Form No. 3374-931 Rev B Workman® HDX Utility Vehicle Model No. 07383—Serial No. 313000001 and Up Model No. 07384—Serial No. 313000001 and Up Model No. 07384TC—Serial No. 313000001 and Up Model No. 07386—Serial No. 313000001 and Up Model No. 07386TC—Serial No. 313000001 and Up Register at www.Toro.com.
This machine is a utility vehicle intended to be used by professional, hired operators in commercial applications. It is primarily designed for the transport of implements used in such applications. This vehicle allows for the safe transport of an operator and one passenger in the identified seats. The bed of this vehicle is not suitable for any riders. This product complies with all relevant European directives. For details please see the separate product specific Declaration of Conformity (DOC) sheet.
Fuses ....................................................................39 Jump Starting the Vehicle.........................................40 Servicing the Battery...............................................40 Drive System Maintenance .........................................41 Changing the Front Differential Oil (Four-wheel drive models only)...............................................41 Inspecting the Constant Velocity Boot (Four-wheel drive models only)..........................................
Safety This is a specialized utility vehicle designed for off–road use only. Its ride and handling will have a different feel than what drivers experience with passenger cars or trucks. So take time to become familiar with your Workman. The machine meets the requirements of SAE J2258. Supervisors, operators and service persons should be familiar with the following standards and publications: (The material may be obtained from the address shown).
• Before operating the vehicle, always check all parts of • • • • the vehicle and any attachments. If something is wrong, stop using vehicle. Make sure the problem is corrected before vehicle or attachment is operated again. Since gasoline is highly flammable, handle it carefully. – Use an approved fuel container. – Do not remove the cap from the fuel tank when the engine is hot or running. – Do not smoke while handling fuel.
• If major repairs are ever needed or assistance is required, • If the machine ever vibrates abnormally, stop immediately, contact an Authorized Toro Distributor. turn engine off, wait for all motion to stop and inspect for damage. Repair all damage before resuming operation. • To be sure of optimum performance and safety, • Before getting off the seat: always purchase genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous.
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. 93-9084 2. Tie-down point 1. Lift point 115-7723 1. Warning—the hydraulic oil pressure is 124 bar (1800 PSI). 2. Coupler A 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. 3.
115-7746 1. Warning—do not operate this machine unless you are trained. 3. Fire hazard—stop the engine before fueling. 2. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. 4. Tipping hazard—slow down and turn gradually, use caution and drive slowly when driving on slopes, do not exceed 20 mph (32 kph), and drive slowly over rough terrain or when carrying a full or heavy load. 115-2282 1. Warning—read the Operator's Manual. 2.
115-7756 1. High flow hydraulics—engaged 106-2355 3. Transmission—third high; no fast speed 1. Slow 2. Fast 115-7739 1. Falling, crushing hazard, bystanders—no riders on machine. 93–9868 1. Crushing hazard of hand—read the Operator’s Manual. 121–9669 1. 4WD, Transmission 10A 2. Hazard 10A 5. Fuel pump, supervisor switch 10A 6. Switched power 10A 3. Lights, brake 15A 7. Power outlet 10A 4. Horn, power point 15A Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 6.
6-2377 1. Locked 2. Differential lock 8. Warning—read the Operator's Manual. 3. Unlocked 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.
106-7767 93-9899 1. Warning—read the Operator's Manual; avoid tipping the machine; wear the seat belt; lean away from the direction the machine is tipping. 93-9899 1. Crushing hazard—install the cylinder lock.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 Use Qty. Steering wheel Cap Washer ROPS frame Bolt, 1/2 inch 1 1 1 1 6 No parts required – Install the steering wheel. Mount the ROPS (Rollover Protection System). Check the engine oil, transaxle/hydraulic fluid, and brake fluid levels. Media and Additional Parts Description Use Qty. Operator's Manual 1 Read before operating the vehicle.
3. Check the brake fluid level before the engine is first started, refer to Checking the Brake Fluid (page 22). 2 Product Overview Installing the ROPS (TC Models Only) Controls Note: Determine the left and right sides of the machine from the normal operating position. Parts needed for this procedure: 1 ROPS frame 6 Bolt, 1/2 inch Accelerator Pedal The accelerator pedal (Figure 5) gives the operator the ability to vary the engine and ground speed of the vehicle when the transmission is in gear.
Brake Pedal The brake pedal (Figure 5) is used to apply service brakes to stop or slow vehicle. CAUTION Worn or maladjusted brakes may result in personal injury. If the brake pedal travels to within 3.8 cm (1-1/2 inches) of the vehicle floor board, the brakes must be adjusted or repaired. Figure 7 Gear Shift Lever Fully press the clutch pedal and move the shift lever (Figure 5) into the desired gear selection. A diagram of the shift pattern is indicated in Figure 6. 1. Gear shift lever 4.
