Form No. 3406-508 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. 316000001 and Up 07384—Serial No. 316000001 and Up 07384H—Serial No. 316000001 and Up 07384TC—Serial No. 316000001 and Up 07386—Serial No. 316000501 and Up 07386H—Serial No. 316000001 and Up 07386TC—Serial No.
This machine is to be used by professional, hired operators in commercial applications. It is primarily designed for the transport of implements used in such applications. This machine allows for the safe transport of an operator and one passenger in the identified seats. The bed of this machine 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 Raising the Machine................................................38 Removing the Hood ...............................................39 Installing the Hood.................................................39 Lubrication ...............................................................40 Greasing the Bearings and Bushings ..........................40 Engine Maintenance ..................................................42 Inspecting the Carbon Canister Air Filter ...................
Safety • Wearing safety glasses, safety shoes, and long pants are 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 allow children to operate the machine.
• If fuel is spilled on clothing, change clothing immediately. • Never overfill the fuel tank. Replace the fuel cap and tighten it securely. Operation • The operator and passenger must use seat belts and • • • remain seated whenever the machine is in motion. Keep both hands on the steering wheel, whenever possible, and the passenger should use the handholds provided. Keep your arms and legs within the machine body at all times. Never carry passengers in the box or on attachments.
• Avoid stopping on hills, especially with a load. Stopping • Gross Vehicle Weight (GVW) has a major impact on your • • ability to stop and/or turn. Heavy loads and attachments make the machine harder to stop or turn. The heavier the load, the longer it takes to stop. Decrease the speed of the machine if the cargo box has been removed and there is no attachment installed on the machine.
• Never dump a loaded cargo box while the machine is • If you must run the engine to perform a maintenance sideways on a hill. The change in weight distribution may cause the machine to overturn. adjustment, keep hands, feet, clothing, and any parts of the body away from the engine and any moving parts. Keep everyone away. • When operating with a heavy load in the cargo box, • Do not overspeed the engine by changing the governor reduce your speed and allow for sufficient braking distance.
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. 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. 136-1163 1. Do not exceed a transport load of 1591 kg (3,500 lb). 2. Do not exceed a towing weight of 273 kg (600 lb). 115-7813 1.
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 away from the machine, do not carry passengers in the cargo bed, keep arms and legs inside of the machine at all times, and use seat belts and handholds. 121-9776 1. Warning—read the Operator’s Manual and receive proper training before operating the machine. 4.
93–9868 1. Crushing hazard of hand—read the Operator’s Manual. 115-7756 1. High-flow hydraulics—engaged 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.
106-2377 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 machine. 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 115-2281 1. Headlights 4. Engine—run 2. Horn 5. Engine—start 3.
110–0806 121-6286 1. The coolant level must be checked daily before use. Read the Operator's Manual before checking the coolant level. 2. Do not open or add coolant to the radiator; doing so introduces air into the system and result in engine damage. Only add coolant to the reservoir. 106-7767 1. Warning—read the Operator's Manual; avoid tipping the machine; wear the seat belt; lean away from the direction the machine is tipping. 121-6287 1.
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 Rollover-Protection System (ROPS) 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 21). 2. Check the transaxle/hydraulic-fluid level before the engine is first started; refer to Checking the Transaxle/Hydraulic-Fluid Level (page 24). Procedure 1.
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.
Brake Pedal Product Overview The brake pedal (Figure 6) is used to apply the 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.
• 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). Figure 8 1.
Hour Meter Check the operation of warning lights as follows: The hour meter indicates the total hours of machine operation. The hour meter (Figure 9) starts to function whenever the key switch is rotated to the ON position or if the engine is running. • Engage the parking brake. • Turn the key switch to the ON/PREHEAT position, but do not start the engine. The coolant temperature, charge indicator, and oil-pressure lights should glow.
Speedometer Specifications The speedometer registers the ground speed of the machine (Figure 9). It displays mph but can easily converted to km/h; refer to Converting the Speedometer (page 53). Note: Specifications and design are subject to change without notice. Dimensions Power Point Use the power point (Figure 9) to power optional 12 V electrical accessories.
Lowering the Box Operation WARNING Note: Determine the left and right sides of the machine from the normal operating position. The weight of the box may be heavy. Hands or other body parts could be crushed. CAUTION Keep your hands and other body parts away when lowering the box. Before servicing or making adjustments to the machine, shut off the engine, engage the parking brake, and remove the key from the key switch.
