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Contents

Introduction .................................................................. 2
Safety ........................................................................... 5

Setup ...........................................................................13

1 Checking the Fluid Levels .....................................13

Product Overview .........................................................14

Controls ...............................................................14
Specifications ........................................................17
Attachments/Accessories........................................17

Operation ....................................................................17

Checking the Engine-oil Level..................................17
Adding Fuel...........................................................18
Checking the Coolant Level .....................................19
Checking the Transaxle/Hydraulic Fluid

Level .................................................................19

Checking the High-flow Hydraulic Fluid (If so

equipped) ..........................................................20

Checking the Front-differential-oil Level

(Four-wheel-drive Models Only) ...........................20

Vehicle ..............................................................26

Four Wheel Drive (Four-wheel-drive Models

Only) ................................................................26

Transporting the Vehicle .........................................26
Towing the Vehicle .................................................27
Towing a Trailer with the Vehicle ..............................27

Maintenance .................................................................28

Recommended Maintenance Schedule(s) ......................28

Heavy-duty Operation ............................................30

Premaintenance Procedures ........................................30

Removing the Full Bed ............................................30

Installing the Full Bed .............................................30
Jacking Up the Vehicle ............................................31
Removing the Hood ...............................................31

Lubrication ...............................................................32

Greasing Bearings and Bushings ...............................32

Engine Maintenance ..................................................35

Servicing the Air Cleaner .........................................35
Changing the Engine Oil and Filter ...........................35

Fuel System Maintenance ...........................................36

Fuel Lines and Connections .....................................36
Servicing the Water Separator/Fuel Filter...................36

Electrical System Maintenance ....................................37

Fuses ....................................................................37
Jump Starting the Vehicle.........................................38
Servicing the Battery...............................................38

Drive System Maintenance .........................................39

Changing the Front Differential Oil

(Four-wheel-drive Models Only) ...........................39

Inspecting the Constant Velocity Boot

(Four-wheel-drive Models Only) ...........................39

Adjusting the Shift Cables........................................40
Adjusting the High–Low Cable ................................40
Inspecting the Tires ................................................40
Checking the Front Wheel Alignment........................40

Cooling System Maintenance ......................................41

Removing Debris from the Cooling System ................41
Changing the Engine Coolant...................................42

Brake Maintenance ....................................................43

Adjusting the Parking Brake .....................................43
Adjusting the Brake Pedal ........................................44

Belt Maintenance ......................................................44

Adjusting Belts.......................................................44

Controls System Maintenance .....................................45

Adjusting the Accelerator Pedal ................................45
Adjusting the Clutch Pedal.......................................45
Converting the Speedometer....................................46

Hydraulic System Maintenance ....................................46

Changing the Hydraulic Fluid and Cleaning the

Strainer..............................................................46

Replacing the Hydraulic Filter ..................................47
Changing the High-flow Hydraulic Oil and Filter

(If so equipped) ..................................................47

Storage ........................................................................49
Schematics ...................................................................50

Содержание 7379

Страница 1: ...Form No 3379 623 Rev A Industrial Workman HDX D Utility Vehicle with Bed Model No 07379 Serial No 313000001 and Up Register at www Toro com Original Instructions EN 3379 623 A ...

Страница 2: ...s known to the State of California to cause cancer birth defects or other reproductive harm 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 and accessory information help finding a dealer or to ...

Страница 3: ...ignals a hazard that may cause serious injury or death if you do not follow the recommended precautions Figure 2 1 Safety alert symbol This manual uses 2 other words to highlight information Important calls attention to special mechanical information and Note emphasizes general information worthy of special attention 3 ...

Страница 4: ...he Vehicle 27 Maintenance 28 Recommended Maintenance Schedule s 28 Heavy duty Operation 30 Premaintenance Procedures 30 Removing the Full Bed 30 Installing the Full Bed 30 Jacking Up the Vehicle 31 Removing the Hood 31 Lubrication 32 Greasing Bearings and Bushings 32 Engine Maintenance 35 Servicing the Air Cleaner 35 Changing the Engine Oil and Filter 35 Fuel System Maintenance 36 Fuel Lines and C...

Страница 5: ...manuals To reduce the potential for injury or death comply with the following safety instructions Supervisor s Responsibilities Make sure that all operators are thoroughly trained and familiar with the Operator s Manual and all labels on the vehicle Be sure to establish your own special procedures and work rules for unusual operating conditions e g slopes too steep for vehicle operation Use the 3r...

