Toro 68037G User manual

Operator’s Manual
Ultra Buggy e2500
Model—Serial Range
68037—400000000 and Up
68037G—400000000 and Up
3465-683A Original Instructions (EN) *3465-683*A

Disclaimers and Regulatory Information
WARNING
CALIFORNIA
Proposition 65
The power cord on this product contains lead, a chemical known to the State of California to
cause birth defects or other reproductive harm. Wash hands after handling.
Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and reproductive harm. Wash hands after
handling.
Use of this product may cause exposure to chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
FCC
This device complies with Part 15 of the FCC Rules. Operation is subject to the following
conditions: (1) this device may not cause harmful interference, and (2) this device must
accept any interference received, including interference that may cause undesired
operation. Changes or modifications not expressly approved by Toro could void the user’s
authority to operate the equipment.
In addition, while in charging mode this equipment has been tested and found to comply with
the limits for a Class B digital device, pursuant to Part 15 of the FCC rules. These limits are
designed to provide reasonable protection against harmful interference in a residential
installation. This equipment generates, uses and can radiate radio frequency energy and, if
not installed and used in accordance with the instructions, may cause harmful interference
to radio communications. However, there is no guarantee that interference will not occur in a
particular installation. If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on, the user is
encouraged to try to correct the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect equipment into an outlet on a circuit different from that to which the receiver is
connected.
• Consult the dealer or an experienced radio/TV technician for help.
© 2023—The Toro®Company
8111 Lyndale Ave So
Bloomington, MN 55044
Contact us at www.Toro.com
Printed in the USA
All rights reserved

Table of Contents
Disclaimers and Regulatory Information.............................................................................................. 2
Chapter 1: Introduction........................................................................................................................ 1–1
Intended Use ..................................................................................................................................... 1–1
Getting Help....................................................................................................................................... 1–1
Manual Conventions........................................................................................................................ 1–2
Safety Alert Classifications......................................................................................................... 1–2
Chapter 2: Safety.................................................................................................................................. 2–1
General Safety .................................................................................................................................. 2–1
Safety and Instructional Decals .................................................................................................... 2–1
Chapter 3: Product Overview ............................................................................................................ 3–1
Controls............................................................................................................................................... 3–1
Electrical Service Disconnect Switch....................................................................................... 3–1
Directional Switch......................................................................................................................... 3–2
Dump Controls .............................................................................................................................. 3–2
Emergency Stop ........................................................................................................................... 3–2
Key Switch ..................................................................................................................................... 3–3
Light Switch.................................................................................................................................... 3–3
Throttle Control ............................................................................................................................. 3–3
Display ............................................................................................................................................ 3–4
Specifications .................................................................................................................................... 3–7
Attachments/Accessories............................................................................................................... 3–7
Chapter 4: Operation ........................................................................................................................... 4–1
Before Operation .............................................................................................................................. 4–1
Before Operation Safety ............................................................................................................. 4–1
Performing Daily Maintenance .................................................................................................. 4–2
During Operation .............................................................................................................................. 4–2
During Operation Safety ............................................................................................................. 4–2
Starting the Machine.................................................................................................................... 4–4
Shutting off the Machine ............................................................................................................. 4–4
Operating the Machine................................................................................................................ 4–4
Operator Platform......................................................................................................................... 4–5
Operating the Hopper.................................................................................................................. 4–6
After Operation.................................................................................................................................. 4–7
After Operation Safety................................................................................................................. 4–7
Lowering the Hopper without Power........................................................................................ 4–8
Raising the Hopper without Power........................................................................................... 4–9
Haul the Machine........................................................................................................................ 4–10
Chapter 5: Maintenance ..................................................................................................................... 5–1
Maintenance Safety ......................................................................................................................... 5–1
Recommended Maintenance Schedule...................................................................................... 5–2
Pre-Maintenance Procedures ....................................................................................................... 5–3
Retrieving a Machine................................................................................................................... 5–3
Lifting the Machine ....................................................................................................................... 5–4
Using the Cylinder Lock .............................................................................................................. 5–5
Lubrication.......................................................................................................................................... 5–6
Greasing the Machine ................................................................................................................. 5–6
Electrical System Maintenance..................................................................................................... 5–7
Checking the Anti-Static Strap .................................................................................................. 5–7
Battery Service.............................................................................................................................. 5–7
Drive System Maintenance .......................................................................................................... 5–10
Inspecting the Tires.................................................................................................................... 5–10
3465-683 A Disclaimers and Regulatory Information:

Torquing the Wheel Lug Nuts .................................................................................................. 5–10
Drive-Motor Gear Oil Specifications ...................................................................................... 5–10
Changing the Drive-Motor Gear Oil........................................................................................ 5–11
Hydraulic System Maintenance .................................................................................................. 5–12
Hydraulic Fluid Specifications ................................................................................................. 5–12
Checking the Hydraulic Lines.................................................................................................. 5–12
Changing the Hydraulic Fluid .................................................................................................. 5–12
Cleaning............................................................................................................................................ 5–13
Removing Debris ........................................................................................................................ 5–13
Washing the Machine ................................................................................................................ 5–13
Chapter 6: Storage............................................................................................................................... 6–1
Storage Safety .................................................................................................................................. 6–1
Preparing the Machine for Storage Over 30 Days.................................................................... 6–1
Battery Storage Requirements...................................................................................................... 6–1
Chapter 7: Troubleshooting ............................................................................................................... 7–1
California Proposition 65 Warning Information
Disclaimers and Regulatory Information: Page 4 3465-683 A

Chapter 1
Introduction
Intended Use
This machine is intended to be used by professional, hired operators on indoor and outdoor
improved surfaces in commercial applications. It is primarily designed to move concrete,
mortar, gravel, dirt, or debris around job sites. Using this product for purposes other than its
intended use could prove dangerous to you and bystanders.
Read this information carefully to learn how to operate and maintain your product properly
and to avoid injury and product damage. You are responsible for operating the product
properly and safely.
Getting Help
G425720
Visit www.Toro.com for product safety and
operation training materials, accessory
information, help finding a dealer, or to register
your product.
Whenever you need service, genuine Toro parts,
or additional information, contact an Authorized
Service Dealer or Toro Customer Service and have
the model and serial numbers of your product ready. These numbers are located on the
serial plate on your product . Write the numbers in the space provided.
IMPORTANT
With your mobile device, you can scan the QR code on the serial number decal (if
equipped) to access warranty, parts, and other product information.
Model
Number:
Serial
Number:
3465-683 A Page 1–1 Introduction

Manual Conventions
This manual identifies potential hazards and has safety messages identified by the safety-
alert symbol, which signals a hazard that may cause serious injury or death if you do not
follow the recommended precautions.
G405934
This manual uses 2 words to highlight information. Important calls attention to special
mechanical information and Note emphasizes general information worthy of special
attention.
Safety Alert Classifications
The safety-alert symbol shown in this manual and on the machine identifies important safety
messages that you must follow to prevent accidents.
Safety-alert symbol appears above information that alerts you to unsafe actions or situations
and is followed by the word DANGER,WARNING, or CAUTION.
DANGER
Danger indicates an imminently hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING
Warning indicates a potentially hazardous situation which, if not avoided, could result
in death or serious injury.
CAUTION
Caution indicates a potentially hazardous situation which, if not avoided, may result
in minor or moderate injury.
Introduction: Manual Conventions Page 1–2 3465-683 A

Chapter 2
Safety
General Safety
• Read and understand the contents of this Operator’s Manual before starting the
machine.
• Do not operate the machine without all guards and other safety protective devices in
place and functioning properly on the machine.
• Park the machine on a level surface, lower the hopper, shut off the machine, and remove
the key (if applicable) before leaving the operating position.
• Keep your hands and feet away from moving parts. If possible, do not make adjustments
with the machine running.
Improperly using or maintaining the machine can result in injury.
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.
Decal Part: 115-4858
decal115-4858
Force from above can cause
crushing of fingers, hands, toes, or feet
—install the cylinder lock.
Decal Part: 125-4959
decal125-4959
Force from above can cause
crushing of the whole body—never
place your head under the hopper.
3465-683 A Page 2–1 Safety

Decal Part: 125-4967
decal125-4967
Lift point
Decal Part: 125-6694
decal125-6694
Tie-down location
Decal Part: 133-8061
s_decal133-8061
Decal Part: 144-0275
decal144-0275
Batteries are flammable.
Safety: Safety and Instructional Decals Page 2–2 3465-683 A

Decal Part: 144-0277
decal144-0277
Positive terminal
Read the Operator’s Manual.
Recycle the battery.
Do not dispose improperly.
Do not expose to fire.
Decal Part: 145-1168
decal145-1168
Warning—read the Operator’s Manual.
Warning—all operators should read the Operator’s
Manual and be trained before operating the
machine.
Warning—keep bystanders away; look behind and
down when moving in reverse.
Warning—stay away from moving parts; keep all
guards and shields in place.
Warning—wear hearing protection.
Tipping hazard—do not drive forward with the
hopper raised; do not drive down slopes with the
hopper raised; do not drive across slopes with the
hopper raised.
Warning—shut off the machine and remove the
key before leaving the operator’s position.
Horn
Raise the hopper.
Lower the hopper.
Toggle the switch forward to set the machine
direction to forward.
Toggle the switch to the middle position to put the
machine in neutral.
Toggle the switch backward to set the machine
direction to backward.
Fast
Slow
Decal Part: 145-1169
decal145-1169
Warning—shut off the machine.
Off
On
3465-683A Page 2–3 Safety: Safety and Instructional Decals

