Toro Ultra Buggy 2500 User manual

Operator’s Manual
Ultra Buggy® 2500
Model—Serial Range
68038—410171431 and Up
3461-467A Original Instructions (EN) *3461-467*A

Disclaimers and Regulatory Information
It is a violation of California Public Resource Code Section 4442 or 4443 to use or operate
the engine on any forest-covered, brush-covered, or grass-covered land unless the engine
is equipped with a spark arrester, as defined in Section 4442, maintained in effective
working order or the engine is constructed, equipped, and maintained for the prevention of
fire.
Because in some areas there are local, state, or federal regulations requiring that a spark
arrester be used on the engine of this machine, a spark arrester is available as an option. If
you require a spark arrester, contact your Authorized Service Dealer. Genuine Toro spark
arresters are approved by the USDA Forestry Service.
The enclosed engine owner's manual is supplied for information regarding the US
Environmental Protection Agency (EPA) and the California Emission Control Regulation of
emission systems, maintenance, and warranty. Replacements may be ordered through the
engine manufacturer.
WARNING
CALIFORNIA
Proposition 65
The engine exhaust from this product contains chemicals known to the State of California to
cause cancer, birth defects, or other reproductive harm.
Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals
known to the State of California to cause cancer and reproductive harm. Wash hands after
handling.
Use of this product may cause exposure to chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
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
Chapter 2: Safety.................................................................................................................................. 2–1
General Safety .................................................................................................................................. 2–1
Safety and Instructional Decals .................................................................................................... 2–1
Chapter 3: Product Overview ............................................................................................................ 3–1
Controls............................................................................................................................................... 3–1
Brake Pedal ................................................................................................................................... 3–1
Parking Brake................................................................................................................................ 3–2
Drive Controls................................................................................................................................ 3–2
Dump Controls .............................................................................................................................. 3–2
Fuel Gauge .................................................................................................................................... 3–3
© 2022—The Toro®Company
8111 Lyndale Ave So
Bloomington, MN 55044
Contact us at www.Toro.com
Printed in the USA
All rights reserved

Engine Controls ............................................................................................................................ 3–3
Specifications .................................................................................................................................... 3–4
Attachments/Accessories............................................................................................................... 3–5
Chapter 4: Operation ........................................................................................................................... 4–1
Before Operation .............................................................................................................................. 4–1
Before Operation Safety ............................................................................................................. 4–1
Fuel .................................................................................................................................................. 4–2
Performing Daily Maintenance.................................................................................................. 4–3
During Operation .............................................................................................................................. 4–3
During Operation Safety ............................................................................................................. 4–3
Starting the Engine....................................................................................................................... 4–5
Shutting Off the Engine ............................................................................................................... 4–6
Operating the Machine................................................................................................................ 4–6
Operator Platform......................................................................................................................... 4–7
Operating the Hopper.................................................................................................................. 4–8
After Operation.................................................................................................................................. 4–9
After Operation Safety................................................................................................................. 4–9
Haul the Machine.......................................................................................................................... 4–9
Removing the Outer Wheels.................................................................................................... 4–13
Chapter 5: Maintenance ..................................................................................................................... 5–1
Maintenance Safety ......................................................................................................................... 5–1
Recommended Maintenance Schedule...................................................................................... 5–2
Pre-Maintenance Procedures ....................................................................................................... 5–2
Moving a Non-Functional Machine........................................................................................... 5–2
Lifting the Machine ....................................................................................................................... 5–3
Removing the Cowl...................................................................................................................... 5–4
Lubrication.......................................................................................................................................... 5–4
Greasing the Machine ................................................................................................................. 5–4
Engine Maintenance........................................................................................................................ 5–5
Servicing the Air Cleaner ............................................................................................................ 5–5
Engine Oil Service........................................................................................................................ 5–6
Replacing the Spark Plug ........................................................................................................... 5–8
Cleaning the Blower Housing .................................................................................................... 5–8
Fuel System Maintenance.............................................................................................................. 5–9
Cleaning the Sediment Cup ....................................................................................................... 5–9
Replacing the Fuel Filter............................................................................................................. 5–9
Draining the Fuel Tank .............................................................................................................. 5–10
Drive System Maintenance .......................................................................................................... 5–10
Checking the Transmission Neutral Position ....................................................................... 5–10
Inspecting the Tires.................................................................................................................... 5–11
Torquing the Wheel Lug Nuts .................................................................................................. 5–11
Brake Maintenance ........................................................................................................................ 5–12
Checking the Brake Pedal........................................................................................................ 5–12
Checking the Parking Brake .................................................................................................... 5–12
Adjusting the Parking Brake..................................................................................................... 5–12
Hydraulic System Maintenance .................................................................................................. 5–13
Hydraulic Fluid Specifications ................................................................................................. 5–13
Checking the Hydraulic Fluid................................................................................................... 5–14
Changing the Hydraulic Fluid .................................................................................................. 5–14
Replacing the Hydraulic Filter ................................................................................................. 5–15
Checking the Hydraulic Lines .................................................................................................. 5–16
Cleaning............................................................................................................................................ 5–16
Removing Debris ........................................................................................................................ 5–16
3461-467 A Page 3 Disclaimers and Regulatory Information:

