Form No. 3392-850 Rev A Workman® HDX-D Utility Vehicle with Bed Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 07385—Serial No. 315000001 and Up 07385H—Serial No. 315000001 and Up 07385TC—Serial No. 315000001 and Up 07387—Serial No. 315000001 and Up 07387H—Serial No. 315000001 and Up 07387TC—Serial No.
WARNING CALIFORNIA Proposition 65 Warning This product contains a chemical or chemicals known to the State of California to cause cancer, birth defects, or reproductive harm. Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Figure 1 1. Model and serial number location This machine is a utility vehicle intended to be used by professional, hired operators in commercial applications.
Contents Raising the Machine................................................36 Removing the Hood ...............................................37 Installing the Hood.................................................37 Lubrication ...............................................................38 Greasing the Bearings and Bushings ..........................38 Engine Maintenance ..................................................40 Servicing the Air Cleaner .........................................
Safety Improper use or maintenance by the operator or owner 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. Operation • The operator and passenger must use seat belts and remain seated whenever the machine is in motion.
• Slow the machine down before starting up or down a hill. • If the engine stalls or you begin to lose momentum while 4. Remove the starter key. • Note: If the machine is on an incline, block the wheels after getting off of the machine. Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter. • • Braking • Slow down before you approach an obstacle. This gives • • • you extra time to stop or turn away.
Whole Body • Be aware that the stability and control of the machine are reduced when the load in the cargo box is poorly distributed. • Measured vibration level = 0.3 m/s2 • Uncertainty Value (K) = 0.5 m/s2 • Carrying oversized loads in the cargo box changes the stability of the machine. Measured values were determined according to the procedures outlined in EN 1032.
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 lost. 106-6755 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual. 115-7740 1. Warning—maximum trailer weight is 680 kg (1500 lb), maximum tongue weight is 90 kg (200 lb). 2.
115-2282 1. Warning—read the Operator's Manual. 2. Warning—stay away from moving parts, keep all guards and shields in place. 3. Crushing/dismemberment hazard of bystanders—keep bystanders a safe distance from the vehicle, do not carry passengers in the cargo bed, keep arms and legs inside of the vehicle at all times, and use seat belts and handholds. 115-7746 1. Warning—do not operate this machine unless you are trained. 3. Fire hazard—stop the engine before fueling. 2.
3-9879 1. Stored energy hazard—read the Operator's Manual. Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6. Keep bystanders a safe distance from the battery. 2. No fire, open flame, or smoking. 7. Wear eye protection; explosive gases can cause blindness and other injuries 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 5.
6-2377 1. Locked 2. Differential lock 3. Unlocked 8. Warning—read the Operator's Manual. 9. Entanglement hazard, shaft—keep bystander's a safe distance from the vehicle. 10. Retract hydraulics 4. Hydraulic lock 11. Extend hydraulics 5. Engage 12. Transmission—high speed 6. Power take-off (PTO) 13. Transmission—low speed 7. Disengage 14. Parking brake 115-2281 1. Headlights 4. Engine—run 2. Horn 5. Engine—start 3.
121-6287 121-6286 1. Read the Operator's Manual before checking the engine coolant level. 1. Fill the reservoir with engine coolant to the bottom of the standpipe. 2. Do not add engine coolant to the radiator; add engine coolant to the reservoir, 93-9852 1. Warning—read the Operator’s Manual. 2. Crushing hazard—install the cylinder lock.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 Description Use Qty. Steering wheel 1 Install the steering wheel (TC models only). ROPS frame Bolt (1/2 inch) 1 6 Mount the Rollover Protection System (ROPS). No parts required – Check the engine oil, the transaxle/hydraulic fluid, and the brake fluid levels. Note: Determine the left and right side of the machine from the normal operating position.
2 3 Installing the Rollover Protection System (ROPS) Checking the Fluid Levels No Parts Required Parts needed for this procedure: 1 ROPS frame 6 Bolt (1/2 inch) Procedure 1. Check the engine-oil level before and after the engine is first started; refer to Checking the Engine-oil Level (page 19). Procedure 2. Check the transaxle/hydraulic-fluid level before the engine is first started; refer to Checking the Transaxle/Hydraulic-fluid Level (page 21). 1.
