Toro Workman HDX--D User manual

Brand: Toro

Model: Workman HDX--D

Category: Motorcycles

Type: User manual

This manual is also suitable for

7379

FormNo.3379-623RevA

IndustrialWorkman

HDX-D

UtilityVehiclewithBed

ModelNo.07379—SerialNo.313000001andUp

Registeratwww.Toro.com.

OriginalInstructions(EN)

*3379-623*A

Thismachineisautilityvehicleintendedtobeusedby

professional,hiredoperatorsincommercialapplications.Itis

primarilydesignedforthetransportofimplementsusedin

suchapplications.Thisvehicleallowsforthesafetransport

ofanoperatorandonepassengerintheidentiedseats.The

bedofthisvehicleisnotsuitableforanyriders.

Introduction

WARNING

CALIFORNIA

Proposition65Warning

Thisproductcontainsachemicalorchemicals

knowntotheStateofCaliforniatocausecancer,

birthdefects,orreproductiveharm.

Dieselengineexhaustandsomeofits

constituentsareknowntotheStateof

Californiatocausecancer,birthdefects,

andotherreproductiveharm.

Useofthisproductmaycauseexposureto

chemicalsknowntotheStateofCalifornia

tocausecancer,birthdefects,orother

reproductiveharm.

Readthisinformationcarefullytolearnhowtooperateand

maintainyourproductproperlyandtoavoidinjuryand

productdamage.Youareresponsibleforoperatingthe

productproperlyandsafely.

YoumaycontactTorodirectlyatwww.Toro.comforproduct

andaccessoryinformation,helpndingadealer,ortoregister

yourproduct.

Wheneveryouneedservice,genuineToroparts,oradditional

information,contactanAuthorizedServiceDealerorToro

CustomerServiceandhavethemodelandserialnumbersof

yourproductready.Figure1identiesthelocationofthe

modelandserialnumbersontheproduct.Writethenumbers

inthespaceprovided.

Figure1

1.Modelandserialnumberlocation

ModelNo.

SerialNo.

8111LyndaleAvenueSouth

Bloomington,MN55420

Contactusatwww.Toro.com.

PrintedintheUSA.

AllRightsReserved

Thismanualidentiespotentialhazardsandhassafety

messagesidentiedbythesafetyalertsymbol(Figure2),

whichsignalsahazardthatmaycauseseriousinjuryordeath

ifyoudonotfollowtherecommendedprecautions.

Figure2

1.Safetyalertsymbol

Thismanualuses2otherwordstohighlightinformation.

Importantcallsattentiontospecialmechanicalinformation

andNoteemphasizesgeneralinformationworthyofspecial

attention.

Contents

Introduction..................................................................2

Safety...........................................................................5

