . 30

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

Hea vy Duty Operation . . . . . . . . . . . . . . . . . . . . . . 30

J ac king the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

W here to Add Grease . . . . . . . . . . . . . . . . . . . . . . . . 31

Electrical System Maintenance . . . . . . . . . . . . . . . . . . . 32

Maintaining the Batteries . . . . . . . . . . . . . . . . . . . 32

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

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

Dri v e System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 35

Inspecting the Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Adjusting the F ront

Suspension . . . . . . . . . . . . . . . . . . . . . . . . 35

Adjusting F ront W heel T oe-In . . . . . . . . . . . 36

Chec king the T ransaxle Oil

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Brak e Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Inspecting the Brak es . . . . . . . . . . . . . . . . . . . . . . . . . 37

Chec king the Brak e Fluid

Lev el . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Adjusting the P arking Brak e . . . . . . . . . . . . . . . 38

Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

W ashing the V ehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Storag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

T roubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Sc hematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

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):

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.

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.

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).

Note: T his v ehicle has a super visor speed limit switc h to allo w y ou to limit the maxim um speed that the operator can dri v e the v ehicle . R efer to Super visor Speed Limit Switc h section in Operation , pag e 24 .

Before Operating

• Operate the v ehicle 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 .

• 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 v ehicle 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 v ehicle .

• Alw a ys w ear substantial shoes . Do not operate the v ehicle 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 .

• 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.

Operation

• 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.

• 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 system of the v ehicle

can produce sparks capable of 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 .

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

stop w or k and ask y our super visor .

• If the v ehicle 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 v ehicle .

2. Set the parking brak e .

3. T ur n the k ey to Off .

4. R emo v e the 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 on Hills

Operating the v ehicle on a hill may cause tipping or r olling of the v ehicle, or the motor 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 operate on ex cessi v el y steep slopes.

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

• If the batteries r un lo w 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 batteries r un lo w 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 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.

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 20 , for v ehicle w eight limits . T he load rating is for lev el surf aces onl y .

• 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 .

• 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.

Handling and Servicing Batteries

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

• Alw a ys disconnect and remo v e a batter y cable before ser vicing any electrical components .

• Disconnecting any batter y cable will inhibit operation of the electrical system.

• Batter y electrolyte contains sulfuric acid. Sulfuric acid produces h y drog en g as whic h, in the right propor tions is explosi v e .

– Alw a ys ser vice , store , and c harg e the

v ehicle in a w ell v entilated area.

– K ee p sparks and open ﬂames a w a y from

the batteries .

– Do not smok e near the batteries .

– Nev er use an open ﬂame to c hec k the lev el

or leakag e of batter y electrolyte .

• Use caution when handling and w orking around electrolyte . T he sulfuric acid in electrolyte can bur n skin and damag e clothing . Fur ther more , it can be emitted as a g as that can damag e y our lungs .

– W ear proper eye , hand, and face protection.

– 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).

– Do not lean o v er the batteries at any time .

– A v oid breathing batter y fumes .

– Fill the batteries where clean w ater is alw a ys

a v ailable for ﬂushing the skin.

– If y ou g et electrolyte on y our skin or eyes ,

ﬂush the affected area for 20 min utes with clean w ater . R emo v e acid soak ed clothing . Seek medical attention immediately .

– K ee p c hildren and pets a w a y from the

batteries and electrolyte .

• Electrolyte is v er y poisonous .

– Do not drink electrolyte .

– If electrolyte is sw allo w ed, do not induce

v omiting; instead, drink larg e amounts of w ater or milk follo w ed b y milk of magnesia, beaten ra w eg gs , or v eg etable oil. Get medical attention immediately .

– K ee p c hildren and pets a w a y from the

batteries and electrolyte .

• W hen not ﬁlling the batteries , k ee p the batter y v ent caps tight on the batteries . Nev er operate the v ehicle if any of the v ent caps are missing or damag ed.

• W hen remo ving or installing the batteries , do not allo w the batter y ter minals to touc h any 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 . R emo v e all jew elr y and w atc hes before ser vicing the batteries .

• Do not c hec k a batter y c harg e b y placing a metal object across the posts . T his will cause sparks whic h can cause an explosion.

• Alw a ys k ee p the batter y retainers in place to protect and secure the batteries .

• R ead and understand the c harging instr uctions before c harging the batteries; refer to Charging the Batteries in Maintenance , pag e 29 . Also , tak e the follo wing precautions and actions when c harging the batteries:

– T ur n the v ehicle On/Off switc h to Off

before connecting the c harg er to a po w er source .

– Use only the batter y c harg er supplied with

the v ehicle to c harg e the batteries .

– Do not c harg e a damag ed or frozen batter y .

– Alw a ys unplug the A C po w er cord from the

po w er outlet before unplug ging it from the v ehicle c harging rece ptacle to a v oid sparks .

