Toro Groundsmaster 7200 Series User manual

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

The TORO WORKMANRwas developed to provide an efficient, versatile, trouble free and econo ical work vehicle.
The latest concepts of engineering, design and safety have been incorporated into this achine, along with the
highest quality parts and work anship. Excellent service will be derived if proper operation and aintenance
practices are followed.

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You know, since you have purchased the industry leader in aintenance excellence, that future perfor ance and
dependability are of pri e i portance. TORO also is concerned about future use of the achine and of safety to the
user. Therefore, this anual ust be read by you and those involved with the WORKMANRto ake sure that safety,
proper setĆup, operation and aintenance procedures are followed at all ti es. The ajor sections of the anual
are:
 ! -1 ',-+.-$(',
  -2) ',-+.-$(',
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 $'- ''
Safety, echanical and so e general infor ation in this anual are e phasized. , and
 identify safety essages. Whenever the triangle safety sy bol appears, it is followed by a safety
essage that ust be read and understood. For ore details concerning safety, read the safety instructions on
pages 5 - 7.  identifies special echanical infor ation and  identifies general infor ation
worthy of special attention.
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.



The TORO WORKMANRmeets the requirements of ANSI B56.8a-1994.
Supervisors, operators and service persons should be familiar with the following standards and publications:
(The material may be obtained from the address shown).
DFlammable and Combustible Liquids Code:
ANSI/NF A 30
DNational Fire rotection Association:
ANSI/NF A #505; owered Industrial Trucks
ADDRESS:
National Fire revention Association
Barrymarch ark
Quincy, Massachusetts 02269 U.S.A
DANSI/ASME B56.8 ersonal Burden Carriers
ADDRESS:
American National Standards Institute, Inc.
1430 Broadway
New York, New York 10018 U.S.A.
DANSI/UL 558; Internal Combustion Engine owered Industrial Trucks
ADDRESS:
American National Standards Institute, Inc.
1430 Broadway
New York, New York 10018 U.S.A.
OR
Underwriters Laboratories
333 fingsten Road
Northbrook, Illinois 60062 U.S.A.
  
In some places a spark arrester muffler must be used because of local, state or federal regulations. The spark
arrester available from your local Toro Distributor is approved by the United States Department of Agriculture and
the United States Forest Service.
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If help concerning set up, operation, maintenance or safety is ever needed, contact your local Authorized TORO
Distributor. In addition to genuine TORO replacement parts, the distributor also has optional equipment for the
complete line of TORO turf care equipment. Keep your TORO all TORO. Buy genuine TORO parts and accessories.


  
  5-7....................
    8-10......
 11...........................
   12......................
  13-17................
Install Rear Fenders 13.......................
Install Wheels 13............................
Install Steering Wheel 13.....................
Install Front Fenders 14......................
Install Seat Frame 14........................
Install Seat Back Cushions, Manual Tube and
Bed Support 14.............................
Install R PS 15.............................
Activate and Charge Battery 15...............
Full Bed Removal 16.........................
Re-install Full Bed 17.......................
  18-21...................
Check Crankcase il 18......................
Fill Fuel Tank 18.............................
Check Cooling System 19....................
Check Transaxle / Hydraulic Fluid 19...........
Check Front Differential il 19.................
Check Torque f Wheel Nuts r Bolts 20.......
Check Tire Pressure 20......................
Check Brake Fluid 21........................
 22-24.............................
  25-31............
Pre-starting Checks 25......................
Starting Engine 25...........................
Driving Vehicle 25...........................
Stopping Vehicle 25.........................
Stopping Engine 25.........................
New Vehicle Break-in 26....................
Check Interlock System 26...................
perating Characteristics 27..................
Passengers 26..............................
Speed 27...................................
Turning 27..................................
Braking 27..................................
Tipovers 27.................................
Hills 28.....................................
Loading And Dumping 29....................
Using The Differential Lock 29................
Four Wheel Drive 30.........................
Transporting Vehicle 30......................
Towing Vehicle 30...........................
Trailer Towing 31............................
Remote Hydraulic Control 31.................
   33.................
 34-35..........................
    36........
 37-47.........................
Using Bed Safety Support 37.................
Jacking Vehicle 38..........................
General Air Cleaner Maintenance Practices 38..
Servicing Dust Cup And Baffle 38.............
Servicing Air Cleaner Filter 39.................
Inspecting Filter Element 39..................
Changing Engine il And Filter 39.............
Fuel System 39.............................
Removing Debris From Cooling System 40.....
Changing Engine Coolant 40.................
Adjusting Belts 40..........................
Checking il Level In Governor 41.............
Adjusting Accelerator 42.....................
Changing Transaxle / Hydraulic Fluid 42.......
Replacing Hydraulic Filter 42.................
Change Front Differential il 43...............
Cleaning Hydraulic Strainer 43................
Replacing Spark Plugs 43....................
Adjusting Brake Pedal 44.....................
Adjusting Clutch Pedal 44....................
Adjusting Parking Brake 45...................
Adjusting Shifter Cable 45...................
Adjusting High-Low Cable 45................
Adjusting Differential Lock Cable 45...........
Inspect Brakes 45...........................
Inspect Tires 45.............................
Front Wheel Toe-in 46.......................
Inspect Constant Velocity Boot 46.............
Emergency Box Raising (Without Starting
Engine) 46.................................
Fuses 46...................................
Jump Starting Procedure 46..................
Battery Storage 47...........................
Battery Care 47.............................
  48..................
  49-50..............
  51-52...............
   53............
Model And Serial Numbers 53................
   BACK C VER..............

