TORO 07236TC Workman® MDX-D Utility Vehicle Instruction Manual

07236TC Workman® MDX-D Utility Vehicle

Form No. 3442-977 Rev C
Workman® MDX-D Utility Vehicle
Model No. 07236TC–Serial No. 407300000 and Up

Register at www.Toro.com. Original Instructions (EN)

3442-977

This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate the engine on any forest-covered, brush-covered, or grass- covered land unless the engine is equipped with a spark arrester, as defined in Section 4442, maintained in effective working order or the engine is constructed, equipped, and maintained for the prevention of fire.
The enclosed engine owner’s manual is supplied for information regarding the US Environmental Protection Agency (EPA) and the California Emission Control Regulation of emission systems, maintenance, and warranty. Replacements may be ordered through the engine manufacturer.
WARNING
CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash
hands after handling.
Use of this product may cause exposure to chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.

Introduction
This utility vehicle is intended to be primarily used off-highway to transport people and material loads. Using this product for purposes other than its intended use could prove dangerous to you and bystanders.
Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage. You are responsible for operating the product properly and safely.
Visit www.Toro.com for product safety and operation training materials, accessory information, help finding a dealer, or to register your product.
Whenever you need service, genuine Toro parts, or additional information, contact an Authorized Service Distributor or Toro Customer Service and have the model and serial numbers of your product ready. Figure 1 identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.
Important: With your mobile device, you can scan the QR code on the serial number decal (if equipped) to access warranty, parts, and other product information.

© 2021–The Toro® Company 8111 Lyndale Avenue South Bloomington, MN 55420

Figure 1 1. Model and serial number location

g236856

Model No.

Serial No.

This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.
The safety-alert symbol (Figure 2) appears both in this manual and on the machine to identify important

Contact us at www.Toro.com.

2

Printed in the USA All Rights Reserved

safety messages that you must follow to avoid accidents. This symbol will appear with the word Danger, Warning, or Caution.
· Danger indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
· Warning indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
· Caution indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Figure 2 Safety-alert symbol

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Contents
Safety …………………………………………………………….. 4 General Safety …………………………………………… 4 Safety and Instructional Decals …………………….. 4
Setup ……………………………………………………………… 7 1 Installing the Steering Wheel………………………. 7 2 Connecting the Battery ……………………………… 7 3 Checking the Fluid Levels and Tire Pressure ………………………………………………… 8 4 Burnishing the Brakes……………………………….. 8 5 Reading the Manual and Viewing the Setup Material…………………………………………. 9
Product Overview …………………………………………… 10 Controls ……………………………………………………11 Specifications ………………………………………….. 14 Attachments/Accessories …………………………… 14
Before Operation …………………………………………. 15 Before Operation Safety …………………………….. 15 Performing Daily Maintenance…………………….. 15 Checking the Tire Pressure…………………………. 15 Adding Fuel ……………………………………………… 16 Breaking in a New Machine ………………………… 16
During Operation …………………………………………. 17 During Operation Safety …………………………….. 17 Operating the Cargo Bed ……………………………. 18 Starting the Engine ……………………………………. 20 Stopping the Machine ………………………………… 20 Shutting Off the Engine………………………………. 20 Loading the Cargo Bed ………………………………. 20
After Operation ……………………………………………. 21 After Operation Safety ……………………………….. 21 Hauling the Machine ………………………………….. 22 Towing the Machine …………………………………… 22 Towing a Trailer ………………………………………… 22

Maintenance ………………………………………………….. 23 Maintenance Safety…………………………………… 23
Recommended Maintenance Schedule(s) ……….. 23 Daily Maintenance Checklist……………………….. 25 Maintaining the Machine under Special Operating Conditions ……………………………… 25
Pre-Maintenance Procedures ………………………… 26 Preparing the Machine for Maintenance………… 26 Lifting the Machine ……………………………………. 26 Accessing the Hood…………………………………… 27
Lubrication …………………………………………………. 27 Greasing the Front Wheel Bearings ……………… 27
Engine Maintenance ……………………………………. 30 Engine Safety …………………………………………… 30 Servicing the Air Filter………………………………… 30 Servicing the Engine Oil……………………………… 31
Fuel System Maintenance …………………………….. 33 Inspecting Fuel Lines and Connections…………. 33 Replacing the Fuel Filter …………………………….. 33
Electrical System Maintenance ……………………… 34 Electrical System Safety …………………………….. 34 Servicing the Battery………………………………….. 34 Replacing the Fuses ………………………………….. 35 Maintaining the Headlights …………………………. 35
Drive System Maintenance ……………………………. 37 Maintaining the Tires …………………………………. 37 Inspecting the Steering and Suspension Components …………………………………………. 38 Adjusting the Front Wheel Alignment ……………. 39 Checking the Transaxle-Fluid Level ……………… 40 Changing the Transaxle Fluid ……………………… 40 Checking and Adjusting Neutral…………………… 41 Inspecting the Primary Drive Clutch ……………… 41 Maintaining the Primary Drive Clutch ……………. 42
Cooling System Maintenance ………………………… 42 Cooling System Safety ………………………………. 42 Cleaning the Engine-Cooling Areas ……………… 42 Servicing the Radiator ……………………………….. 43
Brake Maintenance ……………………………………… 44 Inspecting the Brakes ………………………………… 44 Adjusting the Parking-Brake Handle …………….. 44 Adjusting the Brake Cables…………………………. 44 Checking the Brake-Fluid Level …………………… 45 Changing the Brake Fluid …………………………… 46
Belt Maintenance ………………………………………… 46 Servicing the Drive Belt………………………………. 46 Checking the Belt-Pull Bumper ……………………. 47
Chassis Maintenance……………………………………. 47 Adjusting the Cargo-Bed Latches ………………… 47
Cleaning …………………………………………………….. 48 Washing the Machine ………………………………… 48
Storage …………………………………………………………. 49 Storage Safety………………………………………….. 49 Storing the Machine…………………………………… 49

3

Safety
This machine has been designed in accordance with the requirements of SAE J2258 (Nov 2016).
General Safety
This product is capable of causing personal injury. Always follow all safety instructions to avoid serious personal injury.
· Read and understand the contents of this Operator’s Manual before you start the machine. Ensure that everyone using this product knows how to use it and understands the warnings.
· Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.

· Do not put your hands or feet near moving components of the machine.
· Do not operate the machine without all guards and other safety protective devices in place and working on the machine.
· Keep bystanders and children out of the operating area. Never allow children to operate the machine.
· Stop and shut off the machine and remove the key before servicing or fueling.
Improperly using or maintaining this machine can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety-alert symbol , which means Caution, Warning, or Danger–personal safety instruction. Failure to comply with these instructions may result in personal injury or death.

Safety and Instructional Decals

Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing.

99-7345

decal99-7345

1. Warning–read the Operator’s Manual.
2. Warning–do not touch the hot surface.
3. Entanglement hazard, belt–stay away from moving parts; keep all guards in place.
4. Crushing hazard, cargo box–use the prop rod to support the cargo bed.

1. Choke 2. Reverse

99-7952
3. Neutral 4. Forward

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4

106-6755

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1. Engine coolant under pressure.
2. Explosion hazard–read the Operator’s Manual.

3. Warning–do not touch the hot surface.
4. Warning–read the Operator’s Manual.

115-2412

decal115-2412

1. Warning–read the Operator’s Manual; no storage.

115-7739

decal115-7739

1. Falling, crushing hazard–do not carry passengers.

1. Horn 2. Hour meter 3. Headlights
4. Engine–shut off 5. Engine–on 6. Engine–start

119-9727

decal119-9727

7. Power point 8. Warning–read the Operator’s Manual.
9. Collision hazard–do not operate the machine on public streets, roads, or highways.
10. Falling hazard–do not carry passengers in the cargo bed.
11. Falling hazard–do not allow children to operate the machine.

120-0627

decal120-0627

1. Cutting/dismemberment hazard, fan–stay away from moving parts, keep all guards and shields in place.

5

120-4837

decal120-4837

1. Read the Operator’s Manual for information on fuses.
2. Alarm/power point (10 A)
3. Engine (10 A)
4. Headlights (10 A)

5. Machine fuse (15 A)
6. Lift (15 A) 7. Rear lift (15 A) 8. Horn (30 A)

121-9775

decal121-9775

1. Warning–read the Operator’s Manual and receive training before operating the machine.
2. Warning–wear hearing protection.
3. Fire hazard–shut off the engine before refueling.

4. Tipping hazard–drive slowly on or across inclines; take turns slowly; do not exceed speeds of 31 kph (19 mph); drive slowly when hauling a load or when driving on uneven terrain.
5. Falling hazard; severing hazard of hand or foot–do not carry passengers in the bed; do not carry a third passenger; do not put your hands or feet outside the machine while operating.

136-1164

decal136-1164

1. Do not exceed a tongue 2. Do not exceed a transport

weight of 45 kg (100 lb).

load of 363 kg (800 lb).

6

Setup

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

Procedure
1 2 3 4
5

Description Steering wheel Cover Washer (1/2 inch)
No parts required
No parts required
No parts required
Operator’s Manual Engine owner’s manual Registration card Predelivery Inspection Form Certificate of Quality Key

Qty.

Use

1

1

Install the steering wheel.

1

­

Connect the battery.

­

Check the fluid levels and tire pressure.

­

Burnish (break-in) the brakes.

1

1

1 1

Read the Operator’s Manual and view the setup material before operating the machine.

1

2

Note: Determine the left and right sides of the machine from the normal operating position.

1
Installing the Steering Wheel

Parts needed for this procedure:

1 Steering wheel

1 Cover

1 Washer (1/2 inch)

Figure 3

g033840

Procedure
1. If the cover is installed, remove it from the hub of the steering wheel (Figure 3).

1. Cover 2. Locknut (1/2 inch) 3. Washer (1/2 inch)

4. Steering wheel 5. Steering shaft

2. Remove the locknut (1/2 inch) from the steering shaft (Figure 3).

3. Slide the steering wheel and washer (1/2 inch) onto the steering shaft (Figure 3).

4. Secure the steering wheel to the shaft with the locknut (1/2 inch) and tighten it to 27 to 34 Nm (20 to 25 ft-lb).

5. Install the cover on the steering wheel (Figure 3).

7

2
Connecting the Battery

No Parts Required

Procedure
WARNING
Incorrect battery cable routing could damage the machine and cables, causing sparks. Sparks can cause the battery gases to explode, resulting in personal injury. · Always disconnect the negative (black)
battery cable before disconnecting the positive (red) cable. · Always connect the positive (red) battery cable before connecting the negative (black) cable.
1. Squeeze the battery cover to release the tabs from the battery base (Figure 4).

Figure 5

g228187

1. Insulator boot (positive battery cable)
2. Negative battery cable (black)

3. Negative battery post

4. Slide the insulator boot over the positive terminal.
Note: The insulator boot prevents a possible short-to-ground from occurring.
5. Connect the negative battery cable (black) to the negative (­) terminal of the battery and secure the cable with the bolts and nuts.
6. Align the battery cover to the battery base (Figure 4).
7. Squeeze the battery cover, align the tabs to the battery base, and release the battery cover (Figure 4).