Speed Limiter Switch High is for higher speed driving on level, dry surfaces with light loads. Move the speed limiter switch (Figure 8) to the slow position and remove the key. The switch limits the engine to 2,200 rpm when the machine is in third gear in the High range, which limits the top speed to 21 km/h (13 mph). Low is for low speed driving. Use this range when greater than normal power or control is required.
Fuel Gauge Passenger Hand Hold The fuel gauge shows the amount of fuel in the tank. It operates only when ignition switch is in the On position (Figure 8). Red indicates low fuel level and blinking red indicates near empty. The passenger hand hold is located on the dashboard (Figure 10). High Flow Hydraulics Switch (TC models only) Turn on the switch to activate the high flow hydraulics (Figure 8). Horn Button (TC models only) Pressing the horn button activates the horn (Figure 8).
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 160 cm (63 inches) Overall Length w/o bed: 326 cm (128.25 inches) w/full bed: 331 cm (130.38 inches) w/2/3 bed in rear mounting location: 346 cm (136.38 inches) Base Weight (Dry) Rated Capacity (includes 91 kg (200 lb) operator, 91 kg (200 lb) passenger and loaded attachment) Maximum.
1 G021228 2 Figure 14 Figure 13 1. Note clearance 1. Filler cap 2. Dipstick 4. Install the dipstick firmly in place. 3. If the oil level is low, remove the filler cap (Figure 13) and add enough oil to raise the level to the Full mark on the dipstick. Adding Fuel Toro strongly recommends the use of fresh, clean, unleaded regular grade gasoline in Toro gasoline powered products.
1. Clean the area around the fuel tank cap. DANGER 2. Remove the fuel tank cap (Figure 15). In certain conditions, gasoline is extremely flammable and highly explosive. A fire or explosion from gasoline can burn you and others and can damage property. • Before removing the fuel tank cap, make sure the vehicle is positioned on a level surface. Open fuel tank cap slowly. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills.
Checking the High Flow Hydraulic Fluid (TC models only) 3. If coolant is low, remove the reserve tank cap and add a 50/50 mixture of water and permanent ethylene glycol antifreeze. Do not overfill. 4. Install the reserve tank cap. Service Interval: Before each use or daily Checking the Transaxle/Hydraulic Fluid Level The high flow hydraulics reservoir is filled with approximately 15 l (4 gallons) of high quality hydraulic fluid.
Checking the Torque of the Wheel Nuts WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. Service Interval: After the first 2 hours After the first 10 hours Every 200 hours • Make sure all hydraulic fluid hoses and lines are in good condition and all hydraulic connections and fittings are tight before applying pressure to the hydraulic system. WARNING • Keep your body and hands away from pin hole leaks or nozzles that eject high pressure hydraulic fluid.
Checking the Brake Fluid Service Interval: Before each use or daily—Check the brake fluid level. Every 1,000 hours/Every 2 years (whichever comes first)—Change the brake fluid. The brake fluid reservoir is shipped from the factory filled with DOT 3 brake fluid. Check the level before the engine is first started and every 8 hours or daily, thereafter. The brake fluid reservoir is located under the dash. 1. Park the machine on a level surface. 2.
Stopping the Vehicle 4. Ensure that the hydraulic lift lever is in the center position. To stop the vehicle, remove your foot from the accelerator pedal, press the clutch pedal, then press the brake pedal. 5. Keep your foot off of the accelerator pedal. 6. Insert key into ignition switch and rotate it clockwise to start the engine. Release key when engine starts. Stopping the Engine Important: To prevent overheating of the starter motor, do not engage starter longer than 15 seconds.
Verifying the Clutch Interlock Switch those used for braking, steering, and transmission shifting. Learn how your vehicle handles on different surfaces. Your operating skills will improve with experience, but as in operating any vehicle, take it easy as you begin. Be sure you know how to stop quickly in an emergency. If you need help, ask your supervisor for assistance. 1. Sit on the operator’s seat and engage the parking brake. Move the shift lever to the Neutral position.
operating speed by moving the speed limiter switch to the slow position. Turning Turning is another important variable leading to accidents. Turning too sharply for the conditions can cause the vehicle to lose traction and skid, or even tip over. Wet, sandy, and slippery surfaces make turning more difficult and risky. The faster you are going, the worse this situation becomes so, slow down before turning. During a sharp turn at higher speeds, the inside rear wheel may lift off of the ground.
can also be increased by adding weight to the rear of the vehicle in one of the following ways: • Adding weight to inside of box, making sure it is secured. • Mounting wheel weights to rear wheels. • Adding liquid ballast (calcium chloride) to rear tires. • Traction will increase with no passenger in front seat.
