Form No. 3362-385 Rev A Industrial Workman® HDX-D Utility Vehicle with Bed Model No. 07354—Serial No. 311000001 and Up To register your product or download an Operator's Manual or Parts Catalog at no charge, go to 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.
Contents Maintenance............................................................... 30 Recommended Maintenance Schedule(s) ................ 30 Service Interval Chart......................................... 31 Heavy Duty Operation ....................................... 32 Premaintenance Procedures.................................... 32 Removing the Full Bed ....................................... 32 Installing the Full Bed......................................... 32 Jacking the Vehicle....................
Safety The machine meets the requirements of SAE J2258. feel than what drivers experience with passenger cars or trucks. So take time to become familiar with your Workman. Supervisors, operators and service persons should be familiar with the following standards and publications: (The material may be obtained from the address shown). • Flammable and Combustible Liquids Code: Not all of the attachments that adapt to the Workman are covered in this manual.
• Wearing safety glasses, safety shoes, long pants, and a helmet is advisable and required by some local safety and insurance regulations. • Keep everyone, especially children and pets, away from the areas of operation. • 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 diesel fuel is highly flammable, handle it carefully.
• • • • – Keep all bystanders away. Before backing up, look to the rear and ensure that no one is behind the vehicle. Back up slowly. – Watch out for traffic when near or crossing roads. Always yield the right of way to pedestrians and other vehicles. This vehicle is not designed for use on streets or highways. Always signal your turns or stop early enough so other persons know what you plan to do. Obey all traffic rules and regulations.
• Measured vibration level for left hand = 0.2 m/s2 • Uncertainty Value (K) = 0.5 m/s2 Measured values were determined according to the procedures outlined in EN 1032. Whole Body • Measured vibration level = 0.3 m/s2 • Uncertainty Value (K) = 0.5 m/s2 Measured values were determined according to the procedures outlined in EN 1032. Sound Level Certification When tested per ITSDF B56-11-5-2005 the vehicle meets Alcoa 30.3.2 Section 4.1.
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 1. Falling, crushing hazard, bystanders—no riders on machine. 115-2047 1. Warning—do not touch the hot surface. 115-7723 1. Warning—the hydraulic oil pressure is 124 bar (1800 PSI). 2. Coupler A 3.
115-2281 1. Headlights 2. Horn 3. Engine—stop 4. Engine—run 5. Engine—start 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 4. Tipping hazard—slow down and turn gradually, use caution remove the ignition key before leaving the machine. 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.
115-7814 106-6755 1. Engine coolant under pressure. 2. Explosion hazard—read the Operator’s Manual. 115-7813 1. Power outlet 10A 2. Switched power 10A 3. Fuel pump, supervisor switch 10A 4. Horn, power point 15A 3. Warning—do not touch the hot surface. 4. Warning—read the Operator’s Manual. 5. Lights, brake 15A 6. Hazard 10A 7. 4WD, Transmission 10A 93-9879 1. Stored energy hazard—read the Operator’s Manual. 93-7814 1. Entanglement hazard, belt—stay away from moving parts. 115-7741 1.
93-9850 1. Do not repair or revise—read the Operator’s Manual. 105-4215 1. Warning—avoid pinch points. 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. 106-2353 93-9899 1. Electrical power point 93-9899 1. Crushing hazard—install the cylinder lock. 106-2355 1. Slow 3. Transmission—third high; no fast speed 2. Fast 115-7756 1.
106-2377 1. Locked 2. Differential lock 3. 4. 5. 6. 7. 8. Warning—read the Operator’s Manual. 9. Entanglement hazard, shaft—keep bystander’s a safe distance from the vehicle. 10. Retract hydraulics 11. Extend hydraulics 12. Transmission—high speed 13. Transmission—low speed 14. Parking brake Unlocked Hydraulic lock Engage Power take-off (PTO) Disengage Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 No parts required Qty. Use – Check the engine oil, transaxle/hydraulic fluid, and brake fluid levels Media and Additional Parts Description Use Qty.
