Form No. 3374-948 Rev B Workman® HDX-D Utility Vehicle with Bed Model No. 07385—Serial No. 313000001 and Up Model No. 07385TC—Serial No. 313000001 and Up Model No. 07387—Serial No. 313000001 and Up Model No. 07387TC—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.
Contents Maintenance .................................................................32 Recommended Maintenance Schedule(s) ......................32 Heavy Duty Operation............................................33 Premaintenance Procedures ........................................34 Using the Bed Safety Support ...................................34 Removing the Full Bed............................................34 Installing the Full Bed .............................................
Safety Not all of the attachments that adapt to the Workman are covered in this manual. See the specific Operator’s Manual provided with each attachment for additional safety instructions. Read these manuals. 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).
• • • • stop using vehicle. Make sure the problem is corrected before vehicle or attachment is operated again. Since diesel fuel 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. – Fill the fuel tank outdoors and to about one inch below the top of tank (bottom of filler neck). Do not overfill. – Wipe up any spilled fuel.
• If the engine must be running to perform a maintenance Make sure there is enough room over head to easily clear the vehicle and your head. adjustment, keep hands, feet, clothing, and any parts of the body away from the engine and any moving parts. Keep everyone away. – If ever unsure about safe operation, stop work and ask your supervisor. • Do not overspeed the engine by changing the governor • Do not touch engine, transaxle, radiator, muffler or settings. The maximum engine speed is 3650 RPM.
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. 93-9852 1. Warning—read the Operator’s Manual. 2. Crushing hazard—install the cylinder lock. 115-7739 115-2047 1. Falling, crushing hazard, bystanders—no riders on machine. 1. Warning—do not touch the hot surface. 115-2281 1. Headlights 4. Engine—run 2. Horn 5. Engine—start 3. Engine—stop 93-9084 1.
115-7740 1. Warning—maximum trailer weight is 1500 lb (680 kg), maximum tongue weight is 200 lb (90 kg). 2. Warning—trailer brakes are required when towing greater than 1500 lb (680 kg), maximum trailer weight with trailer brakes is 3500 lb (1591 kg) , maximum tongue weight with trailer brakes is 600 lb (273 kg). 115-7723 1. Warning—the hydraulic oil pressure is 124 bar (1800 PSI). 2. Coupler A 3. Coupler B 115-7746 1. Warning—do not operate this machine unless you are trained. 3.
3-7814 1. Entanglement hazard, belt—stay away from moving parts. 93–9868 1. Crushing hazard of hand—read the Operator’s Manual. 115-7813 1. Power outlet 10A 5. Lights, brake 15A 2. Switched power 10A 6. Hazard 10A 3. Fuel pump, supervisor switch 10A 4. Horn, power point 15A 7. 4WD, Transmission 10A 93-9850 115-7741 1. Do not repair or revise—read the Operator's Manual. 1. Read the Operator’s Manual before servicing transmission fluid. 105-4215 1. Warning—avoid pinch points. 106-6755 1.
1. Slow 93-9899 106-2355 3. Transmission—third high; no fast speed 93-9899 2. Fast 1. Crushing hazard—install the cylinder lock. 115-7756 1. High flow hydraulics—engaged 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.
106-2377 1. Locked 8. Warning—read the Operator's Manual. 2. Differential lock 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 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.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 1 1 1 6 Steering wheel Cap Washer ROPS frame Bolt, 1/2 inch 1 2 3 4 Use Qty. Electrolyte A/R – No parts required Install the steering wheel. Mount the ROPS (Rollover Protection System). Activate and charge the battery. Check the engine oil, transaxle/hydraulic fluid, and brake fluid levels. Media and Additional Parts Description Use Qty.
charged. Bulk electrolyte with 1.260 specific gravity can be purchased from a local battery supply outlet. 2 WARNING Installing the ROPS (TC models only) CALIFORNIA Proposition 65 Warning Parts needed for this procedure: 1 ROPS frame 6 Bolt, 1/2 inch 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. Procedure 1.
WARNING 4 Charging the battery produces gasses that can explode. Checking Fluid Levels Never smoke near the battery and keep sparks and flames away from battery. No Parts Required 5. When the battery is charged, disconnect the charger from the electrical outlet and battery posts (Figure 6). Procedure 1. Check the engine oil level before and after the engine is first started, refer to Checking the Engine Oil Level (page 19). 2.
Product Overview Gear Shift Lever Controls Fully press the clutch pedal and move the shift lever (Figure 8) into the desired gear selection. A diagram of the shift pattern is indicated below. Note: Determine the left and right sides of the machine from the normal operating position. Accelerator Pedal The accelerator pedal (Figure 7) gives the operator the ability to vary the engine and ground speed of the vehicle, when the transmission is in gear.
High is for higher speed driving on level, dry surfaces with light loads. Low is for low speed driving. Use this range when greater than normal power or control is required. For example, steep grades, difficult terrain, heavy loads, slow speed but high engine speed (spraying). Important: There is a location between High and Low in which the transaxle is in neither range.