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 Make sure operators are thoroughly trained and
familiar with the Operator's Manual and all labels on the
vehicle.
 Be sure to establish your own special procedures
and work rules for unusual operating conditions (e.g.
slopes too steep for vehicle operation). Use the 3rd
High Lockout switch if high speed could result in a
safety or vehicle abuse situation.
   "
 Operate the machine only after reading and
understanding the contents of this manual. A
replacement manual is available by sending complete
model and serial number to: he oro Company, 8111
Lyndale Avenue South, Minneapolis, Minnesota
55420.
 Never allow children to operate the vehicle. Never
allow adults to operate it without proper instructions.
Only trained and authorized persons should operate
this vehicle. Make sure all operators are physically and
mentally capable of operating the vehicle. Anyone who
operates the vehicle should have a motor vehicle
license.
 his vehicle is designed to carry only you, the
operator, and one passenger in the seat provided by
the manufacturer. Never carry any other passengers
on the vehicle.
 Never operate the vehicle when under the
influence of drugs or alcohol.
 Become familiar with the controls and know how to
stop the engine quickly.
 Keep all shields, safety devices and decals in
place. If a shield, safety device or decal is
malfunctioning, illegible, or damaged, repair or replace
it before operating the machine.
 Always wear substantial shoes. Do not operate
machine while wearing sandals, tennis shoes or
sneakers. Do not wear loose fitting clothing or jewelry
which could get caught in moving parts and cause
personal injury.
 Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local
safety and insurance regulations.
 Keep everyone, especially children and pets, away
from the areas of operation.
 Before operating the vehicle, always check all
parts of the vehicle and any attachments. If something
is wrong, stop using vehicle. Make sure problem is
corrected before vehicle or attachment is operated
again.
 Since gasoline is highly flammable, handle it
carefully.
 Use an approved gasoline container.
 Do not remove cap from fuel tank when engine
is hot or running.
 Do not smoke while handling gasoline.
 Fill fuel tank outdoors and to about one inch
below top of tank (bottom of filler neck). Do not
overfill.
 Wipe up any spilled gasoline.
 Check the safety interlock system daily for proper
operation; refer to page 26. If a switch should
malfunction, replace the switch before operating
machine. After every two years, replace the interlock
switches in the safety system, whether they are
working properly or not.
%  "
 Operator and passenger should remain seated
whenever the vehicle is in motion. Operator should
keep both hands on steering wheel, whenever
possible and passenger should use hand holds
provided. Keep arms and legs within the vehicle body
at all times. Never carry passengers in box or on
attachments. Remember your passenger may not be
expecting you to brake or turn and may not be ready.
 Never overload your vehicle. Name plate (located
under dash on passenger side) shows load limits for
vehicle. Never overfill attachments or exceed the
vehicle maximum GVW.


 
 Wh n starting th ngin :
 Sit on op rator's s at and ngag parking
brak .
 Dis ngag PTO (if so quipp d) and r turn
hand throttl l v r to OFF position (if so quipp d).
 Mov shift l v r to NEUTRAL and d pr ss
clutch p dal.
 K p foot off acc l rator p dal.
 Turn ignition k y to START.
 Using th machin d mands att ntion. Failur to
op rat v hicl saf ly may r sult in a accid nt, tip ov r
of v hicl and s rious injury or d ath. Driv car fully. To
pr v nt tipping or loss of control:
 Us xtr m caution, r duc sp d and
maintain a saf distanc around sand traps,
ditch s, cr ks, ramps, any unfamiliar ar as or
oth r hazards.
 Watch for hol s or oth r hidd n hazards.
 Us caution wh n op rating v hicl on a st p
slop . Normally trav l straight up and down
slop s. R duc sp d wh n making sharp turns
or wh n turning on hillsid s. Avoid turning on
hillsid s wh n v r possibl .
 Us xtra caution wh n op rating v hicl on
w t surfac s, at high r sp ds or with a full load.
Stopping tim will incr as with a full load. Shift
into a low r g ar b for starting up or down a hill.
 Wh n loading b d, distribut load v nly. Us
xtra caution if th load xc ds th dim nsions of
th v hicl /b d. Op rat v hicl with xtra caution
wh n handling off-c nt r loads that cannot b
c nt r d. K p loads balanc d and s cur to
pr v nt th m from shifting.
 Avoid sudd n stops and starts. Do not go from
r v rs to forward or forward to r v rs without
first coming to a compl t stop.
 Do not att mpt sharp turns or abrupt
man uv rs or oth r unsaf driving actions that
may caus a loss of v hicl control.
 Wh n dumping, do not l t anyon stand
b hind v hicl and do not dump load on any on 's
f t. R l as tailgat latch s from sid of box, not
from b hind.
 B for backing up, look to th r ar and assur
no on is b hind. Back up slowly.
 Watch out for traffic wh n n ar or crossing
roads. Always yi ld th right of way to p d strians
and oth r v hicl s. This v hicl is not d sign d for
us on str ts or highways. Always signal your
turns or stop arly nough so oth r p rsons know
what you plan to do. Ob y all traffic rul s and
r gulations.
 N v r op rat v hicl in or n ar an ar a wh r
th r is dust or fum s in th air which ar xplosiv .
Th l ctrical and xhaust syst ms of th v hicl
can produc sparks capabl of igniting xplosiv
mat rials.
 Always watch out for and avoid low ov r hangs
such as tr limbs, door jambs, ov r h ad
walkways, tc. Mak sur th r is nough room
ov r h ad to asily cl ar th v hicl and your h ad.
 If v r unsur about saf op ration, STOP
WORK and ask your sup rvisor.
 Do not touch ngin , transaxl , radiator, muffl r or
muffl r shi ld whil ngin is running or soon aft r it
has stopp d b caus th s ar as may b hot nough
to caus burns.
 If th machin v r vibrat s abnormally, stop
imm diat ly, turn ngin off, wait for all motion to stop
and insp ct for damag . R pair all damag b for
comm ncing op ration.
 B for g tting off th s at:
 Stop mov m nt of th machin .
 Low r b d.
. Shut ngin off and wait for all mov m nt to
stop.
 S t parking brak .
 R mov k y from ignition.
 Block wh ls if machin is on an inclin .