Product Overview Gear Shift Lever Controls Fully press the clutch pedal and move the shift lever (Figure 4) 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 3) gives the operator the ability to vary the engine and ground speed of the vehicle, when the transmission is in gear.
Figure 5 1. Gear shift lever 2. Parking brake 3. High–low range shifter Figure 6 1. High flow hydraulics switch (Optional) 2. Horn 3. Tachometer 4. Hour meter 5. Speedometer 6. Coolant temperature gauge and light 7. Fuel gauge High–Low Range Shifter The high–low range shifter adds three additional speeds for precise speed control (Figure 5). • The vehicle must be completely stopped before shifting between High and Low range. • Shift only on level ground. 8. Ignition switch 9. 10. 11. 12. 13.
High Flow Hydraulics Switch (If so equipped) either a bulb is burned out or there is a malfunction in the system which must be repaired. Note: If engine was just turned off, it may take 1 to 2 minutes for the light to come on. Turn on the switch to activate the high flow hydraulics (Figure 6). Low Oil Pressure Shut Down Horn Button If the engine oil pressure drops below a safe level, for more than 10 seconds, the engine will shut down. Contact your local Toro distributor for assistance.
Specifications Note: Specifications and design are subject to change without notice. Dimensions Figure 8 1. Passenger hand hold 2. Storage compartment Overall Width 63 inches (160 cm) Overall Length w/o bed: 128.25 inches (326 cm) w/full bed: 130.38 inches (331 cm) w/2/3 bed in rear mounting location: 136.38 inches (346 cm) Base Weight (Dry) 1806 lb (819 kg) Rated Capacity (includes 200 lb. operator, 200 lb. passenger and loaded attachment). 3044 lb (1381 kg) Maximum.
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. Checking the Engine Oil Level Service Interval: Before each use or daily Figure 11 The engine is shipped with approximately 3.5 quarts (3.3 l) (w/ filter) of oil in the crankcase; however, you should check the oil level before and after the engine is first started.
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.
Figure 15 1. Reserve tank 2. Hot line 3. Cold line Figure 14 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. 1. Fuel tank cap 3. Fill the tank to about one inch below the top of the tank, (bottom of the filler neck), then install the cap. Do not overfill. 4. Install the reserve tank cap. Checking the Transaxle/Hydraulic Fluid Level 4. Wipe up any fuel that may have spilled to prevent a fire hazard.
3. Unscrew the dipstick from the top of the transaxle and wipe it with a clean rag. 4. Screw the dipstick into the transaxle and ensure that it is fully seated. 5. Unscrew the dipstick and check the fluid level. WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury. • 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.
Checking the Torque of the Wheel Nuts Service Interval: After the first 2 hours After the first 10 hours Every 200 hours WARNING Figure 20 Failure to maintain proper torque of the wheel nuts could result in failure or loss of a wheel and may result in personal injury. 1. Over inflated tire Torque the front and rear wheel nuts to 80 to 90 ft-lb (109 to 122 N-m) after 1 to 4 hours of operation and again after 10 hours of operation. Torque every 200 hours thereafter.
• Initial start up of a new machine. • The engine has ceased running due to lack of fuel. • You have performed maintenance upon the fuel system components; i.e., filter replaced, separator serviced, etc. 1. Sit on the operator’s seat and engage the parking brake. 2. Disengage the PTO and high flow hydraulics (if so equipped) and move the hand throttle lever to the Off position (if so equipped). 3. Move the shift lever to the Neutral position and press the clutch pedal. 4.
Use the chart below to determine the ground speed of the vehicle. Gear Range Ratio 1 L 82.83 : 1 2.9 4.7 1.9 3.0 2 L 54.52 : 1 4.5 7.2 2.9 4.6 3 L 31.56 : 1 7.7 12.4 4.9 7.9 1 H 32.31 : 1 7.6 12.2 4.9 7.8 2 H 21.27 : 1 11.5 18.5 7.3 11.8 3 H 12.31 : 1 19.8 31.9 12.7 20.4 R L 86.94 : 1 2.8 4.5 1.8 2.9 R H 33.91 : 1 7.1 11.4 4.5 7.