SafeOperatingPractices...........................................5

Supervisor’sResponsibilities.....................................5

BeforeOperating....................................................5

Operation...............................................................6

Maintenance...........................................................7

SoundPressure.......................................................7

Vibration................................................................7

SoundLevelCertication.........................................7

SafetyandInstructionalDecals.................................8

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

1CheckingtheFluidLevels.....................................13

ProductOverview.........................................................14

Controls...............................................................14

Specications........................................................17

Attachments/Accessories........................................17

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

CheckingtheEngine-oilLevel..................................17

AddingFuel...........................................................18

CheckingtheCoolantLevel.....................................19

CheckingtheTransaxle/HydraulicFluid

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

CheckingtheHigh-owHydraulicFluid(Ifso

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

CheckingtheFront-differential-oilLevel

(Four-wheel-driveModelsOnly)...........................20

CheckingtheTorqueoftheWheelNuts.....................21

CheckingtheTirePressure......................................21

CheckingtheBrakeFluid.........................................21

Pre-startingChecks.................................................22

StartingtheEngine.................................................22

DrivingtheVehicle.................................................22

StoppingtheVehicle...............................................23

StoppingtheEngine...............................................23

Break-inNewVehicle.............................................23

CheckingtheInterlockSystem.................................23

OperatingCharacteristics........................................23

Passengers.............................................................24

Speed....................................................................24

TurningtheVehicle................................................25

BrakingtheVehicle.................................................25

PreventingTipOvers..............................................25

OperatingtheVehicleonHills..................................25

LoadingontoandDumpingFromthe

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

FourWheelDrive(Four-wheel-driveModels

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

TransportingtheVehicle.........................................26

TowingtheVehicle.................................................27

TowingaTrailerwiththeVehicle..............................27

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

RecommendedMaintenanceSchedule(s)......................28

Heavy-dutyOperation............................................30

PremaintenanceProcedures........................................30

RemovingtheFullBed............................................30

InstallingtheFullBed.............................................30

JackingUptheVehicle............................................31

RemovingtheHood...............................................31

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

GreasingBearingsandBushings...............................32

EngineMaintenance..................................................35

ServicingtheAirCleaner.........................................35

ChangingtheEngineOilandFilter...........................35

FuelSystemMaintenance...........................................36

FuelLinesandConnections.....................................36

ServicingtheWaterSeparator/FuelFilter...................36

ElectricalSystemMaintenance....................................37

Fuses....................................................................37

JumpStartingtheVehicle.........................................38

ServicingtheBattery...............................................38

DriveSystemMaintenance.........................................39

ChangingtheFrontDifferentialOil

(Four-wheel-driveModelsOnly)...........................39

InspectingtheConstantVelocityBoot

(Four-wheel-driveModelsOnly)...........................39

AdjustingtheShiftCables........................................40

AdjustingtheHigh–LowCable................................40

InspectingtheTires................................................40

CheckingtheFrontWheelAlignment........................40

CoolingSystemMaintenance......................................41

RemovingDebrisfromtheCoolingSystem................41

ChangingtheEngineCoolant...................................42

BrakeMaintenance....................................................43

AdjustingtheParkingBrake.....................................43

AdjustingtheBrakePedal........................................44

BeltMaintenance......................................................44

AdjustingBelts.......................................................44

ControlsSystemMaintenance.....................................45

AdjustingtheAcceleratorPedal................................45

AdjustingtheClutchPedal.......................................45

ConvertingtheSpeedometer....................................46

HydraulicSystemMaintenance....................................46

ChangingtheHydraulicFluidandCleaningthe

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

ReplacingtheHydraulicFilter..................................47

ChangingtheHigh-owHydraulicOilandFilter

(Ifsoequipped)..................................................47

Storage........................................................................49

Schematics...................................................................50

Safety

ThismachinemeetstherequirementsofSAEJ2258.

Supervisors,operatorsandservicepersonsshouldbefamiliar

withthefollowingstandardsandpublications:(Thematerial

maybeobtainedfromtheaddressshown).

•FlammableandCombustibleLiquidsCode:

ANSI/NFPA30

•NationalFireProtectionAssociation:

ANSI/NFPA#505;PoweredIndustrialTrucks

ADDRESS:

NationalFirePreventionAssociation

BarrymarchPark

Quincy,Massachusetts02269U.S.A

•ANSI/ASMEB56.8PersonalBurdenCarriers

ADDRESS:

AmericanNationalStandardsInstitute,Inc.

1430Broadway

NewYork,NewYork10018U.S.A.

•ANSI/UL558;InternalCombustionEnginePowered

IndustrialTrucks

ADDRESS:

AmericanNationalStandardsInstitute,Inc.

1430Broadway

NewYork,NewYork10018U.S.A.

UnderwritersLaboratories

333PngstenRoad

Northbrook,Illinois60062U.S.A.

SafeOperatingPractices

WARNING

TheWorkmanisanoff–highwayvehicleonly,and

isnotdesigned,equipped,ormanufacturedforuse

onpublicstreets,roads,orhighways.

Thismachinewasdesignedandtestedtooffersafeservice

whenoperatedandmaintainedproperly.Althoughhazard

controlandaccidentpreventionpartiallydependuponthe

designandcongurationofthemachine,thesefactorsalso

dependupontheawareness,concern,andpropertrainingof

thepersonnelinvolvedintheoperation,maintenanceand

storageofthemachine.Improperuseormaintenanceofthe

machinecanresultininjuryordeath.

Thisisaspecializedutilityvehicledesignedforoff–roaduse

only.Itsrideandhandlingwillhaveadifferentfeelthanwhat

driversexperiencewithpassengercarsortrucks.Sotaketime

tobecomefamiliarwiththisvehicle.

NotalltheattachmentsthatadapttotheWorkmanare

coveredinthismanual.SeethespecicOperator’sManual

providedwitheachattachmentforadditionalsafety

instructions.Readthesemanuals.

Toreducethepotentialforinjuryordeath,complywith

thefollowingsafetyinstructions.

Supervisor’sResponsibilities

•Makesurethatalloperatorsarethoroughlytrainedand

familiarwiththeOperator’sManualandalllabelsonthe

vehicle.

•Besuretoestablishyourownspecialproceduresand

workrulesforunusualoperatingconditions(e.g.,slopes

toosteepforvehicleoperation).Usethe3rdhighlockout

switchifdrivingathighspeedcouldendangeryouand

othersordamagethevehicle.

BeforeOperating

•Operatethemachineonlyafterreadingandunderstanding

thecontentsofthismanual.Areplacementmanualis

availablebysendingcompletemodelandserialnumber

to:TheToroCompany,8111LyndaleAvenueSouth,

Minneapolis,Minnesota55420.

•Neverallowchildrentooperatethevehicle.Never

allowadultstooperateitwithoutproperinstructions.

Onlytrainedandauthorizedpersonsshouldoperatethis

vehicle.Makesurethatalloperatorsarephysicallyand

mentallycapableofoperatingthevehicle.

•Thisvehicleisdesignedtocarryonlyyou,theoperator,

and1passengerintheseatprovidedbythemanufacturer.

Nevercarryanyotherpassengersonthevehicle.

•Neveroperatethevehiclewhenundertheinuenceof

drugsoralcohol.

•Becomefamiliarwiththecontrolsandknowhowtostop

theenginequickly.

•Keepallshields,safetydevices,anddecalsinplace.If

ashield,asafetydevice,oradecalismalfunctioning,

illegible,ordamaged,repairorreplaceitbeforeoperating

themachine.

•Alwayswearsubstantialshoes.Donotoperatethe

machinewhilewearingsandals,tennisshoes,orsneakers.

Donotwearloosettingclothingorjewelrywhichcould

getcaughtinmovingpartsandcausepersonalinjury.

•Wearingsafetyglasses,safetyshoes,longpants,anda

helmetisadvisableandrequiredbysomelocalsafetyand

insuranceregulations.

•Keepeveryone,especiallychildrenandpets,awayfrom

theareasofoperation.

•Beforeoperatingthevehicle,alwayscheckallpartsof

thevehicleandanyattachments.Ifsomethingiswrong,

stopusingthevehicle.Makesurethattheproblemis

correctedbeforeoperatingthevehicleortheattachment.

•Sincedieselfuelishighlyammable,handleitcarefully.

–Useanapprovedfuelcontainer.

