Toro Workman 07390, Workman 07390TC Operator's Manual

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Page 1

FormNo.3431-106RevA

Workman

HDX-AutoUtility

Vehicle

ModelNo.07390—SerialNo.403430001andUp ModelNo.07390TC—SerialNo.403430001andUp

Registeratwww.T oro.com. OriginalInstructions(EN)

*3431-106*A

Page 2

ThisproductcomplieswithallrelevantEuropean directives;fordetails,pleaseseetheseparateproduct specicDeclarationofConformity(DOC)sheet.

Figure1identiesthelocationofthemodelandserial

numbersontheproduct.Writethenumbersinthe spaceprovided.

ItisaviolationofCaliforniaPublicResourceCode Section4442or4443touseoroperatetheengineon anyforest-covered,brush-covered,orgrass-covered landunlesstheengineisequippedwithaspark arrester,asdenedinSection4442,maintainedin effectiveworkingorderortheengineisconstructed, equipped,andmaintainedforthepreventionofre.

Theenclosedengineowner'smanualissupplied forinformationregardingtheUSEnvironmental ProtectionAgency(EPA)andtheCaliforniaEmission ControlRegulationofemissionsystems,maintenance, andwarranty.Replacementsmaybeorderedthrough theenginemanufacturer.

WARNING

CALIFORNIA

Proposition65Warning

Theengineexhaustfromthisproduct

containschemicalsknowntotheStateof

Californiatocausecancer,birthdefects,

orotherreproductiveharm.

Batteryposts,terminals,andrelated

accessoriescontainleadandlead

compounds,chemicalsknownto

theStateofCaliforniatocause

cancerandreproductiveharm.Wash

handsafterhandling.

Important:Withyourmobiledevice,youcan

scantheQRcodeontheserialnumberdecal(if equipped)toaccesswarranty,parts,andother productinformation.

g239323

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

Thismanualidentiespotentialhazardsandhas safetymessagesidentiedbythesafety-alertsymbol (Figure2),whichsignalsahazardthatmaycause seriousinjuryordeathifyoudonotfollowthe recommendedprecautions.

Introduction

Thisutilityvehicleisintendedtobeprimarilyused off-highwaytotransportpeopleandmaterialloads. Usingthisproductforpurposesotherthanitsintended usecouldprovedangeroustoyouandbystanders.

Readthisinformationcarefullytolearnhowtooperate andmaintainyourproductproperlyandtoavoid injuryandproductdamage.Youareresponsiblefor operatingtheproductproperlyandsafely .

Visitwww.Toro.comforproductsafetyandoperation trainingmaterials,accessoryinformation,helpnding adealer,ortoregisteryourproduct.

Wheneveryouneedservice,genuineToroparts,or additionalinformation,contactanAuthorizedService DistributororT oroCustomerServiceandhavethe modelandserialnumbersofyourproductready.

Figure2

Safety-alertsymbol

Thismanualuses2wordstohighlightinformation. Importantcallsattentiontospecialmechanical informationandNoteemphasizesgeneralinformation worthyofspecialattention.

g000502

Contactusatwww.Toro.com.

PrintedintheUSA

AllRightsReserved

Page 3

Contents

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

GeneralSafety...................................................4

SafetyandInstructionalDecals..........................5

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

1InstallingtheSteeringWheel..........................12

2ConnectingtheBattery..................................12

3CheckingtheFluidLevelsandTire

Pressure.......................................................13

4InstallingtheRollBar.....................................13

5ConnectingtheCVT-IntakeDuct....................13

6BurnishingtheBrakes....................................14

ProductOverview...................................................15

Controls...........................................................15

ControlPanel................................................17

InstrumentCluster.........................................17

Specications..................................................20

Attachments/Accessories.................................20

BeforeOperation.................................................21

BeforeOperationSafety...................................21

PerformingDailyMaintenance..........................21

CheckingtheTirePressure...............................21

AddingFuel......................................................22

BreakinginaNewMachine..............................22

CheckingtheSafety-InterlockSystem..............23

DuringOperation.................................................24

DuringOperationSafety...................................24

OperatingtheCargoBed..................................25

StartingtheEngine...........................................26

DrivingtheMachine..........................................27

StoppingtheMachine.......................................27

ShuttingOfftheEngine.....................................27

UsingtheSpeed-RangeControl......................27

UsingtheDifferentialLock................................28

UsingtheHydraulicControl..............................28

AfterOperation....................................................30

AfterOperationSafety......................................30

HaulingtheMachine.........................................31

TowingtheMachine..........................................31

TowingaTrailer................................................31

Maintenance...........................................................32

MaintenanceSafety..........................................32

RecommendedMaintenanceSchedule(s)...........32

MaintainingtheMachineunderSpecial

OperatingConditions....................................34

Pre-MaintenanceProcedures..............................35

PreparingtheMachineforMaintenance............35

UsingtheBedSupport......................................35

RemovingtheFullBed......................................36

InstallingtheFullBed........................................36

RaisingtheMachine.........................................37

RemovingandInstallingtheHood....................38

Lubrication..........................................................39

GreasingtheBearingsandthe

Bushings.......................................................39

EngineMaintenance...........................................40

EngineSafety...................................................40

ServicingtheAirFilter.......................................40

ServicingtheEngineOil....................................41

CheckingtheOil-Pressure-Warning

Light..............................................................43

ServicingtheSparkPlugs.................................43

FuelSystemMaintenance...................................44

InspectingtheCarbonCanisterAir

Filter..............................................................44

ReplacingtheFuelFilter...................................44

InspectingFuelLinesandConnections.............44

ElectricalSystemMaintenance...........................45

ElectricalSystemSafety...................................45

ServicingtheFuses..........................................45

Jump-StartingtheMachine...............................46

ServicingtheBattery.........................................47

DriveSystemMaintenance..................................47

InspectingtheTires..........................................47

CheckingtheT orqueoftheWheel

Nuts..............................................................48

CheckingtheFrontWheelAlignment................48

MaintainingtheTransmission...........................49

MaintainingtheDifferentialandAxles...............52

CoolingSystemMaintenance..............................53

CoolingSystemSafety.....................................53

CheckingtheEngine-CoolantLevel..................53

RemovingDebrisfromtheCooling

System..........................................................54

ChangingtheEngineCoolant...........................55

BrakeMaintenance.............................................56

CheckingtheBrake-FluidLevel........................56

AdjustingtheParkingBrake..............................56

AdjustingtheBrakePedal.................................57

ControlsSystemMaintenance.............................58

ConvertingtheSpeedometer............................58

HydraulicSystemMaintenance...........................59

HydraulicSystemSafety...................................59

ServicingtheHydraulicSystem........................59

RaisingtheCargoBedinanEmergency...........62

Cleaning..............................................................64

WashingtheMachine.......................................64

Storage...................................................................65

StorageSafety..................................................65

StoringtheMachine..........................................65

Troubleshooting......................................................66

Page 4

Safety

Thismachinehasbeendesignedinaccordancewith therequirementsofSAEJ2258(Nov2016).

GeneralSafety

Thisproductiscapableofcausingpersonalinjury. Alwaysfollowallsafetyinstructionstoavoidserious personalinjury.

•Readandunderstandthecontentsofthis

Operator’sManualbeforeyoustartthemachine. Ensurethateveryoneusingthisproductknows howtouseitandunderstandsthewarnings.

•Useyourfullattentionwhileoperatingthe

machine.Donotengageinanyactivitythat causesdistractions;otherwise,injuryorproperty damagemayoccur.

•Donotputyourhandsorfeetnearmoving

componentsofthemachine.

•Donotoperatethemachinewithoutallguards

andothersafetyprotectivedevicesinplaceand workingonthemachine.

•Keepbystandersandchildrenoutoftheoperating

area.Neverallowchildrentooperatethemachine.

•Stopandshutoffthemachineandremovethekey

beforeservicingorfueling.

Improperlyusingormaintainingthismachinecan resultininjury .T oreducethepotentialforinjury, complywiththesesafetyinstructionsandalways payattentiontothesafety-alertsymbol meansCaution,Warning,orDanger—personalsafety instruction.Failuretocomplywiththeseinstructions mayresultinpersonalinjuryordeath.

,which

Page 5

SafetyandInstructionalDecals

93-9899

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea ofpotentialdanger.Replaceanydecalthatisdamagedormissing.

BatterySymbols

Someorallofthesesymbolsareonyourbattery .

decalbatterysymbols

1.Explosionhazard6.Keepbystandersaway fromthebattery .

2.Nore,opename,or

smoking

3.Causticliquid/chemical

burnhazard

7.Weareyeprotection; explosivegasescan causeblindnessandother injuries.

8.Batteryacidcancause blindnessorsevereburns.

93-9850

1.Donotrepairorrevise—readtheOperator'sManual.

4.Weareyeprotection.9.Flusheyesimmediately withwaterandgetmedical helpfast.

5.ReadtheOperator's

Manual.

10.Containslead;donot discard

93-9852

1.Warning—readtheOperator’sManual.2.Crushinghazard—installthecylinderlock.

decal93-9868

93–9868

decal93-9850

decal93-9852

1.Crushinghazardofhand—readtheOperator’sManual.

93-9879

1.Storedenergyhazard—readtheOperator'sManual.

decal93-9879

decal93-9899

93-9899

1.Crushinghazard—installthecylinderlock.

Page 6

1.Warning—avoidpinchpoints.

1.Electricalpowerpoint

decal105-4215

105-4215

decal106-2353

106-2353

decal106-7767

106-7767

1.Warning—readtheOperator'sManual;avoidtippingthe machine;weartheseatbelt;leanawayfromthedirection themachineistipping.

decal106-6755

106-6755

1.Enginecoolantunder pressure.

2.Explosionhazard—read theOperator'sManual.

3.Warning—donottouchthe hotsurface.

4.Warning—readthe

Operator'sManual.

115-2047

1.Warning—donottouchthehotsurface.

115-2282

1.Warning—readtheOperator'sManual.

2.Warning—stayawayfrommovingparts;keepallguardsandshieldsinplace.

3.Crushinghazard—keepbystandersoutoftheoperatingarea;donotcarrypassengersinthecargobed;keeparmsandlegs insideofthevehicleatalltimes;useseatbeltsandhandholds.

decal115-2047

decal115-2282

Page 7

115-7723

1.Warning—thehydraulic-uidpressureis124bar(1,800psi).

2.CouplerA

3.CouplerB

decal115-7739

115-7739

1.Falling,crushinghazard—donotcarrypassengers.

decal115-7756

115-7756

1.High-owhydraulics—engaged

decal115-7723

121-9776

1.Warning—readtheOperator’sManualandreceiveproper trainingbeforeoperatingthemachine.

2.Warning—wearhearingprotection.5.Tippinghazard—taketurnsslowly;driveslowlyupandacross

3.Firehazard—shutofftheenginebeforerefuelingthemachine.

4.Warning—engagetheparkingbrake,shutofftheengine,and removethekeyfromthekeyswitchbeforewalkingawayfrom themachine.

cliffs;withnoload,donotexceed32kph(20mph);while carryingaloadorwhendrivingonuneventerrain,driveslowly.

decal121-9776

Page 8

decal121-9890

121-9890

1.Parkingbrake

2.Hydraulicsystem—unlock

4.Cylinderretract

5.Cylinderextend

3.Hydraulicsystem—lock6.Transport

127-8620

1.Headlights4.Horn7.Engine—start

2.Differentiallock—lock5.Engine—shutoff

3.Differentiallock—unlock

6.Engine—run

7.Fast

8.Slow

decal127-8620

8.Brake

Page 9

127-8626

1.Powertakeoff(15A)5.Differentiallock(15A)

2.Startengine(10A)6.Speedometer(10A)

3.Hazardlights(10A)

7.Headlightsandrearlights (15A)

4.Engineignition(10A)8.Horn(30A)

136-1163

decal127-8626a

decal136-1163

decal138-3371

138-3371

1.Park4.Low

2.Reverse5.Drive

3.Neutral6.Attention—readthe Operator’sManual;stop themachinebefore changinggears.

1.Donotexceedatransport loadof1591kg(3,500lb).

2.Donotexceedatongue weightof273kg(600lb).

Page 10

1.Tank3.Pressure

2.Warning—the hydraulic-uidpressureis 138bar(2,000psi).

decal139-3341

139-3341

Page 11

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

2 3

4 5

MediaandAdditionalParts

Description

Operator'sManual

OperatorTrainingMaterial

Steeringwheel Cover Washer(5/8inch)

Nopartsrequired

Rollbar1 Flange-headbolt(1/2x1-1/4inches)

Nopartsrequired

Qty.

Readbeforeoperatingthemachine.

Viewbeforeoperatingthemachine.

Qty.

Use

1 1 1

–

Installthesteeringwheel(TCmodels only).

Connectthebattery(TCmodelsonly).

Checktheuidlevelsandtirepressure.

Installtherollbar.

Connectthecontinuously-variable transmissionintakeduct.

Burnishthebrakes.

Use

CVTKit121-9853

CVTAdapter127-8750

ConnecttheCVTIntakeDuct(TCModelsOnly)

Note:Determinetheleftandrightsideofthemachinefromthenormaloperatingposition.

Page 12

InstallingtheSteering Wheel

TCModelsOnly

Partsneededforthisprocedure:

Steeringwheel

Cover

Washer(5/8inch)

Procedure

1.Ifthecoverisinstalled,removeitfromthehub

ofthesteeringwheel(Figure3).

2.Removethenutfromthesteeringshaft(Figure

3).

3.Slidethesteeringwheelandwasherontothe

steeringshaft(Figure3).

4.Securethesteeringwheeltotheshaftwiththe

nutandtightenitto27to34N∙m(20to25ft-lb).

5.Installthecoveronthesteeringwheel(Figure3).

ConnectingtheBattery

TCModelsOnly

NoPartsRequired

Procedure

WARNING

Incorrectlyroutingthebatterycablecould damagethemachineandcables,causing sparks.Sparkscancausethebatterygasses toexplode,resultinginpersonalinjury.

•Alwaysdisconnectthenegativebattery cable(black)beforedisconnectingthe positivebatterycable(red).

•Alwaysconnectthepositivebatterycable (red)rst.

1.Squeezethebatterycovertoreleasethetabs fromthebatterybase(Figure4).

Figure3

1.Cover4.Steeringwheel

2.Nut

3.Washer(5/8inch)

5.Steeringshaft

g010326

g024240

1.Batterycover

2.Removethebatterycoverfromthebatterybase (Figure4).

3.Connectthepositivebatterycable(red)tothe positive(+)terminalofthebatteryandsecure thecablewiththeboltsandnuts(Figure5).

Figure4

Page 13

4.Checkthebrake-uidlevelbeforeyourststart theengine;refertoCheckingtheBrake-Fluid

Level(page56).

5.Checktheairpressureinthetires;referto

CheckingtheTirePressure(page21).

InstallingtheRollBar

Figure5

1.Insulatorboot(positive batterycable)

2.Negativebatterypost

4.Slidetheinsulatorbootoverthepositive

terminal.

Note:Theinsulatorbootpreventsapossible

short-to-groundfromoccurring.

5.Connectthenegativebatterycable(black)tothe

negative(–)terminalofthebatteryandsecure thecablewithboltsandnuts.

6.Alignthebatterycovertothebatterybase

(Figure4).

7.Squeezethebatterycover,alignthetabsto

thebatterybase,andreleasethebatterycover (Figure4).

3.Negativebatterycable (black)

g026250

Partsneededforthisprocedure:

1Rollbar

Flange-headbolt(1/2x1-1/4inches)

Procedure

1.Applymedium-grade(service-removable) thread-lockingcompoundtothethreadsofthe6 ange-headbolts(1/2x1-1/4inches).

2.Aligneachsideoftherollbarwiththemounting holesoneachsideofthemachineframe(Figure

6).

CheckingtheFluidLevels andTirePressure

NoPartsRequired

Procedure

1.Checktheengine-oillevelbeforeandafter yourststarttheengine;refertoCheckingthe

Engine-OilLevel(page41).

2.Checkthetransmission-uidlevelbeforeyou rststarttheengine;refertoCheckingthe

Transmission-FluidLevel(page49).

3.Checktheengine-coolantlevelbeforeyou rststarttheengine;refertoCheckingthe

Engine-CoolantLevel(page53).

Figure6

1.Rollbarmountingbracket

3.Securetherollbarmountingbrackettothe machineframeusing3ange-headbolts(1/2x 1-1/4inches)oneachside(Figure6).

4.Torquetheange-headbolts(1/2x1-1/4inches) to115N∙m(85ft-lb).

2.Flange-headbolt(1/2x 1-1/4inches)

g009812

Page 14

ConnectingtheCVT-Intake Duct

NoPartsRequired

Procedure

4.Removethebedsupport,lowerthebed,shutoff theengine,andremovethekey.

BurnishingtheBrakes

NoPartsRequired

Important:Removetheplasticbagcoveringthe

endoftheCVTductbeforestartingtheengine.

TheCVTKit(PartNo.121-9853)andAdapterKit (PartNo.127-8750)arerequiredforthisprocedure.

1.Loosenthehoseclampsecuringtheplasticbag attheendoftheCVT-intakehoseandremove thebag.

2.Raisethecargobedbyperformingthefollowing:

A.Engagetheparkingbrake.

B.Starttheengine.

C.Movethehydraulic-liftleverrearwardto

raisethecargobox.

