Form No. 3414-280 Rev A Workman® HDX-D Utility Vehicle with Bed Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 07385—Serial No. 316000001 and Up 07385—Serial No. 400000000 and Up 07385H—Serial No. 316000001 and Up 07385TC—Serial No. 316000001 and Up 07385TC—Serial No. 400000000 and Up 07387—Serial No. 316000501 and Up 07387—Serial No. 400000000 and Up 07387H—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. g002070 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 Lubrication ...............................................................42 Greasing the Bearings and Bushings ..........................42 Engine Maintenance ..................................................44 Servicing the Air Cleaner .........................................44 Changing the Engine Oil and Filter ...........................44 Fuel System Maintenance ...........................................45 Checking the Fuel Lines and Connections ..................
Safety • Never operate the machine when tired, ill, or under the 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. • Wear substantial, slip-resistant shoes. Do not wear influence of drugs or alcohol.
• • equipment with a portable container rather than from a fuel-dispenser nozzle. If fuel is spilled on clothing, change clothing immediately. Never overfill the fuel tank. Replace the fuel cap and tighten it securely. – Watch for holes or other hidden hazards. – Use caution when operating the machine on a slope. Normally, travel straight up and down slopes. Reduce your speed when making sharp turns or when turning on hillsides. Avoid turning on hillsides whenever possible.
• Before getting off the seat: Take these precautions when operating the machine on a hill: • Slow the machine down before starting up or down a hill. • If the engine stalls or you begin to lose momentum while climbing a hill, gradually apply the brakes and slowly back the machine straight down the hill. • Turning while traveling up or down hills can be dangerous. If you have to turn while on a hill, do it slowly and cautiously. Never make sharp or fast turns. • Heavy loads affect stability.
• The steering, braking , and stability of the machine are relieved by shutting off the engine, cycling the dump valve from raise to lower and/or lowering box and attachments. Place the remote hydraulics lever in the float position. If the box must be in raised position, secure it with the safety support. affected when carrying a load where the weight of the material cannot be bound to the machine, such as the liquid in a large tank.
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. decal106-6755 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. decal136-1163 136-1163 1. Do not exceed a transport load of 1591 kg (3,500 lb). 2.
decal121-9776 121-9776 1. Warning—read the Operator’s Manual and receive proper training before operating the machine. 4. Warning—engage the parking brake, shut off the engine, and remove the key from the key switch before walking away from the machine. 5. Tipping hazard—take turns slowly; drive slowly up and across cliffs; with no load, do not exceed 32 kph (20 mph); while carrying a load or when driving on uneven terrain, drive slowly. 2. Warning—wear hearing protection. 3.
decal93-9879 93-9879 1. Stored energy hazard—read the Operator's Manual. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders a safe distance away 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.
decal106-2377 106-2377 1. Locked 8. Warning—read the Operator's Manual. 2. Differential lock 9. Entanglement hazard, shaft—keep bystander's a safe distance away from the machine. 3. Unlocked 10. Retract hydraulics 4. Hydraulic lock 11. Extend hydraulics 5. Engage 12. Transmission—high speed 6. Power takeoff (PTO) 13. Transmission—low speed 7. Disengage 14. Parking brake decal115-2281 115-2281 1. Headlights 4. Engine—run 2. Horn 5. Engine—start 3.
decal121-6287 121-6287 decal121-6286 121-6286 1. The coolant level must be checked daily before use. 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 open or add coolant to the radiator; doing so introduces air into the system and results in engine damage. Add only engine coolant to the reservoir. decal93-9852 93-9852 1. Warning—read the Operator’s Manual. 2.
decal115-7814 115-7814 13
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 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). 3 No parts required – Check the engine oil, the transaxle/hydraulic fluid, and the brake-fluid levels. 4 5 No parts required – Adjust the ball switch. No parts required – Burnish (break-in) the brakes.
2 3 Installing the Checking the Fluid Levels Rollover-Protection System No Parts Required (ROPS) Procedure Parts needed for this procedure: 1 ROPS frame 6 Bolt (1/2 inch) 1. Check the engine-oil level before and after the engine is first started; refer to Checking the Engine-Oil Level (page 22). 2. Check the transaxle/hydraulic-fluid level before the engine is first started; refer to Checking the Transaxle/Hydraulic-Fluid Level (page 25). Procedure 3.