 B for s rvicing or making adjustm nts to th
machin , stop ngin , s t parking brak and r mov
k y from ignition to pr v nt accid ntal starting of th
ngin .
 N v r work und r a rais d b d without placing b d
saf ty support on fully xt nd d cylind r rod.
 Mak sur all hydraulic lin conn ctors ar tight,
and all hydraulic hos s and lin s ar in good condition
b for applying pr ssur to th syst m.
 K p body and hands away from pin hol l aks or
nozzl s that j ct hydraulic fluid und r high pr ssur .
Us pap r or cardboard, not hands, to s arch for
l aks. Hydraulic fluid scaping und r pr ssur can
hav suffici nt forc to p n trat skin and do s rious
damag . If fluid is inj ct d into th skin it must b
surgically r mov d within a f w hours by a doctor
familiar with this form of injury or gangr n may r sult.


 
 Before disconnecting or performing any work on
the hydraulic system, all pressure in system must be
relieved by stopping engine, cycling dump valve from
raise to lower and/or lowering box and attachments.
Place the remote hydraulics lever in the float position. If
box must be in raised position, secure with safety
support.
 o make sure entire machine is in good condition,
keep all nuts, bolts and screws properly tightened.
 o reduce potential fire hazard, keep the engine
area free of excessive grease, grass, leaves and
accumulation of dirt.
 If the engine must be running to perform a
maintenance adjustment, keep hands, feet, clothing,
and any parts of the body away from the engine and
any moving parts. Keep everyone away.
 Do not overspeed engine by changing governor
settings. Maximum engine speed is 3650 rpm. o
assure safety and accuracy, have an Authorized ORO
Distributor check maximum engine speed with a
tachometer.
 If major repairs are ever needed or assistance is
required, contact an Authorized ORO Distributor.
 o be sure of optimum performance and safety,
always purchase genuine ORO replacement parts
and accessories. Replacement parts and accessories
made by other manufacturers could be dangerous.
Altering this vehicle in any manner may affect the
vehicle's operation, performance, durability or its use
may result in injury or death. Such use could void the
product warranty of he ORO Company.
 his vehicle should not be modified without the
ORO Company's authorization. Direct any inquiries
to:
he ORO Company
Commercial Division
Vehicle Engineering Dept.
300 West 82nd St.
Bloomington, Minnesota 55420-1196. USA
  
his unit has an equivalent continuous AĆweighted
sound pressure at the operator ear of: 78 dB(A), based
on measurements of identical machines per Directive
84/538/EEC and amendments.
 
$(&#
his unit does not exceed a vibration level of 2.5 m/s@
at the hands based on measurements of identical
machines per ISO 5349 procedures.
!%" %'
his unit does not exceed a vibration level of 0.5 m/s@
at the posterior based on measurements of identical
machines per ISO 2631 procedures.


