Workman® HDX Utility Vehicle

• Operate the machine only after reading and understanding the contents of this manual.

• Never allow children to operate the machine. Never allow adults to operate it without proper instructions. Only trained and authorized persons should operate this machine. Make sure all operators are physically and mentally capable of operating the machine.

• This machine is designed to carry only you, the operator, and one passenger in the seat provided by the manufacturer. Never carry any other passengers on the machine.

• Never operate the machine when under the influence of drugs or alcohol.

• Become familiar with the controls and know how to stop the engine quickly.

• Keep all shields, safety devices and decals in place. If a shield, safety device or decal is malfunctioning, illegible, or damaged, repair or replace it before operating the machine.

• Always wear substantial shoes. Do not operate the machine while wearing sandals, tennis shoes, or sneakers. Do not wear loose fitting clothing or jewelry which could get caught in moving parts and cause personal injury.

• Wearing safety glasses, safety shoes, long pants, and a helmet is advisable and required by some local safety and insurance regulations.

• Keep everyone, especially children and pets, away from the areas of operation.

• Before operating the machine, always check all parts of the machine and any attachments. If something is wrong, stop using machine. Make sure the problem is corrected before machine or attachment is operated again.

• Since diesel fuel is highly flammable, handle it carefully.

  • Use an approved fuel container.

  • Do not remove the cap from the fuel tank when the engine is hot or running.

  • Do not smoke while handling fuel.

  • Fill the fuel tank outdoors and to about one inch below the top of tank (bottom of filler neck). Do not overfill.

  • Wipe up any spilled fuel.

• Operate the machine only outdoors or in a well-ventilated area.

• Use only an approved nonmetal, portable fuel container. Static electric discharge can ignite fuel vapors in a ungrounded fuel container. Remove the fuel container from the bed of the machine and place it on the ground away from the machine before filling. Keep the nozzle in contact with the container while filling. Remove equipment from machine bed before filling.

• Check the safety-interlock system daily for proper operation. If a switch should malfunction, replace the switch before operating machine. After every two years, replace the interlock switches in the safety system, whether they are working properly or not.

• The operator and passenger must use seat belts and remain seated whenever the machine is in motion. The operator should keep both hands on the steering wheel, whenever possible, and the passenger should use the hand holds provided. Keep arms and legs within the vehicle body at all times. Never carry passengers in the box or on attachments. Remember your passenger may not be expecting you to brake or turn and may not be ready.

• 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 machine maximum gross vehicle weight (GVW).

• When starting the engine:

  • Sit on the operator’s seat and ensure that the parking brake is engaged.

  • Disengage PTO (if so equipped) and return the hand throttle lever to the Off position (if so equipped).

  • Make sure the hydraulic-lift lever is in the center position.

  • Move shift lever to Neutral and press the clutch pedal.

  • Keep your foot off of the accelerator pedal.

  • Turn ignition switch to the On position. When the glow plug indicator goes off, the engine is ready to start.

  • Turn the ignition key to the Start position.

  Note: The glow-plug indicator will turn on, for an additional 15 seconds, when the switch returns to the Start position.

• Using the machine demands attention. Failure to operate machine safely may result in an accident, tip over of the machine, 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 caution when operating the machine on a steep slope. Normally, travel straight up and down slopes. Reduce speed when making sharp turns or when turning on hillsides. Avoid turning on 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 handling off-center loads that cannot be centered. Keep loads balanced and secure to prevent them from shifting.

  • Avoid sudden stops and starts. Do not go from reverse to forward or forward to reverse without first coming to a complete stop.

  • Do not attempt sharp turns or abrupt maneuvers or other unsafe driving actions that may cause a loss of machine control.

  • Do not pass another machine traveling in the same direction at intersections, blind spots, or at other dangerous locations.

  • When dumping, do not let anyone stand behind the machine, and do not dump the load on any one’s feet. Release the tailgate latches from the side of box, not from behind.

  • Keep all bystanders away. Before backing up, look to the rear and ensure that no one is behind the machine. Back up slowly.

