Toro Workman HDX 07383 Operator'S Manual Download | Manualshive

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g010571

Figure 30

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Clutch (1)

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Brake (1)

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g024682

Figure 31

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U-joint (18)

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4-wheel drive shaft (3)

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g010359

Figure 32

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Summary of Contents for Workman HDX 07383

Page 1: ...383 Serial No 404350001 and Up Model No 07384 Serial No 404350001 and Up Model No 07384TC Serial No 404350001 and Up Model No 07386 Serial No 404350001 and Up Model No 07386TC Serial No 404350001 and Up Register at www Toro com Original Instructions EN 3427 789 A ...

Page 2: ...s intended use could prove dangerous to you and bystanders 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 Visit www Toro com for product safety and operation training materials accessory information help finding a dealer or to register your product Wh...

Page 3: ...ngine Safety 38 Servicing the Air Cleaner 38 Servicing the Engine Oil 39 Replacing the Spark Plugs 41 Fuel System Maintenance 41 Inspecting the Carbon Canister Air Filter 41 Replacing the Fuel Filter 41 Inspecting Fuel Lines and Connections 42 Electrical System Maintenance 42 Electrical System Safety 42 Servicing the Fuses 42 Jump Starting the Machine 43 Servicing the Battery 44 Drive System Maint...

Page 4: ...ry or property damage may occur Do not put your hands or feet near moving components of the machine Do not operate the machine without all guards and other safety protective devices in place and working on the machine Keep bystanders and children out of the operating area Never allow children to operate the machine Stop and shut off the machine and remove the key before servicing or fueling Improp...

Page 5: ...injuries 3 Caustic liquid chemical burn hazard 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes immediately with water and get medical help fast 5 Read the Operator s Manual 10 Contains lead do not discard decal93 9850 93 9850 1 Do not repair or revise read the Operator s Manual decal93 9852 93 9852 1 Warning read the Operator s Manual 2 Crushing hazard install...

Page 6: ...fast speed 2 Fast 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 Transmission low speed 7 Disengage 14 Parking brake 6 ...

Page 7: ...ard read the Operator s Manual 4 Warning read the Operator s Manual 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 decal110 0806 110 0806 decal115 2047 115 2047 1 Warning do not touch the hot surface 7 ...

Page 8: ...ndholds decal115 7723 115 7723 1 Warning the hydraulic fluid pressure is 124 bar 1 800 psi 2 Coupler A 3 Coupler B decal115 7739 115 7739 1 Falling crushing hazard do not carry passengers decal115 7741 115 7741 1 Read the Operator s Manual before servicing transmission fluid decal115 7756 115 7756 1 High flow hydraulics engaged decal115 7813 115 7813 1 Power outlet 10 A 5 Lights brake 15 A 2 Switc...

Page 9: ...ator 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 2 Warning wear hearing protection 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 terrai...

Page 10: ... 9896 1 4x4 engage button decal138 3523 138 3523 1 Headlights 4 Engine Run 2 Horn 5 Engine Start 3 Engine Shut off decal139 3341 139 3341 1 Tank 3 Pressure 2 Warning the hydraulic fluid pressure is 138 bar 2 000 psi 10 ...

Page 11: ...over 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 Note 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 positioned onto the ...

Page 12: ...ore and after you first start the engine refer to Checking the Engine Oil Level page 39 2 Check the transaxle hydraulic fluid level before you first start the engine refer to Checking the Transaxle Hydraulic Fluid Level page 55 3 Check the brake fluid level before you first start the engine refer to Checking the Brake Fluid Level page 50 4 Check the coolant level refer to Checking the Engine Coola...

Page 13: ...dal decreases the engine speed and ground speed g021226 Figure 6 1 Clutch pedal 3 Accelerator pedal 2 Brake pedal Clutch Pedal You must fully press the clutch pedal Figure 6 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 Important Do n...

Page 14: ...h speeds refer to Adjusting Differential Lock Cable page 46 g240581 Figure 8 1 Parking brake lever 5 High low range shifter 2 Hydraulic bed lift 6 4 wheel drive button 4 wheel drive models only 3 Hydraulic lift lock 7 Gear shift lever 4 Differential lock Parking Brake Lever Whenever you shut off the engine engage the parking brake Figure 8 to prevent the machine from accidentally moving To engage ...

