Form No. 3427-811 Rev A Workman® HD Utility Vehicle Model No. 07369—Serial No. 404350001 and Up Register at www.Toro.com.
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Contents Replacing the Fuel Filter ................................... 41 Electrical System Maintenance ........................... 41 Electrical System Safety ................................... 41 Servicing the Fuses .......................................... 41 Jump-Starting the Machine............................... 42 Servicing the Battery......................................... 43 Drive System Maintenance .................................. 43 Adjusting the Shift Cables...............................
Safety This machine has been designed in accordance with the requirements of SAE J2258 (Nov 2016). General Safety This product is capable of causing personal injury. Always follow all safety instructions to avoid serious personal injury. • Read and understand the contents of this Operator’s Manual before you start the machine. Ensure that everyone using this product knows how to use it and understands the warnings. • Use your full attention while operating the machine.
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. decalbatterysymbols Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 6. Keep bystanders away 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.
decal105-4215 105-4215 decal106-2355 1. Warning—avoid pinch points. 106-2355 1. Slow 3. Transmission—third high; no fast speed 2. Fast decal106-2353 106-2353 1. Electrical power point decal106-2377 106-2377 1. Locked 8. Warning—read the Operator's Manual. 2. Differential lock 9. Entanglement hazard, shaft—keep bystanders out of the operating area. 3. Unlocked 10. Retract hydraulics 4. Hydraulic lock 11. Extend hydraulics 5. Engage 12. Transmission—high speed 6. Power takeoff (PTO) 13.
decal106-7767 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. decal115-2047 115-2047 1. Warning—do not touch the hot surface. decal115-2282 115-2282 1. Warning—read the Operator's Manual. 2. Warning—stay away from moving parts; keep all guards and shields in place. 3.
decal115-7741 115-7741 1. Read the Operator’s Manual before servicing transmission fluid. decal115-7723 115-7723 1. Warning—the hydraulic-fluid pressure is 124 bar (1,800 psi). 2. Coupler A 3. Coupler B decal115-7813 115-7813 1. Power outlet (10 A) decal115-7739 115-7739 1. Falling, crushing hazard—do not carry passengers. 5. Lights, brake (15 A) 2. Switched power (10 A) 6. Hazard (10 A) 3. Fuel pump, supervisor switch (10 A) 7. 4WD, Transmission (10 A) 4.
decal121-9776 121-9776 1. Warning—read the Operator’s Manual and receive proper training before operating the machine. 4. Warning—engage the parking brake, shut off the engine, and remove the key from the key switch before walking away from the machine. 5. Tipping hazard—take turns slowly; drive slowly up and across cliffs; with no load, do not exceed 32 kph (20 mph); while carrying a load or when driving on uneven terrain, drive slowly. 2. Warning—wear hearing protection. 3.
decal138-3523 138-3523 1. Headlights 4. Engine—Run 2. Horn 5. Engine—Start 3.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 Description Qty. Use No parts required – Check the fluid levels and tire pressure. Roll bar Flange-head bolt (1/2 x 1-1/4 inches) 1 6 Install the roll bar. No parts required – Burnish the brakes. Note: Determine the left and right sides of the machine from the normal operating position. 1 Checking the Fluid Levels and Tire Pressure No Parts Required Procedure 1.
2 3 Installing the Roll Bar Burnishing the Brakes Parts needed for this procedure: No Parts Required 1 Roll bar 6 Flange-head bolt (1/2 x 1-1/4 inches) Procedure To ensure optimum performance of the brake system, burnish the brakes before use. Procedure 1. Apply medium-grade (service-removable) thread-locking compound to the threads of the 6 flange-head bolts (1/2 x 1-1/4 inches). 2. Align each side of the roll bar with the mounting holes on each side of the machine frame (Figure 3). 1.
Clutch Pedal Product Overview You must fully press the clutch pedal (Figure 5) to disengage the clutch when starting the engine or shifting transmission gears. Release the pedal smoothly when the transmission is in gear to prevent unnecessary wear on the transmission and other related parts. Controls Become familiar with all the controls before you start the engine and operate the machine. Important: Do not ride the clutch pedal during Control Panel operation.
Differential Lock Hydraulic-Lift Lever The differential lock (Figure 7) allows the rear axle to lock for increased traction. You can engage the differential lock when the machine is in motion. The hydraulic lift raises and lowers the bed. Move it rearward to raise the bed, and forward to lower it (Figure 7). Move the lever forward and to the right to engage the lock.
Hour Meter Charge Indicator The hour meter indicates the total hours of machine operation. The hour meter (Figure 4) starts to function whenever you rotate the key switch to the ON position or if the engine is running. The charge indicator illuminates when the battery discharges. If the light illuminates during operation, stop the machine, shut off the engine, and check for possible causes, such as the alternator belt (Figure 4).
Passenger Handhold The passenger handhold is located on the dashboard (Figure 8). g009815 Figure 8 1. Passenger handhold 2. Storage compartment Seat-Adjustment Lever You can adjust the seat forward and rearward for your comfort (Figure 9). g021227 Figure 9 1.
Specifications Note: Specifications and design are subject to change without notice.
Performing Daily Maintenance Operation Note: Determine the left and right sides of the machine from the normal operating position. Service Interval: Before each use or daily Before Operation Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 28).
Adding Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an cetane rating of 87 or higher ((R+M)/2 rating method). • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use.
Checking the Safety-Interlock System During Operation Service Interval: Before each use or daily During Operation Safety The purpose of the safety-interlock system is to prevent the engine from cranking or starting, unless you press the clutch pedal. General Safety • The owner/operator can prevent and is responsible for accidents that may cause personal injury or property damage.
Rollover Protection System (ROPS) Safety • Operate the machine only in good visibility. Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles. Use care when approaching blind corners, shrubs, trees, or other objects that may obscure your vision. • The ROPS is an integral safety device. • Do not remove the ROPS from the machine.
on level ground. If you must stop the machine, avoid sudden speed changes, which can cause the machine to tip or roll over. Do not engage the brakes suddenly when rolling rearward, as this may cause the machine to overturn. CAUTION If a load is concentrated near the back of the cargo bed when you release the latches, the bed may unexpectedly tip open, injuring you or bystanders. Loading and Dumping Safety • Center loads in the cargo bed, if possible.
Driving the Machine 1. Disengage the parking brake. 2. Fully press the clutch pedal. 3. Move the gear-shift lever to first gear. 4. 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. 6. Repeat the procedure until the desired speed is attained.
Using the Hydraulic Control Using the Differential Lock 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. WARNING Tipping or rolling the machine on a hill will cause serious injury. • The extra traction available with the differential lock can be enough to get you into dangerous situations, such as climbing slopes that are too steep to turn around.
Using the Hydraulic Bed-Lift Lever to Control Hydraulic Attachments This position is similar to the LOWER (QUICK COUPLER B POSITION). It also directs hydraulic fluid to quick coupler B, except that the lever is held in this position by a detent lever in the control panel. This allows hydraulic fluid to flow continuously to equipment that use a hydraulic motor. • OFF Position This is the normal position for the control valve when it is not in use.
Troubleshooting the Hydraulic Control After Operation • Difficulty in connecting or disconnecting quick couplers. After Operation Safety The pressure is not relieved (the quick coupler is under pressure). General Safety • Before you leave the operating position, do the • The power steering is turning with great difficulty or it is not turning at all. following: – The hydraulic-fluid level is low. – Park the machine on a level surface. – The hydraulic-fluid temperature is too hot.
Hauling the Machine Towing the Machine • Use care when loading or unloading the machine In case of an emergency, you can tow the machine for a short distance; however, this is not the standard operating procedure. into a trailer or a truck. • Use full-width ramps for loading the machine into a trailer or a truck. WARNING • Tie the machine down securely. Towing at excessive speeds could cause a loss of steering control, resulting in personal injury.
Maintenance • Do not charge the batteries while servicing the Maintenance Safety • To ensure that the entire machine is in good • Do not allow untrained personnel to service the • To reduce the potential fire hazard, keep the machine. condition, keep all hardware properly tightened. machine. machine area free of excessive grease, grass, leaves, and accumulation of dirt.
Maintenance Service Interval Maintenance Procedure Before each use or daily • Inspect the seat belt(s) for wear, cuts, and other damage. Replace the seat belt(s) if any component does not operate properly. • Check the tire pressure. • Check the operation of the safety-interlock system. • Check engine oil level. • Check the brake-fluid level. Check the brake-fluid level before you first start the engine. • Check the transaxle/hydraulic-fluid level.
Note: Download a free copy of the electrical schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. Important: Refer to your engine owner’s manual for additional maintenance procedures. WARNING Failing to properly maintain the machine could result in premature failure of machine systems, causing possible harm to you or bystanders. Keep the machine well maintained and in good working order as indicated in these instructions.
Pre-Maintenance Procedures end of the cylinder barrel and cylinder-rod end (Figure 19). Preparing the Machine for Maintenance 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Empty and raise the cargo bed; refer to Raising the Cargo Bed (page 22). 4. Shut off the engine and remove the key. 5. Allow the machine to cool before performing maintenance. g009164 Using the Bed Support Figure 19 1. Bed support Important: Always install or remove the bed 3. Bed 2.
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. 2. Release the lift lever and shut off the engine. 3. Remove the lynch pins from the outer ends of the cylinder rod clevis pins (Figure 20). 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.
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, as the engine vibration or wheel movement could cause the machine to slip off the jack. • Always remove the key from the key switch before getting off the machine. • Block the tires when the machine is on a jack. g002370 Figure 22 1. Wear block 3.
3. Pivot the top of the hood forward and unplug the wire connectors from the headlights (Figure 25). 4. Remove the hood. Installing the Hood g009824 Figure 24 1. Rear jacking points Removing and Installing the Hood 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 25). g010314 Figure 25 1. Hood 2.
Lubrication Greasing the Bearings and Bushings Service Interval: Every 100 hours (lubricate more frequently in heavy-duty applications). Grease Type: No. 2 lithium grease 1. Use a rag to wipe the grease fitting clean so that foreign matter cannot be forced into the bearing or bushing. 2. With a grease gun, apply grease into the grease fittings on the machine. 3. g010571 Figure 27 Wipe any excess grease off the machine.
g010359 Figure 29 36
Engine Maintenance B. Note: Do not wring the pre-cleaner. Allow Engine Safety it to air dry. • Shut off the engine, remove the key, and wait for C. all moving parts to stop before checking the oil or adding oil to the crankcase. Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces. • Wrap the foam pre-cleaner in a cloth and press dry. 3. Saturate the foam pre-cleaner in clean engine oil and press it remove any excess oil.
Servicing the Engine Oil Note: Change the oil more frequently when operating conditions are extremely dusty or sandy. Note: Dispose of the used engine oil and oil filter at a certified recycling center. Engine-Oil Specifications Oil Type: Detergent engine oil (API SJ or higher) Crankcase Capacity: 1.9 L (2 US qt) when the filter is changed Viscosity: See the table below. g010512 Figure 32 1.
4. When the oil stops draining, install the drain plug. 5. Remove the oil filter from the filter adapter (Figure 34). 6. Wipe clean the sealing base of the of the filter adapter. 7. Apply a light coat of clean oil to the seal of the new filter. 8. Install the filter until the gasket contacts the sealing base of the filter adapter, then tighten the filter clockwise and additional 1/2 to 2/3 of a turn. Note: Do not overtighten the engine-oil filter. 9. g002373 Figure 33 1.
Servicing the Spark Plugs Fuel System Maintenance Service Interval: Every 100 hours/Yearly (whichever comes first) Replace the spark plugs if necessary. Inspecting Fuel Lines and Connections Type: Champion RC12YC (or equivalent) Air Gap: 1 mm (0.04 inch) Service Interval: Every 400 hours/Yearly (whichever comes first) Important: A cracked, fouled, dirty, or malfunctioning spark plug must be replaced.
2. Electrical System Maintenance Ensure that the opening on the bottom of the filter is clear and open. Replacing the Fuel Filter Electrical System Safety Service Interval: Every 400 hours 1. Raise the bed and place the safety support on the extended-lift cylinder to hold up the bed. 2. Place a drain pan under the fuel filter (Figure 37). • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last.
decal115-7813 Figure 39 1. Power outlet (10 A) 5. Lights/brake (15 A) 2. Switched power (10 A) 6. Hazard lights (10 A) 3. Fuel pump/supervisor switch (10 A) 7. 4WD/transmission (10 A) g010326 Figure 40 1. Battery cover 4. Horn/power point (15 A) 2. Connect a jumper cable between the positive posts of the 2 batteries (Figure 41). Note: The positive post may be identified by a + sign on top of the battery cover. Jump-Starting the Machine 3.
4. Drive System Maintenance Start the engine in the machine providing the jump-start. Note: Let it run for a few minutes, then start your engine. 5. 6. Adjusting the Shift Cables Remove the negative jumper cable first from your engine, then the battery in the other machine. Service Interval: After the first 10 hours Install the battery cover to the battery base. Every 200 hours Servicing the Battery 1. Move the shift lever to the NEUTRAL position. 2.
Adjusting Differential-Lock Cable Inspecting the Tires Service Interval: Every 200 hours Front tires air pressure specification: 220 kPa (32 psi) 1. 2. Service Interval: Every 100 hours Move the differential-lock lever to the OFF position. Rear tires air pressure specification: 124 kPa (18 psi) Loosen the jam nuts securing the differential-lock cable to the bracket on the transaxle (Figure 43).
Checking the Front Wheel Alignment Service Interval: Every 400 hours/Yearly (whichever comes first) 1. Ensure that the tires are facing straight ahead. 2. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires (Figure 46). Note: The measurement must be within 0 ± 3 mm (0 ± 0.12 inch) at the front of the tire then at the rear of the tire. Rotate the tire 90° and check the measurement. g010329 Figure 47 Important: Check the measurements at 1.
Torquing the Wheel Lug Nuts Cooling System Maintenance Service Interval: After the first 2 hours After the first 10 hours Cooling System Safety Every 200 hours • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. Wheel lug nut torque specification: 109 to 122 N∙m (80 to 90 ft-lb) • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
Brake Maintenance Checking the Brake-Fluid Level Service Interval: Before each use or daily—Check the brake-fluid level. Check the brake-fluid level before you first start the engine. Every 1,000 hours/Every 2 years (whichever comes first)—Change the brake fluid. g002379 Figure 50 Brake-fluid type: DOT 3 1. Brake-fluid reservoir 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the engine and remove the key. 4.
Adjusting the Brake Pedal Adjusting the Parking Brake Service Interval: Every 200 hours Service Interval: After the first 10 hours Note: Remove the font hood to make the adjustment procedure easier. Every 200 hours 1. 1. Remove the rubber grip from the parking-brake lever (Figure 51). Remove the cotter pin and clevis pin securing the master cylinder yoke to the brake-pedal pivot (Figure 53). g033487 Figure 51 g002417 1. Grip Figure 53 2. Parking-brake lever 1. Master cylinder yoke 2.
Belt Maintenance Adjusting the Pump-Drive Belt Checking the Pump-Belt Tension 1. Raise the bed and position the safety support on the extended lift cylinder to secure the bed. 2. Check the tension by pressing the belt at mid span between the crankshaft and the pump pulleys with 10 kg (22 lb) of force. Service Interval: After the first 10 hours Every 200 hours Note: A new belt should deflect 12 to 15 mm (0.48 to 0.58 inch). A used belt should deflect 14 to 16.5 mm (0.55 to 0.65 inch).
Controls System Maintenance Adjusting the Clutch Pedal Service Interval: Every 200 hours Note: You can adjust the clutch-pedal cable at the bell housing or at the clutch-pedal pivot. You can remove the front hood to easily access to the pedal pivot. 1. g009276 Figure 57 Loosen the jam nuts securing the clutch cable to the bracket on the bell housing (Figure 56). 1. Clutch pedal Note: You may remove and rotate the ball joint, if additional adjustment is required. 2. 9.2 to 9.
Adjusting the Accelerator Service Interval: Every 200 hours 1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key. 2. With the return spring installed, hold the engine governor arm toward the operator’s side of the machine and adjust the low-idle stop to obtain a 0.25 to 1.25 mm (0.01 to 0.05 inch) gap between the outside diameter of the hole in the throttle lever and the inside of the governor-spring hook (Figure 59). 4.
Converting the Speedometer Hydraulic System Maintenance You can convert the speedometer from mph to km/h or km/h to mph. 1. Hydraulic System Safety Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key. 2. Remove the hood; refer to Removing the Hood (page 34). 3. Locate the 2 loose wires next to the speedometer. 4. Remove the connector plug from the harness wire and connect the wires together.
g009623 Figure 62 1. Hydraulic reservoir 2. Drain plug g002376 Figure 61 1. Dipstick 5. Unscrew the dipstick from the top of the transaxle and wipe it with a clean rag. 6. Screw the dipstick into the transaxle and ensure that it is fully seated. 7. Unscrew the dipstick and check the fluid level. 5. Note the orientation of the hydraulic hose and 90° fitting connected to the strainer on the side of the reservoir (Figure 63). 6. Remove the hydraulic hose and 90° fitting. 7.
13. Raising the Cargo Bed in an Emergency Check the hydraulic-fluid level and replenish it, if required. Important: Use only the hydraulic fluid specified. Other fluids could damage the system. The cargo bed can be raised in an emergency without starting the engine by cranking starter or by jumping the hydraulic system. Replacing the Hydraulic Filter Service Interval: After the first 10 hours—Replace the hydraulic filter.
g019543 Figure 67 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 raises the disabled cargo bed. 9. Move the hydraulic-lift lever to the NEUTRAL position, and engage the lift-lever lock. g009822 Figure 65 1. Quick-coupler hose A 2. Quick-coupler hose B 10. 3. On the disabled machine, connect the 2 jumper hoses to the hoses that were disconnected (Figure 66). 4. Cap the unused fittings.
Cleaning Washing the Machine Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine. Important: Do not use brackish or reclaimed water to clean the machine. 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 for about 50 days at temperatures lower than 4°C (40°F). If the temperatures will be above 4°C (40°F), check the water level in the battery and charge it every 30 days. Storage Safety • Shut off the machine, remove the key (if equipped), and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it. 12. Check and tighten all bolts, nuts, and screws. Repair or replace any part that is damaged. 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.
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Conditions and Products Covered Parts 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 2 years or 1,500 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).