Chapter 6: Storage............................................................................................................................... 6–1
Storage Safety .................................................................................................................................. 6–1
Preparing the Machine for Storage Over 30 Days.................................................................... 6–1
Chapter 7: Troubleshooting ............................................................................................................... 7–1
California Proposition 65 Warning Information
Disclaimers and Regulatory Information: Page 4 3461-467 A

Chapter 1
Introduction
Intended Use
This machine is intended to be used by professional, hired operators in commercial
applications. This machine is a stable, reliable, and productive machine for carrying and
moving materials for any job site. 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
g328431
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:
3461-467 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.
Introduction: Manual Conventions Page 1–2 3461-467 A

Chapter 2
Safety
General Safety
• Read and understand the contents of this Operator’s Manual before starting the engine.
• 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 engine, 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 engine running.
Improperly using or maintaining the machine can result in injury. To reduce the potential for
injury, comply with these safety instructions and always pay attention to the safety-alert
symbol , which means Caution,Warning, or Danger—personal safety instruction.
Failure to comply with the instruction may result in personal injury or death.
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger. Replace any decal that is damaged or missing.
3461-467 A Page 2–1 Safety

Decal Part: 125-4958
decal125-4958
Read the Operator's Manual for information on
starting the engine—1) Engage the parking brake;
2) Set the drive to neutral; 3) Open the choke; 4)
Turn the engine switch on; 5) Engage the fuel
switch; 6) Pull the recoil starter and set the throttle
to fast; 7) Close the choke.
Read the Operator’s Manual for information on
shutting off the engine—1) Set the throttle to slow;
2) Engage the parking brake; 3) Set the drive to
neutral; 4) Turn the engine switch to stop; 5)
Disengage the fuel switch.
Decal Part: 125-4959
decal125-4959
Force from above can cause
crushing of the whole body—never
place your head under the hopper.
Safety: Safety and Instructional Decals Page 2–2 3461-467 A

Decal Part: 125-4960
decal125-4960
Forward
Decal Part: 125-4961
decal125-4961
Reverse
3461-467A Page 2–3 Safety: Safety and Instructional Decals

Decal Part: 125-4962
decal125-4962
Engage the parking brake.
Disengage the parking brake.
Decal Part: 125-4963
decal125-4963
Warning—stay away from hot
surfaces.
Decal Part: 125-4964
decal125-4964
Read the Operator’s Manual for
hydraulic oil information.
Safety: Safety and Instructional Decals Page 2–4 3461-467 A

Decal Part: 125-4967
decal125-4967
Lift point
Decal Part: 125-6694
decal125-6694
Tie-down location
Decal Part: 125-8190
decal125-8190
Press down on the pedal to engage
the service brake.
Release the pedal to disengage the
service brake.
3461-467A Page 2–5 Safety: Safety and Instructional Decals

Decal Part: 127-2855
decal127-2855
Warning—read the Operator’s Manual; wear
hearing protection.
Warning—all operators should read the Operator’s
Manual and be trained before operating the
machine.
Warning—stay away from moving parts; keep all
guards and shields in place.
Warning—keep bystanders away; look behind and
down when moving in reverse.
Tipping hazard—do not drive forward with the
hopper raised; drive slowly with the hopper
lowered; raise the hopper slowly.
Asphyxiation hazard, poisonous fumes, or toxic
gases—do not run the engine in an enclosed
space.
Explosion hazard—shut off the engine and do not
expose to fire or open flame while fueling.
Safety: Safety and Instructional Decals Page 2–6 3461-467 A

Decal Part: 130-2844
decal130-2844
Release the pedal to lower the
hopper.
Press down on the pedal to raise
the hopper.
Decal Part: 133-8062
s_decal133-8062
3461-467A Page 2–7 Safety: Safety and Instructional Decals

