Form No. 3393-430 Rev A Workman® HD Utility Vehicle with Bed Model No. 07369—Serial No. 315000001 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.
Contents Servicing the Air Cleaner .........................................35 Changing the Engine Oil And Filter ..........................35 Replacing the Spark Plugs ........................................36 Fuel System Maintenance ...........................................37 Replacing the Fuel Filter..........................................37 Inspecting the Fuel Lines and Connections.................37 Electrical System Maintenance ....................................37 Servicing the Fuses .........
Safety • Become familiar with the controls and know how to stop Safe Operating Practices • Keep all shields, safety devices and decals in place. If a the engine quickly. shield, safety device or decal is malfunctioning, illegible, or damaged, repair or replace it before operating the machine. Important: The machine is designed primarily as an off-road vehicle and is not intended for extensive use on public roads.
• • the machine. Never overfill attachments or exceed the machine maximum gross machine weight (GVW). When starting the engine: – Sit on operator’s seat and ensure that the parking brake is engaged. – Disengage PTO (if so equipped) and return the hand throttle lever to the Off position (if so equipped). – Move shift lever to Neutral and press clutch pedal. – Make sure the hydraulic lift lever is in the center position.
• Before disconnecting or performing any work on the • • • • ensure safety and accuracy, have an Authorized Toro Distributor check the maximum engine speed with a tachometer. hydraulic system, all pressure in the system must be relieved by stopping the engine, cycling the dump valve from raise to lower and/or lowering box and attachments. Place the remote hydraulics lever in the float position. If the box must be in raised position, secure it with the safety support.
93-9879 1. Stored energy hazard—read the Operator's Manual. 115-2047 1. Warning—do not touch the hot surface. 115-7739 93-9899 1. Falling, crushing hazard, bystanders—no riders on machine. 93-9899 1. Crushing hazard—install the cylinder lock. 105-4215 1. Warning—avoid pinch points. 115-7740 1. Warning—maximum trailer weight is 680 kg (1500 lb), maximum tongue weight is 90 kg (200 lb). 2.
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. Read the Operator's Manual. 115-7723 10.
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. 115-2281 1. Headlights 4. Engine—run 2. Horn 5. Engine—start 3. Engine—stop 117–2718 115-7813 9 1. Power outlet—10A 5. Lights, brake—15A 2.
115-7814 115-7746 1. Warning—do not operate this machine unless you are trained. 3. Fire hazard—stop the engine before fueling. 2. Warning—lock the parking brake, stop the engine, and remove the ignition key before leaving the machine. 4. Tipping hazard—slow down and turn gradually, use caution and drive slowly when driving on slopes, do not exceed 32 kph (20 mph), and drive slowly over rough terrain or when carrying a full or heavy load.
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 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.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 No parts required – Check the engine oil, the transaxle/hydraulic fluid, and the brake fluid levels. 2 ROPS frame Flange-head bolt (1/2 x 1-1/4 inch) 1 6 Mount the ROPS (Rollover Protection System). Media and Additional Parts Description Use Qty.
Product Overview Controls Note: Determine the left and right sides of the machine from the normal operating position. Accelerator Pedal The accelerator pedal (Figure 4) gives the operator the ability to vary the engine and ground speed of the machine when the transmission is in gear. Pressing the pedal increases the engine rpm and ground speed. Releasing the pedal decreases the engine rpm and ground speed of the machine. Figure 3 1. ROPS mounting bracket 2. Flange-head bolt 3.
Gear Shift Lever Fully press the clutch pedal and move the shift lever (Figure 6) into the desired gear selection. A diagram of the shift pattern is in Figure 5. Figure 6 Figure 5 Important: Do not shift the transaxle to the reverse or forward gear unless the machine is standing still. Damage to the transaxle may occur. 1. Gear shift lever 4. Hydraulic lift lock 2. Parking brake 5. Differential lock 3. Hydraulic bed lift 6.
Light Switch High is for higher speed driving on level, dry surfaces with light loads. Push the light switch (Figure 7), to toggle the headlights on or off. 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).
Choke Specifications To start a cold engine, close the carburetor choke by pulling the choke control (Figure 7) out to the On position. After the engine starts, regulate the choke to keep the engine running smoothly. As soon as possible, open the choke by pushing in the choke control to the Off position. A warm engine requires little or no choking. Note: Specifications and design are subject to change without notice.
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 hands and other body parts clear when lowering the box. 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.
• Above –20 degrees C (0 degrees F)—Use 10W-30. • Below 0 degrees C (32 degrees F)—Use SAE 5W-30. Note: SAE 10W-40 and straight weight oils (SAE 30, etc.) are not recommended in Kohler® engines due to problems with pump-up of hydraulic lifters with those oils. Either synthetic or mineral based oils may be used, but oil drain intervals should be the same (per recommendations). 1. Position the machine on a level surface. 2. Remove the dipstick (Figure 12) and wipe it with a clean rag. Figure 13 1.