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

2* 4 wheel step through, out front operator style,
two person vehicle. Certified to meet ANSI
Specifications B56.8a-1994.
(!#( itsubishi 27 hp, three cylinder, liquid
cooled, counterbalanced, gasoline engine; regulated
to a maximum of 23 hp at 3650 rpm by a mechanical
governor. 40 cu. in. (657 cc) displacement. Forced
lubrication by gear pump. 40 amp alternator with I/C
regulator. Spin-on oil filter.
#+ &(+ Heavy duty, 2Ćstage, remote mounted
air cleaner.
--+2 12 volt with 370 cold cranking Amps @ 0
degrees F.
))&#(! 2,-' id mounted radiator with
removable screen and lower clean out access. Cooling
system capacity is approximately 4 qts. of 50/50
mixture of ethylene glycol anti-freeze.
.& 2,-' Gasoline tank capacity is 7 gallons.
12 volt, electric fuel pump.
+(,'#,,#)( Rear transaxle configuration, twin
axle drive. 3 speed synchromesh, H-shift pattern with
high-low range providing 6 forward and 2 reverse
speeds. anual engage differential lock. 4 wheel drive
output shaft (4 wd only).
&.-" 7.5" clutch and pressure plate.
+)(- # +(-#& (4wd only) 5.0 to 1 ratio
(-+ # +(-#& (4wd only) Bi-directional
overrunning clutch
+' Welded, high strength steel channels and
tubes.
+)(- .,*(,#)( Independent A" frame control
arm, dual coil springs and dual shock absorbers with
anti-sway bar.
+ .,*(,#)( DeDion axle (weight carrying axle
is independent of transaxle), leaf spring and dual
shock absorbers.
-+#(! 2,-' Power assist, 3 position tilt
steering wheel, 3-3/4 turns lock-to-lock. 17.5 to 1
ratio, 14" diameter steering wheel.
#+,:Front tires: 20" x 10"Ć10, 4Ćply rating, rib tread.
Rear tires: 24" x 13"Ć12, 4Ćply rating, turf tread.
Optional tires - 2wd only: 23" x 10.5"Ć12, 4Ćply rating,
turf tread.
+%, 4 wheel hydraulic, dual safety circuit self
adjusting drum: 7" diameter front and 8" diameter rear
(2wd) 8" diameter front and rear (4wd). Hand actuated
parking brake actuates rear brake shoes.
 2 post roll over protection structure with
shoulder restraint.
2+.&#, 4 gpm pressure balanced gear pump
provides hydraulic flow for power steering, lift and
optional remote hydraulics. Lift control valve and dual
cylinders for lifting dump box. Transaxle is used for
reservoir for hydraulic system. 8 quart total capacity.
Spin-on 25 micron hydraulic oil filter. 100 mesh
strainer in transaxle.
- Twin molded cushions and backrests, with
shoulder and hip restraints.
)(-+)&, Foot operated accelerator, clutch and
brake pedals. Hand operated shifter, differential lock,
parking brake, high-low range shifter, hydraulic lift
and tilt steering levers. Ignition switch, light switch,
horn button and 3rd high lockout switch.
.!, Hour meter, fuel gauge, coolant
temperature gauge. Warning light cluster includes
engine low oil pressure and charge indicator.
Tachometer optional.
#!"-, Twin halogen headlights and single taillight.
Rear stop light.
)0 #-" Hitch has hole for ball or pin.
(-+&)%, Clutch pedal must be depressed to start
engine.
+).( *
)+0+ *, 0 + #+,
High range: 7.6/11.5/19.8 mph
Low range: 2.9/4.5/7.7 mph
/+, *, 0 #+,
High range: 7.2 mph
Low range: 2.8 mph
(+& *# #-#)(, **+)1
Base Weight: Dry w/o flatbed 1400lbs. (2wd)
1600 lbs. (4wd)
Rated Capacity: *2,600 lbs.
*includes 200 lb. operator and 200 lb. passenger
and loaded attachment.
aximum. Gross Vehicle Weight: 4,000 lbs. (2wd)
4,200 lbs. (4wd)
Tow Capacity Tongue weight 200 lbs.
aximum trailer weight 1,500 lbs.
Overall Width: 63"
Overall Length: 124.5"w/o bed
127" w/full bed
133" w/2/3 bed
in rear mounting location
Height: 75" to top of ROPS
Ground Clearance: 7" w/ no load
Wheel Base: 70"
Wheel Tread: (center line to center line) 46" Front
49.7" Rear
(47.7" Rear w/optional 23" rear Tire)
*# #-#)(, ( ,#!( ,.$- -) "(!
0#-").- ()-#


  
 Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these
parts, total setĆup cannot be completed. Some parts may have already been assembled at factory.
  
Fenders-Rear 2
Capscrew 5/16-18 x 1" lg. 4
Flatwasher .344" I.D. 4
Locknut 5/16-18 4
Capscrew 1/4-20 x 1" lg. 12 Mount rear fenders
Flatwasher .281" I.D. 12
Locknut 1/4-20 12
Trusshead Screw 6
Locknut 3/8-16 6
Wheel Nut 10
Wheel-Front 2
Wheel Nut 10 Mount wheels.
Wheel-Rear 2
Steering wheel 1
Foam Seal 1
Washer 1 Install steering wheel
Nut 1
Cap 1
Fenders-Front 2
Phillips Screw 10-24 14 Install front fenders
Washer 14
Locknut 10-24 14
Seat Frame 1
Seat Frame Bracket 2
Carriage Bolts 3/8-16 x 3/4" lg. 4 Install seat frame
Flange Locknut 3/8-16 4
Capscrew 1/2-13 x 1" lg. 2
Locknut 1/2-13 2
Capscrew 3/8-16 x 1" lg. 2
Lockwasher 3/8-16 2
Seat Back Cushion 2
Seat Back Bracket 4
Capscrew 1/4-20 x 3/4" lg. 8
Washer 1/4" 8 Install seat back cushion and manual tube
Carriage Bolts 5/16-18 x 5/8" lg. 8
Flange Locknuts 5/16-18 8
Manual Tube 1
R-Clamp 2
ROPS 1
Capscrew 1/2-13 x 3" lg. 4 Mount ROPS
Locknuts 1/2-13 4
Operator's Manual ( ehicle) 2 Read before operating machine.
Parts Catalog 1
Registration Card 1 Fill out and return to Toro