  • Watch out for traffic when near or crossing roads. Always yield the right of way to pedestrians and other machines. This machine is not designed for use on streets or highways. Always signal your turns or stop early enough so other persons know what you plan to do. Obey all traffic rules and regulations.

  • Never operate the machine in or near an area where there is dust or fumes in the air which are explosive. The electrical and exhaust systems of the machine can produce sparks capable of igniting explosive materials.

  • Always watch out for and avoid low overhangs such as tree limbs, door jambs, over head walkways, etc. Make sure there is enough room over head to easily clear the machine and your head.

  • If ever unsure about safe operation, stop work, and ask your supervisor.

• Do not touch the engine, transaxle, radiator, muffler, or muffler manifold while engine is running or soon after it has stopped because these areas may be hot enough to cause burns.

• If the machine ever vibrates abnormally, stop immediately, turn engine off, wait for all motion to stop and inspect for damage. Repair all damage before resuming operation.

• Before getting off of the seat:

  1. Stop the movement of the machine.

  2. Set the parking brake.

  3. Turn the ignition key to the Off position.

  4. Remove the ignition key.

     Note: If the machine is on an incline, block the wheels after getting off of the machine.

• Lightning can cause severe injury or death. If lightning is seen or thunder is heard in the area, do not operate the machine; seek shelter.

• Before servicing or making adjustments to the machine, stop the engine, set the parking brake, and remove the key from the ignition to prevent accidental starting of the engine.

• Never work under a raised bed without placing the bed safety support on the fully extended cylinder rod.

• Make sure that all hydraulic-line connectors are tight, and that all hydraulic hoses and lines are in good condition before applying pressure to the system.

• Before disconnecting or performing any work on the hydraulic system, all pressure in the system must be relieved by stopping the engine, cycling the dump valve from raise to lower and/or lowering box and attachments. Place the remote hydraulics lever in the float position. If the box must be in raised position, secure it with the safety support.

• To make sure that the entire machine is in good condition, keep all nuts, bolts, and screws properly tightened.

• To reduce the potential fire hazard, keep the engine area free of excessive grease, grass, leaves, and accumulation of dirt.

• If the engine must be running to perform a maintenance adjustment, keep hands, feet, clothing, and any parts of the body away from the engine and 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 assistance is required, contact an Authorized Toro Distributor.

• To be sure of optimum performance and safety, always purchase genuine Toro replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous. Altering this vehicle in any manner may affect the vehicle’s operation, performance, durability or its use may result in injury or death. Such use could void the product warranty of The Toro® Company.

• Measured vibration level for right hand = 0.34 m/s²

• Measured vibration level for left hand = 0.43 m/s²

• Uncertainty Value (K) = 0.5 m/s²

Measured values were determined according to the procedures outlined in EN 1032.

• Measured vibration level = 0.33 m/s²

• Uncertainty Value (K) = 0.5 m/s²

Measured values were determined according to the procedures outlined in EN 1032.

Move the lever backward to raise the cargo box (Figure 12).

Figure 12

1. Cargo box lever

Move the lever forward to lower the cargo box (Figure 12).

1. Ensure that the cargo box is lowered completely.

2. Open the latches on the left and right side of the cargo box and lower the tailgate (Figure 13).

   

   Figure 13

   1. Latch handle
   2. Latch gate
   3. Latch pin

Use a fuel stabilizer/conditioner in the machine to provide the following benefits:

• Keeps gasoline fresh during storage of 90 days or less. For longer storage it is recommended that the fuel tank be drained.

• Cleans the engine while it runs

• Eliminates gum-like varnish buildup in the fuel system, which causes hard starting

  Important: Do not use fuel additives containing methanol or ethanol.

  Add the correct amount of gas stabilizer/conditioner to the gas.

  Note: A fuel stabilizer/conditioner is most effective when mixed with fresh gasoline. To minimize the chance of varnish deposits in the fuel system, use fuel stabilizer at all times.

1. Clean the area around the fuel-tank cap.

2. Remove the fuel-tank cap (Figure 17).

   

   Figure 17

   1. Fuel-tank cap

3. Fill the tank to about one inch below the top of the tank, (bottom of the filler neck), then install the cap.

   Note: Do not overfill the fuel tank.

