Toro 07280TC User manual

FormNo.3355-949RevB
Workman®e2050UtilityVehicle
ModelNo.07280TC—SerialNo.250000001andUp
G0041 17
Registeratwww.Toro.com.OriginalInstructions(EN)

Introduction
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoidinjury
andproductdamage.Youareresponsibleforoperating
theproductproperlyandsafely.
YoumaycontactTorodirectlyatwww .Toro.comfor
productandaccessoryinformation,helpndinga
dealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineToroparts,or
additionalinformation,contactanAuthorizedService
DealerorToroCustomerServiceandhavethemodel
andserialnumbersofyourproductready.Figure1
identiesthelocationofthemodelandserialnumbers
ontheproduct.Writethenumbersinthespace
provided.
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
Thismanualidentiespotentialhazardsandhas
safetymessagesidentiedbythesafetyalertsymbol
(Figure2),whichsignalsahazardthatmaycauseserious
injuryordeathifyoudonotfollowtherecommended
precautions.
Figure2
1.Safetyalertsymbol
Thismanualuses2otherwordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
Contents
Introduction.................................................................2
Safety...........................................................................3
SafeOperatingPractices.......................................3
BeforeOperating.................................................3
Operation.............................................................4
HandlingandServicingBatteries...........................6
GeneralMaintenance............................................7
SafetyandInstructionalDecals.............................8
Setup..........................................................................11
1InstallingtheRearWheels................................11
2InstallingtheFrontWheels..............................12
3InstallingtheSteeringWheel............................12
4InstallingtheBumper.......................................13
5InstallingtheSeats...........................................13
6InstallingtheHitch..........................................13
7InstallingtheBatteries......................................14
8InstallingtheCargoBox...................................15
9CheckingtheTirePressure...............................16
10SettingtheChargerVoltage............................16
11AdjustingtheFrontWheelToe-in...................17
12ReadingtheManualandViewingtheSafety
Video.............................................................18
ProductOverview......................................................19
Controls.............................................................19
Specications.....................................................22
Attachments/Accessories...................................22
Operation...................................................................22
ThinkSafetyFirst...............................................22
Pre-StartingChecks............................................22
CheckingtheTirePressure.................................22
OperatingtheVehicle.........................................23
StoppingtheVehicle...........................................23
ParkingtheVehicle.............................................23
UnderstandingandUsingtheBattery
System............................................................23
OperatingtheCargoBox....................................25
BreakinginaNewVehicle..................................26
LoadingtheCargoBox.......................................26
TransportingtheVehicle.....................................26
TowingtheVehicle.............................................26
TowingaTrailer..................................................27
Maintenance...............................................................28
RecommendedMaintenanceSchedule(s)................28
DailyMaintenanceChecklist...............................28
PremaintenanceProcedures....................................29
HeavyDutyOperation.......................................29
JackingtheVehicle..............................................29
©2006—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA.
AllRightsReserved

Lubrication.............................................................30
WheretoAddGrease.........................................30
ElectricalSystemMaintenance................................31
MaintainingtheBatteries....................................31
ReplacingtheFuses............................................33
ReplacingtheHeadlights....................................33
DriveSystemMaintenance.....................................34
InspectingtheTires............................................34
AdjustingtheFrontSuspension..........................34
AdjustingFrontWheelToe-In............................35
CheckingtheTransaxleOilLevel........................35
BrakeMaintenance.................................................36
InspectingtheBrakes.........................................36
AdjustingtheBrakePedal...................................36
Cleaning.................................................................37
WashingtheVehicle............................................37
Storage.......................................................................38
Troubleshooting.........................................................39
Schematics.................................................................40
Safety
Improperuseormaintenancebytheoperatororowner
canresultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalwayspay
attentiontothesafetyalertsymbol,whichmeans
Caution,Warning,orDanger—“personalsafety
instruction.”Failuretocomplywiththeinstructionmay
resultinpersonalinjuryordeath.
Supervisors,operators,andservicepersonsshouldbe
familiarwiththefollowingstandardsandpublications
(thematerialmaybeobtainedfromtheaddressshown):
SAEJ2258LightUtilityVehicle
SAEInternational,400CommonwealthDrive,
Warrendale,PA15096-0001U.S.A.
SafeOperatingPractices
TheWorkmanisanoff-highwayvehicleonly
andisnotdesigned,equipped,ormanufactured
foruseonpublicstreets,roads,orhighways.
Supervisor’sResponsibilities
•Makesurethatoperatorsarethoroughlytrainedand
familiarwiththeOperator’sManualandalllabelson
thevehicle.
•Besuretoestablishyourownspecialproceduresand
workrulesforunusualoperatingconditions(e.g.
slopestoosteepforvehicleoperation).
Note:Thisvehiclehasasupervisorspeedlimitswitch
toallowyoutolimitthemaximumspeedthatthe
operatorcandrivethevehicle.RefertoSupervisor
SpeedLimitSwitchsectioninOperation,page22.
BeforeOperating
•Operatethevehicleonlyafterreadingand
understandingthecontentsofthismanual.
•Neverallowchildrentooperatethevehicle.Anyone
whooperatesthevehicleshouldhaveamotor
vehiclelicense.
•Neverallowotheradultstooperatethevehicle
withoutrstreadingandunderstandingtheOperator’s
Manual.Onlytrainedandauthorizedpersonsshould
operatethisvehicle.Makesurethatalloperators
arephysicallyandmentallycapableofoperatingthe
vehicle.
3