3
Checking the Fluid Levels and Tire Pressure

1. Battery cover

Figure 4

g228188

2. Remove the battery cover from the battery base (Figure 4).
3. Connect the positive battery cable (red) to the positive (+) terminal of the battery and secure the cable with the bolts and nuts (Figure 5).

No Parts Required
Procedure
1. Check the engine-oil level before and after you first start the engine; refer to Checking the Engine-Oil Level (page 31).
2. Check the brake-fluid level before you first start the engine; refer to Checking the Brake-Fluid Level (page 45).
3. Check the transaxle-fluid level before you first start the engine; refer to Checking the Transaxle-Fluid Level (page 40).
4. Check the air pressure in the tires; refer to Checking the Tire Pressure (page 15).

8

4
Burnishing the Brakes
No Parts Required
Procedure
To ensure optimum performance of the brake system, burnish (break-in) the brakes before use.
1. Bring the machine up to full speed, apply the brakes to rapidly stop the machine without locking up the tires.
2. Repeat this procedure 10 times, waiting 1 minute between stops, to avoid overheating the brakes. Important: This procedure is most effective if the machine is loaded with 227 kg (500 lb).
5
Reading the Manual and Viewing the Setup Material
Parts needed for this procedure:
1 Operator’s Manual 1 Engine owner’s manual 1 Registration card 1 Predelivery Inspection Form 1 Certificate of Quality 2 Key
Procedure
· Read the Operator’s Manual and the engine owner’s manual.
· Fill out the registration card. · Complete the Predelivery Inspection Form. · Review the Certificate of Quality.
9

Product Overview

1. Hood latch 2. Parking-brake lever

3. Cargo bed 4. Towing tongue

Figure 6
5. Gear-shift selector 6. Fuel-tank cap

7. Cargo-bed lever

g033215

10

Controls
Become familiar with all the controls before you start the engine and operate the machine.
Control Panel

Brake Pedal
Use the brake pedal to stop or slow the machine (Figure 7).
CAUTION
Operating a machine with worn or incorrectly adjusted brakes can may result in personal injury. If the brake pedal travels to within 25 mm (1 inch) of the machine floor board, adjust or repair the brakes.

Parking-Brake Lever
The parking-brake lever is located between the seats (Figure 6 and Figure 7). Whenever you shut off the engine, engage the parking brake to prevent the machine from accidentally moving. To engage the parking brake, pull up the parking-brake lever. To disengage the parking brake, push the lever down.

Figure 7

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1. Steering wheel 2. Cup holder
3. Passenger handhold 4. Brake pedal

5. Accelerator pedal
6. Parking-brake handle (center console)
7. Operator’s Manual storage tube

Gear-Shift Selector
The gear-shift selector is located between the seats and below the parking- brake lever. The gear-shift selector has 3 positions: FORWARD, REVERSE, and NEUTRAL (Figure 6).
Note: The engine starts and runs in any of the 3 positions.
Important: Always stop the machine before changing gears.

Accelerator Pedal
Use the accelerator pedal (Figure 7) to vary the ground speed of the machine. Pressing down the accelerator pedal starts the engine. Pressing the pedal farther increases the ground speed. Releasing the pedal slows the machine, and the engine shuts off.
Note: The maximum forward speed is 26 km/h (16 mph).

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Horn Button
The horn button is located at the lower, left corner of the dash panel (Figure 8). Press the horn button to sound the horn.

operate the engine. If the light comes on and remains lit, shut off the engine, and check the engine-oil level. Add oil to the engine if necessary; refer to Servicing the Engine Oil (page 31).
Note: The oil light may flicker; this is normal and no action is needed.

Figure 8

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1. Horn button
2. Hour meter 3. Light switch 4. Battery light 5. Engine oil-pressure light

6. Engine coolant-temperature light
7. Glow plug indicator light
8. Key switch
9. Power point

Engine Coolant-Temperature Light
The engine coolant-temperature light (Figure 8) warns you that the coolant temperature of the engine is too hot to continue operating the engine (the engine is overheating). Shut off the engine and allow the machine to cool down. Check the coolant level and the belts to the fan and water pump. Fill the coolant reservoir with coolant as necessary and replace any worn, damaged, or slipping belts.
Important: If the engine overheating problem persists, contact your Authorized Service Dealer for diagnostics and repair.
Glow-Plug Indicator Light
The glow-plug indicator light (Figure 8) illuminates red when the glow plugs are activated.
Important: The glow-plug indicator light turns on for an additional 15 seconds when the switch returns to the START position.

Light Switch
Use the light switch (Figure 8) to illuminate the headlights. Push the light switch up to turn on the headlights. Push the light switch down to turn off the lights.
Hour Meter
The hour meter indicates the total hours of machine operation. The hour meter (Figure 8) starts to function whenever you rotate the key switch to the ON position or if the engine is running.

Key Switch
Use the key switch (Figure 8), to start and shut off the engine.
The key switch has 3 positions: OFF, ON, and START. Rotate the key clockwise to the ON position to activate the glow plugs. When the glow-plug-indicator light turns off, rotate the key clockwise to the START position. When the engine starts, turn the key counterclockwise to the RUN position.
To shut off the engine, rotate the key counterclockwise to the OFF position.

Battery Light
The battery light (Figure 8) turns on for several seconds when you first start the engine, and turns off when the engine is running. If the light remains on while the engine is running, the alternator, battery, or electrical system is damaged.

Power Point
Use the power point (Figure 8) to power optional 12 V electrical accessories.

Engine Oil-Pressure Light
The engine oil-pressure light (Figure 8) warns you if the engine-oil pressure drops below a safe level to

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Fuel Gauge
The fuel gauge (Figure 9) is located on the fuel tank next to the filler cap, at the left side of the machine. The gauge displays the amount of fuel in the tank.

1. Empty 2. Full 3. Needle

Figure 9
4. Fuel gauge 5. Fuel-tank cap

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Passenger Handholds
The passenger handholds are located on the right side of the dash panel and at the outside of each seat (Figure 10).

Figure 10

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1. Handhold–hip restraint 2. Passenger handhold

13

Specifications

Note: Specifications and design are subject to change without notice.

Base weight
Rated capacity (on level ground)
Gross vehicle weight (GVW)–on level ground Maximum cargo capacity (on level ground) Towing capacity: Standard hitch
Heavy-duty hitch Overall width Overall length Ground clearance Wheel base Wheel tread (center line to center line) Cargo bed length Cargo bed width Cargo bed height Maximum speed Engine speed (non-adjustable)

Dry 590 kg (1,300 lb) 749 kg (1,650 lb) total, including 90.7 kg (200 lb) operator and 90.7 kg (200 lb) passenger, load, trailer tongue weight, gross trailer weight, accessories, and attachments 1341 kg (2,950 lb) total, including all of the weights listed above 567 kg (1,250 lb) total, including trailer tongue weight and gross trailer weight
Tongue weight: 45 kg (100 lb) Gross trailer weight (GTW): 363 kg (800 lb) Tongue weight: 45 kg (100 lb) Gross trailer weight (GTW): 544 kg (1,200 lb) 150 cm (59 inches) 299 cm (117-3/4 inches) 25 cm (10 inches) at the front with no load or operator, 18 cm (7 inches) at the rear with no load or operator 206 cm (81 inches) 125 cm (49 inches) in the front, 120 cm (47-1/4 inches) in the rear 117 cm (46 inches) inside, 133 cm (52-1/4 inches) outside 125 cm (49 inches) inside, 150 cm (59 inches) at outside of the molded fenders 25 cm (10 inches) inside 26 km/h (16 mph) Low idle: 1,200 to 1,300 rpm High idle: 3,420 to 3,520 rpm

Attachments/Accessories
A selection of Toro approved attachments and accessories is available for use with the machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or authorized Toro distributor or go to www.Toro.com for a list of all approved attachments and accessories.
To ensure optimum performance and continued safety certification of the machine, use only genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous, and such use could void the product warranty.

14

Operation
Note: Determine the left and right sides of the machine from the normal operating position.
Before Operation

Performing Daily Maintenance
Service Interval: Before each use or daily
Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 23).

Before Operation Safety
General Safety
· Never allow children or people who are not trained or physically capable to safely operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics.
· Become familiar with the safe operation of the equipment, operator controls, and safety signs.
· Shut off the machine, remove the key, and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
· Know how to stop and shut off the machine quickly.
· Ensure that there are not more occupants (you and your passenger(s)) than the number of handholds equipped on the machine.
· Check that all safety devices and decals are in place. Repair or replace all safety devices and replace all illegible or missing decals. Do not operate the machine unless they are present and functioning properly.

Checking the Tire Pressure
Service Interval: Before each use or daily
Tire air pressure specification: 55 to 103 kPa (8 to 22 psi)
Important: Do not exceed the maximum air pressure indicated on the sidewall of the tire.
Note: The air pressure needed in the tires is determined by the payload that you intend to carry.
1. Check the air pressure in the tires.
Note: The air pressure in the front and rear tires should be between 55 to 103 kPa (8 to 22 psi). · Use lower air pressure in the tires for lighter
payloads, for less soil compaction, for a smoother ride, and to minimize tire marks on the ground. · Use higher air pressure in the tires for carrying heavier payloads at higher speeds.
2. If necessary, adjust the air pressure in the tires by adding or removing air in the tires.

Fuel Safety
· Use extreme care in handling fuel. It is flammable and its vapors are explosive.
· Extinguish all cigarettes, cigars, pipes, and other sources of ignition.
· Use only an approved fuel container.
· Do not remove the fuel cap or fill the fuel tank while the engine is running or hot.
· Do not add or drain fuel in an enclosed space.
· Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance.
· If you spill fuel, do not attempt to start the engine; avoid creating any source of ignition until the fuel vapors have dissipated.

Figure 11

g001055

15

Adding Fuel
Recommended Fuel
The engine runs on clean, fresh diesel fuel with a minimum cetane rating of 40. Purchase fuel in quantities that you can use within 30 days to ensure fuel freshness.
Use summer-grade diesel fuel (No. 2-D) at temperatures above -7°C (20°F) and winter grade diesel fuel (No. 1-D or No. 1-D/2-D blend) below -7°C (20°F). Use of winter-grade diesel fuel at lower temperatures provides lower flash point and pour point characteristics, allowing easier starts and lessening the chances of chemical separation of the fuel due to lower temperatures.
Using summer-grade diesel fuel above -7°C (20°F) contributes toward longer life of the fuel-pump components.
Important: Never use kerosene or gasoline in place of diesel fuel. Failure to observe this caution will damage the engine.
Filling the Fuel Tank
Fuel-tank capacity: 26.5 L (7 US gallons)
1. Clean the area around the fuel-tank cap.
2. Remove the fuel-tank cap (Figure 12).

4. Install the fuel-tank cap securely. 5. Wipe up any spilled fuel.
Breaking in a New Machine
Service Interval: After the first 100 hours–Perform the guidelines for breaking in a new machine.
Perform the following guidelines to provide proper performance for the machine. · Ensure that the brakes are burnished; refer to 4
Burnishing the Brakes (page 8). · Check the fluid and engine-oil levels regularly.
Remain alert for signs that the machine or its components are overheating. · After starting a cold engine, let it warm up for about 15 seconds before using the machine.
Note: Allow more time for the engine to warm up when operating in cold temperatures. · Vary the machine speed during operation. Avoid fast starts and quick stops. · A break-in oil for the engine is not required. Original engine oil is the same type specified for regular oil changes. · Refer to Maintenance (page 23) for any special, low-hour checks. · Check the front suspension positioning and adjust it, if necessary; refer to Adjusting the Front Wheel Alignment (page 39).