4. Wipe up any fuel that may have spilled to prevent a fire hazard.

1. Sit on the operator’s seat and engage the parking brake.

2. Move the shift lever to the Neutral position.

   Note: The engine will not crank if the hydraulic-lift lever is locked in the forward position.

3. Without pressing the clutch pedal, rotate the ignition key clockwise to the Start position.

   Note: If the engine cranks or starts, there is a malfunction in the interlock system that must be repaired before operating the machine.

1. Sit on the operator’s seat and engage the parking brake.

2. Move the shift lever to the Neutral position and ensure that the hydraulic-lift lever is in the center position.

3. Press clutch pedal.

4. Move the hydraulic-lift lever forward and rotate the ignition key clockwise to the start position.

   Note: If engine cranks or starts, there is a malfunction in the interlock system that must be repaired before operating the machine.

• Off Position

  This is the normal position for the control valve when it is not being used. In this position the work ports of the control valve are blocked and any load will be held by the check valves in both directions.

• Raise (Quick Coupler “A” Position)

  This is the position which will lift the bed, rear hitch attachment or apply pressure to quick coupler A. This also allows hydraulic fluid to return from quick coupler B to flow back into the valve and then out to the reservoir. This is a momentary position and when the lever is released it spring returns to the center Off position.

  

  Figure 30

  1. Quick coupler A position
  2. Quick coupler B position

• Lower (Quick Coupler B Position)

  This position will lower the bed, rear hitch attachment, or apply pressure to quick coupler B. This also allows hydraulic fluid to return from quick coupler A to flow back into the valve and then out to the reservoir. This is a momentary position and when the lever is released it spring returns to the center off position. Momentarily holding and then releasing the control lever in this position will provide hydraulic fluid flow to quick coupler B which provides power down on the rear hitch. When released, it will hold the down pressure on the hitch.

  Important: If used with a hydraulic cylinder, holding the control lever in the lower position causes the hydraulic-fluid flow to go over a relief valve which can damage the hydraulic system.

• On Position

  This position is similar to Lower (quick coupler B position). It also directs hydraulic fluid to quick coupler B except that the lever is held in this position by a detent lever in the control panel. This allows hydraulic fluid to flow continuously to equipment that 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 can damage the hydraulic system. Use this position only momentarily or with a motor attached.

  Important: Check hydraulic-fluid level after installation of an attachment. Check the operation of the attachment by cycling the attachment several times to purge air from system, then recheck hydraulic-fluid level. The attachment cylinder will slightly affect fluid level in the transaxle. Operation of vehicle with low hydraulic-fluid level can damage the pump, remote hydraulics, power steering, and the vehicle transaxle.

Important: Clean dirt from quick couplers before connecting. Dirty couplers can introduce contamination into the hydraulic system

1. Pull back the locking ring on the coupler.

2. Insert the hose nipple into the coupler until it snaps into position.

Note: When attaching remote equipment to the quick couplers, determine which side requires pressure, then attach that hose to quick coupler B, which will have pressure when the control lever is pushed forward or locked in the On position.

Note: With both the vehicle and attachment turned off, move the lift lever back and forth to remove the system pressure and ease the disconnection of the quick couplers.

1. Pull back the locking ring on the coupler.

2. Pull the hose firmly from the coupler.

   Important: Clean and install the dust plug and dust covers to the quick coupler ends when not in use.

• Difficulty in connecting or disconnecting quick couplers.

  The pressure not relieved (the quick coupler is under pressure).

• The power steering is turning with great difficulty or it is not turning at all.

  • The hydraulic-fluid level is low.

  • The hydraulic-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.

• The engine will not start.

  The hydraulic lever is locked in forward position

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 31).

   

   Figure 31

   1. Bed support

3. Push the bed support onto the cylinder rod, making sure that the support end tabs rest on the end of cylinder barrel, and on the cylinder rod end (Figure 32).

   

   Figure 32

   1. Bed support
   2. Cylinder barrel
   3. Bed

4. Remove the bed support from the cylinder and insert it into the brackets on the back of the ROPS panel.

   Caution

   Do not try to lower bed with bed safety support on cylinder.