   
   )'  
 Loosen the locknuts and capscrews securing tail
light plates to right and le t rame brackets.
 Pivot tail light plates rearward and tighten
capscrews and locknuts.
 ")+ +)'(1 /+"1&
 0",& #0"$*&1
 ")+ +)'(1 ,.2-1)-' #0"$*&1
)'20& 


 Secure rear o each tail light plate to rear o rame
brackets with a 5/16-18 x 1" lg. capscrew, .281" I.D.
latwasher and nut, as shown in igure 1.
 On le t side, remove (2) capscrews, washers and
nuts securing tail light mounting bracket to tail light
plate.
 &-%&0
 &-%&0 ,.2-1)-' #0"$*&1
)'20& 


 Position a ender over each tail light plate, aligning
mounting holes.
 On le t side, loosely secure tail light mounting
bracket, rear o ender and tail light plate together with
(2) capscrews, washers and nuts, previously removed.
 On right side, secure rear o ender to tail light plate
with (2) 1/4-20 x 1" lg. capscrews, .281" I.D.
latwashers and nuts
 Loosely secure ront o each ender mounting
bracket to rame with a 1/4-20 x 1" lg. capscrew and
locknut.
 Loosely secure side o each ender to rame (3)
3/8-16 x 1" lg. truss head screws and locknuts.
.1& Capscrews securing ronts o enders to
mounting brackets may have to be loosened to align all
mounting holes.
 Tighten all asteners.
 ! )' 
 Remove and discard asteners securing wheels.
 Mount wheels and torque nuts to 45Ć55 tĆlb.
 !(&&+
 !(&&+ 21
)'20& 

  ! )' 
 Remove jam nut rom steering sha t. Slide oam
seal, steering wheel and washer onto steering sha t.
 Secure steering wheel to sha t with jam nut and
tighten it to 10-15 tĆlb.
 Install cap to steering wheel.


 !  ! 
 4''2+/) "*''-
 #. 54
 #1
+)52' 
 "#3*'2
 0#. '#-





    +) 
 Mou t a fe der to each side of skirt with (7) 10-24
Phillips screws, flat washers a d lock uts.
 '/&'2
+)52' 

    +) 
 Mou t a seat frame bracket to each e d of seat
frame with (2) 3/8-16 x 3/4" carriage bolts a d fla ge
lock uts.
 Positio seat frame o vehicle, alig i g mou ti g
holes i frame with holes i vehicle.
 Secure fro t legs of seat frame to sides of vehicle
floor with (2) 1/2-13 x 1" lg. capscrews a d lock uts.
 Secure bottom of each seat frame bracket to
vehicle frame with a 3/8-16 x 1" capscrew a d
lockwasher.
 '#4 (2#.'
 '#4 (2#.' $2#%,'4
+)52' 


    !
! !   !
+) 
 Mou t (2) seat back brackets to each seat back
cushio with (4) 1/4-20 x 3/4" lg. capscrews a d 1/4"
flat washers. Positio brackets o seat back cushio s
as show i figure 7.
 53*+0/ 3'#4 $#%,
 '#4 $#%, $2#%,'4
+)52' 




!"  !"!
 Mount cushion with seat back brackets to right
side o seat back with (4) 5/16-18 x 5/8" lg. carriage
bolts and lange locknuts.
 Slide manual tube into (2) R-clamps.
.,96* 
 97-.43 7*&8 '&(0
 *&8 '&(0 '6&(0*8
 *&8 '&(0
 &39&1 89'*
 (1&25





 Mount cushion with seat back brackets and
manual tube R-clamps to le t seat back with (4)
5/16-18 x 5/8" lg. carriage bolts and lange locknuts.
 Slide bed support onto storage stud (Fig. 9).
.,96* 
 *) 7955468
 846&,* 789)


-4;3 ;.8- 7*&8 '&(0 6*24:*)
 !  ., 
 Insert each side o ROPS into mounting bracket on
each side o vehicle rame, positioning ROPS as shown
in igure 10.
 Secure each side o ROPS to mounting brackets
with (2) 1/2-13 x 3" lg. capscrews and locknuts.
 
 4938.3, '6&(0*87
.,96* 
!