D.Shutofftheengine.

E.Removethebedsupportfromthestorage

bracketsonthebackoftheROPSpanel andinstallthesupportontothecylinderrod ofthebed-liftcylinder;refertoUsingthe

BedSupport(page35).

3.AligntheCVT-intakehoseontotheintake-tube connectoratthebacksideoftheROPSpanel andtightenthehoseclamp(Figure7).

Procedure

Toensureoptimumperformanceofthebrakesystem, burnishthebrakesbeforeuse.

1.Bringthemachineuptofullspeed,applythe brakestorapidlystopthemachinewithout lockingupthetires.

2.Repeatthisprocedure10times,waiting1minute betweenstops,toavoidoverheatingthebrakes.

Important:Thisprocedureismosteffective

ifthemachineisloadedwith454kg(1,000 lb).

1.CVT-intakehose

2.Hoseclamp

g026251

Figure7

3.Intake-tubeconnector

Page 15

ProductOverview

Controls

Becomefamiliarwithallthecontrolsbeforeyoustart theengineandoperatethemachine.

AcceleratorPedal

Usetheacceleratorpedal(Figure8)tovarytheground speedofthemachinewhenthetransmissionisin gear.Pressingdowntheacceleratorpedalincreases theenginespeedandgroundspeed.Releasingthe pedaldecreasestheenginespeedandgroundspeed.

TransmissionLever

Usethetransmissionlever(Figure9)toshiftthe transmissionbetweenP(PARK),R(REVERSE),N (NEUTRAL),L(LOWFORWARD),andD(DRIVE)ground operation.

Important:Donotshiftthetransmissiontothe

REVERSE,LOW,orDRIVEgearunlessthemachine ismotionlessandtheengineisatlowidle; otherwise,youcoulddamagethetransmission.

Figure8

1.Brakepedal2.Acceleratorpedal

BrakePedal

Usethebrakepedaltostoporslowthemachine (Figure8).

CAUTION

Operatingamachinewithwornorincorrectly adjustedbrakescanmayresultinpersonal injury.

Ifthebrakepedaltravelstowithin25mm(1 inch)ofthemachineoorboard,adjustor repairthebrakes.

g028609

Figure9

g024307

1.Transmissionlever

2.P(park)5.L(lowforward)

3.R(reverse)6.D(drive)

4.N(neutral)

Page 16

Parking-BrakeLever

Wheneveryoushutofftheengine,engagethe parkingbrake(Figure10)topreventthemachinefrom accidentallymoving.Ifthemachineisparkedona steepgrade,ensurethatyouengagetheparking brake.

•Toengagetheparkingbrake,pullbackonthe

parking-brakelever.

•Todisengagetheparkingbrake,pushthe

parking-brakeleverforward.

Note:Disengagetheparkingbrakebefore

movingthemachine.

•Ifyouparkthemachineonasteepuphillor

downhillgrade,shiftthetransmissionintoP(PARK) andengagetheparkingbrake.Placechocksat thedownhillsideofthewheels.

Figure10

1.Parking-brakelever

g024361

Figure11

1.Lowerthebed4.Unlocked

2.Raisethebed

3.Locked

5.Hydraulic-liftlock

6.Hydraulic-liftlever

Hydraulic-LiftLock

Thehydraulic-liftlocksecurestheliftlever,sothatthe hydrauliccylindersdonotoperatewhenthemachine isnotequippedwithabed(Figure11).Italsolocksthe liftleverintheONpositionwhenusingthehydraulics forattachments.

Speed-RangeLever

Usethespeed-rangelever(Figure12)toselect1of the4work-speedrangesforprecisecontrolofthe

g028610

maximumgroundspeedoratransportspeedrange formovingthemachinebetweenjobsites.

Hydraulic-LiftLever

Thehydraulicliftraisesandlowersthebed.Move thehydraulic-liftleverrearwardtoraisethebed,and forwardtolowerit(Figure1 1).

Important:Whenloweringthebed,holdthelever

intheforwardpositionfor1to2secondsafterthe bedcontactstheframetosecureitinthelowered position.Donotholdthehydraulicliftintheraise orlowerpositionformorethan5seconds,once thecylindersreachtheendoftheirtravel.

g024320

Figure12

1.Speed-rangelever4.C(mid-highrange)

2.T(transportrange)5.B(mid-lowrange)

3.D(highrange)6.A(lowrange)

Page 17

ControlPanel

KeySwitch

Usethekeyswitch(Figure13)tostartandshutoffthe engine.T oshutofftheengine,rotatethekeyswitch counterclockwisetotheOFFposition.

Thekeyswitchhas3positions:OFF,RUN,and START.RotatethekeyswitchclockwisetotheSTART positiontoengagethestartermotor.Releasethekey switchwhentheenginestarts.Thekeyswitchmoves automaticallytotheONposition.

PowerPoint

Usethepowerpoint(Figure13)topoweroptional12 Velectricalaccessories.

Figure13

1.High-owhydraulics switch(TCmodelsonly)

2.Lightswitch

3.Differentialswitch8.Start

4.Hornbutton(TCmodels only)

5.Keyswitch

High-FlowHydraulicsSwitch

6.Off

7.On

9.Powerpoint

TCModelsOnly

Pushtheswitchdowntostartthehigh-owhydraulics andpushtheswitchuptoshutoffthehydraulics (Figure13).

Note:Y oumustsetthehigh-owhydraulicsswitchto

theOFFpositiontostarttheengine.

LightSwitch

Pushthelightswitch(Figure13)totogglethe headlightsonoroff.

Differential-LockSwitch

g024365

InstrumentCluster

1.Tachometer

2.Hourmeter

3.Speedometer

4.Fuelgauge

Tachometer

g024370

Figure14

5.Charge-indicatorlight

6.Check-enginelight

7.Low-oilpressurelight

8.Coolant-temperature gauge

Thetachometerdisplaysthespeedoftheengine (Figure14).

Thedifferential-lockswitchallowsyoutolocktherear axleforincreasedtraction.Pushthedifferential-lock switch(Figure13)totogglethedifferentiallockonor off.

Note:Y oumaylockandunlockthedifferentialwhile

themachineisinmotion.

HornButton

InternationalModelsOnly

Thehornbuttonislocatedonthecontrolpanel(Figure

13).Pressthehornbuttontosoundthehorn.

Note:Thewhitetriangleindicatesthedesiredengine

speedfor540rpmPTOoperation.

Page 18

Note:Theoil-pressurelightshouldglowred.

Ifthelightdoesnotfunction,eitherabulbis burnedoutorthereisamalfunctioninthe systemthatyoumustrepair.

Note:Ifenginewasjustshutoff,itmaytake1

to2minutesforthelighttocomeon.

Coolant-TemperatureGaugeandLight

Thecoolant-temperaturegaugeandlightregistersthe coolanttemperatureintheengineandoperatesonly whenthekeyswitchisinONposition(Figure14).The indicatorlightblinksrediftheengineoverheats.

FuelGauge

Figure15

1.Enginespeed(rpm)2.3,300rpmfor540rpm PTOoperation

HourMeter

Thehourmeterindicatesthetotalhoursofmachine operation.Thehourmeter(Figure14)startsto functionwheneveryourotatethekeyswitchtotheON positionoriftheengineisrunning.

Speedometer

Thespeedometerregistersthegroundspeedofthe machine(Figure14).Thespeedometerisinmph,but youcaneasilyconvertittokm/h;refertoConverting

theSpeedometer(page58).

Check-EngineLight

Thecheck-enginelight(Figure14)illuminatestonotify theoperatorofanenginemalfunction.

ContactyourauthorizedTorodistributor.

g024371

Thefuelgaugeshowstheamountoffuelinthetank. ItdisplaysonlywhenkeyswitchisintheONposition (Figure14).Theredsegmentofthedisplayindicates alow-fuellevelandtheashingredlightindicatesthat thefuelinthetankisnearempty.

Oil-Pressure-WarningLight

Theoil-pressure-warninglight(Figure14)illuminates iftheengine-oilpressuredropsbelowasafelevel whiletheengineisrunning.

Important:Ifthelightickersorremainson,

stopthemachine,shutofftheengine,andcheck theoillevel.Iftheoillevelislow,butadding oildoesnotcausethelighttogooutwhenthe engineisstarted,shutofftheengineimmediately, andcontactyourAuthorizedServiceDealerfor assistance.

Checktheoperationofthewarninglightsasfollows:

1.Engagetheparkingbrake.

2.TurnthekeyswitchtotheON/PREHEATposition,

butdonotstarttheengine.

Page 19

PassengerHandhold

Thepassengerhandholdislocatedonthedashboard (Figure16).

Figure16

g009815

1.Passengerhandhold

2.Storagecompartment

Seat-AdjustmentLever

Youcanadjusttheseatforwardandrearwardforyour comfort(Figure17).

Figure17

1.Seat-adjustmentlever

g021227

Page 20

Specications

Note:Specicationsanddesignaresubjectto

changewithoutnotice.

Overallwidth165.1cm(65inches)

Withoutbed:326cm(128inches)

Withfullbed:331cm(130inches) Overalllength

With2/3bedinrear-mountinglocation:346cm(136inches)

Baseweight(dry)

Ratedcapacity(includes91kg(200lb)operator, 91kg(200lb)passenger,andloadedattachment)

Maximumgrossvehicleweight(GVW)2363kg(5,210lb)

Towcapacity

Groundclearance18cm(7inches)withnoload

Wheelbase

Model07390:866kg(1,905lb)

Model07390TC:887kg(1,951lb)

Model07390:1498kg(3,295lb)

Model07390TC:1477kg(3,249lb)

Tongueweight:272kg(600lb)

Maximumtrailerweight:1587kg(3,500lb)

118cm(70inches)

Wheeltread(centerlinetocenterline)

Height

Front:117cm(46inches)

Rear:121cm(48inches)

192.5cm(75-13/16inches)totopofROPS

Attachments/Accessories

AselectionofToroapprovedattachmentsandaccessoriesisavailableforusewiththemachinetoenhance andexpanditscapabilities.ContactyourAuthorizedServiceDealerorauthorizedT orodistributororgoto www.T oro.comforalistofallapprovedattachmentsandaccessories.

Toensureoptimumperformanceandcontinuedsafetycerticationofthemachine,useonlygenuineT oro replacementpartsandaccessories.Replacementpartsandaccessoriesmadebyothermanufacturerscouldbe dangerous,andsuchusecouldvoidtheproductwarranty .

Page 21

Operation

PerformingDaily Maintenance

BeforeOperation

BeforeOperationSafety

GeneralSafety

•Neverallowchildrenorpeoplewhoarenottrained

orphysicallycapabletosafelyoperateorservice themachine.Localregulationsmayrestrictthe ageoftheoperator.Theownerisresponsiblefor trainingalloperatorsandmechanics.

•Becomefamiliarwiththesafeoperationofthe

equipment,operatorcontrols,andsafetysigns.

•Shutofftheengine,removethekey(ifequipped),

andwaitforallmovementtostopbeforeyouleave theoperator’sposition.Allowthemachinetocool beforeadjusting,servicing,cleaning,orstoringit.

•Knowhowtostopandshutoffthemachinequickly.

•Ensurethattherearenotmoreoccupants(youand

yourpassenger(s))thanthenumberofhandholds equippedonthemachine.

ServiceInterval:Beforeeachuseordaily

Beforestartingthemachineeachday ,performthe EachUse/DailyprocedureslistedinMaintenance

(page32).

CheckingtheTirePressure

ServiceInterval:Beforeeachuseordaily

Fronttiresairpressurespecication:220kPa(32

psi)

Teartiresairpressurespecication:124kPa(18 psi)

Important:Checkthetirepressurefrequently

toensureproperination.Ifthetiresarenot inatedtothecorrectpressure,thetireswillwear prematurelyandmaycausethe4-wheeldriveto bind.

Figure18showsanexampleoftirewearcausedby

under-ination.

•Checkthatallsafetydevicesanddecalsarein

place.Repairorreplaceallsafetydevicesand replaceallillegibleormissingdecals.Donot operatethemachineunlesstheyarepresentand functioningproperly.

FuelSafety

•Useextremecareinhandlingfuel.Itisammable

anditsvaporsareexplosive.

•Extinguishallcigarettes,cigars,pipes,andother

sourcesofignition.

•Useonlyanapprovedfuelcontainer.

•Donotremovethefuelcaporllthefueltank

whiletheengineisrunningorhot.

•Donotaddordrainfuelinanenclosedspace.

•Donotstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such asonawaterheaterorotherappliance.

•Ifyouspillfuel,donotattempttostarttheengine;

avoidcreatinganysourceofignitionuntilthefuel vaporshavedissipated.

g010294

Figure18

1.Under-inatedtire

Figure19showsanexampleoftirewearcausedby

over-ination.

g010293

Figure19

1.Over-inatedtire

Page 22

AddingFuel

•Forbestresults,useonlyclean,fresh(lessthan

30daysold),unleadedgasolinewithancetane ratingof87orhigher((R+M)/2ratingmethod).

•Ethanol:Gasolinewithupto10%ethanol

(gasohol)or15%MTBE(methyltertiarybutyl ether)byvolumeisacceptable.Ethanoland MTBEarenotthesame.Gasolinewith15% ethanol(E15)byvolumeisnotapprovedforuse.

Neverusegasolinethatcontainsmorethan 10%ethanolbyvolume,suchasE15(contains

15%ethanol),E20(contains20%ethanol),orE85 (containsupto85%ethanol).Usingunapproved gasolinemaycauseperformanceproblemsand/or enginedamagewhichmaynotbecoveredunder warranty.

•Donotusegasolinecontainingmethanol.

•Donotstorefueleitherinthefueltankorfuel

containersoverthewinterunlessyouuseafuel stabilizer.

•Donotaddoiltogasoline.

g009814

Figure20

1.Fuel-tankcap

3.Fillthetanktoapproximately25mm(1inch) belowthebottomofthellerneck,andinstall thecap.

UsingStabilizer/Conditioner

Usefuelstabilizer/conditionerinthemachinetokeep thefuelfreshlongerwhenusedasdirectedbythe fuel-stabilizermanufacturer.

Important:Donotusefueladditivescontaining

methanolorethanol.

Addtheamountoffuelstabilizer/conditionertofresh fuelasdirectedbythefuel-stabilizermanufacturer.

FillingtheFuelTank

Fuel-tankcapacity:25L(6.5USgallons).

1.Cleantheareaaroundthefuel-tankcap.

2.Removethefuel-tankcap(Figure20).

Note:Donotoverllthefueltank.

4.Wipeupanyspilledfueltopreventarehazard.

BreakinginaNewMachine

ServiceInterval:Aftertherst100hours—Perform

theguidelinesforbreakinginanew machine.

Performthefollowingtoprovideproperperformance forthemachine:

•Ensurethatthebrakesareburnished;referto6

BurnishingtheBrakes(page14).

•Checktheuidandengine-oillevelsregularly.

Remainalertforsignsthatthemachineorits componentsareoverheating.

•Afterstartingacoldengine,letitwarmupforabout

15secondsbeforeusingthemachine.

Note:Allowmoretimefortheenginetowarmup

whenoperatingincoldtemperatures.

•Varythemachinespeedduringoperation.Avoid

faststartsandquickstops.

•Abreak-inoilfortheengineisnotrequired.

Originalengineoilisthesametypespeciedfor regularoilchanges.

•RefertoMaintenance(page32)foranyspecial,

low-hourchecks.

Page 23

Checkingthe Safety-InterlockSystem

ServiceInterval:Beforeeachuseordaily

VerifyingtheBrakePedal Safety-InterlockSwitch

1.Sitontheoperator’sseatandengagethe parkingbrake.

Thepurposeofthesafety-interlocksystemisto preventtheenginefromcrankingorstarting,unless youpressthebrakepedalandhavethehydraulic-lift leverintheNEUTRALposition.

CAUTION

Ifthesafety-interlockswitchesare disconnectedordamaged,themachinecould operateunexpectedly,causingpersonal injury.

•Donottamperwiththesafety-interlock switches.

•Checktheoperationofthesafety-interlock switchesdaily,andreplaceanydamaged switchesbeforeoperatingthemachine.

Note:RefertotheattachmentOperator’sManual

forproceduresoncheckingtheattachmentinterlock system.

VerifyingtheHydraulic-LiftLever Safety-InterlockSwitch

1.Sitontheoperator’sseatandengagethe parkingbrake.

2.MovetheshiftlevertotheNEUTRALposition andensurethatthehydraulic-liftleverisinthe centerposition.

3.Ifyouhaveanon-TCmodelwiththeHigh-Flow HydraulicKit(optional)orTCmodel,setthe high-owhydraulicswitchtotheOFFposition.

4.Pressthebrakepedal.

5.Movethehydraulic-liftleverforwardandrotate thekeyswitchclockwisetotheST ARTposition.

2.MovetheshiftlevertotheNEUTRALposition andensurethatthehydraulic-liftleverisinthe centerposition.

3.Ifyouhaveanon-TCmodelwiththeHigh-Flow HydraulicKit(optional)orTCmodel,setthe high-owhydraulicswitchtotheOFFposition.

4.RotatethekeyswitchclockwisetotheSTART position.

Note:Donotpressthebrakepedal.

Note:Iftheenginecranksorstarts,thereis

amalfunctionintheinterlocksystemthatyou mustrepairbeforeoperatingthemachine.