1. Start the engine, engage the hydraulic-lift lever, and lower the bed until the cylinders are loose in the slots.

2. Release the lift lever and turn off the engine.

3. Remove the lynch pins from the outer ends of the cylinder rod clevis pins (Figure 33).

   

   Figure 33

   1. Cylinder rod end
   2. Bed-mounting plate
   3. Clevis pin
   4. Lynch pin
   5. Rear slots (full bed)
   6. Front slots (2/3 bed)

4. Remove the clevis pins securing the cylinder rod ends to the bed-mounting plates by pushing the pins towards the inside (Figure 33).

5. Remove the lynch pins and clevis pins securing the pivot brackets to the frame channels (Figure 33).

6. Lift the bed off of the machine.

   Caution

   The full bed weighs approximately 148 kg (325 lb), so do not try 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.

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.

Note: Ensure that the rear pivot plates are bolted to the bed frame/channel so that lower end angles to the rear (Figure 34).

Figure 34

1. Left, rear corner of bed
2. Machine frame channel
3. Pivot plate
4. Clevis pin
5. Lynch pin

Note: Ensure that the spacer brackets and wear blocks (Figure 35) are installed with the carriage bolt heads positioned inside the machine.

Figure 35

1. Wear block
2. Spacer bracket
3. Carriage bolt

1. Ensure that the lift cylinders are fully retracted.

2. Carefully set the bed onto the machine frame aligning the rear bed pivot-plate holes with the holes in the rear frame channel and install 2 clevis pins and lynch pins (Figure 35).

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 toward the outside (Figure 35).

   Note: The rear slots are for a full bed installation and front slots are for a 2/3 bed installation.

   Note: The engine may need to be started to extend or retract the cylinders for alignment with the holes.

   Note: The unused slot can be plugged with a bolt and nut to prevent assembly errors.

5. Start the engine and engage the hydraulic lift lever to raise the bed.

6. Release the lift lever and turn off the engine.

7. Install the bed safety support to prevent accidental lowering of the bed; refer to Using the Bed Support.

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.

• Do not start the engine while the machine is on a jack, because the engine vibration or wheel movement could cause the machine to slip off of the jack.

• Do not work under the machine without jack stands supporting it. The machine could slip off a jack, injuring anyone 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 machine frame.

• The jacking point at the front of the machine is under the front center frame support (Figure 36) and at the rear it is under the axle (Figure 37).

  

  Figure 36

  1. Front jacking points
  

  Figure 37

  1. Rear jacking points

1. While grasping the hood in the headlight openings, lift up on the hood to release the lower mounting tabs from the frame slots (Figure 38).

   

   Figure 38

   1. Hood

2. Pivot the bottom of the hood upward until the top mounting tabs can be pulled from the frame slots (Figure 38).

3. Pivot the top of the hood forward, and unplug the wire connectors from the head lights (Figure 38).

4. Remove 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 top, sides and bottom grooves.

The machine has grease fittings that must be lubricated regularly with No. 2 General Purpose 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 39)

• Spring tower (2) (Figure 40)

• Clutch (1) and brake (1) (Figure 41)

• U-joint (18) and 4 wheel drive shaft (3) (Figure 42)

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 or bushing.

2. Pump grease into each bearing or bushing.

3. Wipe off excess grease.

Figure 39

Figure 40

Figure 41

Figure 42

Inspect the air cleaner and hoses periodically to maintain maximum engine protection and to ensure maximum service life. Check the air-cleaner body for damage which could possibly cause an air leak. Replace a damaged air-cleaner body.

Inspect and change the air-cleaner filter as described in the following procedure:

1. Release the latches on the air cleaner and pull the air-cleaner cover off the air-cleaner body (Figure 43).

   

   Figure 43

   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 43).

   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 shining a bright light on the outside of the filter.

   Note: Holes in the filter will appear as bright spots.Inspect the element for tears, an oily film, or damage to the rubber seal. If the filter is damaged do not use it.To prevent engine damage, always operate the engine with the air filter and cover installed.Take special care to keep particulates from dropping into the clean areas of the air filter housing.