4 5 Adjusting the Ball Switch Burnishing the Brakes No Parts Required No Parts Required Procedure Procedure 1. Move the shift lever to the NEUTRAL position. To ensure optimum performance of the brake system, burnish (break-in) the brakes before use. 2. Ensure that the ball switch is in front of the bump on the shift lever (Figure 5). 1. Bring the machine up to full speed, apply the brakes to rapidly stop the machine without locking up the tires. 2.
Product Overview CAUTION Worn or maladjusted brakes may result in personal injury. Controls If the brake pedal travels to within 3.8 cm (1-1/2 inches) of the machine floor board, the brakes must be adjusted or repaired. Note: Determine the left and right sides of the machine from the normal operating position. Accelerator Pedal Gear-Shift Lever The accelerator pedal (Figure 6) gives the operator the ability to vary the engine and ground speed of the machine when the transmission is in gear.
• The machine must be completely stopped before shifting between the HIGH and LOW range. • Shift only on level ground. • 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).
Hour Meter position (Figure 9). The indicator light blinks red if the engine overheats. The hour meter indicates the total hours of machine operation. The hour meter (Figure 9) starts to function whenever you rotate the key switch to the ON position or if the engine is running. Charge Indicator The charge indicator illuminates when the battery is discharging.
Tachometer Passenger Handhold Registers the speed of the engine (Figure 9 and Figure 10). The white triangle indicates 540 rpm for PTO operation (Figure 10). The passenger handhold is located on the dashboard (Figure 11). g010514 Figure 10 g009815 1. Speed of the engine Figure 11 2. 3,300 rpm for 540 rpm PTO operation 1. Passenger handhold Speedometer 2. Storage compartment Seat-Adjustment Lever The speedometer registers the ground speed of the machine (Figure 9).
Specifications Operation Note: Specifications and design are subject to change without notice. Note: Determine the left and right sides of the machine from the normal operating position. Dimensions Overall Width CAUTION 160 cm (63 inches) A raised bed full of material without the proper safety support may lower unexpectedly. Working under an unsupported raised bed may cause injury to you or others.
g024612 Figure 13 1. Cargo-box lever Lowering the Box WARNING g026141 Figure 14 The weight of the box may be heavy. Hands or other body parts could be crushed. 1. Latch handle 3. Latch pin 2. Latch gate Keep your hands and other body parts away when lowering the box. Checking the Engine-Oil Level Move the lever forward to lower the cargo box (Figure 13). Opening the Tailgate 1. Ensure that the cargo box is lowered completely. Service Interval: Before each use or daily 2.
Note: The best time to check the engine oil is when the engine is cool before it has been started for the day. If it 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.
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 the 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 3. Remove the dipstick (Figure 21) from the filler neck and wipe it with a clean rag. 4. Insert the dipstick into the filler neck, then remove it and check the fluid level. TC Models Only Note: The fluid level should be between the 2 marks on the dipstick. Service Interval: Before each use or daily (check the level of hydraulic fluid before the engine is first started, and daily thereafter). 5.
Checking the Tire Pressure Checking the Front-Differential-Oil Level Service Interval: Before each use or daily 4-Wheel-Drive Models Only The air pressure in the front tires should be 220 kPa (32 psi) and the rear tires should be 124 kPa (18 psi). Service Interval: Every 100 hours/Monthly (whichever comes first) Important: Check the tire pressure frequently to ensure proper inflation.
Checking the Brake-Fluid Level Service Interval: Before each use or daily—Check the brake-fluid level. (Check the level before the engine is first started and every 8 hours or daily, thereafter.) Every 1,000 hours/Every 2 years (whichever comes first)—Change the brake fluid. Brake fluid type: DOT 3 brake fluid The brake-fluid reservoir is located under the dash. 1. Park the machine on a level surface. 2. Ensure that the fluid level is up to the Full line on the reservoir (Figure 25). g009817 Figure 26 1.
Starting the Engine Use the chart below to determine the ground speed of the machine at 3,600 rpm. 1. Sit on the operator’s seat and engage the parking brake. Gear Range Ratio Speed (kmh) Speed (mph) 1 L 82.83 : 1 4.7 2.9 2 L 54.52 : 1 7.2 4.5 3 L 31.56 : 1 12.5 7.7 1 H 32.31 : 1 12.2 7.6 2 H 21.27 : 1 18.5 11.5 5. Keep your foot off the accelerator pedal. 3 H 12.31 : 1 31.9 19.8 6. Rotate the key switch to the ON position. R L 86.94 : 1 4.5 2.8 R H 33.
Checking the Safety-Interlock System Ensuring Passenger Safety Whenever you have a passenger riding in the machine, make sure that 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.