– If during c harging a batter y g ets hot, begins

emitting larg e amounts of g asses , or spews electrolyte , immediately disconnect the c harg er po w er cord from the po w er outlet. Ha v e the v ehicle ser viced b y an A uthorized Ser vice Dealer before using it ag ain.

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

• 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 .

General Maintenance

• 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 v ehicle , stop the v ehicle , set the parking brak e , and remo v e the k ey to prev ent someone from accidentally star ting it.

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

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.

1. Horn

2. Headlights

3. Battery/hour meter 6. Cargo bed lift

4. Light on, OK 7. Rear lift

5. Light blinking, read the Operator’s

Manual.

104-7214

8. Forward

9. Reverse

104–7215

1. Warning—read the Operator’s Manual.

2. Explosion hazard—no re, open ames, or smoking around batteries.

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 16 MPH (26 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.

104-7207

1. Poison hazard—read the Operator’s Manual.

2. Explosion hazard—no re, open ames, or smoking.

3. Caustic liquid/chemical burn hazard—to perform rst aid, ush with water.

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

99–7350

112-3049

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 800 lb (362 kg).

4. The base weight of the vehicle is 1500 lb (680 kg).

5. The maximum gross vehicle weight is 2700 lb (1225 kg).

107-0295

1. Warning—read the Operator’s Manual for more information on batteries; batteries contain lead, do not discard; disconnect the power cord from power source before driving vehicle.

2. Explosion hazard—no re, open ames, or smoking; avoid sparks.

107-0356

1. Warning—do not touch moving objects, fan; do not touch the hot surfaces; read the Operator’s Manual.

107-0257

1. Battery schematic

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.

107-0287

1. Vehicle fuse, 10A

2. For fuse service, read the

Operator’s Manual.

3. Open, 10A

4. Accessory fuse, 10A

Battery Symbols

Some or all of these symbols are on your battery

1. Explosion hazard 6. Keep bystanders a safe

2. No re, open ame, or smoking.

3. Caustic liquid/chemical burn hazard

4. Wear eye protection

5. Read the Operator’s

Manual.

distance from the battery.

7. Wear eye protection; explosive gases can cause blindness and other injuries

8. Battery acid can cause blindness or severe burns.

9. Flush eyes immediately with water and get medical help fast.

10. Contains lead; do not discard.

Setup

Loose Parts

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

Step

1 2 3 4 5 6

Wheel assembly

Steering wheel

Bumper 1

Seat 2

Hitch

Battery hold down Battery hold down rod Battery cables Battery tray pads Battery pad Flange nut (3/8 inch) Battery terminal protector spray 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)

Description

Qty.

2 2 7 4 1 2 1 1 1 1 4 1 1

Install the rear wheels.

Install the front wheels.

Install the steering wheel.

Install the bumper.

Install the seats.

Install the hitch.

Install the batteries.

Install the cargo box.

Use

9 10 11

No parts required

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

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

–

1 1 1 1 1

Check the tire pressure.

Set the charger voltage.

Adjust the front wheel toe-in.

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

Step

Installing the Rear Wheels

Parts needed for this step:

Wheel assembly

Procedure

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).

3. Apply thread loc k er (blue) to the screw threads .

4. Mount the wheels with the previously remo v ed fasteners ( Figure 4 ) and tor que the bolts to 135-165 ft-lb (183-224 N ⋅ m).

Figure 4

1. Tire and wheel assembly 4. Large washer

2. Spindle

3. Small washer

5. Screw

6. Dust cap

Step

Figure 3

1. Wheel assembly

2. Wheel nut

Step

Installing the Front Wheels

Parts needed for this step:

3. Wheel stud (rear wheel hub shown)

Installing the Steering Wheel

Parts needed for this step:

Steering wheel

Procedure

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 w asher and n ut ( Figure 5 ). T or que the n ut to 18-22 ft-lb (24-29 N ⋅ m)

Wheel assembly

Procedure

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

2. R emo v e the shipping brac k et from the spindles .

Step

Installing the Seats

Parts needed for this step:

2 Seat

Figure 5

1. Steering wheel 3. Washer

2. Nut

4. Foam seal

Step

Installing the Bumper

Parts needed for this step:

1 Bumper

Procedure

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 6 ).

Procedure

Inser t the seat brac k et into the seat base opening and pi v ot the seat do wnw ard ( Figure 7 ).

Figure 7

1. Seat bracket 2. Seat base

Figure 6

1. Bumper

Step

Installing the Hitch

Parts needed for this step:

Hitch

Procedure

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 8 ).

Installing the Batteries

Parts needed for this step:

Battery hold down

Battery hold down rod

Battery cables

Battery tray pads

Battery pad

Flange nut (3/8 inch)

Battery terminal protector spray

Procedure

T oro recommends the use of either T rojan T105 or T145, or US . Batter y US2200 or US145.