•Thisvehicleisdesignedtocarryonlyyou,the
operator,andonepassengerintheseatprovidedby
themanufacturer.Nevercarryanyotherpassengers
onthevehicle.
•Neveroperatethevehiclewhenundertheinuence
ofdrugsoralcohol.Evenprescriptiondrugsand
coldmedicinescancausedrowsiness.
•Donotdrivethevehiclewhenyouaretired.Besure
totakeoccasionalbreaks.Itisveryimportantthat
youstayalertatalltimes.
•Becomefamiliarwiththecontrolsandknowhowto
stopthevehiclequickly.
•Keepallshields,safetydevices,anddecalsinplace.
Ifashield,safetydevice,ordecalismalfunctioning,
illegible,ordamaged,repairorreplaceitbefore
operatingthevehicle.
•Alwayswearsubstantialshoes.Donotoperate
thevehiclewhilewearingsandals,tennisshoesor
sneakers.Donotwearloosettingclothingor
jewelrywhichcouldgetcaughtinmovingpartsand
causepersonalinjury.
•Wearingsafetyglasses,safetyshoes,longpantsanda
helmetisadvisableandrequiredbysomelocalsafety
andinsuranceregulations.
•Avoiddrivingwhenitisdark,especiallyinunfamiliar
areas.Ifyoumustdrivewhenitisdark,besure
todrivecautiously,usetheheadlights,andeven
consideraddingadditionallights.
•Beextremelycarefulwhenoperatingaroundpeople.
Alwaysbeawareofwherebystandersmightbe.
•Beforeoperatingthevehicle,alwayscheckthe
designatedareasofthevehiclethatarestatedinthe
pre-startingsectionofthismanual.Ifsomething
iswrong,donotusethevehicle.Makesurethat
theproblemiscorrectedbeforethevehicleor
attachmentisoperated.
Operation
•Theoperatorandpassengershouldremainseated
wheneverthevehicleisinmotion.Theoperator
shouldkeepbothhandsonthesteeringwheel
wheneverpossible,andthepassengershoulduse
thehandholdsprovided.Keepyourarmsandlegs
withinthevehiclebodyatalltimes.
•Driveslowerandturnlesssharplywhenyouare
carryingapassenger.Rememberyourpassengermay
notbeexpectingyoutobrakeorturnandmaynot
beready.
•Alwayswatchoutforandavoidlowoverhangssuch
astreelimbs,doorjambs,andover-headwalkways.
Makesurethereisenoughroomoverheadtoeasily
clearthevehicleandyourhead.
•Failuretooperatethevehiclesafelymayresultinan
accident,tipoverofthevehicle,andseriousinjury
ordeath.Drivecarefully.Topreventtippingorloss
ofcontrol:
–Useextremecaution,reducespeed,andmaintain
asafedistancearoundsandtraps,ditches,creeks,
ramps,unfamiliarareas,oranyareasthathave
abruptchangesingroundconditionsorelevation.
–Watchforholesorotherhiddenhazards.
–Useextracautionwhenoperatingthevehicleon
wetsurfaces,inadverseweatherconditions,at
higherspeeds,orwithafullload.Stoppingtime
anddistancewillincreasewithafullload.
–Avoidsuddenstopsandstarts.Donotgofrom
reversetoforwardorforwardtoreversewithout
rstcomingtoacompletestop.
–Slowdownbeforeturning.Donotattempt
sharpturnsorabruptmaneuversorotherunsafe
drivingactionsthatmaycausealossofvehicle
control.
–Whendumping,donotletanyonestandbehind
thevehicleanddonotdumptheloadonanyone’s
feet.Releasethetailgatelatchesfromthesideof
thebox,notfrombehind.
–Onlyoperatethevehiclewhenthecargoboxis
downandlatched.
–Beforebackingup,looktotherearandensure
thatnooneisbehindyou.Backupslowly.
–Watchoutfortrafcwhenyouarenearor
crossingroads.Alwaysyieldtherightofway
topedestriansandothervehicles.Thisvehicle
isnotdesignedforuseonstreetsorhighways.
Alwayssignalyourturnsorstopearlyenough
sothatotherpeopleknowwhatyouplantodo.
Obeyalltrafcrulesandregulations.
–Theelectricalsystemofthevehiclecanproduce
sparkscapableofignitingexplosivematerials.
Neveroperatethevehicleinornearanarea
wherethereisdustorfumesintheairwhichare
explosive.
–Ifyouareeverunsureaboutsafeoperation,stop
workandaskyoursupervisor.
•Ifthevehicleevervibratesabnormally,stop
immediately,waitforallmotiontostop,andinspect
thevehiclefordamage.Repairalldamagebefore
commencingoperation.
•Beforegettingoffoftheseat:
4

