Form No. 3382-454 Rev B Workman® HDX Utility Vehicle Model No. Model No. Model No. Model No. Model No. Model No. Model No. Register at www.Toro.com. Original Instructions (EN) 07383—Serial No. 314000001 and Up 07384—Serial No. 314000001 and Up 07384H—Serial No. 314000001 and Up 07384TC—Serial No. 314000001 and Up 07386—Serial No. 314000001 and Up 07386H—Serial No. 314000001 and Up 07386TC—Serial No.
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.
Contents Removing the Full Bed............................................37 Installing the Full Bed .............................................37 Raising the Machine................................................38 Removing the Hood ...............................................39 Installing the Hood.................................................39 Lubrication ...............................................................40 Greasing the Bearings and Bushings ..........................
Safety • Keep everyone, especially children and pets, away from 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.
– Never operate the machine in or near an area where there is dust or fumes in the air which are explosive. The electrical and exhaust systems of the machine can produce sparks capable of igniting explosive materials. – Turn ignition switch to the On position. When the glow plug indicator goes off, the engine is ready to start. – Turn the ignition key to the Start position. – Always watch out for and avoid low overhangs such as tree limbs, door jambs, over head walkways, etc.
Operating on Hills WARNING Sudden changes in terrain may cause abrupt steering wheel movement, possibly resulting in hand and arm injuries. • Reduce your speed when operating on rough terrain and near curbs. • Grip the steering wheel loosely around the perimeter keeping thumbs up and out of the way of the steering wheel spokes. WARNING Operating the machine on a hill may cause tipping or rolling of the machine, or the engine may stall and you could lose headway on the hill.
accessories. Replacement parts and accessories made by other manufacturers could be dangerous. Altering this vehicle in any manner may affect the vehicle’s operation, performance, durability or its use may result in injury or death. Such use could void the product warranty of The Toro® Company. the machine. Never overfill attachments or exceed the machine maximum gross vehicle weight (GVW).
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 1500 lb (680 kg), maximum tongue weight is 200 lb (90 kg). 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.
93-9879 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.
106-2377 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.
1-6287 1. Fill the reservoir with engine coolant to the bottom of the standpipe. 110–0806 121-6286 1. Read the Operator's Manual before checking the engine coolant level. 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 Description Use Qty. 1 2 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. Note: Determine the left and right sides of the machine from the normal operating position.
2 3 Installing the Rollover Protection System (ROPS)—TC models only Checking the Fluid Levels No Parts Required 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 20). 2. Check the transaxle/hydraulic-fluid level before the engine is first started; refer to Checking the Transaxle/Hydraulic-fluid Level (page 23). Procedure 1.
Brake Pedal Product Overview The brake pedal (Figure 5) is used to apply service brakes to stop or slow the machine. Controls Note: Determine the left and right sides of the machine from the normal operating position. 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 machine floor board, the brakes must be adjusted or repaired.
• 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). Figure 7 1. Gear-shift lever 4. Hydraulic-lift lock 2. Parking brake 5. Differential lock 3.
Hour Meter • Apply the parking brake. • Turn the ignition key to the On/Preheat position, but do The hour meter 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. not start the engine. The coolant temperature, charge indicator, and oil-pressure lights should glow.
Power Point Specifications Use the power point (Figure 8) to power optional 12 volt electrical accessories. Note: Specifications and design are subject to change without notice. Dimensions Passenger Hand Hold Overall Width 160 cm (63 inches) Overall Length Without bed: 326 cm (128 inches) With full bed: 331 cm (130 inches) With 2/3 bed in rear-mounting location: 346 cm (136 inches) The passenger hand hold is located on the dashboard (Figure 10).
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.
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 (Figure 15) and wipe it with a clean rag. 1 Figure 13 1. Latch handle 3. Latch pin G021228 2. Latch gate 2 Figure 15 Checking the Engine-oil Level 1. Filler cap 2.
DANGER 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. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Never fill the fuel tank inside an enclosed trailer. • Do not fill the fuel tank completely full. Add gasoline to the fuel tank until the level is 6 to 13 mm (1/4 to 1/2 inch) below the bottom of the filler neck.
3. Fill the tank to about one inch below the top of the tank, (bottom of the filler neck), then install the cap. WARNING Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. • Avoid prolonged breathing of vapors. • Keep face away from nozzle and gas tank or conditioner bottle opening. • Avoid contact with skin; wash off spillage with soap and water. Note: Do not overfill the fuel tank. 4.
Checking the Transaxle/Hydraulic-fluid Level Service Interval: Before each use or daily (check the fluid level before the engine is first started and every 8 hours or daily, thereafter.) Transaxle fluid type: Dexron III ATF 1. Position the machine on a level surface. 2. Clean the area around the dipstick (Figure 19). Figure 18 1. Reserve tank-cap 2. Reserve tank 3. If coolant is low, remove the reserve tank cap and add a 50/50 mixture of water and permanent ethylene-glycol antifreeze. Figure 19 1.
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 55).
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 22 is an example of tire wear caused by under inflation. Figure 21 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. Insert the key into the ignition switch and rotate it clockwise to start the engine. Note: Release key when engine starts. Important: To prevent overheating of the starter motor, do not engage starter longer than 15 seconds. After 15 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again. Driving the Machine Figure 24 1. Release the parking brake. 1. Brake-fluid reservoir 2. Fully press the clutch pedal. 3.
Stopping the Machine Checking the Safety-interlock System 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 ignition 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 Determine the left and right sides of the machine from the normal operating position. CAUTION Only qualified and authorized personnel shall be permitted to maintain, repair, adjust, or inspect the machine. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check level or leakage of fuel, battery electrolyte, or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.