–Donotremovethecapfromthefueltankwhenthe

engineishotorrunning.

–Donotsmokewhilehandlingfuel.

–Fillthefueltankoutdoorsandtoabout1inchbelow

thetopoftank(bottomofllerneck).Donot

overllthetank.

–Wipeupanyspilledfuel.

•Operatethevehicleonlyoutdoorsorinawell-ventilated

area.

•Useonlyanapprovednonmetal,portablefuelcontainer.

Staticelectricdischargecanignitefuelvaporsina

ungroundedfuelcontainer.Removethefuelcontainer

fromthebedofthevehicleandplaceitontheground

awayfromthevehiclebeforelling.Keepthenozzle

incontactwiththecontainerwhilelling.Removethe

equipmentfromvehiclebedbeforellingthetank.

•Checkthesafetyinterlocksystemdailyforproper

operation.Ifaswitchmalfunctions,replacetheswitch

beforeoperatingthemachine.

Operation

•Theoperatorandpassengershoulduseseatbeltsand

remainseatedwheneverthevehicleisinmotion.The

operatorshouldkeepbothhandsonthesteeringwheel

wheneverpossible,andthepassengershouldusethehand

holdsprovided.Keeparmsandlegswithinthevehicle

bodyatalltimes.Nevercarrypassengersintheboxoron

attachments.Rememberthatyourpassengermaynotbe

expectingyoutobrakeorturnandmaynotbeready.

•Neveroverloadyourvehicle.Thenameplate(located

underthemiddleofthedash)showstheloadlimitsfor

thevehicle.Neveroverllattachmentsorexceedthe

vehiclemaximumgrossvehicleweight(GVW).

•Whenstartingtheengine:

–Sitonoperator’sseatandensurethattheparking

brakeisengaged.

–DisengagethePTO(ifsoequipped)andreturn

thehandthrottlelevertotheOffposition(ifso

equipped).

–MovetheshiftlevertotheNeutralpositionandpress

theclutchpedal.

–Keepyourfootofftheacceleratorpedal.

–TurntheignitionswitchtotheOnposition.When

theglowplugindicatorgoesoff,theengineisready

tostart.

–TurntheignitionkeytotheStartposition.

Note:Theglowplugindicatorwillturnonforan

additional15secondswhenyoureturntheswitchtothe

Onposition.

•Usingthemachinedemandsattention.Failuretooperate

vehiclesafelymayresultinanaccident,tippingoverof

thevehicle,andseriousinjuryordeath.Drivecarefully.

Topreventtippingorlossofcontrol,takethefollowing

precautions:

–Useextremecaution,reducespeed,andmaintain

asafedistancearoundsandtraps,ditches,creeks,

ramps,anyunfamiliarareas,orotherhazards.

–Watchforholesorotherhiddenhazards.

–Usecautionwhenoperatingthevehicleonasteep

slope.Normally,travelstraightupanddownslopes.

Reducespeedwhenmakingsharpturnsorwhen

turningonhillsides.Avoidturningonhillsides

wheneverpossible.

–Useextracautionwhenoperatingthevehicleon

wetsurfaces,athigherspeeds,orwithafullload.

Stoppingtimewillincreasewithafullload.Shiftinto

alowergearbeforestartingupordownahill.

–Whenloadingthebed,distributetheloadevenly.

Useextracautioniftheloadexceedsthedimensions

ofthevehicle/bed.Operatethevehiclewithextra

cautionwhenhandlingoff-centerloadsthatcannot

becentered.Keeploadsbalancedandsecureto

preventthemfromshifting.

–Avoidsuddenstopsandstarts.Donotgofrom

reversetoforwardorforwardtoreversewithoutrst

comingtoacompletestop.

–Donotattemptsharpturnsorabruptmaneuversor

otherunsafedrivingactionsthatmaycausealossof

vehiclecontrol.

–Donotpassanothervehicletravelinginthesame

directionatintersections,blindspots,oratother

dangerouslocations.

–Keepallbystandersaway.Beforebackingup,lookto

therearandensurethatnooneisbehindthevehicle.

Backupslowly.

–Watchoutfortrafcwhennearorcrossingroads.

Alwaysyieldtherightofwaytopedestriansandother

vehicles.Thisvehicleisnotdesignedforuseon

streetsorhighways.Alwayssignalyourturnsorstop

earlyenoughsothatotherpersonsknowwhatyou

plantodo.Obeyalltrafcrulesandregulations.

–Neveroperatethevehicleinornearanareawhere

thereisdustorfumesintheair,whichareexplosive.

Theelectricalandexhaustsystemsofthevehiclecan

producesparkscapableofignitingexplosivematerials.

–Alwayswatchoutforandavoidlowoverhangs,such

astreelimbs,doorjambs,overheadwalkways,etc.

Makesurethatthereisenoughroomover-headto

easilyclearthevehicleandyourhead.

–Ifyouareeverunsureaboutsafeoperation,stop

workandaskyoursupervisor.

•Donottouchtheengine,transaxle,radiator,muferor

mufermanifoldwhiletheengineisrunningorsoon

afterithasstopped,becausetheseareasmaybehot

enoughtocauseburns.

•Ifthemachineevervibratesabnormally,stopimmediately,

turnengineoff,waitforallmotiontostopandinspectfor

damage.Repairalldamagebeforeresumingoperation.

•Beforegettingofftheseat:

–Stopthemachine.

–Shutofftheengineandwaitforallmovementtostop.

–Settheparkingbrake.

–Removethekeyfromtheignition.