Operating Characteristics One of the most important rules to follow is to go slower in unfamiliar areas. It is surprising how much damage and injury common things can cause. Tree branches, fences, wires, other vehicles, tree stumps, ditches, sand traps, streams, and other things found in most parks and golf courses can be hazardous to the operator and passenger. The vehicle is designed with safety in mind. It has four wheels for added stability.
Braking It is good practice to slow down before you get near an obstacle. This gives you extra time to stop or turn away. Hitting an obstacle can damage the vehicle and its contents. More important, it can injure you and your passenger. Gross vehicle weight has a major impact on your ability to stop and/or turn. Heavier loads and heavier attachments make a vehicle harder to stop or turn.
if the operator is using the ROPS system and seat belts and is following the instructions provided. • Adding liquid ballast (calcium chloride) to rear tires. • Traction will increase with no passenger in front seat. Hills Loading and Dumping WARNING The weight and position of the cargo and passenger can change the vehicle center of gravity and vehicle handling. To avoid loss of control resulting in personal injury, follow these guidelines.
Heavy loads increase stopping distance and reduce your ability to turn quickly without tipping over. The rear cargo space is intended for load carrying purposes only, not for passengers. Four Wheel Drive (Four Wheel Drive Models Only) The Automatic on Demand four wheel drive feature, on this vehicle does not require operator activation. The front wheel drive is not engaged (no power delivered to front wheels) until the rear wheels begin to lose traction.
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 3500 lb (1587 kg).
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 condition and tension of the alternator belt. After the first 10 hours • • • • • After the first 50 hours • Change engine oil and filter. • Adjust the engine valve clearance. Before each use or daily • • • • • • • • • Torque the front and rear wheel nuts. Check the adjustment of the shift cables.
Maintenance Service Interval Every 800 hours Every 1,000 hours Maintenance Procedure • • • • Change the front differential oil. Change the hydraulic fluid and clean the strainer. Replace the hydraulic filter. Change the high flow hydraulic oil and filter (if so equipped). • 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.
Heavy Duty Operation Important: If the vehicle is subjected to any of the conditions listed below, maintenance should be performed twice as frequently: • Desert operation • Cold climate operation below 32 degrees F (0 degrees C) • Trailer towing • Frequent operation on dusty roads • Construction work • After extended operation in mud, sand, water, or similar dirty conditions, have your brakes inspected and cleaned as soon as possible. This will prevent any abrasive material from causing excessive wear.
1. Carefully set the bed onto the vehicle frame aligning the rear bed pivot plate holes with the holes in the rear frame channel and install 2 clevis pins and lynch pins (Figure 29). 2. On each side of the machine, secure the bed mounting bracket to the frame bracket with the flange head bolt and flange nut previously removed (Figure 28) Jacking the Vehicle DANGER Figure 31 A vehicle on a jack may be unstable and slip off of the jack, injuring anyone beneath it. 1.
Lubrication To install the hood, complete the following: 1. Connect the lights. 3. Insert the lower mounting tabs into the frame slots. Greasing Bearings and Bushings 4. Ensure that the hood is fully engaged in the top, sides and bottom grooves. Service Interval: Every 100 hours (Lubricate more frequently in heavy duty applications) 2. Insert the top mounting tabs into the frame slots. The vehicle has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
Figure 34 Figure 36 Figure 35 35
Figure 37 36
Engine Maintenance 5. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister. Servicing the Air Cleaner 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. Service Interval: Every 200 hours—Change the air cleaner filter. (more frequently in dusty or dirty conditions) 7.
4. Screw the filter on until the gasket contacts the mounting plate, then tighten the filter 1/2 to 2/3 of a turn. Do not overtighten. Fuel System Maintenance 5. Add oil to the crankcase; refer to Checking the Engine Oil Level. 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.