Страница 6: ...mands attention Failure to operate vehicle safely may result in an accident tipping over of the vehicle and serious injury or death Drive carefully To prevent tipping or loss of control take the following precautions Use extreme caution reduce speed and maintain a safe distance around sand traps ditches creeks ramps any unfamiliar areas or other hazards Watch for holes or other hidden hazards Use ...

Страница 7: ...othing and any parts of your body away from the engine and from any moving parts Keep everyone away Do not overspeed the engine by changing the governor settings The maximum engine speed is 3650 rpm To ensure safety and accuracy have an Authorized Toro Distributor check the maximum engine speed with a tachometer If major repairs are ever needed or if assistance is required contact an Authorized To...

Страница 8: ...zard bystanders no riders on machine 115 2047 1 Warning do not touch the hot surface 93 9084 1 Lift point 2 Tie down point 115 7723 1 Warning the hydraulic oil pressure is 124 bar 1800 psi 2 Coupler A 3 Coupler B 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 tra...

Страница 9: ...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 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 carr...

Страница 10: ...ant under pressure 3 Warning do not touch the hot surface 2 Explosion hazard read the Operator s Manual 4 Warning read the Operator s Manual 93 9879 1 Stored energy hazard read the Operator s Manual 93 7814 1 Entanglement hazard belt stay away from moving parts 93 9868 1 Crushing hazard of hand read the Operator s Manual 93 9850 1 Do not repair or revise read the Operator s Manual 105 4215 1 Warni...

Страница 11: ...ed 2 Fast 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 93 9899 93 9899 1 Crushing hazard install the cylinder lock 115 7756 1 High flow hydraulics engaged 11 ...

Страница 12: ...7 Disengage 14 Parking brake 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 8 Battery acid can cause blindness or severe burns 4 Wear eye protection 9 Flush eyes imm...

Страница 13: ...ew the manual before operating themachine Note Determine the left and right side of the machine from the normal operating position 1 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 17 2 Check the transaxle hydraulic fluid level before the engine is first started refer to Chec...

Страница 14: ...avels 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 4 into the desired gear selection A diagram of the shift pattern is indicated below Figure 4 Important Do not shift the transaxle to the reverse or forward gear unless the vehicle is standing still Damage to the transax...

Страница 15: ...ed to third gear when in High range The key is removable in either position Oil Pressure Warning Light The oil pressure warning light glows Figure 6 if the engine oil pressure drops below a safe level while the engine is running If the light flickers or remains on stop the vehicle turn off the engine and check the oil level If the oil level was low but adding oil does not cause the light to go out...

Страница 16: ... Switch If so equipped Turn on the switch to activate the high flow hydraulics Figure 6 Horn Button Pressing the horn button activates the horn Figure 6 Tachometer Registers the rpm of the engine Figure 6 Figure 7 White triangle indicates the desired rpm for PTO operation Figure 7 Figure 7 1 Rpm of the engine 2 3300 rpm for 540 rpm PTO operation Speedometer Registers the ground speed of the vehicl...

Страница 17: ... Note Determine the left and right sides of the machine from the normal operating position CAUTION Before servicing or making adjustments to the machine stop the engine set the parking brake and remove the key from the switch Checking the Engine oil Level Service Interval Before each use or daily Note The best time to check the engine oil is when the engine is cool before it has been started for t...

Страница 18: ...ion from fuel can burn you and others and can cause property damage Before removing the fuel tank cap make sure the vehicle is positioned on a level surface Open the 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 2...

Страница 19: ...d open the cap slowly to allow steam to escape Do not check the coolant level at the radiator only check the coolant level at the reserve tank 2 Check the coolant level at the reserve tank Figure 13 The coolant should be up to the bottom of the filler neck Figure 13 1 Coolant reserve tank 3 If the coolant is low remove the reserve tank cap and add a 50 50 mixture of water and permanent ethylene gl...

Страница 20: ...Start the engine and turn on the attachment Let them run for about two minutes to purge air from the system Stop the engine and attachment and check for leaks Important The vehicle must be running before starting the high flow hydraulics WARNING Hydraulic fluid escaping under pressure can penetrate skin and cause injury Make sure all hydraulic fluid hoses and lines are in good condition and all hy...

Страница 21: ...is an example of tire wear caused by under inflation Figure 17 1 Under inflated tire Figure 18 is an example of tire wear caused by over inflation Figure 18 1 Over inflated tire Checking the Brake Fluid 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 fact...