Product Overview Gear-shift Lever Controls Fully press the clutch pedal and move the shift lever (Figure 6) into the desired gear selection. A diagram of the shift pattern is shown below. Note: Determine the left and right sides of the machine from the normal operating position. Accelerator Pedal The accelerator pedal (Figure 5) gives the operator the ability to vary the engine and ground speed of the machine when the transmission is in gear.
• Press the clutch pedal fully. • Move the lever fully forward for High and fully rearward for Low. High is for higher speed driving on level, dry surfaces with light loads. Low is for low-speed driving. Use this range when greater than normal power or control is required. For example, steep grades, difficult terrain, heavy loads, slow speed but high-engine speed (spraying). Important: There is a location between High and Low in which the transaxle is in neither range.
Hour Meter engine, and check for possible causes, such as the alternator belt (Figure 8). Indicates the total hours of machine operation. The hour meter (Figure 8) starts to function whenever the key switch is rotated to the On position or if the engine is running. Important: If the alternator belt is loose or broken, do not operate the machine until adjustment or repair is complete. Failure to observe this precaution may result in damage to the engine.
Speedometer Specifications Registers the ground speed of the machine (Figure 8). The speedometer is in mph but can easily converted to km/h; refer to Converting the Speedometer (page 51). Note: Specifications and design are subject to change without notice. Dimensions Power Point Use the power point (Figure 8) to power optional 12 volt electrical accessories.
Operation Note: Determine the left and right sides of the machine from the normal operating position. CAUTION Before servicing or making adjustments to the machine, stop the engine, set the parking brake, and remove the key from the switch. Remove any load material from the bed or other attachment before working under a raised bed. Never work under a raised bed without positioning the safety support on a fully extended cylinder rod. Figure 12 1.
engine has already ran, allow the oil to drain back down to the sump for at least 10 minutes before checking. If the oil level is at or below the Add mark on the dipstick, add oil to bring the oil level to the Full mark. Do not overfill the engine with oil. If the oil level is between the Full and Add marks, no additional oil is required. 1. Position the machine on a level surface. 2. Remove the dipstick and wipe it with a clean rag (Figure 15). Figure 13 1. Latch handle 3. Latch pin 2.
Adding Fuel Using Biodiesel Fuel Fuel tank capacity: 22 L (5.85 US gallons). This machine can also use a biodiesel blended fuel of up to B20 (20% biodiesel, 80% petrodiesel). The petrodiesel portion should be low or ultra low sulfur. Observe the following precautions: Use only clean, fresh diesel fuel or biodiesel fuels with low (<500 ppm) or ultra low (<15 ppm) sulfur content. The minimum cetane rating should be 40. Purchase fuel in quantities that can be used within 180 days to ensure fuel freshness.
Checking the Coolant Level 3. If coolant is low, remove the reserve tank cap and add a 50/50 mixture of water and permanent ethylene-glycol antifreeze. Service Interval: Before each use or daily Cooling system capacity: 3.7 L (4 US qt) Note: Do not overfill the reserve tank with coolant. Coolant type: a 50/50 solution of water and permanent ethylene-glycol antifreeze. 4. Install the reserve-tank cap.
Checking the High Flow Hydraulic-fluid Level (TC models only) 4. Insert the dipstick into the filler neck, then remove it and check the fluid level. Service Interval: Before each use or daily (check the level of hydraulic fluid before the engine is first started, and daily thereafter) 5. If the level is low, add the appropriate fluid to raise the level to the upper mark; refer to Changing the High-flow Hydraulic fluid and Filter (TC models only) (page 53).
Checking the Tire Pressure Service Interval: Before each use or daily The air pressure in the front tires is 220 kPa (32 psi) and the rear tires is 124 kPa (18 psi). Check the tire pressure frequently to ensure proper inflation. If the tires are not inflated to the correct pressure, the tires will wear prematurely. Figure 21 is an example of tire wear caused by under inflation. Figure 20 1. Fill/check plug 2. Drain plug 3. Remove the fill/check plug and check the level of the oil.
5. Keep your foot off of the accelerator pedal. 6. Turn the starter switch to the On position. When the glow plug indicator light goes off, the engine is ready to start. 7. Rotate the starter key switch to the Start position. Release the key immediately when the engine starts and allow it to return to the Run position. Note: The glow plug indicator will turn on for an additional 15 seconds, when the switch returns to the Run position.