VerifyingtheHigh-FlowHydraulic Safety-InterlockSwitch

Note:Thisprocedureisforanon-TCmodelwiththe

High-FlowHydraulicKit(optional)oraTCmodel

1.Sitontheoperator’sseatandengagethe parkingbrake.

2.MovetheshiftlevertotheNEUTRALposition andensurethatthehydraulic-liftleverisinthe centerposition.

3.Setthehigh-owhydraulicswitchtotheON position.

4.Pressthebrakepedal.

5.RotatethekeyswitchclockwisetotheSTART position.

Note:Iftheenginecranksorstarts,thereis

amalfunctionintheinterlocksystemthatyou mustrepairbeforeoperatingthemachine.

Note:Iftheenginecranksorstarts,thereis

amalfunctionintheinterlocksystemthatyou mustrepairbeforeoperatingthemachine.

Page 24

DuringOperation

DuringOperationSafety

GeneralSafety

•Theowner/operatorcanpreventandisresponsible

foraccidentsthatmaycausepersonalinjuryor propertydamage.

•Passengersshouldsitinthedesignatedseating

positionsonly.Donotcarrypassengersinthe cargobed.Keepbystandersandchildrenoutof theoperatingarea.

•Wearappropriateclothing,includingeye

protection;longpants;substantial,slip-resistant footwear;andhearingprotection.Tiebacklong hairanddonotwearlooseclothingorloose jewelry.

•Useyourfullattentionwhileoperatingthe

machine.Donotengageinanyactivitythat causesdistractions;otherwise,injuryorproperty damagemayoccur.

•Donotoperatethemachinewhileill,tired,or

undertheinuenceofalcoholordrugs.

•Operatethemachineoutdoorsorina

well-ventilatedareaonly.

•Donotexceedthemaximumgrossvehicleweight

(GVW)ofthemachine.

•Useextracautionwhenoperatingbrakingor

turningthemachinewithaheavyloadinthecargo bed.

•Carryingoversizedloadsinthecargobedreduces

thestabilityofthemachine.Donotexceedthe carryingcapacityofthebed.

•Carryingmaterialthatcannotbeboundtothe

machine,suchasalargetankofliquid,adversely affectsthesteering,braking,andstabilityofthe machine.Whenyoucarrymaterialthatcannotbe boundtothemachine,usecautionwhensteering orbraking.

•Carryareducedloadandreducetheground

speedofthemachinewhenoperatingonrough, uneventerrain,andnearcurbs,holes,andother suddenchangesinterrain.Loadsmayshift, causingthemachinetobecomeunstable.

•Beforeyoustartthemachine,ensurethatthe

transmissionisinneutral,theparkingbrakeis engaged,andyouareintheoperatingposition.

•Youandyourpassengersshouldremainseated

wheneverthemachineismoving.Keepyour handsonthesteeringwheel;yourpassengers shouldusethehandholdsprovided.Keepyour armsandlegswithinthemachinebodyatalltimes.

•Operatethemachineonlyingoodvisibility.

Watchforholes,ruts,bumps,rocks,orother hiddenobjects.Uneventerraincouldoverturnthe machine.Tallgrasscanhideobstacles.Usecare whenapproachingblindcorners,shrubs,trees,or otherobjectsthatmayobscureyourvision.

•Donotdrivethemachineneardrop-offs,ditches,

orembankments.Themachinecouldsuddenly rolloverifawheelgoesovertheedgeorifthe edgegivesway.

•Alwayswatchoutforandavoidlowoverhangs

suchastreelimbs,doorjambs,overhead walkways,etc.

•Lookbehindanddownbeforereversingthe

machinetobesureofaclearpath.

•Whenusingthemachineonpublicroads,follow

alltrafcregulationsanduseanyadditional accessoriesthatmayberequiredbylaw,suchas lights,turnsignals,slow-movingvehicle(SMV) signs,andothersasrequired.

•Ifthemachineevervibratesabnormally ,stop

andshutoffthemachineimmediately,waitfor allmovementtostop,andinspectfordamage. Repairalldamagetothemachinebeforeresuming operation.

•Itcantakelongertostopthemachineonwet

surfacesthanondrysurfaces.T odryoutwet brakes,driveslowlyonalevelsurfacewhile puttinglightpressureonthebrakepedal.

•Operatingthemachineathighspeedandthen

quicklystoppingmaycausetherearwheelstolock up,whichimpairsyourcontrolofthemachine.

•Donottouchtheengine,transmission,mufer,or

mufermanifoldwhiletheengineisrunning,or soonafteryoushutofftheengine,becausethese areasmaybehotenoughtocauseburns.

•Donotleavearunningmachineunattended.

•Beforeyouleavetheoperatingposition,dothe

following:

–Parkthemachineonalevelsurface.

–ShiftthetransmissiontotheNEUTRALposition.

–Engagetheparkingbrake.

–Lowerthecargobed.

–Shutoffthemachineandremovethekey(if

equipped).

–Waitforallmovementtostop

•Donotoperatethemachinewhenthereistherisk

oflightning.

•Useaccessoriesandattachmentsapprovedby

TheT oro®Companyonly.

Page 25

RolloverProtectionSystem (ROPS)Safety

•TheROPSisanintegralsafetydevice.

•DonotremovetheROPSfromthemachine.

•Alwayswearyourseatbelt;ensurethatitis

attachedandthatyoucanreleaseitquicklyinan emergency.

•Checkcarefullyforoverheadobstructionsanddo

notcontactthem.

•KeeptheROPSinsafeoperatingconditionby

thoroughlyinspectingitperiodicallyfordamage andkeepingallthemountingfastenerstight.

•ReplacedamagedROPScomponents.Donot

repairoralterthem.

SlopeSafety

Slopesareamajorfactorrelatedtoloss-of-control andtip-overaccidents,whichcanresultinsevere injuryordeath.

•Surveythesitetodeterminewhichslopesare

safeforoperatingthemachineandestablishyour ownproceduresandrulesforoperatingonthose slopes.Alwaysusecommonsenseandgood judgmentwhenperformingthissurvey.

•Ifyoufeeluneasyoperatingthemachineona

slope,donotdoit.

avoidsuddenspeedchanges,whichcancause themachinetotiporrollover.Donotengagethe brakessuddenlywhenrollingrearward,asthis maycausethemachinetooverturn.

LoadingandDumpingSafety

•Donotexceedthegrossvehicleweight(GVW)

ofthemachinewhenoperatingitwithaloadin thecargobedand/ortowingatrailer;referto

Specications(page20).

•Distributetheloadinthecargobedevenlyto

improvethestabilityandcontrolofthemachine.

•Beforedumping,ensurethatthereisnoone

behindthemachine.

•Donotdumpaloadedcargobedwhilethe

machineissidewaysonaslope.Thechange inweightdistributionmaycausethemachineto overturn.

OperatingtheCargoBed

RaisingtheCargoBed

WARNING

Araisedbedcouldfallandinjurepersonsthat areworkingbeneathit.

•Keepallmovementonslopesslowandgradual.

Donotsuddenlychangethespeedordirectionof themachine.

•Avoidoperatingthemachineonwetterrain.Tires

maylosetraction.Arollovercanoccurbeforethe tireslosetraction.

•Travelstraightupanddownaslope.

•Ifyoubegintolosemomentumwhileclimbinga

slope,graduallyengagethebrakesandslowly reversethemachinestraightdowntheslope.

•Turningwhilegoingupordownaslopecanbe

dangerous.Ifyoumustturnonaslope,doitslowly andcautiously.

•Heavyloadsaffectstabilityonaslope.Carrya

reducedloadandreduceyourgroundspeedwhen operatingonaslopeoriftheloadhasahigh centerofgravity.Securetheloadtothecargobed ofthemachinetopreventtheloadfromshifting. Takeextracarewhenhaulingloadsthatshifteasily (e.g.,liquids,rock,sand,etc.).

•Avoidstarting,stopping,orturningthemachine

onaslope,especiallywithaload.Stoppingwhile goingdownaslopetakeslongerthanstopping onlevelground.Ifyoumuststopthemachine,

•Alwaysusetheproprodtoholdthebedup beforeworkingunderthebed.

•Removeanyloadmaterialfromthebed beforeraisingit.

WARNING

Drivingthemachinewiththecargobedraised couldcausethemachinetotiporrolleasier. Youcoulddamagethestructureofthecargo bedifyouoperatethemachinewiththebed raised.

•Operatethemachinewhenthecargobed isdown.

•Afteremptyingthecargobed,lowerit.

Page 26

CAUTION

Ifaloadisconcentratednearthebackofthe cargobedwhenyoureleasethelatches,the bedmayunexpectedlytipopen,injuringyou orbystanders.

•Centerloadsinthecargobed,ifpossible.

•Holdthecargobeddownandensurethat nooneisleaningoverthebedorstanding behinditwhenreleasingthelatches.

•Removeallcargofromthebedbefore liftingthebeduptoservicethemachine.

Movetheleverrearwardtoraisethecargobed (Figure21).

g026141

Figure22

1.Latchhandle3.Latchpin

2.Latchgate

Figure21

1.Cargobedlever

LoweringtheCargoBed

WARNING

Theweightofthebedmaybeheavy.Hands orotherbodypartscouldbecrushed.

Keepyourhandsandotherbodypartsaway whenloweringthebed.

Movetheleverforwardtolowerthecargobed(Figure

21).

OpeningtheTailgate

1.Ensurethatthecargobedisdownandlatched.

2.Openthelatchesontheleftandrightsideofthe cargobedandlowerthetailgate(Figure22).

StartingtheEngine

g024612

Important:Donotattempttopushortowthe

machinetogetitstarted.Damagetothedrive traincouldresult.

1.Sitontheoperatorseatandengagetheparking brake.

2.DisengagethePTOandthehigh-owhydraulics (ifequipped)andmovethehand-throttleleverto theOFFposition(ifequipped).

3.MovethetransmissionlevertotheP(PARK) position.

4.Ensurethatthehydraulic-liftleverisintheOFF position(center).

5.Pressthebrakepedal.

Note:Keepyourfootofftheacceleratorpedal.

6.Insertthekeyintothekeyswitchandrotateit clockwisetostarttheengine.

Note:Releasethekeyswitchwhentheengine

starts.

Note:Theoil-pressurewarninglightshould

turnoff.

Important:Topreventoverheatingofthe

startermotor,donotengagestarterlonger than15seconds.After15secondsof

Page 27

continuouscranking,wait60secondsbefore engagingstartermotoragain.

UsingtheSpeed-Range Control

DrivingtheMachine

1.Pressthebrakepedal.

2.Disengagetheparkingbrake.

3.Movethetransmissionlevertothedesiredgear.

4.Releasetheservicebrakeandgraduallypress intheacceleratorpedal.

Important:Alwaysstopthemachinebefore

shiftingtoreverseaforwardgearortoa forwardgearfromreverse.

Usethechartbelowtodeterminetheground speedofeachgearwhenoperatingthe machinewiththespeed-rangecontrolintheT (TRANSPORT)position.

GearSpeed(km/h)Speed(mph)

R(REVERSE)

L(LOWFORWARD)

D(DRIVE)

Note:Avoididlingtheengineforlongperiods

oftime.

Note:LeavingthekeyswitchintheONposition

forlongperiodsoftimewithoutstartingthe enginedischargesthebattery.

0to210to13

0to180to1 1

0to320to20

Usetheleverofthespeed-rangecontroltolimitthe maximumgroundspeedofthemachineforoperations thatrequireaconstantspeedlikesprayingandtop dressing.Thespeed-rangelever(Figure23)isused toselect1ofthe4work-speedrangesthatareused tolimitmaximumgroundspeedoratransport-speed rangethatisusedwhenyoumovethemachine betweenjobsites.

Note:Youmustreleasetheacceleratorpedalin

ordertoshiftbetweenspeedranges,butyoudonot needtostopthemachineinordertoshift.

•Movethespeed-rangeleverintothedetentfor

speedrangesA,B,C,andDwhenprecisecontrol ofmaximum-groundspeedisdesired.

•Movethespeed-rangelevertotheT(TRANSPORT)

positionbymovingthespeed-rangeleveroutof thedetentforrangeA,B,C,orD,thenforwardto theT(TRANSPORT)position.

Note:Usethespeed-rangecontroltolimitthe

maximumgroundspeedineachrangeby4to18 km/h(2.5to11mph)withthetransmissionleverin theL(LOWFORWARD)positionor8to32km/h(5to 20mph)withthetransmissionleverintheintheD (DRIVE)position.

StoppingtheMachine

Tostopthemachine,removeyourfootfromthe acceleratorpedal,thenpressthebrakepedal.

ShuttingOfftheEngine

1.Stopthemachine.

2.MovethetransmissionlevertotheP(PARK) position.

3.Engagetheparkingbrake.

4.RotatethekeyswitchtotheOFFpositionand removethekey.

g024320

Figure23

1.Speed-rangelever4.C(mid-highrange)

2.T(transportrange)5.B(mid-lowrange)

3.D(highrange)6.A(lowrange)

Page 28

UsingtheDifferentialLock

WARNING

Tippingorrollingthemachineonahillcan causeaseriousinjury.

•Theextratractionavailablewiththe differentiallockcanbeenoughtogetyou intodangeroussituationssuchasclimbing slopesthataretoosteeptoturnaround. Beextracarefulwhenoperatingwiththe differentiallockon,especiallyonsteeper slopes.

•Ifthedifferentiallockisonwhenmakinga sharpturnatahigherspeedandtheinside rearwheelliftsofftheground,theremay bealossofcontrol,whichcouldcausethe machinetoskid.Usethedifferentiallock onlyatslowerspeeds.

Figure24

1.Lockposition (differential-lockswitch)

2.Unlockposition (differential-lockswitch)

UsingtheHydraulicControl

Thehydrauliccontrolsupplieshydraulicpowerfrom themachinepumpwhenevertheengineruns.You canusethepowerthroughthequickcouplersatthe rearofthemachine.

g025547

CAUTION

Turningwiththedifferentiallockoncanresult inlossofmachinecontrol.Donotoperate withdifferentiallockonwhenmakingsharp turnsorathighspeeds.

Thedifferentiallockincreasesthetractionofthe machinebylockingtherearwheelssothatawheel doesnotspinout.Thiscanhelpwhenyouhave heavyloadstohaul,onwetturforslipperyareas, goinguphills,andonsandysurfaces.Itisimportant torememberthatthisextratractionisonlyfor temporary,limiteduse.Itsusedoesnotreplacethe safeoperationalreadydiscussedconcerningsteep hillsandheavyloads.

Thedifferentiallockcausestherearwheelstospin atthesamespeed.Whenusingthedifferentiallock, yourabilitytomakesharpturnsissomewhatrestricted andmayscufftheturf.Usethedifferentiallockonly whenneededandatslowerspeeds.

Note:Machinemotionplusaslightturnisrequiredto

engageordisengagedifferentiallock.

WARNING

Hydraulicuidescapingunderpressurecan havesufcientforcetopenetrateskinand cancauseseriousinjury.

Usecarewhenconnectingordisconnecting hydraulicquickcouplers.Shutoffthe engine,engagetheparkingbrake,lowerthe attachment,andplacetheremotehydraulic valveintheoatdetentpositiontorelieve thehydraulicpressurebeforeconnectingor disconnectingthequickcouplers.

Important:Ifmultiplemachinesusethe

sameattachment,cross-contaminationofthe transmissionuidmayoccur.Changethe transmissionuidmorefrequently.

•Pressthedifferential-lockswitchuptolockthe

differential(Figure24).

Note:Thelightinthedifferential-lockswitch

illuminateswhentheswitchisinthelockposition.

•Pressthedifferential-lockswitchuptounlockthe

differential(Figure24).

Page 29

UsingtheHydraulicBed-LiftLever toControlHydraulicAttachments

•OFFPosition

Thisisthenormalpositionforthecontrolvalve whenitisnotinuse.Inthisposition,thework portsofthecontrolvalveareblockedandanyload isheldbythecheckvalvesinbothdirections.

ThispositionissimilartotheLOWER(QUICK

COUPLERBPOSITION).Italsodirectshydraulicuid

toquickcouplerB,exceptthattheleverisheldin thispositionbyadetentleverinthecontrolpanel. Thisallowshydraulicuidtoowcontinuouslyto equipmentthatuseahydraulicmotor.

Usethispositiononlyonattachmentswitha hydraulicmotorattached.

•RAISE(QuickCouplerA)Position

Thispositionliftsthebedandrearhitch attachment,orappliespressuretoquickcoupler A.Thispositionalsoallowshydraulicuidtoreturn fromquickcouplerBtoowbackintothevalve andthenouttothereservoir.Thisisamomentary position,andwhenyoureleasethelever,it spring-returnstothecenter,OFFposition.

Important:Ifyouuseitwithahydraulic

cylinderornoattachment,theONposition causesthehydraulic-uidowtogoovera reliefvalve,whichcandamagethehydraulic system.Usethispositiononlymomentarilyor withamotorattached.

Important:Checkthehydraulic-uidlevel

afterinstallationofanattachment.Checkthe operationoftheattachmentbycyclingthe attachmentseveraltimestopurgeairfrom thesystem,thencheckhydraulic-uidlevel again.Theattachmentcylinderslightlyaffects theuidlevelinthetransaxle.Operatingthe machinewithalowhydraulic-uidlevelcan damagethepump,remotehydraulics,power steering,andmachinetransaxle.

