TORO Workman GTX EFI Utility Vehicle with Extended Chassis Instruction Manual

Workman GTX EFI Utility Vehicle with Extended Chassis

Form No. 3422-243 Rev C
Workman® GTX EFI Utility Vehicle with Extended Chassis
Model No. 07042EX–Serial No. 400000000 and Up

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

3422-243

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.
Please refer to the engine manufacturer’s information included with the machine.
WARNING
CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or 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.

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.

Figure 1 Bottom of Seat Assembly Shown
1. Model and serial-number location

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Model No.
Serial No.
This manual identifies potential hazards and has safety messages identified by the safety-alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions.

Introduction
This utility vehicle is intended to be primarily used off-highway to transport people and material loads.
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.
You may contact Toro directly at 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 Dealer 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.

Figure 2 Safety-alert symbol

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This manual uses 2 words to highlight information. Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention.

© 2021–The Toro® Company

Contact us at www.Toro.com.

8111 Lyndale Avenue South Bloomington, MN 55420

2

Printed in the USA All Rights Reserved

Contents
Safety …………………………………………………………….. 4 General Safety …………………………………………… 4 Safety and Instructional Decals …………………….. 5
Setup ……………………………………………………………… 8 1 Installing the Steering Wheel (International Models Only)…………………………………………… 8 2 Checking the Fluid Levels and Tire Pressure ………………………………………………… 8 3 Burnishing the Brakes……………………………….. 9 4 Reading the Manual and Viewing the Setup Material…………………………………………. 9
Product Overview …………………………………………… 10 Controls ………………………………………………….. 10 Specifications ………………………………………….. 13 Attachments/Accessories …………………………… 13
Before Operation …………………………………………. 14 Before Operation Safety …………………………….. 14 Performing Daily Maintenance…………………….. 14 Checking the Tire Pressure…………………………. 14 Adding Fuel ……………………………………………… 15 Breaking in a New Machine ………………………… 15
During Operation …………………………………………. 16 During Operation Safety …………………………….. 16 Operating the Cargo Bed ……………………………. 18 Using the Rear Cargo Bed Accessory Mount…………………………………………………… 20 Loading the Cargo Bed ………………………………. 21 Starting the Engine ……………………………………. 21 Stopping the Machine ………………………………… 22
After Operation ……………………………………………. 22 After Operation Safety ……………………………….. 22 Transporting the Machine …………………………… 22 Towing the Machine …………………………………… 23 Towing a Trailer ………………………………………… 23
Maintenance ………………………………………………….. 24 Recommended Maintenance Schedule(s) ……….. 25 Daily Maintenance Checklist……………………….. 26 Maintaining the Machine under Special Operating Conditions ……………………………… 26 Pre-Maintenance Procedures ………………………… 27 Maintenance Safety…………………………………… 27 Preparing the Machine for Maintenance………… 27 Lifting the Machine ……………………………………. 28 Accessing the Hood…………………………………… 28 Removing the Bench Cushion……………………… 29 Installing the Bench Cushion ………………………. 29 Lubrication …………………………………………………. 30 Greasing the Machine………………………………… 30 Greasing the Front Wheel Bearings ……………… 30 Engine Maintenance ……………………………………. 33 Engine Safety …………………………………………… 33 Servicing the Air Cleaner ……………………………. 33 Servicing the Engine Oil……………………………… 35 Servicing the Spark Plug…………………………….. 36 Adjusting the High/Low Idle ………………………… 37 Fuel System Maintenance …………………………….. 37

Inspecting Fuel Lines and Connections…………. 37 Replacing the Fuel Filter …………………………….. 37 Servicing the Carbon Canister …………………….. 38 Electrical System Maintenance ……………………… 39 Electrical System Safety …………………………….. 39 Servicing the Battery………………………………….. 39 Replacing the Fuses ………………………………….. 41 Maintaining the Headlights …………………………. 42 Drive System Maintenance ……………………………. 43 Maintaining the Tires …………………………………. 43 Inspecting the Steering and Suspension
Components …………………………………………. 44 Adjusting the Front Wheel Alignment ……………. 44 Checking the Transaxle-Fluid Level ……………… 45 Changing the Transaxle Fluid ……………………… 45 Checking the Neutral Gear-Shift
Position ………………………………………………… 46 Adjusting the Neutral Gear-Shift
Position ………………………………………………… 46 Maintaining the Primary-Drive Clutch……………. 47 Reducing the Top Speed…………………………….. 47 Cooling System Maintenance ………………………… 48 Cooling System Safety ………………………………. 48 Cleaning the Engine-Cooling Areas ……………… 48 Brake Maintenance ……………………………………… 49 Checking the Parking Brake ……………………….. 49 Adjusting the Parking Brake………………………… 49 Checking the Brake- Fluid Level …………………… 49 Inspecting the Brakes ………………………………… 50 Changing the Brake Fluid …………………………… 50 Belt Maintenance ………………………………………… 50 Servicing the Drive Belt………………………………. 50 Adjusting the Starter-Generator Belt …………….. 51 Chassis Maintenance……………………………………. 51 Adjusting the Cargo-Bed Latches ………………… 51 Cleaning …………………………………………………….. 52 Washing the Machine ………………………………… 52 Storage …………………………………………………………. 53 Storage Safety………………………………………….. 53 Storing the Machine…………………………………… 53

3

Safety
Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety-alert symbol (Figure 2), which means Caution, Warning, or Danger–personal safety instruction. Failure to comply with the instruction may result in personal injury or death.
This machine has been designed in accordance with the requirements of SAE J2258.
General Safety
This product is capable of causing personal injury. Always follow all safety instructions to avoid serious personal injury.
Using this product for purposes other than its intended use could prove dangerous to you and bystanders. · Read and understand the contents of this
Operator’s Manual before you start the engine. 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 the machine a safe distance away from bystanders while it is moving. · Keep children out of the operating area. Never allow children to operate the machine. · Stop the machine, shut off the engine, 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.
You can find additional safety information where needed throughout this manual.
4

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. Hot surface/burn hazard–stay a safe distance away from the hot surface.
3. Entanglement hazard, belt–stay away from moving parts; keep all guards in place.
4. Crushing hazard, cargo bed–use the prop rod to support the cargo bed.

131-8410 1. Fire hazard–shut off the engine before fueling.

decal131-8410

115-2047 1. Warning–do not touch the hot surface.

decal115-2047

115-7739

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

120-9570

decal120-9570

1. Warning–stay away from moving parts; keep all guards and shields in place.

131-8414

decal131-8414

1. Warning–read the Operator’s Manual.
2. Warning–receive proper training before operating the machine.

3. Tipping hazard–drive slowly across or up slopes; take turns slowly; do not exceed speeds of 25 kph (16 mph); drive slowly when hauling cargo; drive slowly on uneven terrain.
4. Falling hazard; severing hazard of limbs–do not carry passengers in the bed; do not carry extra passengers in between the seats; do not put your arms or legs outside of the machine while operating.

5

1. Forward 2. Neutral

200 LBS 91 KG

1500 LBS 680 KG

131-8463 3. Reverse

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137-9984

137-9984

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

weight of 91 kg (200 lb).

load of 680 kg (1,500 lb).

