Form No. 3326-661 Workman 2100 Utility Vehicle Model No. 07253—210001473 and Up Model No.
Warning Starting the Engine . . . . . . . . . . . . . . . . . . . . . . . . Stopping the Vehicle . . . . . . . . . . . . . . . . . . . . . . . Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . Cargo Bed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tailgate Latches . . . . . . . . . . . . . . . . . . . . . . . . . . New Vehicle Break-In . . . . . . . . . . . . . . . . . . . . . Loading the Cargo Box . . . . . . . . . . . . . . . . . . . . Transporting the Vehicle . . . . .
Supervisors, operators, and service persons should be familiar with the following standards and publications: (The material may be obtained from the address shown). • Flammable and Combustible Liquids Code: ANSI/NFPA 30 • National Fire Protection Association: ANSI/NFPA #505; Powered Industrial Trucks National Fire Prevention Association Barrymarch Park Quincy, Massachusetts 02269 U.S.A. 1 • ANSI/ASME B56.8 Personal Burden Carriers American National Standards Institute, Inc.
• Never allow other adults to operate the vehicle without first reading and understanding the Operator’s Manual. Only trained and authorized persons should operate this vehicle. Make sure that all operators are physically and mentally capable of operating the vehicle. While Operating Warning • This 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.
– Before backing up, look to the rear and ensure that no one is behind you. Back up slowly. standing water deep enough to get the brakes wet, they will not work well until they are dry. After driving through water, you should test the brakes to make sure they work properly. If they do not, drive slowly while putting light pressure on the brake pedal. This will dry the brakes out. – Watch out for traffic when you are near or crossing roads. Always yield the right of way to pedestrians and other vehicles.
• Always secure loads so that they do not shift. If a load is not secured, or you are transporting a liquid in a large container such as a sprayer, the load can shift. This shifting happens most often while turning, going up or down hills, suddenly changing speeds, or while driving over rough surfaces. Shifting loads can cause the vehicle to tip over. Operating on Rough Terrain Reduce speed and load when operating on rough terrain, uneven ground, and near curbs, holes, and other sudden changes in terrain.
• If the engine must be running to perform a maintenance adjustment, keep your hands, feet, clothing, and any parts of your body away from the engine and any moving parts. Keep everyone away. • Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. • Do not adjust the ground speed governor. To ensure safety and accuracy, have an Authorized Toro Distributor check the ground speed. • If major repairs are ever needed or assistance is required, contact an Authorized Toro Distributor.
Slope Chart ALIGN THIS EDGE WITH A VERTICAL SURFACE (TREE, BUILDING, FENCEPOST, POLE, ETC.) FOLD ALONG APPROPRIATE LINE. EXAMPLE: COMPARE SLOPE WITH FOLDED EDGE.
Safety and Instruction 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 lost. 99-7350 1. Maximum tongue weight is 50 lb. (23 kg) 99-7346 2. Maximum trailer weight is 400 lb. (181 kg) 1. Parking brake 2. Parking brake on 3. Parking brake off 99-7348 1. Read the operator’s manual for further instructions. 2. The maximum combined operator and passenger weight should not exceed 400 lb. (181 kg).
99-7343 1. 2. 3. 4. 5. 6. 7. 8. 9. Warning—read the operator’s manual. Only drive this vehicle off-highway. This vehicle is not made for use on public streets, roads, or highways. Do not carry passengers in the cargo bed. They may fall out of the vehicle. Do not allow children to operate this vehicle. Hour meter Headlights Ignition off Ignition on To start the vehicle, sit in the operator’s seat. Release the parking brake. Turn the ignition on. Pull the choke lever out (if needed). Depress the accelerator.
99-7352 1. Read the operator’s manual for information on fuses. 2. 10 amp. fuse for optional Road Light Kit 3. 15 amp. fuse for optional Rear Lift Kit 4. 10 amp. fuse—open 5. 10 amp. fuse for headlights 6. 10 amp. fuse for ignition system 7. 15 amp. fuse for optional Electric Bed Lift Kit Specifications Note: Specifications and design are subject to change without notice. Base weight Dry 1000 lb. (454 kg) Rated capacity (on level ground) 1650 lb. (749 kg) total, including 200 lb. (90.
Setup Note: Determine the left and right sides of the machine from the normal operating position. Loose Parts Note: Use the chart below to verify that all parts have been shipped. Description Qty. Use Wheel assembly 2 Installing the rear wheels (Model No. 07253TC) Wheel assembly 2 Washer 2 Dust cap 2 Steering wheel 1 Installing the steering wheel (Model No. 07253TC) Bumper 1 Installing the bumper (Model No. 07253TC) Hitch 1 Installing the hitch (Model No.