Ensuring Proper Speed 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. Speed is an important variable leading to accidents. Driving too fast for the conditions can cause you to lose control and have an accident. Speed can also make a minor accident worse.
at a slow speed and without a load, tip-overs are more likely if you turn on a hill. The height and weight of the load has a significant influence on tip overs. The higher a load is stacked, the more likely the machine is to tip over. You may find that 1477 kg (3,249 lb) stacks too high for safe operation. Reducing the total weight is one way to reduce the risk of a tip over. Distributing the load as low as possible is another way to reduce the risk of a tip-over.
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. Be extra careful when operating with the differential lock on, especially on steeper slopes.
Towing a Trailer with the Machine Using the Hydraulic-Bed-Lift Lever to Control Hydraulic Attachments • OFF Position The machine is capable of pulling trailers and attachments of greater weight than the machine itself. This is the normal position for the control valve when it is not in use. In this position, the work ports of the control valve are blocked and any load is held by the check valves in both directions.
Troubleshooting the Hydraulic Control to flow continuously to equipment that uses a hydraulic motor. Use this position only on attachments with a hydraulic motor attached. • Difficulty in connecting or disconnecting quick couplers. Important: If you use it 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.
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 (4-wheel-drive models only). 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.
Pre-Maintenance Procedures 3. Push the bed support onto the cylinder rod, ensuring that the support end tabs rest on the end of the cylinder barrel, and on the cylinder-rod end (Figure 33). Many of the subjects covered in this maintenance section require raising and lowering the bed. To prevent serious injury or death, take the following precautions. WARNING A raised bed full of material without the proper safety support rod may lower unexpectedly.
Removing the Full Bed Installing 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 you install the bed sides on the flat bed, it is easier to install them before installing the bed on the machine. 2. Release the lift lever and shut off the engine. Note: Ensure that the rear pivot plates are bolted to the bed frame/channel so that the lower end angles to the rear (Figure 35). 3.
Raising the Machine DANGER A machine on a jack may be unstable and slip off the jack, injuring anyone beneath it. • Do not start the machine while the machine is on a jack. • Always remove the key from the key 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, g002370 because the engine vibration or wheel movement could cause the machine to slip off the jack. Figure 36 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. g009824 Figure 38 1. Rear jacking points Removing the Hood 1. While grasping the hood in the headlight openings, lift up the hood to release the lower mounting tabs from the frame slots (Figure 39). g010314 Figure 39 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 lithium grease.
g010359 Figure 43 43
Engine Maintenance Note: Take special care to keep particulates from dropping into the clean areas of the air-filter housing. 5. Carefully slide the filter over the body tube (Figure 44). Servicing the Air Cleaner Note: Ensure that it is fully seated by pushing on the outer rim of the filter while installing it. Service Interval: Every 25 hours—Remove the air-cleaner cover and clean out the debris. Every 100 hours—Change the air-cleaner filter (more frequently in dusty or dirty conditions). 6.
Fuel System Maintenance Checking the Fuel Lines and Connections Service Interval: Every 400 hours/Yearly (whichever comes first) Every 1,000 hours/Every 2 years (whichever comes first) G021292 2 1 Inspect the fuel lines and connections for deterioration, damage, or loose connections. g021292 Figure 46 1. Engine-oil-drain plug Servicing the Fuel Filter/Water Separator 2. Engine-oil filter 3. When the oil stops, install the drain plug. Draining the Fuel Filter/Water Separator 4.
Changing the Fuel Filter Electrical System Maintenance Service Interval: Every 400 hours—Replace the fuel filter. 1. Drain the water from the water separator; refer to Draining the Fuel Filter/Water Separator (page 45). Servicing the Fuses 2. Clean the area where the filter mounts (Figure 47). 3. Remove the filter and clean the mounting surface. The fuses for the electrical system are located under the center of the dash panel (Figure 48 and Figure 49). 4.
Jump-Starting the Machine Note: Do not connect the other end of the jumper cable to the negative post of the discharged battery. Connect the jumper cable to the engine or frame. Do not connect the jumper cable to the fuel system. WARNING Jump-starting the machine can be dangerous, causing personal injury or damage to the electrical components in the machine. • Never jump-start with a voltage source greater than 15 VDC; this damages the electrical system.
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 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.