1. Light–On

2. Light–Off

138-3524 3. Raise the bed.

decal138-3524
4. Lower the bed.

6

1. Horn 2. Off
3. On

138-3528 EFI Models Only

decal138-3528

1. Read the Operator’s Manual before performing maintenance.
2. Engine intake/air filter
3. Fuel filter 4. Spark plug

5. Spark plug air gap
6. Engine oil 7. Transmission fluid 8. Brake fluid

138-3397 EFI Models Only

decal138-3397

4. Engine–start
5. To start the engine: 1) Sit in the operator’s position; 2) Disengage the parking brake; 3) Turn the key to the engine START position; 4) Press the brake pedal.
6. To shut off the engine: 1) Release the brake pedal; 2) Engage the parking brake; 3) Turn the key to the OFF position; 4) Remove the key.

138-5599

decal138-5599

1. Read the Operator’s Manual for fuse information.
2. Horn (30 A)
3. Main power (15 A)
4. Headlights (10 A)

5. USB power point/options (10 A)
6. Fuel (10 A) 7. Optional lift kit (15 A)

7

Setup

Loose Parts

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

Procedure
1 2

Description Steering wheel Steering wheel cover Washer (1/2 inch) Dust cover
No parts required

Qty.

Use

1

1

Install the steering wheel (International

1

models only).

1

­

Check the fluid levels and tire pressure.

3

No parts required

Operator’s Manual

Engine owner’s manual

4

Registration card Predelivery Inspection Form

Certificate of Quality

Key

­

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 (International Models Only)

4. Secure the steering wheel to the shaft with the locknut (1/2 inch) and tighten it to 18 to 30 Nm (13 to 22 ft-lb).
5. Install the cover on the steering wheel (Figure 3).

Parts needed for this procedure:

1 Steering wheel

1 Steering wheel cover

1 Washer (1/2 inch)

1 Dust cover

Figure 3

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Procedure
1. If the cover is installed, remove it from the hub of the steering wheel (Figure 3).
2. Remove the locknut (1/2 inch) from the steering shaft (Figure 3).
3. Slide the steering wheel, dust cover, and washer (1/2 inch) onto the steering shaft (Figure 3).

1. Steering wheel cover 2. Locknut (1/2 inch) 3. Washer (1/2 inch)

4. Steering wheel 5. Dust cover 6. Steering shaft

Note: With the front wheels straight, orient the steering wheel so that the smaller spoke on the steering wheel is vertical.

8

2
Checking the Fluid Levels and Tire Pressure

4
Reading the Manual and Viewing the Setup Material

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 35).
2. Check the brake-fluid level before you first start the engine; refer to Checking the Brake-Fluid Level (page 49).
3. Check the transaxle-fluid level before you first start the engine; refer to Checking the Transaxle-Fluid Level (page 45).
4. Check the air pressure in the tires; refer to Checking the Tire Pressure (page 14).
3
Burnishing the Brakes

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 owners’s manual.
· Fill out the registration card. · Complete the Predelivery Inspection Form. · Review the Certificate of Quality.

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).

9

Product Overview
Controls
Become familiar with all the controls before you start the engine and operate the machine. Note: Determine the left and right sides of the machine from the normal operating position.
Control Panel

1. Steering wheel 2. Gear-shift indicator 3. Gear-shift lever 4. Horn button (International models only) 5. Key switch

Figure 4
6. USB power point 7. Parking-brake lever 8. Choke control 9. Brake pedal 10. Accelerator pedal

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Accelerator Pedal
Use the accelerator pedal (Figure 4) 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).

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.

Brake Pedal
Use the brake pedal to stop or slow the machine (Figure 4).

10

Key Switch
The key switch is located at the lower, right corner of the dash panel (Figure 4).
The key switch has 3 positions: OFF, ON, and START.
There are 2 modes of starting the machine; refer to Starting the Engine (page 21).
Parking-Brake Lever
The parking-brake lever is located on the control panel (Figure 4).
Whenever you shut off the engine, engage the parking brake to prevent the machine from accidentally moving. If the machine is parked on a steep grade, ensure that you engage the parking brake.
To engage the parking brake, pull the parking-brake lever toward you (Figure 5).

Choke Control
The choke control is located on the control panel. Use the choke to help start a cold engine by pulling the choke control outward (Figure 4). After the engine starts, adjust the choke to keep the engine running smoothly. As the engine warms up, push in the choke control to the OFF position.
Gear-Shift Lever and Gear-Shift Indicator
The gear-shift lever can be set to 3 positions on the gear-shift indicator: FORWARD, REVERSE, and NEUTRAL (Figure 7).
Note: The engine starts and runs in any of the 3 positions.
From the NEUTRAL position, you can move the gear-shift lever left to the FORWARD position or right to the REVERSE position (Figure 7).
Important: Always stop the machine before changing gears.

Figure 5 1. Parking-brake lever

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To disengage the parking brake, push down the button on top of the parking- brake lever, pull the parking-brake lever toward you to release pressure, and then push the parking-brake lever forward (Figure 6).

Figure 7

1. Gear-shift indicator

2. Gear-shift lever

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Figure 6 1. Parking-brake lever

Horn Button
International Models Only
The horn button is located on the control panel (Figure 4). Press the horn button to sound the horn.
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11

Light Switch
The light switch is located to the left of the steering column (Figure 8). Use the light switch to illuminate the headlights. Push the light switch up to turn on the headlights. Push the light switch down to turn off the lights.

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

1. Light switch

Figure 8 2. Hour meter

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Hour Meter
The hour meter is located to the right of the light switch (Figure 8). Use the hour meter to find out the total number of engine hours. The hour meter starts to function whenever you turn the key switch to the ON position, START position, or if the engine is running.
Note: When the machine is running, the hour meter blinks continuously, recording usage.
USB Power Point
The USB power point is located to the left of the parking-brake lever (Figure 4). Use the power point to power mobile devices.
Important: When you are not using the USB power point, insert the rubber plug to prevent damage to the power point.

1. Empty 2. Half full 3. Needle

Figure 9
4. Full 5. Fuel-tank cap 6. Fuel gauge

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Passenger Handholds
The passenger handholds are located on the outside of each seat (Figure 10).

Figure 10 Passenger Side Shown 1. Passenger handhold
12

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Specifications

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

Base weight Rated capacity (on level ground) Maximum gross vehicle weight (GVW)–on level ground Maximum cargo capacity (on level ground) Maximum rear cargo-bed-accessory mount capacity Tow capacity Overall width Overall length Overall height Ground clearance Wheel base Wheel tread (center line to center line)
Cargo bed length
Cargo bed width Cargo bed height Engine speed

397 kg (875 lb) 544 kg (1,200 lb) total, including 90.7 kg (200 lb) operator and 91 kg (200 lb) passenger, load, accessories, and attachments 941 kg (2,075 lb) total, including all of the weights listed above 363 kg (800 lb) total, including rear-mounted accessories 45 kg (100 lb) total Tongue weight: 91 kg (200 lb) Maximum trailer weight: 680 kg (1,500 lb) 119 cm (47 inches) 302 cm (119 inches) 127.5 cm (50.2 inches) 21.6 cm (8.5 inches) at the front with no load or operator 14 cm (5.5 inches) at the rear with no load or operator 220 cm (86.6 inches) Front: 119 cm (47 inches) Rear: 119 cm (47 inches) Inside: 102 cm (40 inches) Outside: 114.3 cm (45 inches) Inside: 98 cm (38.5 inches) Outside of the molded fenders: 107.3 cm (42.25 inches) 28 cm (11 inches) inside Low idle: 1,250 to 1,350 rpm High idle: 3,650 to 3,750 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 Distributor or go to www.Toro.com for a list of all approved attachments and accessories.