Page 15: ...ch moves automatically to the ON position To shut the engine off rotate the key switch counterclockwise to the OFF position Hour Meter The hour meter indicates the total hours of machine operation The hour meter Figure 5 starts to function whenever you rotate the key switch to the ON position or if the engine is running Speed Limiter Switch Move the speed limiter switch Figure 5 to the SLOW positi...

Page 16: ...ive Switch 4 Wheel Drive Models Only When the 4WD switch Figure 5 is on the machine automatically engages the 4 wheel drive if the sensor detects the back wheels spinning freely When the 4 wheel drive is engaged the 4WD switch light turns on 4WD works only in the forward direction in AUTO mode If you want it in REVERSE press the 4WD button High Flow Hydraulics Switch TC Models Only Turn on the swi...

Page 17: ...ld is located on the dashboard Figure 10 g009815 Figure 10 1 Passenger handhold 2 Storage compartment Seat Adjustment Lever You can adjust the seat forward and rearward for your comfort Figure 11 g021227 Figure 11 1 Seat adjustment lever 17 ...

Page 18: ...ed attachment Model 07386TC 1410 kg 3 109 lb Maximum gross vehicle weight GVW 2359 kg 5 200 lb Tongue weight 272 kg 600 lb Tow capacity Maximum trailer weight 1587 kg 3 500 lb Ground clearance 18 cm 7 inches with no load Wheel base 118 cm 70 inches Front 117 cm 46 inches Wheel tread center line to center line Rear 121 cm 48 inches Height 191 cm 75 inches to top of ROPS Attachments Accessories A se...

Page 19: ...It is flammable and its vapors are explosive Extinguish all cigarettes cigars pipes and other sources of ignition Use only an approved fuel container Do not remove the fuel cap or fill the fuel tank while the engine is running or hot Do not add or drain fuel in an enclosed space Do not store the machine or fuel container where there is an open flame spark or pilot light such as on a water heater o...

Page 20: ...bilizer conditioner to fresh fuel as directed by the fuel stabilizer manufacturer Filling the Fuel Tank Fuel tank capacity 25 L 6 5 US gallons 1 Clean the area around the fuel tank cap 2 Remove the fuel tank cap Figure 14 g009814 Figure 14 1 Fuel tank cap 3 Fill the tank to approximately 25 mm 1 inch below the bottom of the filler neck and install the cap Note Do not overfill the fuel tank 4 Wipe ...

Page 21: ...responsible for accidents that may cause personal injury or property damage Passengers should sit in the designated seating positions only Do not carry passengers in the cargo bed Keep bystanders and children out of the operating area Wear appropriate clothing including eye protection long pants substantial slip resistant footwear and hearing protection Tie back long hair and do not wear loose clo...

Page 22: ...o stop Do not operate the machine when there is the risk of lightning Use accessories and attachments approved by The Toro Company only Rollover Protection System ROPS Safety The ROPS is an integral safety device Do not remove the ROPS from the machine Always wear your seat belt ensure that it is attached and that you can release it quickly in an emergency Check carefully for overhead obstructions...

Page 23: ...NING Driving the machine with the cargo bed raised could cause the machine to tip or roll easier You could damage the structure of the cargo bed if you operate the machine with the bed raised Operate the machine when the cargo bed is down After emptying the cargo bed lower it CAUTION If a load is concentrated near the back of the cargo bed when you release the latches the bed may unexpectedly tip ...

Page 24: ...ly engages the 4 wheel drive if the sensor detects the back wheels spinning freely When the 4 wheel drive is engaged the 4WD switch light turns on Important When in reverse the machine does not automatically engage the 4 wheel drive In reverse you must manually engage the 4 wheel drive using the 4WD button To engage the 4 wheel drive manually press and hold the 4WD button on the center console whi...

Page 25: ... can result in loss of machine control Do not operate with differential lock on when making sharp turns or at high speeds The differential lock increases the machine traction by locking the rear wheels so that a wheel does not spin out This can help when you have heavy loads to haul on wet turf or slippery areas going up hills or on sandy surfaces It is important to remember however that this extr...

Page 26: ... 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 Use this position only on attachments with a hydraulic motor attached Important If you use it with a hydraulic cylinder or no attachment the ON position causes the hydraulic fluid flow to go over a relief valve which can dam...

Page 27: ... fluid to flow over the relief valve The belt is loose The engine does not start The hydraulic lever is locked in the FORWARD position After Operation After Operation Safety General Safety Before you leave the operating position do the following Park the machine on a level surface Shift the transmission to the NEUTRAL position Engage the parking brake Lower the cargo bed Shut off the machine and r...