Inspecting the Constant-Velocity Boot Adjusting the High-to-Low Cable 4-Wheel-Drive Models Only Service Interval: Every 200 hours 1. Remove the clevis pin securing the high-to-low cable to the transaxle (Figure 53). Service Interval: Every 200 hours (4-wheel-drive models only). 2. Loosen the clevis jam nut and adjust the clevis so that the clevis hole aligns with the hole in the transaxle bracket. Inspect the constant-velocity boot for cracks, holes, or a loose clamp.
Inspecting the Tires Note: The measurement must be within 0 ± 3 mm (0 ± 0.12 inch) at the front of the tire then at the rear of the tire. Rotate the tire 90° and check the measurement. Service Interval: Every 100 hours Important: Check the measurements at consistent locations on the tire. The machine should be on a flat surface with the tires facing straight ahead. The air pressure in the front tires should be 220 kPa (32 psi) and the rear tires should be 124 kPa (18 psi).
Cooling System Maintenance 5. Install the cooler and screen to the radiator. Changing the Engine Coolant Removing Debris from the Cooling System Service Interval: Every 1,000 hours/Every 2 years (whichever comes first) Service Interval: Before each use or daily (clean more frequently in dirty conditions). Coolant type: 50/50 mixture of water and permanent ethylene-glycol antifreeze 1. Turn the engine off and clean the engine area thoroughly of all debris.
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 63). g026143 Figure 62 1. Reserve tank-cap g033487 2. Reserve tank Figure 63 1. Grip 5. Disconnect the lower radiator hose and allow coolant to flow into a drain pan. 2. Parking-brake lever 2. Loosen the set screw securing the knob to the parking-brake lever (Figure 64). 6. When coolant stops, connect the lower radiator hose. 7.
Adjusting the Brake Pedal Service Interval: Every 200 hours Note: Remove the font hood to ease the adjustment procedure. 1. Remove the cotter pin and clevis pin securing the master cylinder yoke to the brake-pedal pivot (Figure 65). g036549 Figure 66 1. Clutch pedal 2. Brake pedal g002417 Figure 65 1. Master cylinder yoke 2. Brake-pedal pivot 2. Lift up on the brake pedal (Figure 66) until it contacts the frame. 3. Loosen the jam nuts securing the yoke to the master cylinder shaft (Figure 66). 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. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key. Every 200 hours—Check the condition and tension of the alternator belt. 2. Adjust the ball joint on the accelerator cable (Figure 68) to allow 2.54 to 6.35 mm (0.100 to 0.
Adjusting the Clutch Pedal 5. Check the 9.2 to 9.8 cm (3-5/8 to 3-7/8 inches) dimension after the jam nuts have been tightened to ensure proper adjustment. Service Interval: Every 200 hours Note: Adjust again if it is necessary. Note: You can adjust the clutch-pedal cable at the bell housing or at the clutch-pedal pivot. You can remove the front hood to ease the access to the pedal pivot. 6. Connect the return spring to the clutch lever.
Hydraulic System Maintenance Changing the Hydraulic Fluid and Cleaning the Strainer Service Interval: Every 800 hours Hydraulic-fluid capacity: 7 L (7.5 US qt) Hydraulic-fluid type: Dexron III ATF 1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key. g002416 Figure 74 1. Hydraulic strainer 2. Remove the drain plug from the side of the reservoir, and let the hydraulic fluid flow into a drain pan (Figure 73). 6. Install the strainer. 7.
Replacing the Hydraulic Filter Alternate fluids: If the Toro fluid is not available, another conventional petroleum–based fluid may be used provided it meets the following material properties and industry specifications. Consult with your lubricant distributor to identify a satisfactory product.
7. Verify the fluid level. 8. Dispose of the fluid properly. Raising the Cargo Box in an Emergency The cargo box can be raised in an emergency without starting the engine by cranking starter or by jumping the hydraulic system. Raising the Cargo Box using the Starter Crank the starter while holding the lift lever in the Raise position. Run the starter for 10 seconds, then wait 60 seconds before engaging the starter again.
G019543 1 g019543 Figure 78 1. Jumper hoses 7. Keep all bystanders away from the machines. 8. Start the second machine and move the lift lever to the raise position, which raises the disabled cargo box. 9. Move the hydraulic-lift lever to the NEUTRAL position, and engage the lift-lever lock. 10. Install the bed support onto the extended lift cylinder; refer to Using the Bed Support (page 38).
Cleaning Storage Washing the Machine 1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key. Wash the machine as needed. Use water alone or with a mild detergent. You may use a rag when washing the machine. 2. Clean dirt and grime from the entire machine, including the outside of the engine cylinder head fins and blower housing. Important: Do not use power-washing equipment to wash the machine.
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The Toro 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).