5. Carefully slide the filter over the body tube (Figure 43).

   Note: Ensure that it is fully seated by pushing on the outer rim of the filter while installing it.

6. Install the air-cleaner cover with the side facing up, and secure the latches (Figure 43).

Engine-oil quantity: 3.2 L (3.4 US qt) (with a filter)

Engine-oil type: Detergent engine oil API SJ or higher

Engine-oil viscosity: 10W-30; Choose an engine-oil viscosity according to the ambient-air temperature to the table in Figure 44.

Figure 44

1. Raise the bed (if equipped), and place the safety support on the extended-lift cylinder to hold up the bed.

2. Remove the drain plug and let the oil flow into a drain pan (Figure 45).

3. When the oil stops, install the drain plug.

   

   Figure 45

   1. Engine-oil drain plug
   2. Engine-oil filter

4. Remove the oil filter (Figure 45).

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; refer to Checking the Engine-oil Level.

The spark plug usually lasts a long time; however, the plug should be removed and checked whenever the engine malfunctions, or every 400 hours. Replace the spark plug to ensure proper engine performance and reduce exhaust emission level.

The correct spark plug to use is an NGK-R BKR5E.

The recommended air gap is 0.81 mm (0.032 inch).

1. Clean the area around the spark plugs, so that foreign matter cannot fall into the cylinder when you remove the spark plug.

2. Pull wires off of the spark plugs and remove the plugs from the cylinder head.

3. Check the condition of the side electrode, center electrode, and the center electrode insulator to ensure that there is no damage.

   Important: A cracked, fouled, dirty, or otherwise malfunctioning spark plug must be replaced. Do not sand blast, scrape, or clean electrodes by using a wire brush because grit may eventually release from the plug and fall into the cylinder. The result is usually a damaged engine.

   

   Figure 46

   1. Air gap at 0.81 mm (0.032 inch)

4. For each spark plug, set the air gap between the center and side electrodes to 0.81 mm (0.032 inch).

5. Install the correctly gapped spark plugs and tighten each one to 24.5 to 29 N-m (18 to 22 ft-lb).

6. Install the spark-plug wires.

1. Raise the bed (if equipped), and place the safety support on the extended-lift cylinder to hold up the bed.

2. Unplug the wiring-harness connectors from the fuel pump (Figure 47).

3. Loosen the hose clamp and disconnect the fuel line from the fuel-pump cap (Figure 47).

   

   Figure 47

   1. Fuel pump
   2. Hose clamp
   3. Fuel line/fuel filter

4. Remove the fuel-pump cap from the top of the fuel tank (Figure 47).

   Note: Do not allow the fuel-pump assembly to rotate in the tank while removing the fuel pump. Damage to the float assembly can occur if the fuel pump rotates inside the fuel tank.

5. Remove the fuel-pump assembly and the fuel filter from the tank (Figure 47).

6. Remove the clamp securing the fuel filter hose to the fuel-pump fitting.

7. Remove the hose from the fitting (Figure 47).

8. Insert the new hose clamp onto the new fuel-filter hose.

9. Insert the hose onto the fuel pump and secure the clamp.

10. Insert the assembly into the fuel tank, and tighten 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.

Inspect the fuel lines and connections for deterioration, damage, or loose connections.

The fuses for the electrical system are located under the center of the dash panel (Figure 48 and Figure 49).

Figure 48

1. Fuses

Figure 49

1. Power outlet—10A
2. Switched power—10A
3. Fuel pump, supervisor switch—10A
4. Horn, power point—15A
5. Lights, brake—15A
6. Hazard—10A
7. 4WD, Transmission—10A

1. Squeeze the battery cover to release the tabs from battery base, and remove the battery cover from the battery base (Figure 50).

   

   Figure 50

   1. Battery cover

2. Connect a jumper cable between the positive posts of the 2 batteries (Figure 51). 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 cover.

   Note: Do not connect the other end of the jumper cable to the negative post of the discharged battery. Connect the jumper cable to the engine or frame. Do not connect the jumper cable to the fuel system.

   

   Figure 51

   1. Battery

4. Start the engine in the machine providing the jump start.

   Note: Let it run a few minutes, then start your engine.

