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Toro Workman HDX Auto Service Manual

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Form No. 15217SL Rev C
Workman
HDX Auto
®
Original Instructions (EN)

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Summary of Contents for Toro Workman HDX Auto

  • Page 1 Form No. 15217SL Rev C Workman HDX Auto ® Original Instructions (EN)
  • Page 2 THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
  • Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
  • Page 4 NOTES...
  • Page 5 IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company - - 2015, 2018, 2019, 2020...
  • Page 6 This page is intentionally blank. Workman HDX Auto...

  • Page 7: Table Of Contents

    ....... 5 -- 8 Service and Repairs ..... . . 5 -- 10 Workman HDX Auto...
  • Page 8 This page is intentionally blank. Workman HDX Auto...
  • Page 9 ....SAFETY AND INSTRUCTION DECALS ..Workman HDX Auto Safety Page 1 − 1...

  • Page 10: Safety Instructions

    Before Operating 1. Review and understand the contents of the Opera- 4. Since fuel used in Workman HDX Auto vehicles is tor’s Manual and Operator’s DVD before starting and highly flammable, handle it carefully: operating the vehicle. Become familiar with the controls A.

  • Page 11: While Operating

    F. Turn ignition key to START. Release key when E. Remove key from ignition switch. engine starts. 6. Do not park on slopes unless wheels are chocked or blocked. Workman HDX Auto Safety Page 1 − 3...

  • Page 12: Maintenance And Service

    5. Make sure all hydraulic line connectors are tight and 16.To ensure optimum performance and continued that all hydraulic hoses and lines are in good condition, safety of the vehicle, use genuine Toro replacement before applying pressure to the system. parts and accessories. Replacement parts and acces- sories made by other manufacturers may result in non- 6.

  • Page 13: Jacking Vehicle

    (or similar material) between jack and vehicle frame support. 4. The jacking point at the rear of the vehicle is under the axle (Fig. 2). Figure 2 1. Rear jacking point Workman HDX Auto Safety Page 1 − 5...

  • Page 14: Safety And Instruction Decals

    Safety and Instruction Decals Numerous safety and instruction decals are affixed to the Workman HDX Auto vehicle. If any decal becomes illegible or damaged, install a new decal. Decal part numbers are listed in your Parts Catalog.

  • Page 15: Product Records

    ......Product Records Insert Operator’s Manual and Parts Catalog for your Workman HDX Auto vehicle at the end of this chapter. Refer to Operator’s Manual for recommended mainte- nance intervals. Additionally, insert Installation Instruc- tions, Operator’s Manuals, Parts Catalogs and Service...

  • Page 16: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 − 2 Workman HDX Auto...

  • Page 17: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.

  • Page 18: Standard Torque For Dry, Zinc Plated And Steel Fasteners (Inch Series Fasteners)

    The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Product Records and Maintenance Page 2 − 4 Workman HDX Auto...

  • Page 19: Standard Torque For Dry, Zinc Plated And Steel

    The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Workman HDX Auto Page 2 − 5 Product Records and Maintenance...

  • Page 20: Other Torque Specifications

    All torque values are based on non−lubri- cated fasteners. Conversion Factors in−lb X 11.2985 = N−cm N−cm X 0.08851 = in−lb ft−lb X 1.3558 = N−m N−m X 0.7376 = ft−lb Product Records and Maintenance Page 2 − 6 Workman HDX Auto...
  • Page 21 Engine Installation ......KOHLER AEGIS SERVICE MANUAL Workman HDX Auto Kohler Gasoline Engine Page 3 − 1...

  • Page 22: Specifications

    2.1 U.S. quarts (2 liters) with filter Cooling System Capacity 4.0 U.S. quarts (3.7 liters) Starter 12 VDC, Solenoid Shift Battery Charging System 12 VDC 25 Amp Dry Weight (approximate) 116 pounds (52.6 kilograms) Kohler Gasoline Engine Workman HDX Auto Page 3 − 2...

  • Page 23: Chapter 3 - - Kohler Gasoline Engine

    Service and repair parts for Kohler engines are supplied through your local Toro distributor. Be prepared to pro- vide your distributor with both the Toro and Kohler model and serial numbers. Operator’s Manual The Workman Operator’s Manual provides information...

  • Page 24: Adjustments

    1. Speed control bellcrank 4. High speed screw C. Tighten jam nut to secure adjustment of high 2. Throttle lever 5. Throttle bracket speed screw. 3. Governor spring 6. Governor spring Kohler Gasoline Engine Workman HDX Auto Page 3 − 4...