1.Stopthemovementofthevehicle.
2.Settheparkingbrake.
3.TurnthekeytoOff.
4.Removethekey.
Note:Ifthevehicleisonanincline,blockthe
wheelsaftergettingoffofthevehicle.
Braking
•Slowdownbeforeyouapproachanobstacle.This
givesyouextratimetostoporturnaway.Hitting
anobstaclecandamagethevehicleanditscontents.
Moreimportant,itcaninjureyouandyourpassenger.
•GrossVehicleWeight(GVW)hasamajorimpacton
yourabilitytostopand/orturn.Heavyloadsand
attachmentsmakeavehiclehardertostoporturn.
Theheaviertheload,thelongerittakestostop.
•Decreasethevehiclespeedifthecargoboxhasbeen
removedandthereisnoattachmentonthevehicle.
Thebrakingcharacteristicschangeandfaststops
maycausetherearwheelstolockup,whichmay
affectthecontrolofthevehicle.
•Turfandpavementaremuchmoreslipperywhen
theyarewet.Itcantake2to4timesaslongtostop
onwetsurfacesasondrysurfaces.Ifyoudrive
throughstandingwaterdeepenoughtogetthe
brakeswet,theywillnotworkwelluntiltheyare
dry.Afterdrivingthroughwater,youshouldtestthe
brakestomakesuretheyworkproperly.Iftheydo
not,driveslowlywhileputtinglightpressureonthe
brakepedal.Thiswilldrythebrakesout.
OperatingonHills
Operatingthevehicleonahillmaycause
tippingorrollingofthevehicle,orthemotor
maystallandyoucouldloseheadwayonthe
hill.Thiscouldresultinpersonalinjury.
•Donotoperateonexcessivelysteepslopes.
•Donotacceleratequicklyorslamonthe
brakeswhenbackingdownahill,especially
withaload.
•Ifthebatteriesrunloworyouloseheadway
onahill,slowlybackstraightdownthehill.
Neverattempttoturnthevehiclearound.
•Operatethevehicleslowlyonahillanduse
caution.
•Avoidturningonahill.
•Reduceyourloadandthespeedofthe
vehicle.
•Avoidstoppingonhills,especiallywitha
load.
Theseextracautionsneedtobetakenwhenoperating
thevehicleonahill:
•Slowdownbeforestartingupordownahill.
•Ifthebatteriesrunloworyoubegintoloseheadway
whileclimbingahill,graduallyapplythebrakesand
slowlybackstraightdownthehill.
•Turningwhiletravelingupordownhillscanbe
dangerous.Ifyouhavetoturnwhileonahill,do
itslowlyandcautiously.Nevermakesharporfast
turns.
•Heavyloadsaffectstability.Reducetheweightofthe
loadandyourspeedwhenoperatingonhillsorif
theloadhasahighcenterofgravity.Securetheload
topreventitfromshiftingandtakeextracarewhen
haulingloadsthatshifteasily(liquid,rock,sand,etc.).
•Avoidstoppingonhills,especiallywithaload.
Stoppingwhilegoingdownahillwilltakelonger
thanstoppingonlevelground.Ifthevehiclemust
bestopped,avoidsuddenspeedchanges,whichmay
initiatetippingorrollingofthevehicle.Donotslam
onthebrakeswhenrollingbackward,asthismay
causethevehicletooverturn.
•Westronglyrecommendinstallingtheoptional
ROPSKitwhenoperatingonhillyterrain.
5