1. Empty 2. Full 3. Needle

Figure 12
4. Fuel gauge 5. Fuel-tank cap

g008398

3. Fill the tank to approximately 25 mm (1 inch) below the bottom of the filler neck and install the cap.
Note: Do not overfill the fuel tank.

16

During Operation
During Operation Safety
General Safety
· The owner/operator can prevent and is responsible for accidents that may cause personal injury or property damage.
· Passengers should sit in the designated seating positions only. Do not carry passengers in the cargo bed. Keep bystanders and children out of the operating area.
· Wear appropriate clothing, including eye protection; long pants; substantial, slip-resistant footwear; and hearing protection. Tie back long hair and do not wear loose clothing or loose jewelry.
· Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur.
· Do not operate the machine while ill, tired, or under the influence of alcohol or drugs.
· Operate the machine outdoors or in a well-ventilated area only.
· Do not exceed the maximum gross vehicle weight (GVW) of the machine.
· Use extra caution when operating, braking, or turning the machine with a heavy load in the cargo bed.
· Carrying oversized loads in the cargo bed reduces the stability of the machine. Do not exceed the carrying capacity of the bed.
· Carrying material that cannot be bound to the machine adversely affects the steering, braking, and stability of the machine. When you carry material that cannot be bound to the machine, use caution when steering or braking.
· Carry a reduced load and reduce the ground speed of the machine when operating on rough, uneven terrain, and near curbs, holes, and other sudden changes in terrain. Loads may shift, causing the machine to become unstable.
· Before you start the machine, ensure that the transmission is in neutral, the parking brake is engaged, and you are in the operating position.
· You and your passengers should remain seated whenever the machine is moving. Keep your hands on the steering wheel; your passengers should use the handholds provided. Keep arms and legs within the machine body at all times.
· Operate the machine only in good visibility. Watch for holes, ruts, bumps, rocks, or other

hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles. Use care when approaching blind corners, shrubs, trees, or other objects that may obscure your vision.
· Do not drive the machine near drop-offs, ditches, or embankments. The machine could suddenly roll over if a wheel goes over the edge or if the edge gives way.
· Always watch out for and avoid low overhangs such as tree limbs, door jambs, overhead walkways, etc.
· Look behind and down before reversing the machine to be sure of a clear path.
· When using the machine on public roads, follow all traffic regulations and use any additional accessories that may be required by law, such as lights, turn signals, slow-moving vehicle (SMV) signs, and others as required.
· If the machine ever vibrates abnormally, stop and shut off the machine immediately, wait for all movement to stop, and inspect for damage. Repair all damage to the machine before resuming operation.
· It can take longer to stop the machine on wet surfaces than on dry surfaces. To dry out wet brakes, drive slowly on a level surface while putting light pressure on the brake pedal.
· Operating the machine at high speed and then quickly stopping may cause the rear wheels to lock up, which impairs your control of the machine.
· Do not touch the engine, transmission, muffler, or muffler manifold while the engine is running, or soon after you shut off the engine, because these areas may be hot enough to cause burns.
· Do not leave a running machine unattended.
· Before you leave the operating position, do the following:
­ Park the machine on a level surface.
­ Shift the transmission to the NEUTRAL position.
­ Engage the parking brake.
­ Shut off the machine and remove the key.
­ Wait for all movement to stop.
· Do not operate the machine when there is the risk of lightning.
· Use accessories and attachments approved by The Toro® Company only.
Slope Safety
Note: A 2-post Rollover Protection System (ROPS) is available for this machine as an accessory. Use a ROPS if you will work next to drop-offs, near water, in rough terrain, or on a slope, which could result in

17

a rollover. Contact an authorized Toro distributor for more information.
Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death.
· Survey the site to determine which slopes are safe for operating the machine and establish your own procedures and rules for operating on those slopes. Always use common sense and good judgment when performing this survey.
· If you feel uneasy operating the machine on a slope, do not do it.
· Keep all movement on slopes slow and gradual. Do not suddenly change the speed or direction of the machine.
· Avoid operating the machine on wet terrain. Tires may lose traction. A rollover can occur before the tires lose traction.
· Travel straight up and down a slope.
· If you begin to lose momentum while climbing a slope, gradually engage the brakes and slowly reverse the machine straight down the slope.
· Turning while going up or down a slope can be dangerous. If you must turn on a slope, do it slowly and cautiously.
· Heavy loads affect stability on a slope. Carry a reduced load and reduce your ground speed when operating on a slope or if the load has a high center of gravity. Secure the load to the cargo bed of the machine to prevent the load from shifting. Take extra care when hauling loads that shift easily (e.g., liquids, rock, sand, etc.).
· Avoid starting, stopping, or turning the machine on a slope, especially with a load. Stopping while going down a slope takes longer than stopping on level ground. If you must stop the machine, avoid sudden speed changes, which can cause the machine to tip or roll over. Do not engage the brakes suddenly when rolling rearward, as this may cause the machine to overturn.
Loading and Dumping Safety
· Do not exceed the gross vehicle weight (GVW) of the machine when operating it with a load in the cargo bed and/or towing a trailer; refer to Specifications (page 14).
· Distribute the load in the cargo bed evenly to improve the stability and control of the machine.
· Before dumping, ensure that there is no one behind the machine.
· Do not dump a loaded cargo bed while the machine is sideways on a slope. The change

in weight distribution may cause the machine to overturn.
Operating the Cargo Bed
Raising the Cargo Bed
WARNING
A raised bed could fall and injure persons that are working beneath it. · Always use the prop rod to hold the bed up
before working under the bed. · Remove any load material from the bed
before raising it.
WARNING
Driving the machine with the cargo bed raised could cause the machine to tip or roll easier. You could damage the structure of the cargo bed if you operate the machine with the bed raised. · Operate the machine when the cargo bed
is down. · After emptying the cargo bed, lower it.
CAUTION
If a load is concentrated near the back of the cargo bed when you release the latches, the bed may unexpectedly tip open, injuring you or bystanders. · Center loads in the cargo bed, if possible. · Hold the cargo bed down and ensure that
no one is leaning over the bed or standing behind it when releasing the latches. · Remove all cargo from the bed before lifting the bed up to service the machine.
1. Lift the lever on either side of the bed and lift the bed up (Figure 13).

18

Opening the Tailgate
1. Ensure that the cargo bed is down and latched.
2. Lift up the finger pulls at the back panel of the tailgate (Figure 15).

1. Lever 2. Prop rod

Figure 13 3. Detent slot

g014860

2. Pull the prop rod into the detent slot to secure the bed (Figure 14).

Figure 15

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1. Tailgate flange (cargo bed) 3. Lift up (finger pull)

2. Lock flange (tailgate)

4. Rotate rearward and down

1. Detent slot

Figure 14 2. Prop rod

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Lowering the Cargo Bed
WARNING
The weight of the bed may be heavy. Hands or other body parts could be crushed. Keep your hands and other body parts clear when lowering the bed.

3. Align the lock flanges of the tailgate with the openings between the tailgate flanges of the cargo bed (Figure 15).
4. Rotate the tailgate rearward and down (Figure 15).
Closing the Tailgate
If you unloaded loose material such as sand, landscaping rock, or wood chips from the cargo bed of the machine, some of the material that you unloaded may have lodged in the hinge area of the tailgate. Perform the following before closing the tailgate.
1. Use your hands to remove as much of the material from the hinge area as possible.
2. Rotate the tailgate to approximately the 45° position (Figure 16).

1. Raise the cargo bed slightly by lifting up the latch lever (Figure 13).
2. Pull the prop rod out of the detent slot (Figure 14).
3. Lower the bed until it latches securely into place (Figure 14).

19

Figure 16

1. Rotate the tailgate to approximately the 45° position.
2. Rotate the tailgate back and forth several times.

3. Hinge area

g024491

3. Use a short, shaking motion to rotate the tailgate back and forth several times (Figure 16).
Note: This action helps move material away from the hinge area.
4. Lower the tailgate and check for material remaining in the hinge area.
5. Repeat steps 1 through 4 until the material is removed from the hinge area.
6. Rotate the tailgate up and forward until the lock flanges of the tailgate are flush with the tailgate pocket in the cargo bed (Figure 15).
Note: Raise or lower the tailgate in order to align the lock flanges of the tailgate with the vertical openings between the tailgate flanges of the cargo bed.
7. Lower the tailgate until it is seated in the back of the cargo bed (Figure 15).
Note: The lock flanges of the tailgate are fully secured by the tailgate flanges of the cargo bed.

Starting the Engine
Important: Do not attempt to push or tow the machine to get it started.
1. Sit in the operator’s seat, insert the key into the key switch, press down on the brake, and rotate the key clockwise to the ON position.
Note: If the backup alarm is installed and the gear-shift selector is in the REVERSE position, the buzzer sounds to warn the operator.
2. When the glow-plug-indicator light turns off, rotate the key clockwise to the START position.
3. When the engine starts, turn the key counterclockwise to the RUN position.
4. Disengage the parking brake.

Stopping the Machine
Important: When stopping the machine on an incline, use the service brakes to stop the machine and engage the parking brake to hold the machine in place. Using the accelerator to stall the machine on the hill can damage the machine.
1. Remove your foot from the accelerator pedal.
2. Slowly press the brake pedal to apply the service brakes until the machine comes to a complete stop.
Note: The stopping distance may vary depending on the machine load and speed.
Shutting Off the Engine
1. Park the machine on a level surface.
2. Engage the parking brake.
3. Rotate the key switch to the OFF position and remove the key.
Loading the Cargo Bed
Use the following guidelines when loading the cargo bed and operating the machine:
· Observe the weight capacity of the machine and limit the weight of the load that you carry in the cargo bed as described in Specifications (page 14) and on the gross vehicle weight tag of the machine.
Note: The load rating is specified for machine operation on a level surface only.
· Reduce the weight of the load that you carry in the cargo bed when operating the machine on hills and rough terrain.
· Reduce the weight of the load that you carry when the materials are tall (and have a high center of gravity), such as a stack of bricks, landscaping timbers, or fertilizer bags. Distribute the load as low as possible to ensure that the load does not reduce your ability to see behind the machine when operating it.
· Keep loads centered by loading the cargo bed as follows:
­ Evenly position the weight in the cargo bed from side to side.
Important: Tipping over is more likely to occur if the cargo bed is loaded to 1 side.
­ Evenly position the weight in the cargo bed from front to back.

20

Important: Loss of steering control or the machine may tip over if you position the load behind the rear axle and the traction on the front tires is reduced.
· Use extra caution when transporting oversized loads in the cargo bed, particularly when you cannot center the weight of the oversize load to the cargo bed.
· Whenever possible, secure the load by binding it to the cargo bed so that it does not shift.
· When transporting liquids, use caution when driving the machine uphill or downhill, when suddenly changing speed or stopping, or when driving over rough surfaces.