  • Page 25: Service And Repairs

    Accelerator Control Two styles of accelerator control have been used on SERIAL NUMBER BELOW 315000000 Workman HDX Auto machines. On vehicles with serial numbers below 315000000 (Fig. 4), the accelerator control includes a bellcrank that is rotated by the accel- erator cable to change engine speed.

  • Page 26: Air Cleaner System

    Figure 6 1. Engine 4. Air cleaner assembly 7. Flange head screw (2) 2. Hose clamp (2) 5. Air inlet hood 8. Flange nut (2) 3. Intake hose 6. Mounting bracket Kohler Gasoline Engine Workman HDX Auto Page 3 − 6...
  • Page 27 3. Element 7. Vacuator valve positioned straight upward. The vacuator valve on the 4. Gasket air cleaner assembly should be positioned downward. 2. Lower or install cargo bed or attachment(s). Workman HDX Auto Kohler Gasoline Engine Page 3 − 7...

  • Page 28: Fuel Tank

    18. Tank vent hose 5. Grommet 12. Hose clamp (2) 19. Fuel hose (2) 6. Rollover valve 13. Fuel hose 20. Fuel pump retainer 7. Retainer plate 14. Fresh air filter 21. Gasket Kohler Gasoline Engine Workman HDX Auto Page 3 − 8...
  • Page 29 6. Remove washer head screws (item 8) and retainer plate (item 7) that secure fuel tank to vehicle. Figure 9 7. Remove fuel tank from vehicle. 1. Retainer plate 3. Tank vent hose 2. Fuel supply hose Workman HDX Auto Kohler Gasoline Engine Page 3 − 9...

  • Page 30: Fuel Evaporative Control System

    AND ENGINE PURGE PORT to venting issues. If the fuel tank returns to it’s normal shape when the fuel cap is removed, restriction in the evaporative control system is likely. Figure 11 Kohler Gasoline Engine Workman HDX Auto Page 3 − 10...
  • Page 31 Also, secure all hoses with hose clamps. Figure 13 1. Retainer plate 3. Tank vent hose 2. Lower or install the cargo bed or other attachment(s). 2. Fuel supply hose Workman HDX Auto Kohler Gasoline Engine Page 3 − 11...

  • Page 32: Fuel Pump

    Store fuel in a clean, safety−approved container and keep cap in place. Use fuel for the engine only; not for any other purpose. Kohler Gasoline Engine Workman HDX Auto Page 3 − 12...
  • Page 33 2. Fuel supply hose pump assembly. 3. Carefully insert fuel pump assembly and gasket into tank. Orientate fuel fitting so that it is pointing toward the vehicle frame (Fig. 15). Workman HDX Auto Kohler Gasoline Engine Page 3 − 13...

  • Page 34: Exhaust System

    9. Flange nut (4) 2. Muffler 6. Clamp assembly (2) 10. Exhaust gasket (2) 3. Carriage screw (4) 7. Intermediate exhaust pipe 11. Oxygen sensor 4. Flange nut (4) 8. Exhaust manifold Kohler Gasoline Engine Workman HDX Auto Page 3 − 14...
  • Page 35 Figure 16 as a guide. 3. Lower or install the cargo bed or other attachment(s). 5. Discard exhaust gaskets and thoroughly clean flange surfaces of exhaust manifold and muffler. Workman HDX Auto Kohler Gasoline Engine Page 3 − 15...

  • Page 36: Radiator

    If bed is raised, place safety support on lift cylin- 5. If vehicle is equipped with high flow hydraulics kit, ro- der. tate oil cooler latches and place oil cooler away from ra- diator. Kohler Gasoline Engine Workman HDX Auto Page 3 − 16...
  • Page 37 3. Position radiator assembly to the radiator mount. Se- cure radiator assembly to the vehicle with removed flange head screws, flat washers and flange nuts. Workman HDX Auto Kohler Gasoline Engine Page 3 − 17...

  • Page 38: Oil Filter Assembly

    18. Hydraulic tube 5. Washer head screw (2) 12. Hydraulic tube 19. O−ring 6. Flange head screw 13. O−ring 20. Hydraulic fitting 7. Tube clamp (2) 14. 90 hydraulic fitting 21. O−ring Kohler Gasoline Engine Workman HDX Auto Page 3 − 18...
  • Page 39 2. Check and adjust engine oil level. 3. Lower or install the cargo bed or other attachment(s). Workman HDX Auto Kohler Gasoline Engine Page 3 − 19...