13

Operation
Note: Determine the left and right sides of the machine from the normal operating position.
Before Operation
Before Operation Safety
General Safety
· Never allow children or untrained people to 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.
· Know how to stop the machine and shut off the engine quickly.
· Ensure that you and your passengers do not exceed 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
Front and rear tires air pressure specification: 165 to 207 kPa (24 to 30 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. · 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

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Performing Daily Maintenance
Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 24).

14

Adding Fuel

Recommended Fuel
· For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with a cetane rating of 87 or higher ((R+M)/2 rating method).
· Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use. Never use gasoline that contains more than 10% ethanol by volume, such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains up to 85% ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.
· Do not use gasoline containing methanol.
· Do not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used.
· Do not add oil to gasoline.
Filling the Fuel Tank
The fuel-tank capacity is approximately 18.9 L (5 US gallons).
1. Park the machine on a level surface.
2. Engage the parking brake.
3. Shut off the engine and remove the key.
4. Clean the area around the fuel-tank cap (Figure 12).

1. Empty 2. Half full 3. Needle

Figure 12
4. Full 5. Fuel-tank cap 6. Fuel gauge

g033956

5. Remove the fuel-tank cap. 6. Fill the tank to about 25 mm (1 inch) below the
top of tank (bottom of the filler neck).
Note: This space in the tank allows fuel to expand. Do not overfill the fuel tank. 7. Install the fuel-tank cap securely. 8. 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 3
Burnishing the Brakes (page 9). · 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.

15

· 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 24) for any special, low-hour checks.
· Check the front suspension positioning and adjust it, if necessary; refer to Adjusting the Front Wheel Alignment (page 44).
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 pets away from the machine during operation.
· Wear appropriate clothing, including eye protection; long pants; substantial, slip-resistant footwear; and hearing protection. Tie back long hair and do not wear loose jewelry.
· 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 the machine with a heavy load in the cargo bed. The heavier the load, the more difficult it is to turn or stop.
· Carrying oversized loads in the cargo bed reduces the stability of the machine.
· Carrying material that cannot be bound to the machine, such as a large tank of liquid, adversely affects the steering, braking, and stability of the machine.
· Before you start the engine, 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 your 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.
· 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.
· 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.
· 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 the machine immediately, shut off the engine, remove the key, wait for all movement to stop, and inspect for damage. Repair all damage to the machine before resuming operation.
· 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.
· It can take longer to stop the machine on wet surfaces than on dry surfaces. To dry out wet brakes, drive slowly on level ground while putting light pressure on the brake pedal.
· Sudden changes in terrain may move the steering wheel unexpectedly, which could result in hand and arm injuries. Reduce your speed and grip the steering wheel loosely around the perimeter, keeping your thumbs out of the way of the steering wheel spokes.
· Reduce the speed when you operate the machine with the cargo bed removed. 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 leaving the operating position, do the following:
­ Park the machine on level ground.
­ Engage the parking brake.
­ Lower the cargo bed.
­ Shut off the engine and remove the key.

16

· Do not operate the machine when there is the risk of lightning.
· Use accessories and attachments approved by The Toro® Company only.
Multi-Passenger Safety
· You must account for the extra passengers contributing to the overall gross vehicle weight (GVW) of the machine.
· If you have a load in the cargo bed, ensure that you do not exceed the capacity of the machine by having too many passengers.
· Passengers should sit in the designated seating positions only. Do not allow passengers to sit in the cargo bed.
· You and your passengers should remain seated whenever the machine is in motion.
· The additional machine length results in a larger turn radius, so allow more space to maneuver the machine.
Slope Safety
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 13).
· 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.

17

Operating the Cargo Bed
Raising the Cargo Bed to the Dump Position
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.

1. Cargo-bed lever

Figure 13

g034019

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

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. Pull the lever on left, inside of the cargo bed toward you and lift the cargo bed up (Figure 13).

Figure 14

g034021

1. Service position detent slot
2. Prop rod

3. Dump position detent slot

18

Raising the Cargo Bed to the Service Position
1. Pull the lever on left, inside of the cargo bed toward you and lift the cargo bed up (Figure 13).
2. Pull prop rod into the service position detent slot to secure the bed for maintenance (Figure 14).

Opening the Tailgate
1. Ensure that the cargo bed is down and latched.
2. Using both hands, raise the tailgate using the ridge near the top of the tailgate (Figure 15).
3. Lower the tailgate until it is flush with the bottom of the cargo bed (Figure 15).

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 away when lowering the bed.
1. Raise the cargo bed slightly by lifting up on 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.

Figure 15

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19

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 steps 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).

Using the Rear Cargo Bed Accessory Mount
Use the rear cargo bed accessory mount to attach accessories to the rear of the machine.
Capacity: 45 kg (100 lb)
1. Loosen the “T” handle by rotating it clockwise (Figure 17).

Figure 16

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

3. Hinge area

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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 lift the tailgate into the notches in the cargo bed.

1. Receiver

Figure 17 2. “T” handle

g034525

2. Insert your accessory into the receiver until the holes align (Figure 17).
3. Secure the assembled accessory to the receiver tube using the clevis pin and hairpin cotter supplied with the accessory.
4. Tighten the “T” handle by rotating it counterclockwise (Figure 18).

1. “T” handle

Figure 18

g034526

20

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 13) 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.
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 wight 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 liquid in a large tank (such as a sprayer tank), use caution when driving the machine uphill or downhill, when suddenly changing speed or stopping, or when driving over tough surfaces.
The capacity of the cargo bed is 0.28 m3 (10 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 Bed Capacity
(on level ground) Full
3/4 Full
Full
3/4 full
Full Full
3/4 Full (approximately)

Starting the Engine
1. Sit in the operator seat, insert the key into the key switch, and rotate the key clockwise to the ON or START position.
There are 2 modes of starting the machine:
· Pedal Start–turn the key switch to the ON position, press down the accelerator pedal, then release your foot from the accelerator pedal.
Note: When you remove your foot from the accelerator pedal, the engine shuts off.
· Key Start–turn the key switch to the START position and the engine remains on until the is turned to the OFF position.
Note: When using key start mode, you can engage the parking brake and work away from the machine while the engine still runs and the battery holds a charge.
Note: If you turn the key to the START position, the engine cranks until it starts. If the engine cranks for more than 10 seconds, return to the OFF position, and determine the issue (e.g., the choke controls needs to be engaged, check the air cleaner for restrictions, ensure that the fuel tank is full, the spark is bad, etc.) before starting the machine again.
Note: When equipped with the optional backup alarm, if you move the gear-shift selector to the REVERSE position when the key switch is in the ON or START position, a buzzer sounds to warn the operator that the machine is in reverse gear.
2. Move the gear-shift selector to the desired direction of travel for the machine.