•Lightningcancausesevereinjuryordeath.Iflightning

isseenorthunderisheardinthearea,donotoperate

themachine;seekshelter.

Maintenance

•Beforeservicingormakingadjustmentstothemachine,

stoptheengine,settheparkingbrake,andremovethe

keyfromtheignitiontopreventaccidentalstartingof

theengine.

•Makesurethatallhydrauliclineconnectorsaretightand

allhydraulichosesandlinesareingoodconditionbefore

applyingpressuretothesystem.

•Keepyourbodyandhandsawayfrompin-holeleaksor

nozzlesthatejecthydraulicuidunderhighpressure.

Usepaperorcardboard,notyourhands,tosearchfor

leaks.Hydraulicuidescapingunderpressurecanhave

sufcientforcetopenetrateskinanddoseriousdamage.

Ifuidisinjectedintotheskin,itmustbesurgically

removedwithinafewhoursbyadoctorfamiliarwiththis

formofinjury;otherwise,gangrenemayresult.

•Tomakesurethattheentiremachineisingoodcondition,

keepallnuts,bolts,andscrewsproperlytightened.

•Toreducethepotentialrehazard,keeptheenginearea

freeofexcessivegrease,grass,leaves,anddirt.

•Iftheenginemustberunningtoperformamaintenance

adjustment,keepyourhands,feet,clothing,andanyparts

ofyourbodyawayfromtheengineandfromanymoving

parts.Keepeveryoneaway.

•Donotoverspeedtheenginebychangingthegovernor

settings.Themaximumenginespeedis3650rpm.To

ensuresafetyandaccuracy,haveanAuthorizedToro

Distributorcheckthemaximumenginespeedwitha

tachometer.

•Ifmajorrepairsareeverneededorifassistanceis

required,contactanAuthorizedToroDistributor.

•Tobesureofoptimumperformanceandsafety,

alwayspurchasegenuineTororeplacementpartsand

accessories.Replacementpartsandaccessoriesmadeby

othermanufacturerscouldbedangerous.Alteringthis

vehicleinanymannermayaffectthevehicle’soperation,

performance,durabilityoritsusemayresultininjuryor

death.SuchusecouldvoidtheproductwarrantyofThe

ToroCompany.

•ThisvehicleshouldnotbemodiedwithoutThe

ToroCompany’sauthorization.Directanyinquiries

toTheToroCompany,CommercialDivision,Vehicle

EngineeringDept.,8111LyndaleAve.So.,Bloomington,

Minnesota55420–1196USA

SoundPressure

Thisunithasasoundpressurelevelattheoperator’searof82

dBA,whichincludesanUncertaintyValue(K)of1dBA.

Thesoundpressurelevelwasdeterminedaccordingtothe

proceduresoutlinedinENISO11201.

Vibration

Hand-Arm

•Measuredvibrationlevelforrighthand=0.41m/s

•Measuredvibrationlevelforlefthand=0.2m/s

•UncertaintyValue(K)=0.5m/s

Measuredvaluesweredeterminedaccordingtotheprocedures

outlinedinEN1032.

WholeBody

•Measuredvibrationlevel=0.3m/s

•UncertaintyValue(K)=0.5m/s

Measuredvaluesweredeterminedaccordingtotheprocedures

outlinedinEN1032.

SoundLevelCertication

WhentestedperITSDFB56-11-5-2005thevehiclemeets

Alcoa30.3.2Section4.1.2aforenginespeedsupto:

•3650withoutcab@80dBA

•2850withcab@80dBA

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential

danger.Replaceanydecalthatisdamagedorlost.

93-9852

1.Warning—readtheOperator’sManual.2.Crushinghazard—installthecylinderlock.

115-7739

1.Falling,crushinghazard,bystanders—noriderson

machine.

115-2047

1.Warning—donottouchthehotsurface.

93-9084

1.Liftpoint

2.Tie-downpoint

115-7723

1.Warning—thehydraulicoilpressureis124bar(1800psi).

2.CouplerA

3.CouplerB

115-7740

1.Warning—maximumtrailerweightis680kg(1500lb),

maximumtongueweightis90kg(200lb).

2.Warning—trailerbrakesarerequiredwhentowinggreater

than680kg(1500lb),maximumtrailerweightwithtrailer

brakesis1591kg(3500lb),maximumtongueweightwith

trailerbrakesis273kg(600lb).

115-2281

1.Headlights4.Engine—run

2.Horn5.Engine—start

3.Engine—stop

115-7746

1.Warning—donotoperatethismachineunlessyouaretrained.

3.Firehazard—stoptheenginebeforefueling.

2.Warning—locktheparkingbrake,stoptheengine,and

removetheignitionkeybeforeleavingthemachine.

4.Tippinghazard—slowdownandturngradually,usecaution

anddriveslowlywhendrivingonslopes,donotexceed32

kph(20mph),anddriveslowlyoverroughterrainorwhen

carryingafullorheavyload.

115-2282

1.Warning—readtheOperator'sManual.

2.Warning—stayawayfrommovingparts,keepallguardsandshieldsinplace.

3.Crushing/dismembermenthazardofbystanders—keepbystandersasafedistancefromthevehicle,donotcarrypassengersin

thecargobed,keeparmsandlegsinsideofthevehicleatalltimes,anduseseatbeltsandhandholds.

115-7813

1.Poweroutlet10A5.Lights,brake15A

2.Switchedpower10A

6.Hazard10A

3.Fuelpump,supervisor

switch10A

7.4WD,Transmission10A

4.Horn,powerpoint15A

115-7741

1.ReadtheOperator’sManualbeforeservicingtransmission

uid.