Batter y Speciﬁcation: 6V 225AH @ 20hr rate Dimensions: (LxWxH) (10-1/4 x 7-1/8 x 11-1/4 inc hes)

1. T ur n the k ey switc h to the Off position and remo v e the k ey .

1. Hitch

2. Left pivot bracket

2. Install the batter y tra y pads into the rear frame assembly as sho wn Figure 9 .

Figure 8

Figure 9

1. Battery tray pads

2. Rear frame assembly

3. R emo v e the adhesi v e strip from the bac k of the batter y pad and install it to the front inside face of the rear frame as sho wn in Figure 10 .

Note: T he pad should be appro ximately 1/4 inc h belo w the bottom edg e of the upper set of cut-out holes ( Figure 10 ).

Figure 10

1. Battery pad 3. Upper cut-out holes

2. Front inside face

4. Install the batteries as sho wn in Figure 11 . Note: P a y attention to the batter y polarity

when installing the new batteries ( Figure 11 ).

Figure 11

5. Install the batter y retainers and tor que the n uts to 150 to 200 in-lb (17 to 22 N ⋅ m).

6. Connect the batteries tog ether with the batter y cables included in loose par ts , as sho wn in Figure 11 . Ensure the cable routing does not allo w cables to contact any shar p edg es .

Important: Check all high cur r ent batter y connections to ensur e they ha v e been pr oper l y secur ed.

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 ensur e the batter y polarity when making connections.

Batteries can gi v e y ou a po w erful electrical shock.

• Use tools with plastic handles or wrap the handles of metal tools with electrical tape.

• Be car eful not to contact both a positi v e ter minal and a negati v e ter minal at the same time.

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 11 ).

8. Connect the long, red, main positi v e lead betw een the bank of batteries and the v ehicle ( Figure 11 ).

9. Connect the long, blac k, main neg ati v e lead betw een the bank of batteries and the v ehicle ( Figure 11 ).

Loose or impr oper l y secur ed batter y connections 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 ensur e the batter y polarity when making connections.

10. T or que the n uts securing all batter y cables to 120 to 180 inc h-lb (13.5 to 21 N ⋅ m).

11. Coat the batter y ter minals with T oro batter y ter minal protector .

12. Ensure that the r ubber boots on eac h batter y cable are securely seated o v er the batter y ter minals .

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)

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 . T or que the screws to 16 ft-lb (22 N ⋅ m).

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 13 ).

Figure 13

1. Prop rod

2. Prop rod clip

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

Procedure

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). T or que the screws to 16 ft-lb (22 N ⋅ m). P osition the brac k et as sho wn in Figure 8 .

3. Slide the carg o bo x mounting hole onto the pi v ot brac k et ( Figure 12 ).

7. Tighten the bolt and secure the other side of the clip with a new bolt (5/16 x 3/4 inc h) ( Figure 13 ).

8. Lo w er the carg o bo x.

Step

Checking the Tire Pressure

No Parts Required

Procedure

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 (55-152 kP a).

Figure 12

1. Cargo box 3. Cargo box mounting hole

2. Pivot bracket

T he air pressure needed is deter mined b y the pa yload car ried. Lo w er air pressure will pro vide less compaction, a smoother ride , and few er tire marks . Lo w er pressure should not be used for hea vy pa yloads at high speeds .

Higher pressures should be used for hea vier

220 200 100 120

G005241

pa yloads at higher speeds . Do not ex ceed the maxim um pressure .

occur . Contact y our A uthorized T oro Dealer to obtain the cor rect po w er cord if necessar y .

Step

Setting the Charger Voltage

No Parts Required

Procedure Important: T he incor r ect v olta ge setting on

the batter y charger can impair function and dama ge the charger .

Alw a ys mak e sure the c harg er v oltag e setting matc hes the v oltag e used to po w er the c harg er .

1. Locate the v oltag e selector on the rear of the c harg er ( Figure 14 ).

2. Adjust the v oltag e setting b y mo ving the switc h on the v oltag e selector upw ard or do wnw ard to c hang e the v oltag e setting ( Figure 14 ).

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).

• 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 29 .

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

Figure 14

1. Voltage selector 3. Switch

2. Voltage setting window 4. Voltages by switch position

Adjust the v oltag e setting b y mo ving the switc h on the v oltag e selector upw ard or do wnw ard to c hang e the v oltag e setting

Alw a ys use the appropriate po w er cord for the po w er outlet of the countr y or region c harging will

• 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 15 ). 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 15 ).

Figure 15

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

Step

Reading the Manual and Viewing the Safety Video

Parts needed for this step:

Operator’s Manual

Parts Catalog

Safety Video

Registration Card

Predelivery Inspection Form

2 Key

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 16 ).

Figure 16

1. Jam nut

2. Tie rod

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.

Procedure

• R ead the Operator’ s Manual .

• View the safety video .

• Fill out the registration card.

• Complete the Pr edeli ver y Inspection F or m .