21

3. Disengage the parking brake.
4. Slowly step on the accelerator pedal.
Note: If the engine is cold, press and hold the accelerator pedal about half- way down, and pull the choke knob out to the ON position. Return the choke knob to the OFF position after the engine warms up.
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.

After Operation
After Operation Safety
General Safety
· Allow the engine to cool before storing the machine in any enclosure.
· 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.
· Keep all parts of the machine in good working condition and all hardware tightened.
· Replace all worn, damaged, or missing decals.
Transporting 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 19 and Figure 20 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.

CAUTION
Loose seats may fall off the machine and trailer when transporting the machine, and the seats may land on another machine or obstruct the roadway.
Remove the seats or make sure that the seats are securely fastened to the coupling in the seat shroud.

22

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.

Figure 19

g236535

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

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).
Note: The power steering does not function, making it difficult to steer.
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 23)
1. Remove the drive belt from the machine; refer to Replacing the Drive Belt (page 51).
2. Affix a tow line to the tongue at the front of the machine’s frame (Figure 20).
3. Move the transmission to the NEUTRAL position and disengage the parking brake.

Figure 20 1. Rear tie-down points

g034273 Towing a Trailer
The machine is capable of pulling trailers. A tow hitch is available for the machine. Contact your authorized Toro distributor 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.

23

Maintenance
Note: Determine the left and right sides of the machine from the normal operating position. Note: Download a 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
Failure 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 key switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the key switch and disconnect the wires from the spark plugs before you do any maintenance. Set the wires aside so that they do not accidentally contact the spark plugs.
24

Recommended Maintenance Schedule(s)

Maintenance Service Interval
After the first 5 hours After the first 8 hours After the first 50 hours After the first 100 hours Before each use or daily
Every 50 hours
Every 100 hours
Every 200 hours Every 300 hours Every 400 hours Every 800 hours Every 1,000 hours
Yearly

Maintenance Procedure
· Change the engine oil.
· Check the condition of the drive belt. · Check the tension of the starter- generator belt.
· Check the air filter for the carbon canister.
· Perform the guidelines for breaking in a new machine.
· Check the tire pressure. · Check the engine-oil level. · Check gear-shift operation. · Check the brake-fluid level.
· Remove the air-cleaner cover and clean out the debris. Do not remove the filter. · Clean out the debris in the dust cap.
· Grease the bearings and bushings. · Replace the air filter. Replace the air- filter element sooner if dirty or damaged. · Service the air filter (more frequently in extreme dusty or dirty conditions). · Change the engine oil. · Check the spark plug. · 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.
· Check the air filter for the carbon canister. · Check the condition and tension of the drive belt. · Check the tension of the starter-generator belt.
· Grease the front wheel bearings.
· Inspect the fuel lines and connections. · Replace the fuel filter. · Clean the primary-drive clutch.
· Change the transaxle fluid.
· Change the brake fluid.
· Complete all of the yearly maintenance procedures that are specified in the engine owner’s manual.

25

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 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.

Lubricate all grease fittings.

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, have your brakes inspected and
cleaned as soon as possible. This prevents any abrasive material from causing excessive wear.

26

Pre-Maintenance Procedures
Maintenance Safety
· Do not allow untrained personnel to service the machine.
· Before servicing or making any adjustments to the machine, park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key to prevent accidental starting of the machine.
· Remove any load material from the cargo bed before working underneath it.
· Always use the prop rod to hold the cargo bed up before working underneath it.
· Use jack stands to support the machine or components when required.
· Carefully release pressure from components with stored energy.
· Do not charge the batteries while servicing the machine.
· To ensure that the entire machine is in good condition, keep all the nuts, bolts, and screws properly tightened.
· To reduce the potential fire hazard, keep the engine area free of excessive grease, grass, leaves, and accumulation of dirt.
· If possible, do not perform maintenance while the engine is running. Keep away from moving parts.
· If you must run the engine to perform a maintenance adjustment, keep your hands, feet, clothing, and any parts of the body away from the engine and any moving parts. Keep bystanders away from the machine.
· Clean up oil and fuel spills. · Check the parking brake operation frequently.
Adjust and service as required.
· Keep all parts in good working condition and all hardware 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. Check their proper operation regularly.
· Do not overspeed the engine by changing the governor settings. To ensure safety and accuracy, have an authorized Toro distributor to check the maximum engine speed with a tachometer.
· If major repairs are ever necessary or assistance is required, contact an authorized Toro distributor.
· To ensure optimum performance and safety, always purchase genuine Toro replacement

parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous. 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.
Preparing the Machine for Maintenance
1. Park the machine on a level surface.
2. Engage the parking brake.
3. Shut off the engine and remove the key.
4. Empty and raise the cargo bed; refer to Raising the Cargo Bed to the Dump Position (page 18).

27

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. · Always remove the key from the key switch
before getting off the machine. · 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 21).

1. Rear lifting points

Figure 22

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Accessing the Hood
Raising the Hood
1. Lift up the handle of the rubber latches on each side of the hood (Figure 23).

1. Front lifting point

Figure 21

g034043

· The lifting point at the rear of the machine is located under the axle tubes (Figure 22).

Figure 23

g034045

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 23).

28

Removing the Bench Cushion
1. Push the bench cushion forward to the raised position.
2. Slide the cushion to the side, out of the pins, and lift the cushion upward (Figure 24).

Installing the Bench Cushion
Slide the bench cushion onto the pins and lower the cushion (Figure 25).

Figure 24

g237191

Figure 25

g237190

29

Lubrication
Greasing the Machine
Service Interval: Every 100 hours/Yearly (whichever comes first)–Grease the bearings and bushings. Grease the machine more frequently when using it for heavy-duty operations.
Grease Type: No. 2 lithium grease
1. Use a rag to wipe the grease fitting clean so that foreign matter cannot be forced into the bearing or bushing.
2. With a grease gun, apply 1 or 2 pumps of grease into the grease fittings on the machine.
3. Wipe the excess grease off the machine.
The grease fittings are located at the inner end of the control arms, the tie- rod ball joint, and the outer end of the control arms (Figure 26 and Figure 27).

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 28).

Figure 26

1. Hub 2. Wheel

Figure 28 3. Lug nut

g033046

3. Remove the flange-head bolts (3/8 x 3/4 inch)

g034057

that secure the bracket for the brake assembly

to the spindle and separate the brake from the

spindle (Figure 29).

Note: Support the brake assembly before proceeding to the next step.

Figure 27

g034058

30

Figure 29

g033047

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

3. Caliper bracket (brake assembly)

1. Spindle

Figure 31

g192347

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 30).

1. Cotter pin 2. Spindle 3. Tab washer

Figure 30
4. Spindle nut 5. Nut retainer 6. Dust cap

g192346

5. Remove the cotter pin and nut retainer from the spindle and spindle nut (Figure 30).
6. Remove the spindle nut from the spindle, and separate the hub and rotor assembly from the spindle (Figure 30 and Figure 31).

31

Greasing the Wheel Bearings
1. Remove the outboard bearing and bearing race from the hub (Figure 32).

Installing the Hub and Rotor
1. Apply a light coat of the specified grease to the spindle (Figure 33).