Checking the Safety-interlock System Stopping the Machine To stop the machine, remove your foot from the accelerator pedal, press the clutch pedal, then press the brake pedal. Service Interval: Before each use or daily The purpose of the safety-interlock system is to prevent the engine from cranking or starting unless the clutch pedal is pressed. Stopping the Engine To stop the engine, rotate the starter key to the Off position and engage the parking brake.
Ensuring Passenger Safety Ensuring Proper Speed Whenever you have a passenger riding in the machine, make sure he or she is wearing the seat belt and holding on securely. Drive slower and turn less sharply because your passenger does not know what you are going to do next and may not be prepared for turning, stopping, accelerating, and bumps. Speed is one of the most important variables leading to accidents. Driving too fast for the conditions can cause you to lose control and have an accident.
and cautiously as possible. Never make sharp or fast turns on a hill. Do not downshift for braking on icy or slippery surfaces (wet grass) or while going down a hill because engine braking may cause skidding and loss of control. Shift to a lower gear before starting down a hill. If you stall or begin to lose headway while climbing a steep hill, quickly apply the brakes, shift to neutral, start the engine and shift to reverse.
If the load is positioned toward one of the sides, it will make the machine much more likely to tip over on that side. This is especially true when turning if the load is on the outside of the turn. WARNING Tipping or rolling the machine on a hill will cause serious injury. • The extra traction available with the differential lock can be enough to get you into dangerous situations such as climbing slopes that are too steep to turn around.
Towing a Trailer with the Machine and transport and secure it separately or the hood may blow off during transport. The machine is capable of pulling trailers and attachments of greater weight than the machine itself. Several types of tow hitches are available for the machine, depending on your application. Contact your Authorized Toro Distributor for details.
Using the Hydraulic-bed Lift Lever to Control Hydraulic Attachments hydraulic motor. This position must only be used on attachments with a hydraulic motor attached. • Off Position Important: If used with a hydraulic cylinder or no attachment, the On position causes the hydraulic-fluid flow to go over a relief valve which can damage the hydraulic system. Use this position only momentarily or with a motor attached. This is the normal position for the control valve when it is not being used.
Troubleshooting the Hydraulic Control • Difficulty in connecting or disconnecting quick couplers. The pressure not relieved (the quick coupler is under pressure). • The power steering is turning with great difficulty or it is not turning at all. – The hydraulic-fluid level is low. – The hydraulic-fluid temperature is hot. – The pump is not operating. • There are hydraulic leaks. – The fittings are loose. – The fitting is missing the o-ring. • An attachment does not function.
Maintenance Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 2 hours • Torque the front and rear wheel nuts. After the first 8 hours • Check the condition and tension of the alternator belt. After the first 10 hours • • • • • After the first 50 hours • Change the engine oil and filter. • Adjust the engine valve clearance. Before each use or daily Torque the front and rear wheel nuts. Check the adjustment of the shift cables.
Maintenance Service Interval Every 800 hours Every 1,000 hours Maintenance Procedure • • • • Change the front-differential oil. Change the hydraulic fluid and clean the strainer. Replace the hydraulic filter. Change the high-flow hydraulic fluid and filter (TC models only). • Change the brake fluid. • Drain/flush the fuel tank. • Flush or replace the coolant-system fluid. Note: Determine the left and right sides of the machine from the normal operating position.
Premaintenance Procedures Many of the subjects covered in this maintenance section require raising and lowering the bed. The following precautions must be taken or serious injury or death could result. WARNING Before servicing or making adjustments to the machine, stop engine, set parking brake, and remove the key from the starter switch. Remove any load material from the bed or other attachment before working under a raised bed.
Installing the Full Bed Removing the Full Bed 1. Start the engine, engage the hydraulic-lift lever, and lower the bed until the cylinders are loose in the slots. Note: If the bed sides will be installed on the flat bed, it is easier to install them before installing the bed on the machine. 2. Release the lift lever and turn off the engine. Note: Ensure that the rear pivot plates are bolted to the bed frame/channel so that lower end angles to the rear (Figure 33). 3.
Raising the Machine DANGER A machine on a jack may be unstable and slip off of the jack, injuring anyone beneath it. • Do not start the machine while the machine is on a jack. • Always remove the key from the switch before getting off of the machine. • Block the tires when the machine is on a jack. • Do not start the engine while the machine is on a jack, because the engine vibration or wheel movement could cause the machine to slip off of the jack. Figure 34 1. Wear block 3.