3rd High Lockout Switch • Apply parking brake. • Turn the ignition key to the On/Preheat position, but do Move the 3rd high lockout switch (Figure 10) to the slow position and remove the key to prevent the use of third gear when in the High range. The engine will shut off if the shift lever is moved to third gear when in High range. The key is removable in either position. not start the engine. The coolant temperature, charge indicator, and oil pressure lights should glow.
Passenger Hand Hold Specifications The passenger hand hold is located on the dashboard (Figure 12). Note: Specifications and design are subject to change without notice. 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.
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.
DANGER Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Before removing the fuel tank cap, make sure the vehicle is positioned on a level surface. Open fuel tank cap slowly. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full.
Checking the Coolant Level Service Interval: Before each use or daily 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. Cooling system capacity: 3.7 l (4 qt) 4. Install the reserve tank cap. The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol antifreeze. 1. Park the machine on a level surface.
Checking the Transaxle/Hydraulic Fluid Level Service Interval: Before each use or daily The transaxle reservoir is filled with Dexron III ATF. Check the level before the engine is first started and every 8 hours or daily, thereafter. Capacity of system is . Figure 19 Transaxle reservoir capacity: 7 l (7.5 qt). 1. Position the vehicle on a level surface. 2. Clean the area around the dipstick (Figure 18). 1. Cap 2. Remove the dipstick (Figure 19) from the filler neck and wipe it with a clean rag.
Checking the Front Differential Checking the Tire Pressure Oil Level (Four-wheel drive Service Interval: Before each use or daily models only) The air pressure in the front tires is 220 kPa (32 psi) and the rear tires is 124 kPa (18 psi). Service Interval: Every 100 hours/Monthly (whichever comes first) Check the tire pressure frequently to ensure proper inflation. If the tires are not inflated to the correct pressure, the tires will wear prematurely.
• Check the brake pedal operation. • Check to see that the lights and horn are working. • Turn the steering wheel to the left and right to check the steering response. • Stop the engine and wit for moving parts to stop, then check for oil leaks, loose parts, and any other noticeable malfunctions. If any of the above items are not correct, notify your mechanic or check with your supervisor before taking the vehicle out for the day.
Important: Always stop the vehicle before shifting to reverse a forward gear or to a forward gear from reverse. • A break–in oil for the engine is not required. The Note: Avoid long periods of engine idling. • Use the chart below to determine the ground speed of the vehicle at 3600 rpm. 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 3 H 12.31 : 1 31.9 19.
Passengers pedal, accelerator pedal, and gear shifter. It is important to remember, however, that this vehicle is not a passenger car. It is a work vehicle and is designed for off road use only. Whenever you have a passenger riding in the vehicle 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 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.
vehicle is to tip over. You may find that 1360 kg (3000 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.
vehicle hood to the frame with a strap, or remove the hood and transport and secure it separately or the hood may blow off during transport. WARNING Tipping or rolling the vehicle 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 Vehicle The Workman is capable of pulling trailers and attachments of greater weight than the vehicle itself. Several types of tow hitches are available for the Workman, depending on your application. Contact your Authorized Toro Distributor for details. When equipped with a tow hitch bolted onto the rear axle tube, your Workman can tow trailers or attachments with a Gross Trailer Weight (GTW) up to 1587 kg (3500 lb).
– Quick couplers are interchanged CAUTION • Squealing noise Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage. Care must be used when connecting or disconnecting hydraulic quick couplers. Stop the engine, apply the parking brake, lower the attachment, and place the remote hydraulic valve in the float detent position to relieve hydraulic pressure before connecting or disconnecting quick couplers.
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.
Maintenance Service Interval Every 800 hours Every 1,000 hours Maintenance Procedure • • • • Change the front differential oil. Change the hydraulic fluid and clean the strainer. Replace the hydraulic filter. Change the high flow hydraulic oil and filter (TC models only). • Change the brake fluid. • Drain/flush the fuel tank. • Flush/replace the coolant system fluid. Note: Determine the left and right sides of the machine from the normal operating position.
Premaintenance Procedures Many of the subjects covered in this maintenance section require raising and lowering the bed. The following precautions must be taken or serious injury or death could result. WARNING Before servicing or making adjustments to the machine, stop engine, set parking brake, and remove key from the ignition switch. Remove any load material from the bed or other attachment before working under a raised bed.
Figure 33 Figure 32 1. Bed mounting plate 4. Lynch pin 2. Cylinder rod end 5. Rear slots (Full bed) 3. Clevis pin 6. Front slots (2/3 bed) 1. Left rear corner of bed 4. Clevis pin 2. Vehicle frame channel 5. Lynch pin 3. Pivot plate CAUTION 3. Remove the clevis pins securing the cylinder rod ends to the bed mounting plates by pushing the pins towards the inside (Figure 32). The full bed weighs approximately 147.5 kg (325 lb), so do not try to install or remove it by yourself.
frame channel and install 2 clevis pins and lynch pins (Figure 34). 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 34). 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.