  • Page 40: Engine

    29. Tube clamp (2) 44. Throttle bell crank 14. Negative battery cable 30. Flange head screw 45. Flange nut 15. Cap screw (2) 16. Flat washer (2) 31. Hydraulic tube 46. Shoulder bolt Kohler Gasoline Engine Workman HDX Auto Page 3 − 20...

  • Page 41: Engine Removal

    11. Disconnect fuel supply hose from fuel fitting on en- 1. Spanner plate 2. Screw (5) gine. Plug end of fuel hose to prevent contamination and fuel spillage. Position disconnected fuel hose away from engine. Workman HDX Auto Kohler Gasoline Engine Page 3 − 21...

  • Page 42: Engine Installation

    5. Flange screw (2) 13. Spacer (2) screws that secure mount to engine base. Remove 6. Fuse 14. Relay 7. Flange screw (3) 15. Clip nut (2) pump mount from engine. 8. Fuse Kohler Gasoline Engine Workman HDX Auto Page 3 − 22...
  • Page 43 3. Pump coupler adapter 8. Rubber coupler 4. Engine flywheel 9. Socket head screw coolant pipes, spanner plate or other parts while in- 5. Set screw (2) stalling the engine. Workman HDX Auto Kohler Gasoline Engine Page 3 − 23...
  • Page 44 22.Lower cargo bed or install bed or attachment(s). 16.Secure wire harness, hoses and cables to the engine with clamps and cable ties in locations noted during en- gine removal. Kohler Gasoline Engine Workman HDX Auto Page 3 − 24...

  • Page 45: Specifications

    ....Transmission Assembly ....Workman HDX Auto Page 4 − 1 Drive Train...

  • Page 46: Specifications

    Rear Differential Oil 80W90 API GLI−5 Rear Differential Oil Capacity 18.6 fluid ounces (550 milliliter) System Capacity (approximate) Front Differential (Optional Kit) See Chapter 8 − Four Wheel Drive (Optional Kit) Drive Train Page 4 − 2 Workman HDX Auto...

  • Page 47: General Information

    Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Opera- tor’s Manual for additional information when servicing the vehicle. Workman HDX Auto Page 4 − 3 Drive Train...

  • Page 48: Drive Train Operation

    Drive Train Operation Drive Train Operation Workman HDX Auto vehicles have a variable speed drive system with positions for neutral, forward high and low range, reverse and park. Drive system components include an engine driven primary clutch, a secondary clutch, a CVT drive belt, a transmission, a drive shaft driven rear differential and two (2) CV (constant velocity) axles to drive the rear wheels.

  • Page 49: Clutch System Operation

    The secondary clutch is mounted to the operate at optimum efficiency. transmission input shaft and responds to changes in drive system load. Workman HDX Auto Page 4 − 5 Drive Train...

  • Page 50: Primary Clutch Operation

    4. Speed limiter cover spring is greater than that of the clutch weights. Speed Control System Operation Toro’s proprietary Speed Control insures precise ground speed to engine speed critical for accurate application rates with bed mounted topdressers and sprayers. The speed range of the vehicle can easily be adjusted with the speed range lever to limit the maximum−ground...

  • Page 51: Secondary Clutch Operation

    The fixed cam on the secondary clutch moveable sheave rotates on a pair of rollers in the stationary sheave base to allow low friction movement of the move- able sheave. Workman HDX Auto Page 4 − 7 Drive Train...

  • Page 52: Special Tools

    2. Adapter Piston Installation Tool The piston installation tool is used to install the piston in- to the speed limiter assembly. Toro Part Number: TOR6034 Figure 8 Secondary Clutch Press Tool The secondary clutch press tool is used to compress the...

  • Page 53: Troubleshooting

    Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Workman HDX Auto Page 4 − 9...

  • Page 54: Transmission

    Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Drive Train Page 4 − 10 Workman HDX Auto...

  • Page 55: Adjustments

    Figure 11 1. Transmission 5. Cable clevis 2. Shift cable 6. Jam nut (2) 3. Hairpin 7. Jam nut (2) 4. Clevis pin Workman HDX Auto Page 4 − 11 Drive Train...