106-6755

1.Enginecoolantunder

pressure.

3.Warning—donottouchthe

hotsurface.

2.Explosionhazard—read

theOperator'sManual.

4.Warning—readthe

Operator'sManual.

93-9879

1.Storedenergyhazard—readtheOperator'sManual.

93-7814

1.Entanglementhazard,belt—stayawayfrommovingparts.

93–9868

1.Crushinghazardofhand—readtheOperator’sManual.

93-9850

1.Donotrepairorrevise—readtheOperator'sManual.

105-4215

1.Warning—avoidpinchpoints.

106-2353

1.Electricalpowerpoint

106-2355

1.Slow

3.Transmission—thirdhigh;

nofastspeed

2.Fast

106-7767

1.Warning—readtheOperator'sManual;avoidtippingthe

machine;weartheseatbelt;leanawayfromthedirection

themachineistipping.

93-9899

1.Crushinghazard—installthecylinderlock.

115-7756

1.Highowhydraulics—engaged

106-2377

1.Locked

8.Warning—readtheOperator'sManual.

2.Differentiallock9.Entanglementhazard,shaft—keepbystander'sasafe

distancefromthevehicle.

3.Unlocked10.Retracthydraulics

4.Hydrauliclock11.Extendhydraulics

5.Engage12.Transmission—highspeed

6.Powertake-off(PTO)

13.Transmission—lowspeed

7.Disengage14.Parkingbrake

BatterySymbols

Someorallofthesesymbolsareonyourbattery

1.Explosionhazard

6.Keepbystandersasafe

distancefromthebattery.

2.Nore,opename,or

smoking.

7.Weareyeprotection;

explosivegasescan

causeblindnessandother

injuries

3.Causticliquid/chemical

burnhazard

8.Batteryacidcancause

blindnessorsevereburns.

4.Weareyeprotection9.Flusheyesimmediately

withwaterandgetmedical

helpfast.

5.ReadtheOperator's

Manual.

10.Containslead;donot

discard.

Setup

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescription

Qty.

Use

Nopartsrequired

–

Checktheuidlevels

MediaandAdditionalParts

Description

Qty.

Use

Operator'sManual

Readthemanualbeforeoperatingthevehicle.

PartsManual1

Usethemanualtoreferencethepartnumbers.

OperatorTrainingMaterial

Viewthemanualbeforeoperatingthemachine.

Note:Determinetheleftandrightsideofthemachinefrom

thenormaloperatingposition.

CheckingtheFluidLevels

NoPartsRequired

Procedure

1.Checktheengineoillevelbeforeandaftertheengine

isrststarted;refertoCheckingtheEngine-oilLevel

(page17).

2.Checkthetransaxle/hydraulicuidlevelbefore

theengineisrststarted;refertoCheckingthe

Transaxle/HydraulicFluidLevel(page19).

3.Checkthebrakeuidlevelbeforetheengineisrst

started;refertoCheckingtheBrakeFluid(page21).

ProductOverview

Controls

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

AcceleratorPedal

Theacceleratorpedal(Figure3)givesyoutheabilityto

varytheengineandgroundspeedofthevehiclewhenthe

transmissionisingear.Pressingthepedalincreasesengine

speedandthegroundspeed.Releasingthepedaldecreases

theenginespeedandthegroundspeedofthemachine.

Figure3

1.Acceleratorpedal3.Brakepedal

2.Clutchpedal

ClutchPedal

Presstheclutchpedal(Figure3)fullytodisengagetheclutch

whenstartingtheengineorshiftingthetransmissiongears.

Releasethepedalsmoothlywhenthetransmissionisingear

topreventunnecessarywearonthetransmissionandother

relatedparts.

Important:Donotridetheclutchpedalduring

operation.Theclutchpedalmustbefullyoutorthe

clutchwillslipcausingheatandwear.Neverholdthe

vehiclestoppedonahillusingtheclutchpedal.Damage

totheclutchmayoccur.

BrakePedal

Usethebrakepedal(Figure3)toapplytheservicebrakes

tostoporslowthevehicle.

CAUTION

Wornormaladjustedbrakesmayresultinpersonal

injury.Ifthebrakepedaltravelstowithin3.8cm

(1-1/2inches)ofthevehicleoorboard,thebrakes

mustbeadjustedorrepaired.

GearShiftLever

Fullypresstheclutchpedalandmovetheshiftlever(Figure

4)intothedesiredgearselection.Adiagramoftheshift

patternisindicatedbelow.

Figure4

Important:Donotshiftthetransaxletothereverseor

forwardgearunlessthevehicleisstandingstill.Damage

tothetransaxlemayoccur.

CAUTION

Downshiftingfromtoohighaspeedcancause

therearwheelstoskidresultinginlossofvehicle

controlaswellasclutchand/ortransmission

damage.Shiftsmoothlytoavoidgrindinggears.

ParkingBrake

Whenevertheengineisshutoff,theparkingbrake(Figure

5)mustbeengagedtopreventaccidentalmovementofthe

vehicle.Toengagetheparkingbrake,pullbackonthelever.

Todisengage,pushtheleverforward.Releasetheparking

brakebeforemovingthevehicle.Ifyouparkthevehicle

onasteepgrade,applytheparkingbrake.Also,shiftthe

transmissioninto1stgearonauphillgradeorreverseona

downhillgrade.Placechocksatthedownhillsideofthe

wheels.

Figure5

1.Gearshiftlever3.High–lowrangeshifter

2.Parkingbrake

High–LowRangeShifter

Thehigh–lowrangeshifteraddsthreeadditionalspeedsfor

precisespeedcontrol(Figure5).