DANGER WARNING 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. Gasoline is harmful or fatal if swallowed. Long-term exposure to vapors can cause serious injury and illness. • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any gasoline that spills. • Keep face away from nozzle and gas tank or conditioner bottle opening.
Checking the Torque of the Wheel Nuts 2. Clean the area around the dipstick (Figure 15). Service Interval: After the first 2 hours After the first 10 hours Every 200 hours WARNING Failure to maintain proper torque of the wheel nuts could result in failure or loss of a wheel and may result in personal injury. Torque the front and rear wheel nuts to 109 to 122 N-m (80 to 90 ft-lb) after 1 to 4 hours of operation and again after 10 hours of operation. Torque every 200 hours thereafter. Figure 15 1.
Checking the Brake-fluid Level Service Interval: Before each use or daily—Check the brake-fluid level. Every 1,000 hours/Every 2 years (whichever comes first)—Change the brake fluid. The brake-fluid reservoir is shipped from the factory filled with DOT 3 brake fluid. Check the level before the engine is first started and every 8 hours or daily, thereafter. The brake-fluid reservoir is located under the dash. 1. Park the machine on a level surface. 2.
Driving the Machine • Check the fluid and engine oil levels regularly and be alert 1. 2. 3. 4. Release the parking brake. Fully press the clutch pedal. Move the gear shift lever to 1st gear. Release the clutch pedal smoothly while pressing the accelerator pedal. 5. When the machine gains enough speed, remove your foot from the accelerator pedal, fully press the clutch pedal, move the gear shift lever to the next gear and release the clutch pedal while pressing the accelerator pedal.
Verifying the Hydraulic-lift Lever Interlock Switch 1. Sit on the operator’s seat and engage the parking brake. 2. Move the shift lever to the Neutral position and ensure that the hydraulic-lift lever is in the center position. 3. Press clutch pedal. 4. Move the hydraulic-lift lever forward and rotate the ignition key clockwise to the start position. Note: If engine cranks or starts, there is a malfunction in the interlock system that must be repaired before operating the machine.
Ensuring Proper Braking Operating on Hills 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 machine and its contents. More important, it can injure you and your passenger. Gross machine weight has a major impact on your ability to stop and/or turn. Heavier loads and heavier attachments make a machine harder to stop or turn.
Using The Differential Lock Do not carry loads which exceed the load limits described on the machine weight label. The differential lock increases the machine’s traction by locking the rear wheels so one wheel will not spin out. This can help when you have heavy loads to haul on wet turf or slippery areas, going up hills, and on sandy surfaces. It is important to remember however, that this extra traction is only for temporary limited use.
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). Always load a trailer with 60% of the cargo weight in the front of the trailer. This places approximately 10% (272 kg (600 lb) max.) of the Gross Trailer Weight (GTW) on the tow hitch of the machine.
CAUTION 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. Connecting the Quick Couplers Important: Clean dirt from quick couplers before connecting.
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 air cleaner paper element. 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. Check the condition and tension of the pump drive belt.
Operating in Adverse Conditions Important: If the machine is subjected to any of the conditions listed below, maintenance should be performed twice as frequently: • Desert operation • Cold climate operation below 0° C (32° F) • 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.
Figure 29 Figure 28 1. Cylinder rod end 4. Lynch pin 2. Bed mounting plate 5. Rear slots (Full bed) 3. Clevis pin 6. Front slots (2/3 bed) 1. Left rear corner of bed 4. Clevis pin 2. Machine frame channel 5. Lynch pin 3. Pivot plate Note: Ensure that the spacer brackets and wear blocks (Figure 30) are installed with the carriage bolt heads positioned inside the machine. 4.
4. Insert the clevis pin from outside of the bed with the lynch pin toward the outside (Figure 29). Note: 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. Keep fingers out! Note: The unused slot can be plugged with a bolt and nut to prevent assembly errors. 5. Start the engine and engage the hydraulic lift lever to raise the bed.
Lubrication Greasing 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 35 Figure 36 Figure 37 34
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 38). 1 Figure 39 1. Knob and O-ring 5. Breather seal 2. Air cleaner cover 6. Foam pre-cleaner 3. Wing nut 7. Paper element 4. Inner cover 2. Remove the foam pre-cleaner by sliding it off of the paper element, and clean it as follows: A. Wash the foam pre-cleaner in detergent and warm water. B.
1. Raise the bed (if so equipped) and place the safety support on the extended lift cylinder to hold up the bed. Replacing the Spark Plugs 2. Remove the drain plug and let oil flow into a drain pan (Figure 40). When the oil stops, install the drain plug. The spark plugs usually last a long time; however, the plugs should be removed and checked whenever the engine malfunctions. Replace the spark plugs to ensure proper engine performance and reduce exhaust emission level.