The capacity of the cargo box is 0.37 m3 (13 ft3). The amount (volume) of material that you can place in the bed without exceeding the load ratings of the machine can vary greatly depending on the density of the material.

Refer to the following table for load volume limits with various materials:

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

Density
1522 kg/m3 (95 lb/ft3)
1922 kg/m3 (120 lb/ft3)
1442 kg/m3 (90 lb/ft3)
1922 kg/m3 (120 lb/ft3)
721 kg/m3 (45 lb/ft3)
<721 kg/m3 (<45 lb/ft3)
1602 kg/m3 (100 lb/ft3)

Maximum Cargo Box Capacity
(on level ground) Full
3/4 Full
Full
3/4 Full
Full Full
3/4 Full (approximately)

After Operation
After Operation Safety
General Safety
· Before you leave the operating position, do the following: ­ Park the machine on a level surface. ­ Shift the transmission to the NEUTRAL position. ­ Engage the parking brake. ­ Shut off the machine and remove the key. ­ Wait for all movement to stop.
· Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
· Do not store the machine where there is an open flame, spark, or pilot light, such as on a water heater or other appliance.
· Keep all parts of the machine in good working condition and all hardware tightened.
· Maintain and clean the seat belt(s) as necessary. · Replace all worn, damaged, or missing decals.

21

Hauling the Machine
· Use care when loading or unloading the machine into a trailer or a truck.
· Use full-width ramps for loading the machine into a trailer or a truck.
· Tie the machine down securely.
Refer to Figure 17 and Figure 18 for the tie-down locations on the machine.
Note: Load the machine on the trailer with the front of the machine facing forward. If that is not possible, secure the machine hood to the frame with a strap, or remove the hood and transport and secure it separately or the hood may blow off during transport.

Towing the Machine
In case of an emergency, you can tow the machine for a short distance; however, this should not be a standard operating procedure.
WARNING
Towing at excessive speeds could cause a loss of steering control, resulting in personal injury.
Never tow the machine at faster than 8 km/h (5 mph).
Towing the machine is a 2-person job. If you must move the machine a considerable distance, transport it on a truck or trailer; refer to Towing a Trailer (page 22)
1. Remove the drive belt from the machine; refer to Replacing the Drive Belt (page 46).
2. Affix a tow line to the tongue at the front of the machine frame (Figure 17).
3. Move the transmission to the NEUTRAL position and disengage the parking brake.

Figure 17

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1. Towing tongue and tie-down point (front of the machine)

Figure 18 1. Rear tie-down points

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Towing a Trailer
The machine is capable of pulling trailers. A tow hitch is available for the machine. Contact your Authorized Service Dealer for details.
When hauling cargo or towing a trailer, do not overload your machine or trailer. Overloading either the machine or the trailer can cause poor performance or damage to the brakes, axle, engine, transaxle, steering, suspension, body structure, or tires.
Always load a trailer with 60% of the cargo weight in the front of the trailer. This places approximately 10% of the gross trailer weight (GTW) on the tow hitch of the machine.
To provide adequate braking and traction, always load the cargo bed when using a trailer. Do not exceed the GTW or GVW limits.
Avoid parking a machine with a trailer on a hill. If you must park on a hill, engage the parking brake, and chock the tires of the trailer.

22

Maintenance
Maintenance Safety
· Do not allow untrained personnel to service the machine.
· Before you leave the operating position, do the following: ­ Park the machine on a level surface. ­ Shift the transmission to the NEUTRAL position. ­ Engage the parking brake. ­ Shut off the machine and remove the key. ­ Wait for all movement to stop.
· Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
· Support the machine with jack stands whenever you work under the machine.
· Do not work under a raised bed without the proper bed safety support in place.
· Do not charge the batteries while servicing the machine.
· To ensure that the entire machine is in good condition, keep all hardware properly tightened.
· To reduce the potential fire hazard, keep the machine area free of excessive grease, grass, leaves, and accumulation of dirt.

· If possible, do not perform maintenance while the machine is running. Keep away from moving parts.
· If you must run the machine to perform a maintenance adjustment, keep your hands, feet, clothing, and any parts of the body away from any moving parts. Keep bystanders away from the machine.
· Clean up oil and fuel spills.
· Check the parking brake operation as recommended in the maintenance schedule and adjust and service it as required.
· Keep all parts of the machine in good working condition and all the hardware properly tightened. Replace all worn or damaged decals.
· Never interfere with the intended function of a safety device or reduce the protection provided by a safety device.
· Do not overspeed the engine by changing the governor settings. To ensure safety and accuracy, have an Authorized Service Dealer check the maximum engine speed with a tachometer.
· If major repairs are ever necessary or assistance is required, contact an authorized Toro distributor.
· Altering this machine in any manner may affect the operation of the machine, performance, durability, or its use may result in injury or death. Such use could void the product warranty of The Toro® Company.

Recommended Maintenance Schedule(s)

Maintenance Service Interval
After the first 8 hours After the first 50 hours After the first 100 hours
Before each use or daily

Maintenance Procedure
· Check the condition of the drive belt.
· Change the engine oil. · Change the engine-oil filter. · Adjust the engine- valve clearance.
· Perform the guidelines for breaking in a new machine.
· Inspect the seat belt(s) for wear, cuts, and other damage. Replace the seat belt(s) if any component does not operate properly.
· Check the tire pressure. · Check the engine-oil level. · Check gear-shift operation. · Inspect the primary drive clutch. · Check the radiator-coolant level. · Check the brake-fluid level. Check the brake-fluid level before you first start the
engine. · Wash the machine.

23

Maintenance Service Interval
Every 100 hours
Every 150 hours Every 200 hours Every 300 hours Every 400 hours Every 600 hours Every 800 hours Every 1,000 hours

Maintenance Procedure
· Replace the air filter. Replace the air-filter element sooner if it dirty or damaged. · Check the condition of the tires and rims. · Torque the wheel-lug nuts. · Inspect the steering and suspension for loose or damaged components. · Check the front wheel camber and toe-in. · Check the transaxle-fluid level. · Check the operation of the neutral gear-shift position. · Clean the engine- cooling areas. · Inspect the brakes.
· Change the engine oil (twice as often in special operating conditions; refer to . · Change the engine-oil filter. Change the oil twice as often during special operating
conditions.
· Clean the primary drive clutch (more often in dusty or dirty conditions). · Adjust the parking brake, if needed. · Check the condition and tension of the drive belt. · Inspect the service and parking brakes.
· Grease the front wheel bearings.
· Inspect the fuel lines and connections. · Visually inspect the brakes for worn brake shoes.
· Adjust the engine-valve clearance.
· Replace the fuel filter. · Change the transaxle fluid.
· Change the radiator coolant. · Change the brake fluid.

Note: Download a free copy of the electrical schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. Important: Refer to your engine owner’s manual for additional maintenance procedures.

WARNING
Failing to properly maintain the machine could result in premature failure of machine systems, causing possible harm to you or bystanders.
Keep the machine well maintained and in good working order as indicated in these instructions.

CAUTION
Only qualified and authorized personnel should maintain, repair, adjust, or inspect the machine. · Avoid fire hazards and have fire-protection equipment present in the work area. Do not use
an open flame to check fluid levels or leakage of fuel, battery electrolyte, or coolant. · Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.

CAUTION
If you leave the key in the switch, someone could accidently start the engine and seriously injure you or other bystanders.
Shut off the engine and remove the key from the switch before you perform any maintenance.

24

Daily Maintenance Checklist

Duplicate this page for routine use.

Maintenance Check Item For the week of:

Monday

Tuesday

Check the brake and parking brake operation.

Check the gear shift/neutral operation.

Check the fuel level.

Check the engine-oil level.

Check the brake-fluid level.

Check the transaxle-fluid level.

Inspect the air filter.

Inspect the engine-cooling fins.

Check for unusual engine noises.

Check for unusual operating noises.

Check the tire pressure.

Check for fluid leaks.

Check the instrument operation.

Check the accelerator operation.

Wash the machine.

Touch up any damaged paint.

Wednesday

Thursday

Friday

Saturday

Sunday

Maintaining the Machine under Special Operating Conditions
Important: If the machine is subjected to any of the conditions listed below, perform maintenance twice as frequently: · Desert operation · Cold climate operation–below 10°C (50°F) · Trailer towing · Frequent operation in dusty conditions · Construction work · After extended operation in mud, sand, water, or similar dirty conditions, do the following:
­ Have your brakes inspected and cleaned as soon as possible. This prevents any abrasive material from causing excessive wear.
­ Wash the machine using water alone or with a mild detergent. Important: Do not use brackish or reclaimed water to clean the machine.
25

Pre-Maintenance Procedures
Many of the subjects covered in this maintenance section require raising and lowering the bed. To prevent serious injury or death, take the following precautions.

Preparing the Machine for Maintenance
1. Park the machine on a level surface. 2. Shift the transmission to the NEUTRAL position. 3. Engage the parking brake. 4. Shut off the engine and remove the key. 5. Empty and raise the cargo bed.

1. Front lifting point

Figure 19

g033043

· The lifting point at the rear of the machine is located under the axle tubes (Figure 20).

Lifting the Machine

DANGER

The machine may be unstable when using a jack. The machine could slip off the jack, injuring anyone beneath it.

· Do not start the machine while the machine

is on a jack.

g312722

· Always remove the key from the key switch

Figure 20

before getting off the machine.

1. Rear lifting points

· Block the tires when the machine is supported by lifting equipment.

· Use jack stands to support the machine once you have lifted it.

Important: Whenever you run the machine for routine maintenance and/or diagnostics, ensure that the rear wheels of the machine are 25 mm (1 inch) off the ground, with the rear axle supported on jack stands.
· The lifting point at the front of the machine is located at the front of the frame, behind the towing tongue (Figure 19).

26

Accessing the Hood

Lubrication

Raising the Hood
1. Lift up the handle of the rubber latches on each side of the hood (Figure 21).

Greasing the Front Wheel Bearings
Service Interval: Every 300 hours
Grease specification: Mobilgrease XHPTM-222

Removing the Hub and Rotor
1. Lift the front of the machine and support it with jack stands.
2. Remove the 4 lug nuts that secure the wheel to the hub (Figure 22).

Figure 21

g312721

2. Raise the hood.
Closing the Hood
1. Gently lower the hood. 2. Secure the hood by aligning the rubber latches
onto the latch anchors on each side of the hood (Figure 21).

1. Hub 2. Wheel

Figure 22 3. Lug nut

g033046

3. Remove the flange-head bolts (3/8 x 3/4 inch) that secure the bracket for the brake assembly to the spindle and separate the brake from the spindle (Figure 23).
Note: Support the brake assembly before proceeding to the next step.

27

Figure 23

g033047

1. Flange-head bolts (3/8 x 3/4 inch)
2. Spindle

3. Caliper bracket (brake assembly)

1. Spindle

Figure 25

g033049

2. Hub and rotor assembly

7. Wipe clean the spindle with a rag.
8. Repeat steps 1 through 7 to the hub and rotor at the other side of the machine.

4. Remove the dust cap from the hub (Figure 24).

1. Cotter pin 2. Spindle 3. Tab washer

Figure 24
4. Spindle nut 5. Nut retainer 6. Dust cap

g033048

5. Remove the cotter pin and nut retainer from the spindle and spindle nut (Figure 24).
6. Remove the spindle nut from the spindle, and separate the hub and rotor assembly from the spindle (Figure 24 and Figure 25).