Страница 22: ... the engine is ready to start 7 Rotate the ignition key switch to the Start position Release the key immediately when the engine starts and allow it to return to the Run position Note The glow plug indicator will turn on for an additional 15 seconds when the switch returns to the Run position Note Do not run the starter motor more than 10 seconds at a time or premature starter failure may result I...

Страница 23: ...g or starting unless the clutch pedal is pressed CAUTION If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury Do not tamper with the interlock switches Check the operation of the interlock switches daily and replace any damaged switches before operating the machine Note Refer to Attachment Operator s Manual for procedures on checki...

Страница 24: ... most parks and golf courses can be hazardous to the operator and passenger Avoid driving when it is dark especially in unfamiliar areas If you must drive when it is dark be sure to drive cautiously use the head lights and even consider adding additional lights Passengers Whenever you have a passenger riding in the vehicle make sure he or she is wearing the seat belt and holding on securely Drive ...

Страница 25: ...t the operator from all possible injuries Replace a damaged ROPS do not repair or revise Any alteration of the ROPS must be approved by the manufacturer The best way to prevent accidents involving utility vehicles is through continuous supervision and training of operators and paying constant attention to the area in which vehicle is being operated The best way for operators to prevent serious inj...

Страница 26: ...t secured or you are transporting a liquid in a large container such as a sprayer it can shift This shifting happens most often while turning going up or down hills suddenly changing speeds or while driving over rough surfaces Shifting loads can lead to tip overs Always secure loads so that they do not shift Never dump the load while the vehicle is sideways on the hill Heavy loads increase stoppin...

Страница 27: ...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 Traile...

Страница 28: ...requently 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 differential oil four wheel drive models only Grease all bearings and bushings Lubricate more frequently in heavy du...

Страница 29: ...e from the normal operating position DANGER Only qualified and authorized personnel shall be permitted to maintain repair adjust or inspect the vehicle 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 CA...

Страница 30: ...e 25 1 Bed mounting bracket 2 Remove the lynch pins and clevis pins securing the pivot brackets to the frame channels Figure 26 Figure 26 1 Left rear corner of bed 4 Clevis pin 2 Vehicle frame channel 5 Lynch pin 3 Pivot plate 3 Lift the bed off of the vehicle CAUTION The full bed weighs approximately 147 5 kg 325 lb so do not try to install or remove it by yourself Use an overhead hoist or get th...

Страница 31: ...e vehicle without jack stands supporting it The vehicle could slip off a jack injuring any one beneath it When jacking up the front of the vehicle always place a 2 x 4 block or similar material between the jack and the vehicle frame The jacking point at the front of the vehicle is under the front center frame support Figure 27 and at the rear it is under the axle Figure 28 Figure 27 1 Front jackin...

Страница 32: ...rpose lithium base grease The grease fitting locations and quantities are as follows Ball joints 4 tie rods 2 pivot mounts 2 and steering cylinder 2 Figure 30 Spring tower 2 Figure 31 Clutch 1 accelerator 1 brake qty 1 Figure 32 Accelerator arm 1 Figure 33 U joint 18 and 4 wheel drive shaft 3 Figure 34 Important When greasing the drive shaft universal shaft bearing crosses pump grease until it com...

Страница 33: ...Figure 31 Figure 32 Figure 33 33 ...

Страница 34: ...Figure 34 34 ...

Страница 35: ...ng the filter into the side of the body Note Do not attempt to clean the primary filter 5 Remove the safety filter only if you intend to replace it Important Never attempt to clean the safety filter If the safety filter is dirty then the primary filter is damaged and both filters should be replaced 6 Inspect the new filter s for damage by looking into the filter while shining a bright light on the...

Страница 36: ...r loose connections Servicing the Water Separator Fuel Filter Draining the Fuel Filter Water Separator Service Interval Before each use or daily Drain water or other contaminants from the water separator 1 Place a clean container under the fuel filter Figure 38 2 Loosen the drain plug on the bottom of the filter canister Figure 38 1 Water separator filter canister 3 Tighten the drain plug on the b...

Страница 37: ...asket 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 Fuses The fuses for the machine s electrical system are located under the center of the dash panel Figure 39 Figure 40 Figure 39 1 Fuses Figure 40 37 ...

Страница 38: ... The negative terminal has NEG on the battery cover 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 Figure 42 1 Battery 4 Start the engine in the vehicle providing the jump start Let it run a few minutes then start your engine 5 Remove the negative jumper cable first...