Installing the Rear Wheels 1 Note: This procedure is only needed for Model No. 07253TC. 3 1. Remove the fasteners securing the wheels. 4 2 2. Remove the shipping bracket secured to the wheel studs. 5 6 3. Mount the wheels with the previously removed fasteners (Fig. 2) and torque to 45–65 ft.-lb. (61–88 N⋅m). Figure 3 1. Tire and wheel assembly 2. Spindle 3. Small washer 1 4. Large washer 5. Screw 6. Dust cap 2 Installing the Steering Wheel 3 Note: This procedure is only needed for Model No.
Installing the Bumper Installing the Hitch Note: This procedure is only needed for Model No. 07253TC. Note: This procedure is only needed for Model No. 07253TC. 1. Remove the 2 bolts, washers, and nuts secured to the front of the frame. 1. Remove the 4 bolts and nuts from the inside rear of the frame. 2. Align the mounting holes and secure the bumper to the frame with the fasteners previously removed (Fig. 5). 2. Align the hitch with the mounting holes on the frame.
Activating the Battery Note: This procedure is only needed for Model No. 07253TC. If the battery is not filled with electrolyte or activated, it must be removed from the vehicle, filled with electrolyte, and charged. Bulk electrolyte with 1.260 specific gravity must be purchased from a local battery supply outlet. 1. Remove the rubber strap securing the battery to the battery base. Lift the battery out of the battery base.
Checking the Crankcase Oil Fuel Tank The engine is shipped with oil in the crankcase; however, the level of oil must be checked before and after the engine is first started. Recommended Gasoline 1. Position the machine on a level surface. Use fresh, clean, unleaded regular gasoline suitable for automotive use (85 pump octane minimum). Leaded gasoline may be used if unleaded regular is not available. 2. Remove the dipstick and wipe it with a clean rag (Fig. 11).
Filling the Fuel Tank Brake Pedal Fuel tank capacity is approximately 7 gallons. The brake pedal is used to stop or slow the vehicle (Fig. 13). 1. Shut the engine off and set the parking brake. 2. Clean the area around the fuel tank cap (Fig. 12). Caution Brakes can become worn or can be misadjusted resulting in personal injury. 1 If brake pedal travels to within 1 of the vehicle floor board, the brakes must be adjusted or repaired.
Light Switch Toggle the switch to activate the headlights. Push it to turn the lights on (Fig. 15). Power Point 1 The power point is used to power optional electrical accessories (Fig. 15). 3 2 4 Figure 14 1. Choke 2. Gear shift selector 2 Gear Shift Selector 1 5 m–4885 Figure 15 The gear shift selector moves the vehicle in the desired direction—forward or reverse (Fig. 14). The vehicle will start in either direction. 1. Ignition switch 2. Hour meter 3.
Passenger Hand Holds 2. Move the gear shift selector to the desired position. The passenger hand holds are located on the right side of the dash panel and at the outside of each seat (Fig. 17). 3. Slowly step on the accelerator pedal. Note: The parking brake will automatically disengage when the accelerator pedal is depressed. 2 Note: If the engine is cold, depress and hold the accelerator pedal about half-way down and pull the choke knob out to the On position.
New Vehicle Break-In To provide proper performance and long vehicle life, follow these guidelines for the first 100 operating hours: 1 • Check the fluid and engine oil levels regularly and be alert for indications of overheating in any component of the vehicle. • After starting a cold engine, let it warm up for about 15 seconds before accelerating. • Avoid hard braking situations for the first several hours of new vehicle break-in operation.
Transporting the Vehicle 3. Put the vehicle in neutral (see Neutral Lock Assembly, page 27) and release the parking brake. For moving the vehicle long distances, a trailer should be used. Make sure that the vehicle is secured to the trailer. Refer to Figures 21 and 22 for the location of the tie down points. Caution Loose seats may fall off of the vehicle and trailer when transporting and land on another vehicle or become an obstruction on the road.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Recommended Maintenance Schedule Maintenance Service Interval After first 8 hours Every 8 hours After first 20 hours Maintenance Procedure • Change the engine oil. • Check the drive belt tension. • Check the starter belt tension. • Check the engine oil. • Check the tire pressure. • Check the front wheel toe-in at the proper ride height. Every 50 hours • Check the battery fluid level.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Check the brake and parking brake operation. Check the gear shift operation. Check the fuel level. Check the engine oil level. Check the transaxle oil level. Inspect the air filter. Inspect the engine cooling fins. Check any unusual engine noises. Check any unusual operating noises. Check the tire pressure. Check for fluid leaks. Check the instrument operation.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition and disconnect the wire(s) from the spark plug(s) before you do any maintenance. Set the wire(s) aside so that it does not accidentally contact the spark plug(s). Jacking the Vehicle Warning Whenever the engine is run for routine maintenance and/or engine diagnostics, the rear wheels of the vehicle should be 1 in.