28

Greasing the Wheel Bearings
1. Remove the outboard bearing and bearing race from the hub (Figure 26).

Installing the Hub and Rotor
1. Apply a light coat of the specified grease to the spindle (Figure 27).

Figure 26

g033050

1. Seal 2. Inboard bearing 3. Inboard-bearing race

4. Bearing cavity (hub) 5. Outboard-bearing race 6. Outboard bearing

2. Remove the seal, inboard bearing from the hub (Figure 26).
3. Wipe clean the seal and check for wear and damage.
Note: Do not use cleaning solvent to clean the seal. Replace the seal if it is worn or damaged.
4. Clean the bearings and races, and check these parts for wear and damage.
Note: Replace all worn or damaged parts. Ensure that the bearings and races are clean and dry.
5. Clean the cavity of the hub of all grease, dirt, and debris (Figure 26).
6. Pack the bearings with the specified grease.
7. Fill the cavity of hub 50 to 80% full of the specified grease (Figure 26).
8. Assemble the inboard bearing onto the race at the inboard side of the hub and install the seal (Figure 26).
9. Repeat steps 1 through 8 to the bearings for the other hub.

1. Nut retainer 2. Spindle nut
3. Tab washer

Figure 27

g033051

4. Outer bearing
5. Hub, rotor, inner bearing, race, and seal
6. Spindle

2. Assemble the hub and rotor onto the spindle with the rotor inboard (Figure 27).
3. Assemble the outboard bearing onto the spindle and seat the bearing to the outboard race (Figure 27).
4. Assemble the tab washer onto the spindle (Figure 27).
5. Thread the spindle nut onto the spindle and tighten the nut to 15 Nm (11 ft-lb), while rotating the hub to seat the bearing (Figure 27).
6. Loosen the spindle nut until the hub rotates freely.
7. Torque the spindle nut to 170 to 225 Ncm (15 to 20 in-lb).
8. Install the retainer over the nut and check the alignment of the slot in the retainer and the hole in the spindle for the cotter pin (Figure 28).
Note: If the slot in the retainer and the hole in the spindle are not aligned, tighten the spindle nut to align the slot and hole to a maximum torque of 226 Ncm (20 in-lb) on the nut.

29

Engine Maintenance

Engine Safety
· Shut off the engine, remove the key, and wait for all moving parts to stop before checking the oil or adding oil to the crankcase.
· Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces.

1. Cotter pin 2. Nut retainer

Figure 28 3. Dust cap

g033054

9. Install the cotter pin and bend each legs around the retainer (Figure 28).
10. Install the dust cap onto the hub (Figure 28).
11. Repeat steps 1 through 10 for the hub and rotor at the other side of the machine.

Installing the Brakes and Wheels
1. Clean the 2 flange-head bolts (3/8 x 3/4 inch) and apply a coat of medium- strength thread-locking compound to the threads of the bolts.
2. Align the brake pads to either side of the rotor (Figure 23) and the holes in the caliper bracket with the holes in the brake mount of the spindle frame (Figure 27).
3. Secure the caliper bracket to the spindle frame (Figure 23) using the 2 flange-head bolts (3/8 x 3/4 inch).
Torque the 2 flange-head bolts to 47 to 54 Nm (35 to 40 ft-lb).
4. Align the holes in the wheel to the studs of the hub and assemble the wheel to the hub with the valve stem outward (Figure 22).
Note: Ensure that the mounting surface of the wheel is flush with the hub.
5. Secure the wheel to the hub using the lug nuts (Figure 22).
Torque the lug nuts to 108 to 122 Nm (80 to 90 ft-lb).
6. Repeat steps 1 through 5 for the brake and wheel on the other side of the machine.

Servicing the Air Filter
Service Interval: Every 100 hours Replace the air-filter element sooner if it dirty or damaged.
Note: Service the air filter more frequently if operating conditions are extremely dusty or sandy.
Checking the Air Filter
1. Raise the cargo bed and secure it with the prop rod.
2. Check the air-filter body for damage that could possibly cause an air leak (Figure 29).
Note: Ensure that the air-filter cover is sealing around the air-filter housing.
Note: Replace a damaged air-filter cover or housing.

1. Dirt-ejection port 2. Latch 3. Air-filter cover

Figure 29

g027724

4. Air-filter element 5. Air-filter housing 6. Rear of the machine

3. Pull the latch outward and rotate the air-filter cover counterclockwise (Figure 29).
4. Remove the cover from the air-filter body.
5. Gently slide the air-filter element out of the air-filter housing (Figure 29) to reduce the amount of dust dislodged.

30

Note: Avoid knocking the filter against the air-filter housing. 6. Inspect the air-filter element. · If the air-filter element is clean, install the
filter element. · If the air-filter element is damaged, replace
the filter element; refer to Replacing the Air Filter (page 31).
Replacing the Air Filter
1. Remove the air-filter element. 2. Inspect the new filter for shipping damage.
Note: Check the sealing end of the filter. Important: Do not install a damaged filter. 3. Install the new air filter; refer to Installing the Air Filter (page 31).

Servicing the Engine Oil
Note: Change the oil more frequently when operating conditions are extremely dusty or sandy. Note: Dispose of the used engine oil and oil filter at a certified recycling center.
Engine-Oil Specifications
Oil Type: Detergent oil (API service CH-4, CI-4, CJ-4, or higher) Crankcase Capacity: 1.4 L (1.5 US qt) when the filter is changed Viscosity: See the table below.

Installing the Air Filter
Important: To prevent engine damage, always operate the engine with the complete air-filter assembly installed.
Note: Do not use a damaged element.
Note: Cleaning a used air-filter element is not recommended due to the possibility of damage to the filter media.
1. Clean the dirt-ejection port located on the air-filter cover (Figure 29).
2. Remove the rubber outlet valve from the cover, clean the cavity, and replace the outlet valve (Figure 29).
3. Insert the air-filter element into the air-filter housing by applying pressure to the outer rim of the element to seat it into the air-filter housing (Figure 29).
Note: Ensure that the filter seals properly by applying pressure to the outer rim of the filter when installing it. Do not press on the flexible center of the filter.
4. Align the air-filter cover with the air-filter housing with the rubber outlet valve in a downward position (approximately between the 5 o’clock and 7 o’clock positions when viewed from the end) as shown in Figure 29.
5. Secure the cover to the housing with the latches (Figure 29).
6. Lower the cargo bed.

Figure 30

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Checking the Engine-Oil Level
Service Interval: Before each use or daily 1. Park the machine on a level surface.
2. Engage the parking brake.
3. Shut off the engine and remove the key.
4. Raise the cargo bed.
5. Use a rag to clean around the oil dipstick (Figure 31) so that dirt cannot fall into the dipstick tube or oil-filler neck and damage the engine.

31

1. Fill cap

Figure 31 2. Oil dipstick

g016858

6. Remove the dipstick and wipe it clean.
7. Slide the dipstick into the dipstick tube and ensure that fully seats (Figure 31).
8. Pull the dipstick out and look at the end.
Note: Add the oil slowly and check the oil level often during this process. Do not overfill the engine with oil. 9. Install the oil dipstick and firmly seat it (Figure 31).
10. Lower the cargo bed.
Changing the Engine Oil
Service Interval: After the first 50 hours Every 150 hours (twice as often in special operating conditions; refer to Maintaining the Machine under Special Operating Conditions (page 25).
1. Park the machine on a level surface.
2. Engage the parking brake.
3. Start the machine and let the engine run for a few minutes.
4. Shut off the engine and remove the key.
5. Raise the cargo bed and secure it with the prop rod.
6. Disconnect the negative battery cable; refer to Disconnecting the Battery (page 34).
7. Place a drain pan under the drain plug (Figure 32).

1. Engine-oil filter

Figure 32 2. Drain plug

g027838

8. Remove the drain plug (Figure 32).
Note: Allow the oil to completely drain from the engine.
9. Install the drain plug and seal (Figure 32) and torque the plug to 45 to 53 Nm (33 to 39 ft-lb).
10. Pour oil into the fill opening until the oil level is up to the Full mark on the dipstick.
11. Add the oil slowly and check the level often during this process.
Note: Do not overfill the engine with oil. 12. Install the oil-fill cap and dipstick firmly in place.
13. Connect the battery and lower the cargo bed.
Changing the Engine-Oil Filter
Service Interval: After the first 50 hours Every 150 hours/Yearly (whichever comes first) Change the oil twice as often during special operating conditions.
1. Drain the oil from the engine.
2. Remove the existing oil filter (Figure 32).
3. Apply a light coat of clean oil to the new filter gasket.
4. Thread the new filter onto the filter adapter until the gasket contacts the mounting plate, then tighten the filter an additional 1/2 to 3/4 turn (Figure 32).
Important: Do not overtighten the oil filter. 5. Fill the crankcase with the specified oil (Figure
30).

32

6. Start and run the engine to check for oil leaks.
7. Shut off the engine and check the engine-oil level.
Note: If necessary, add the specified oil into the engine until the oil level is at the Full mark on the dipstick.

Fuel System Maintenance
Inspecting Fuel Lines and Connections
Service Interval: Every 400 hours/Yearly (whichever comes first)
Inspect the fuel lines, fittings, and clamps for signs of leaking, deterioration, damage, or loose connections. Note: Repair any damaged or leaking fuel system component before using the machine.
Replacing the Fuel Filter
Service Interval: Every 800 hours/Yearly (whichever comes first)
1. Raise the bed and support it with the prop rod. 2. Rotate the key switch to the OFF position and
remove the key. 3. Place a drain pan under the fuel filter. 4. Unscrew the fuel filter from the bracket (Figure
33).

1. Fuel filter

Figure 33

g017504

5. Install the replacement filter by turning it until the filter contacts the top of the bracket, then tighten it an additional 3/4 of a turn.

33

Electrical System Maintenance
Electrical System Safety
· Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.
· Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery. Wear protective clothing and use insulated tools.
Servicing the Battery
Battery voltage: 12 V with 300 A (cold-cranking) at -18°C (0°F). · Always keep the battery clean and fully charged. · If the battery terminals are corroded, clean them
with a solution of 4 parts water and 1 part baking soda. · Apply a light coating of grease to the battery terminals to prevent corrosion.

WARNING
Battery terminals or metal tools could short against metal machine components, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. · When removing or installing the battery,
do not allow the battery terminals to touch any metal parts of the machine. · Do not allow metal tools to short between the battery terminals and metal parts of the machine.
1. Squeeze the sides of the battery cover and remove the cover from the top of the battery (Figure 34).

Disconnecting the Battery
WARNING
Incorrect battery cable routing could damage the machine and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. · Always disconnect the negative (black)
battery cable before disconnecting the positive (red) cable. · Always connect the positive (red) battery cable before connecting the negative (black) cable. · Always keep the battery strap in place to protect and secure the battery.