OperatingonRoughTerrain
Reducespeedandloadwhenoperatingonroughterrain,
unevenground,andnearcurbs,holes,andothersudden
changesinterrain.Loadsmayshift,causingthevehicle
tobecomeunstable.
WestronglyrecommendinstallingtheoptionalROPS
Kitwhenoperatingonroughterrain.
Suddenchangesinterrainmaycauseabrupt
steeringwheelmovement,possiblyresultingin
handandarminjuries.
•Reduceyourspeedwhenoperatingonrough
terrainandnearcurbs.
•Gripthesteeringwheellooselyaroundthe
perimeter.Keepyourhandsclearofthe
steeringwheelspokes.
LoadingandDumping
Theweightandpositionofthecargoandpassenger
canchangethevehiclecenterofgravityandvehicle
handling.Toavoidlossofcontrolandpersonalinjury,
followtheseguidelines:
•Donotcarryloadswhichexceedtheloadlimits
describedonthevehicleweightlabel;referto
SpecicationsinProductOverview,page19,for
vehicleweightlimits.Theloadratingisforlevel
surfacesonly.
•Reducetheweightoftheloadwhenoperating
onhillsandroughterraintoavoidtippingor
overturningofthevehicle.
•Reducetheweightoftheloadifthecenterofgravity
ishigh.Itemssuchasbricks,fertilizer,orlandscape
timbersstackhigherinthebox.Thehigheraload
isstacked,themorelikelythevehicleistotipover.
Distributetheloadaslowaspossible,makingsure
thattheloaddoesnotaffectrearvisibility.
•Positiontheweightoftheloadevenlyfromsideto
side.Ifyoupositiontheloadtowardoneofthesides,
thevehicleismorelikelytotipoverwhileturning.
•Positiontheweightofaloadevenlyfromfrontto
back.Ifyoupositiontheloadbehindtherearaxle,
itwillreducetheweightonthefrontwheels.This
mayresultinalossofsteeringcontrolorcausethe
vehicletotipoveronhillsorbumpyterrain.
•Useextracautioniftheloadexceedsthedimensions
oftheboxandwhenhandlingoff-centerloadsthat
cannotbecentered.Keeploadsbalancedandsecure
topreventthemfromshifting.
•Alwayssecureloadssothattheydonotshift.Ifa
loadisnotsecured,oryouaretransportingaliquidin
alargecontainersuchasasprayer,theloadcanshift.
Thisshiftinghappensmostoftenwhileturning,
goingupordownhills,suddenlychangingspeeds,or
whiledrivingoverroughsurfaces.Shiftingloadscan
causethevehicletotipover.
Theweightoftheboxmaybeheavy.Handsor
otherbodypartscouldbecrushed.
–Keephandsandotherbodypartsclearwhen
loweringthebox.
–Donotdumpmaterialsonbystanders.
•Neverdumpaloadedcargoboxwhilethevehicleis
sidewaysonahill.Thechangeinweightdistribution
maycausethevehicletooverturn.
•Whenoperatingwithaheavyloadinthecargobox,
reduceyourspeedandallowforsufcientbraking
distance.Donotsuddenlyapplythebrakes.Use
extracautiononslopes.
•Beawarethatheavyloadsincreaseyourstopping
distanceandreduceyourabilitytoturnquickly
withouttippingover.
•Therearcargospaceisintendedforloadcarrying
purposesonly,notforpassengers.
•Neveroverloadyourvehicle.Thedecal(locatedon
therearframe)showsloadlimitsforthevehicle.
NeveroverloadtheattachmentsorexceedtheGross
VehicleWeight(GVW).
HandlingandServicing
Batteries
•Toreducethepotentialforre,keepthebatteries
andmotorareafreeofexcessivegrease,grass,leaves,
andaccumulationofdirt.
•Alwaysdisconnectandremoveabatterycablebefore
servicinganyelectricalcomponents.
•Disconnectinganybatterycablewillinhibitoperation
oftheelectricalsystem.
•Batteryelectrolytecontainssulfuricacid.Sulfuric
acidproduceshydrogengaswhich,intheright
proportionsisexplosive.
6

–Alwaysservice,store,andchargethevehicleina
wellventilatedarea.
–Keepsparksandopenamesawayfromthe
batteries.
–Donotsmokenearthebatteries.
–Neveruseanopenametocheckthelevelor
leakageofbatteryelectrolyte.
•Usecautionwhenhandlingandworkingaround
electrolyte.Thesulfuricacidinelectrolytecanburn
skinanddamageclothing.Furthermore,itcanbe
emittedasagasthatcandamageyourlungs.
–Wearpropereye,hand,andfaceprotection.
–Donotleanoverthebatteriesatanytime.
–Avoidbreathingbatteryfumes.
–Fillthebatterieswherecleanwaterisalways
availableforushingtheskin.
–Ifyougetelectrolyteonyourskinoreyes,ush
theaffectedareafor20minuteswithcleanwater.
Removeacidsoakedclothing.Seekmedical
attentionimmediately.
–Keepchildrenandpetsawayfromthebatteries
andelectrolyte.
•Electrolyteisverypoisonous.
–Donotdrinkelectrolyte.
–Ifelectrolyteisswallowed,donotinduce
vomiting;instead,drinklargeamountsofwater
ormilkfollowedbymilkofmagnesia,beaten
raweggs,orvegetableoil.Getmedicalattention
immediately.
–Keepchildrenandpetsawayfromthebatteries
andelectrolyte.
•Whennotllingthebatteries,keepthebatteryvent
capstightonthebatteries.Neveroperatethevehicle
ifanyoftheventcapsaremissingordamaged.
•Whenremovingorinstallingthebatteries,donot
allowthebatteryterminalstotouchanymetalparts
ofthevehicle.
•Donotallowmetaltoolstoshortbetweenthe
batteryterminalsandmetalpartsofthevehicle.
Removealljewelryandwatchesbeforeservicingthe
batteries.
•Donotcheckabatterychargebyplacingametal
objectacrosstheposts.Thiswillcausesparkswhich
cancauseanexplosion.
•Alwayskeepthebatteryretainersinplacetoprotect
andsecurethebatteries.
•Readandunderstandthecharginginstructions
beforechargingthebatteries;refertoChargingthe
BatteriesinMaintenance,page28.Also,takethe
followingprecautionsandactionswhenchargingthe
batteries:
–TurnthevehicleOn/OffswitchtoOffbefore
connectingthechargertoapowersource.
–Useonlythebatterychargersuppliedwiththe
vehicletochargethebatteries.
–Donotchargeadamagedorfrozenbattery.
–AlwaysunplugtheACpowercordfromthe
poweroutletbeforeunpluggingitfromthe
vehiclechargingreceptacletoavoidsparks.
–Ifduringchargingabatterygetshot,begins
emittinglargeamountsofgasses,orspews
electrolyte,immediatelydisconnectthecharger
powercordfromthepoweroutlet.Havethe
vehicleservicedbyanAuthorizedServiceDealer
beforeusingitagain.
GeneralMaintenance
•Onlyqualiedandauthorizedpersonnelshallbe
permittedtomaintain,repair,adjust,orinspectthe
vehicle.
•Beforeservicingormakingadjustmentstothe
vehicle,stopthevehicle,settheparkingbrake,
andremovethekeytopreventsomeonefrom
accidentallystartingit.
•Tomakesurethattheentirevehicleisingood
condition,keepallnuts,bolts,andscrewsproperly
tightened.
•Donotuseopenpansoffuelorammablecleaning
uidsforcleaningparts.
•Ifmajorrepairsareeverneededorassistanceis
required,contactanAuthorizedToroDistributor.
•Tobesureofoptimumperformanceandsafety,
alwayspurchasegenuineTororeplacementpartsand
accessories.Replacementpartsandaccessoriesmade
byothermanufacturerscouldbedangerous.Altering
thisvehicleinanymannerthatmayaffectvehicle
operation,performance,durability,oritsuse,may
resultininjuryordeath.Suchusecouldvoidthe
productwarranty.
7