!#!   !!%
., 
I Battery is not illed with electrolyte or activated, it
must be removed rom vehicle, illed with electrolyte
and charged. Bulk electrolyte with 1.260 speci ic
gravity can be purchased rom a local battery supply
outlet.
1*(8641=8* ,&7*7 &6* *<5147.:* &3) (&3
(&97* 7*6.497 .3/96= 84 *=*7 193,7 &3)
70.3 $*&6 7&+*8= ,4,,1*7 &3) 69''*6
,14:*7 ;-*3 ;460.3, ;.8- *1*(8641=8* 46
'&88*6= -&6,* 8-* '&88*6= .3 & ;*11 :*38.>
1&8*) 51&(* 74 ,&77*7 564)9(*) ;-.1*
(-&6,.3, (&3 ).77.5&8* .3(* 8-* ,&7*7
&6* *<5147.:* 0**5 45*3 +1&2*7 &3)
*1*(86.(&1 75&60 &;&= +642 8-* '&88*6= )4
348 7240* &97*& 2&= 6*7918 .+ 8-* ,&7*7
&6* .3-&1*) "3519, (-&6,*6 +642 *1*(86.(&1
4981*8 '*+46* (433*(8.3, 84 46 ).7(433*(8>
.3, (-&6,*6 1*&)7 +642 '&88*6= 54787
"!
 Loosen knobs securing battery cover to battery
base and slide cover o .
 Remove capscrew, washers and locknut securing
battery hold down to battery base. Remove hold down
and slide battery out o battery base.


#$%! #$"%$ #
0.;8, 
 (::,8> *6<,8
 56)
 (::,8> )(9,




 Remove filler caps from battery and slowly fill eac
cell until electrolyte is just above t e plates.
 Replace filler caps and connect a 3 to 4 amp
battery c arger to t e battery posts. C arge t e battery
at a rate of 3 to 4 amperes for 4 to 8 ours.
0.;8, 
 !690:0<,  *()3,
 63+ +6=5


 W en battery is c arged, disconnect c arger from
electrical outlet and battery posts.
 Remove filler caps. Slowly add electrolyte to eac
cell until level is up to fill ring. Install filler caps.
! "$$:6 56: 6<,8-033 )(::,8> 3,*:863>:, =033
6<,8-36= 65:6 6:/,8 7(8:9 6- :/, <,/0*3, (5+ 9,<,8,
*68869065 (5+ +,:,8068(:065 =033 8,9;3:
 Slide battery into battery base so battery terminals
are toward t e rear of t e ve icle.
 Install t e positive cable (red) to t e positive (+)
terminal and t e negative cable (black) to t e negative
(Ċ) terminal of t e battery and secure wit capscrews
and nuts. Slide t e rubber boot over t e positive
terminal to prevent possible s ort-out from occurring.
'"
655,*:05. *()3,9 :6 :/, =865. 769:
*6;3+ 8,9;3: 05 7,8965(3 051;8> (5+68
+(4(., :6 :/, ,3,*:80*(3 9>9:,4 (2,
9;8, )(::,8> 68 *()3,9 +6 56: 05:,8-,8, 68
8;) 65 (5> 46<05. 68 /6: 7(8:9
 Install battery old down and secure to base wit
capscrew, was ers and locknut.
 Reinstall battery cover to battery base and tig ten
knobs.
%  " & 6+,3  653>
 Start engine. Engage ydraulic lift lever and lower
bed until cylinders are loose in slots. Release lift lever
and turn off engine.
 Remove lync pins from outer ends of cylinder rod
clevis pins (Fig. 13).
0.;8, 
 ,+ 46;5:05. 73(:,
 >305+,8 86+ ,5+
 3,<09 705
 




 >5*/ 705
 ",(8 936:9 ;33 ),+
 865: 936:9  ),+
 Remove clevis pins securing cylinder rod ends to
bed mounting plates by pus ing pins towards inside
(Fig. 14).
 Remove lync pins and clevis pins securing pivot
brackets to frame c annels (Fig. 14).
 Lift bed off ve icle.
%$  T e full bed weig s approximately 210
pounds, so do not try to install or remove it by yourself.
Get t e elp of two or t ree ot er people.


   
 Stor cylind rs in storag clips. Engag hydraulic
lift lock l v r on v hicl to pr v nt accid ntal xt nsion
of lift cylind rs.
   
0&'-  0/-7
 If b d sid s will b install d on flat b d, it is
asi r to install th m b for b d is install d on v hicl .
 Assur r ar pivot plat s ar bolt d to th b d
fram /chann l so that low r nd angl s to th r ar
(Fig. 14).
+)52' 
 '(4 2'#2 %02/'2 0( $'&
 !'*+%-' (2#.' %*#//'-
 +604 1-#4'
 -'6+3 1+/
 7/%* 1+/





04' Mak sur spac r brack ts and w ar blocks
(Fig. 15) ar install d or radiator cov r may b
damag d.
+)52' 
 1#%'2 $2#%,'4
 "'#2 $-0%,