Figure 34

1. Positive battery terminal 2. Positive battery cable 3. Negative battery cable 4. Negative battery terminal

5. Battery cover 6. Battery clamp 7. Locknut 8. Carriage bolt

g024429

2. Disconnect the negative battery cable from the terminal of the battery (Figure 34).
3. Disconnect the positive battery cable from the terminal of the battery (Figure 34).
Removing the Battery
1. Disconnect the battery cables; refer to Disconnecting the Battery (page 34).
2. Remove the locknut, carriage bolt, and battery clamp that secures the battery to the battery tray (Figure 34).
3. Remove the battery from the battery tray (Figure 34).

34

Installing the Battery
1. Align the battery to the battery tray of the machine (Figure 34).
Note: Ensure that the positive and negative posts of the battery are aligned as shown in Figure 34.
2. Secure the battery to the battery tray with the battery clamp, carriage bolt, and locknut (Figure 34).
3. Connect the battery cables; refer to Connecting the Battery (page 35).
Connecting the Battery
1. Connect the positive battery cable to the terminal of the battery (Figure 34).
2. Connect the negative battery cable to the terminal of the battery (Figure 34).
3. Install the battery cover onto the top of the battery (Figure 34).

Replacing the Fuses

There are 7 fuses in the electrical system. They are located beneath the hood (Figure 35).

Alarm/Power Point Engine Headlights Machine fuse Lift Rear lift Horn

10 A 10 A 10 A 15 A 15 A 15 A 30 A

Charging the Battery

WARNING
Charging the battery produces gasses that can explode.
Never smoke near the battery and keep sparks and flames away from battery.
Important: Always keep the battery fully charged. This is especially important to prevent battery damage when the temperature is below 0°C (32°F).
1. Remove the battery from the machine; refer to Disconnecting the Battery (page 34).
2. Connect a 3 to 4 A battery charger to the battery posts. Charge the battery at a rate of 3 to 4 A for 4 to 8 hours (12 V).
Note: Do not overcharge the battery.
3. Install the battery; refer to Installing the Battery (page 35).
Storing the Battery
If you are storing the machine for more than 30 days, remove the battery and charge it fully. Either store it on the shelf or on the machine. Leave the cables disconnected if it is stored on the machine. Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery. To prevent the battery from freezing, make sure that it is fully charged.

1. Fuse block

Figure 35 2. Ground block

g036871

Maintaining the Headlights
Replacing the Bulbs
CAUTION
If you install a higher wattage bulb than the system is designed for, you may damage the 12 V power supply, or at a minimum, blow the fuse. Always use the specified Toro LED bulb to prevent this issue.

35

CAUTION
The bulbs become extremely hot when in operation. Handling a hot bulb can cause severe burns and personal injury.
Always allow enough time to for the bulbs to cool before replacing them. Use care whenever handling the bulbs.
Specification: See your Parts Catalog.
1. Disconnect the battery; refer to Disconnecting the Battery (page 34).
2. Open the hood.
3. Disconnect the electrical connector for the harness from the connector of the lamp assembly at the back of the headlight housing (Figure 36).

Replacing the Headlight
1. Disconnect the battery; refer to Disconnecting the Battery (page 34).
2. Open the hood; refer to Raising the Hood (page 27).
3. Disconnect the electrical connector for the harness from the connector of the lamp assembly (Figure 37).

1. Headlight housing 2. Lamp assembly

Figure 36
3. Harness-electrical connector

g036872

4. Rotate the lamp assembly 1/4 turn counterclockwise and moving it rearward, out of the headlight housing (Figure 36).
5. Insert the new lamp assembly and headlight housing and align the tabs in the lamp assembly with the slots in the headlight housing (Figure 36).
6. Secure lamp assembly by turning it 1/4 turn clockwise (Figure 36).
7. Connect the electrical connector for the harness to the connector of the new lamp assembly (Figure 36).
8. Connect the battery and close the hood; refer to Connecting the Battery (page 35).

Figure 37

1. Speed clip 2. Opening in the bumper 3. Adjustment screw

4. Headlight
5. Lamp assembly
6. Harness-electrical connector

g036873

4. Remove the speed clips that secure the headlight to the headlight bracket (Figure 37).
Note: Retain all parts for installation of the new headlight.
5. Remove the headlight assembly by moving it forward through the opening in the front bumper (Figure 37).
6. Install the new headlight through the opening in the bumper (Figure 37).
Note: Ensure the adjustment posts are lined up with the holes in the mounting bracket behind the bumper.
7. Secure the headlight assembly with the speed clips that you removed in step 4.
8. Connect the electrical connector for the harness to the connector of the lamp assembly (Figure 37).
9. Adjust the headlights to direct the beams to the desired position, refer to Adjusting the Headlights (page 37).

36

Adjusting the Headlights
Use the following procedure to adjust the headlight beam position whenever a headlight assembly is replaced or removed.
1. Turn the key switch to the ON position, and turn on the headlights.
2. At the back of the headlight assembly, rotate adjustment screws (Figure 37) to pivot the headlight assembly and align the position of the cast beam.

Drive System Maintenance
Maintaining the Tires
Service Interval: Every 100 hours–Check the condition of the tires and rims.
Every 100 hours–Torque the wheel-lug nuts.
1. Inspect the tires and rims for signs of wear and damage.
Note: Operating accidents, such as hitting curbs, can damage a tire or rim and also disrupt wheel alignment, so inspect tire condition after an accident.
2. Torque the wheel lug nuts to 108 to 122 Nm (80 to 90 ft-lb).

37

Inspecting the Steering and Suspension Components

Service Interval: Every 100 hours–Inspect the steering and suspension for loose or damaged components.

With the steering wheel at the centered position (Figure 38), turn the steering wheel to the left or right. If you turn the steering wheel more than 13 mm (1/2 inch) to the left or right, and the tires do not turn, check the following steering and suspension components to ensure that they are not loose or damaged:
· Steering shaft to the steering-rack assembly joint

Figure 39

g313201

Important: Inspect the condition and security of the pinion-shaft seal (Figure 39).

1. Pinion-shaft seal

· Steering-rack assembly tie rods

Figure 38

g313199

1. Steering wheel at the centered position

2. 13 mm (1/2 inch) from the center of the steering wheel

38

Adjusting the Front Wheel Alignment
Service Interval: Every 100 hours/Yearly (whichever comes first)–Check the front wheel camber and toe-in.
Preparing to Adjust Camber or Toe-in
1. Check the tire pressure to ensure that the front tires are inflated to 82 kPa (12 psi).
2. Either add weight to the driver’s seat equal to the average operator who will run the machine, or have an operator sit on the seat. The weight or operator must remain on the seat for the duration of the adjustment procedure.
3. On a level surface, roll the machine straight back 2 to 3 m (6 to 10 ft) and then straight forward to the original starting position. This allows the suspension to settle into the operating position.
Adjusting the Camber
Owner provided tools: spanner wrench, Toro Part 132-5069; refer to your authorized Toro distributor.
Important: Make the camber adjustments only if you are using a front attachment or if there is uneven tire wear.
1. Check the camber alignment at each wheel; the alignment should be as close to neutral (zero) as possible.
Note: The tires should be aligned with the tread evenly on the ground to reduce uneven wear.
2. If the wheel camber is out of alignment, use the spanner wrench to rotate the collar on the shock absorber to align the wheel (Figure 40).

Adjusting the Front Wheel Toe-in
Important: Before adjusting toe-in, ensure that the camber adjustment is as close to neutral as possible; refer to Adjusting the Camber (page 39).
1. Ensure that the front tires are facing straight ahead.
2. Measure the distance between both of the front tires at the axle height at both the front and rear of the front tires (Figure 41).

Figure 41

1. Tire center line–back 2. Tire center line–front

3. Axle center line

g009235

3. If the measurement does not fall within 0 to 6 mm (0 to 1/4 inch), loosen the jam nuts at the outer end of the tie rods (Figure 42).

1. Tie rod

Figure 42 2. Jam nut

g033219

Figure 40

1. Shock-absorber spring 2. Collar

3. Spring length

4. Rotate both tie rods to move the front of the tire inward or outward.

5. Tighten the tie rod jam nuts when the adjustment is correct.

6. Ensure that there is full travel of the steering

g033218

wheel in both directions.

39

Checking the Transaxle-Fluid Level
Service Interval: Every 100 hours
Fluid Type: SAE 10W30 (API service SJ or higher)
1. Park the machine on a level surface, shift the transmission to the NEUTRAL position, engage the parking brake, shut off the engine, and remove the key.
2. Remove the bolt from the level-indicating hole (Figure 43).
Note: The transaxle fluid level should be at the bottom of the level indicator hole.

Figure 43 1. Level-indicator hole

g002082

3. If the transaxle fluid is not level with the bottom of the level indicating hole, fill the reservoir with the specified fluid; refer to Changing the Transaxle Fluid (page 40).

Changing the Transaxle Fluid
Service Interval: Every 800 hours/Yearly (whichever comes first)
Fluid Type: SAE 10W30 (API service SJ or higher)
Fluid Capacity: 1.4 L (1.5 US qt)
1. Park the machine on a level surface, shift the transmission to the NEUTRAL position, engage the parking brake, shut off the engine, and remove the key.
2. Wipe the area around the fill and drain plugs clean with a rag (Figure 44).

1. Drain plug

Figure 44 2. Fill plug

g002109

3. Align a drain pan with a capacity of 2 L (2.1 qt) or more under the drain plug.
4. Remove the fill plug by rotating it counterclockwise (Figure 44).
Note: Retain the fill plug and gasket for installation in step 8.
5. Remove the drain plug by rotating it counterclockwise (Figure 44).
Note: Retain the drain plug and gasket for installation in step 6.
Note: Allow the fluid to drain from the transaxle completely.
6. Install and tighten the drain plug and gasket into the drain-plug hole of the transmission (Figure 44).
Note: Dispose of the used fluid at a certified recycling center.
7. Fill the reservoir (Figure 45) through the fill-plug hole with approximately 1.4 L (1.5 US qt) of the specified fluid or until the fluid level in the transmission is even with the bottom of the threads. (Figure 44).

1. Fluid fill

Figure 45

g004048

8. Install and tighten the fill plug and gasket into the fill-plug hole of the transmission (Figure 44).
9. Start the engine and operate the machine.

40

10. Check the fluid level and add more fluid if the level is below the threads of the fill-plug hole (Figure 44).
Checking and Adjusting Neutral
Service Interval: Every 100 hours
When performing routine maintenance and/or engine diagnostics, the transaxle must be shifted into NEUTRAL (Figure 46). The machine has a NEUTRAL position on the shift lever, which controls the neutral in the transaxle. Perform the following steps to ensure that the neutral shift lever operates the transaxle neutral correctly:
1. Shift the transmission to the NEUTRAL position
2. Ensure that the neutral bracket is in the NEUTRAL position (level to the cable mounting bracket located below the shift bracket) by turning the driven clutch (Figure 46).
Note: The machine should not roll back and forth. If it does, manually move the neutral bracket to the NEUTRAL position.

5. Pull up on each shift cable an ensure that there is a 0.76 to 1.52 mm (0.03 to 0.06 inch) between the nut/washer and the neutral bracket (Figure 47).
Note: If there is a not a gap, adjust the nuts to achieve the specified gap.