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaof
potentialdanger.Replaceanydecalthatisdamagedorlost.
104-7214
1.Horn4.Lighton,OK7.Rearlift
2.Headlights5.Lightblinking,readtheOperator’s
Manual.
8.Forward
3.Battery/hourmeter6.Cargobedlift9.Reverse
104–7215
1.Warning—readtheOperator’sManual.
2.Explosionhazard—nore,openames,orsmokingaroundbatteries.
3.Tippinghazard—receivetrainingbeforeoperatingthemachine,usecautionanddriveslowlywhileonslopes;driveslowlywhen
turning,keepthevehiclespeedunder16MPH(26km/h)whencarryingafullorheavyloadandwhendrivingonroughterrain.
4.Fallingandarm/leginjuryhazards—donotcarrypassengersinthecargobedandkeeparmsandlegsinsideofthevehicleatall
times.
104-7207
1.Poisonhazard—readtheOperator’sManual.
2.Explosionhazard—nore,openames,orsmoking.
3.Causticliquid/chemicalburnhazard—toperformrstaid,
ushwithwater.
99–7350
1.Maximumtongueweightis50lb.(23kg);maximumtrailer
weightis400lb.(181kg).
8

104-7131
1.ReadtheOperator’sManual.
2.Themaximumcombinedoperatorandpassengerweightis
400lb.(181kg.).
3.Themaximumcargoweightis800lb.(362kg).
4.Themaximumgrossvehicleweightis2650lb.(1202kg).
107-0257
1.Batteryschematic
107-0295
1.Warning—readtheOperator’sManualformoreinformation
onbatteries;batteriescontainlead,donotdiscard;
disconnectthepowercordfrompowersourcebefore
drivingvehicle.
2.Explosionhazard—nore,openames,orsmoking;avoid
sparks.
107-0356
1.Warning—donottouchmovingobjects,fan;donottouch
thehotsurfaces;readtheOperator’sManual.
99–7954
1.Warning—readtheOperator’sManual.
2.Fallinghazard—donotcarrypassengersinthecargobed.
3.Explosionhazard,staticdischargeintofuelcontainer—do
notllfuelcontainersinthecargobed;placefuelcontainers
onthegroundbeforelling.
107-0287
1.Vehiclefuse,10A3.Open,10A
2.Forfuseservice,readthe
Operator’sManual.
4.Accessoryfuse,10A
9

BatterySymbols
Someorallofthesesymbolsareonyourbattery
1.Explosionhazard6.Keepbystandersasafe
distancefromthebattery.
2.Nore,opename,or
smoking.
7.Weareyeprotection;
explosivegasescan
causeblindnessandother
injuries
3.Causticliquid/chemical
burnhazard
8.Batteryacidcancause
blindnessorsevereburns.
4.Weareyeprotection9.Flusheyesimmediately
withwaterandgetmedical
helpfast.
5.ReadtheOperator’s
Manual.
10.Containslead;donot
discard.
10

Setup
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Wheelassembly2Installtherearwheels.
2Wheelassembly2Installthefrontwheels.
3Steeringwheel1Installthesteeringwheel.
4Bumper1Installthebumper.
5Seat2Installtheseats.
6Hitch1Installthehitch.
Batteryholddown2
Batteryholddownrod2
Batterycables7
Batterytraypads4
Batterypad1
Flangenut(3/8inch)2
7
Batteryterminalprotectorspray1
Installthebatteries.
Cargobox1
Right-handpivotbracket1
Left-handpivotbracket1
Flangeheadscrew(3/8x1inch)4
Bolt(5/16x3/4inch)1
8
Flangenut(5/16inch)1
Installthecargobox.
9Nopartsrequired–Checkthetirepressure.
10Nopartsrequired–Setthechargervoltage.
11Nopartsrequired–Adjustthefrontwheeltoe-in.
Operator’sManual1
PartsCatalog1
SafetyVideo1
RegistrationCard1
PredeliveryInspectionForm1
12
Key2
ReadtheOperator’sManualandwatch
thevideobeforeoperatingthemachine.
Note:Determinetheleftandrightsidesofthemachine
fromthenormaloperatingposition.
11