•Thevehiclemustbecompletelystoppedbeforeshifting

betweenHighandLowrange.

•Shiftonlyonlevelground.

•Pressclutchpedalfully.

•MovetheleverfullyforwardforHighandfullyrearward

forLow.

Highisforhigherspeeddrivingonlevel,drysurfaceswith

lightloads.

Lowisforlowspeeddriving.Usethisrangewhengreater

thannormalpowerorcontrolisrequired.Forexample,steep

grades,difcultterrain,heavyloads,slowspeedbuthigh

enginespeed(spraying).

Important:ThereisalocationbetweenHighandLow

inwhichthetransaxleisinneitherrange.Donotuse

thispositionasaneutralpositionbecausethevehicle

couldmoveunexpectedlyiftheHigh–Lowshifteris

bumpedandthegearshiftleverisingear.

IgnitionSwitch

Usetheignitionswitch(Figure6)tostartandstoptheengine.

Ithasthreepositions:Off,On/Preheat,andStart.Rotate

thekeyclockwisetotheStartpositiontoengagethestarter

motor.Releasethekeywhentheenginestarts.Thekeywill

moveautomaticallytotheOnposition.Toshuttheengine

off,rotatethekeycounterclockwisetotheOffposition.

Figure6

1.Highow

hydraulicsswitch

(Optional)

8.Ignitionswitch

2.Horn9.Powerpoint

3.Tachometer10.3rdhighlockoutswitch

4.Hourmeter

11.Oilpressurewarninglight

5.Speedometer12.Glowplugindicator

6.Coolanttemperature

gaugeandlight

13.Chargeindicator

7.Fuelgauge

HourMeter

Indicatesthetotalhoursofmachineoperation.Thehour

meter(Figure6)startstofunctionwheneverthekeyswitchis

rotatedtotheOnpositionoriftheengineisrunning.

ThirdHighLockoutSwitch

Movethe3rdhighlockoutswitch(Figure6)totheslow

positionandremovethekeytopreventtheuseofthirdgear

whenintheHighrange.Theenginewillshutoffiftheshift

leverismovedtothirdgearwheninHighrange.Thekeyis

removableineitherposition.

OilPressureWarningLight

Theoilpressurewarninglightglows(Figure6)iftheengine

oilpressuredropsbelowasafelevelwhiletheengineis

running.Ifthelightickersorremainson,stopthevehicle,

turnofftheengine,andchecktheoillevel.Iftheoillevelwas

low,butaddingoildoesnotcausethelighttogooutwhen

theengineisrestarted,turntheengineoffimmediatelyand

contactyourlocalTorodistributorforassistance.

Checktheoperationofwarninglightsasfollows:

1.Applytheparkingbrake.

2.TurntheignitionkeytotheOn/Preheatposition,but

donotstarttheengine.Theoilpressurelightshould

glowred.Ifthelightdoesnotfunction,eitherabulb

isburnedoutorthereisamalfunctioninthesystem

whichmustberepaired.

Note:Ifenginewasjustturnedoff,itmaytake1to2

minutesforthelighttocomeon.

LowOilPressureShutDown

Iftheengineoilpressuredropsbelowasafelevel,formore

than10seconds,theenginewillshutdown.Contactyour

localTorodistributorforassistance.

GlowPlugIndicator

Glowplugindicator(Figure6)willglowredwhentheglow

plugsareactivated.

Important:Theglowplugindicatorwillturnon,foran

additional15seconds,whentheswitchreturnstothe

Onposition.

CoolantTemperatureGaugeandLight

Registersthecoolanttemperatureintheengine.Operates

onlywhentheignitionswitchisinOnposition(Figure6).

Theindicatorlightwillilluminateblinkingrediftheengine

overheats.

ChargeIndicator

Thechargeindicatorilluminateswhenthebatteryisbeing

discharged.Ifthelightilluminatesduringoperation,stopthe

vehicle,turnofftheengineandcheckforpossiblecauses,

suchasthealternatorbelt(

Figure6).

Important:Ifthealternatorbeltislooseorbroken,

donotoperatethevehicleuntiladjustmentorrepairis

complete.Failuretoobservethisprecautionmayresult

indamagetotheengine.

Checktheoperationofwarninglightsasfollows:

•Applytheparkingbrake.

•TurntheignitionkeytotheOn/Preheatposition,butdo

notstarttheengine.Thecoolanttemperature,charge

indicator,andoilpressurelightsshouldglow.Ifanylight

doesnotfunction,eitherabulbisburnedoutorthereisa

malfunctioninthesystemwhichmustberepaired.

FuelGauge

Thefuelgaugeshowstheamountoffuelinthetank.It

operatesonlywhentheignitionswitchisintheOn/Preheat

position(Figure6).Redindicateslowfuellevelandblinking

redindicatesnearempty.

High-owHydraulicsSwitch(Ifso

equipped)

Turnontheswitchtoactivatethehighowhydraulics(Figure

6).

HornButton

Pressingthehornbuttonactivatesthehorn(Figure6).

Tachometer

Registerstherpmoftheengine(Figure6&Figure7).White

triangleindicatesthedesiredrpmforPTOoperation(Figure

7).

Figure7

1.Rpmoftheengine2.3300rpmfor540rpmPTO

operation

Speedometer

Registersthegroundspeedofthevehicle(Figure6).The

speedometerisinmphbutcaneasilyconvertedtokph.Refer

toConvertingtheSpeedometer(page46).