system continues to deliver power to the front wheels until the rear wheels have enough traction to move the vehicle without slipping. Once this occurs, the system stops delivering power to the front wheels and the handling characteristics become similar to that of a two wheel drive vehicle. The four wheel drive system functions in both froward and reverse, however, when turning the rear wheels will slip slightly more before power is delivered to the front wheels.
performance or damage to the brakes, axle, engine, transaxle, steering, suspension, body structure, or tires. Important: To reduce potential for drive line damage, use low range. When towing fifth wheel attachments, like a fairway aerator, always install the wheely bar (included with the fifth wheel kit) to prevent the front wheels from lifting off the ground if the towed attachments movement is suddenly impaired.
return oil from quick coupler A to flow back into the valve and then out to the reservoir. This is a momentary position and when the lever is released it spring returns to the center off position. Momentarily holding and then releasing the control lever in this position will provide flow to quick coupler B which provides power down on the rear hitch. When released, it will hold the down pressure on the hitch.
Maintenance CAUTION If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Determine the left and right sides of the machine from the normal operating position. CAUTION Remove the key from the ignition before you do any maintenance. Only qualified and authorized personnel shall be permitted to maintain, repair, adjust, or inspect the vehicle. Avoid fire hazards and have fire protection equipment present in the work area.
Maintenance Service Interval Maintenance Procedure • • • • • • • • • • • • • Torque the front and rear wheel nuts Inspect opening on filter. Change the air cleaner filter. (more frequently in dusty or dirty conditions) Change the engine oil and filter. Inspect the constant velocity boot for cracks, holes, or a loose clamp (four wheel drive models only). Check the adjustment of the shift cables. Check the adjustment of the high–low cable. Check the adjustment of the differential lock cable.
Removing the Full Bed Using the Bed Safety Support 1. Start the engine. Engage the hydraulic lift lever and lower the bed until the cylinders are loose in the slots. Release the lift lever and turn off the engine. Important: Always install or remove the bed support from the outside of the bed. 1. Raise the bed until the lift cylinders are fully extended. 2. Remove the lynch pins from the outer ends of the cylinder rod clevis pins (Figure 30). 2.
frame channel and install 2 clevis pins and lynch pins (Figure 32). 3. With the bed lowered, secure each cylinder rod end, to the appropriate slots in the bed mounting plates with a clevis pin and lynch pin. Insert the clevis pin from outside of the bed with the lynch pin toward the outside (Figure 32). The rear slots are for a full bed installation and front slots are for a 2/3 bed installation. Note: The engine may need to be started to extend or retract the cylinders for alignment with the holes.
Figure 33 1. Front jacking points Figure 35 1. Hood 2. Pivot the bottom of the hood upward until the top mounting tabs can be pulled from the frame slots (Figure 35). 3. Pivot the top of hood forward and unplug the wire connectors from the head lights (Figure 35). Figure 34 4. Remove the hood. 1. Rear jacking points To install the hood, complete the following: 1. Connect the lights. Removing the Hood 2. Insert the top mounting tabs into the frame slots. 3.
Lubrication Greasing Bearings and Bushings Service Interval: Every 100 hours (lubricate more frequently in heavy duty applications). The vehicle has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
Figure 39 Engine Maintenance Inspecting the Carbon Canister Air Filter 1 Service Interval: After the first 50 hours Every 200 hours 1. Locate the air filter on the bottom of the carbon canister (Figure 40). G016089 Figure 40 1.
6. Clean the dirt ejection port located in the removable cover. Remove the rubber outlet valve from the cover, clean the cavity, and replace the outlet valve. 2. Ensure that the opening on the bottom of the filter is clear and open. Servicing the Air Cleaner 7. Install the cover orienting the rubber outlet valve in a downward position—between approximately 5:00 to 7:00 when viewed from the end. Service Interval: Every 200 hours—Change the air cleaner filter.
Replacing the Spark Plug Fuel System Maintenance Service Interval: Every 400 hours The spark plug usually lasts a long time; however, the plug should be removed and checked whenever the engine malfunctions or every 400 hours. Replace the spark plug to ensure proper engine performance and reduce exhaust emission level. Replacing the Fuel Filter Service Interval: Every 400 hours 1. Raise the bed (if so equipped) and place the safety support on the extended lift cylinder to hold up the bed.
Inspecting the Fuel Lines and Connections Electrical System Maintenance Service Interval: Every 400 hours/Yearly (whichever comes first) Fuses Every 1,000 hours/Every 2 years (whichever comes first) The fuses for the electrical system are located under the center of the dash panel (Figure 45 and Figure 46). Inspect the fuel lines and connections for deterioration, damage, or loose connections. Figure 45 1. Fuses Figure 46 1. 4WD, Transmission 10A 2. Hazard 10A 5. Fuel pump, supervisor switch 10A 6.