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

Product Overview

G005085

Figure 17

1. Steering wheel

2. Parking brake 4. Charging receptacle 6. Cargo box

3. Towing tongue

5. Cargo box release lever

Controls

Accelerator Pedal

T he accelerator pedal ( Figure 18 ) gi v es y ou the ability to v ar y g round speed of the v ehicle . Pressing the pedal when the On/Off switc h is on star ts the motor . Pressing the pedal far ther increases g round speed. R eleasing the pedal will slo w the v ehicle and the motor will stop r unning .

Figure 18

1. Accelerator pedal 2. Brake pedal

Brake Pedal

T he brak e pedal is used to stop or slo w the v ehicle ( Figure 18 ).

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 19 ). W henev er the v ehicle is shut off or when lea ving the v ehicle , 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 .

side . F or detailed infor mation on the batter y meter , refer to Understanding and Using the Batter y System in Operation , pag e 24 .

T he hour meter is located at the bottom of the LCD screen. It logs operating hours whenev er the k ey is in the On position and the v ehicle is in motion.

Figure 19

1. Parking brake lever

On/Off Switch

T he On/Off switc h ( Figure 20 ) used to acti v ate the electrical systems of the v ehicle , has tw o positions: Off and On. R otate the k ey cloc kwise to the On position to allo w operation of the v ehicle and accessories . After stopping the v ehicle , rotate the k ey countercloc kwise to the Off position. R emo v e the k ey before lea ving the v ehicle .

Vehicle Direction Switch

Use this switc h ( Figure 20 ) to tog gle betw een forw ard and rev erse operation.

Vehicle Status Light

T he v ehicle contains a computer that monitors the state of the v ehicle electrical systems . T his computer comm unicates the status of the v ehicle to y ou through the v ehicle status light. Alw a ys c hec k this light when y ou tur n the On/Off switc h to the On position ( Figure 24 ) W hen there are no problems and the v ehicle is operational, the light is on.

W hen there is a problem, the light ﬂashes . T he light ﬂashes at v arious inter v als for different problems and ev ents . If the light blinks , refer to T roubleshooting , pag e 40 for a description of the ﬂash codes .

Light Switch

Figure 20

1. On/Off switch 5. Vehicle status light

2. Horn button 6. Power cargo bed switch

3. Light switch

4. Battery/hour meter 8. Vehicle direction switch

(optional)

7. Rear lift switch (optional)

Horn Button

Press the hor n button to acti v ate the v ehicle hor n ( Figure 20 ).

Gear Shift Selector

T he batter y/hour meter pro vides y ou with an indication of ho w m uc h c harg e is contained in the batteries ( Figure 20 and Figure 24 ) and the n umber of operating hours on the v ehicle . T he batter y meter is located at the top of the LCD screen. W hen the v ehicle batteries are fully c harg ed, ten bars extend from the 0 to the 1 position. As the c harg e is used, bars disappear star ting on the right

Use this switc h to tur n the headlights on and off ( Figure 20 ).

Cargo Bed Lift Switch (Optional)

Use this switc h to raise and lo w er the carg o bed ( Figure 20 ).

Rear Lift Switch (Optional)

Use this switc h to raise and lo w er the rear lift ( Figure 20 ).

Supervisor Speed Limit Switch

T he super visor speed limit switc h, located under the cup holder ( Figure 21 ) has tw o positions: Off and On. R otate the k ey cloc kwise to the On position to limit the maxim um v ehicle speed to a factor y setting of 12 mph (19 kph). R otate the k ey countercloc kwise to the Off position to restore the maxim um speed of the v ehicle .

Figure 21

1. Supervisor speed limit switch

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 22 ).

Figure 22

1. Passenger hand hold

2. Hip restraint

Specications

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

Base weight Rated capacity (on level ground) 1200 lb (544.5 kg)* total, including 200 lb (90.7 kg) operator and 200 lb (90.7

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

1500 lb (680 kg)*

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

2700 lb (1225 kg) total, including all of the weights listed above

800 lb (362 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 in (152.4 cm) 119 in (302.3 cm) 9-1/4 inches (23.5 cm) at the front with no load or operator, 7 inches (18 cm) at

the rear with no load or operator 81 in (205.7 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

* S p e c i ﬁ c a t i o n s l i s t e d a r e w i t h T r o j a n T 1 0 5 b a t t e r i e s . I f t h e m a c h i n e i s

e q u i p p e d w i t h T r o j a n T 1 4 5 b a t t e r i e s t h e b a s e w e i g h t i s i n c r e a s e d b y 8 0

l b ( 3 6 k g ) a n d c a p a c i t i e s a r e d e c r e a s e d b y t h e s a m e a m o u n t .

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 .

Operation

Note: Deter mine the left and right sides of the

mac hine from the nor mal operating position.

2. Sit in the Operator’ s seat, inser t the k ey into the On/Off switc h, and rotate the k ey cloc kwise to the On position.

3. Mo v e the v ehicle direction switc h button to the desired 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:

• Chec k the tire pressure .

• Chec k the brak e pedal operation.