Figure 32

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 32).
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 32).
6. Pack the bearings with the specified grease.
7. Fill the cavity of hub 50 to 80% full of the specified grease (Figure 32).
8. Assemble the inboard bearing onto the race at the inboard side of the hub and install the seal (Figure 32).
9. Repeat steps 1 through 8 to the bearings for the other hub.

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

Figure 33

g192344

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 33).
3. Assemble the outboard bearing onto the spindle and seat the bearing to the outboard race (Figure 33).
4. Assemble the tab washer onto the spindle (Figure 33).
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 33).
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 34).
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.

32

Engine Maintenance

1. Cotter pin 2. Nut retainer

Figure 34 3. Dust cap

g192345

9. Install the cotter pin and bend each legs around the retainer (Figure 34).
10. Install the dust cap onto the hub (Figure 34).
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 29) and the holes in the caliper bracket with the holes in the brake mount of the spindle frame (Figure 33).
3. Secure the caliper bracket to the spindle frame (Figure 29) 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 28).
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 28).
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.

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.
Servicing the Air Cleaner
Service Interval: Every 100 hours Replace the air-filter element sooner if dirty or damaged.
Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy.
Servicing the Air-Cleaner Cover
Service Interval: Every 50 hours–Remove the air-cleaner cover and clean out the debris. Do not remove the filter.
Every 50 hours
Check the air-cleaner body for damage which could cause an air leak. Replace a damaged air-cleaner body.
Clean the air-cleaner cover and remove the debris from the dust cap as shown in Figure 35.

33

4. Install the air-cleaner cover with the side indicated as “UP” facing upward and secure the latches (Figure 36).

Figure 35

g236567

Servicing the Air Filter
Service Interval: Every 100 hours (more frequently in extreme dusty or dirty conditions).
1. Gently slide the air filter out of the air-cleaner body (Figure 36).
Note: Avoid knocking the air filter into the side of the body.
Important: Do not attempt to clean the air filter.
2. Inspect the new filter for damage by looking into the filter while shining a bright light on the outside of the filter.
Note: Holes in the filter appear as bright spots. Inspect the element for tears, an oily film, or damage to the rubber seal. If the filter is damaged, do not use it.
3. Carefully slide the air filter into the air filter housing.
Important: Do not press on the soft inside area of the filter.

34

Figure 36

g034313

Servicing the Engine Oil
Service Interval: After the first 5 hours Every 100 hours (Change the oil twice as often during special operating conditions; refer to Maintaining the Machine under Special Operating Conditions (page 26)).
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
Crankcase Capacity: 1.0 L (1.1 US qt)
Oil Type: API service class SJ or higher detergent oil
Viscosity: See the table below.

Figure 38

g192771

Figure 37

g034082

Checking the Engine-Oil Level
Service Interval: Before each use or daily
Note: The machine is shipped with oil in the crankcase; however, check the oil before and after you start the engine.
Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If you have already run the engine, allow the oil to drain back down to the sump for at least 10 minutes before checking. If the oil level is low, add oil to bring the oil level to the Full mark. Do not overfill.
Check the engine-oil level as shown in Figure 38.

35

Changing the Engine Oil
1. Start the machine and let the engine run for a few minutes.
2. Park the machine on a level surface.
3. Engage the parking brake.
4. Shut off the engine and remove the key.
5. Raise the cargo box and secure it with the prop rod; refer to Raising the Cargo Bed to the Service Position (page 19).
6. Change the engine oil as shown in Figure 39.

Figure 39

g192770

Servicing the Spark Plug
Checking and Replacing the Spark Plug
Service Interval: Every 100 hours/Yearly (whichever comes first) Replace the spark plug if necessary.
Carburetor Model Spark Plug Type: Champion XC12YC
EFI Model Spark Plug Type: Champion RC12LC4
Air Gap: 0.76 mm (0.03 inch)
Important: You must replace a cracked, fouled, dirty, or malfunctioning spark plug. Do not sand-blast, scrape, or clean electrodes by using a wire brush because grit may eventually release from the plug and fall into the cylinder. The result is usually a damaged engine.
Note: The spark plug usually lasts a long time; however, the plug should be removed and checked whenever the engine malfunctions.
1. Clean the area around the spark plug so that foreign matter cannot fall into the cylinder when you remove the spark plug.
2. Pull the wire off the terminal of the spark plug. 3. Remove the plug from the cylinder head. 4. Check the condition of the side electrode, center
electrode, and center electrode insulator to ensure that there is no damage (Figure 40).
Note: Do not use a damaged or worn spark plug. Replace it with a new spark plug of the specified type.

Figure 40

g238425

1. Center electrode insulator 3. Air gap (not to scale) 2. Side electrode

5. Set the air gap between the center and side of the electrodes at 0.76 mm (0.03 inch) as shown in Figure 40.

36

6. Install the spark plug into the cylinder head, and torque the plug to 27 Nm (20 ft-lb).
7. Install the spark-plug wire.
8. Repeat steps 1 through 7 for the other spark plug.
Adjusting the High/Low Idle
1. Lift the cargo bed and secure it with the prop rod.
2. At the throttle cable housing, loosen the forward jam nut and tighten the rear jam nut to increase the low idle (Figure 41).

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.

Figure 41

1. Throttle cable housing 2. Jam nuts

3. Throttle lever

g229954

3. Test the high idle with a tachometer:
A. Ensure that the shift lever is in the NEUTRAL position.
B. Start the engine.
C. Fully depress the accelerator pedal and measure the engine speed with a tachometer; the engine speed should be between 3650 to 3750 rpm. If it kis not, shut off the engine and adjust the cable jam nuts.
Important: Do not lower the high idle. Test with a tachometer to ensure that the high idle is between 3650 to 3750 rpm.
4. Lower and secure the cargo bed.

Replacing the Fuel Filter
Service Interval: Every 400 hours/Yearly (whichever comes first)
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 bed and support it with the prop rod; refer to Raising the Cargo Bed to the Dump Position (page 18).
5. Disconnect the battery; refer to Disconnecting the Battery (page 39).
6. Place a clean container under the fuel filter and replace the fuel filter as shown in Figure 42.

37

Servicing the Carbon Canister
Checking the Air Filter for the Carbon Canister
Service Interval: After the first 50 hours Every 200 hours
Check the opening at the bottom of the air filter for the carbon canister to ensure that it is clean and free of debris and obstructions (Figure 43).
Clean the air filter for the carbon canister with clean, compressed air.

Figure 42

g029685

Figure 43 Located Beneath the Driver’s Seat

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7. Connect the battery, and lower the cargo bed; refer to Connecting the Battery (page 41) and Lowering the Cargo Bed (page 19).

1. Air-filter opening

38

Electrical System Maintenance
Electrical System Safety
WARNING
CALIFORNIA Proposition 65 Warning 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.

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 reconnect the positive (red) battery cable before reconnecting the negative (black) cable. · Always keep the battery strap in place to protect and secure the battery.

· 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.
Disconnect the battery as shown in Figure 44.

Figure 44

g034311

39

Removing the Battery
1. Disconnect the battery cables; refer to Disconnecting the Battery (page 39).
2. Remove the battery as shown in Figure 45.

Installing the Battery
1. Install the battery as shown in Figure 46.

Figure 45

Figure 46

g034327

g034326
2. Connect the battery cables; refer to Connecting the Battery (page 41).