 Assur lift cylind rs ar fully r tract d.
  Th full b d w ighs approximat ly 210
pounds, so do not try to install or r mov it by yours lf.
G t th h lp of two or thr oth r p opl .
 Car fully s t b d onto v hicl fram aligning r ar
b d pivot plat hol s with hol s in r ar fram chann l
and install (2) cl vis pins and lynch pins (Fig. 14).
 With b d low r d, s cur ach cylind r rod nd, to
appropriat slots in b d mounting plat s with cl vis pin
and lynch pin. Ins rt cl vis pin from outsid of b d with
lynch pin toward outsid (Fig. 13). R ar slots ar for full
b d installation and front slots ar for 2/3 b d
installation.
 Engin may n d to b start d to xt nd or
r tract cylind rs for alignm nt with hol s. ''1
(+/)'23 054
04' Unus d slot can b plugg d with a capscr w
and nut to pr v nt ass mbly rrors.
 Start ngin and ngag hydraulic lift l v r to rais
b d. R l as lift l v r and turn off ngin . S cur
rais d b d with a hoist or block it to pr v nt it from
accid ntally falling.
 Install lynch pins to insid nds of cl vis pins.
 If automatic tail gat r l as has b n install d
on b d, mak sur front dump link rod has b n plac d
on insid of l ft sid cl vis pin b for lynch pin is
install d.
 Onc cylind r installation has b n compl t d, th
b d saf ty support can b us d to pr v nt accid ntal
low ring of th b d. R f r to Using B d Saf ty
Support, pag 37.


   "
#"
+,58+ 9+8</)/4- 58 3'1/4- '*0;9:3+4:9 :5 :.+
3')./4+ 9:56 +4-/4+ 9+: 6'81/4- (8'1+ '4*
8+35<+ 1+? ,853 :.+ 9=/:). 4? 25'* 3':+8/'2
3;9: (+ 8+35<+* ,853 (+* 58 5:.+8 '::').@
3+4: (+,58+ =581/4- ;4*+8 8'/9+* (+* 2='?9
85:':+ 9',+:? 9;6658: :5 :.+ *5=4 659/:/54 (+@
,58+ =581/4- ;4*+8 8'/9+* (+*
  !  /- 
The engine is shipped with approximately 3 quarts
(w/ filter) of oil in the crankcase; however, level of oil
must be checked before and after the engine is first
started.
 Position machine on a level surface.
 Remove dipstick and wipe it with a clean rag. Insert
dipstick into tube and make sure it is seated fully.
Remove dipstick and check level of oil . If oil level is low,
remove filler cap and add enough oil to raise level to
FULL mark on dipstick.
/-;8+ 
 /69:/)1
 /22+8 )'6


 The engine uses any highĆquality detergent oil
having the American Petroleum Institute ĆAPIĆ service
classification" SG or SG/CD. See viscosity chart for
recommended weight to use.
 Pour oil into fill opening until the oil level is up to the
FULL" mark on the dipstick. Add the oil slowly and
check the level often during this process. DO OT
OVERFILL.
 "" .+)1 2+<+2 5, 5/2 +<+8?  56+8':/4-
.5;89 58 *'/2? .'4-+ 5/2 '4* ,/2:+8 /4/:/'22? ',:+8 :.+
,/89:  .5;89 5, 56+8':/54 :.+8+',:+8 ).'4-+ 5/2
'4* ,/2:+8 +<+8?  .5;89 5=+<+8 ).'4-+ 5/2
358+ ,8+7;+4:2? =.+4 +4-/4+ /9 56+8':+* /4
+>:8+3+2? *;9:? 58 */8:? )54*/:/549
 Install the dipstick firmly in place.
4:/)/6':+* ':3596.+8/)
:+36+8':;8+ 8'4-+ ! </9)59/:? 5
C°F°
49 120
38 100
27 80
16 60
032
-12 10
-23 -10
-29 -20
* SAE 5W-20 ot recommended for sustained high
speed vehicle operation.
20w20
20w40
20w50
10w30
10w40
10w50
*5w20
5w30
5w40
 # " /- 
Fuel tank capacity is approximately 7 gallons.
THE TORO COMPA Y STRO GLY RECOMME DS
THE USE OF FRESH, CLEA , # REGULAR
GRADE GASOLI E I TORO GASOLI E POWERED
PRODUCTS. U LEADED GASOLI E BUR S
CLEA ER, EXTE DS E GI E LIFE, A D
PROMOTES GOOD STARTI G BY REDUCI G THE
BUILD-UP OF COMBUSTIO CHAMBER DEPOSITS.
LEADED GASOLI E CA BE USED IF U LEADED IS
OT AVAILABLE. MI IMUM OCTA E RATI G OF 87.
" $ #! " !
" " !
"   "  "
! "$!  %" ! #!
 # !&!"  # !#"
 Clean area around fuel tank cap.
/-;8+ 
 ;+2 :'41 )'6



   "
 R mov fu l tank cap.
 Fill tank to about on inch b low top of tank,
(bottom of fill r n ck).  " $  Th n install
cap.
 Wip up any fu l that may hav spill d to pr v nt a
fir hazard.