Installing the Hood 1. Connect the lights. 2. Insert the top mounting tabs into the frame slots. 3. Insert the lower mounting tabs into the frame slots. 4. Ensure that the hood is fully engaged in the top, sides and bottom grooves. Figure 36 1. Rear jacking points Removing the Hood 1. While grasping the hood in the headlight openings, lift up on the hood to release the lower mounting tabs from the frame slots (Figure 37). Figure 37 1. Hood 2.
Lubrication Greasing the Bearings and Bushings Service Interval: Every 100 hours (lubricate more frequently in heavy duty applications). The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium-Base Grease. The grease fitting locations and quantities are as follows: • Ball joints (4), tie rods (2), pivot mounts (2) and steering cylinder (2) (Figure 38) • Spring tower (2) (Figure 39) Figure 39 • Clutch (1), accelerator (1), brake (qty.
Figure 41 39
Engine Maintenance Note: Inspect the element for tears, an oily film, or damage to the rubber seal. If the filter is damaged do not use it. Servicing the Air Cleaner 6. If you are replacing the safety filter, carefully slide the new filter into the filter body (Figure 42). Service Interval: Before each use or daily—Check the air filter service indicator. Every 25 hours Every 600 hours—Change the safety air filter (more frequently in dusty or dirty conditions).
Fuel System Maintenance Checking the Fuel Lines and Connections Service Interval: Every 400 hours/Yearly (whichever comes first) Figure 44 1. Engine oil-drain plug Every 1,000 hours/Every 2 years (whichever comes first) 3. When the oil stops, install the drain plug. Inspect the fuel lines and connections for deterioration, damage, or loose connections. 4. Remove the oil filter (Figure 45).
Changing the Fuel-filter Canister Electrical System Maintenance Service Interval: Every 400 hours—Replace the fuel-filter canister. 1. Drain the water from the water separator; refer to Draining the Fuel Filter/Water Separator (page 41). Servicing the Fuses 2. Clean the area where the filter-canister mounts (Figure 46). The fuses for the electrical system are located under the center of the dash panel (Figure 47 and Figure 48). 3. Remove the filter canister and clean the mounting surface. 4.
Jump Starting the Machine Connect the jumper cable to the engine or frame. Do not connect the jumper cable to the fuel system. WARNING Jump starting can be dangerous. To avoid personal injury or damage to electrical components in machine, observe the following warnings: • Never jump start with a voltage source greater than 15 volts DC This will damage the electrical system. • Never attempt to jump start a discharged battery that is frozen. It could rupture or explode during jump starting.
Servicing the Battery Drive System Maintenance Service Interval: Every 50 hours—Check the battery-fluid level (every 30 days if in storage). Every 50 hours—Check the battery-cable connections. Changing the Front-differential Oil (4-wheel drive models only) WARNING CALIFORNIA Proposition 65 Warning 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.
Adjusting the Shift Cables Service Interval: After the first 10 hours Every 200 hours 1. Move the shift lever to the Neutral position. 2. Remove the clevis pins securing the shift cables to the transaxle-shift arms (Figure 52). Figure 53 3. Spring 2. Transaxle bracket 4. 0.25 to 1.5 mm (0.01 to 0.06 inch) gap 3. Adjust the jam nuts to obtain a 0.25 to 1.5 mm (0.01 to 0.06 inch) gap between the spring hook and the OD of the hole in the transaxle lever. Figure 52 1. Shift arm (1st to reverse) 1.
Figure 55 1. Over-inflated tire Figure 57 Checking the Front Wheel Alignment 1. Tie rods Service Interval: Every 400 hours/Yearly (whichever comes first) B. Rotate the tie rod to move the front of the tire inward or outward to achieve the center to center distances from front to back. C. Tighten the tie rod jam nut when the adjustment is correct. D. Check to ensure that the tires turn an equal amount to the right and to the left. 1. Make sure the tires are facing straight ahead. 2.
Cooling System Maintenance 5. Install the cooler and screen to the radiator. Changing the Engine Coolant Service Interval: Every 1,000 hours/Every 2 years (whichever comes first) Removing Debris from the Cooling System Coolant type: 50/50 mixture of water and permanent ethylene-glycol antifreeze Service Interval: Before each use or daily (clean more frequently in dirty conditions). 1. Park the machine on a level surface. 1. Turn the engine off and clean the engine area thoroughly of all debris. 2.