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

4. R elease the parking brak e .

5. Slo wly ste p on the accelerator pedal to dri v e the v ehicle .

Note: T he parking brak e will automatically diseng ag e when y ou press the accelerator pedal.

Stopping the Vehicle

Important: W hen stopping the v ehicle on

an incline, use the brak e to stop the v ehicle and the par king brak e to hold it in place. Using the accelerator to stall the v ehicle can dama ge the v ehicle.

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

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 On/Off k ey to Off .

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

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 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 .

Operating the Vehicle

1. Disconnect the batter y c harg er .

Understanding and Using the Battery System

Understanding Deep Cycle Batteries

T he v ehicle contains 8 dee p cycle , lead-acid batteries whic h supply po w er to the motor and accessories . A dee p cycle batter y is not the same as an automobile batter y . An automobile batter y is designed to pro vide a surg e of po w er to star t the v ehicle and moderate po w er to r un the lights and accessories when the motor if off or idling . T he alter nator then contin uously rec harg es it as the automobile r uns . As suc h, an automobile batter y seldom drops belo w 90% of maxim um c harg e lev el.

A dee p cycle batter y is designed to be a primar y po w er source to pro vide a sustained output. Dee p cycle batteries are typically disc harg ed as lo w as

20% to 30% of the maxim um c harg e lev el. A disc harg e this lo w is considered a dee p disc harg e .

Lead acid batteries produce electricity through a c hemical reaction betw een coated lead plates and sulfuric acid. Charging a batter y rev erses the c hemical reaction, allo wing the batter y to once ag ain produce electricity .

A batter y is a perishable item that has a limited life time ( Figure 23 ). W hen a batter y is new , it requires a break-in period to establish efﬁcient electrical production. T his break in period usually requires 20 to 50 disc harg e/c harg e cycles .

Figure 23

1. Battery capacity

2. Discharge/charge cycles 5. End of battery life

3. Break-in period (20 to 50 cycles)

4. Prime battery life

Figure 24

1. Battery/hour meter 2. Charge indicator bars

As y ou use the v ehicle , the bars will disappear as the electrical capacity of the batteries is used.

W hen only 2 bars are left, the red w ar ning light on the meter will illuminate and the batter y icon will begin ﬂashing on the screen ( Figure 25 ). T his indicates that the batter y capacity is nearly drained and y ou should c harg e the batteries as soon as possible to prev ent batter y damag e .

After the break-in period, the batter y will maintain a high capacity for many cycles . T he n umber of cycles a batter y will perfor m is de pendant on the follo wing:

• Batter y maintenance—improper maintenance will sev erely reduce the life of the batteries .

• De pth of disc harg e betw een c harg e cycles— the deeper the batteries ar e

discharged on a r egular basis betw een charges, the less life they will ha v e.

• R ec harg e frequency—c harg e the batteries whenev er they are not in use . Full y discharging the batteries will dama ge them and r educe their life.

At the end of the batter y life , the coating on the lead plates begins to deteriorate , causing the batteries to rapidly lose electric capacity .

Using the Battery System

W hen y our batteries are fully c harg ed, the batter y meter will ha v e ten bars sho wing from left to right ( Figure 24 ).

Figure 25

1. Battery icon

2. Warning light—on

W hen only one bar is left, the w ar ning light will begin ﬂashing and the v ehicle will g o into an energ y sa ving mode ( Figure 26 ). In this mode , the v ehicle will only dri v e at 3 mph. R ec harg e the batteries immediately to prev ent serious damag e to them.

If the batteries become fully disc harg ed, the v ehicle will shut do wn. Do not allo w the batteries to

become full y discharged.

Important: T o obtain maximum batter y life, al w ays charge the batteries when ther e ar e 2 or mor e bar s visible on the scr een. Depleting the batteries lo w er than 2 bar s, especiall y on a r egular basis, will r educe the life of the batteries.

Figure 26

1. Battery icon

2. Warning light-ashing

Figure 27

1. Lever

2. Pull the prop rod into the detent slot, securing the bo x ( Figure 28 ).

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.

• 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 27 ).

Figure 28

1. Prop rod 2. Detent slot

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.

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 29 ).

Figure 29

1. Latch 3. Latch post

2. Nut

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 29 ).

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

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:

• 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).

• 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 35 .

Loading the Cargo Box

Operating the Tailgate Latches

1. T o open the tailg ate latc hes , lift the latc h handles up ( Figure 30 ). 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 30

1. Tailgate latch

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 .

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 g reatly ex ceeds the load rating .

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

)

Max. cargo box

capacity (on level

ground)

1/2 full 1/3 full 1/2 full 1/3 full

Full Full

1/2 full

Gravel, dry95 Gravel, wet Sand, dry Sand, wet Wood Bark Earth, packed

Material Material

(lb/ft

95 120 90 120 45 <45 100

Transporting the Vehicle

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

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 31 and Figure 32 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.

Figure 31

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 .

Figure 32

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 , motor , 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 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 .