ConnectingtheQuickCouplers

Important:Cleandirtfromthequickcouplers

beforeconnectingthem.Dirtycouplerscan introducecontaminationintothehydraulic system.

Figure25

1.QuickcouplerAposition2.QuickcouplerBposition

•LOWER(QuickCouplerB)Position

Thispositionlowersthebed,rearhitchattachment, orappliespressuretoquickcouplerB.Thisalso allowshydraulicuidtoreturnfromquickcoupler Atoowbackintothevalveandthenouttothe reservoir.Thisisamomentaryposition,andwhen youreleasethelever,itspring-returnstothe center,OFFposition.Momentarilyholdingandthen releasingthecontrolleverinthispositionprovides hydraulic-uidowtoquickcouplerB,which providespowerdownontherearhitch.Whenyou releaseit,itholdsthedown-pressureonthehitch.

Important:Ifyouuseitwithahydraulic

cylinder,holdingthecontrolleverinthelower positioncausesthehydraulic-uidowto gooverareliefvalve,whichcandamagethe hydraulicsystem.

g009822

1.Pullbackthelockingringonthecoupler.

2.Insertthehosenippleintothecoupleruntilit snapsintoposition.

Note:Whenattachingremoteequipmenttothequick

couplers,determinewhichsiderequirespressure, thenattachthathosetoquickcouplerB,whichhas pressurewhenyoupushthecontrolleverforwardor lockedintheONposition.

DisconnectingtheQuickCouplers

Note:Withboththemachineandattachmentshut

off,movetheliftleverbackandforthtoremovethe systempressureandeasethedisconnectionofthe quickcouplers.

1.Pullbackthelockingringonthecoupler.

2.Pullthehosermlyfromthecoupler.

Important:Cleanandinstallthedustplug

anddustcoverstothequickcouplerends whennotinuse.

•ONPosition

Page 30

TroubleshootingtheHydraulic Control

AfterOperation

•Difcultyinconnectingordisconnectingquick

couplers.

Thepressureisnotrelieved(thequickcoupleris underpressure).

•Thepowersteeringisturningwithgreat

difcultyoritisnotturningatall.

–Thehydraulic-uidlevelislow.

–Thehydraulic-uidtemperatureistoohot.

–Thepumpisnotoperating.

•Therearehydraulicleaks.

–Thettingsareloose.

–ThettingismissingtheO-ring.

•Anattachmentdoesnotfunction.

–Thequickcouplersarenotfullyengaged.

–Thequickcouplersareinterchanged.

•Thereisasquealingnoise.

–RemovethevalveleftintheONpositiondetent,

causinghydraulicuidtoowovertherelief valve.

–Thebeltisloose.

•Theenginedoesnotstart.

AfterOperationSafety

GeneralSafety

•Beforeyouleavetheoperatingposition,dothe

following:

–Parkthemachineonalevelsurface.

–ShiftthetransmissiontotheNEUTRALposition.

–Engagetheparkingbrake.

–Lowerthecargobed.

–Shutoffthemachineandremovethekey(if

equipped).

–Waitforallmovementtostop

•Allowthemachinetocoolbeforeadjusting,

servicing,cleaning,orstoringit.

•Donotstorethemachinewherethereisanopen

ame,spark,orpilotlight,suchasonawater heaterorotherappliance.

•Keepallpartsofthemachineingoodworking

conditionandallhardwaretightened.

•Maintainandcleantheseatbelt(s)asnecessary.

•Replaceallworn,damaged,ormissingdecals.

ThehydraulicleverislockedintheFORWARD position.

Page 31

HaulingtheMachine

TowingtheMachine

•Usecarewhenloadingorunloadingthemachine

intoatraileroratruck.

•Usefull-widthrampsforloadingthemachineinto

atraileroratruck.

•Tiethemachinedownsecurely.

RefertoFigure26andFigure27forthetie-down locationsonthemachine.

Note:Loadthemachineonthetrailerwiththefront

ofthemachinefacingforward.Ifthatisnotpossible, securethemachinehoodtotheframewithastrap, orremovethehoodandtransportandsecureit separately;otherwise,thehoodmayblowoffduring transport.

Incaseofanemergency,youcantowthemachine forashortdistance;however,thisisnotthestandard operatingprocedure.

WARNING

Towingatexcessivespeedscouldcausea lossofsteeringcontrol,resultinginpersonal injury.

Nevertowthemachineatfasterthan8km/h (5mph).

Note:Thepowersteeringdoesnotfunction,

makingitdifculttosteer.

Towingthemachineisa2-personjob.Ifyoumust movethemachineaconsiderabledistance,transport itonatruckortrailer.

1.Afxatowlinetothetongueatthefrontofthe frameofthemachine(Figure26).

2.MovethetransmissiontotheNEUTRALposition anddisengagetheparkingbrake.

Figure26

1.Eyeholeintheframe(eachside)

Figure27

1.Axle2.Hitchplate

TowingaTrailer

g009820

g009821

Themachineiscapableofpullingtrailersand attachmentsofgreaterweightthanthemachineitself. Severaltypesoftowhitchesareavailableforthe machine,dependingonyourapplication.Contactyour AuthorizedServiceDealerfordetails.

Whenequippedwithatowhitchboltedontothe rearaxletube,yourmachinecantowtrailersor attachmentswithamaximumgrosstrailerweight (GTW)upto1587kg(3,500lb).

Alwaysloadatrailerwith60%ofthecargoweightin thefrontofthetrailer.Thisplacesapproximately10% (272kg(600lb)maximum)ofthegrosstrailerweight (GTW)onthetowhitchofthemachine.

Whenhaulingcargoortowingatrailer(attachment), donotoverloadthemachineortrailer.Overloading cancausepoorperformanceordamagetothebrakes, axle,engine,transaxle,steering,suspension,body structure,ortires.

Important:T oreducepotentialfordriveline

damage,uselowrange.

Whentowingfth-wheelattachments,likeafairway aerator,alwaysinstallthewheelbar(includedwiththe fthwheelkit)topreventthefrontwheelsfromlifting offthegroundifthetowedattachmentsmovementis suddenlyimpaired.

Page 32

Maintenance

MaintenanceSafety

•Donotallowuntrainedpersonneltoservicethe

machine.

•Beforeyouleavetheoperatingposition,dothe

following:

–Parkthemachineonalevelsurface.

–ShiftthetransmissiontotheNEUTRALposition.

–Engagetheparkingbrake.

–Lowerthecargobed.

–Shutoffthemachineandremovethekey(if

equipped).

–Waitforallmovementtostop

•Allowthemachinetocoolbeforeadjusting,

servicing,cleaning,orstoringit.

•Supportthemachinewithjackstandswhenever

youworkunderthemachine.

•Donotworkunderaraisedbedwithouttheproper

bedsafetysupportinplace.

•Ensurethatallhydraulic-lineconnectorsaretight

andthatallthehydraulichosesandlinesarein goodconditionbeforeapplyingpressuretothe system.

•Beforedisconnectingorperforminganyworkon

thehydraulicsystem,relieveallpressureinthe systembyshuttingoffthemotor,cyclingthedump valvefromraisetolower,and/orloweringthecargo bedandattachments.Placetheremotehydraulics leverintheoatposition.Ifthebedmustbein raisedposition,secureitwiththesafetysupport.

•Carefullyreleasepressurefromcomponentswith

storedenergy.

•Donotchargethebatterieswhileservicingthe

machine.

•Toensurethattheentiremachineisingood

condition,keepallhardwareproperlytightened.

•Toreducethepotentialrehazard,keepthe

machineareafreeofexcessivegrease,grass, leaves,andaccumulationofdirt.

•Ifpossible,donotperformmaintenancewhilethe

machineisrunning.Keepawayfrommovingparts.

•Ifyoumustrunthemachinetoperforma

maintenanceadjustment,keepyourhands,feet, clothing,andanypartsofthebodyawayfrom anymovingparts.Keepbystandersawayfrom themachine.

•Cleanupoilandfuelspills.

•Checktheparkingbrakeoperationas

recommendedinthemaintenancescheduleand adjustandserviceitasrequired.

•Keepallpartsofthemachineingoodworking

conditionandallthehardwareproperlytightened. Replaceallwornordamageddecals.

•Neverinterferewiththeintendedfunctionofa

safetydeviceorreducetheprotectionprovided byasafetydevice.

•Donotoverspeedtheenginebychangingthe

governorsettings.T oensuresafetyandaccuracy, haveanAuthorizedServiceDealercheckthe maximumenginespeedwithatachometer.

•Ifmajorrepairsareevernecessaryorassistance

isrequired,contactanAuthorizedServiceDealer.

•Alteringthismachineinanymannermayaffectthe

operationofthemachine,performance,durability, oritsusemayresultininjuryordeath.Suchuse couldvoidtheproductwarrantyofTheT oro® Company.

RecommendedMaintenanceSchedule(s)

MaintenanceService

Interval

Aftertherst2hours

Aftertherst10hours

Aftertherst50hours

Aftertherst100hours

MaintenanceProcedure

•T orquethefrontandrearwheelnuts.

•Checktheadjustmentoftheparkingbrake.

•Changetheengineoilandlter.

•Inspecttheopeningonthelter.

•Checkthetransmission-uidlevel.

•Performtheguidelinesforbreakinginanewmachine.

Page 33

MaintenanceService

Interval

Beforeeachuseordaily

MaintenanceProcedure

•Inspecttheseatbelt(s)forwear,cuts,andotherdamage.Replacetheseatbelt(s)if anycomponentdoesnotoperateproperly.

•Checkthetirepressure.

•Checktheoperationofthesafety-interlocksystem.

•Checktheengine-oillevel.(Checktheoillevelbeforeandaftertheengineisrst startedanddailythereafter.)

•Checktheoil-pressure-warninglight.

•Checkthelevelofthecoolant.ChecktheCoolantlevelattheoverowreservoir only.Donotremovetheradiatorcap.(Checkthecoolantlevelbeforetheengineis rststartedanddailythereafter.)

•Removedebrisfromtheengineareaandradiator.(Cleanitmorefrequentlyin dirtyconditions.)

•Checkthebrake-uidlevel.(Checkthelevelbeforetheengineisrststartedand dailythereafter.)

•Checkthehydraulic-uidlevel.(Checkthelevelofhydraulicuidbeforetheengine isrststartedanddailythereafter.)

•Washthemachine.

Every25hours

Every50hours

Every100hours

Every200hours

Every400hours

Every800hours

•Removetheair-cleanercoverandcleanoutthedebris.

•Checkthebattery-uidlevel(every30daysifinstorage).

•Checkthebatterycableconnections.

•Greasethebearingsandbushings(lubricatemorefrequentlyinheavy-duty applications).

•Changetheair-cleanerlter(morefrequentlyindustyordirtyconditions).

•Checkthesparkplugs.

•Inspecttheconditionofthetires.

•Checktheconstant-velocitybootsfordamageandleakinglubricant.

•Changetheengineoilandlter.

•Changethecarboncanisterairlter.

•T orquethefrontandrearwheelnuts

•Checktheuidlevelinthereservoirforthespeed-controlcylinder.

•Checktheadjustmentoftheparkingbrake.

•Checktheadjustmentofthebrakepedal.

•Inspecttheserviceandparkingbrakes.

•Replacethefuellter.

•Inspectthefuellinesandconnections.

•Checkthefrontwheelalignment.

•Checkthetransmission-uidlevel.

•Checktheconditionofthedrivebelt.

•Cleantheclutches.

•Visuallyinspectthebrakesforwornbrakeshoes.

•Ifyouarenotusingtherecommendedhydraulicuidorhaveeverlledthereservoir withanalternativeuid,replacethehydraulicuidandlter.

Every1,000hours

Every2,000hours

•Flush/replacethecoolantsystemuid.

•Changethebrakeuid.

•Ifyouareusingtherecommendedhydraulicuid,replacethehydrauliclter.

•Ifyouareusingtherecommendedhydraulicuid,changethehydraulicuid.

Yearly

•Completealloftheyearlymaintenanceproceduresspeciedintheengineowner’s manual.

Page 34

Note:Downloadafreecopyoftheelectricalschematicbyvisitingwww.Toro.comandsearchingforyour

machinefromtheManualslinkonthehomepage.

Important:Refertoyourengineowner’smanualforadditionalmaintenanceprocedures.

WARNING

Failingtoproperlymaintainthemachinecouldresultinprematurefailureofmachinesystems, causingpossibleharmtoyouorbystanders.

Keepthemachinewellmaintainedandingoodworkingorderasindicatedintheseinstructions.

CAUTION

Onlyqualiedandauthorizedpersonnelshouldmaintain,repair,adjust,orinspectthemachine.

•Avoidrehazardsandhavere-protectionequipmentpresentintheworkarea.Donotuse anopenametocheckuidlevelsorleakageoffuel,batteryelectrolyte,orcoolant.

•Donotuseopenpansoffuelorammablecleaninguidsforcleaningparts.

CAUTION

Ifyouleavethekeyintheswitch,someonecouldaccidentlystarttheengineandseriously injureyouorotherbystanders.

Shutofftheengineandremovethekeyfromtheswitchbeforeyouperformanymaintenance.

MaintainingtheMachineunderSpecialOperating Conditions

Important:Ifthemachineissubjectedtoanyoftheconditionslistedbelow,performmaintenance

twiceasfrequently:

•Desertoperation

•Coldclimateoperation—below10°C(50°F)

•Trailertowing

•Frequentoperationindustyconditions

•Constructionwork

•Afterextendedoperationinmud,sand,water,orsimilardirtyconditions,dothefollowing:

–Haveyourbrakesinspectedandcleanedassoonaspossible.Thispreventsanyabrasivematerial

fromcausingexcessivewear.

–Washthemachineusingwateraloneorwithamilddetergent.

Important:Donotusebrackishorreclaimedwatertocleanthemachine.

Page 35

Pre-Maintenance Procedures

PreparingtheMachinefor Maintenance

1.Parkthemachineonalevelsurface.

2.Engagetheparkingbrake.

3.Emptyandraisethecargobed;refertoRaising

theCargoBed(page25).

4.Shutofftheengineandremovethekey.

5.Allowthemachinetocoolbeforeperforming maintenance.

UsingtheBedSupport

Important:Alwaysinstallorremovethebed

supportfromtheoutsideofthebed.

endofthecylinderbarrelandcylinder-rodend (Figure29).

g009164

Figure29

1.Bedsupport3.Bed

2.Cylinderbarrel

1.Raisethebeduntiltheliftcylindersarefully extended.

2.Removethebedsupportfromthestorage bracketsonthebackoftheROPSpanel(Figure

28).

4.Removethebedsupportfromthecylinder,and insertitintothebracketsonthebackofthe ROPSpanel.

Important:Donottrytolowerthebedwith

thebed-safetysupportonthecylinder.

Figure28

1.Bedsupport

3.Pushthebedsupportontothecylinderrod,and ensurethatthesupport-endtabsrestonthe

g026142

Page 36

RemovingtheFullBed

InstallingtheFullBed

1.Starttheengine,engagethehydraulic-liftlever, andlowerthebeduntilthecylindersareloose intheslots.

2.Releasetheliftleverandshutofftheengine.

3.Removethelynchpinsfromtheouterendsof thecylinderrodclevispins(Figure30).

Note:Ifyouareinstallingthebedsidesontheat

bed,itiseasiertoinstallthembeforeinstallingthe bedonthemachine.

Ensurethattherearpivotplatesareboltedtothebed frame/channelsothatthelowerendanglestotherear (Figure31).

Figure30

1.Cylinderrodend

2.Bed-mountingplate

3.Clevispin6.Frontslots(2/3fullbed)

4.Removetheclevispinssecuringthecylinderrod endstothebed-mountingplatesbypushingthe pinstowardtheinside(Figure30).

5.Removethelynchpinsandclevispinssecuring thepivotbracketstotheframechannels(Figure

30).

6.Liftthebedoffthemachine.

4.Lynchpin

5.Rearslots(fullbed)

CAUTION

Thefullbedweighsapproximately148kg (325lb),sodonottrytoinstallorremove itbyyourself.

Useanoverheadhoistorgetthehelpof 2or3otherpeople.

g002368

1.Left,rearcornerofbed4.Clevispin

2.Machineframechannel

3.Pivotplate

Figure31

5.Lynchpin

g002369

CAUTION

Thefullbedweighsapproximately148kg (325lb),sodonottrytoinstallorremoveit byyourself.

Useanoverheadhoistorgetthehelpof2or3 otherpeople.

Ensurethatthespacerbracketsandwearblocks (Figure32)areinstalledwiththecarriage-boltheads positionedinsidethemachine.

7.Storethecylindersinthestorageclips.

8.Engagethehydrauliclift-lockleveronthe machinetopreventaccidentalextensionofthe liftcylinders.

Page 37

RaisingtheMachine

DANGER

Amachineonajackmaybeunstableandslip offthejack,injuringanyonebeneathit.

•Donotstartthemachinewhilethemachine isonajack,astheenginevibrationor wheelmovementcouldcausethemachine toslipoffthejack.

•Alwaysremovethekeyfromthekeyswitch beforegettingoffthemachine.

Figure32

1.Wearblock

2.Spacerbracket

1.Ensurethattheliftcylindersarefullyretracted.