Checking the Engine-Oil Level 3. Insert the dipstick into the tube and make sure that it is seated fully (Figure 16). Service Interval: Before each use or daily Engine-oil type: Detergent engine oil API SJ or higher 4. Remove dipstick and check the level of the oil (Figure 16). Engine-oil viscosity: 10W-30; Choose an engine-oil viscosity according to the ambient-air temperature to the table in Figure 15. 5.
Adding Fuel DANGER • For best results, use only clean, fresh (less than 30 days In certain conditions during fueling, static electricity can be released causing a spark which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. • Always place fuel containers on the ground away from your machine before filling.
of varnish deposits in the fuel system, use fuel stabilizer at all times. CAUTION If the engine has been running, the pressurized, hot coolant can escape and cause burns. Filling the Fuel Tank • Do not open the radiator cap. 1. Clean the area around the fuel-tank cap. • Allow the engine to cool at least 15 minutes or until the reserve tank is cool enough to touch without burning your hand. 2. Remove the fuel-tank cap (Figure 18).
Checking the Transaxle/Hydraulic-Fluid Level Checking the High Flow 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.
Checking the Front-Differential-Oil Level 4. Insert the dipstick into the filler neck, then remove it and check the fluid level. Note: The fluid level should be between the 2 marks on the dipstick. 4-Wheel-Drive Models Only 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 (page 55). Service Interval: Every 100 hours/Monthly (whichever comes first) Differential-oil type: Mobil 424 hydraulic fluid 6.
Checking the Tire Pressure Service Interval: Before each use or daily The air pressure in the front tires should be 220 kPa (32 psi) and the rear tires should be 124 kPa (18 psi). Important: Check the tire pressure frequently to ensure proper inflation. If the tires are not inflated to the correct pressure, the tires will wear prematurely and may cause 4-wheel drive to bind. Figure 23 is an example of tire wear caused by under-inflation. Figure 25 1. Brake-fluid reservoir 3.
Starting the Engine Important: Do not attempt to push or tow the machine to get it started. Damage to the drive train could result. 1. Sit on the operator’s seat and engage the parking brake. 2. Disengage the PTO and the high-flow hydraulics (if equipped) and move the throttle lever to the OFF position (if equipped). Stopping the Machine 3. Move the shift lever to the NEUTRAL position and press the clutch pedal.
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 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. Speed can also make a minor accident worse.
machine is to tip over. You may find that 1,477 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. at a slow speed and without a load, tip-overs are more likely if you turn on a hill. Slow down and shift into a lower gear before starting up or down a hill. If you have to turn while on a hill, do it as slowly and cautiously as possible.
Transporting the Machine WARNING Tipping or rolling the machine on a hill causes serious injury. For moving the machine long distances, use a trailer. Make sure that the machine is secured to the trailer. Refer to Figure 29 and Figure 30 for the location of the tie-down points. • 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 the Machine Using the Hydraulic Control In case of an emergency, the machine can be towed for a short distance. However, Toro does not recommend this as a standard procedure. The hydraulic control supplies hydraulic power from the machine pump whenever the engine runs. You can use the power through the quick couplers at the rear of the machine. CAUTION WARNING Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage.
Disconnecting the Quick Couplers • LOWER (Quick Coupler “B” Position) This position lowers the bed, rear hitch attachment, or apply pressure to quick coupler B. This also allows hydraulic fluid to return from quick coupler A to flow back into the valve and then out to the reservoir. This is a momentary position, and when you release the lever, it spring returns to the center-off position.
Maintenance Determine the left and right sides of the machine from the normal operating position. CAUTION Only qualified and authorized personnel should 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 the 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 • • • • • • • • • • • • Torque the front and rear wheel nuts. Change the carbon canister air filter. Change the engine oil and filter. Inspect the constant-velocity boot for cracks, holes, or a loose clamp (4-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. Check the adjustment of the parking brake. Check the adjustment of the brake pedal.
Premaintenance Procedures 3. Push the bed support onto the cylinder rod, ensuring that the support end tabs rest on the end of 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 may lower unexpectedly.
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 you are installing 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 switch before getting off 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 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. 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). 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.
Figure 43 41
Engine Maintenance 1. Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body (Figure 45). Inspecting the Carbon Canister Air Filter Service Interval: After the first 50 hours—Inspect the opening on the carbon canister air filter. Every 100 hours—Inspect the opening on the carbon canister air filter. Every 200 hours—Change the carbon canister air filter. 1. Locate the air filter on the bottom of the carbon canister (Figure 44). Figure 45 1. Air-cleaner cover 1 2.