1
InstallingtheRearWheels
Partsneededforthisprocedure:
2Wheelassembly
Procedure
1.Removethefastenerssecuringthewheels.
2.Removetheshippingbracketsecuredtothewheel
studs.
3.Mountthewheelswiththepreviouslyremoved
fasteners(Figure3)andtorqueto45-65ft-lb
(61-88N-m).
Figure3
1.Wheelassembly3.Wheelstud(rearwheel
hubshown)
2.Wheelnut
2
InstallingtheFrontWheels
Partsneededforthisprocedure:
2Wheelassembly
Procedure
1.Removethefastenerssecuringthewheels.
2.Removetheshippingbracketfromthespindles.
3.Applythreadlocker(blue)tothescrewthreads.
4.Mountthewheelswiththepreviouslyremoved
fasteners(Figure4)andtorquetheboltsto135-165
ft-lb(183-224N-m).
Figure4
1.Tireandwheelassembly4.Largewasher
2.Spindle5.Screw
3.Smallwasher6.Dustcap
3
InstallingtheSteeringWheel
Partsneededforthisprocedure:
1Steeringwheel
Procedure
1.Removethenutandlockwasherfromthesteering
shaft.
2.Slidethesteeringwheelandwasherontotheshaft.
Positionthesteeringwheelontheshaftsothatthe
crossbeamishorizontalwhenthetiresarepointed
straightaheadandthethickerspokeofthesteering
wheelisdownward.
3.Securethesteeringwheeltotheshaftwiththenut
(Figure5).
12

Figure5
1.Steeringwheel3.Washer
2.Nut4.Foamseal
4
InstallingtheBumper
Partsneededforthisprocedure:
1Bumper
Procedure
1.Removethe2bolts,washers,andnutssecuredtothe
frontoftheframe.
2.Alignthemountingholesandsecurethebumper
totheframewiththefastenerspreviouslyremoved
(Figure6).
Figure6
1.Bumper
5
InstallingtheSeats
Partsneededforthisprocedure:
2Seat
Procedure
Inserttheseatbracketintotheseatbaseopeningand
pivottheseatdownward(Figure7).
Figure7
1.Seatbracket2.Seatbase
6
InstallingtheHitch
Partsneededforthisprocedure:
1Hitch
Procedure
1.Removethe4boltsandnutsfromtheinsiderear
oftheframe.
2.Alignthehitchwiththemountingholesonthe
frame.Securethehitchwiththescrewsandnuts
(Figure8).
13

Figure8
1.Hitch
2.Leftpivotbracket
7
InstallingtheBatteries
Partsneededforthisprocedure:
2Batteryholddown
2Batteryholddownrod
7Batterycables
4Batterytraypads
1Batterypad
2Flangenut(3/8inch)
1Batteryterminalprotectorspray
Procedure
TororecommendstheuseofeitherTrojanT105or
T145,orUS.BatteryUS2200orUS145.
BatterySpecication:6V225AH@20hrrate
Dimensions:(LxWxH)(10-1/4x7-1/8x11-1/4inches)
1.TurnthekeyswitchtotheOffpositionandremove
thekey.
2.Installthebatterytraypadsintotherearframe
assemblyasshownFigure9.
Figure9
1.Batterytraypads
2.Rearframeassembly
3.Removetheadhesivestripfromthebackofthe
batterypadandinstallittothefrontinsidefaceof
therearframeasshowninFigure10.
Note:Thepadshouldbeapproximately1/4inch
belowthebottomedgeoftheuppersetofcut-out
holes(Figure10).
Figure10
1.Batterypad3.Uppercut-outholes
2.Frontinsideface
4.InstallthebatteriesasshowninFigure11.
Note:Payattentiontothebatterypolaritywhen
installingthenewbatteries(Figure11).
14

Incorrectbatterycableroutingcoulddamage
thevehicleandcablescausingsparks.Sparks
cancausethebatterygassestoexplode,
resultinginpersonalinjury.
Alwaysensurethebatterypolaritywhenmaking
connections.
Batteriescangiveyouapowerfulelectrical
shock.
•Usetoolswithplastichandlesorwrapthe
handlesofmetaltoolswithelectricaltape.
•Becarefulnottocontactbothapositive
terminalandanegativeterminalatthesame
time.
Figure11
5.Installthebatteryretainersandtorquethenutsto
150to200in-lb(17to22N-m).
6.Connectthebatteriestogetherwiththebattery
cablesincludedinlooseparts,asshowninFigure11.
Ensurethecableroutingdoesnotallowcablesto
contactanysharpedges.
Important:Checkallhighcurrentbattery
connectionstoensuretheyhavebeenproperly
secured.
7.Tightentheboltandsecuretheothersideoftheclip
withanewbolt(5/16x3/4inch)andangenut
(5/16inch)(Figure11).
8.Connectthelong,red,mainpositiveleadbetween
thebankofbatteriesandthevehicle(Figure11).
9.Connectthelong,black,mainnegativeleadbetween
thebankofbatteriesandthevehicle(Figure11).
Looseorimproperlysecuredbattery
connectionscoulddamagethevehicleand
cablescausingsparks.Sparkscancausethe
batterygassestoexplode,resultinginpersonal
injury.
Alwaysensurethebatterypolaritywhenmaking
connections.
10.Torquethenutssecuringallbatterycablesto120to
180inch-lb(13.5to21N-m).
11.CoatthebatteryterminalswithTorobatteryterminal
protector.
12.Ensurethattherubberbootsoneachbatterycable
aresecurelyseatedoverthebatteryterminals.
8
InstallingtheCargoBox
Partsneededforthisprocedure:
1Cargobox
1Right-handpivotbracket
1Left-handpivotbracket
4Flangeheadscrew(3/8x1inch)
1Bolt(5/16x3/4inch)
1Flangenut(5/16inch)
Procedure
1.Positionthecargoboxontotheframe.Thecargo
boxmustlayatandbecentered.
2.Mountthelefthandpivotbrackettotheleftrear
corneroftheframewith2angeheadscrews(3/8
x1inch).Torquethescrewsto16ft-lb(22N-m).
PositionthebracketasshowninFigure8.
3.Slidethecargoboxmountingholeontothepivot
bracket(Figure12).
15