40

Connecting the Battery
Connect the battery as shown in Figure 47.
Figure 47

Replacing the Fuses

There are 4 fuses in the electrical system. They are located beneath the seat assembly (Figure 48).

Note: If you install the optional lift kit, you will receive another fuse block to install next to the fuse block installed currently.

g034315

Horn Main power Headlights USB power point/options Optional lift kit (open–extra fuse block comes with kit)

30 A 15 A 10 A 10 A 15 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 (1.260 specific gravity). 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 Removing the Battery (page 40).

2. Connect a 3 to 4 A battery charger to the battery

g034618

posts. Charge the battery at a rate of 3 to 4 A

Figure 48

for 4 to 8 hours (12 V).

1. Ground block

2. Fuse block

Note: Do not overcharge the battery.

3. Install the battery in the chassis; refer to Installing the Battery (page 40).

Storing the Battery
If you store 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 it is fully charged.

41

Maintaining the Headlights
Replacing the Bulbs
CAUTION
If you install a higher wattage bulb than the system is designed for, you may blow the fuse. Always use the specified Toro LED bulb to prevent this issue.
CAUTION
The bulbs become extremely hot when in operation. Handling a hot bulb can cause severe burns and personal injury. Always allow enough time for the bulbs to cool before replacing them. Use care whenever handling the bulb.
Specification: See your Parts Catalog. 1. Disconnect the battery; refer to Disconnecting the Battery (page 39). 2. Open the hood; refer to Raising the Hood (page 28). 3. Disconnect the electrical connector for the harness from the connector of the lamp assembly at the back of the headlight housing (Figure 49).

with the slots in the headlight housing (Figure 49).
6. Secure lamp assembly by turning it 1/4 turn clockwise (Figure 49).
7. Connect the electrical connector for the harness to the connector of the new lamp assembly (Figure 49).
8. Connect the battery and close the hood; refer to Connecting the Battery (page 41).
Replacing the Headlight
1. Disconnect the battery; refer to Disconnecting the Battery (page 39).
2. Open the hood; refer to Raising the Hood (page 28).
3. Disconnect the electrical connector for the harness from the connector of the lamp assembly (Figure 50).

1. Headlight housing 2. Lamp assembly

Figure 49
3. Harness-electrical connector

g035852

4. Rotate the lamp assembly 1/4 turn counterclockwise and moving it rearward, out of the headlight housing (Figure 49).
5. Insert the new lamp assembly and headlight housing and align the tabs in the lamp assembly

Figure 50

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

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

g035853

4. Remove the speed clips that secure the headlight to the headlight bracket (Figure 50).
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 50).
6. Install the new headlight through the opening in the bumper (Figure 50).

42

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 50).
9. Adjust the headlights to direct the beams to the desired position, refer to Adjusting the Headlights (page 43).
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 50) to pivot the headlight assembly and align the position of the cast beam.
3. Connect the battery and close the hood; refer to Connecting the Battery (page 41).

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 an 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).

43

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 51), 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
Important: Inspect the condition and security of the pinion-shaft seal (Figure 52).
· Steering-rack assembly tie rods

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.

Figure 51

g313578

1. Steering wheel at the centered position

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

Adjusting the Camber
Owner provided tools: spanner wrench, Toro Part No. 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 53).

1. Pinion-shaft seal

Figure 52

g313576

Figure 53

1. Shock-absorber spring 2. Collar

3. Spring length

g033218

44

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 44).
1. Measure the distance between both of the front tires at the axle height at both the front and rear of the front tires (Figure 54).

Checking the Transaxle-Fluid Level
Service Interval: Every 100 hours
Fluid Type: SAE 80W-90 (API MT-1) or SAE 80W-90 (API GL-5)
1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the engine and remove the key. 4. Remove the fill plug on the transaxle (Figure 56).
Note: The fluid level should be even with the bottom of the fill plug.

Figure 54

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

3. Axle center line

g009235

2. 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 55).

1. Drain plug

Figure 56 2. Fill plug

g035761

5. If the fluid level is low, remove the fill plug and add the specified fluid until it runs out of the hole (Figure 56).
6. Replace the fill plug and torque it to 20 to 27 Nm (15 to 20 ft-lb).

1. Tie rod

Figure 55 2. Jam nut

g033219

3. Rotate both tie rods to move the front of the tire inward or outward.
4. Tighten the tie rod jam nuts when the adjustment is correct.
5. Ensure that there is full travel of the steering wheel in both directions.

Changing the Transaxle Fluid
Service Interval: Every 800 hours/Yearly (whichever comes first)
Fluid Type: SAE 80W-90 (API MT-1) or SAE 80W-90 (API GL-5)
Fluid Capacity: 1.6 L (1.7 US qt) 1. Align a drain pan under the drain plug (Figure 56). 2. Remove the fill plug and the seal (Figure 56).
Note: Retain the fill plug and seal for installation in step 6. 3. Remove the drain plug and the seal, and allow the fluid to drain completely (Figure 56).

45

Note: Retain the drain plug and seal for installation in step 4.
4. Install the drain plug and seal, and torque it to 20 to 27 Nm (15 to 20 ft-lb).
5. Fill the transaxle with the specified fluid until it runs out of the fill hole.
6. Install the fill plug and seal, and torque it to 20 to 27 Nm (15 to 20 ft- lb).

Adjusting the Neutral Gear-Shift Position
1. Loosen the jam nuts on the gear-shift cable and adjust them as necessary (Figure 57).

Checking the Neutral Gear-Shift Position
Service Interval: Every 100 hours
When performing routine maintenance and/or engine diagnostics, the transaxle must be shifted into NEUTRAL. The machine has a NEUTRAL position on the gear- shift selector, which controls the neutral in the transaxle. The following steps should be taken to make sure that the neutral shift lever operates the transaxle neutral correctly:
1. Set the gear-shift selector to the NEUTRAL position.
2. Rotate the secondary clutch (Figure 63) to see if it spins freely in the NEUTRAL position.
3. Set the gear-shift selector to the FORWARD position.
4. Rotate the secondary clutch (Figure 63) to see if it rotates the rear wheels.
5. Set the gear-shift selector to the REVERSE position.
6. Rotate the secondary clutch (Figure 63) to see if it rotates the rear wheels.
7. If any of these tests fail, proceed to Adjusting the Neutral Gear-Shift Position (page 46).

1. Shift lever 2. Spanner bar

Figure 57
3. Gear-shift cable 4. Jam nuts

g034455

2. Test the gear-shift position by rotating the gear-shift selector to the 3 different positions and check to see if the shift lever (Figure 57) shifts properly when shifting the gears; refer to Gear-Shift Lever and Gear-Shift Indicator (page 11).
3. Verify that all of the positions are working correctly by repeating the steps in Checking the Neutral Gear-Shift Position (page 46).

46

Maintaining the Primary-Drive Clutch
Service Interval: Every 400 hours/Yearly (whichever comes first)
CAUTION
The dust in the clutch becomes airborne and could damage your eyes, or you could inhale it, causing breathing difficulties. Wear eye and respiratory protection when performing this procedure.
1. Raise and latch the cargo bed; refer to Raising the Cargo Bed to the Dump Position (page 18).
2. Remove the 3 bolts securing the cover to the clutch, and remove the cover (Figure 58). Note: Retain the cover and bolts for installation.