Page 28: ...iler 1 Affix a tow line to the tongue at the front of the frame of the machine Figure 19 2 Move the transmission to the NEUTRAL position and disengage the parking brake Towing a Trailer The machine is capable of pulling trailers and attachments of greater weight than the machine itself Several types of tow hitches are available for the machine depending on your application Contact your Authorized ...

Page 29: ...ervicing the machine To ensure that the entire machine is in good condition keep all hardware properly tightened To reduce the potential fire hazard keep the machine area free of excessive grease grass leaves and accumulation of dirt If possible do not perform maintenance while the machine is running Keep away from moving parts If you must run the machine to perform a maintenance adjustment keep y...

Page 30: ...he high flow hydraulic fluid level TC models only Check the level of hydraulic fluid before the engine is first started and daily thereafter Every 25 hours Remove the air cleaner cover and clean out the debris Every 50 hours Check the battery fluid level every 30 days if in storage Check the battery cable connections Every 100 hours Grease the bearings and bushings lubricate more frequently in hea...

Page 31: ... 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 CAUTIO...

Page 32: ... use brackish or reclaimed water to clean the machine Pre Maintenance Procedures 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 23 4 Shut off the engine and remove the key 5 Allow the machine to cool before performing maintenance Using the Bed Support Important Always install...

Page 33: ...g002368 Figure 23 1 Cylinder rod end 4 Lynch pin 2 Bed mounting plate 5 Rear slots full bed 3 Clevis pin 6 Front slots 2 3 full bed 4 Remove the clevis pins securing the cylinder rod ends to the bed mounting plates by pushing the pins toward the inside Figure 23 5 Remove the lynch pins and clevis pins securing the pivot brackets to the frame channels Figure 23 6 Lift the bed off the machine CAUTIO...

Page 34: ...oles in the rear frame channel and install the 2 clevis pins and lynch pins Figure 25 3 With the bed lowered secure each cylinder rod end to the appropriate slots in the bed mounting plates with a clevis pin and lynch pin 4 Insert the clevis pin from outside of the bed with the lynch pin oriented toward the outside Figure 25 Note The rear slots are for a full bed installation the front slots are f...

Page 35: ... similar material between the jack and the machine frame The jacking point at the front of the machine is located under the front center frame support Figure 26 g009823 Figure 26 1 Front jacking points The jacking point at the rear of the machine is located under the axle Figure 27 g009824 Figure 27 1 Rear jacking points Removing and Installing the Hood Removing the Hood 1 While grasping the hood ...

Page 36: ...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 Wipe any excess grease off the machine Important When greasing the drive shaft universal shaft bearing crosses pump grease until it comes out of all 4 cu...

Page 37: ...g010571 Figure 30 Clutch 1 refer to Figure 31 Brake 1 refer to Figure 31 g024682 Figure 31 U joint 18 refer to Figure 32 4 wheel drive shaft 3 refer to Figure 32 g010359 Figure 32 37 ...

Page 38: ...e air cleaner cover off the air cleaner body Figure 33 g002401 Figure 33 1 Air cleaner cover 2 Filter 2 Squeeze the dust cap sides to open it and knock the dust out 3 Gently slide the filter out of the air cleaner body Figure 33 Note Avoid knocking the filter into the side of the body Note Do not attempt to clean the filter 4 Inspect the new filter for damage by looking into the filter while shini...

Page 39: ...gine with oil If the oil level is between the Full and Add marks no additional oil is required 1 Park the machine on a level surface 2 Engage the parking brake 3 Shut off the engine and remove the key 4 Remove the dipstick and wipe it with a clean rag Figure 35 g028637 Figure 35 1 Filler cap 2 Dipstick 5 Insert the dipstick into the tube and ensure that it seats fully Figure 35 6 Remove dipstick a...

Page 40: ...Engine oil filter 3 When the oil stops install the drain plug 4 Remove the oil filter Figure 37 5 Apply a light coat of clean oil to the new filter seal before screwing it on 6 Screw the filter on until the gasket contacts the mounting plate Then tighten the filter 1 2 to 2 3 of a turn Note Do not overtighten 7 Add the specified oil to the crankcase Responding to a Check Engine Light Note Engine f...