1. Neutral bracket 2. Pull up
3. Cable boot

Figure 47

g002094

4. 0.76 to 1.52 mm (0.03 to 0.06 inch) gap
5. Wrong–adjust the to achieve a gap of 0.76 to 1.52 mm (0.03 to 0.06 inch)

6. Start the engine and shift into FORWARD, REVERSE, and NEUTRAL several times to ensure that the neutral bracket is operating properly.

1. Neutral bracket

Figure 46 2. Locknuts

g002093

3. Rotate 1 of the locknuts (Figure 46) to achieve a 0.762 to 1.524 mm (0.030 to 0.060 inch) gap between the bottom of the nut/washer and the neutral bracket.
Note: You must hold the threaded shaft below the bracket when adjusting the locknut position on top.
4. Rotate the other locknut to achieve a 0.76 to 1.52 mm (0.03 to 0.06 inch) gap between the bottom of the nut/washer and the neutral bracket.

Inspecting the Primary Drive Clutch
Service Interval: Before each use or daily
Clutch operation should be monitored daily for proper shifting. If shifting is sticky or sluggish, or the clutch does not return completely to neutral when idling, the clutch requires a simple cleaning.
Note: Focus debris removal in and around moving parts.
1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key.
2. Raise and secure the cargo bed.
3. Remove dirt and mud buildup on the clutch with water and dry the clutch immediately with compressed air to remove excess water and debris.
Note: Remaining debris may be removed using a fast-drying contact cleaner.

41

Maintaining the Primary Drive Clutch
Service Interval: Every 200 hours–Clean the primary drive clutch (more often in dusty or dirty conditions).
Note: Operating the machine with a dirty clutch can increase wear to internal components.
1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key.
2. Raise and secure the cargo bed.
3. Remove the 6 flange-head bolts securing the clutch cover.
4. Set aside the cover, spacer, and spring (Figure 48).

Cooling System Maintenance
Cooling System Safety
· Swallowing engine coolant can cause poisoning; keep out of reach from children and pets.
· Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
­ Always allow the engine to cool at least 15 minutes before removing the radiator cap.
­ Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape.
· Do not operate the machine without the covers in place.
· Keep your fingers, hands and clothing clear of rotating fan and drive belt.
· Shut off the engine and remove the key before performing maintenance.

1. Clutch shaft 2. Spring
3. Spacer

Figure 48
4. Clutch cover 5. Flange-head bolt

g017170

5. Remove dirt and mud buildup with water and dry immediately with compressed air to remove excess water and debris.
6. Remove any remaining debris using a fast-drying contact cleaner or brake cleaner.
Note: Remove the debris in and around moving parts.
7. If debris or buildup exists around the belt or along the clutch shaft, use a fine abrasive pad or a similar product to remove it.
8. Install the spring, clutch cover, and flange-head bolts.
9. Torque the bolts to 12 to 13.5 Nm (105 to 120 in-lb).

Cleaning the Engine-Cooling Areas
Service Interval: Every 100 hours Clean the cooling system twice as often during special operating conditions; refer to Maintaining the Machine under Special Operating Conditions (page 25).
Important: Operating the engine with a blocked rotating screen, dirty or plugged cooling fins, or with the cooling shrouds removed, causes engine damage due to overheating.
Important: Never clean the engine with a pressure washer because water could contaminate the fuel system.
Clean the rotating screen, cooling fins, and external surfaces of the engine.
Note: Clean the engine cooling components more often under extremely dusty and dirty conditions.

42

Servicing the Radiator
Checking the Radiator-Coolant Level
Service Interval: Before each use or daily
Note: Use a 50/50 mix of ethylene glycol and water for coolant.
1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.
2. Remove the radiator-overflow tank cap (Figure 49).
3. If the coolant level is low, fill the tank with coolant to the bottom of the filler neck.
Note: Do not overfill. 4. Replace the radiator-overflow tank cap and
clean any spills.

Changing the Radiator Coolant
Service Interval: Every 1,000 hours/Every 2 years (whichever comes first)
CAUTION
If the engine has been running, the pressurized, hot coolant can escape and cause burns. · Do not open the radiator cap when the
engine is running. · Allow engine to cool at least 15 minutes
or until the radiator cap is cool enough to touch without burning your hand. · Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape.
Note: Use a 50/50 mix of ethylene glycol and water for coolant.
1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key.
2. Remove the fill cap (Figure 49) and fill with coolant.

1. Fill cap

Figure 49

g016859

2. Radiator-overflow tank cap

3. Replace the fill cap and remove the radiator-overflow tank cap (Figure 49).
Note: Never leave both caps off at the same time; this adversely affects the filling of the tank.
4. Fill with coolant to the bottom of the filler neck.
5. Replace the radiator-overflow tank cap and clean any spills.

43

Brake Maintenance
Inspecting the Brakes
Service Interval: Every 100 hours
Important: Brakes are a critical safety component of the machine. Closely inspect them at the recommended service interval to ensure optimum performance and safety. · Inspect the brake lining for wear or damage. If the
lining (brake pad) thickness is less than 1.6 mm (1/16 inch), replace the brake lining. · Inspect the backing plate and other components for signs of excessive wear or deformation. Replace any deformed components. · Check the brake-fluid level; refer to Checking the Brake-Fluid Level (page 45).

procedure for adjusting the brake cables; refer to Adjusting the Brake Cables (page 44).
4. Tighten the set screw and install the hand grip (Figure 50).
Adjusting the Brake Cables
1. Remove the handgrip from the parking-brake lever (Figure 50).
2. Loosen the set screw (Figure 50) securing the brake-adjustment knob to the parking-brake lever, disengage the parking brake, and loosen the brake- adjustment knob.
3. At the bottom of the machine, loosen the rear jam nut for the threaded adjuster of the parking-brake cable 4 turns (Figure 51).

Adjusting the Parking-Brake Handle
Service Interval: Every 200 hours
1. Remove the handgrip from the parking-brake lever (Figure 50).

Figure 51

g029672

1. Forward jam nut
2. Rear jam nut 3. Brake-cable bracket

4. Threaded adjuster (parking-brake cable)
5. Front of the machine

Figure 50

g029671

1. Handgrip 2. Brake-adjustment knob

3. Set screw 4. Parking-brake lever

2. Loosen the set screw securing the brake-adjustment knob to the parking- brake lever (Figure 50).
3. Rotate the brake-adjustment knob until you reach a force of 133 to 156 N (30 to 35 lbf) to engage the parking-brake lever (Figure 50).
Note: If you rotated the brake-adjustment knob the full travel of the adjuster, and cannot attain the force of 133 to 156 N (30 to 35 lbf) required to engage the parking-brake lever, perform the

4. Tighten the forward jam nut (Figure 51).
5. Rotate the brake-adjustment knob (Figure 50) until a force of 133 to 156 N (30 to 35 lbf) is required to engage the parking-brake lever.
· If you cannot adjust the brake-adjustment knob by loosening it and engage the parking-brake lever with a force of 133 to 156 N (30 to 35 lbf), perform the following:
A. Loosen the forward jam nut (Figure 51) for the threaded adjuster of the parking-brake cable 1 turn.
B. Tighten the rear jam nut (Figure 51).
C. Rotate the brake-adjustment knob (Figure 50) until a force of 133 to 156 N (30 to 35 lbf) is required to engage the parking-brake lever.
D. Repeat steps A through C up to 2 more times to attain the parking brake force between 133 to 156 N (30 to 35 lbf).

44

· If you cannot adjust the brake-adjustment knob by tightening it and engage the parking-brake lever with a a force of 133 to 156 N (30 to 35 lbf), perform the following:
A. Loosen the rear jam nut (Figure 51) for the threaded adjuster of the parking-brake cable 1 turn.
B. Tighten the forward jam nut (Figure 51).
C. Rotate the brake-adjustment knob (Figure 50) until a force of 133 to 156 N (30 to 35 lbf) is required to engage the parking-brake lever.
D. Repeat steps A through C up to 3 more times to attain the parking brake force between 133 to 156 N (30 to 35 lbf).
Note: If you cannot adjust the parking-brake cable enough to get the brake- adjustment knob within its adjustment range, check the brake pads for excessive wear.
· Tighten the set screw and install the handgrip (Figure 50).

Checking the Brake-Fluid Level
Service Interval: Before each use or daily–Check the brake-fluid level. Check the brake-fluid level before you first start the engine.
Brake-fluid type: DOT 3
1. Park the machine on a level surface.
2. Engage the parking brake.
3. Shut off the engine and remove the key.
4. Raise the hood to access to the master brake cylinder and reservoir (Figure 52).

Figure 52

1. Filler neck (reservoir) 2. Reservoir cap

3. DOT 3 brake fluid

g033037

5. Look at the outline of the fluid level at the side of the reservoir (Figure 53).
Note: The level should be above the Minimum line.

Figure 53

1. Brake-fluid reservoir

2. Minimum line

g002136

6. If the fluid level is low, preform the following:
A. Clean the area around the reservoir cap and remove the cap (Figure 52).

45

B. Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line (Figure 53). Note: Do not overfill the reservoir with brake fluid.
C. Install the reservoir cap (Figure 52). 7. Close the hood.
Changing the Brake Fluid
Service Interval: Every 1,000 hours Contact your authorized Toro distributor.

Belt Maintenance
Servicing the Drive Belt
Checking the Drive Belt
Service Interval: After the first 8 hours Every 200 hours
1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key.
2. Raise the cargo bed and secure it with the prop rod.
3. Shift the transmission to the NEUTRAL position. 4. Rotate and inspect the belt (Figure 54) for signs
of excessive wear or damage.
Note: Replace the belt if it is excessively worn or damaged; refer to Replacing the Drive Belt (page 46).

1. Drive belt 2. Primary clutch

Figure 54 3. Secondary clutch

g011948

5. Lower the cargo bed.
Replacing the Drive Belt
1. Raise the cargo bed.
2. Shift the transmission into NEUTRAL, engage the parking brake, rotate the key switch to the OFF position, and remove the key.
3. Rotate and route the belt over the secondary clutch (Figure 54).
4. Remove the belt from the primary clutch (Figure 54).
Note: Discard the old belt. 5. Align the new belt over the primary clutch
(Figure 54).
6. Rotate and route the belt over the secondary clutch (Figure 54).

46

7. Lower the cargo bed.

Chassis Maintenance

Checking the Belt-Pull Bumper
Note: Check the belt-pull bumper only when troubleshooting vibration, performing a rebuild, or experiencing an engine-mount failure.
The belt-pull bumper (Figure 55) should maintain a gap of 2.2 mm (0.09 inches).
If the bumper is too close to the engine bracket, the belt causes excessive vibration; if the bumper is too far from the engine bracket, the belt causes harmful engine stress.
To adjust the gap, loosen the 3 flanged-head bolts securing the bracket to the frame and slide the bracket the appropriate distance.
Once the gap is correct, tighten the 3 flanged-head bolts.

Adjusting the Cargo-Bed Latches
If the cargo-bed latch is out of adjustment, the cargo bed vibrates up and down as you drive the machine. You can adjust the latch posts to make the latches hold the cargo bed snugly to the chassis.
1. Loosen the locknut on the end of the latch post (Figure 56).

1. Latch 2. Locknut

Figure 56 3. Latch post

g002181

2. Rotate the latch post clockwise until it is snug against the hook portion of the latch (Figure 56).
3. Torque the locknut to 19.7 to 25.4 Nm (175 to 225 in-lb).
4. Repeat this steps 1 through 3 for the latch on the other side of the machine.