Figure12
1.Cargobox3.Cargoboxmountinghole
2.Pivotbracket
4.Inserttherighthandpivotbracketintothemounting
holeinthecargoboxandthenmountittotheframe.
Torquethescrewsto16ft-lb(22N-m).
5.Haveanotherpersonhelptoraisethecargobox.
6.Loosentheboltsecuringtheproprodcliptothe
frameuntilyoucanslidetheJ-hookendoftheprop
rodundertheclip(Figure13).
Figure13
1.Proprod3.Bolt(5/16x3/4inch)
2.Proprodclip
7.Tightentheboltandsecuretheothersideoftheclip
withanewbolt(5/16x3/4inch)(Figure13).
8.Lowerthecargobox.
9
CheckingtheTirePressure
NoPartsRequired
Procedure
Checkthetirepressureevery8hoursordailytoensure
properlevels.
Theairpressurerangeinthefrontandreartiresis8-22
psi(55-152kPa).
Theairpressureneededisdeterminedbythepayload
carried.Lowerairpressurewillprovidelesscompaction,
asmootherride,andfewertiremarks.Lowerpressure
shouldnotbeusedforheavypayloadsathighspeeds.
Higherpressuresshouldbeusedforheavierpayloadsat
higherspeeds.Donotexceedthemaximumpressure.
10
SettingtheChargerVoltage
NoPartsRequired
Procedure
Important:Theincorrectvoltagesettingonthe
batterychargercanimpairfunctionanddamage
thecharger.
Alwaysmakesurethechargervoltagesettingmatches
thevoltageusedtopowerthecharger.
1.Locatethevoltageselectorontherearofthecharger
(Figure14).
2.Adjustthevoltagesettingbymovingtheswitchon
thevoltageselectorupwardordownwardtochange
thevoltagesetting(Figure14).
16

Figure14
1.Voltageselector3.Switch
2.Voltagesettingwindow4.Voltagesbyswitchposition
Adjustthevoltagesettingbymovingtheswitchonthe
voltageselectorupwardordownwardtochangethe
voltagesetting
Note:Usethe100Vsettingforvoltagesrangingfrom
100Vto120V .
Alwaysusetheappropriatepowercordforthepower
outletofthecountryorregionchargingwilloccur.
ContactyourAuthorizedToroDealertoobtainthe
correctpowercordifnecessary.
11
AdjustingtheFrontWheel
Toe-in
NoPartsRequired
Procedure
Thetoe-inshouldbe1/8-5/8inch(3-16mm)withthe
followingparameters:
•Thetirepressureshouldbeat12psi(83kPa).
•Therideheightshouldbecorrectbeforesettingthe
toe-in;refertotheAdjustingtheFrontSuspension
procedureinMaintenance,page28.
•Thevehicleshouldbedrivenbackandforthafew
timestorelaxtheA-arms.
•Measurethetoe-inwiththewheelsfacingstraight
aheadanda175-225lb(79-102kg)operatorinthe
driver’sseat.
Note:Thedrivershoulddriveuptothe
measurementareaandstayseatedinthevehicle
whilethemeasurementisbeingtaken.
Ifthevehiclewillberunwithmediumtoheavyloads
mostofthetime,setthetoe-inonthehighsideof
therecommendedamount.Ifitisgoingtoberun
withalightloadmostofthetime,setthetoe-inon
thelowsideoftherecommendedamount.
1.Measurethedistancebetweenbothofthefronttires
attheaxleheightatboththefrontandrearofthe
fronttires(Figure15).Axtureoralignmentgauge
isneededfortherearmeasurementofthefronttires
ataxleheight.Usethesamextureoralignment
gaugetoaccuratelymeasurethefrontofthefront
tiresataxleheight(Figure15).
Figure15
1.Tirecenterline-back4.Fixture
2.Tirecenterline-front5.Axlecenterlinedistance
3.Axlecenterline6.6inches(15cm)ruler
2.Ifthemeasurementdoesnotfallwithinthespecied
range(refertothedimensionsandparametersatthe
beginningofthisprocedure),loosenthejamnutsat
bothendsofthetierods(Figure16).
17