  • Page 56: Service And Repairs

    C. Disconnect cable from transmission shift lever. 4. Remove hair pin and clevis pin that secure shift cable clevis (item 10) to transmission lever (item 1) in shift plate opening of seat base. Drive Train Page 4 − 12 Workman HDX Auto...
  • Page 57 8. Install shift and control plates to seat base and then secure knobs to control levers (Fig. 13). Figure 14 1. Transmission 5. Cable clevis 2. Shift cable 6. Jam nut (2) 3. Hairpin 7. Jam nut (2) 4. Clevis pin Workman HDX Auto Page 4 − 13 Drive Train...

  • Page 58: Bleed Speed Control System

    5. After speed control system bleeding, install control plate to seat base and secure with six (6) washer head screws. Install knobs to speed range lever and hydraulic lift lever. Drive Train Page 4 − 14 Workman HDX Auto...
  • Page 59 This page is intentionally blank. Workman HDX Auto Page 4 − 15 Drive Train...

  • Page 60: Speed Control System

    B. Remove six (6) washer head screws that secure 1. Speed range lever 3. Hydraulic lift lever control plate to seat base. 2. Speed range settings 4. Control plate C. Lift control plate from seat base. Drive Train Page 4 − 16 Workman HDX Auto...
  • Page 61 2. Worm clamp 9. Cylinder 3. O−ring 10. Clevis pin 4. Reservoir fitting 11. Hair pin 5. Washer head screw 12. Clevis pin 6. Banjo washer 13. Speed control hose 7. Banjo bolt Workman HDX Auto Page 4 − 17 Drive Train...

  • Page 62: Speed Limiter Assembly

    (Fig. 22) is used to select one of the four (4) work−speed ranges that are used to limit maxi- mum ground speed or a transport speed range that is used when the machine is moved between job sites. Drive Train Page 4 − 18 Workman HDX Auto...
  • Page 63 1. Position speed limiter assembly to the primary 1. Speed limiter assembly 3. Screw (6) clutch. Make sure that compression springs (items 10 2. Speed control hose and 11) are properly placed onto primary clutch. Workman HDX Auto Page 4 − 19 Drive Train...

  • Page 64: Speed Limiter Cover Service

    5. Rotary union 9. Quad ring 2. Button head screw (3) 6. O−ring (2) 10. Hydraulic piston 3. Retainer 7. Speed limiter control cover 11. Sleeve bushing 4. Banjo washer 8. U−cup Drive Train Page 4 − 20 Workman HDX Auto...
  • Page 65 System in this section). guide and insert piston into control cover. 10.Install speed limiter assembly with attached hy- draulic hose to primary clutch (see Speed Limiter As- sembly in this section). Workman HDX Auto Page 4 − 21 Drive Train...

  • Page 66: Cvt Enclosure Cover

    5. CVT drive belt 12. Compression spring 19. Hose clamp (2) 6. Washer head screw (3) 13. Speed control hose 20. Cylinder 7. Speed limiter cover 14. CVT enclosure cover 21. Reservoir Drive Train Page 4 − 22 Workman HDX Auto...
  • Page 67 (Fig. 27). 5. Separate CVT enclosure cover from spanner plate and remove from vehicle. Figure 27 1. CVT enclosure cover 3. Longer screw (2) 2. Speed limiter cover Workman HDX Auto Page 4 − 23 Drive Train...

  • Page 68: Cvt Drive Belt

    5. CVT drive belt 12. Compression spring 19. Hose clamp (2) 6. Washer head screw (3) 13. Speed control hose 20. Cylinder 7. Speed limiter cover 14. CVT enclosure cover 21. Reservoir Drive Train Page 4 − 24 Workman HDX Auto...
  • Page 69 6. Install CVT enclosure cover (see CVT Enclosure Cover in this section). 7. Remove bed support from cargo bed lift cylinder and lower bed. Workman HDX Auto Page 4 − 25 Drive Train...

  • Page 70: Primary And Secondary Clutches

    17. Socket head screw 26. Hose clamp (2) 8. Flange head screw (6) 18. Flat washer 27. Speed control cylinder 9. Speed limiter assembly 19. CVT fan 28. Speed control reservoir 10. Compression spring Drive Train Page 4 − 26 Workman HDX Auto...
  • Page 71 B. Remove secondary clutch from transmission in- put shaft. Use of clutch removal tool and secondary clutch adapter (see Special Tools in this chapter) may be needed to loosen clutch from shoulder on input shaft. Workman HDX Auto Page 4 − 27 Drive Train...