Reducing the Top Speed
CAUTION
The dust in the clutch will become airborne and could damage your eyes or you could inhale it, causing breathing difficulties. Wear safety goggles and a dust mask or other eye and respiratory protection when performing this procedure.
1. Raise and latch the cargo bed; refer to Raising the Cargo Bed to the Service Position (page 19).
2. Remove the bolts securing the primary clutch cover as shown in Figure 59. Important: Use caution when removing the clutch cover; the spring is under compression. Important: Take note of the X orientation on the clutch covers and clutch assemblies for later installation.

1. Cover

Figure 58 2. Bolts

g011947

3. Thoroughly clean the inside of the cover and the inner components of the clutch using compressed air.
4. Install the clutch cover and secure it with the 3 bolts (Figure 58) that you removed in 2.
5. Lower the cargo bed.

1. Clutch spacer

Figure 59

g026341

3. Remove the spring.
4. Add or remove spacers to adjust the top speed. Use the following table to determine the amount of spacers needed.

Spacers 2 (standard) 3 4 5 6

Top Speed 16 mph (standard) 12 mph 9 mph 6 mph 4 mph

Important: Do not operate the machine without at least 2 clutch spacers in place. 5. Install the spring and clutch cover.

47

Important: Ensure that the X is placed back in the original location.
6. Torque the bolts to 179 to 228 N­m (132 to 168 in-lbs).

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.

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.
Important: Operating the engine with a blocked rotating screen, dirty or plugged cooling fins, or 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 inlet, cooling fins, and external surfaces of the engine.
Note: Clean the engine cooling components more often under extremely dusty and dirty conditions.

48

Brake Maintenance
Checking the Parking Brake
1. Engage the parking brake by pulling the parking-brake lever toward you, until you feel tension.
2. If you do not feel tension when pulling the parking-brake toward you within 11.4 to 16.5 cm (4-1/2 to 6-1/2 inches) from the “P” symbol on the dash, then you need to adjust the parking brake; refer to Adjusting the Parking Brake (page 49).
Adjusting the Parking Brake
1. Ensure that the parking brake is disengaged.
2. Using jack stands, lift the rear of the machine; refer to Lifting the Machine (page 28).
3. Using 2 wrenches, hold the adjusting post on the caliper in place with 1 wrench, and loosen the jam nut 1/4 turn with the other wrench (Figure 60).

8. Verify that the parking brake is adjusted to the proper tension; refer to Checking the Parking Brake (page 49).
Note: If you cannot adjust the parking brake to the required tension, the brake pads may be worn and need to be replace. Contact your Authorized Service Dealer for assistance.
Checking the Brake-Fluid Level
Service Interval: Before each use or daily Check the brake-fluid level before the motor is first used.
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 gain access to the master-brake cylinder and reservoir (Figure 61).

1. Adjusting post 2. Jam nut

Figure 60 3. Caliper

g034434

4. While holding the adjusting post and the jam nut in place, turn the adjusting post in to tighten (Figure 60).
Note: Perform this step until you feel drag on the wheel.
5. While holding the adjusting post and the jam nut in place, back off 1/4 turn (Figure 60).
6. While holding the adjusting post and the jam nut in place, tighten the jam nut (Figure 60).
7. Perform steps 1 through 6 to the other side.

Figure 61

1. Filler neck (reservoir) 2. Reservoir cap

3. DOT 3 brake fluid

g034314

5. Look at the outline of the fluid level at the side of the reservoir (Figure 62).
Note: The level should be above the Minimum line.

49

Belt Maintenance

Servicing the Drive Belt

Figure 62

1. Brake-fluid reservoir

2. Minimum line

g002136

6. If the fluid level is low, perform the following:
A. Clean the area around the reservoir cap and remove the cap (Figure 61).
B. Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line (Figure 62).
Note: Do not overfill the reservoir with brake fluid.
C. Install the reservoir cap (Figure 61).
7. Close the hood of the machine.

Checking the Drive Belt
Service Interval: After the first 8 hours
Every 200 hours
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 and secure it with the prop rod; refer to Raising the Cargo Bed to the Dump Position (page 18).
5. Shift the transmission into NEUTRAL.
6. Rotate and inspect the belt (Figure 63) 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 51).

Inspecting the Brakes
Service Interval: Every 100 hours
Brakes are a critical safety component of the machine. As with all safety components, they should be closely inspected at regular intervals to ensure optimum performance and safety.
· Inspect the brake shoes and pads for wear or damage. If the lining (brake pad) thickness is less than 1.6 mm (1/16 inch), the brake shoes should be replaced.
· Inspect the backing plate and other components for signs of excessive wear or deformation. If any deformation is found, the appropriate components must be replaced.
· Check the brake-fluid level; refer to Checking the Brake-Fluid Level (page 49).
Changing the Brake Fluid
Service Interval: Every 1,000 hours
Refer to your Authorized Service Dealer.

Figure 63

g034106

1. Generator-pivot nut 2. Generator-pivot bracket 3. Starter generator 4. Secondary clutch

5. Drive belt 6. Primary clutch 7. Starter-generator belt

7. Lower the cargo bed.

50

Replacing the Drive Belt
1. Raise the cargo bed; refer to Raising the Cargo Bed to the Dump Position (page 18).
2. Shift the transmission into the NEUTRAL position, 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 63).
4. Remove the belt from the primary clutch (Figure 63).
Note: Discard the old belt.
5. Align the new belt over the primary clutch (Figure 63).
6. Rotate and route the belt over the secondary clutch (Figure 63).
7. Lower the cargo bed.
Adjusting the Starter-Generator Belt
Service Interval: After the first 8 hours
Every 200 hours
1. Raise the cargo bed; refer to Raising the Cargo Bed to the Dump Position (page 18).
2. Loosen the pivot nut for the starter generator (Figure 63).
3. Align a pry bar between the engine mount and starter.
4. Apply downward pressure to the pry bar to rotate the starter down in the slot until the belt tension only allows 6 mm (1/4 inch) belt deflection with 44 Nm (10 ft-lb) of force (Figure 63).
5. Tighten the pivot nut hand tight, and remove the pry bar (Figure 63).
6. Torque the pivot nut to 88 to 115 Nm (65 to 85 ft-lb).
7. Lower the cargo bed.

Chassis Maintenance
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. Verify that the cargo bed is latching.
Note: If the cargo bed does not latch, the bed-latch striker is likely too low. If the cargo bed latches, but vibrates up and down as you drive, the bed- latch striker is likely too high.
2. Raise the cargo bed; Raising the Cargo Bed to the Dump Position (page 18).
3. Loosen the 2 bolts on the bed-latch striker and move the striker up or down, depending on if the striker is too high or too low (Figure 64).

1. Bolts

Figure 64 2. Bed-latch striker

g034451

4. Tighten the 2 bolts on the bed-latch striker (Figure 64).
5. Verify that the adjustment is correct by latching the cargo bed several times.