2.Carefullysetthebedontothemachineframe, aligningtherearbedpivot-plateholeswiththe holesintherearframechannel,andinstallthe2 clevispinsandlynchpins(Figure32).

3.Withthebedlowered,secureeachcylinderrod endtotheappropriateslotsinthebed-mounting plateswithaclevispinandlynchpin.

4.Inserttheclevispinfromoutsideofthebedwith thelynchpinorientedtowardtheoutside(Figure

32).

3.Carriagebolt

Note:Therearslotsareforafullbed

installation;thefrontslotsarefora2/3-fullbed installation.

Note:Y oumayneedtostarttheengineto

extendorretractthecylindersforalignmentwith theholes.

g002370

•Blockthetireswhenthemachineisona jack.

Whenjackingupthefrontofthemachine,always placeawoodenblock(orsimilarmaterial)between thejackandthemachineframe.

Thejackingpointatthefrontofthemachineislocated underthefront,centerframesupport(Figure33).

g009823

Figure33

1.Frontjackingpoints

Note:Y oucanplugtheunusedslotwithabolt

andnuttopreventassemblyerrors.

5.Starttheengineandengagethehydraulic-lift levertoraisethebed.

6.Releasetheliftleverandshutofftheengine.

7.Installthebed-safetysupporttoprevent accidentallyloweringthebed;refertoUsingthe

BedSupport(page35).

8.Installthelynchpinstotheinsideendsofthe clevispins.

Note:Iftheautomatictailgatereleaseis

installedonthebed,ensurethatthefrontdump linkrodisplacedontheinsideoftheleftclevis pinbeforeyouinstallthelynchpin.

Thejackingpointattherearofthemachineislocated undertheaxle(Figure34).

Page 38

3.Pivotthetopofthehoodforwardandunplugthe wireconnectorsfromtheheadlights(Figure35).

4.Removethehood.

InstallingtheHood

1.Connectthelights.

2.Insertthetopmountingtabsintotheframeslots (Figure35).

3.Insertthelowermountingtabsintotheframe slots(Figure35).

Figure34

1.Rearjackingpoints

RemovingandInstalling theHood

RemovingtheHood

1.Whilegraspingthehoodintheheadlight openings,liftupthehoodtoreleasethelower mountingtabsfromtheframeslots(Figure35).

g009824

4.Ensurethatthehoodisfullyengagedinthetop, sides,andbottomgrooves.

Figure35

1.Hood

2.Pivotthebottomofthehoodupwarduntilyou canpullthetopmountingtabsfromtheframe slots(Figure35).

g010314

Page 39

Lubrication

GreasingtheBearingsand theBushings

ServiceInterval:Every100hours(lubricate

morefrequentlyinheavy-duty applications).

GreaseType:No.2lithiumgrease

Important:Whengreasingthedriveshaft

universalshaftbearingcrosses,pumpgrease untilitcomesoutofall4cupsateachcross.

1.Usearagtowipethegreasettingcleansothat foreignmattercannotbeforcedintothebearing orbushing.

2.Withagreasegun,applygreaseintothegrease ttingsonthemachine.

•Springtower(2);refertoFigure37

g010571

Figure37

3.Wipeanyexcessgreaseoffthemachine.

Thegreasettinglocationsandquantitiesareas follows:

•Balljoints(4);refertoFigure36

•Pivotmounts(2);refertoFigure36

•Steeringcylinder(2);refertoFigure36

•Tierods(2);refertoFigure36

•Brake(1);refertoFigure38

•Throttle(1);refertoFigure38

g025519

Figure38

Figure36

g010360

Page 40

•DriveshaftU-joints(2);refertoFigure39

•Slidingyolk(1);refertoFigure39

Figure39

EngineMaintenance

EngineSafety

•Shutofftheengine,removethekey ,andwaitfor

allmovingpartstostopbeforecheckingtheoilor addingoiltothecrankcase.

•Keepyourhands,feet,face,clothing,andother

bodypartsawayfromthemuferandotherhot surfaces.

ServicingtheAirFilter

ServiceInterval:Every25hours—Removethe

air-cleanercoverandcleanoutthe debris.

Every100hours—Changetheair-cleanerlter

g025546

(morefrequentlyindustyordirtyconditions).

Inspecttheairlterandhosesperiodicallytomaintain maximumengineprotectionandtoensuremaximum servicelife.Checktheair-ltercoverandhousingfor damage,whichcouldcauseanairleak.Replaceany damagedair-ltercomponents.

1.Pullthelatchoutwardandrotatetheair-lter covercounterclockwise(Figure40).

Figure40

1.Latch4.Dustvalve

2.Air-ltercover

3.Airlter

2.Beforeremovingthelter,uselow-pressure air(40psi,cleananddry)toremovelarge accumulationsofdebrispackedbetweenthe outsideoftheairlterandtheair-lterhousing.

5.Air-lterhousing

g025523

Important:Avoidusinghigh-pressureair,

whichcouldforcedirtthroughthelter intotheintaketract.Thiscleaningprocess preventsdebrisfrommigratingintothe intakewhentheprimarylterisremoved.

Page 41

3.Removetheairlterfromthehousing(Figure

40).

Note:Donotcleanausedlterelement

becauseyoumaydamagetheltermedia.

4.Wipecleantheinterioroftheair-ltercoverand housing(Figure40).

5.Removetherubberdustvalvefromthecover (Figure40).

6.Cleanthedirt-ejectionportlocatedinthe air-cleanercover,thedust-valvecavity,and replacethedustvalve(Figure40).

7.Inspectthenewairlterforshippingdamage, checkingthesealingendofthelterandthe body.

Important:Donotuseadamagedelement.

8.Insertthenewairlterbyapplyinglightpressure totheouterrimoftheltertoseatitinthe air-lterhousing(Figure40).

9.Aligntheair-ltercoverwiththedustvalveatthe 6o’clockpositionwhenviewedfromtheleftend ofthecover(Figure40).

10.Securethelatchoftheair-ltercover(Figure

40).

CheckingtheEngine-OilLevel

ServiceInterval:Beforeeachuseordaily—Check

theengine-oillevel.(Checktheoil levelbeforeandaftertheengineis rststartedanddailythereafter.)

Note:Thebesttimetochecktheengineoiliswhen

theengineiscoolbeforeithasbeenstartedforthe day.Iftheenginehasalreadyran,shutitoffandwait foratleast10minutesbeforecheckingtheoillevel.

1.Parkthemachineonalevelsurface.

2.Engagetheparkingbrake.

3.Shutofftheengineandremovethekey.

4.Removethedipstickandwipeitwithacleanrag (Figure42).

Note:Resettheindicatorifitshowsred(if

equipped).

ServicingtheEngineOil

Note:Changetheoilmorefrequentlywhenoperating

conditionsareextremelydustyorsandy .

Note:Disposeoftheusedengineoilandoillterata

certiedrecyclingcenter.

Engine-OilSpecications

OilType:Detergentengineoil(APISJorhigher)

CrankcaseCapacity:2.0L(2.1USqt)whenthe

lterischanged

Viscosity:Seethetablebelow.

g025526

Figure42

1.Dipsticktube3.Fillercap

2.Fillerneck4.Dipstick

5.Insertthedipstickintothetubeandensurethat itseatsfully.

6.Removedipstickandchecktheoillevel(Figure

42).

7.Iftheoillevelislow,removethellercap(Figure

42)andaddenoughoiltoraisetheleveltothe

Fullmarkonthedipstick.

Note:Whenaddingoil,removedipstickto

allowproperventing.Slowlypourtheoilintothe llerneck,andchecktheleveloftenduringthis process.Donotoverlltheenginewithoil.

Figure41

g001902

Page 42

Figure43

g025525

Figure44

1.Drainplug

g002373

2.Forward

1.Notetheclearancebetweenthelldeviceandtheoil-ll neck.

Important:Whenaddingengineoilorlling

oil,theremustbeclearancebetweentheoil lldeviceandtheoilllneckinthevalve coverasshowninFigure43.Thisclearance isnecessarytopermitventingwhenadding oil.

8.Installthellercapontothellerneck(Figure

42).

9.Firmlyinstallthedipstick(Figure42).

ChangingtheEngineOilandFilter

ServiceInterval:Aftertherst50hours

Every200hours

1.Raisethebedandplacethesafetysupporton

theextendedliftcylindertoholdupthebed.

2.Alignalargedrainpanundertheoil-drainplug

(Figure44).

3.Removethedrainplugandlettheoilowintoa drainpan(Figure44).

4.Whentheoilstopsdraining,installthedrain plug.

5.Removetheoillterfromthelteradapter (Figure45).

g025524

Figure45

1.Forward3.Filteradapter

2.Oillter

6.Wipecleanthesealingbaseoftheofthelter adapter(Figure45).

7.Applyalightcoatofcleanoiltothesealofthe newlter.

8.Installthelteruntilthegasketcontactsthe sealingbaseofthelteradapter,thentighten thelterclockwiseandadditional1/2to2/3of aturn(Figure45).

Note:Donotovertightentheengine-oillter.

Page 43

9.Addthespeciedoiltothecrankcaseofthe engine.

Checkingthe

ServicingtheSparkPlugs

ServiceInterval:Every100hours/Yearly(whichever

comesrst)Replacethesparkplugs ifnecessary.

Oil-Pressure-Warning Light

ServiceInterval:Beforeeachuseordaily

Note:Ifyoujustshutofftheengine,itmaytake1to

2minutesforthelighttocomeon.

1.Engagetheparkingbrake.

2.TurnthekeyswitchtotheONposition,butdo notstarttheengine.

Note:Theoil-pressurelightshouldglowred.

Note:Ifthelightdoesnotfunction,eitherabulb

isburnedout,orthereisamalfunctioninthe systemthatyoumustrepair.

Type:ChampionRN14YC(orequivalent)

AirGap:0.762mm(0.03inch)

Important:Acracked,fouled,dirty,or

malfunctioningsparkplugmustbereplaced.Do notsand-blast,scrape,orcleanelectrodesby usingawirebrushbecausegritmayeventually releasefromtheplugandfallintothecylinder. Theresultisusuallyadamagedengine.

Note:Theplugshouldberemovedandchecked

whenevertheenginemalfunctions.

1.Cleantheareaaroundthesparkplugsothat foreignmattercannotfallintothecylinderwhen youremovethesparkplug.

2.Pullthewireofftheterminalofthesparkplug.

3.Removetheplugfromthecylinderhead.

4.Checktheconditionofthesideelectrode,center electrode,andcenterelectrodeinsulatorto ensurethatthereisnodamage(Figure46).

Note:Donotuseadamagedorwornspark

plug.Replaceitwithanewsparkplugofthe speciedtype.

Figure46

1.Sideelectrode

2.Centerelectrodeinsulator

5.Settheairgapbetweenthecenterandside oftheelectrodesat0.762mm(0.030inch)as showninFigure46.

6.Installthesparkplugintothecylinderhead,and torquetheplugto20N∙m(14.7ft-lb).

7.Installthespark-plugwire.

8.Repeatsteps1through7fortheotherspark plug.

3.Airgap(nottoscale)

g238425

Page 44

FuelSystem Maintenance

InspectingtheCarbon CanisterAirFilter

ServiceInterval:Aftertherst50hours—Inspectthe

openingonthelter.

Every200hours—Changethecarboncanister airlter.

1.Locatetheairlteronthebottomofthecarbon canister(Figure47).

Figure47

1.Filteropening

2.Ensurethattheopeningonthebottomofthe lterisclearandopen.

3.Removeandinstallthenewlter(ifnecessary).

g010330

Figure48

1.Fuelpump

2.Hoseclamp

4.Removethefuel-pumpcapfromthetopofthe fueltank(Figure48).

3.Fuelline/fuellter

Important:Donotallowthefuel-pump

assemblytorotateinthetankwhileremoving thefuelpump.Damagetotheoatassembly canoccurifthefuelpumprotatesinsidethe fueltank.

5.Removethefuel-pumpassemblyandthefuel

g025520

lterfromthetank(Figure48).

6.Removetheclampsecuringthefuellterhose tothefuel-pumptting.

7.Removethehosefromthetting(Figure48).

8.Insertthenewhoseclampontothenew fuel-lterhose.

9.Insertthehoseontothefuelpumpandsecure theclamp.

ReplacingtheFuelFilter

ServiceInterval:Every400hours

1.Raisethebedandplacethesafetysupporton theextended-liftcylindertoholdupthebed.

2.Unplugthewire-harnessconnectorsfromthe fuelpump(Figure48).

3.Loosenthehoseclampanddisconnectthefuel linefromthefuel-pumpcap(Figure48).

10.Inserttheassemblyintothefueltank,and tightenthecapto20to22N∙m(175to200in-lb).

11.Connectthewiresandsecurethehosewiththe hoseclamp.

InspectingFuelLinesand Connections

ServiceInterval:Every400hours/Yearly(whichever

comesrst)

Inspectthefuellines,ttings,andclampsforsignsof leaking,deterioration,damage,orlooseconnections.

Note:Repairanydamagedorleakingfuelsystem

componentbeforeusingthemachine.

Page 45

ElectricalSystem

ServicingtheFuses

Maintenance

ElectricalSystemSafety

•Disconnectthebatterybeforerepairingthe

machine.Disconnectthenegativeterminalrst andthepositivelast.Connectthepositiveterminal rstandthenegativelast.

•Chargethebatteryinanopen,well-ventilated

area,awayfromsparksandames.Unplugthe chargerbeforeconnectingordisconnectingthe battery.Wearprotectiveclothinganduseinsulated tools.

Thefusesfortheelectricalsystemarelocatedunder thecenterofthedashpanel(Figure49andFigure50).

g025637

Figure49

1.Fuses

Figure50

1.Powertakeoff(15A)5.Differentiallock(15A)

2.Enginestart(10A)6.Speedometer(10A)

3.Hazards(10A)

4.Engineignition(10A)8.Horn(30A)

7.Headlightsandrearlights (15A)

decal127-8626a

Page 46

Jump-StartingtheMachine

Note:Thenegativeterminalhas“NEG”onthe

batterycover.

WARNING

Jump-startingcanbedangerous.T oavoid personalinjuryordamagetoelectrical componentsinmachine,observethe followingwarnings:

•Neverjump-startwithavoltagesource greaterthan15VDC;thisdamagesthe electricalsystem.

•Neverattempttojump-startadischarged batterythatisfrozen.Itcouldruptureor explodeduringjump-starting.

•Observeallbatterywarningswhile jump-startingyourmachine.

•Besureyourmachineisnottouchingthe jump-startmachine.

•Connectingcablestothewrongpostcould resultinpersonalinjuryand/ordamageto theelectricalsystem.

1.Squeezethebatterycovertoreleasethetabs fromthebatterybaseandremovethebattery coverfromthebatterybase(Figure51).

Note:Donotconnecttheotherendofthe

jumpercabletothenegativepostofthe dischargedbattery.Connectthejumpercableto theengineorframe.Donotconnectthejumper cabletothefuelsystem.

g010325

Figure52

1.Battery

4.Starttheengineinthemachineprovidingthe jump-start.

Figure51

1.Batterycover

2.Connectajumpercablebetweenthepositive postsofthe2batteries(Figure52).

Note:Thepositivepostmaybeidentiedbya

+signontopofthebatterycover.

Note:Letitrunforafewminutes,thenstart

yourengine.

5.Removethenegativejumpercablerstfrom yourengine,thenthebatteryintheother machine.

6.Installthebatterycovertothebatterybase.

g010326

3.Connect1endoftheotherjumpercabletothe negativeterminalofthebatteryintheother machine.

Page 47

ServicingtheBattery

DriveSystem

ServiceInterval:Every50hours—Checkthe

battery-uidlevel(every30daysif instorage).

Every50hours—Checkthebatterycable connections.

DANGER

Batteryelectrolytecontainssulfuricacid, whichisfatalifconsumedandcausessevere burns.

•Donotdrinkelectrolyteorallowitto contactyourskin,eyesorclothing.Wear safetyglassestoshieldyoureyesand rubberglovestoprotectyourhands.

•Fillthebatterywherecleanwaterisalways availableforushingtheskin.

•Alwayskeepthebatterycleanandfullycharged.

•Ifthebatteryterminalsarecorroded,cleanthem

withasolutionof4partswaterand1partbaking soda.

Maintenance

InspectingtheTires

ServiceInterval:Every100hours

Fronttiresairpressurespecication:220kPa(32

psi)

Reartiresairpressurespecication:124kPa(18 psi)

Operatingaccidents,suchashittingcurbs,can damageatireorrimandalsodisruptwheelalignment, soinspectthetireconditionafteranaccident.

Important:Checkthetirepressurefrequently

toensureproperination.Ifthetiresarenot inatedtothecorrectpressure,thetireswillwear prematurelyandmaycause4-wheeldrivetobind.

Figure53isanexampleoftirewearcausedby

under-ination.

•Applyalightcoatingofgreasetothebattery

terminalstopreventcorrosion.

•Maintainthebatteryelectrolytelevel.

•Keepthetopofthebatterycleanbywashingit

periodicallywithabrushdippedinammoniaor bicarbonateofsodasolution.Flushthetopsurface withwateraftercleaning.Donotremovethell capwhilecleaning.

•Ensurethatthebatterycablesarekepttightonthe

terminalstoprovidegoodelectricalcontact.