1 1 1 Figure 24 1. Rear jacking points Figure 26 1. Secondary clutch Neutral Lock Assembly When performing routine maintenance and/or engine diagnostics, the transaxle must be shifted into a neutral position. The vehicle does not have a neutral position on the shift lever. The following steps must be performed to put the vehicle in neutral: Servicing the Engine Oil Service Interval/Specification Check the oil level before each use. 1.
Changing and Draining the Oil Cleaning the Engine Cooling Areas 1. Start the vehicle and let it run for a few minutes to warm the oil. Clean the rotating screen, cooling fins, and external surfaces of the engine every 100 hours of operation or more often under extremely dusty and dirty conditions. 2. Park the machine on a level surface, set the parking brake, turn the ignition off, and remove the key. 3. Raise the bed and secure it with the prop rod.
4. Gently slide the filter out of the air cleaner body to reduce the amount of dust dislodged (Fig. 28). Avoid knocking the filter against the air cleaner body. Greasing the Machine 5. Inspect the filter and discard it if it is damaged. Lubricate all bearings and bushings after every 100 hours or once a year, whichever occurs first. Grease them more frequently when using the vehicle for heavy-duty operations.
2 1 m–4848 Figure 32 Figure 31 1. Cable adjusting screw Servicing the Brakes 2. Brake equalizer Inspecting the Tires Inspecting the Brakes Check the tire condition at least every 100 hours of operation. Operating accidents, such as hitting curbs, can damage a tire or rim and also disrupt wheel alignment, so inspect tire condition after an accident. Brakes are a critical safety component of the vehicle.
Replacing the Drive Belt 9. Repeat the procedure on the opposite side of the vehicle. 1. Rotate and route the belt over the secondary clutch (Fig. 34). 2. Remove the belt from the primary clutch (Fig. 34). 3. To replace the belt, reverse the procedure. Adjusting the Starter Generator Belt Check the tension of the starter generator belt after the first day of operation and every 200 operating hours thereafter. 1.
Adjusting Front Wheel Toe-In Servicing the Fuel System Check the front wheel toe-in after every 100 operating hours, or annually, whichever occurs first. Fuel Lines and Connections Check the lines and connections every 400 hours or yearly, whichever occurs first. Inspect them for deterioration, damage, or loose connections. 1. Ensure that the distance from the bottom of the tongue to the ground is 9 to 9-3/4 in. (22.9 to 24.8 cm) when the tires are inflated to 12 psi. (83 kPa).
Checking and Replacing the Spark Plug 1. Clean the area around the spark plugs so that foreign matter cannot fall into the cylinder when the spark plug is removed. 2. Pull the spark plug wires off of the spark plugs and remove the plugs from the cylinder head. 1 3. Check the condition of the side electrode, center electrode, and center electrode insulator to ensure that there is no damage. 2 m–4849 0.030 in. (0.762 mm) Figure 40 1. Drain plug 2. Level indicator hole 3. Fill the reservoir (Fig.
Replacing the Fuses There are 3 fuses in the electrical system. They are located beneath the bed in a box on the right hand side of the frame (Fig. 42). Ignition system 10 amp. Lights 10 amp. Power point 3 2 10 amp. (15 amp. max.) 4 1 Figure 43 1 1. Rubber seal 2. Inside notch—align with notch on headlight 2 3 6. Attach the headlight to the wire harness using the previously removed screws. m–5323 7. Align the notch on the outside of the seal with the notch in the hood.
Removing the Battery Installing the Battery 1. Position the vehicle on a level surface, set the parking brake, turn the ignition off, and remove the key. 1. Set the battery on the battery base so that the battery posts are toward the rear of the vehicle. 2. Raise the bed and secure it with the prop rod. 2. Connect the positive (red) cable to the positive (+) battery post and the negative (black) cable to the negative (–) battery post using the bolts and wing nuts.
Charging the Battery Washing the Vehicle Important Always keep the battery fully charged (1.260 specific gravity). This is especially important to prevent battery damage when the temperature is below 32°F (0°C). The vehicle should be washed as needed. Use water alone or with a mild detergent. A rag may be used, however the hood will loose some of its luster. Important Pressurized water is not recommended when washing the machine.
(–) (+) LOW OIL PRESSURE 37 ENGINE OIL PRESSURE P3–3 W/BU BU 2 5 OR F4 Y F1 10 A F2 10 A HEAD LIGHTS LIGHT SWITCH OPTIONAL FUSES 6 4 3 1 M+ M– KEY–SWITCH (OFF) 2 1 SPARK PLUG 10 A F3 BK PK BU BK IGNITION MODULES 1 4 2 3 BN/W BU R P3–2 GN VOLTAGE REGULATOR GN R A2 DF F2 BK HOUR METER BK (–) HR (+) BU BK armature fields 85 30 2 86 87a 87 R BN GY BK P3–1 BK BACKUP ALARM (+) (–) GY AIR VALVE ENGINE / FRAME GROUND BU SHUTDOWN MODULE SOLENOID
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