Electrical System Maintenance 3. Remove the filter canister and clean the mounting surface. 4. Lubricate the gasket on the filter canister with clean oil. Fuses 5. Install the filter canister by hand until the gasket contacts mounting surface, then rotate it an additional 1/2 turn. The fuses for the machine’s electrical system are located under the center of the dash panel (Figure 42 & Figure 43). 6. Tighten the drain plug on the bottom of the filter canister. Figure 42 1.
Jump Starting the Vehicle Connect it to the engine or frame. Do not connect the jumper cable to the fuel system. 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.
Drive System Maintenance DANGER Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands. Changing the Front Differential Oil (Four Wheel Drive Models Only) • Fill the battery where clean water is always available for flushing the skin. Service Interval: Every 800 hours 1.
Adjusting the Shift Cables Check the tire pressure frequently to ensure proper inflation. If the tires are not inflated to the correct pressure, the tires will wear pre maturely. 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 47). Figure 48 is an example of tire wear caused by under inflation. Figure 48 1.
Cooling System Maintenance Removing Debris from the Cooling System Service Interval: Before each use or daily (Clean more frequently in dirty conditions.) Figure 50 1. Front of vehicle 2. 0 ± 0.12 inch (0 ± 3 mm) front to rear of tire 1. Turn the engine off. Clean the engine area thoroughly of all debris. 3. Center to center distance 2. Remove the (5) bolts securing radiator screen/guard to the radiator The guard is not shown in the figure. (Figure 52). Remove the screen/guard. 3.
Note: Blow debris away from the radiator. 5. Install the cooler and screen to the radiator. 5. Open the bleed screw on top of the water pump (Figure 56). Changing Engine Coolant Service Interval: Every 1,000 hours/Every 2 years (whichever comes first) 1. Park the machine on a level surface. 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 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 59). Every 200 hours 1. Remove the rubber grip from the parking brake lever (Figure 57). Figure 57 1. Parking brake lever Figure 59 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 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 62) to allow 0.100 to 0.250 inch (2.54 to 6.
Adjusting the Clutch Pedal 5. Recheck the 3.75 ± 0.12 inch (9.5 ± 0.3 cm) dimension after the jam nuts have been tightened to ensure proper adjustment. Readjust, if necessary. Service Interval: Every 200 hours 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. 6. Connect the return spring to the clutch lever.
Hydraulic System Maintenance Changing the Hydraulic Fluid and Cleaning the Strainer Service Interval: Every 800 hours 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 67). Figure 68 1. Hydraulic strainer Note: Clean the hydraulic strainer. Refer to Cleaning Hydraulic Strainer. 5. Install the strainer. 6.
• Viscosity—ASTM D445 cSt @ 40ºC: 44 to 48/cSt @ 100ºC: 7.9 to 8.5 • Viscosity Index, ASTM D2270—140 to 152 • Pour Point, ASTM D97— -35ºF to -46ºF • FZG, Fail stage—11 or better • Water content (new fluid)—500 ppm (maximum) Industry Specifications: Figure 69 1. Hydraulic filter Vickers I-286-S, Vickers M-2950-S, Denison HF-0, Vickers 35 VQ 25 (Eaton ATS373-C) 2. High flow hydraulics filter Note: Many hydraulic fluids are almost colorless, making it difficult to spot leaks.
Storage Paint is available from your Authorized Service Dealer. 1. Position the machine on a level surface, set the parking brake, stop the engine, and remove the ignition key. 15. Store the machine in a clean, dry garage or storage area. 16. Remove the ignition key and put it in a safe place out of the reach of children. 2. Clean dirt and grime from the entire machine, including the outside of the engine cylinder head fins and blower housing. 17. Cover the machine to protect it and keep it clean.
Schematics Hydraulic Schematic (Rev.
High Flow Hydraulics Schematic (Optional) (Rev.
Electrical Schematic (Rev.
Notes: 54
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).