Brake Maintenance Adjusting the Parking Brake Service Interval: After the first 10 hours Every 200 hours 1. Remove the rubber grip from the parking-brake lever (Figure 62). Figure 61 Figure 62 1. Reserve tank-cap 1. Parking-brake lever 2. Reserve tank 2. Grip 5. Disconnect the lower radiator hose and allow coolant to flow into a drain pan. 2. Loosen the set screw securing the knob to the parking brake lever (Figure 63). 6. When coolant stops, connect the lower radiator hose. 3.
Adjusting the Brake Pedal Service Interval: Every 200 hours Note: Remove the font hoot to ease the adjustment procedure. 1. Remove the cotter pin and clevis pin securing the master cylinder yoke to the brake-pedal pivot (Figure 64). Figure 65 1. Brake pedal Figure 64 1. Master cylinder yoke 2. Brake-pedal pivot 2. Lift up on the brake pedal (Figure 65) until it contacts the frame. 3. Loosen the jam nuts securing the yoke to the master cylinder shaft (Figure 65). 4.
Belt Maintenance Controls System Maintenance Adjusting the Alternator Belt Adjusting the Accelerator Pedal Service Interval: After the first 8 hours—Check the condition and tension of the alternator belt. 1. Position the machine on a level surface, stop the engine, and engage the parking brake. Every 200 hours—Check the condition and tension of the alternator belt. 2. Adjust the ball joint on the accelerator cable (Figure 67) to allow 2.54 to 6.35 mm (0.100 to 0.
Adjusting the Clutch Pedal Note: Adjust again if it is necessary. 6. Connect the return spring to the clutch lever. Service Interval: Every 200 hours Important: Ensure that the rod end is positioned squarely on the ball, not twisted, and remains parallel to the clutch pedal after the jam nut is tightened (Figure 71). Note: You can adjust the clutch-pedal cable at the bell housing or at the clutch-pedal pivot. The front hood can be removed to ease the access to the pedal pivot. 1.
Hydraulic System Maintenance Changing the Hydraulic fluid and Cleaning the Strainer Service Interval: Every 800 hours Hydraulic-fluid capacity: approximately 7 L (7.5 US qt) Hydraulic-fluid type: Dexron III ATF 1. Position the machine on a level surface, stop the engine, engage the parking brake, and remove the key from the starter switch. Figure 73 2. Remove the drain plug from the side of the reservoir, and let the hydraulic fluid flow into a drain pan (Figure 72). 1. Hydraulic strainer 6.
• Pour Point, ASTM D97— -35ºF to -46ºF • FZG, Fail stage—11 or better • Water content (new fluid)—500 ppm (maximum) Industry Specifications: Vickers I-286-S, Vickers M-2950-S, Denison HF-0, Vickers 35 VQ 25 (Eaton ATS373-C) Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks. A red dye additive for the hydraulic system fluid is available in 20 ml (2/3 oz.) bottles. One bottle is sufficient for 15–22 1 (4–6 gal) of hydraulic fluid. Order part no.
Raising the Cargo Box by Jumping the Hydraulic System CAUTION Before servicing or making adjustments to the machine, stop the engine, set the parking brake, and remove the key from the switch. Remove all load material that is loaded into the bed or other attachment before working under a raised bed. Never work under a raised bed without positioning the safety support on the fully extended cylinder rod.
Cleaning Storage Washing the Machine 1. Position the machine on a level surface, set the parking brake, stop the engine, and remove the starter key. The machine should be washed as needed. Use water alone or with a mild detergent. A rag may be used when washing the machine, however the hood will loose some of its luster. 2. Clean dirt and grime from the entire machine, including the outside of the engine cylinder head fins and blower housing.
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International Distributor List Distributor: Country: Phone Number: Distributor: Phone Number: 57 1 236 4079 Colombia Japan 81 3 3252 2285 Czech Republic 420 255 704 220 420 255 704 Slovakia 220 Argentina 54 11 4 821 9999 Russia 7 495 411 61 20 Ecuador 593 4 239 6970 Finland 358 987 00733 Agrolanc Kft Balama Prima Engineering Equip. B-Ray Corporation Hungary Hong Kong Korea 36 27 539 640 852 2155 2163 82 32 551 2076 Maquiver S.A. Maruyama Mfg. Co. Inc. Mountfield a.s.
Toro General Commercial Product 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 Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