1. Engine bracket 2. Bumper

Figure 55
3. Bracket 4. Flanged-head bolt

g017511

47

Cleaning
Washing the Machine
Service Interval: Before each use or daily–Wash the machine.
Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine. Important: Do not use brackish or reclaimed water to clean the machine. Important: Do not use power-washing equipment to wash the machine. Power-washing equipment may damage the electrical system, loosen important decals, or wash away necessary grease at friction points. Avoid excessive use of water near the control panel, engine, and battery. Important: Do not wash the machine with the engine running. Washing the machine with the engine running may result in internal engine damage.
48

Storage
Storage Safety
· Shut off the machine, remove the key, and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
· Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance.
Storing the Machine
Service Interval: Every 200 hours–Inspect the service and parking brakes.
Every 400 hours–Visually inspect the brakes for worn brake shoes.
After the first 50 hours
Every 600 hours/Yearly (whichever comes first)
1. Position the machine on a level surface, engage the parking brake, shut off the engine, and remove the key.
2. Clean dirt and grime from the entire machine, including the outside of the engine.
3. Inspect the brakes; refer to Inspecting the Brakes (page 44).
4. Service the air cleaner; refer to Servicing the Air Filter (page 30).
5. Seal the air-cleaner inlet and the exhaust outlet with weatherproof tape.
6. Change the engine oil; refer to Servicing the Engine Oil (page 31).
7. Flush the fuel tank with fresh, clean fuel.
8. Secure all fuel system fittings.
9. Check the tire pressure; refer to Checking the Tire Pressure (page 15).
10. Check anti-freeze protection and add a 50/50 solution of water and anti freeze as needed for expected minimum temperature in your area.
11. Remove the battery from the machine and fully charge the battery; refer to Removing the Battery (page 34).
Note: Do not connect the battery cables to the battery posts during storage.
Important: The battery must be fully charged to prevent it from freezing and being damaged at temperatures below 0°C (32°F).

A fully charged battery maintains its charge for about 50 days at temperatures lower than 4°C (40°F). If the temperatures will be below 4°C (40°F), charge it every 30 days. 12. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged.
13. Paint all scratched or bare metal surfaces.
Note: Paint is available from your Authorized Service Dealer.
14. Store the machine in a clean, dry garage or storage area.
15. Cover the machine to protect it and keep it clean.

49

EEA/UK Privacy Notice
Toro’s Use of Your Personal Information The Toro Company (“Toro”) respects your privacy. When you purchase our products, we may collect certain personal information about you, either directly from you or through your local Toro company or dealer. Toro uses this information to fulfil contractual obligations – such as to register your warranty, process your warranty claim or to contact you in the event of a product recall – and for legitimate business purposes – such as to gauge customer satisfaction, improve our products or provide you with product information which may be of interest. Toro may share your information with our subsidiaries, affiliates, dealers or other business partners in connection these activities. We may also disclose personal information when required by law or in connection with the sale, purchase or merger of a business. We will never sell your personal information to any other company for marketing purposes. Retention of your Personal Information Toro will keep your personal information as long as it is relevant for the above purposes and in accordance with legal requirements. For more information about applicable retention periods please contact legal@toro.com. Toro’s Commitment to Security Your personal information may be processed in the US or another country which may have less strict data protection laws than your country of residence. Whenever we transfer your information outside of your country of residence, we will take legally required steps to ensure that appropriate safeguards are in place to protect your information and to make sure it is treated securely. Access and Correction You may have the right to correct or review your personal data, or object to or restrict the processing of your data. To do so, please contact us by email at legal@toro.com. If you have concerns about the way in which Toro has handled your information, we encourage you to raise this directly with us. Please note that European residents have the right to complain to your Data Protection Authority.
374-0282 Rev C

California Proposition 65 Warning Information
What is this warning?
You may see a product for sale that has a warning label like the following:
WARNING: Cancer and Reproductive Harm–www.p65Warnings.ca.gov.
What is Prop 65?
Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California. It mandates that the Governor of California maintain and publish a list of chemicals known to cause cancer, birth defects, and/or other reproductive harm. The list, which is updated annually, includes hundreds of chemicals found in many everyday items. The purpose of Prop 65 is to inform the public about exposure to these chemicals. Prop 65 does not ban the sale of products containing these chemicals but instead requires warnings on any product, product packaging, or literature with the product. Moreover, a Prop 65 warning does not mean that a product is in violation of any product safety standards or requirements. In fact, the California government has clarified that a Prop 65 warning “is not the same as a regulatory decision that a product is safe’ orunsafe.'” Many of these chemicals have been used in everyday products for years without documented harm. For more information, go to https://oag.ca.gov/prop65/faqs-view-all. A Prop 65 warning means that a company has either (1) evaluated the exposure and has concluded that it exceeds the “no significant risk level”; or (2) has chosen to provide a warning based on its understanding about the presence of a listed chemical without attempting to evaluate the exposure.
Does this law apply everywhere?
Prop 65 warnings are required under California law only. These warnings are seen throughout California in a wide range of settings, including but not limited to restaurants, grocery stores, hotels, schools, and hospitals, and on a wide variety of products. Additionally, some online and mail order retailers provide Prop 65 warnings on their websites or in catalogs.
How do the California warnings compare to federal limits?
Prop 65 standards are often more stringent than federal and international standards. There are various substances that require a Prop 65 warning at levels that are far lower than federal action limits. For example, the Prop 65 standard for warnings for lead is 0.5 g/day, which is well below the federal and international standards.
Why don’t all similar products carry the warning?
· Products sold in California require Prop 65 labelling while similar products sold elsewhere do not. · A company involved in a Prop 65 lawsuit reaching a settlement may be required to use Prop 65 warnings for its products, but other companies
making similar products may have no such requirement.
· The enforcement of Prop 65 is inconsistent. · Companies may elect not to provide warnings because they conclude that they are not required to do so under Prop 65; a lack of warnings for a
product does not mean that the product is free of listed chemicals at similar levels.
Why does Toro include this warning?
Toro has chosen to provide consumers with as much information as possible so that they can make informed decisions about the products they buy and use. Toro provides warnings in certain cases based on its knowledge of the presence of one or more listed chemicals without evaluating the level of exposure, as not all the listed chemicals provide exposure limit requirements. While the exposure from Toro products may be negligible or well within the “no significant risk” range, out of an abundance of caution, Toro has elected to provide the Prop 65 warnings. Moreover, if Toro does not provide these warnings, it could be sued by the State of California or by private parties seeking to enforce Prop 65 and subject to substantial penalties.
Rev A

The Toro Warranty
Two-Year or 1,500 Hours Limited Warranty

Conditions and Products Covered

Parts

The Toro Company warrants your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for 2 years or 1,500 operational hours, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products). Where a warrantable condition exists, we will repair the Product at no cost to you including diagnostics, labor, parts, and transportation. This warranty begins on the date the Product is delivered to the original retail purchaser. Product equipped with an hour meter.
Instructions for Obtaining Warranty Service
You are responsible for notifying the Commercial Products Distributor or Authorized Commercial Products Dealer from whom you purchased the Product as soon as you believe a warrantable condition exists. If you need help locating a Commercial Products Distributor or Authorized Dealer, or if you have questions regarding your warranty rights or responsibilities, you may contact us at:

Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part. Parts replaced under this warranty are covered for the duration of the original product warranty and become the property of Toro. Toro will make the final decision whether to repair any existing part or assembly or replace it. Toro may use remanufactured parts for warranty repairs.
Deep Cycle and Lithium-Ion Battery Warranty
Deep cycle and Lithium-Ion batteries have a specified total number of kilowatt-hours they can deliver during their lifetime. Operating, recharging, and maintenance techniques can extend or reduce total battery life. As the batteries in this product are consumed, the amount of useful work between charging intervals will slowly decrease until the battery is completely worn out. Replacement of worn out batteries, due to normal consumption, is the responsibility of the product owner. Note: (Lithium-Ion battery only): Refer to the battery warranty for additional information.

Toro Commercial Products Service Department 8111 Lyndale Avenue South Bloomington, MN 55420-1196
952­888­8801 or 800­952­2740 E-mail: commercial.warranty@toro.com
Owner Responsibilities
As the product owner, you are responsible for required maintenance and adjustments stated in your Operator’s Manual. Repairs for product issues caused by failure to perform required maintenance and adjustments are not covered under this warranty.

Lifetime Crankshaft Warranty (ProStripe 02657 Model Only)
The Prostripe which is fitted with a genuine Toro Friction Disc and Crank-Safe Blade Brake Clutch (integrated Blade Brake Clutch (BBC) + Friction Disc assembly) as original equipment and used by the original purchaser in accordance with recommended operating and maintenance procedures, are covered by a Lifetime Warranty against engine crankshaft bending. Machines fitted with friction washers, Blade Brake Clutch (BBC) units and other such devices are not covered by the Lifetime Crankshaft Warranty.
Maintenance is at Owner’s Expense

Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the warranty period are defects in materials or workmanship. This warranty does not cover the following:
· Product failures which result from the use of non-Toro replacement parts, or from installation and use of add-on, or modified non-Toro branded accessories and products.
· Product failures which result from failure to perform recommended maintenance and/or adjustments.
· Product failures which result from operating the Product in an abusive, negligent, or reckless manner.
· Parts consumed through use that are not defective. Examples of parts which are consumed, or used up, during normal Product operation include, but are not limited to, brake pads and linings, clutch linings, blades, reels, rollers and bearings (sealed or greasable), bed knives, spark plugs, castor wheels and bearings, tires, filters, belts, and certain sprayer components such as diaphragms, nozzles, flow meters, and check valves.
· Failures caused by outside influence, including, but not limited to, weather, storage practices, contamination, use of unapproved fuels, coolants, lubricants, additives, fertilizers, water, or chemicals.
· Failure or performance issues due to the use of fuels (e.g. gasoline, diesel, or biodiesel) that do not conform to their respective industry standards.
· Normal noise, vibration, wear and tear, and deterioration. Normal “wear and tear” includes, but is not limited to, damage to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows.

Engine tune-up, lubrication, cleaning and polishing, replacement of filters, coolant, and completing recommended maintenance are some of the normal services Toro products require that are at the owner’s expense.
General Conditions
Repair by an Authorized Toro Distributor or Dealer is your sole remedy under this warranty.
The Toro Company is not liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty. Except for the Emissions warranty referenced below, if applicable, there is no other express warranty. All implied warranties of merchantability and fitness for use are limited to the duration of this express warranty.
Some states do not allow exclusions of incidental or consequential damages, or limitations on how long an implied warranty lasts, so the above exclusions and limitations may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.
Note Regarding Emissions Warranty
The Emissions Control System on your Product may be covered by a separate warranty meeting requirements established by the U.S. Environmental Protection Agency (EPA) and/or the California Air Resources Board (CARB). The hour limitations set forth above do not apply to the Emissions Control System Warranty. Refer to the Engine Emission Control Warranty Statement supplied with your product or contained in the engine manufacturer’s documentation.

Countries Other than the United States or Canada
Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining guarantee information, contact your Authorized Toro Service Center.

374-0253 Rev H

References

• p65Warnings.ca.gov

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