PowerPoint

Usethepowerpoint(Figure6)topoweroptional12volt

electricalaccessories.

PassengerHandHold

Thepassengerhandholdislocatedonthedashboard(Figure

8).

Figure8

1.Passengerhandhold

2.Storagecompartment

SeatAdjustingLever

Theseatscanbeadjustedforeandaftforoperatorcomfort

(Figure9).

Figure9

1.Seatadjustinglever

Specications

Note:Specicationsanddesignaresubjecttochange

withoutnotice.

Dimensions

OverallWidth160cm(63inches)

OverallLength

w/obed:326cm(128.25inches)

w/fullbed:331cm(130.38inches)

w/2/3bedinrearmountinglocation:

346cm(136.38inches)

BaseWeight(Dry)819kg(1806lb)

RatedCapacity

(includes200lb.

operator,200lb.

passengerandloaded

attachment).

1381kg(3044lb)

Maximum.Gross

VehicleWeight

2200kg(4,850lb)

TowCapacityTongueweight272kg(600lb)

Maximumtrailerweight1587kg

(3,500lb)

GroundClearance18cm(7inches)w/noload

WheelBase

118cm(70inches)

WheelTread(center

linetocenterline)

Front:117cm(46inches)

Rear:121cm(47.7inches)

Height

190.5cm(75inches)totopofROPS

Attachments/Accessories

AselectionofToroapprovedattachmentsandaccessoriesis

availableforusewiththemachinetoenhanceandexpand

itscapabilities.ContactyourAuthorizedServiceDealeror

Distributororgotowww .Toro.comforalistofallapproved

attachmentsandaccessories.

Operation

Note:Determinetheleftandrightsidesofthemachine

fromthenormaloperatingposition.

CAUTION

Beforeservicingormakingadjustmentstothe

machine,stoptheengine,settheparkingbrake,

andremovethekeyfromtheswitch.

CheckingtheEngine-oilLevel

ServiceInterval:Beforeeachuseordaily

Note:Thebesttimetochecktheengineoiliswhenthe

engineiscoolbeforeithasbeenstartedfortheday.Ifithas

alreadybeenrun,allowtheoiltodrainbackdowntothe

sumpforatleast10minutesbeforechecking.Iftheoillevelis

atorbelowtheAddmarkonthedipstick,addoiltobringthe

oilleveltotheFullmark.Donotoverll.Iftheoillevelis

betweentheFullandAddmarks,noadditionaloilisrequired.

TheengineusesanyDetergentdieselengineoil(APIservice

CH-4orhigher).Chooseaviscosityaccordingtothetable

inFigure10.

Figure10

1.Positionthemachineonalevelsurface.

2.Removethedipstickandwipeitwithacleanrag.Insert

thedipstickintothetubeandmakesureitisseated

fully.Removethedipstickandchecktheleveloftheoil.

3.Iftheoillevelislow,removethellercap(

Figure11)

andaddenoughoiltoraisetheleveltotheFullmark

onthedipstick.

Figure11

1.Fillercap

4.Installthedipstickrmlyinplace.

AddingFuel

Useonlyclean,freshdieselfuelorbiodieselfuelswithlow

(<500ppm)orultralow(<15ppm)sulfurcontent.The

minimumcetaneratingshouldbe40.Purchasefuelin

quantitiesthatcanbeusedwithin180daystoensurefuel

freshness.

Fueltankcapacity:22l(5.85gallons).

Usesummergradedieselfuel(No.2-D)attemperatures

above-7°C(20°F)andwintergrade(No.1-DorNo.

1-D/2-Dblend)belowthattemperature.Useofwintergrade

fuelatlowertemperaturesprovideslowerashpointand

coldowcharacteristicswhichwilleasestartingandreduce

fuellterplugging.

Useofsummergradefuelabove-7°C(20°F)willcontribute

towardlongerfuelpumplifeandincreasedpowercompared

towintergradefuel.

Important:Donotusekeroseneorgasolineinsteadof

dieselfuel.Failuretoobservethiscautionwilldamage

theengine.

WARNING

Fuelisharmfulorfatalifswallowed.Long-term

exposuretovaporscancauseseriousinjuryand

illness.

•Avoidprolongedbreathingofvapors.

•Keepyourfaceawayfromthenozzleandgas

tankorconditioneropening.

•Keepfuelawayfromyoureyesandskin.

DANGER

Undercertainconditions,dieselfuelandfuel

vaporsarehighlyammableandexplosive.Are

orexplosionfromfuelcanburnyouandothersand

cancausepropertydamage.

•Beforeremovingthefueltankcap,makesure

thevehicleispositionedonalevelsurface.Open

thefueltankcapslowly.

•Useafunnelandllthefueltankoutdoors,in

anopenarea,whentheengineisoffandiscold.

Wipeupanyfuelthatspills.

•Donotllthefueltankcompletelyfull.Addfuel

tothefueltankuntilthelevelis25mm(1inch)

belowthebottomofthellerneck.Thisempty

spaceinthetankallowsthefueltoexpand.

•Neversmokewhenhandlingfuel,andstayaway

fromanopenameorwherefuelfumesmaybe

ignitedbyaspark.

•Storefuelinaclean,safety-approvedcontainer

andkeepthecapinplace.

BiodieselReady

Thismachinecanalsouseabiodieselblendedfuelofup

toB20(20%biodiesel,80%petrodiesel).Thepetrodiesel

portionshouldbeloworultralowsulfur.Observethe

followingprecautions:

•Thebiodieselportionofthefuelmustmeetspecication

ASTMD6751orEN14214.