,*(:8, .(85204, 08 -2(33()2, *(:9054
3:89 ), :8,+ </,4 895704. 57 /(4+204. 09
5 459 -022 -:,2 9(41 </02, ,4.04, 08 7:4404.
/59 57 </,4 3(*/04, 08 04 (4 ,4*258,+
(7,( $(6578 3(> ):02+ :6 (4+ ), 0.409,+
)> ( 86(71 57 -2(3, 85:7*, 3(4> -,,9
(<(>  " ! </02, -02204. 9/, -:,2
9(41 95 67,;,49 9/, 65880)0209> 5- (4 ,=625@
8054 2<(>8 -022 -:,2 9(41 5:980+, (4+ <06,
:6 (4> 86022,+ .(85204, ),-57, 89(7904.
,4.04, #8, ( -:44,2 57 865:9 95 67,;,49
8602204. .(85204, (4+ -022 9(41 45 /0./,7
9/(4 54, 04*/ ),25< 956 5- 9(41 )59953 5-
-022,7 4,*1  " $  !957,
.(85204, 04 ( *2,(4 8(-,9> (6675;,+ *54@
9(04,7 (4+ 1,,6 9/, *(6 54 9/, *549(04,7
,,6 .(85204, 04 ( *552 <,22;,4902(9,+
62(*, 4,;,7 04 (4 ,4*258,+ (7,( 8:*/ (8 (
/59 8957(., 8/,+ "5 (88:7, ;52(90209> +5
459 ):> 357, 9/(4 (  +(> 8:662> 5-
.(85204, (85204, 08 ( -:,2 -57 049,74(2
*53):89054 ,4.04,8 9/,7,-57, +5 459 :8,
09 -57 (4> 59/,7 6:7658, !04*, 3(4>
*/02+7,4 201, 9/, 83,22 5- .(8 1,,6 09 5:9 5-
9/,07 7,(*/ ),*(:8, 9/, -:3,8 (7, ,=625@
80;, (4+ +(4.,75:8 95 04/(2,
  !'!" 0. 
Capacity of cooling syst m is approximat ly 4 qts.
Th cooling syst m is fill d with a 50/50 solution of
wat r and p rman nt thyl n glycol anti-fr z .
Ch ck l v l of coolant at b ginning of ach day b for
starting th ngin .
 Park machin on a l v l surfac .
- ,4.04, /(8 ),,4 7:4404. 67,88:70?,+
/59 *552(49 *(4 ,8*(6, 0- 7(+0(957 *(6 08
7,35;,+ (4+ *(:8, ):748 225< ,4.04,
95 *552 (9 2,(89  304:9,8 57 :4902 9/,
7(+0(957 *(6 08 *552 ,45:./ 95 95:*/
<09/5:9 ):7404. /(4+
#"
 Ch ck coolant l v l. Coolant should b up to
COLD lin on r s rv tank, wh n ngin is cold.
0.:7, 
 ,8,7;, 9(41  52+ 204,  59 204,



 If coolant is low, r mov r s rv tank cap and add
a 50/50 mixtur of wat r and p rman nt thyl n
glycol anti-fr z .  " $ .
 Install r s rv tank cap.
 " !&  ' # #
0. 
Th transaxl r s rvoir is fill d with D xron IIl ATF.
Ch ck l v l b for ngin is first start d and v ry 8
hours or daily, th r aft r. Capacity of syst m is 7.5 qt.
 Position th v hicl on a l v l surfac .
 Cl an ar a around dipstick.
 Unscr w dipstick from top of transaxl and wip it
with a cl an rag.
0.:7, 
 06890*1

 Scr w dipstick into transaxl and mak sur it is
s at d fully. Unscr w dipstick and ch ck fluid l v l.
Fluid should b up to top of flat portion of dipstick. If
l v l is low, add nough fluid to achi v th prop r
l v l.
  "  " 
5:7 %/,,2 70;, 5+,2 42> 0. 
Th diff r ntial is fill d with 10W30 oil. Ch ck l v l of
oil v ry 100 hours or monthly. Capacity of syst m is
1 qt.
 Position th v hicl on a l v l surfac .
 Cl an ar a around fill/ch ck plug on sid of
diff r ntial.


 # !#%
1/=:- 
 :76< ,1..-:-6<1)4
 144+0-+3 84=/
 :)16 84=/



 Remove fill/check plu and check level of oil. Oil
should be up to hole. If oil is low, add 10W30 oil.
 Re-install fill/check plu .
 % #"&  ' &%$
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Check tire pressure every 8 hours or daily to assure
proper levels.
Maximum air pressure in front tires is 20 psi and rear
(24") tires is 18 psi.
 The air pressure needed is determined by the
payload carried.
 The lower the air pressure, the less the compaction
and tire marks are minimized. Lower pressure should
not be used for heavy payloads at hi h speeds. Tire
dama e may result.
 Hi her pressures should be used for heavier
payloads at hi her speeds. Do not exceed the
maximum pressure. Use the followin charts to
determine correct tire pressures for tire size and
payload of vehicle.
! #%% When replacin tires, on the 4wd
vehicle, only use replacements approved for the
Workman. Use of tires not approved may cause turf
dama e or accelerated drive train dama e.
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