51

Cleaning
Washing the Machine
Wash the machine as needed. Use water alone or with a mild detergent. You may use a rag when washing the machine; however, the hood loses some of its luster. 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.
52

Storage
Storage Safety
· Let the engine cool before storing the machine. · Do not store the machine or fuel near flames or
drain the fuel indoors.
Storing the Machine
1. Park the machine on a level surface.
2. Engage the parking brake.
3. Shut off the engine and remove the key.
4. Clean the dirt and grime from the entire machine, including the outside of the cylinder-head fins of the engine and blower housing.
Important: You can wash the machine with mild detergent and water. Do not use power-washing equipment to wash the machine. Pressure washing the machine may damage the electrical system or wash away necessary grease at friction points. Avoid excessive use of water near the control panel, lights, engine, and the battery.
5. Inspect the brakes; refer to Inspecting the Brakes (page 50).
6. Service the air cleaner; refer to Servicing the Air Cleaner (page 33).
7. Grease the machine; refer to Greasing the Machine (page 30).
8. Change the engine oil; refer to Changing the Engine Oil (page 36).
9. Check the tire pressure; refer to Checking the Tire Pressure (page 14).
10. For storage over 30 days, prepare the fuel system as follows:
A. Add a petroleum based fuel stabilizer/conditioner to fuel in the tank.
Important: Do not store stabilizer/conditioned fuel over 90 days.
Follow mixing instructions from fuel stabilizer manufacturer–29.5 ml (1 fl oz per gallon).
Important: Do not use an alcohol-based fuel stabilizer (ethanol or methanol).
Note: The use of fuel stabilizer/conditioner is most effective when mixed with fresh gasoline and used at all times.

B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes).
C. Shut off the engine, allow the engine to cool, and drain the fuel tank.
Note: Dispose of fuel properly. Recycle as according to local codes.
D. Start the engine again and run it until it stops.
E. Choke the engine.
F. Start and run the engine until it does not start again.
11. Remove the spark plug and check their condition; refer to Servicing the Spark Plug (page 36).
12. With the spark plugs removed from the engine, pour 2 tablespoons of engine oil into the spark plug hole.
13. Use the electric starter to crank the engine and distribute the oil inside the cylinder.
14. Install the spark plug(s) and tighten it to recommended torque; refer to Checking and Replacing the Spark Plug (page 36).
Note: Do not install the wire on the spark plug(s).
15. Remove the battery from the chassis, and charge it fully; refer to Removing the Battery (page 40).
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).
16. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged.
17. Paint all scratched or bare metal surfaces.
Note: Paint is available from your Authorized Service Dealer.
18. Store the machine in a clean, dry garage or storage area.
19. Remove the key from the key switch and put it in a safe place out of the reach of children.
20. Cover the machine to protect it and keep it clean.

53

European Privacy Notice
The Information Toro Collects Toro Warranty Company (Toro) respects your privacy. In order to process your warranty claim and contact you in the event of a product recall, we ask you to share certain personal information with us, either directly or through your local Toro company or dealer. The Toro warranty system is hosted on servers located within the United States where privacy law may not provide the same protection as applies in your country. BY SHARING YOUR PERSONAL INFORMATION WITH US, YOU ARE CONSENTING TO THE PROCESSING OF YOUR PERSONAL INFORMATION AS DESCRIBED IN THIS PRIVACY NOTICE. The Way Toro Uses Information Toro may use your personal information to process warranty claims, to contact you in the event of a product recall and for any other purpose which we tell you about. Toro may share your information with Toro’s affiliates, dealers or other business partners in connection with any of these activities. We will not sell your personal information to any other company. We reserve the right to disclose personal information in order to comply with applicable laws and with requests by the appropriate authorities, to operate our systems properly or for our own protection or that of other users. Retention of your Personal Information We will keep your personal information as long as we need it for the purposes for which it was originally collected or for other legitimate purposes (such as regulatory compliance), or as required by applicable law. Toro’s Commitment to Security of Your Personal Information We take reasonable precautions in order to protect the security of your personal information. We also take steps to maintain the accuracy and current status of personal information. Access and Correction of your Personal Information If you would like to review or correct your personal information, please contact us by email at legal@toro.com.
Australian Consumer Law
Australian customers will find details relating to the Australian Consumer Law either inside the box or at your local Toro Dealer.
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
A Two-Year Limited Warranty

Conditions and Products Covered
The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours, whichever occurs 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

· 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, etc.
Parts
Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part. Parts replaced under this warranty 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.

You are responsible for notifying the Commercial Products Distributor or Authorized Commercial Products Dealer from whom you purchased the Product as soon as you believe a warrantable condition exists. If you need help locating a Commercial Products Distributor or Authorized Dealer, or if you have questions regarding your warranty rights or responsibilities, you may contact us at:
Toro Commercial Products Service Department Toro Warranty Company 8111 Lyndale Avenue South Bloomington, MN 55420-1196
952­888­8801 or 800­952­2740 E-mail: commercial.warranty@toro.com

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. Battery replacement may be required during the normal product warranty period at owner’s expense. Note: (Lithium- Ion battery only): A Lithium-Ion battery has a part only prorated warranty beginning year 3 through year 5 based on the time in service and kilowatt hours used. Refer to the Operator’s Manual for additional information.

Owner Responsibilities
As the Product owner, you are responsible for required maintenance and adjustments stated in your Operator’s Manual. Failure to perform required maintenance and adjustments can be grounds for disallowing a warranty claim.
Items and Conditions Not Covered
Not all product failures or malfunctions that occur during the warranty period are defects in materials or workmanship. This 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. A separate warranty may be provided by the manufacturer of these items.
· Product failures which result from failure to perform recommended maintenance and/or adjustments. Failure to properly maintain your Toro product per the Recommended Maintenance listed in the Operator’s Manual can result in claims for warranty being denied.
· Product failures which result from operating the Product in an abusive, negligent, or reckless manner.
· Parts subject to consumption through use unless found to be defective. Examples of parts which are consumed, or used up, during normal Product operation include, but are not limited to, 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, and check valves, etc.
· Failures caused by outside influence. Conditions considered to be outside influence include, but are not limited to, weather, storage practices, contamination, use of unapproved fuels, coolants, lubricants, additives, fertilizers, water, or chemicals, etc.
· 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.

Maintenance is at Owner’s Expense
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.
Neither The Toro Company nor Toro Warranty Company is liable for indirect, incidental or consequential damages in connection with the use of the Toro Products covered by this warranty, including any cost or expense of providing substitute equipment or service during reasonable periods of malfunction or non-use pending completion of repairs under this warranty. Except for the Emissions warranty referenced below, if applicable, there is no other express warranty. All implied warranties of merchantability and 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 engine warranty:
The Emissions Control System on your Product may be covered by a separate warranty meeting requirements established by the U.S. Environmental Protection Agency (EPA) and/or the California Air Resources Board (CARB). The hour limitations set forth above do not apply to the Emissions Control System Warranty. Refer to the Engine Emission Control Warranty Statement supplied with your product or contained in the engine manufacturer’s documentation for details

Countries Other than the United States or Canada

Customers who have purchased Toro products exported from the United States or Canada should contact their Toro Distributor (Dealer) to obtain

guarantee policies for your country, province, or state. If for any reason you are dissatisfied with your Distributor’s service or have difficulty obtaining

guarantee information, contact the Toro importer.

374-0253 Rev D

References

• p65Warnings.ca.gov

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