1. T ur n off the On/Off switc h and remo v e the k ey .

2. Afﬁx a to w line to the tongue on the front of the frame ( Figure 32 ).

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

T he maxim um carg o load shall not ex ceed 800 lb (362 kg), including the GTW and tongue w eight. F or example , if the GTW = 200 lb and tongue w eight = 50 lb , then the maxim um carg o load = 550 lb .

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 .

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 25

operating hours

Before each use or daily

Every 25 hours

Every 100 hours

Every 200 hours

Every 800 hours

Maintenance Procedure

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

• Check the tire pressure.

• Charge the batteries.

• Check the brake uid level.

• Clean the batteries.

• Check the battery electrolyte level.

• Lubricate all grease ttings.

• 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.

• Check the transaxle uid.

• Inspect the brakes.

• Adjust the parking brake.

• Change the transaxle uid.

Daily Maintenance Checklist

Duplicate this page for routine use.

Maintenance Check Item

Check brake and parking brake operation.

Check gear shift/neutral operation.

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 On/Of f s witch, someone could accidentl y star t the v ehicle and seriousl y injur e y ou or other bystander s.

R emo v e the k ey fr om the On/Of f s witch and disconnect a batter y ca ble bef or e y ou do an y maintenance.

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.

Premaintenance Procedures

• Deser t operation

• Cold climate operation (belo w 32 deg rees F)

• T railer to wing

Heavy Duty Operation

• F requent operation on dusty roads

• Constr uction w ork

Important: If the v ehicle is subjected to an y of the conditions listed belo w , maintenance should be perf or med twice as fr equentl y:

• 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 .

• Under frequent hea vy duty operating conditions , lubricate all g rease ﬁttings .

Jacking the Vehicle

W henev er the motor is r un for routine maintenance and/or diagnostics , the rear wheels of the v ehicle should be 1 inc h (25 mm) off of 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 v ehicle 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.

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

Where to Add Grease

T he g rease ﬁttings are located at the four tie rod ends ( Figure 35 ) and the tw o king pins ( Figure 36 ).

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 .

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 33 ) T he jac king point at the rear of the v ehicle is under the axle tubes ( Figure 34 ).

Figure 33

1. Front jacking point

Figure 35

Figure 36

1. Rear jacking points

Figure 34

Electrical System Maintenance

batter y life , c harg e the batteries whenev er y ou are not using the v ehicle . De pending on ho w disc harg ed the batteries are , it ma y tak e up to 16 hours to c harg e the batteries to full capacity .

Maintaining the Batteries

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.

• Al w ays k eep the batter y r etainer s in place to pr otect and secur e the batteries.

Warning

CALIFORNIA

Pr oposition 65 W ar ning

Important: Lead-acid batteries do not dev elop a charge memor y and do not need to be full y discharged bef or e charging them. Full y discharging the batteries may dama ge them. Charge the batteries whenev er the v ehicle gets lo w on po w er and an y time it is not in use; r efer to Using the Batter y System section in Operation , pa ge 24 .

Charging the batter y pr oduces gasses that can explode.

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

1. P osition the v ehicle in a w ell v entilated area near a 115 v ac , 15 amp po w er outlet.

2. Connect the c harg er cord to the c harging rece ptacle on the v ehicle (located on the panel betw een the seats).

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 .

Cleaning the Batteries

Clean the batteries ev er y da y before use .

1. Ensure that all of the batter y caps are tight.

2. Use a paper to w el to clean the batteries .

3. 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. Also , clean the posts and cable clamps with a post and clamp cleaner . T he posts and clamps should ha v e a bright metallic shine .

4. Apply a light coating of T oro batter y ter minal protector .

Charging the Batteries

3. Plug the c harg er po w er cord into a 115 v ac , 15 amp po w er outlet.

W hile the batteries are c harging, the g reen light on the c harg er will blink on and off . W hen the batteries are fully c harg ed, the g reen light stops blinking and sta ys on.

4. Disconnect the cord from the po w er outlet.

5. Disconnect the c harg er from the v ehicle .

Important: Do not car r y the charger on the v ehicle. Ex cessi v e or pr olonged jar ring may dama ge it.

Adding Water to the Batteries

Chec k the electrolyte lev el and add w ater if needed ev er y 25 operating hours or , if the v ehicle is in storag e , ev er y 30 da ys . Use onl y clean, distilled

w ater to ﬁll the batteries.

A c harg er is supplied with the v ehicle . Alw a ys k ee p the c harg er in a dr y location. F or maxim um

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 and a v oid contact with 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.

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 may r esult. Also, o v erﬁlling the batter y will r educe the life of the batter y .

8. R e place the ﬁller caps on all batteries .

Replacing Used Batteries

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

• Nev er add acid to a batter y .

1. Raise the carg o bed, tur n the k ey off , and remo v e it.

2. R emo v e the ﬁller caps from eac h batter y .

3. If the electrolyte is not o v er the top of the plates in eac h batter y cell, add just enough distilled w ater to co v er the plates .