•TheblendedfuelcompositionshouldmeetASTMD975

orEN590.

•Paintedsurfacesmaybedamagedbybiodieselblends.

•UseB5(biodieselcontentof5%)orlesserblendsincold

weather.

•Monitorseals,hoses,gasketsincontactwithfuelasthey

maybedegradedovertime.

•Fuellterpluggingmaybeexpectedforatimeafter

convertingtobiodieselblends.

•Contactyourdistributorifyouwishformoreinformation

onbiodiesel.

1.Cleantheareaaroundthefueltankcap.

2.Removethefueltankcap(Figure12).

Figure12

1.Fueltankcap

3.Fillthetanktoaboutoneinchbelowthetopofthe

tank,(bottomofthellerneck),theninstallthecap.

Donotoverll.

4.Wipeupanyfuelthatmayhavespilledtopreventa

rehazard.

CheckingtheCoolantLevel

ServiceInterval:Beforeeachuseordaily

Coolingsystemcapacity:3.7l(4qt)

Thecoolingsystemislledwitha50/50solutionofwater

andpermanentethyleneglycolantifreeze.

1.Parkthemachineonalevelsurface.

CAUTION

Iftheenginehasbeenrunning,the

pressurized,hotcoolantcanescapeandcause

burns.

•Donotopentheradiatorcap.

•Allowtheenginetocoolatleast15minutes

oruntiltheradiatorcapiscoolenoughto

touchwithoutburningyourhand.

•Usearagwhenopeningthereservetank

cap,andopenthecapslowlytoallow

steamtoescape.

•Donotcheckthecoolantlevelatthe

radiator;onlycheckthecoolantlevelatthe

reservetank.

2.Checkthecoolantlevelatthereservetank(Figure13).

Thecoolantshouldbeuptothebottomoftheller

neck.

Figure13

1.Coolantreservetank

3.Ifthecoolantislow,removethereservetankcapand

adda50/50mixtureofwaterandpermanentethylene

glycolantifreeze.Donotoverll.

4.Installthereservetankcap.

Checkingthe

Transaxle/HydraulicFluid

Level

ServiceInterval:Beforeeachuseordaily

ThetransaxlereservoirislledwithDexronIIIATF.Check

thelevelbeforetheengineisrststartedandevery8hoursor

daily,thereafter.Capacityofsystemis.

Transaxlereservoircapacity:7.5qt(7l).

1.Positionthevehicleonalevelsurface.

2.Cleantheareaaroundthedipstick(

Figure14).

Figure14

1.Dipstick

3.Unscrewthedipstickfromthetopofthetransaxleand

wipeitwithacleanrag.

4.Screwthedipstickintothetransaxleandensurethat

itisfullyseated.

5.Unscrewthedipstickandchecktheuidlevel.

Theuidshouldbeuptotopoftheatportionof

thedipstick.

6.Ifthelevelislow ,addenoughuidtoachievethe

properlevel.

CheckingtheHigh-ow

HydraulicFluid(Ifso

equipped)

ServiceInterval:Beforeeachuseordaily

Thehighowhydraulicsreservoirislledwithapproximately

15l(4USgallons)ofhighqualityhydraulicuid.Checkthe

levelofhydraulicuidbeforetheengineisrststarted

anddailythereafter.

1.Cleantheareaaroundthellerneckandthecapof

thehydraulictank(Figure15).Removethecapfrom

thellerneck.

Figure15

1.Cap

2.Removethedipstick(Figure15)fromthellerneck

andwipeitwithacleanrag.Insertthedipstickinto

thellerneck;thenremoveitandchecktheuidlevel.

Theuidlevelshouldbebetweenthetwomarkson

thedipstick.

3.Ifthelevelislow,addtheappropriateuidtoraise

theleveltotheuppermark.RefertoChangingthe

HydraulicFluidandCleaningtheStrainer(page46)

4.Installthedipstickandcapontothellerneck.

5.Starttheengineandturnontheattachment.Letthem

runforabouttwominutestopurgeairfromthesystem.

Stoptheengineandattachmentandcheckforleaks.

Important:Thevehiclemustberunningbefore

startingthehighowhydraulics.

WARNING

Hydraulicuidescapingunderpressurecan

penetrateskinandcauseinjury.

•Makesureallhydraulicuidhosesand

linesareingoodconditionandallhydraulic

connectionsandttingsaretightbefore

applyingpressuretothehydraulicsystem.

•Keepyourbodyandhandsawayfrom

pinholeleaksornozzlesthatejecthigh

pressurehydraulicuid.

•Usecardboardorpapertondhydraulic

leaks.

•Safelyrelieveallpressureinthehydraulic

systembeforeperforminganyworkonthe

hydraulicsystem.

•Seekimmediatemedicalattentionifuid

isinjectedintoyourskin.

Checkingthe

Front-differential-oilLevel

(Four-wheel-driveModels

Only)

ServiceInterval:Every100hours/Monthly(whichever

comesrst)

ThedifferentialislledwithMobil424hydraulicoil.

1.Positionthevehicleonalevelsurface.

2.Cleantheareaaroundthell/checkplugonsideof

thedifferential(

Figure16).

Figure16

1.Fill/checkplug

2.Drainplug

3.Removethell/checkplugandcheckthelevelofthe

oil.Theoilshouldbeuptohole.Iftheoilislow,add

Mobil424hydraulicoil.

4.Installthell/checkplug.

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Toro Workman HDX--D User manual

Brand: Toro

Model: Workman HDX--D

Category: Motorcycles

Type: User manual

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