  • Page 72: Primary Clutch Service

    Figure 31 1. Spider assembly 4. Clutch weight (3) 7. Thrust washer (2) 2. Shoulder screw (3) 5. Moveable sheave 8. Bearing 3. Lock nut (3) 6. Cap 9. Stationary sheave Drive Train Page 4 − 28 Workman HDX Auto...
  • Page 73 2. Install new lock nuts on the shoulder screws. DO NOT reuse removed lock nuts. Tighten nuts until they contact screw shoulder and then torque nuts from 40 to 50 in−lb (4.6 to 5.6 N−m). Workman HDX Auto Page 4 − 29 Drive Train...

  • Page 74: Secondary Clutch Service

    Press down on moveable sheave belt face with both hands and cam should release from move- able sheave. Figure 36 1. Cam assembly mark 3. Stationary sheave mark 2. Moveable sheave mark Drive Train Page 4 − 30 Workman HDX Auto...
  • Page 75 IMPORTANT: When assembling the secondary clutch, check the marker lines made during clutch disassembly to make sure the cam assembly, move- able sheave and stationary sheave are properly aligned (Fig. 36). Workman HDX Auto Page 4 − 31 Drive Train...

  • Page 76: Rear Cv (Constant Velocity) Axles

    8. Wheel bearing hub (2) 13. Inboard boot (2) 4. Brake caliper (2) 9. Rear axle 14. Outboard boot (2) 5. Flange head screw (2 per caliper) 10. CV axle assembly (2) Drive Train Page 4 − 32 Workman HDX Auto...

  • Page 77: Test Rear Cv Axle

    6. Install brake rotor, brake caliper and wheel assembly the CV axle. (see Brake System and Wheel Assembly in the Service and Repairs section of Chapter 5 − Chassis). Workman HDX Auto Page 4 − 33 Drive Train...
  • Page 78 F. Use a soft brass or plastic hammer against the outboard joint housing and carefully drive the joint onto the center shaft until spring clip is seated. Drive Train Page 4 − 34 Workman HDX Auto...
  • Page 79 This page is intentionally blank. Workman HDX Auto Page 4 − 35 Drive Train...

  • Page 80: Rear Driveshaft

    3. Rear driveshaft 8. Lock nut (2) 13. Hair pin 4. Socket head screw (4) 9. Brake mount plate 14. Retaining ring 5. Parking brake rotor 10. Spacer 15. Engine/transmission mount Drive Train Page 4 − 36 Workman HDX Auto...
  • Page 81 (20 to 22 kg) to actuate the brake lever. If necessary, adjust parking brake lever (see Parking Brake in the Ad- justments section of Chapter 5 − Chassis). 8. Remove bed support from cargo bed lift cylinder and lower bed. Workman HDX Auto Page 4 − 37 Drive Train...

  • Page 82: Rear Driveshaft Cross And Bearing Service

    Press bearing into yoke. F. Install snap rings into yokes to secure bearings in place. Make sure that snap rings are fully seated in grooves in yokes. G. Repeat procedure for remaining yoke. Drive Train Page 4 − 38 Workman HDX Auto...
  • Page 83 This page is intentionally blank. Workman HDX Auto Page 4 − 39 Drive Train...

  • Page 84: Rear Differential

    8. Lock nut (6) CAUTION The engine, exhaust system and drive system components may be hot. To avoid possible burns, allow all components to cool before work- ing on drive system components. Drive Train Page 4 − 40 Workman HDX Auto...
  • Page 85 For assembly purposes, note that solenoid 1. CV axle (LH shown) 2. Differential assembly controller assembly (item 22) is secured to the machine frame with fasteners for the RH rear mount. Workman HDX Auto Page 4 − 41 Drive Train...
  • Page 86 (48 to 55 N−m). 7. Install rear brake rotor, brake caliper and wheel as- sembly to both sides of machine (see Brake System in the Service and Repairs section of Chapter 5 − Chassis). Drive Train Page 4 − 42 Workman HDX Auto...
  • Page 87 This page is intentionally blank. Workman HDX Auto Page 4 − 43 Drive Train...