5. Remove the negative jumper cable first from your engine, then the battery in the other machine.

6. Install the battery cover to the battery base.

• Keep the battery-electrolyte level properly maintained.

• Keep the top of the battery 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.

• If corrosion occurs at terminals, remove the battery cover, disconnect the cables (negative (–) cable first), and scrape the clamps and terminals separately. Reconnect 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 temperatures are cool.

Differential-oil specification: Mobil 424 hydraulic oil

1. Position the machine on a level surface, stop the engine, set 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 (Figure 52).

3. Place a drain pan under the drain plug.

   

   Figure 52

   1. Fill/check plug
   2. Drain plug

4. Remove the drain plug and let the oil flow into the drain pan.

5. Install and tighten the plug when the oil stops draining.

6. Clean the area around the fill/check plug on the bottom of the differential.

7. Remove the fill/check plug and add specified oil until the oil level is up to the hole.

8. Install the fill/check plug.

Inspect the constant-velocity boot for cracks, holes, or a loose clamp. Contact your Authorized Toro Distributor for repair if you find any damage.

1. Move the shift lever to the Neutral position.

2. Remove the clevis pins securing the shift cables to the transaxle-shift arms (Figure 53).

   

   Figure 53

   1. Shift arm (1st to reverse)
   2. Shift arm (2nd to 3rd)
   3. Shift arm (High to low)

3. Loosen the clevis jam nuts and adjust each clevis, so that the cable free play is equal forward and backward relative to the hole in the transaxle-shift arm (with the transaxle lever free play taken up in the same direction).

4. Install the clevis pins and tighten the jam nuts when finished.

1. Remove the clevis pin securing the High–Low cable to the transaxle (Figure 53).

2. Loosen the clevis jam nut and adjust the clevis so that the clevis hole aligns with the hole in the transaxle bracket.

3. Install the clevis pin and tighten the jam nut when finished.

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 54).

   

   Figure 54

   1. Differential-lock cable
   2. Transaxle bracket
   3. Spring
   4. 0.25 to 1.5 mm (0.01 to 0.06 inch) gap

3. Adjust the 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.

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 prematurely.

Figure 55 is an example of tire wear caused by under inflation.

Figure 55

1. Under-inflated tire

Figure 56 is an example of tire wear caused by over inflation.

Figure 56

1. Over-inflated tire

1. Make sure the tires are facing straight ahead.

2. Measure the center-to-center distance (at axle height) at the front and rear of the steering tires (Figure 57).

   Note: The measurement must be within 0 ± 3 mm (0 ± 0.12 inch) at the front of the tire then at the rear of the tire. Rotate the tire 90° and check the measurement.

   Important: Check the measurements at consistent locations on the tire. The machine should be on a flat surface with the tires facing straight ahead.

   

   Figure 57

   1. Front of the machine
   2. 0 ± 3 mm (0 ± 0.12 inch) front to rear of the tire
   3. Center to center distance

3. Adjust the center-to-center distance as follows:

   1. Loosen the jam nut at the center of the tie rod (Figure 58).

      

      Figure 58

      1. Tie rods
      2. Jam nuts

   2. 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.

   3. Tighten the tie rod jam nut when the adjustment is correct.

   4. Check to ensure that the tires turn an equal amount to the right and to the left.

      Note: If the tires do not turn equally, refer to the Service Manual for the adjustment procedure.

1. Turn the engine off and clean the engine area thoroughly of all debris.

2. Unlatch and remove the radiator screen from the front of the radiator (Figure 59).

   

   Figure 59

   1. Radiator screen
   2. Latch

3. If so equipped, rotate the latches and pivot the oil cooler away from the radiator (Figure 60).

   

   Figure 60

   1. Radiator housing
   2. Oil cooler
   3. Latches

4. Clean the radiator, oil cooler, and screen thoroughly with compressed air.

   Note: Blow debris away from the radiator. Do not use water to clean external surfaces of the radiator.

5. Install the cooler and screen to the radiator.

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

   If the engine has been running, the pressurized, hot coolant can escape and cause burns.

   • Do not open the reserve tank cap when the engine is running.

   • Allow engine to cool at least 15 minutes or until the reserve tank cap 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.