•Maintainthecellelectrolytelevelwithdistilledor

demineralizedwater.Donotllthecellsabovethe bottomofthellringinsideeachcell.

•Ifyoustorethemachineinalocationwhere

temperaturesareextremelyhigh,thebatteryruns downmorerapidlythanifthemachineisstoredin alocationwheretemperaturesarecool.

g010294

Figure53

1.Under-inatedtire

Figure54isanexampleoftirewearcausedby

over-ination.

1.Over-inatedtire

g010293

Figure54

Page 48

CheckingtheTorqueofthe WheelNuts

ServiceInterval:Aftertherst2hours

Aftertherst10hours

Every200hours

WARNING

Failuretomaintainpropertorqueofthewheel nutscouldresultinfailureorlossofawheel andmayresultinpersonalinjury.

Torquethefrontandrearwheelnutsto109 to122N∙m(80to90ft-lb)after1to4hours ofoperationandagainafter10hoursof operation.Torquethewheelnutsevery200 hoursthereafter.

CheckingtheFrontWheel Alignment

ServiceInterval:Every400hours/Yearly(whichever

comesrst)

1.Ensurethatthetiresarefacingstraightahead.

2.Measurethecenter-to-centerdistance(ataxle height)atthefrontandrearofthesteeringtires (Figure55).

Note:Themeasurementmustbewithin0±3

mm(0±0.12inch)atthefrontofthetirethenat therearofthetire.Rotatethetire90°andcheck themeasurement.

3.Adjustthecenter-to-centerdistanceasfollows:

A.Loosenthejamnutatthecenterofthetie

rod(Figure56).

g010329

Figure56

1.Tierods2.Jamnuts

B.Rotatethetierodtomovethefrontofthe

tireinwardoroutwardtoachievethecenter tocenterdistancesfromfronttoback.

C.Tightenthetierodjamnutwhenthe

adjustmentiscorrect.

D.Checktoensurethatthetiresturnanequal

amounttotherightandtotheleft.

Note:Ifthetiresdonotturnequally,refer

totheServiceManualfortheadjustment procedure.

Important:Checkthemeasurementsat

consistentlocationsonthetire.Themachine shouldbeonaatsurfacewiththetires facingstraightahead.

Figure55

1.Frontofthemachine3.Centertocenterdistance

2.0±3mm(0±0.12inch)

fronttorearofthetire

g009169

Page 49

Maintainingthe Transmission

ChangingtheTransmissionFluid

Transmission-uidtype:DexronVI

Transmission-uidcapacity:700ml(23.7oz)

CheckingtheTransmission-Fluid Level

ServiceInterval:Aftertherst50hours

Every400hours

Transmission-uidtype:DexronVI

1.Locatethellplugattheatthelower-inboard areaatthebackofthetransmission(Figure57).

1.Parkthemachinetoalevelsurface.

2.Locatethellplugatthebackinboardarea ofthetransmissioncaseandthelocatethe drainplugatthefrontoutboardsideofthe transmission(Figure58andFigure59).

g025527

Figure58

Figure57

1.Fillport(transmission)

2.Alignadrainpanbelowthellplug.

3.Rotatetheplugcounterclockwiseandremove theplugfromthellportinthetransmission (Figure57).

2.Fillplug

Note:Whenthetransmissionuidlevelis

correct,theuidshouldbelevelwiththebottom ofthethreadsinthellport.

4.Ifthetransmission-uidlevelislow,add transmissionuidofthespeciedtypeintothe transmissionthroughthellportuntiltheuid levelisushwiththebottomofthethreadsin theport(Figure57).

Note:Useafunnelwithaexiblehosewhen

llingthetransmission.

5.ChecktheconditionoftheO-ringatthellplug.

Note:ReplacetheO-ringifitiswarnor

damaged.

1.Fillplug3.Forward

g025534

2.Transmissioncase(back inboardlocation)

g025528

Figure59

1.Forward2.Drainplug

3.Removethellplugfromthellportbyrotating

theplugcounterclockwiseandremovingitfrom thetransmission(Figure58).

6.Installthellplugintothetransmissionand tightenitbyhand(Figure57).

4.Alignadrainpanbelowthedrainplug(Figure

59).

Page 50

5.Removethedrainplugfromthedrainportby rotatingtheplugcounterclockwiseandremoving itfromthetransmission(Figure59).

Note:Allowthetransmissionuidtodrain

completely.

6.Installthedrainplug(Figure59).

7.Add700ml(23.7oz)ofDexronVItransmission uidintothetransmissionthroughthellport (Figure58).

Note:Useafunnelwithaexiblehosewhen

llingthetransmission.

Note:Whenthetransmissionuidlevelis

correct,theuidshouldbelevelwiththebottom ofthethreadsinthellport.

8.Installthellplug(Figure58).

ServicingtheReservoirofthe Speed-ControlCylinder

ServiceInterval:Every200hours

Reservoir-uidtype:DOT3brakeuid

1.Removetheknobsfromthehydraulic-liftlever andthespeed-rangelever(Figure60).

Figure60

g025530

Figure61

1.Cap3.Minmark(reservoir)

2.Maxmark(reservoir)4.DOT3brakeuid

5.Iftheuidlevelislow,performthefollowing:

A.Wipecleantheareaaroundthecapforthe

reservoir(Figure61).

B.Removethecapfromthereservoir(Figure

61).

C.Addthespecieduidtoraisethelevel

midwaybetweentheMinandMaxmarkson thesideofthereservoir(Figure61).

D.Installthecaphandtight(Figure61).

6.Aligntheholesinthecontrol-coverplatetothe holesintheseatbase(Figure60).

7.Securetheplatetothebasewiththe6 hex-washerscrews(Figure60)thatyou removedinstep2.

8.Threadtheknobsontotherodsforthe hydraulic-liftleverandthespeed-rangelever

g025529

(Figure60).

1.Knob(speed-rangelever)4.Rod(hydraulic-liftlever)

2.Rod(speed-rangelever)5.Control-coverplate

3.Knob(hydraulic-liftlever)6.Hex-washerscrews(#10 x3/4inch)

2.Removethe6hex-washerscrews(#10x3/4

inch)thatsecurethecontrol-coverplatetothe seatbase,andremovethecoverplate(Figure

60).

3.Movethespeed-rangelevertotheTRANSPORT

position;refertoUsingtheSpeed-Range

Control(page27).

4.Checktheuidlevelinthereservoirforthe

speed-controlcylinder(Figure61).

Note:ThenormaluidlevelisbetweentheMin

andMaxmarksonthesideofthereservoir.

AdjustingtheSpeedControl

Important:Theminimumcontrolledspeedfor

themachineis4.0kph(2.5mph)atfullengine speed.Controllingthemachinespeedslowerthat

4.0kph(2.5mph)resultsinexcessivebeltand clutchwear.

1.DrivethemachineinspeedrangeA(lowrange), B(mid-lowrange),C(mid-highrange),orD (highrange)inordertodeterminewhichspeed rangeincludesthemaximumgroundspeedthat youwanttoset;refertoUsingtheSpeed-Range

Control(page27).

Note:Usethespeedometertodeterminethe

speedthatthemachineistraveling.

2.Removetheknobsfromthehydraulic-liftlever andthespeed-rangelever(Figure60).

Page 51

3.Removethe6hex-washerscrews(#10x3/4 inch)thatsecurethecontrol-coverplatetothe seatbase,andremovethecoverplate(Figure

60).

4.Movethespeed-rangelevertotheT (TRANSPORT)position(Figure62).

5.Loosenthe2hex-socketscrews(5/16x3/4inch) thatsecurethedetentplatetothelever-support bracket(Figure62).

CheckingtheDriveBelt

ServiceInterval:Every400hours

1.Removethe9hex-washerbolts(1/4x1inch) thatsecurethetransmissioncovertothe mountingplateofthetransmission(Figure63).

Figure62

1.Lever-supportbracket3.Detentplate

2.Hex-socketscrews

6.Movethedetentplateinoneofthefollowing directions:

•Movethedetentplateforwardtoincrease

themaximumgroundspeedlimit(Figure62).

•Movethedetentplaterearwardtodecrease

themaximumgroundspeedlimit(Figure62).

7.Tightenthe2hex-socketscrews(5/16x3/4 inch)to19.8to25.4N∙m(14.6to18.7ft-lb).

8.Drivethemachinewiththespeedcontrolset tospeedrangeforwhichyouaresettingthe maximumgroundspeedlimit.Ifthemaximum groundspeedlimitistoofastortooslow,repeat steps1through8untilthecorrectmaximum groundspeedlimitisattained.

9.Aligntheholesinthecontrol-coverplatetothe holesintheseatbase(Figure60).

10.Securetheplatetothebasewiththe6 hex-washerscrews(Figure60)thatyou removedinstep3.

11.Threadtheknobsontotherodsforthe hydraulic-liftleverandthespeed-rangelever (Figure60).

g025550

1.Hex-washerbolts(1/4x1 inch)

2.Transmissioncover

3.Drivebelt6.Beltwidth—replaceat

Figure63

4.Mountingplate

5.Taperedfaces(primary clutch)

29.5mm(1.16inches)or less

g025548

2.Movethecoverforwarduntilyoucanseethe drivebelt(Figure63).

3.Checkthetaperedfacesoftheprimaryclutch forsignsifdamage(Figure63).

Note:Ifthefacesoftheprimaryclutchare

damaged,replacetheprimaryclutch;contact yourAuthorizedServiceDealer.

4.Checkthedrivebeltformissingordamaged cogs(Figure63).

Note:Ifthecogsofthedrivebeltaremissingor

damaged,replacethedrivebelt.

5.Measureacrossthebeltandrecordthebelt width(Figure63).

Note:Ifthewidthofthebeltis29.5mm(1.16

inches)orless,replacethebelt(Figure63).

6.Aligntheholesinthetransmissioncoverwith theholesinthemountingplate(Figure63).

7.Securethecovertothemountingplate(Figure

63)withthe9hex-washerbolts(1/4x1inch)

Page 52

thatyouremovedinstep1,andtorquethebolts to10.2to12.4N∙m(90to110in-lb).

CleaningtheClutches

ServiceInterval:Every400hours

1.Removethe9hex-washerbolts(1/4x1inch) thatsecurethetransmissioncovertothe mountingplateofthetransmission(Figure64).

MaintainingtheDifferential andAxles

ChangingtheDifferentialOil

Oiltype:80W90APIGL-5

Oilcapacity:550ml(18.6oz)

1.Alignadrainpanunderthedrainplug(Figure

65).

Figure64

1.Hex-washerbolts(1/4x1

inch)

2.Transmissioncover

3.Primaryclutch

2.Attheprimaryandsecondaryclutches,Remove dirtandmudbuildupwithwateranddry immediatelywithcompressedairtoremove excesswateranddebris.

3.Removeanyremainingdebrisusingafast-drying contactcleanerorbrakecleaner.

4.Mountingplate

5.Secondaryclutch

Note:Note:Removethedebrisinandaround

movingparts.

4.Ifdebrisorbuildupexistsaroundthebeltor alongtheclutchshaft,useaneabrasivepad orasimilarproducttoremoveit.

5.Aligntheholesinthetransmissioncoverwith theholesinthemountingplate(Figure64).

6.Securethecovertothemountingplate(Figure

64)withthe9hex-washerbolts(1/4x1inch)

thatyouremovedinstep1,andtorquethebolts to10.2to12.4N∙m(90to110in-lb).

g025556

Figure65

g026981

1.Fillplug3.Drainport

2.Fillport4.Drainplug

2.Removethellplugfromthellportandthe drainplugfromthedrainportofthedifferential (Figure65).

Note:Allowthedifferentialtocompletelydrain.

3.ChecktheconditionoftheO-ringsontheplugs.

Note:ReplacedamagedorwornO-rings.

4.Installthedrainplugintothedrainport(Figure

65),andtighttheplugto14to19N∙m(10to14

ft-lb).

Note:Thedrainplugismagnetic.Itisnormal

toseesmallamountsofferrous-metalparticles aroundmagnet—expectmoreparticlesaround themagnetaftertheinitialbreak-in.

5.Add550ml(18.6oz)ofthespeciedoilinto thellportofthedifferential(Figure65).

Note:Useafunnelwithaexiblehosetoadd

oiltothedifferential.

6.Installthellplugintothellport(Figure65), andtightentheplugto14to19N∙m(10to14 ft-lb).

Page 53

CheckingtheConstant-Velocity Boots

ServiceInterval:Every100hours

CoolingSystem Maintenance

1.Jackupthebackendofthemachineand supportitwithjackstands;refertoRaisingthe

Machine(page37).

2.ChecktheCV(constantvelocity)bootsatthe rearaxlesfordamageandleakinglubricant (Figure66).

Note:ReplaceanydamagedorleakingCV

bootbeforeoperatingthemachine.

Figure66

3.Removethejackstandsandlowerthemachine totheground.

CoolingSystemSafety

•Swallowingenginecoolantcancausepoisoning;

keepoutofreachfromchildrenandpets.

•Dischargeofhot,pressurizedcoolantortouching

ahotradiatorandsurroundingpartscancause severeburns.

–Alwaysallowtheenginetocoolatleast15

minutesbeforeremovingtheradiatorcap.

–Usearagwhenopeningtheradiatorcap,and

openthecapslowlytoallowsteamtoescape.

•Donotoperatethemachinewithoutthecovers

inplace.

•Keepyourngers,handsandclothingclearof

rotatingfananddrivebelt.

•Shutofftheengineandremovethekeybefore

performingmaintenance.

g025545

Checkingthe Engine-CoolantLevel

ServiceInterval:Beforeeachuseordaily—Check

thelevelofthecoolant.Check theCoolantlevelattheoverow reservoironly.Donotremovethe radiatorcap.(Checkthecoolant levelbeforetheengineisrst startedanddailythereafter.)

Coolanttype:a50/50solutionofwaterand permanentethylene-glycolantifreeze

CAUTION

Iftheenginehasbeenrunning,the pressurized,hotcoolantcanescapeand causeburns.

•Donotopentheradiatorcap.

•Allowtheenginetocoolforatleast15 minutesoruntiltheradiatorcapiscool enoughtotouchwithoutburningyour hand.

•Usearagwhenopeningthereserve-tank cap,andopenthecapslowlytoallow steamtoescape.

•Donotcheckthecoolantlevelatthe radiator;checkthecoolantlevelatthe reservetankonly.

1.Parkthemachineonalevelsurface.

Page 54

2.Engagetheparkingbrake.

3.Shutofftheengineandremovethekey.

4.Checkthecoolantlevelatthereservetank (Figure67).

Note:Thecoolantshouldbeuptothebottom

ofthellerneck.

RemovingDebrisfromthe CoolingSystem

ServiceInterval:Beforeeachuseordaily—Remove

debrisfromtheengineareaand radiator.(Cleanitmorefrequentlyin dirtyconditions.)

1.Parkthemachineonalevelsurface.

2.Engagetheparkingbrake.

3.Shutofftheengineandremovethekey.

4.Cleantheengineareathoroughlyofalldebris.

5.Unlatchandremovetheradiatorscreenfromthe frontoftheradiator(Figure68).

Figure67

1.Coolant-reservetank

5.Ifcoolantislow,removethereserve-tankcap andadda50/50mixtureofwaterandpermanent ethylene-glycolantifreeze.

Note:Donotoverll.

6.Installthereserve-tankcap.

g010315

Figure68

1.Radiatorscreen

2.Latch

g019522

6.Ifequipped,rotatethelatchesandpivottheoil coolerawayfromtheradiator(Figure69).

g010316

Figure69

1.Radiatorhousing3.Latches

2.Oilcooler

7.Cleantheradiator,oilcooler,andscreenwith compressedair.

Note:Blowdebrisawayfromtheradiator.

8.Installthecoolerandscreentotheradiator.

Page 55

ChangingtheEngine Coolant

ServiceInterval:Every1,000hours/Every2years

(whichevercomesrst)

Cooling-systemcapacity:3.7L(4USqt)

Coolanttype:a50/50solutionofwaterand

permanentethylene-glycolantifreeze

1.Parkthemachineonalevelsurface.

2.Raisethebedandinstallthebedsafetysupport ontheextendedliftcylindertosecurethebed.

CAUTION

Iftheenginehasbeenrunning,the coolingsystempressurizeswithhot coolantthatcanescapeandcauseburns.

•Donotopentheradiatorcapwhenthe engineisrunning.

•Allowtheenginetocoolforatleast 15minutesoruntiltheradiatorcapis coolenoughtotouchwithoutburning yourhand.

g026143

Figure71

1.Reservetank-cap

2.Reservetank

•Usearagtoopentheradiatorcap. Openthecapslowlytoallowthe steamtoescape.

3.Removetheradiatorcap(Figure70).

Figure70

1.Radiatorcap

4.Removethereserve-tankcap(Figure70).

5.Disconnectthelowerradiatorhoseandallow thecoolanttoowintoadrainpan.

Note:Whenthecoolantstopsowing,connect

thelowerradiatorhose.

6.Slowlylltheradiatorwitha50/50mixtureof waterandpermanentethylene-glycolantifreeze

7.T opofftheradiatorandinstallthecap(Figure

70).

8.Slowlyllthecoolant-reservetankuntillevel reachesthebottomofthellerneck(Figure71).

9.Installthereserve-tankcap(Figure71).

g010331

10.Starttheengineandoperateituntilitiswarm.