Figure16
1.Jamnut2.Tierod
3.Rotatebothtierodstomovethefrontofthetire
inwardoroutward.
4.Tightenthetierodjamnutswhentheadjustmentis
correct.
5.Ensurethatthereisfulltravelofthesteeringwheel
inbothdirections.
12
ReadingtheManualand
ViewingtheSafetyVideo
Partsneededforthisprocedure:
1Operator’sManual
1PartsCatalog
1SafetyVideo
1RegistrationCard
1PredeliveryInspectionForm
2Key
Procedure
•ReadtheOperator’sManual.
•Viewthesafetyvideo.
•Fillouttheregistrationcard.
•CompletethePredeliveryInspectionForm.
18

ProductOverview
Figure17
1.Steeringwheel3.Towingtongue5.Operator’sposition
2.Cargobox4.Cargoboxreleaselever
Controls
AcceleratorPedal
Theacceleratorpedal(Figure18)givesyoutheabilityto
varygroundspeedofthevehicle.Pressingthepedal
whentheOn/Offswitchisonstartsthemotor.Pressing
thepedalfartherincreasesgroundspeed.Releasing
thepedalwillslowthevehicleandthemotorwillstop
running.
Figure18
1.Acceleratorpedal3.Parkingbrake
2.Brakepedal
BrakePedal
Thebrakepedalisusedtostoporslowthevehicle
(Figure18).
Brakescanbecomewornorcanbemisadjusted
resultinginpersonalinjury.
Ifbrakepedaltravelstowithin1inch(25mm)
ofthevehicleoorboard,thebrakesmustbe
adjustedorrepaired.
ParkingBrake
Theparkingbrakeisbetweentheseats(Figure18).
Whenevertheengineisshutoff,theparkingbrake
mustbeengagedtopreventaccidentalmovementof
thevehicle.Toengagetheparkingbrake,pullbackon
thelever.Todisengage,pushtheleverforward.Ifthe
vehicleisparkedonasteepgrade,makesurethatthe
parkingbrakeisapplied.Placeblocksatthedownhill
sideofthewheels.
On/OffSwitch
TheOn/Offswitch(Figure19)usedtoactivatethe
electricalsystemsofthevehicle,hastwopositions:Off
andOn.RotatethekeyclockwisetotheOnposition
toallowoperationofthevehicleandaccessories.After
stoppingthevehicle,rotatethekeycounterclockwiseto
theOffposition.Removethekeybeforeleavingthe
vehicle.
19

Figure19
1.On/Offswitch5.Vehiclestatuslight
2.Hornbutton6.Powercargobedswitch
(optional)
3.Lightswitch7.Rearliftswitch(optional)
4.Battery/hourmeter8.Vehicledirectionswitch
HornButton
Pressthehornbuttontoactivatethevehiclehorn
(Figure19).
GearShiftSelector
Thebattery/hourmeterprovidesyouwithanindication
ofhowmuchchargeiscontainedinthebatteries
(Figure19andFigure23)andthenumberofoperating
hoursonthevehicle.Thebatterymeterislocatedat
thetopoftheLCDscreen.Whenthevehiclebatteries
arefullycharged,tenbarsextendfromthe0tothe1
position.Asthechargeisused,barsdisappearstarting
ontherightside.Fordetailedinformationonthebattery
meter,refertoUnderstandingandUsingtheBattery
SysteminOperation,page22.
ThehourmeterislocatedatthebottomoftheLCD
screen.Itlogsoperatinghourswheneverthekeyisin
theOnpositionandthevehicleisinmotion.
VehicleDirectionSwitch
Usethisswitch(Figure19)totogglebetweenforward
andreverseoperation.
VehicleStatusLight
Thevehiclecontainsacomputerthatmonitorsthe
stateofthevehicleelectricalsystems.Thiscomputer
communicatesthestatusofthevehicletoyouthrough
thevehiclestatuslight.Alwayscheckthislightwhen
youturntheOn/OffswitchtotheOnposition
(Figure23)Whentherearenoproblemsandthevehicle
isoperational,thelightison.
Whenthereisaproblem,thelightashes.Thelight
ashesatvariousintervalsfordifferentproblemsand
events.Ifthelightblinks,refertoTroubleshooting,
page39foradescriptionoftheashcodes.
LightSwitch
Usethisswitchtoturntheheadlightsonandoff
(Figure19).
CargoBedLiftSwitch(Optional)
Usethisswitchtoraiseandlowerthecargobed
(Figure19).
RearLiftSwitch(Optional)
Usethisswitchtoraiseandlowertherearlift(Figure19).
SupervisorSpeedLimitSwitch
Thesupervisorspeedlimitswitch,locatedunderthe
cupholder(Figure20)hastwopositions:OffandOn.
RotatethekeyclockwisetotheOnpositiontolimitthe
maximumvehiclespeedtoafactorysettingof12mph
(19kph).RotatethekeycounterclockwisetotheOff
positiontorestorethemaximumspeedofthevehicle.
Figure20
1.Supervisorspeedlimitswitch
20