3. Remove the radiator cap.

   

   Figure 61

   1. Radiator cap

4. Remove the reserve-tank cap (Figure 62).

   

   Figure 62

   1. Reserve tank-cap
   2. Reserve tank

5. Disconnect the lower radiator hose and allow coolant to flow into a drain pan.

6. When coolant stops, connect the lower radiator hose.

7. Remove the coolant-drain plug from the engine and allow coolant to flow into a drain pan.

8. When coolant stops, install the drain plug.

9. Slowly fill the radiator with a 50/50 mixture of water and permanent ethylene-glycol antifreeze

10. Install the radiator cap.

11. Fill the reservoir tank to the bottom of the filler neck.

12. Start the engine and allow it to idle.

13. As air escapes, fill the reservoir to the bottom of the filler neck.

    Note: Do not allow the engine to heat up to the running temperature.

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.

1. Remove the rubber grip from the parking-brake lever (Figure 63).

   

   Figure 63

   1. Parking-brake lever
   2. Grip

2. Loosen the set screw securing the knob to the parking brake lever (Figure 64).

3. Rotate the knob until a force of 20 to 22 kg (45 to 50 lb) is required to actuate the lever.

   

   Figure 64

   1. Parking-brake lever
   2. Knob
   3. Set screw

4. Tighten the set screw when finished.

   Note: If no adjustment is left at the handle, loosen the handle to the middle of the adjustment and adjust the cable at the rear, then repeat step 3.

5. Install the rubber grip onto the parking-brake lever.

Note: Remove the font hoot to ease the adjustment procedure.

1. Remove the cotter pin and clevis pin securing the master cylinder yoke to the brake-pedal pivot (Figure 65).

   

   Figure 65

   1. Master cylinder yoke
   2. Brake-pedal pivot

2. Lift up on the brake pedal (Figure 66) until it contacts the frame.

3. Loosen the jam nuts securing the yoke to the master cylinder shaft (Figure 66).

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 pressure when properly adjusted.

   

   Figure 66

   1. Clutch pedal
   2. Brake pedal
   3. Accelerator pedal

1. Raise the bed (if so equipped) and position the safety support on the extended-lift cylinder to hold up the bed.

2. Check the tension by pressing the belt at mid span between the crankshaft and alternator pulleys with 10 kg (22 lb) of force (Figure 67).

   Note: A new belt should deflect 8 to 12 mm (0.3 to 0.5 inch).

   Note: A used belt should deflect 10 to 14 mm (0.4 to 0.55 inch). If the deflection is incorrect, proceed to the next step. If correct, continue operation.

3. To adjust belt tension, complete the following:

   1. Loosen the 2 alternator-mounting bolts (Figure 67).

      

      Figure 67

      1. Alternator belt
      2. Alternator-mounting bolts

   2. Using a pry bar, rotate the alternator until the proper belt tension is attained, then tighten the mounting bolts (Figure 67).

Note: You can adjust the clutch-pedal cable at the bell housing or at the clutch-pedal pivot. The front hood can be removed to ease the access to the pedal pivot.

1. Loosen the jam nuts securing the clutch cable to the bracket on the bell housing (Figure 68).

   

   Figure 68

   1. Clutch cable
   2. Jam nuts
   3. Return spring
   4. Ball joint

   Note: You may remove and rotate the ball joint, if additional adjustment is required.

2. Disconnect the return spring from the clutch lever.

3. Adjust the jam nuts or ball joint until the back, rear edge of the clutch pedal is 9.5 ± 0.3 cm (3.75 ± 0.12 inch) from the top of the floor plate diamond pattern, when an 1.8 kg (4 lb) force is applied to the pedal (Figure 69).

   

   Figure 69

   1. Clutch pedal
   2. 9.5 ± 0.3 cm (3.75 ± 0.12 inch)

   Note: Force is applied so the clutch release bearing lightly contacts the pressure 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 pedal after the jam nut is tightened (Figure 70).

   

   Figure 70

   1. Clutch-cable rod end
   2. Clutch pedal
   3. Rod end jam nut
   4. Parallel

   Note: The clutch free play should never be less than 19 mm (0.75 inch).