11.Shutofftheengine,checkthecoolantlevel,and replenishthecoolant,ifnecessary.

Page 56

BrakeMaintenance

CheckingtheBrake-Fluid Level

ServiceInterval:Beforeeachuseordaily—Check

thebrake-uidlevel.(Checkthe levelbeforetheengineisrst startedanddailythereafter.)

Every1,000hours/Every2years(whichever comesrst)—Changethebrakeuid.

Brake-uidtype:DOT3brakeuid

Note:Thebrake-uidreservoirshipsfromthefactory

lledwithDOT3brakeuid.

1.Parkthemachineonalevelsurface.

2.Engagetheparkingbrake.

3.Shutofftheengineandremovethekey.

4.Removethehood.

5.Checktheuidlevelinthebrake-uidreservoir (Figure72andFigure73).

Note:TheuidlevelshouldbeuptotheFull

lineonthereservoir.

g002379

Figure73

1.Brake-uidreservoir

6.Iftheuidlevelislow,performthefollowing:

A.Cleantheareaaroundthecapforthe

reservoir(Figure73).

B.Removethereservoircap(Figure73).

C.AddthespeciedbrakeuidtotheFullline

onthereservoir(Figure73).

Important:Donotoverllthebrake-uid

reservoir.

D.Installthecap(Figure73).

7.Installthehood.

AdjustingtheParking Brake

ServiceInterval:Aftertherst10hours

Every200hours

1.Brake-uidreservoir

Figure72

1.Removetherubbergripfromtheparking-brake lever(Figure74).

g009817

g033258

Figure74

1.Grip

2.Parking-brakelever

Page 57

2.Loosenthesetscrewsecuringtheknobtothe parking-brakelever(Figure75).

Figure75

1.Knob3.Parking-brakelever

2.Setscrew

3.Rotatetheknob(Figure75)untilaforceof20 to22kg(45to50lb)isrequiredtoactuatethe lever.

4.Tightenthesetscrewwhennished(Figure75).

Note:Ifyoucannolongermakeaparking-brake

adjustmentbyadjustingtheparking-brake lever,loosenthehandletothemiddleofthe adjustmentandadjustthecableattherear,then repeatstep3.

g033259

g025532

Figure76

1.Cotterpin

2.Brake-pedalpivot5.Jamnut

3.Clevispin

4.Mastercylinderyoke

3.Liftuponthebrakepedal(Figure77)untilit contactstheframe.

5.Installtherubbergripontotheparking-brake lever(Figure74).

AdjustingtheBrakePedal

ServiceInterval:Every200hours

1.Removethehood.

2.Removethecotterpinandclevispinsecuring themastercylinderyoketothebrake-pedal pivot(Figure76).

g025531

Figure77

1.Brakepedal2.Acceleratorpedal

4.Loosenthejamnutssecuringtheyoketothe mastercylindershaft(Figure76).

5.Adjusttheyokeuntilitsholesalignwiththehole inthebrake-pedalpivot(Figure76).

6.Securetheyoketothepedalpivotwiththeclevis pinandcotterpin(Figure76).

7.Tightenthejamnutsecuringtheyoketothe mastercylindershaft(Figure76).

Note:Thebrakemastercylindermustrelieve

thepressurefromtheservicebrakewhenitis properlyadjusted.

8.Installthehood.

Page 58

ControlsSystem Maintenance

Convertingthe Speedometer

Youcanconvertthespeedometerfrommphtokpm orkphtomph.

1.Positionthemachineonalevelsurface,shut offtheengine,engagetheparkingbrake,and removethekey.

2.Removethehood.

3.Locatethe2loosewiresnexttothemeter (Figure78).

Figure78

1.Meter(forwardface)3.Speedometerwires

2.Plug

4.Removetheconnectorplugfromtheharness wireandconnectthewirestogether(Figure78).

Note:Themeterswitchesfrommphto

kph.Retainthepluginordertoconvertthe speedometertomph.

5.Installthehood.

g024896

Page 59

HydraulicSystem

productsonlyfromreputablemanufacturerswhowill standbehindtheirrecommendation.

Maintenance

HydraulicSystemSafety

•Seekimmediatemedicalattentionifuidisinjected

intoskin.Injecteduidmustbesurgicallyremoved withinafewhoursbyadoctor.

•Beforedisconnectingorperforminganyworkon

thehydraulicsystem,relieveallpressureinthe systembyshuttingofftheengine,cyclingthe dumpvalvefromraisetolower,and/orlowering thecargobedandattachments.Placetheremote hydraulicsleverintheoatposition.Donotwork underaraisedbedwithouttheproperbedsafety supportinplace.

•Ensurethatallhydraulic-uidhosesandlinesare

ingoodconditionandthatallhydraulicconnections andttingsaretightbeforeapplyingpressureto thehydraulicsystem.

•Keepyourhandsandbodyawayfrompinhole

leaksornozzlesthatejecthigh-pressurehydraulic uid.

•Usecardboardorpapertondhydraulicleaks.

ServicingtheHydraulic System

HydraulicFluidSpecications

Thereservoirislledatthefactorywithhigh-quality hydraulicuid.Checkthelevelofthehydraulicuid beforeyourststarttheengineanddailythereafter; refertoCheckingtheHydraulic-FluidLevel(page59).

HighViscosityIndex/LowPourPoint Anti-wearHydraulicFluid,ISOVG46

MaterialProperties:

Viscosity,ASTMD445cSt@40°C(104°F)

ViscosityIndexASTMD2270

PourPoint,ASTMD97-37°Cto-45°C(-34°F

IndustrySpecications:EatonVickers694(I-286-S,

M-2950-S/35VQ25or

44to48

140orhigher

to-49°F)

M-2952-S)

Note:Manyhydraulicuidsarealmostcolorless,

makingitdifculttospotleaks.Areddyeadditivefor thehydraulicuidisavailablein20ml(0.67oz) bottles.Abottleissufcientfor15to22L(4to6US gallons)ofhydraulicuid.OrderPartNo.44-2500 fromyourauthorizedTorodistributor.

CheckingtheHydraulic-Fluid Level

ServiceInterval:Beforeeachuseordaily—Check

thehydraulic-uidlevel.(Check thelevelofhydraulicuidbefore theengineisrststartedanddaily thereafter.)

Hydraulic-uidcapacityforNon-TCmodel:7.5L (2USgallons)

Hydraulic-uidcapacityforNon-TCmodelwiththe HighFlowHydraulicKit(optional)orTCmodel:

15.1L(4USgallons)

1.Parkthemachineonalevelsurface.

Recommendedreplacementuid:T oroPX ExtendedLifeHydraulicFluid;availablein19L(5US gallon)pailsor208L(55USgallon)drums.

Note:Amachineusingtherecommended

replacementuidrequireslessfrequentuidandlter changes.

Alternativeuids:IfT oroPXExtendedLife HydraulicFluidisnotavailable,youmayuseanother conventional,petroleum-basedhydraulicuidhaving specicationsthatfallwithinthelistedrangeforallthe followingmaterialpropertiesandthatitmeetsindustry standards.Donotusesyntheticuid.Consultwith yourlubricantdistributortoidentifyasatisfactory product.

Note:T orodoesnotassumeresponsibilityfor

damagecausedbyimpropersubstitutions,souse

2.Engagetheparkingbrake.

3.Shutofftheengineandremovethekey.

4.Cleantheareaaroundthellerneckandthe capofthehydraulicreservoir(Figure79and

Figure80).

Page 60

Figure79

Hydraulic-uidlevel(non-TCmodels)

5.Removethecapanddipstickfromthellerneck ofthereservoirandwipethedipstickcleanwith arag(Figure79andFigure80).

6.Insertthedipstickintothellerneck;then removeitandchecktheuidlevel(Figure79 andFigure80).

•Non-TCmodel:Thehydraulic-uidlevel

shouldbebetweenthelowerindentedarea onthedipstick.

•Non-TCmodelwiththe

High-Flow-HydraulicKit(option)or TCmodel:Thehydraulic-uidlevelshould

bebetweentheupperindentedareaonthe dipstick.

7.Ifthelevelislow,addthespeciedhydraulic uidintothereservoirtoraisetheleveltothe middleoftheindentedareaonthedipstick (Figure79andFigure80).

8.Installthedipstickandcaptothellerneckof

g024249

thereservoir(Figure79andFigure80).

1.Cap

2.Dipstick3.Fillerneck

Figure80

Hydraulic-uidlevel(non-TCmodelwiththeHighFlow

HydraulicKit(optionalkit)orTCmodel)

1.Cap

2.Dipstick3.Fillerneck

g024250

Page 61

ReplacingtheHydraulicFilter

ChangingtheHydraulicFluid

ServiceInterval:Every1,000hours—Ifyouare

usingtherecommendedhydraulic

uid,replacethehydrauliclter.

Important:Useofanyotherltermayvoidthe

warrantyonsomecomponents.

1.Parkthemachineonalevelsurface,shutoffthe engine,engagetheparkingbrake,andremove thekey.

2.Cleantheareaaroundlter-mountingarea (Figure81).

ServiceInterval:Every2,000hours—Ifyouare

usingtherecommendedhydraulic

uid,changethehydraulicuid.

Every800hours—Ifyouarenotusingthe recommendedhydraulicuidorhaveeverlled thereservoirwithanalternativeuid,replace thehydraulicuidandlter.

Hydraulic-uidcapacityforNon-TCmodel:7.5L (2USgallons)

Hydraulic-uidcapacityforNon-TCmodelwiththe HighFlowHydraulicKit(optional)orTCmodel:

15.1L(4USgallons)

1.Parkthemachineonalevelsurface,shutoffthe engine,engagetheparkingbrake,andremove thekey.

2.Raisethecargobed.

3.Removethecapanddipstickfromthellerneck ofthehydraulictank(Figure82).

Figure81

1.Filteradapter

2.Hydrauliclter

3.Placeadrainpanunderthelter(Figure81).

4.Removethelterbyrotatingitcounterclockwise (Figure81).

5.Cleanthelter-seatingsurfaceofthelter adapter(Figure81).

6.Lubricatethegasketonthenewlterwiththe speciedhydraulicuid.

7.Threadthelterontothelteradapteruntilthe gasketoftheltercontactstheseatingsurface oftheadapter(Figure81),andthentightenthe lteranadditional1/2turn(Figure81).

8.Starttheengineandletitrunforabout2minutes topurgeairfromthesystem.

9.Shutofftheengineandcheckthehydraulic-uid levelinthehydraulictankandthelterareafor leaks.

g025557

g025578

Figure82

1.Cap4.Siphonequipment

2.Dipstick

3.Fillerneck(hydraulictank)

5.Collectioncontainer

4.Routetheintakehoseofthesiphoning equipmentthroughthellerneckofthehydraulic tankandtothebottomofthetank(Figure82).

5.Directthedischargehoseofthesiphoning equipmentintoacollectioncontainer(Figure82) witha11.4L(3USgallon)capacity—Non-TC modelor18.9L(5USgallon)capacity—Non-TC

Page 62

modelwiththeHighFlowHydraulicKit(option) orTCmodel.

6.Siphonthehydraulicuidfromthehydraulic tank.

7.Removethesiphoningequipmentfromthe hydraulictank(Figure82).

8.Add7.5L(2USgallons)—Non-TCmodelor

15.1L(4USgallons)—Non-TCmodelwiththe HighFlowHydraulicKit(option)orTCmodelof thespeciedhydraulicuidintothehydraulic tank(Figure82).

Important:Useonlythehydraulicuids

specied.Otheruidscouldcausesystem damage.

9.Installthedipstickandcaptothellerneckof thehydraulictank(Figure82).

10.Starttheengineandoperatethemachinetoll thehydraulicsystem.

11.Checkthehydraulic-uidlevelandreplenishit, ifrequired.

RaisingtheCargoBedin anEmergency

Thecargobedcanberaisedinanemergencywithout startingtheenginebycrankingstarterorbyjumping thehydraulicsystem.

RaisingtheCargoBedusingthe Starter

RaisingtheCargoBedbyJumping theHydraulicSystem

CAUTION

Araisedbedfullofmaterialwithouttheproper safetysupportrodmaylowerunexpectedly. Workingunderanunsupportedraisedbed maycauseinjurytoyouorothers.

•Beforeservicingormakingadjustmentsto themachine,parkthemachineonalevel surface,engagetheparkingbrake,shutoff theengine,andremovethekey.

•Removeanyloadmaterialfromthebed orotherattachmentandinsertthesafety supportonafullyextendedcylinderrod beforeworkingunderaraisedbed.

Youwillneed2hydraulichoses,eachwithamale andfemalequickcoupler,thattthemachine couplers,toperformthisoperation.

1.Backanothermachineuptotherearofthe disabledmachine.

Important:Themachinehydraulicsystem

usesDexronIIIATF.T oavoidsystem contamination,makesurethatthemachine usedtojumpthehydraulicsystemusesan equivalentuid.

2.Onbothmachine,disconnectthe2quick-coupler hosesfromthehosessecuredtothecoupler bracket(Figure83).

Crankthestarterwhileholdingtheliftleverinthe Raiseposition.Runthestarterfor10seconds,then wait60secondsbeforeengagingthestarteragain. Iftheenginedoesnotcrank,youmustremovethe loadandbed(attachment)toservicetheengineor transaxle.

g009822

Figure83

1.Quick-couplerhoseA

2.Quick-couplerhoseB

Page 63

3.Onthedisabledmachine,connectthe2jumper hosestothehosesthatweredisconnected (Figure84).

11.Aftercompletingtheoperation,removethe jumperhosesandconnectthehydraulichoses tobothmachines.

4.Captheunusedttings.

Figure84

1.Disconnectedhoses2.Jumperhoses

5.Ontheothermachine,connectthe2hosesto thecouplerstillinthecouplerbracket(connect thetophosetothetopcouplerandthebottom hosetothebottomcoupler)(Figure85).

Important:Checkthehydraulicuid

levels,inbothmachines,beforeresuming operation.

g002429

6.Captheunusedttings.

Figure85

1.Jumperhoses

7.Keepallbystandersawayfromthemachines.

8.Startthesecondmachineandmovetheliftlever totheraiseposition,whichraisesthedisabled cargobed.

9.Movethehydraulic-liftlevertotheNEUTRAL position,andengagethelift-leverlock.

10.Installthebedsupportontotheextendedlift cylinder;refertoUsingtheBedSupport(page

35).

g019543

Note:Withboththemachineturnedoff,move

theliftleverbackandforthtoremovethesystem pressureandeasethedisconnectionofthe quickcouplers.

Page 64

Cleaning

WashingtheMachine

ServiceInterval:Beforeeachuseordaily—Wash

themachine.

Washthemachineasneededusingwateralone orwithamilddetergent.Y oumayusearagwhen washingthemachine.

Important:Donotusebrackishorreclaimed

watertocleanthemachine.

Important:Donotusepower-washingequipment

towashthemachine.Power-washingequipment maydamagetheelectricalsystem,loosen importantdecals,orwashawaynecessarygrease atfrictionpoints.Avoidexcessiveuseofwater nearthecontrolpanel,engine,andbattery.

Important:Donotwashthemachinewiththe

enginerunning.Washingthemachinewiththe enginerunningmayresultininternalengine damage.

Page 65

Storage

StorageSafety

•Shutoffthemachine,removethekey(ifequipped),

andwaitforallmovementtostopbeforeyouleave theoperator’sposition.Allowthemachinetocool beforeadjusting,servicing,cleaning,orstoringit.

•Donotstorethemachineorfuelcontainerwhere

thereisanopename,spark,orpilotlight,such asonawaterheaterorotherappliance.

durationrecommendedbythefuel stabilizermanufacturer.

B.Runtheenginetodistributeconditionedfuel

throughthefuelsystemfor5minutes.

C.Shutofftheengine,allowittocool,and

drainthefueltank.

D.Starttheengineandrunituntilitstops.

E.Startandruntheengineagainuntilitdoes

notstartagain.

F.Disposeofdrainedfuelproperly.Recycle

asperlocalcodes.

StoringtheMachine

ServiceInterval:Every200hours—Inspectthe

serviceandparkingbrakes.

Every400hours—Visuallyinspectthebrakes forwornbrakeshoes.

Yearly

1.Positionthemachineonalevelsurface,engage theparkingbrake,shutofftheengine,and removethekeyfromthekeyswitch.

2.Cleandirtandgrimefromtheentiremachine, includingtheoutsideoftheenginecylinderhead nsandblowerhousing.

Important:Youcanwashthemachine

withmilddetergentandwater.Donot usehigh-pressurewatertowashthe machine.Pressurewashingthemachine maydamagetheelectricalsystemorwash awaynecessarygreaseatfrictionpoints. Avoidexcessiveuseofwater,especiallynear thecontrolpanel,lights,engine,andbattery.

3.Checkandadjustthebrakepedalandparking brake,ifnecessary;refertoAdjustingtheBrake

Pedal(page57)andAdjustingtheParking Brake(page56).

4.Servicetheaircleaner;refertoServicingtheAir

Filter(page40).

5.Greasethemachine;refertoGreasingthe

BearingsandtheBushings(page39).

6.Changetheengineoilandlter;referto

ServicingtheEngineOil(page41).

7.Checkthetirepressure;refertoCheckingthe

TirePressure(page21).