Page 41: ...e 3 Air gap not to scale 2 Center electrode insulator 5 Set the air gap between the center and side of the electrodes at 0 81 mm 0 032 inch as shown in Figure 38 6 Install the spark plug into the cylinder head and torque the plug to 24 5 to 29 N m 18 to 22 ft lb 7 Install the spark plug wire 8 Repeat steps 1 through 7 for the other spark plug Fuel System Maintenance Inspecting the Carbon Canister ...

Page 42: ...n the cap to 20 to 22 N m 175 to 200 in lb 11 Connect the wires and secure the hose with the hose clamp Inspecting Fuel Lines and Connections Service Interval Every 400 hours Yearly whichever comes first Inspect the fuel lines fittings and clamps for signs of leaking deterioration damage or loose connections Note Repair any damaged or leaking fuel system component before using the machine Electric...

Page 43: ...t touching the jump start machine Connecting cables to the wrong post could result in personal injury and or damage to the electrical system 1 Squeeze the battery cover to release the tabs from the battery base and remove the battery cover from the battery base Figure 43 g010326 Figure 43 1 Battery cover 2 Connect a jumper cable between the positive posts of the 2 batteries Figure 44 Note The posi...

Page 44: ...ttery clean by washing it periodically with a brush dipped in ammonia or bicarbonate of soda solution Flush the top surface with water after cleaning Do not remove the fill cap while cleaning Ensure that the battery cables are kept tight on the terminals to provide good electrical contact Maintain the cell electrolyte level with distilled or demineralized water Do not fill the cells above the bott...

Page 45: ...the fill check plug Inspecting the Constant Velocity Boot 4 Wheel Drive Models Only Service Interval Every 200 hours 4 wheel drive models only Inspect the constant velocity boot for cracks holes or a loose clamp Contact your Authorized Service Dealer for repair if you find any damage Adjusting the Shift Cables Service Interval After the first 10 hours Every 200 hours 1 Move the shift lever to the ...

Page 46: ...jam nuts to obtain a 0 25 to 1 5 mm 0 01 to 0 06 inch gap between the spring hook and the OD of the hole in the transaxle lever 4 Tighten the jam nuts when finished Inspecting the Tires Service Interval Every 100 hours Front tires air pressure specification 220 kPa 32 psi Rear tires air pressure specification 124 kPa 18 psi Operating accidents such as hitting curbs can damage a tire or rim and als...

Page 47: ... 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 51 g010329 Figure 51 1 Tie rods 2 Jam nuts B Rotate the tie rod to move the front of the tire inward or outward to achieve the center to center distances from front to back C Tighten the tie rod jam nut when the adjustment is correct D Check to ensure that the tires turn ...

Page 48: ...lycol antifreeze CAUTION If the engine has been running the pressurized hot coolant can escape and cause burns Do not open the radiator cap Allow the engine to cool for at least 15 minutes or until the reserve tank is cool enough to touch without burning your hand Use a rag when opening the reserve tank cap and open the cap slowly to allow steam to escape Do not check the coolant level at the radi...

Page 49: ...diator 8 Install the cooler and screen to the radiator Changing the Engine Coolant Service Interval Every 1 000 hours Every 2 years whichever comes first Cooling system capacity 3 7 L 4 US qt Coolant type a 50 50 solution of water and permanent ethylene glycol antifreeze 1 Park the machine on a level surface 2 Raise the bed and install the bed safety support on the extended lift cylinder to secure...

Page 50: ...ine and operate it until it is warm 11 Shut off the engine check the coolant level and replenish the coolant if necessary 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 Brake fluid type DOT...

Page 51: ...ure 60 g033487 Figure 60 1 Grip 2 Parking brake lever 2 Loosen the set screw securing the knob to the parking brake lever Figure 61 g033488 Figure 61 1 Knob 3 Parking brake lever 2 Set screw 3 Rotate the knob Figure 61 until a force of 20 to 22 kg 45 to 50 lb is required to actuate the lever 4 Tighten the set screw when finished Figure 61 Note If you can no longer make a parking brake adjustment b...

Page 52: ... the brake pedal Figure 63 until it contacts the frame 3 Loosen the jam nuts securing the yoke to the master cylinder shaft Figure 63 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 relieve p...

Page 53: ...44 Figure 64 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 64 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 easi...