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. The grease fitting locations and quantities are as follows: • Ball joints (4), tie rods (2), pivot mounts (2) and steering cylinder (2) (Figure 38) • Spring tower (2) (Figure 39) • Clutch (1), accelerator (1), brake (qty.
Figure 40 Figure 39 Figure 41 38
Engine Maintenance 5. Remove the safety filter only if you intend to replace it. Important: Never attempt to clean the safety filter. If the safety filter is dirty, then the primary filter is damaged and both filters should be replaced. Servicing the Air Cleaner Service Interval: Before each use or daily—Check the air filter service indicator. 6. Inspect the new filter(s) for damage by looking into the filter while shining a bright light on the outside of the filter.
Fuel System Maintenance Fuel Lines and Connections Service Interval: Every 400 hours/Yearly (whichever comes first) Every 1,000 hours/Every 2 years (whichever comes first) Inspect the fuel lines and connections for deterioration, damage, or loose connections. Servicing the Water Separator/Fuel Filter Figure 44 Draining the Fuel Filter/Water Separator 1. Engine oil filter Service Interval: Before each use or daily—Drain water or other contaminants from the water separator. 1.
Electrical System Maintenance 4. Lubricate the gasket on the filter canister with clean oil. 5. Install the filter canister by hand until the gasket contacts mounting surface, then rotate it an additional 1/2 turn. Fuses 6. Tighten the drain plug on the bottom of the filter canister. The fuses for the machine’s electrical system are located under the center of the dash panel (Figure 46 & Figure 47). Figure 46 1. Fuses Figure 47 41 1. 4WD, Transmission 10A 5. Horn, power point 15A 2.
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 D.C. 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 51). Figure 52 3. Spring 2. Transaxle bracket 4. 0.25 to 1.5 mm (0.01 to 0.06 inch) gap 3. Adjust the jam nuts to obtain a 0.25 to 1.5 mm (0.01 to 0.06 inch) gap between the spring hook and the OD of the hole in the transaxle lever. Figure 51 1. Shift arm (1st—Rev.) 1.
Figure 54 1. Over inflated tire Figure 56 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 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.
13. Stop the engine. Check the coolant level and replenish it, if required. 1 G019522 Figure 60 1. Reserve tank cap 5. Disconnect the lower radiator hose and allow coolant to flow into a drain pan. When coolant stops, connect the lower radiator hose. 6. Open the bleed screw on top of the water pump (Figure 61). Figure 61 1. Bleed screw 7. Remove the coolant drain plug from the engine and allow coolant to flow into a drain pan. When coolant stops, install the drain plug. 8.
Brake Maintenance Adjusting the Brake Pedal Service Interval: Every 200 hours Adjusting the Parking Brake Note: Remove the front 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 64). Every 200 hours 1. Remove the rubber grip from the parking brake lever (Figure 62). Figure 62 Figure 64 1. Parking brake lever 2. Grip 1. Master cylinder yoke 2.
Belt Maintenance Controls System Maintenance Adjusting Belts Adjusting the Accelerator Pedal Adjusting the Alternator Belt Service Interval: After the first 8 hours—Check the condition and tension of the alternator belt. 1. Position the vehicle on a level surface, stop the engine, and engage the parking brake. 2. Adjust the ball joint on the accelerator cable (Figure 67) to allow 2.54 to 6.35 mm (0.100 to 0.
1. Loosen the jam nuts securing the clutch cable to the bracket on the bell housing (Figure 69). Figure 69 1. Clutch cable 3. Return spring 2. Jam nuts 4. Ball joint Figure 71 Note: You may remove and rotate the ball joint, if additional adjustment is required. 1. Clutch cable rod end 3. Rod end jam nut 2. Clutch pedal 4. Parallel Note: The clutch free play should never be less than 19 mm (0.75 inch). 2. Disconnect the return spring from the clutch lever. 3.
Hydraulic System Maintenance Changing the Hydraulic Fluid and Cleaning the Strainer Service Interval: Every 800 hours 1. Position the vehicle on a level surface, stop the engine, engage the parking brake, and remove the key from the ignition switch. 2. Remove the drain plug from the side of the reservoir and let the hydraulic fluid flow into a drain pan (Figure 72). Figure 73 Note: Clean the hydraulic strainer. Refer to 1.
• 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 oil is available in 20 ml (2/3 oz.) bottles. One bottle is sufficient for 15–22 1 (4–6 gal) of hydraulic oil. Order part no. 44-2500 from your authorized Toro distributor. Figure 74 1.
Raising the 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. Any load material must be removed from 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.
Storage 1. Position the machine on a level surface, set the parking brake, stop the engine, and remove the ignition key. 2. Clean dirt and grime from the entire machine, including the outside of the engine cylinder head fins and blower housing. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Important: You can wash the machine with mild detergent and water. Do not use high pressure water to wash the machine. Pressure washing may damage the electrical system or wash away necessary grease at friction points.
Schematics Hydraulic Schematic (Rev. B) High Flow Hydraulics Schematic (TC models only) (Rev.
G01951 1 Electrical Schematic (Rev.
Notes: 57
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).