8.Forstorageover30days,preparethefuel systemasfollows:

A.Addapetroleumbased

stabilizer/conditionertothefuelinthe tank.Donotuseanalcohol-basedstabilizer (ethanolormethanol).

Important:Donotstorefuelcontaining

stabilizer/conditionerlongerthanthe

9.Removethesparkplugsandchecktheir condition;refertoServicingtheSparkPlugs

(page43).

10.Withthesparkplugsremovedfromtheengine, pour15ml(2tablespoons)ofengineoilintothe spark-plughole.

11.Usethestartertocranktheengineanddistribute theoilinsidethecylinder.

12.Installthesparkplugsandtighteneachoneto therecommendedtorque;refertoServicingthe

SparkPlugs(page43).

Note:Donotinstallthespark-plugwiresonthe

sparkplugs.

13.Checktheantifreezeprotectionandadda50/50 solutionofwaterandantifreezeasneededfor expectedminimumtemperatureinyourarea.

14.Removethebatteryfromthechassis,and chargeitfully;refertoServicingtheBattery

(page47).

Note:Donotconnectthebatterycablestothe

batterypostsduringstorage.

Important:Thebatterymustbefully

chargedtopreventitfromfreezingandbeing damagedattemperaturesbelow0°C(32°F). Afullychargedbatterymaintainsitscharge forabout50daysattemperatureslower than4°C(40°F).Ifthetemperatureswillbe above4°C(40°F),checkthewaterlevelinthe batteryandchargeitevery30days.

15.Checkandtightenallfasteners.Repairor replaceanypartthatisdamaged.

16.Paintallscratchedorbaremetalsurfaces withpaintavailablefromyourauthorizedToro distributor.

17.Storethemachineinaclean,drygarageor storagearea.

18.Removethekeyfromthekeyswitchandputitin asafeplacethatisoutofthereachofchildren.

19.Coverthemachinetoprotectitandkeepitclean.

Page 66

Troubleshooting

Problem

Thequickcouplersaredifcultto connectordisconnect.

Thepowersteeringmoveshard.

Anattachmentdoesnotfunction.

Asquealingnoiseisheard.

PossibleCauseCorrectiveAction

1.Thehydraulicpressurenotrelieved (thequickcouplerisunderpressure).

1.Thehydraulic-uidlevelislow.1.Servicethehydraulicreservoir.

2.Thehydraulicuidishot.2.Checkthehydraulic-uidleveland

3.Thehydraulicpumpnotoperating.

1.Thettingisloose.1.Tightenthetting. Thehydraulicttingleaks.

2.Thehydraulicttingismissingan O-ring.

1.Thequickcouplersarenotfully connected.

2.Thequickcouplersareinterchanged.2.Disconnectthequickcouplings,align

1.TheHydraulic-liftleverislockedinthe ONposition(causinghydraulicuidto owoverthereliefvalve).

1.Shutofftheengine,movethe hydraulic-liftleverforwardand backwardseveraltimes,andconnect thequickcouplersforthettingsinthe auxiliaryhydraulicpanel.

serviceifitislow.Contactan AuthorizedServiceDealer .

3.ContactanAuthorizedServiceDealer.

2.InstallthemissingO-ring.

1.Disconnectthequickcouplings, removeanddebrisfromthecouplings, connectthecouplings.Replaceany damagedcouplings.

thecouplingstothecorrectportson theauxiliaryhydraulicpanel,connect thecouplings.

1.Setthehydraulic-liftlocktotheUNLOCK positionandmovethehydraulic-lift levertoNEUTRAL.

Theenginedoesnotstart.

Thetransmissionishardtoshift.

Theclutchengagementisabrupt.

1.Thehydraulic-liftleverislockedinthe ONposition.

1.Theengine-idlerpmissettoofast.

2.Theclutchesaredirty .

1.Theengineidleistooslow.1.Adjusttheenginelowidleto1,250to

2.Thebeltisnew.

3.Theacceleratorpedalfreeplayistoo large.

4.Theclutchedaredirty .

1.Setthehydraulic-liftlocktotheUNLOCK position,movethehydraulic-liftleverto NEUTRAL,andstarttheengine.

1.Adjusttheenginelowidleto1,250to 1,350rpm.

2.Cleantheclutches.

1,350rpm.

2.Allow10hoursofnormaloperationfor thebeltbreak-inperiod.

3.Adjusttheacceleratorpedal.

4.Cleantheclutches.

Page 67

Notes:

Page 68

Notes:

Page 69

Notes:

Page 70

CaliforniaProposition65WarningInformation

Whatisthiswarning?

Youmayseeaproductforsalethathasawarninglabellikethefollowing:

WARNING:CancerandReproductiveHarm—www.p65Warnings.ca.gov.

WhatisProp65?

Prop65appliestoanycompanyoperatinginCalifornia,sellingproductsinCalifornia,ormanufacturingproductsthatmaybesoldinorbroughtinto California.ItmandatesthattheGovernorofCaliforniamaintainandpublishalistofchemicalsknowntocausecancer,birthdefects,and/orother reproductiveharm.Thelist,whichisupdatedannually,includeshundredsofchemicalsfoundinmanyeverydayitems.ThepurposeofProp65isto informthepublicaboutexposuretothesechemicals.

Prop65doesnotbanthesaleofproductscontainingthesechemicalsbutinsteadrequireswarningsonanyproduct,productpackaging,orliteraturewith theproduct.Moreover,aProp65warningdoesnotmeanthataproductisinviolationofanyproductsafetystandardsorrequirements.Infact,the CaliforniagovernmenthasclariedthataProp65warning“isnotthesameasaregulatorydecisionthataproductis‘safe’or‘unsafe.’”Manyofthese chemicalshavebeenusedineverydayproductsforyearswithoutdocumentedharm.Formoreinformation,gotohttps://oag.ca.gov/prop65/faqs-view-all

AProp65warningmeansthatacompanyhaseither(1)evaluatedtheexposureandhasconcludedthatitexceedsthe“nosignicantrisklevel”;or(2) haschosentoprovideawarningbasedonitsunderstandingaboutthepresenceofalistedchemicalwithoutattemptingtoevaluatetheexposure.

Doesthislawapplyeverywhere?

Prop65warningsarerequiredunderCalifornialawonly.ThesewarningsareseenthroughoutCaliforniainawiderangeofsettings,includingbutnot limitedtorestaurants,grocerystores,hotels,schools,andhospitals,andonawidevarietyofproducts.Additionally,someonlineandmailorder retailersprovideProp65warningsontheirwebsitesorincatalogs.

HowdotheCaliforniawarningscomparetofederallimits?

Prop65standardsareoftenmorestringentthanfederalandinternationalstandards.TherearevarioussubstancesthatrequireaProp65warning atlevelsthatarefarlowerthanfederalactionlimits.Forexample,theProp65standardforwarningsforleadis0.5μg/day,whichiswellbelow thefederalandinternationalstandards.

Whydon’tallsimilarproductscarrythewarning?

•ProductssoldinCaliforniarequireProp65labellingwhilesimilarproductssoldelsewheredonot.

•AcompanyinvolvedinaProp65lawsuitreachingasettlementmayberequiredtouseProp65warningsforitsproducts,butothercompanies

makingsimilarproductsmayhavenosuchrequirement.

•TheenforcementofProp65isinconsistent.

•CompaniesmayelectnottoprovidewarningsbecausetheyconcludethattheyarenotrequiredtodosounderProp65;alackofwarningsfora

productdoesnotmeanthattheproductisfreeoflistedchemicalsatsimilarlevels.

WhydoesToroincludethiswarning?

Torohaschosentoprovideconsumerswithasmuchinformationaspossiblesothattheycanmakeinformeddecisionsabouttheproductstheybuyand use.T oroprovideswarningsincertaincasesbasedonitsknowledgeofthepresenceofoneormorelistedchemicalswithoutevaluatingthelevelof exposure,asnotallthelistedchemicalsprovideexposurelimitrequirements.WhiletheexposurefromToroproductsmaybenegligibleorwellwithinthe “nosignicantrisk”range,outofanabundanceofcaution,TorohaselectedtoprovidetheProp65warnings.Moreover,ifTorodoesnotprovidethese warnings,itcouldbesuedbytheStateofCaliforniaorbyprivatepartiesseekingtoenforceProp65andsubjecttosubstantialpenalties.

RevA

Page 71

EEA/UKPrivacyNotice

Toro’sUseofYourPersonalInformation

TheT oroCompany(“T oro”)respectsyourprivacy.Whenyoupurchaseourproducts,wemaycollectcertainpersonalinformationaboutyou,eitherdirectly fromyouorthroughyourlocalT orocompanyordealer.T orousesthisinformationtofullcontractualobligations-suchastoregisteryourwarranty , processyourwarrantyclaimortocontactyouintheeventofaproductrecall-andforlegitimatebusinesspurposes-suchastogaugecustomer satisfaction,improveourproductsorprovideyouwithproductinformationwhichmaybeofinterest.T oromayshareyourinformationwithoursubsidiaries, afliates,dealersorotherbusinesspartnersinconnectiontheseactivities.Wemayalsodisclosepersonalinformationwhenrequiredbylaworin connectionwiththesale,purchaseormergerofabusiness.Wewillneversellyourpersonalinformationtoanyothercompanyformarketingpurposes.

RetentionofyourPersonalInformation

Torowillkeepyourpersonalinformationaslongasitisrelevantfortheabovepurposesandinaccordancewithlegalrequirements.Formoreinformation [email protected].

Toro’sCommitmenttoSecurity

YourpersonalinformationmaybeprocessedintheUSoranothercountrywhichmayhavelessstrictdataprotectionlawsthanyourcountryofresidence. Wheneverwetransferyourinformationoutsideofyourcountryofresidence,wewilltakelegallyrequiredstepstoensurethatappropriatesafeguardsare inplacetoprotectyourinformationandtomakesureitistreatedsecurely.

AccessandCorrection

Youmayhavetherighttocorrectorreviewyourpersonaldata,orobjecttoorrestricttheprocessingofyourdata.Todoso,pleasecontactusbyemail [email protected] orohashandledyourinformation,weencourageyoutoraisethisdirectlywithus. PleasenotethatEuropeanresidentshavetherighttocomplaintoyourDataProtectionAuthority.

374-0282RevC

Page 72

TheToroWarranty

Two-Y earor1,500HoursLimitedWarranty

ConditionsandProductsCovered

TheToroCompanyanditsafliate,T oroWarrantyCompany,pursuant toanagreementbetweenthem,jointlywarrantyourT oroCommercial product(“Product”)tobefreefromdefectsinmaterialsorworkmanship for2yearsor1,500operationalhours*,whicheveroccursrst.This warrantyisapplicabletoallproductswiththeexceptionofAerators (refertoseparatewarrantystatementsfortheseproducts).Wherea warrantableconditionexists,wewillrepairtheProductatnocosttoyou includingdiagnostics,labor,parts,andtransportation.Thiswarranty beginsonthedatetheProductisdeliveredtotheoriginalretailpurchaser. *Productequippedwithanhourmeter.

InstructionsforObtainingWarrantyService

YouareresponsiblefornotifyingtheCommercialProductsDistributoror AuthorizedCommercialProductsDealerfromwhomyoupurchasedthe Productassoonasyoubelieveawarrantableconditionexists.Ifyouneed helplocatingaCommercialProductsDistributororAuthorizedDealer,or ifyouhavequestionsregardingyourwarrantyrightsorresponsibilities, youmaycontactusat:

ToroCommercialProductsServiceDepartment ToroWarrantyCompany 811 1LyndaleAvenueSouth Bloomington,MN55420-1196

952–888–8801or800–952–2740 E-mail:[email protected]

OwnerResponsibilities

Astheproductowner,youareresponsibleforrequiredmaintenanceand adjustmentsstatedinyourOperator'sManual.Repairsforproductissues causedbyfailuretoperformrequiredmaintenanceandadjustmentsarenot coveredunderthiswarranty.

ItemsandConditionsNotCovered

Notallproductfailuresormalfunctionsthatoccurduringthewarranty periodaredefectsinmaterialsorworkmanship.Thiswarrantydoesnot coverthefollowing:

•Productfailureswhichresultfromtheuseofnon-Tororeplacement

parts,orfrominstallationanduseofadd-on,ormodiednon-Toro brandedaccessoriesandproducts.

•Productfailureswhichresultfromfailuretoperformrecommended

maintenanceand/oradjustments.

•ProductfailureswhichresultfromoperatingtheProductinanabusive,

negligent,orrecklessmanner.

•Partsconsumedthroughusethatarenotdefective.Examplesofparts

whichareconsumed,orusedup,duringnormalProductoperation include,butarenotlimitedto,brakepadsandlinings,clutchlinings, blades,reels,rollersandbearings(sealedorgreasable),bedknives, sparkplugs,castorwheelsandbearings,tires,lters,belts,andcertain sprayercomponentssuchasdiaphragms,nozzles,andcheckvalves.

•Failurescausedbyoutsideinuence,including,butnotlimitedto,

weather,storagepractices,contamination,useofunapprovedfuels, coolants,lubricants,additives,fertilizers,water ,orchemicals.

•Failureorperformanceissuesduetotheuseoffuels(e.g.gasoline,

diesel,orbiodiesel)thatdonotconformtotheirrespectiveindustry standards.

•Normalnoise,vibration,wearandtear,anddeterioration.Normal

“wearandtear”includes,butisnotlimitedto,damagetoseatsdueto wearorabrasion,wornpaintedsurfaces,scratcheddecalsorwindows.

Parts

Partsscheduledforreplacementasrequiredmaintenancearewarranted fortheperiodoftimeuptothescheduledreplacementtimeforthatpart. Partsreplacedunderthiswarrantyarecoveredforthedurationofthe originalproductwarrantyandbecomethepropertyofT oro.T orowillmake thenaldecisionwhethertorepairanyexistingpartorassemblyorreplace it.T oromayuseremanufacturedpartsforwarrantyrepairs.

DeepCycleandLithium-IonBatteryWarranty

DeepcycleandLithium-Ionbatterieshaveaspeciedtotalnumber ofkilowatt-hourstheycandeliverduringtheirlifetime.Operating, recharging,andmaintenancetechniquescanextendorreducetotal batterylife.Asthebatteriesinthisproductareconsumed,theamount ofusefulworkbetweenchargingintervalswillslowlydecreaseuntilthe batteryiscompletelywornout.Replacementofwornoutbatteries, duetonormalconsumption,istheresponsibilityoftheproductowner. Note:(Lithium-Ionbatteryonly):Pro-ratedafter2years.Refertothe batterywarrantyforadditionalinformation.

LifetimeCrankshaftWarranty(ProStripe02657Model

Only)

TheProstripewhichisttedwithagenuineT oroFrictionDiscand Crank-SafeBladeBrakeClutch(integratedBladeBrakeClutch(BBC)+ FrictionDiscassembly)asoriginalequipmentandusedbytheoriginal purchaserinaccordancewithrecommendedoperatingandmaintenance procedures,arecoveredbyaLifetimeWarrantyagainstenginecrankshaft bending.Machinesttedwithfrictionwashers,BladeBrakeClutch(BBC) unitsandothersuchdevicesarenotcoveredbytheLifetimeCrankshaft Warranty.

MaintenanceisatOwner’sExpense

Enginetune-up,lubrication,cleaningandpolishing,replacementoflters, coolant,andcompletingrecommendedmaintenancearesomeofthe normalservicesT oroproductsrequirethatareattheowner’sexpense.

GeneralConditions

RepairbyanAuthorizedToroDistributororDealerisyoursoleremedy underthiswarranty.

NeitherTheToroCompanynorToroWarrantyCompanyisliablefor indirect,incidentalorconsequentialdamagesinconnectionwiththe useoftheToroProductscoveredbythiswarranty,includingany costorexpenseofprovidingsubstituteequipmentorserviceduring reasonableperiodsofmalfunctionornon-usependingcompletion ofrepairsunderthiswarranty.ExceptfortheEmissionswarranty referencedbelow,ifapplicable,thereisnootherexpresswarranty .All impliedwarrantiesofmerchantabilityandtnessforusearelimitedto thedurationofthisexpresswarranty.

Somestatesdonotallowexclusionsofincidentalorconsequential damages,orlimitationsonhowlonganimpliedwarrantylasts,sotheabove exclusionsandlimitationsmaynotapplytoyou.Thiswarrantygivesyou speciclegalrights,andyoumayalsohaveotherrightswhichvaryfrom statetostate.

NoteRegardingEmissionsWarranty

TheEmissionsControlSystemonyourProductmaybecoveredby aseparatewarrantymeetingrequirementsestablishedbytheU.S. EnvironmentalProtectionAgency(EP A)and/ortheCaliforniaAirResources Board(CARB).Thehourlimitationssetforthabovedonotapplytothe EmissionsControlSystemWarranty.RefertotheEngineEmissionControl WarrantyStatementsuppliedwithyourproductorcontainedintheengine manufacturer’sdocumentation.

CountriesOtherthantheUnitedStatesorCanada

CustomerswhohavepurchasedT oroproductsexportedfromtheUnitedStatesorCanadashouldcontacttheirT oroDistributor(Dealer)toobtain guaranteepoliciesforyourcountry ,province,orstate.IfforanyreasonyouaredissatisedwithyourDistributor'sserviceorhavedifcultyobtaining guaranteeinformation,contactyourAuthorizedToroServiceCenter .

374-0253RevF