  • Page 88: Rear Differential Service

    6. For assembly purposes, note location of dowel pins the output cover (item 18) to the gear case. (item 9) in the cases. Remove pins to prevent them from falling out unexpectedly. Drive Train Page 4 − 44 Workman HDX Auto...
  • Page 89 E. Remove O−ring (item 36) from pinion gear. Dis- Figure 51 card removed O−ring. 1. Hex nut 3. Coupler 2. Lock washer Workman HDX Auto Page 4 − 45 Drive Train...
  • Page 90 3. If bearing (item 29) was removed from differential housing, install new bearing onto housing fully to shoul- der of housing. Press only on inner race of bearing dur- ing installation. Drive Train Page 4 − 46 Workman HDX Auto...
  • Page 91 A. Support output cover on work bench with the shift 12.Install and torque fill and drain plugs from 16 to 19 ft− fork facing up. lb (21 to 25 N−m). Workman HDX Auto Page 4 − 47 Drive Train...

  • Page 92: Transmission

    Auto drive system. Do not loosen engine if transmission is to be removed from machine. En- gine location will be used to align engine and trans- mission during transmission installation. Drive Train Page 4 − 48 Workman HDX Auto...

  • Page 93: Transmission Removal

    10.Carefully raise and rotate transmission to allow it to clear engine and tabs on engine/transmission mount. 9. Remove two (2) flange head screws and flange nuts Remove transmission from vehicle. that secure transmission to tabs on engine/transmission mount. Workman HDX Auto Page 4 − 49 Drive Train...

  • Page 94: Transmission Installation

    (5) flange head screws (Fig. 23). 14.Lower cargo bed (if installed). 5. Secure the transmission in place by fully tightening the two (2) flange nuts and flange head screws. Drive Train Page 4 − 50 Workman HDX Auto...
  • Page 95 This page is intentionally blank. Workman HDX Auto Page 4 − 51 Drive Train...

  • Page 96: Transmission Service

    57. Seal (2) 18. Ball bearing (5) 38. Rear output shaft 58. O−ring 19. Needle bearing 39. Shift lever 59. Seal 20. Ball bearing (2) 40. Shift shaft rail 60. O−ring Drive Train Page 4 − 52 Workman HDX Auto...

  • Page 97: Transmission Disassembly

    (2) marks on the shift shaft sector gear (Fig. 55 item 30) (Fig. 58). Figure 58 1. Shift drum sector gear 3. Alignment marks 2. Shift shaft sector gear Workman HDX Auto Page 4 - 53 Drive Train...
  • Page 98 Lift shift shaft rail (Fig. 55 item 40) with at- tached shift forks from transmission (Fig. 60). Figure 60 1. Shift drum 3. Shift shaft rail 2. Shift fork pins Drive Train Page 4 - 54 Workman HDX Auto...
  • Page 99 (2) shafts (Fig. 63). Once these shafts are separated, shaft components can be re- Figure 63 moved using Figure 55 as a guide. 1. Bearing 3. 67 tooth gear 2. Park shift dog Workman HDX Auto Page 4 - 55 Drive Train...

  • Page 100: Transmission Assembly

    (Fig. 55 items 42 and 48) on reverse shaft (Fig. 66). Figure 66 1. Shift shaft rail 2. Reverse shaft Drive Train Page 4 - 56 Workman HDX Auto...
  • Page 101 Tighten screws in two (2) steps in a crossing pat- 1. Compression spring 3. Detent star 2. Detent pawl 4. O−ring tern and to a final torque of 9 to 12 ft−lb (12 to 16 N−m). Workman HDX Auto Page 4 − 57 Drive Train...
  • Page 102 O−ring (Fig. 55 item 58) and install onto sensor. Slide sensor into gear case bore and secure with button head screw. Torque screw from 7 to 9 ft−lb (10 to 12 N−m). Drive Train Page 4 − 58 Workman HDX Auto...
  • Page 103 ......Operator Cab) ......Workman HDX Auto Page 5 - 1 Chassis...

  • Page 104: Specifications

    24” x 12” − 12, 6 ply Maximum rear tire pressure 18 PSI (124 kPa) Wheel nut torque (all wheels) 80 to 90 ft−lb (109 to 122 N−m) Brake fluid DOT 3 Chassis Page 5 − 2 Workman HDX Auto...

  • Page 105: General Information

    Specifications section of this chapter. 2. If the tires are not inflated to the correct pressure, the tires will wear prematurely. 3. See Operator’s Manual for additional tire pressure information. Workman HDX Auto Page 5 − 3 Chassis...