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 21). 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: • Never jump-start with a voltage source greater than 15 VDC; this damages 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 machine.
Servicing the Battery Connect the jumper cable to the engine or frame. Do not connect the jumper cable to the fuel system. 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.
Drive System Maintenance Inspecting the Constant-Velocity Boot Changing the Front Differential Oil Service Interval: Every 200 hours (4-wheel-drive models only). 4-Wheel-Drive Models Only Inspect the constant-velocity boot for cracks, holes, or a loose clamp. Contact your Authorized Toro Distributor for repair if you find any damage. 4-Wheel-Drive Models Only Service Interval: Every 800 hours (4-wheel-drive models only).
Adjusting the High–Low Cable Inspecting the Tires Service Interval: Every 200 hours Service Interval: Every 100 hours 1. Remove the clevis pin securing the High–Low cable to the transaxle (Figure 55). The air pressure in the front tires should be 220 kPa (32 psi) and the rear tires should be 124 kPa (18 psi). 2. Loosen the clevis jam nut and adjust the clevis so that the clevis hole aligns with the hole in the transaxle bracket.
Cooling System Maintenance Important: Check the measurements at consistent locations on the tire. The machine should be on a flat surface with the tires facing straight ahead. 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 61). Figure 59 1. Front of the machine 2.
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 Note: Multiple cycles of the following procedure may be required to properly flush and change the engine coolant. 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.
Brake Maintenance Adjusting the Brake Pedal Service Interval: Every 200 hours Adjusting the Parking Brake Note: Remove the font hood 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 67). Every 200 hours 1. Remove the rubber grip from the parking-brake lever (Figure 65). Figure 65 1. Grip 2. Parking-brake lever Figure 67 2.
Belt Maintenance Adjusting the Alternator Belt Service Interval: After the first 10 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 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 69). Figure 68 1. Clutch pedal 3.
Controls System Maintenance 4. Tighten the jam nuts after the adjustment has been attained. 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. 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: 7 L (7.5 US qt) Hydraulic-fluid type: Dexron III ATF 1. Position the machine on a level surface, shut off the engine, engage the parking brake, and remove the key from the key switch. Figure 74 2. Remove the drain plug from the side of the reservoir, and let the hydraulic fluid flow into a drain pan (Figure 73). 1. Hydraulic strainer 6. Install the strainer. 7.
Replacing the Hydraulic Filter specifications. Consult with your lubricant distributor to identify a satisfactory product. Service Interval: After the first 10 hours Every 800 hours Note: Toro does not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation. Important: Use of any other filter may void the warranty on some components. 1.
Raising the Cargo Box in an Emergency You can raise the cargo box in an emergency without starting the engine by cranking the 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. If the engine does not crank, you must remove the load and box (attachment) to service the engine or transaxle.
Cleaning Washing the Machine G019543 The machine should be washed as needed. Use water alone or with a mild detergent. A rag may be used when washing the machine. 1 Important: Do not use power washing equipment to wash the machine. Power washing equipment may damage the electrical system, loosen important decals, or wash away necessary grease at friction points. Avoid excessive use of water near the control panel, engine, and battery. Figure 78 1. Jumper hoses 7.
Storage 1. Position the machine on a level surface, engage the parking brake, shut off the engine, and remove the key. 2. Clean dirt and grime from the entire machine, including the outside of the engine. 3. Inspect the brakes; refer to Checking the Brake-Fluid Level (page 26). 4. Service the air cleaner; refer to Servicing the Air Cleaner (page 42). 5. Seal the air-cleaner inlet and the exhaust outlet with weatherproof tape. 6. Grease the machine; refer to Greasing the Bearings and Bushings (page 40). 7.
International Distributor List Distributor: Agrolanc Kft Asian American Industrial (AAI) B-Ray Corporation Brisa Goods LLC Casco Sales Company Ceres S.A. CSSC Turf Equipment (pvt) Ltd. Cyril Johnston & Co. Cyril Johnston & Co. Fat Dragon Femco S.A. FIVEMANS New-Tech Co., Ltd ForGarder OU G.Y.K. Company Ltd. Geomechaniki of Athens Golf international Turizm Hako Ground and Garden Hako Ground and Garden Hayter Limited (U.K.) Hydroturf Int. Co Dubai Hydroturf Egypt LLC Irrimac Irrigation Products Int'l Pvt Ltd.
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).