Page 54: ...d never be less than 19 mm 3 4 inch g009277 Figure 67 1 Clutch cable rod end 3 Rod end jam nut 2 Clutch pedal 4 Parallel Adjusting the Accelerator Pedal 1 Park the machine on a level surface engage the parking brake shut off the engine and remove the key 2 Adjust the ball joint on the accelerator cable Figure 68 to allow 2 54 to 6 35 mm 0 100 to 0 250 inch of clearance between the accelerator peda...

Page 55: ...r and or lowering the cargo bed and attachments Place the remote hydraulics lever in the float position Do not work under a raised bed without the proper bed safety support in place Ensure that all hydraulic fluid hoses and lines are in good condition and that all hydraulic connections and fittings are tight before applying pressure to the hydraulic system Keep your hands and body away from pinhol...

Page 56: ...ff the engine and remove the key 4 Remove the drain plug from the side of the reservoir and let the hydraulic fluid flow into a drain pan Figure 71 g009623 Figure 71 1 Hydraulic reservoir 2 Drain plug 5 Note the orientation of the hydraulic hose and 90 fitting connected to the strainer on the side of the reservoir Figure 72 6 Remove the hydraulic hose and 90 fitting 7 Remove the strainer and clean...

Page 57: ...urface 2 Engage the parking brake 3 Shut off the engine and remove the key 4 Clean the area around the filter mounting area 5 Place a drain pan under the filter and remove the filter Figure 73 g010332 Figure 73 1 Hydraulic filter 2 High flow hydraulic filter 6 Lubricate the gasket on the new filter 7 Ensure that the filter mounting area is clean 8 Screw the filter on until the gasket contacts the ...

Page 58: ...ions Eaton Vickers 694 I 286 S M 2950 S 35VQ25 or M 2952 S Note Many hydraulic fluids are almost colorless making it difficult to spot leaks A red dye additive for the hydraulic fluid is available in 20 ml 0 67 fl oz bottles A bottle is sufficient for 15 to 22 L 4 to 6 US gallons of hydraulic fluid Order Part No 44 2500 from your authorized Toro distributor Checking the High Flow Hydraulic Fluid L...

Page 59: ... fluid level 11 Dispose of the fluid properly Raising the Cargo Bed in an Emergency The cargo bed can be raised in an emergency without starting the engine by cranking starter or by jumping the hydraulic system Raising the Cargo Bed using the Starter Crank the starter while holding the lift lever in the Raise position Run the starter for 10 seconds then wait 60 seconds before engaging the starter ...

Page 60: ...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 10 Install the bed support onto the extended lift cylinder refer to Using the Bed Support page 32 Note With both the machine turned off move the lift lever back ...

Page 61: ...ne 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 Important Do not wash the machine with the engine running Washing the machine with the engine running may result in internal engine...

Page 62: ...earings and Bushings page 36 7 Change the engine oil refer to Changing the Engine Oil and Filter page 40 8 Flush the fuel tank with fresh clean fuel 9 Secure all fuel system fittings 10 Check the tire pressure refer to Checking the Tire Pressure page 19 11 Check anti freeze protection and add a 50 50 solution of water and anti freeze as needed for expected minimum temperature in your area 12 Remov...

Page 63: ...ssure 1 Shut off the engine move the hydraulic lift lever forward and backward several times and connect the quick couplers for the fittings in the auxiliary hydraulic panel 1 The hydraulic fluid level is low 1 Service the hydraulic reservoir 2 The hydraulic fluid is hot 2 Check the hydraulic fluid level and service if it is low Contact an Authorized Service Dealer The power steering moves hard 3 ...

Page 64: ...Notes ...

Page 65: ...Notes ...

Page 66: ...to restaurants grocery stores hotels schools and hospitals and on a wide variety of products Additionally some online and mail order retailers provide Prop 65 warnings on their websites or in catalogs How do the California warnings compare to federal limits Prop 65 standards are often more stringent than federal and international standards There are various substances that require a Prop 65 warnin...

Page 67: ... for marketing purposes Retention of your Personal Information Toro will keep your personal information as long as it is relevant for the above purposes and in accordance with legal requirements For more information about applicable retention periods please contact legal toro com Toro s Commitment to Security Your personal information may be processed in the US or another country which may have le...

Page 68: ...tion of the original product warranty and become the property of Toro Toro will make the final decision whether to repair any existing part or assembly or replace it Toro may use remanufactured parts for warranty repairs Deep Cycle and Lithium Ion Battery Warranty Deep cycle and Lithium Ion batteries have a specified total number of kilowatt hours they can deliver during their lifetime Operating r...

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