Jump Starting the Vehicle WARNING Jump starting can be dangerous. To avoid personal injury or damage to electrical components in vehicle, 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. • Observe all battery warnings while jump starting your vehicle.
Drive System Maintenance • Keep battery electrolyte level properly maintained. • Keep the top of the battery clean by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning. Do not remove the fill cap while cleaning. Changing the Front Differential Oil (Four-wheel drive models only) • Ensure that the battery cables are kept tight on the terminals to provide good electrical contact.
Adjusting the Shift Cables Service Interval: After the first 10 hours Every 200 hours 1. Move shift lever to the Neutral position. 2. Remove the clevis pins securing the shift cables to the transaxle shift arms (Figure 50). Figure 51 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 O.D. of the hole in the transaxle lever. Figure 50 1. Shift arm (1st—Rev.) 1.
Figure 53 1. Over inflated tire Figure 55 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.
Changing the Engine Coolant Cooling System Maintenance Service Interval: Every 1,000 hours/Every 2 years (whichever comes first) 1. Park the machine on a level surface. Removing Debris from the Cooling System 2. Raise the bed (if so equipped) and place the safety support on the extended lift cylinder to hold up the bed. Service Interval: Before each use or daily (Clean more frequently in dirty conditions.) CAUTION 1. Turn the engine off. Clean the engine area thoroughly of all debris.
Brake Maintenance 5. Disconnect the lower radiator hose and allow coolant to flow into a drain pan. When coolant stops, connect the lower radiator hose. Adjusting the Parking Brake 6. Remove the coolant drain plug from the engine and allow coolant to flow into a drain pan. When coolant stops, install the drain plug. Service Interval: After the first 10 hours Every 200 hours 7. Slowly fill the radiator with a 50/50 mixture of water and permanent ethylene glycol anti–freeze 1.
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 62). Figure 63 1. Clutch pedal 2. Brake pedal Figure 62 1. Master cylinder yoke 2. Brake pedal pivot 2. Lift up on the brake pedal (Figure 63) until it contacts the frame. 3. Loosen the jam nuts securing the yoke to the master cylinder shaft (Figure 63). 4.
Belt Maintenance Controls System Maintenance Adjusting the Alternator Belt Adjusting the Clutch Pedal Service Interval: After the first 8 hours—Check condition and tension of the alternator belt. Service Interval: Every 200 hours Every 200 hours—Check condition and tension of the alternator belt. 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 pedal pivot. 1.
Hydraulic System Maintenance 4. Tighten the jam nuts after the adjustment has been attained. 5. Recheck the 9.5 ± 0.3 cm (3.75 ± 0.12 inch) dimension after the jam nuts have been tightened to ensure proper adjustment. Readjust, if necessary. Changing the Hydraulic Fluid and Cleaning the Strainer 6. Connect the return spring to the clutch lever.
Figure 70 1. Hydraulic filter 2. High flow hydraulics filter 3. Lubricate the gasket on the new filter. 4. Ensure that the filter mounting area is clean. Screw the filter on until the gasket contacts the mounting plate. Then tighten the filter one-half turn. Figure 69 1. Hydraulic strainer 5. Start the engine and let it run for about two minutes to purge air from the system. Stop the engine and check the hydraulic oil level and for leaks. 5. Install the strainer. 6.
Raising the Box by Jumping the Hydraulic System • FZG, Fail stage—11 or better • Water content (new fluid)—500 ppm (maximum) Industry Specifications: CAUTION Vickers I-286-S, Vickers M-2950-S, Denison HF-0, Vickers 35 VQ 25 (Eaton ATS373-C) Before servicing or making adjustments to the machine, stop the engine, set the parking brake, and remove the key from the switch. Any load material must be removed from the bed or other attachment before working under a raised bed.
Important: Check the hydraulic fluid levels, in both vehicles, before resuming operation. Figure 72 1. Disconnected hoses 2. Jumper hoses 4. On the other vehicle, connect the two hoses to the coupler still in the coupler bracket (connect the top hose to the top coupler and the bottom hose to the bottom coupler) (Figure 73). Cap the unused fittings. Figure 73 1. Jumper hoses 5. Keep all bystanders away from the vehicles. 6.
Storage 12. Install the spark plugs and tighten to recommended torque; refer to Replacing the Spark Plug (page 38). 1. Position the machine on a level surface, set the parking brake, stop the engine, and remove the ignition key. Note: Do not install the wire on the spark plug(s). 13. Check anti freeze protection and add a 50/50 solution of water and anti freeze as needed for expected minimum temperature in your area. 2.
Schematics Hydraulic Schematic (Rev. B) High Flow Hydraulics Schematic (TC models only) (Rev.
G021231 Electrical Schematic (Rev.
Notes: 55
The Toro Total Coverage Guarantee A 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).