Fuel System Maintenance Electrical System Maintenance Replacing the Fuel Filter Servicing the Fuses Service Interval: Every 400 hours The fuses for the machine’s electrical system are located under the center of the dash panel (Figure 43 & Figure 44). 1. Raise the bed (if so equipped) and place the safety support on the extended lift cylinder to hold up the bed. 2. Place a clean container under the fuel filter (Figure 42). Figure 43 1. Fuses Figure 42 1. Fuel filter 3.
Jump Starting the Machine Note: Do not connect the other end of the jumper cable to the negative post of the discharged battery. 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 machine, observe the following warnings: • Never jump start with a voltage source greater than 15 volts D.C. This will damage the electrical system.
Drive System Maintenance • If corrosion occurs at terminals, remove the battery cover, disconnect the cables (negative (–) cable first), and scrape the clamps and terminals separately. Reconnect the cables (positive (+) cable first) and coat the terminals with petroleum jelly. Adjusting the Shift Cables • If you store the machine in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool.
2. Loosen the jam nuts securing the differential lock cable to the bracket on the transaxle (Figure 48). Figure 50 1. Over inflated tire Checking the Front-wheel Alignment Service Interval: Every 400 hours/Yearly (whichever comes first) Figure 48 1. Differential lock cable 3. Spring 1. Make sure the tires are facing straight ahead. 2. Transaxle bracket 4. 0.25 to 1.5 mm (0.01 to 0.06 inch) gap 2.
Cooling System Maintenance Removing Debris from the Engine Cooling System Service Interval: Every 100 hours (Clean more frequently in dirty conditions.) To ensure proper cooling, clean the blower housing and other cooling shrouds and clean the cooling fins and external surfaces. Figure 52 1. Tie rods Note: Operating the engine with dirty or plugged cooling fins or with the cooling shrouds removed, will cause engine damage due to overheating. 2. Jam nuts B.
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 55). Every 200 hours 1. Remove the rubber grip from the parking brake lever (Figure 53). Figure 53 Figure 55 1. Parking brake lever 2. Grip 1. Master cylinder yoke 2.
Belt Maintenance Controls System Maintenance Checking the Pump Belt Tension Adjusting the Clutch Pedal Service Interval: After the first 10 hours Every 200 hours 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. Check the pump belt for wear, cracking, or improper tension.
Note: Force is applied so the clutch release bearing lightly contacts the pressure plate fingers. 4. Tighten the jam nuts after the adjustment has been attained. 5. Recheck the 9.5 ± 0.3 cm (3.75 ± 0.12 inch) dimension after the jam nuts have been tightened to ensure proper adjustment. Readjust, if necessary. 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 machine on a level surface, stop the engine, engage the parking brake, and remove the key from the ignition switch. Figure 62 2. Remove the drain plug from the side of the reservoir and let the hydraulic fluid flow into a drain pan (Figure 63). 1. 2.54 to 6.35 mm (0.100 to 0.250 inch) clearance Note: The engine must not be running and the return spring must be attached.
Figure 65 1. Hydraulic filter 3. Lubricate the gasket on the new filter. 4. Ensure that the filter mounting area is clean. Screw the filter on until the gasket contacts the mounting plate. Then tighten the filter one-half turn. 5. Start the engine and let it run for about two minutes to purge air from the system. Stop the engine and check the hydraulic oil level and for leaks. Figure 64 1. Hydraulic strainer 5. Install the strainer. 6.
make sure the machine used to jump the hydraulic system uses an equivalent fluid. 2. On both machines, disconnect the 2 quick coupler hoses from the hoses secured to the coupler bracket (Figure 66). Figure 68 1. Jumper hoses 7. Keep all bystanders away from the machines. 8. Start the second machine and move the lift lever to the raise position which will raise the disabled box. Figure 66 1. Quick coupler hose A 9. Move the hydraulic lift lever to the neutral position and engage the lift lever lock. 2.
Cleaning Washing the Machine 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. 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.
Storage 11. Use the starter to crank the engine and distribute the oil inside the cylinder. 1. Position the machine on a level surface, set the parking brake, stop the engine, and remove the ignition key. 12. Install the spark plugs and tighten to recommended torque; refer to Replacing the Spark Plugs (page 36). 2. Clean dirt and grime from the entire machine, including the outside of the engine cylinder head fins and blower housing. Note: Do not install the wire on the spark plug(s). 13.
Troubleshooting Problem Possible Cause Corrective Action The engine does not start, starts hard, or fails to keep running. 1. The hydraulic lever is locked in forward position 1. Move the hydraulic lever out of forward position. 2. 3. 4. 5. 2. 3. 4. 5. The fuel tank is empty. The fuel-shutoff valve is closed. The oil level in the crankcase is low. The throttle is not in the correct position. 6. There is dirt, water, or stale fuel is in the fuel system. 7. The air cleaner is dirty. 8.
Notes: 51
Toro General Commercial Product 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).