Maintenance Service Interval Maintenance Procedure Every 200 hours • • • • • • • • • • • • Torque the front and rear wheel nuts. Inspect opening on filter. Change the engine oil and filter. Inspect the constant-velocity boot for cracks, holes, or a loose clamp. Check the adjustment of the shift cables. Check the adjustment of the high–low cable. Check the adjustment of the differential-lock cable. Check the adjustment of the parking brake. Check the adjustment of the brake pedal.
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 ignition switch. Remove any load material from the bed or other attachment before working under a raised bed.
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 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 34). 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 35 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 37 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 38). Figure 38 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.
Figure 42 41
Engine Maintenance Inspecting the Carbon Canister Air Filter Service Interval: After the first 50 hours Every 200 hours 1. Locate the air filter on the bottom of the carbon canister (Figure 43). Figure 44 1. Air-cleaner cover 1 2. Filter 2. Squeeze the dust cap sides to open it and knock the dust out. 3. Gently slide the primary filter out of the air-cleaner body (Figure 44). Note: Avoid knocking the filter into the side of the body. Note: Do not attempt to clean the primary filter. 4.
Changing the Engine Oil and Filter 6. Screw the filter on until the gasket contacts the mounting plate, then tighten the filter 1/2 to 2/3 of a turn. Service Interval: After the first 50 hours Note: Do not overtighten. Every 200 hours 7. Add the specified oil to the crankcase; refer to Checking the Engine-oil Level (page 20). Engine-oil quantity: 3.2 L (3.
Inspecting the Fuel Lines and Connections Fuel System Maintenance Service Interval: Every 400 hours/Yearly (whichever comes first) Replacing the Fuel Filter Every 1,000 hours/Every 2 years (whichever comes first) Service Interval: Every 400 hours 1. Raise the bed (if equipped), and place the safety support on the extended-lift cylinder to hold up the bed. Inspect the fuel lines and connections for deterioration, damage, or loose connections. 2.
Jump Starting the Machine Electrical System Maintenance WARNING Jump starting can be dangerous. To avoid personal injury or damage to electrical components in machine, observe the following warnings: Servicing the Fuses The fuses for the electrical system are located under the center of the dash panel (Figure 49 and Figure 50). • 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.
Servicing the Battery Service Interval: Every 50 hours—Check the battery-fluid level (every 30 days if in storage). Every 50 hours—Check the battery-cable connections. 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. Figure 52 1. Battery 4. Start the engine in the machine providing the jump start.
Adjusting the Shift Cables Drive System Maintenance Service Interval: After the first 10 hours Every 200 hours 1. Move the shift lever to the Neutral position. Changing the Front-differential Oil (4-wheel drive models only) 2. Remove the clevis pins securing the shift cables to the transaxle-shift arms (Figure 54). Service Interval: Every 800 hours Differential-oil specification: Mobil 424 hydraulic oil 1.
Figure 57 1. Over-inflated tire Checking the Front-wheel Alignment Figure 55 1. Differential-lock cable 3. Spring 2. Transaxle bracket 4. 0.25 to 1.5 mm (0.01 to 0.06 inch) gap Service Interval: Every 400 hours/Yearly (whichever comes first) 1. Make sure the tires are facing straight ahead. 2. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires (Figure 58). 3. Adjust the jam nuts to obtain a 0.25 to 1.5 mm (0.01 to 0.
Cooling System Maintenance Removing Debris from the Cooling System Service Interval: Before each use or daily (clean more frequently in dirty conditions). 1. Turn the engine off and clean the engine area thoroughly of all debris. 2. Unlatch and remove the radiator screen from the front of the radiator (Figure 60). Figure 59 1. Tie rods 2. Jam nuts 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.
Changing the Engine Coolant Service Interval: Every 1,000 hours/Every 2 years (whichever comes first) Coolant type: 50/50 mixture of water and permanent ethylene-glycol antifreeze 1. Park the machine on a level surface. 2. Raise the bed (if so equipped) and place the safety support on the extended-lift cylinder to hold up the bed. CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. • Do not open the radiator cap when the engine is running.
Brake Maintenance Adjusting the Brake Pedal Service Interval: Every 200 hours Adjusting the Parking Brake Note: Remove the font hoot to ease the adjustment procedure. Service Interval: After the first 10 hours 1. Remove the cotter pin and clevis pin securing the master cylinder yoke to the brake-pedal pivot (Figure 66). Every 200 hours 1. Remove the rubber grip from the parking-brake lever (Figure 64). Figure 64 1. Parking-brake lever 2. Grip 2.
Belt Maintenance Adjusting the Alternator Belt Service Interval: After the first 8 hours—Check the condition and tension of the alternator belt. Every 200 hours—Check the condition and tension of the alternator belt. 1. Raise the bed (if so equipped) and position the safety support on the extended-lift cylinder to hold up the bed. 2. Check the tension by pressing the belt at mid span between the crankshaft and alternator pulleys with 10 kg (22 lb) of force (Figure 68). Figure 67 1. Clutch pedal 3.
Controls System Maintenance 4. Tighten the jam nuts after the adjustment has been attained. 5. Check the 9.5 ± 0.3 cm (3.75 ± 0.12 inch) dimension after the jam nuts have been tightened to ensure proper adjustment. Adjusting the Clutch Pedal Note: Adjust again if it is necessary. Service Interval: Every 200 hours 6. Connect the return spring to the clutch lever. Note: You can adjust the clutch-pedal cable at the bell housing or at the clutch-pedal pivot.
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 ignition 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 ignition 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.
Notes: 58
Notes: 59
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).