Chapter 3
Product Overview
G356654
Operator platform
Steer tires
Reverse-speed-control lever
Drive tires
Hopper
Handle bars
Forward-speed-control lever
Dump handle/pedal
Fuel tank
Parking brake
Brake pedal
Controls
Brake Pedal
g356774
Press down on the brake pedal to stop the
machine.
Product Overview Page 3–1 3461-467 A

Parking Brake
g357455
Engage
Disengage
Drive Controls
g356775
Dump Controls
g025722
Dump switch
Dump pedal
Lower the hopper
Dump the hopper
3461-467A Page 3–2 Product Overview: Controls

Fuel Gauge
g357274
Engine Controls
G356777
Recoil starter
Fuel shut-off valve
Choke lever
Throttle lever
Fuel tank shut off valve
On/Off switch
Choke Control
G356784
ENGAGE the choke before starting a
cold engine.
DISENGAGE the choke when the
engine is warm.
Product Overview: Controls Page 3–3 3461-467 A

Engine Controls (continued)
Engine On/Off Control
G356822
On
Off
Fuel Shutoff Controls
g356785s
Fuel tank shutoff control—use
when performing maintenance and
storing the machine.
Engine fuel shutoff control—use
before starting and after stopping the
machine.
Off
On
Recoil Starter
Use the recoil starter handle to start the engine.
Throttle Control
g357324
Specifications
Note: Specifications and design are subject to change without notice.
3461-467A Page 3–4 Product Overview: Specifications

Width (single wheel) 86 cm (34 inches)
Width (single wheel) 117 cm (46 inches)
Length 268 cm (105.5 inches)
Height 114.3 cm (45 inches)
Weight 621 kg (1370 lb)
Hopper capacity 0.45 m3(16 cu.ft.)
Maximum load 1136 kg (2500 lb)
Maximum load (single wheel) 850 kg (1875 lb)
Wheelbase 107 cm (42 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. Replacement parts and accessories
made by other manufacturers could be dangerous, and such use could void the product
warranty.
Product Overview: Attachments/Accessories Page 3–5 3461-467 A

Chapter 4
Operation
Before Operation
Before Operation Safety
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.
• 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 your hands and feet away
from these areas.
• Do not carry passengers on the machine.
• Keep bystanders, especially 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.
• Park the machine on a level surface, engage the parking brake, and shut off the engine.
Wait for all movement to stop and allow the machine to cool before adjusting, servicing,
cleaning, or storing the machine.
Fuel Safety
Use extreme care in handling fuel. It is flammable and its vapors are explosive.
• Extinguish all cigarettes, cigars, pipes, and other sources of ignition.
• Use only an approved container.
• Do not remove the fuel cap or fill the fuel tank while the engine is running or hot.
• Do not add or drain fuel in an enclosed space.
• Do not store the machine or fuel container where there is an open flame, spark, or pilot
light, such as on a water heater or other appliance.
3461-467 A Page 4–1 Operation

Before Operation Safety (continued)
• If you spill fuel, do not attempt to start the engine; avoid creating any source of ignition
until the fuel vapors have dissipated.
• Do not fill containers inside a vehicle or on a truck or trailer bed with a plastic liner.
Always place containers on the ground, away from your vehicle before filling.
• Remove the equipment from the truck or trailer and refuel it while it is on the ground. If
this is not possible, then refuel from a portable container rather than a fuel-dispenser
nozzle.
• Keep the fuel-dispenser nozzle in contact with the rim of the fuel tank or container
opening at all times until fueling is complete. Do not use a nozzle-lock-open device.
• Do not operate the machine without the entire exhaust system in place and working
properly.
• Fuel is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious
injury and illness.
– Avoid prolonged breathing of vapors.
– Keep your face away from the nozzle and fuel tank or conditioner opening.
– Keep fuel away from your eyes and skin.
Fuel
Fuel Specifications
Capacity 21.6 L (5.7 US gallons)
Type Unleaded gasoline
Minimum octane rating 87 (US) or 91 (research octane; outside the US)
Ethanol No more than 10% by volume
Methanol None
MTBE (methyl tertiary butyl ether) Less than 15% by volume
Oil Do not add to the fuel
Use only clean, fresh (no more than 30 days old), fuel from a reputable source.
IMPORTANT
To reduce starting problems, add fuel stabilizer/conditioner to fresh fuel as directed
by the fuel-stabilizer/conditioner manufacturer.
Operation: Before Operation Page 4–2 3461-467 A