Decal Part: 145-1170
decal145-1170
Warning—read the Operator’s
Manual for charging information; do not
operate the machine when the machine
is charging; disconnect the charging
cord before operating the machine.
Decal Part: 145-1173
decal145-1173
Traction drive
Read the Operator’s Manual for
fuse information.
Hopper lift cylinder
Decal Part: 145-1175
decal145-1175
Warning—turn the battery
disconnect switch to the OFF position
before performing maintenance.
Safety: Safety and Instructional Decals Page 2–4 3465-683 A

Decal Part: 145-1181
decal145-1181
Forklift lifting point
Decal Part: 145-1174
decal145-1174
Read the Operator’s Manual for
battery charging information.
Battery charger input specifications
Decal Part: 145-5301
145-5301
Negative battery terminal
Decal Part: 145-5338
decal145-5338
Warning—read the Operator’s Manual.
Warning—do not open the battery; do not use a
damaged battery.
Explosion hazard—do not expose to sparks or
open flame.
Electric shock hazard—do not perform
maintenance on the battery.
Electric shock hazard
3465-683A Page 2–5 Safety: Safety and Instructional Decals

Chapter 3
Product Overview
G380315
Work lights
Handle bars
Control panel
Electrical service disconnect switch
Operator platform
Steering tires
Hopper
Drive tires
Anti-static strap
Controls
Electrical Service Disconnect Switch
G387210
Off—to de-energize the machine
electrically
On—to energize the machine
electrically
Product Overview Page 3–1 3465-683 A

Directional Switch
G380320
Drive forward
Neutral
Drive backward
Dump Controls
G380321
Dump hopper
Lower hopper
Emergency Stop
G380319
Pull to enable the machine.
Note: Turn the key to the OFF then ON
position to continue operating the
machine.
Push to immediately shut off the
machine.
3465-683A Page 3–2 Product Overview: Controls

Key Switch
G380323
Turn the machine off.
Turn the machine on.
Light Switch
G431514
Off
On
Throttle Control
g357324
Product Overview: Controls Page 3–3 3465-683 A

Display
Display Icon Descriptions
Icon Description
Menu access
Next
Previous
Scroll down
Enter
Increase
Decrease
Exit menu
Check PIN entry
Parking brake is engaged.
Hour meter
Battery voltage
Battery charge—each solid bar represents the change in 10% increments.
3465-683A Page 3–4 Product Overview: Controls

Display (continued)
Display Main Menu
Menu Item Description
Faults A list of the recent machine faults. Refer to the Service Manual or your
Authorized Service Dealer for more information on the faults menu.
Service Machine information such as hours of use and other similar numbers.
Diagnostics Displays the state of each machine switch, sensor, and control output. This
tells you which machine controls are on and off which assists in
troubleshooting.
Settings Customize and modify configuration variables on the InfoCenter display.
About Lists the model number, serial number, and software version.
Display Faults Menu
Menu Item Description
Current Lists the total number of key-on hours (i.e., hours that the key has been in
the ON position).
Last Indicates the last key-on hour that the fault occurred on.
First Indicates the first key-on hour that the fault occurred on.
Occurrences Indicates the number of fault occurrences.
Display Service Menu
Menu Item Description
Hours Lists the total number of hours that the key and motor have been on and the
traction controls have been engaged.
Counts Lists the number of times the motor has been started and the amperage
hours for the battery.
Traction Pedal Lists the steps to calibrate the traction pedal.
Steering Wheel Lists the steps to calibrate the steering wheel.
Product Overview: Controls Page 3–5 3465-683 A

Display (continued)
Display Diagnostics Menu
Menu Item Description
Battery Indicates the inputs and outputs for the battery. Inputs include the current
battery voltage; outputs include the battery current and percentage state of
charge.
Left Motor Indicates the speed and current of the left motor.
Right Motor Indicates the speed and current of the right motor.
Display Settings Menu
Menu Item Description
Units Indicates the inputs and outputs for the battery. Inputs include the current
battery voltage; outputs include the battery current and percentage state of
charge.
Language Controls the language used on the InfoCenter.
Brightness Controls the brightness of the LCD display.
Contrast Controls the contrast of the LCD display.
Protected Menus Allows you to access protected menus by inputting a passcode.
Display About Menu
Menu Item Description
Model Lists the model number of the machine.
Serial Lists the serial number of the machine.
Software Lists the part number and software revision.
Left Motor Lists the part number and software revision of the motor controller.
Battery Lists the part number software revision of the battery
3465-683A Page 3–6 Product Overview: Controls