4. R e place the ﬁller caps on all batteries .

5. Charg e the batteries for 16 hours; refer to Charging the Batteries .

6. R emo v e the ﬁller caps from eac h batter y .

7. Add just enough distilled w ater to bring the electrolyte lev el to 1/8 inc h (3 mm) belo w the bottom of eac h ﬁll w ell ( Figure 37 ).

W hen the v ehicle begins to sho w a loss of rang e or when the length of the disc harg e/c harg e cycle is signiﬁcantly reduced, the batteries are probably g etting old and losing their ability to hold a c harg e . T ak e the v ehicle to an A uthorized Ser vice Dealer and ha v e them test the batteries to deter mine whether the batteries need to be re placed. T he Dealer can then re place the batteries for y ou. If y ou wish to re place the batteries y ourself , use the follo wing procedure:

1. Raise the carg o bed, tur n the k ey off , and remo v e it.

2. Disconnect the long, blac k, main neg ati v e lead r unning from the bank of batteries to the v ehicle from the batter y post ( Figure 38 ).

Figure 37

1. Battery plates 3. Electrolyte level

2. Filler cap 4. Battery terminal

Figure 38

3. R emo v e the long, red, main positi v e lead r unning from the bank of batteries to the v ehicle from the batter y post ( Figure 38 ).

4. Disconnect all of the batter y leads from the batteries .

5. R emo v e the batter y retainers located betw een the batteries .

6. R emo v e all of the batteries and recycle them according to y our local codes .

7. Install new batteries in the places v acated b y the old batteries

Note: P a y attention to the batter y polarity when installing the new batteries ( Figure 38 ).

8. Install the batter y retainers and tor que the n uts to 150 to 200 in-lb (17 to 22 N ⋅ m).

9. Connect the batteries tog ether with the batter y cables remo v ed previously , as sho wn in Figure 38 .

10. Connect the long, red, main positi v e lead betw een the bank of batteries and the v ehicle ( Figure 38 ).

11. Connect the long, blac k, main neg ati v e lead betw een the bank of batteries and the v ehicle ( Figure 38 ).

12. T or que the n uts securing all batter y cables to 120 to 180 inc h-lb (13.5 to 21 N ⋅ m).

13. Coat the batter y ter minals with T oro batter y ter minal protector .

14. Ensure that the r ubber boots on eac h batter y cable are securely seated o v er the batter y ter minals .

Storing the Batteries

Charg e the batteries fully before placing the v ehicle into storag e . Plug the c harg er into a w all outlet while the v ehicle and batteries are in storag e . Lea v e the c harg er plug g ed into a w all outlet and c harging rece ptacle during storag e to ensure that the batteries sta y c harg ed and do not freeze; otherwise , c harg e the batteries at least once ev er y 3 months .

Figure 39

1. Vehicle fuse

2. Accessories Fuse

Replacing the Headlights

Speciﬁcation: T oro #104-7312, 28 v olt Note: T he headlights are wired in series;

therefore , when one headlight bur ns out, neither will illuminate . If possible , c hang e both headlights at the same time .

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

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 40 ). Discard the 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 39 ).

Ignition System Lights Power Point

10 amp. (15 amp. max.)

10 amp. 10 amp.

Figure 40

1. Rubber seal 3. Outside notch-align with

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

notch in hood

4. Headlight

5. Align the notc h on the inside of the seal with the notc h on the new headlight ( Figure 40 ). 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.

Drive System Maintenance

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 center bolts on the front wheels to 135-165 ft-lb (183-224 N ⋅ m) and the front and rear lug n uts to 45-65 ft-lb (61-88 NVm).

Adjusting the Front Suspension

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.

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 41 ).

3. Loosen the centering bolts in the front A-ar m ( Figure 41 ).

4. R emo v e the ride height adjustment bolt ( Figure 41 ).

Figure 41

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 41 ).

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 42 ) 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 42 ). 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.

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

Figure 42

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 41 ).

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 43 ). 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 43 ).

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.

Figure 43

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 44 ).

• 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.

Figure 44

1. Jam nut

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

2. Tie rod

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:

• 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.

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 .

Checking the Transaxle Oil Level

Chec k the oil lev el in the transaxle at the rear of the v ehicle ev er y 100 operating hours . Chang e the oil in the transaxle ev er y 800 operating hours .

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

2. R emo v e the c hec k bolt on the transaxle ( Figure 45 ).

T he oil lev el should be ev en with the bottom of the c hec k hole .

• 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 motor 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 46 ). 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.

Figure 45

1. Transaxle 2. Check bolt

3. If the oil lev el is lo w , add 10w30 motor oil to the c hec k hole until it r uns out the hole .

4. R e place the c hec k bolt and tor que it to 15 to 20 ft-lb (20 to 27 N ⋅ m).

Figure 46

1. Brake uid reservoir 2. Minimum line

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 47 ).