Страница 39: ...pidly than if the machine is stored in a location where temperatures are cool Drive System Maintenance Changing the Front Differential Oil Four wheel drive Models Only Service Interval Every 800 hours 1 Position the vehicle on a level surface stop the engine engage the parking brake and remove the key from the ignition switch 2 Clean the area around the drain plug on the side of the differential F...

Страница 40: ...nspecting the Tires Service Interval Every 100 hours Operating accidents such as hitting curbs can damage a tire or rim and also disrupt wheel alignment so inspect the tire condition after an accident Check the tire pressure frequently to ensure proper inflation If the tires are not inflated to the correct pressure the tires will wear pre maturely Figure 45 is an example of tire wear caused by und...

Страница 41: ...r to the Workman Service Manual for the adjustment procedure Cooling System Maintenance Removing Debris from the Cooling System Service Interval Before each use or daily Clean more frequently in dirty conditions 1 Turn the engine off Clean the engine area thoroughly of all debris 2 Remove the 5 bolts securing radiator screen guard to the radiator The guard is not shown in the figure Figure 49 Remo...

Страница 42: ...d Use a rag when opening the radiator cap and open the cap slowly to allow steam to escape Figure 51 1 Radiator cap 3 Remove the reserve tank cap 1 G019522 Figure 52 1 Reserve tank cap 4 Disconnect the lower radiator hose and allow coolant to flow into a drain pan When coolant stops connect the lower radiator hose 5 Open the bleed screw on top of the water pump Figure 53 Figure 53 1 Bleed screw 6 ...

Страница 43: ... the rubber grip from the parking brake lever Figure 54 Figure 54 1 Parking brake lever 2 Grip 2 Loosen the set screw securing the knob to the parking brake lever Figure 55 3 Rotate the knob until a force of 200 to 222 N 45 to 50 lb is required to actuate the lever Figure 55 1 Parking brake lever 3 Set screw 2 Knob 4 Tighten the set screw when finished Note If no adjustment is left at the handle l...

Страница 44: ...der must relieve pressure when properly adjusted Figure 57 1 Brake pedal 2 Clutch pedal Belt Maintenance Adjusting Belts Adjusting the Alternator Belt Service Interval After the first 8 hours Check condition and tension of the alternator belt Every 200 hours Check condition and tension of the alternator belt 1 Check the tension by pressing the belt at mid span between the crankshaft and alternator...

Страница 45: ...utch 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 1 Loosen the jam nuts securing the clutch cable to the bracket on the bell housing Figure 61 Figure 61 1 Clutch cable 3 Return spring 2 Jam nuts 4 Ball joint Note You may remove and rotate the ball joint if additional adjustment is required 2 Disconnect the return sprin...

Страница 46: ...he speedometer 4 Remove the connector plug from the harness wire and connect the wires together The speedometer will switch to kpm or mph 5 Install the hood Hydraulic System Maintenance Changing the Hydraulic Fluid and Cleaning the Strainer Service Interval Every 800 hours 1 Position the vehicle on a level surface stop the engine engage the parking brake and remove the key from the ignition switch...

Страница 47: ...aulic oils are listed below Toro Premium All Season Hydraulic Fluid Available in 5 gallon pails or 55 gallon drums See parts catalog or Toro distributor for part numbers Alternate fluids If the Toro fluid is not available another conventional petroleum based fluid may be used provided it meets the following material properties and industry specifications Consult with your lubricant distributor to ...

Страница 48: ...rn further The filter should now be sealed 3 Fill the hydraulic reservoir with approximately 15 l 4 US gallons of hydraulic oil 4 Start the machine and run it at idle for about two minutes to circulate the fluid and remove any air trapped in the system Stop the machine and recheck the fluid level 5 Verify the oil level 6 Dispose of the oil properly 48 ...

Страница 49: ... Check the tire pressure refer to Checking the Tire Pressure page 21 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 Remove the battery from the chassis check the electrolyte level and charge it fully refer to Servicing the Battery page 38 Note Do not connect the battery cables to the battery posts during ...

Страница 50: ...Schematics Hydraulic Schematic Rev A 50 ...

Страница 51: ...High Flow Hydraulics Schematic Optional Rev A 51 ...

Страница 52: ...Electrical Schematic Rev A 52 ...

Страница 53: ...Notes 53 ...

Страница 54: ...Notes 54 ...

Страница 55: ...Notes 55 ...

Страница 56: ...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 make the final decision whether to repair any existing part or...

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