You can convert the speedometer from mph to km/h or km/h to mph.

1. Position the machine on a level surface, stop the engine, engage the parking brake, and remove the key from the ignition switch.

2. Remove the hood; refer to Removing the Hood.

3. Locate the 2 loose wires next to the speedometer.

4. Remove the connector plug from the harness wire and connect the wires together.

   Note: The speedometer will switch to km/h or mph.

5. Install the hood.

Hydraulic-fluid capacity: approximately 7 L (7.5 US qt)

Hydraulic-fluid type: Dexron III ATF

1. Position the machine on a level surface, stop the engine, engage the parking brake, and remove the key from the ignition switch.

2. Remove the drain plug from the side of the reservoir, and let the hydraulic fluid flow into a drain pan (Figure 71).

   

   Figure 71

   1. Hydraulic reservoir
   2. Drain plug

3. Note the orientation of the hydraulic hose and 90° fitting connected to the strainer on the side of the reservoir (Figure 72).

4. Remove the hydraulic hose and 90° fitting.

5. Remove the strainer and clean it by back flushing it with a clean de-greaser.

   Note: Allow it to air dry before installing.

   

   Figure 72

   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.

10. Start the engine and operate the machine to fill the hydraulic system.

11. Check the hydraulic fluid level and replenish it, if required.

Important: Use only the hydraulic fluid specified. Other fluids could cause system damage.

Important: Use of any other filter may void the warranty on some components.

1. Position the machine on a level surface, stop the engine, engage the parking brake, and remove the key from ignition switch.

2. Clean the area around filter mounting area.

3. Place a drain pan under the filter and remove the filter (Figure 73).

   

   Figure 73

   1. Hydraulic filter
   2. High-flow hydraulic filter

4. Lubricate the gasket on the new filter.

5. Ensure that the filter mounting area is clean.

6. Screw the filter on until the gasket contacts the mounting plate, and tighten the filter 1/2 turn.

7. Start the engine and let it run for about 2 minutes to purge air from the system.

8. Stop the engine and check the hydraulic-fluid level and for leaks.

Hydraulic-fluid capacity: approximately 15 L (4 US gallons)

Hydraulic-fluid type: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 identify a satisfactory product.

Note: Toro will not assume responsibility for damage caused by improper substitutions, so use only products from reputable manufacturers who will stand behind their recommendation.

High Viscosity Index/Low Pour Point Antiwear Hydraulic Fluid, ISO VG 46

Material Properties:

• Viscosity—ASTM D445 cSt @ 40ºC: 44 to 48/cSt @ 100ºC: 7.9 to 8.5

• Viscosity Index, ASTM D2270—140 to 152

• Pour Point, ASTM D97— -35ºF to -46ºF

• FZG, Fail stage—11 or better

• Water content (new fluid)—500 ppm (maximum)

Industry Specifications:

Vickers I-286-S, Vickers M-2950-S, Denison HF-0, Vickers 35 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 the system must be flushed. Contaminated fluid may look milky or black when compared to clean fluid. The service interval may need to be increased if using multiple attachments as the fluid may become contaminated quicker with the mixing of different hydraulic fluids.

1. Clean the area around the high-flow-filter mounting area (Figure 73).

2. Place a drain pan under the filter and remove the filter.

   Note: If the fluid is not going to be drained, disconnect and plug the hydraulic line going to the filter.

3. Lubricate the new filter-sealing gasket and hand turn the filter onto the filter head until the gasket contacts the filter head. Then tighten it 3/4 turn further. The filter should now be sealed.

4. Fill the hydraulic reservoir with approximately 15 L (4 US gallons) of hydraulic fluid.

5. Start the machine and run it at idle for about 2 minutes to circulate the fluid and remove any air trapped in the system.

6. Stop the machine and check the fluid level.

7. Verify the fluid level.

8. Dispose of the fluid properly.

The cargo box can be raised in an emergency without starting the engine by cranking starter or by jumping hydraulic system.

The machine should be washed as needed. Use water alone or with a mild detergent. A rag may be used when washing the machine, however the hood will loose some of its luster.

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 damage.