Figure 47

1. Parking brake lever

2. Knob

3. Set screw

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 .

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: Do not use high pr essur e w ater when w ashing the v ehicle. 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, motor , and batteries.

Storage

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

2. Clean dir t and g rime from the entire mac hine , including the outside of the motor 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, motor , and the batter y .

3. Inspect the brak es; refer to Inspecting the Brak es in Brak e Maintenance , pag e 37 .

4. Grease the mac hine; refer to Lubrication , pag e 31 .

5. Chec k the tire pressure; refer to Chec king the Tire Pressure .

6. Charg e the batteries fully before placing the v ehicle into storag e , refer to Maintaining the Batteries in Electrical System Maintenance , pag e 32 . Plug the c harg er into a w all outlet while the v ehicle and batteries are in storag e . Lea v e the c harg er plug g ed into a w all outlet and c harging rece ptacle during storag e to ensure that the batteries sta y c harg ed and do not freeze; otherwise , c harg e the batteries at least once ev er y 3 months .

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

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

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

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

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

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

Troubleshooting

Vehicle Status Light Flash Pattern

Problem

Always on

1 ash 1. The computer

2 ashes 1. The accelerator pedal

3 ashes

1. The system is functioning

1. The power block has a

Possible Cause Corrective Action

properly.

programming personality is out of range.

was pressed when the On/Off key was turned.

short circuit (MOSFET S/C).

1. None

1. Turn the On/Off key to the Off position, wait a few seconds, and turn the On/Off key to the On position. If the condition continues, refer to your Authorized Service Dealer.

1. Turn the On/Off key to the Off position, release the accelerator pedal, and turn the On/Off key to the On position.

1. Turn the On/Off key to the Off position, wait a few seconds, and turn the On/Off key to the On position. Check all batteries and high current controller connections If the condition continues, refer to your Authorized Service Dealer.

2. A poor batter or power cable connection.

2. Turn the On/Off key to the Off position, wait a few seconds, and turn the On/Off key to the On position. Check all batteries and high current controller connections If the condition continues, refer to your Authorized Service Dealer.

Problem

Possible Cause Corrective Action

4 ashes 1. The line contactor is

not responding to commands.

5 ashes 1. The charger interlock

switch is active.

6 ashes 1. Accelerator POT is out of

adjustment.

7 ashes 1. Battery voltage is out of

range.

8 ashes 1. The controller is

overheated.

1. Turn the On/Off key to

the Off position, wait a few seconds, and turn the On/Off key to the On position. If the condition continues, refer to your Authorized Service Dealer.

1. Turn the On/Off key

to the Off position, disconnect the charger, and turn the On/Off key to the On position.

1. Refer to your Authorized

Service Dealer.

1. Refer to your Authorized

Service Dealer to have the batteries tested and replaced if necessary.

1. The vehicle will continue

to run, but at reduced power until the controller cools down.

9 ashes 1. The motor is over heated

or the battery is nearly discharged (the vehicle will go into the energy saving mode).

1. If the batter meter

displays more than one bar, stop the vehicle and allow the motor to cool before operating it again. If the battery meter displays only one bar, charge the vehicle immediately.

Off 1. The controller has failed. 1. Refer to your Authorized

Service Dealer.

Schematics

Electrical Schematic (Rev. A)

Electric

Workman

Vehicles

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. * Product equipped with hour meter

Instructions for Obtaining Warranty Service

You are responsible for notifying the Commercial Products Distributor or Authorized Commercial Products Dealer from whom you purchased the Product as soon as you believe a warrantable condition exists.

If you need help locating a Commercial Products Distributor or Authorized Dealer, or if you have questions regarding your warranty rights or responsibilities, you may contact us at:

Toro Commercial Products Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196 952-888-8801 or 800-982-2740 E-mail: commercial.service@Toro.com

Owner Responsibilities

As the Product owner, you are responsible for required maintenance and adjustments stated in your operator’s manual. Failure to perform required maintenance and adjustments can be grounds for disallowing a warranty claim.

Items and Conditions Not Covered

Not all product failures or malfunctions that occur during the warranty period are defects in materials or workmanship. This express warranty does not cover the following:

• Product failures which result from the use of non-Toro

replacement parts, or from installation and use of add-on, 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, batteries, carbon brushes, brake components, tires, lters, belts, 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 lubricants, additives, 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. 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 deep cycle battery warranty: Deep cycle batteries have a specic total number of kilowatt-hours they can deliver during their lifetime. Operating, recharging, and maintenance techniques can extend or reduce total battery life. As the batteries in this product are consumed, the amount of useful work between charging intervals will slowly decrease until the battery is completely worn out. Replacement of worn out batteries, due to normal consumption, is the responsibility of the product owner. Battery replacement may be required during the normal warranty period.

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.

374-0068 Rev -

Toro 07287TC, 07288TC, Workman e2060, Workman e2065, 07280 Operator's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual