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Toro 07385 Workman HDX-D, Operator'S Manual

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Toro 07385 Workman HDX-D Operator'S Manual Download Page 33

Maintenance Service

Interval

Maintenance Procedure

Every 800 hours

• Change the front-differential oil.
• Change the hydraulic fluid and clean the strainer.
• Replace the hydraulic filter.
• Change the high-flow hydraulic fluid and filter (TC models only).

Every 1,000 hours

• Change the brake fluid.
• Drain/flush the fuel tank.
• Flush or replace the coolant-system fluid.

Note:

Determine the left and right sides of the machine from the normal operating position.

DANGER

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.

CAUTION

If you leave the key in the starter switch, someone could accidently start the engine and seriously injure
you or other bystanders.

Remove the key from the starter switch before you do any maintenance.

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.

33

 

Summary of Contents for 07385 Workman HDX-D

Page 1: ...5000001 and Up Model No 07385H Serial No 315000001 and Up Model No 07385TC Serial No 315000001 and Up Model No 07387 Serial No 315000001 and Up Model No 07387H Serial No 315000001 and Up Model No 07387TC Serial No 315000001 and Up Register at www Toro com Original Instructions EN 3392 850 A ...

Page 2: ...laws Introduction Read this information carefully to learn how to operate and maintain your product properly and to avoid injury and product damage You are responsible for operating the product properly and safely You may contact Toro directly at www Toro com for product safety and operation training materials accessory information help finding a dealer or to register your product Whenever you nee...

Page 3: ...rse Conditions 33 Premaintenance Procedures 34 Using the Bed Support 34 Removing the Full Bed 35 Installing the Full Bed 35 Raising the Machine 36 Removing the Hood 37 Installing the Hood 37 Lubrication 38 Greasing the Bearings and Bushings 38 Engine Maintenance 40 Servicing the Air Cleaner 40 Changing the Engine Oil and Filter 40 Fuel System Maintenance 41 Checking the Fuel Lines and Connections ...

Page 4: ...hillsides whenever possible Use extra caution when operating the vehicle on wet surfaces at higher speeds or with a full load Stopping time will increase with a full load Shift into a lower gear before starting up or down a hill When loading the bed distribute the load evenly Use extra caution if the load exceeds the dimensions of the machine bed Operate the vehicle with extra caution when handlin...

Page 5: ...achine down before starting up or down a hill If the engine stalls or you begin to lose momentum while climbing a hill gradually apply the brakes and slowly back the machine straight down the hill Turning while traveling up or down hills can be dangerous If you have to turn while on a hill do it slowly and cautiously Never make sharp or fast turns Heavy loads affect stability Reduce the weight of ...

Page 6: ...rakes Use extra caution on slopes Be aware that heavy loads increase your 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 Never overload your machine The name plate located under the middle of the dash shows the load limits for the machine Never overfill attachments or exceed the mach...

Page 7: ...et 10A 5 Lights brake 15A 2 Switched power 10A 6 Hazard 10A 3 Fuel pump supervisor switch 10A 7 4WD Transmission 10A 4 Horn power point 15A 115 2047 1 Warning do not touch the hot surface 115 7740 1 Warning maximum trailer weight is 680 kg 1500 lb maximum tongue weight is 90 kg 200 lb 2 Warning trailer brakes are required when towing greater than 680 kg 1500 lb maximum trailer weight with trailer ...

Page 8: ...Fire hazard stop the engine before fueling 2 Warning lock the parking brake stop the engine and remove the starter 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 2355 1 Slow 3 Transmission third high no fast spee...

Page 9: ...n 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard 115 7739 1 Falling crushing hazard bystanders no riders on machine 93 9899 93 9899 1 Crushing hazard install the cylinder lock 115 7756 1 High flow hydraulics engaged 93 9879 1 Stored energy hazard read the Operator s Manual 93 9850 1 Do not repair or revise read the Operato...

Page 10: ...eep bystander s a safe distance from the vehicle 3 Unlocked 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 115 2281 1 Headlights 4 Engine run 2 Horn 5 Engine start 3 Engine stop 10 ...

Page 11: ...coolant level 2 Do not add engine coolant to the radiator add engine coolant to the reservoir 121 6287 1 Fill the reservoir with engine coolant to the bottom of the standpipe 93 9852 1 Warning read the Operator s Manual 2 Crushing hazard install the cylinder lock 11 ...

Page 12: ...ld the center cover in place and remove the cover from the hub of the steering wheel 2 Remove the locknut and washer from the steering shaft 3 Slide the steering wheel and washer onto the shaft Align the steering wheel on the shaft so that the cross beam is horizontal when the tires are pointed straight ahead and the thicker spoke of the steering wheel is downward Note The dust cover is position o...

Page 13: ... ROPS to frame with 3 flanged bolts 1 2 x 1 1 4 inch and tighten the bolts to 115 N m 85 ft lb 3 Checking the Fluid Levels No Parts Required 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 Check the transaxle hydraulic fluid level before the engine is first started refer to Checking the Transaxle Hydraulic fluid L...

Page 14: ... slow vehicle CAUTION Worn or maladjusted brakes may result in personal injury If the brake pedal travels to within 3 8 cm 1 1 2 inches of the vehicle floor board the brakes must be adjusted or repaired 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 shown below Figure 6 Important Do not shift the tra...

Page 15: ...tely stopped before shifting between the High and Low range Shift only on level ground Press the clutch pedal fully Move the lever fully forward for High and fully rearward for Low High is for higher speed driving on level dry surfaces with light loads Low is for low speed driving Use this range when greater than normal power or control is required For example steep grades difficult terrain heavy ...

Page 16: ...portant The glow plug indicator will turn on for an additional 15 seconds when the switch returns to the Start position Coolant temperature Gauge and Light Registers the coolant temperature of the engine Operates only when the starter switch is in On position Figure 8 The indicator light will illuminate blinking red if the engine overheats Charge Indicator Illuminates when battery is being dischar...

Page 17: ... Dry Model 07385 887 kg 1956 lb Model 07385H 887 kg 1956 lb Model 07385TC 924kg 2037 lb Model 07387 914 kg 2015 lb Model 07387H 914 kg 2015 lb Model 07387TC 951 kg 2096 lb Rated Capacity includes 91 kg 200 lb operator 91 kg 200 lb passenger and loaded attachment Model 07385 1471 kg 3244 lb Model 07385TC 1435 kg 3163 lb Model 07387 1445 kg 3185 lb Model 07387TC 1408 kg 3104 lb Maximum Gross Vehicle...

Page 18: ...the box raised Only operate the machine when the cargo box is down After emptying the cargo box lower it CAUTION If a load is concentrated near the back of the cargo box when you release the latches the box may unexpectedly tip open injuring you or bystanders Center loads in the cargo box if possible Hold the cargo box down and ensure that no one is leaning over the box or standing behind it when ...

Page 19: ... minutes before checking If the oil level is at or below the Add mark on the dipstick add oil to bring the oil level to the Full mark Do not overfill the engine with oil If the oil level is between the Full and Add marks no additional oil is required 1 Position the machine on a level surface 2 Remove the dipstick and wipe it with a clean rag Figure 15 Figure 15 1 Dipstick 2 Oil fill cap 3 Insert t...

Page 20: ...vel 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 Add fuel to the fuel tank until the level is 25 mm 1 inch below the bottom of the filler neck This empty space in the tank allows the fuel to expand Never smoke when handling fuel and stay away f...

Page 21: ...ller neck when the engine is cold Figure 17 1 Reserve tank cap 2 Reserve tank 3 If coolant is low remove the reserve tank cap and add a 50 50 mixture of water and permanent ethylene glycol antifreeze Note Do not overfill the reserve tank with coolant 4 Install the reserve tank cap Checking the Transaxle Hydraulic fluid Level Service Interval Before each use or daily check the fluid level before th...

Page 22: ...gure 19 from the filler neck and wipe it with a clean rag 4 Insert the dipstick into the filler neck then remove it and check the fluid level Note The fluid level should be between the 2 marks on the dipstick 5 If the level is low add the appropriate fluid to raise the level to the upper mark refer to Changing the High flow Hydraulic fluid and Filter TC models only page 53 6 Install the dipstick a...

Page 23: ...ily The air pressure in the front tires is 220 kPa 32 psi and the rear tires is 124 kPa 18 psi Check the tire pressure frequently to ensure proper inflation If the tires are not inflated to the correct pressure the tires will wear prematurely Figure 21 is an example of tire wear caused by under inflation Figure 21 1 Under inflated tire Figure 22 is an example of tire wear caused by over inflation ...

Page 24: ...s to the Run position Note Do not run the starter motor more than 10 seconds at a time or premature starter failure may result If engine fails to start after 10 seconds turn the key to the Off position Check the controls and starting procedure wait 10 additional seconds and repeat the starting operation Driving the Vehicle 1 Release the parking brake 2 Fully press the clutch pedal 3 Move the gear ...

Page 25: ...checks Checking the Safety interlock System Service Interval Before each use or daily The purpose of the safety interlock system is to prevent the engine from cranking or starting unless the clutch pedal is pressed CAUTION If the safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury Do not tamper with the interlock switches Check the o...

Page 26: ...g to accidents Turning too sharply for the conditions can cause the vehicle to lose traction and skid or even tip over Wet sandy and slippery surfaces make turning more difficult and risky The faster you are going the worse this situation becomes so slow down before turning During a sharp turn at higher speeds the inside rear wheel may lift off of the ground This is not a flaw in the design it hap...

Page 27: ...hift 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 Never make sharp or fast turns on a hill If you stall or begin to lose headway while climbing a steep hill quickly apply the brakes shift to neutral start the engine and shift to reverse At idle speed the engine and transaxle drag will aid the brakes in controllin...

Page 28: ...r 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 Be extra careful when operating with the differential lock on especially on steeper slopes If the differential lock is on when making a sharp turn at a higher...

Page 29: ... approximately 10 272 kg 600 lb max of the Gross Trailer Weight GTW on the tow hitch of the machine Trailer brakes are required whenever you tow a trailer over 680 kg 1500 lb GTW is towed behind a machine When hauling cargo or towing a trailer attachment do not overload your machine or trailer Overloading can cause poor performance or damage to the brakes axle engine transaxle steering suspension ...

Page 30: ... 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 uses a hydraulic motor This position must only be used on attachments with a hydraulic motor attached Important If used with a hydraulic cylinder or no attachment the On position causes the hydraulic fluid flow to go over a relief valve which c...

Page 31: ...ydraulic fluid temperature is hot The pump is not operating There are hydraulic leaks The fittings are loose The fitting is missing the o ring An attachment does not function The quick couplers are not fully engaged The quick couplers are interchanged There is a squealing noise Remove the valve left in the On detent position causing hydraulic fluid to flow over the relief valve The belt is loose T...

Page 32: ...n water or other contaminants from the water separator Remove debris from the engine area and radiator clean more frequently in dirty conditions Every 25 hours Remove the air cleaner cover clean out debris and check the air filter service indicator Every 50 hours Check the battery fluid level every 30 days if in storage Check the battery cable connections Every 100 hours Check the level of front d...

Page 33: ...e 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 CAUTION If you leave the key in the starter switch someone could accidently start the engine and seriously injure you or other bystanders Remove the key from the starter switch before you do any maintenance Operating in Adverse Conditions Imp...

Page 34: ...upport on a fully extended cylinder rod Using the Bed Support Important Always install or remove the bed support from the outside of the bed 1 Raise the bed until the lift cylinders are fully extended 2 Remove the bed support from the storage brackets on back of the ROPS panel Figure 30 Figure 30 1 Bed support 3 Push the bed support onto the cylinder rod making sure that the support end tabs rest ...

Page 35: ... to install or remove it by yourself Use an overhead hoist or get the help of 2 or 3 other people 7 Store the cylinders in the storage clips 8 Engage the hydraulic lift lock lever on the machine to prevent accidental extension of the lift cylinders Installing the Full Bed Note If the bed sides will be installed on the flat bed it is easier to install them before installing the bed on the machine N...

Page 36: ...ring of the bed refer to Using the Bed Support page 34 8 Install the lynch pins to the inside ends of the clevis pins Note If the automatic tail gate release has been installed on the bed ensure that the front dump link rod has been placed on the inside of the left side clevis pin before the lynch pin is installed Raising the Machine DANGER A machine on a jack may be unstable and slip off of the j...

Page 37: ...he hood upward until the top mounting tabs can be pulled from the frame slots Figure 37 3 Pivot the top of the hood forward and unplug the wire connectors from the head lights Figure 37 4 Remove the hood Installing the Hood 1 Connect the lights 2 Insert the top mounting tabs into the frame slots 3 Insert the lower mounting tabs into the frame slots 4 Ensure that the hood is fully engaged in the to...

Page 38: ...oints 4 tie rods 2 pivot mounts 2 and steering cylinder 2 Figure 38 Spring tower 2 Figure 39 Clutch 1 accelerator 1 brake qty 1 Figure 40 U joint 18 and 4 wheel drive shaft 3 Figure 41 Important When greasing the drive shaft universal shaft bearing crosses pump grease until it comes out of all 4 cups at each cross 1 Wipe each grease fitting clean so foreign matter cannot be forced into the bearing...

Page 39: ...Figure 41 39 ...

Page 40: ...d 5 Inspect the new filter s for damage by looking into the filter while shining a bright light on the outside of the filter Note Holes in the filter will appear as bright spots Note Inspect the element for tears an oily film or damage to the rubber seal If the filter is damaged do not use it 6 If you are replacing the safety filter carefully slide the new filter into the filter body Figure 42 Not...

Page 41: ...e Checking the 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 Fuel Filter Water Separator Draining the Fuel Filter Water Separator Service Interval Before each use or daily Drain water or other contaminant...

Page 42: ... 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 6 Tighten the drain plug on the bottom of the filter canister Electrical System Maintenance Servicing the Fuses The fuses for the electrical system are located under the center of the dash panel Figure 47 and Figure 48 Figure 47 1 Fuses Figure 48 1 ...

Page 43: ...nd remove the battery cover from the battery base Figure 49 Figure 49 1 Battery cover 2 Connect a jumper cable between the positive posts of the 2 batteries Figure 50 The positive post may be identified by a sign on top of the battery cover 3 Connect one end of the other jumper cable to the negative terminal of the battery in the other machine Note The negative terminal has NEG on the battery cove...

Page 44: ...onnect the cables positive cable first and coat the terminals with petroleum jelly Maintain cell electrolyte level with distilled or demineralized water Do not fill the cells above the bottom of the fill ring inside each cell 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 temperat...

Page 45: ...ll the clevis pin and tighten the jam nut when finished Adjusting Differential lock Cable Service Interval Every 200 hours 1 Move the differential lock lever to the Off position 2 Loosen the jam nuts securing the differential lock cable to the bracket on the transaxle Figure 53 Figure 53 1 Differential lock cable 3 Spring 2 Transaxle bracket 4 0 25 to 1 5 mm 0 01 to 0 06 inch gap 3 Adjust the jam ...

Page 46: ... tire The machine should be on a flat surface with the tires facing straight ahead Figure 56 1 Front of the machine 3 Center to center distance 2 0 3 mm 0 0 12 inch front to rear of the tire 3 Adjust the center to center distance as follows A Loosen the jam nut at the center of the tie rod Figure 57 Figure 57 1 Tie rods 2 Jam nuts B Rotate the tie rod to move the front of the tire inward or outwar...

Page 47: ...faces of the radiator 5 Install the cooler and screen to the radiator Changing the Engine Coolant Service Interval Every 1 000 hours Every 2 years whichever comes first Coolant type 50 50 mixture of water and permanent ethylene glycol antifreeze 1 Park the machine on a level surface 2 Raise the bed if so equipped and place the safety support on the extended lift cylinder to hold up the bed CAUTION...

Page 48: ...re 14 Install the reservoir tank cap 15 Run the machine until it reaches the operating temperature 16 Turn off the machine and allow it to cool 17 Check the coolant level again and replenish it if required Brake Maintenance Adjusting the Parking Brake Service Interval After the first 10 hours Every 200 hours 1 Remove the rubber grip from the parking brake lever Figure 62 Figure 62 1 Parking brake ...

Page 49: ...ft up on the brake pedal Figure 65 until it contacts the frame 3 Loosen the jam nuts securing the yoke to the master cylinder shaft Figure 65 4 Adjust the yoke until its holes align with the hole in the brake pedal pivot 5 Secure the yoke to the pedal pivot with the clevis pin and cotter pin 6 Tighten the jam nuts securing the yoke to the master cylinder shaft Note The brake master cylinder must r...

Page 50: ...or mounting bolts Figure 66 Figure 66 1 Alternator belt 2 Alternator mounting bolts B Using a pry bar rotate the alternator until the proper belt tension is attained then tighten the mounting bolts Figure 66 Controls System Maintenance Adjusting the Accelerator Pedal 1 Position the machine on a level surface stop the engine and engage the parking brake 2 Adjust the ball joint on the accelerator ca...

Page 51: ...essure plate fingers 4 Tighten the jam nuts after the adjustment has been attained 5 Check the 9 5 0 3 cm 3 75 0 12 inch dimension after the jam nuts have been tightened to ensure proper adjustment Note Adjust again if it is necessary 6 Connect the return spring to the clutch lever Important Ensure that the rod end is positioned squarely on the ball not twisted and remains parallel to the clutch p...

Page 52: ...fore installing Figure 73 1 Hydraulic strainer 6 Install the strainer 7 Install the hydraulic hose and 90 fitting to the strainer in the same orientation 8 Install and tighten the drain plug 9 Fill the reservoir with approximately 7 L 7 5 US qt of the specified hydraulic fluid refer to Checking the Transaxle Hydraulic fluid Level page 21 10 Start the engine and operate the machine to fill the hydr...

Page 53: ...5 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 fluid is available in 20 ml 2 3 oz bottles One bottle is sufficient for 15 22 1 4 6 gal of hydraulic fluid Order part no 44 2500 from your authorized Toro distributor Note If the fluid becomes contaminated contact your local Toro distributor because t...

Page 54: ...oupler hose B 3 On the disabled machine connect the 2 jumper hoses to the hoses that were disconnected Figure 76 4 Cap the unused fittings Figure 76 1 Disconnected hoses 2 Jumper hoses 5 On the other machine connect the 2 hoses to the coupler still in the coupler bracket connect the top hose to the top coupler and the bottom hose to the bottom coupler Figure 77 6 Cap the unused fittings G019543 1 ...

Page 55: ...rvice the air cleaner refer to Servicing the Air Cleaner page 40 5 Seal the air cleaner inlet and the exhaust outlet with weatherproof tape 6 Grease the machine refer to Greasing the Bearings and Bushings page 38 7 Change the engine oil refer to Changing the Engine Oil and Filter page 40 8 Flush the fuel tank with fresh clean diesel fuel 9 Secure all fuel system fittings 10 Check the tire pressure...

Page 56: ...Notes 56 ...

Page 57: ...Notes 57 ...

Page 58: ...Notes 58 ...

Page 59: ... 3766 3636 Jean Heybroek b v Netherlands 31 30 639 4611 Victus Emak Poland 48 61 823 8369 European Privacy Notice The Information Toro Collects Toro Warranty Company Toro respects your privacy In order to process your warranty claim and contact you in the event of a product recall we ask you to share certain personal information with us either directly or through your local Toro company or dealer ...

Page 60: ...not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted for the period of time up to the scheduled replacement time for that part Parts replaced under this warranty are covered for the duration of the original product warranty and become the property of Toro Toro will ma...

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