Specifications
Note: Specifications and design are subject to change without notice.
Width (single wheel) 80.65 cm (31.75 inches)
Width (dual wheels) 106.7 cm (42 inches)
Length (with the platform up) 241.3 cm (95 inches)
Length (with the platform down) 282 cm (111 inches)
Height 139.7 cm (55 inches)
Weight 694 kg (1,530 lb)
Hopper capacity 0.40 m3(14 ft3)
Maximum load 1136 kg (2,500 lb)
Wheelbase 104 cm (41 inches)
Discharge height 16.5 cm (6.5 inches)
Attachments/Accessories
A selection of Toro approved attachments and accessories is available for use with the
machine to enhance and expand its capabilities. Contact your Authorized Service Dealer or
authorized Toro distributor or go to www.Toro.com for a list of all approved attachments and
accessories.
To ensure optimum performance and continued safety certification of the machine, use only
genuine Toro replacement parts and accessories.
Product Overview: Specifications Page 3–7 3465-683 A

Chapter 4
Operation
Before Operation
Before Operation Safety
Before Operation General Safety
• Never allow children or untrained people to operate the machine. Local regulations may
restrict the age of the operator. The owner is responsible for training all operators and
mechanics.
• Keep bystanders and children out of the operating area. Allow only people who are
responsible, trained, familiar with the instructions, and physically capable to operate the
machine.
• Become familiar with the safe operation of the equipment, operator controls, and safety
signs.
• Inspect the area where you will use the machine and remove all objects that could
interfere with the operation of the machine.
• Know and mark the locations of all utility lines.
• Check that the operator's presence controls, safety switches, and shields are attached
and functioning properly. Do not operate the machine unless they are functioning
properly.
• Locate the pinch point areas marked on the machine and keep hands and feet away from
these areas.
• Before each work shift, inspect the machine components: the tires; warning devices;
lights; battery; speed and directional controllers; brakes; safety interlocks; and steering
mechanism. If the machine needs repair or is in any way unsafe, report it immediately
and do not use the machine until it has been restored to safe operating condition.
• Identify sharp turns, blind spots, bridge approaches, and other potentially hazardous
areas with a suitable warning to operators of the nature of the hazard and stating the
proper precautions for them to take to avoid the hazard.
• Use only an approved machine in hazardous locations, as defined in the appropriate
safety standards.
• Do not carry passengers on the machine and keep bystanders and children out of the
operating area.
• Ensure that the area is clear of bystanders before operating the machine. Shut off the
machine if a bystander enters the area.
• Keep away from potential hazards, such as edges of ramps and platforms.
3465-683 A Page 4–1 Operation

Before Operation Safety (continued)
• Park the machine on a level surface, engage the parking brake (if applicable), and shut
off the machine. Wait for all movement to stop and allow the machine to cool before
adjusting, servicing, cleaning, or storing the machine.
Performing Daily Maintenance
Before starting the machine each day, perform the Each Use/Daily procedures listed in the
Maintenance Schedule.
During Operation
During Operation Safety
During Operation General Safety
• The owner/user can prevent and is responsible for accidents that may cause personal
injury or property damage.
• Do not exceed the rated operating capacity, as the machine may become unstable,
which may result in loss of control.
• Wear appropriate clothing, including eye protection; long pants; substantial, slip-resistant
footwear; and hearing protection. Tie back long hair and do not wear loose clothing or
loose jewelry.
• Use your full attention while operating the machine. Do not engage in any activity that
causes distractions; otherwise, injury or property damage may occur.
• Do not operate the machine while ill, tired, or under the influence of alcohol or drugs.
• Operate the machine only in good light, keeping away from holes and hidden hazards.
• Ensure that all drives are in the Neutral position before starting the machine. Start the
machine only from the operating position.
• Keep your hands and feet away from moving parts. If possible, do not make adjustments
with the machine running.
• Do not jerk the controls; use a steady motion.
• Use care when approaching blind corners, shrubs, trees, or other objects that may
obscure your vision.
• Slow down and use caution when making turns and crossing roads and sidewalks with
the machine. Always yield the right of way.
• Never leave a running machine unattended.
• Operate the machine only in appropriate weather conditions. Do not operate the machine
when there is the risk of lightning.
• Be aware of obstacles in close proximity to you. Failure to maintain adequate distance
from trees, walls, and other barriers may result in injury as the machine backs up during
operation if you are not attentive to the surroundings.
• Check for overhead clearance (i.e., electrical wires, branches, and doorways) before
driving under any objects and do not contact them.
Operation: During Operation Page 4–2 3465-683 A