  • Page 106: Special Tools

    Compression Spring Tool Use to remove and install the two (2) front suspension 5” compression springs. Quantity Item 1/2” x 20” threaded steel rods 1/2” nuts 5” 1/2” flat washers 20” Figure 1 Chassis Page 5 − 4 Workman HDX Auto...

  • Page 107: Troubleshooting

    Low or uneven tire pressure. Worn or loose wheel bearings. Worn steering linkage bushings. Broken or loose rear leaf spring. Worn shock absorber(s). Incorrect front wheel alignment (toe−in). Worn or loose ball joints. Workman HDX Auto Page 5 − 5 Chassis...

  • Page 108: Brakes

    Excessively worn brake pads or rotors. Broken or worn brake pedal pivot bushing. Squealing brakes. Glazed, saturated or worn brake pads. Contaminants on brake pads and/or rotors. Scored or bent brake rotors. Chassis Page 5 − 6 Workman HDX Auto...
  • Page 109 Sticking brake master cylinder. Wheel bearing is seized. Brakes fade. Overheated brake rotors. Saturated brake pads. Brakes surge at slow speeds and chatter at fast Warped or unevenly worn brake rotors. speeds. Workman HDX Auto Page 5 − 7 Chassis...

  • Page 110: Adjustments

    If necessary, adjust tie rods equally to center steering components and then re− check front wheel alignment. 5. Make sure that all jam nuts are properly torqued. Chassis Page 5 − 8 Workman HDX Auto...
  • Page 111 This page is intentionally blank. Workman HDX Auto Page 5 − 9 Chassis...

  • Page 112: Service And Repairs

    4. Lug nut (5 per wheel) 7. Front knuckle (LH shown) 2. Brake rotor 5. Brake caliper 8. Rear wheel assembly 3. Wheel hub assembly 6. Flange head screw (2 per caliper) 9. Rear axle Chassis Page 5 − 10 Workman HDX Auto...
  • Page 113 (Fig. 5) and in two (2) steps. First, tighten all lug nuts to 40 ft−lb (55 N−m) and then torque all lug nuts to a final torque from 80 to 90 ft−lb (109 to 122 N−m). Workman HDX Auto Page 5 − 11 Chassis...

  • Page 114: Brake System

    2. Brake rotor 6. Flange head screw (2 per caliper) 9. Rear wheel assembly 3. Wheel hub assembly 7. Front knuckle (LH shown) 10. Rear axle 4. Lug nut (5 per wheel) Chassis Page 5 − 12 Workman HDX Auto...
  • Page 115 4. Install wheel to vehicle (see Wheel Assembly in this wheels. section). 2. Repeat this procedure 10 times. To avoid overheating 5. Lower machine to ground. the brakes, wait 1 minute between each stop. Workman HDX Auto Page 5 - 13 Chassis...

  • Page 116: Brake Caliper Service

    Figure 8 1. Bolt (2) 4. Caliper bracket 7. Piston (2) 2. Caliper body 5. Square seal (2) 8. Brake pad (2) 3. O−ring (4) 6. Dust seal (2) 9. Caliper anvil Chassis Page 5 − 14 Workman HDX Auto...
  • Page 117 (37 to 44 N−m). 3. Check that pins on caliper bracket are not worn or damaged. Wear on the pins will prevent smooth brake operation. Workman HDX Auto Page 5 − 15 Chassis...

  • Page 118: Bleed Brake System

    9. After bleeding of brakes is completed, test vehicle to make sure brakes are operating correctly and brake pedal is solid. Chassis Page 5 − 16 Workman HDX Auto...
  • Page 119 This page is intentionally blank. Workman HDX Auto Page 5 − 17 Chassis...

  • Page 120: Brake Master Cylinder

    5. Brake pedal 9. Cotter pin 2. Flange head screw (2) 6. Flange bushing 10. Shoulder screw 3. Clevis pin 7. Flange nut 11. Brake shaft 4. Grease fitting 8. Flange nut (2) Chassis Page 5 − 18 Workman HDX Auto...
  • Page 121 5. Install hood (see Hood in this section). CAUTION After servicing the brakes, always check the brakes in a wide open, level area that is free of other persons and obstructions. 6. Check brake operation. Workman HDX Auto Page 5 − 19 Chassis...

  • Page 122: Brake Master Cylinder Service

    4. Install push rod and secure in place with circlip. Install lower end of dust cover to housing. 5. Push in on push rod so stop pin can be installed to retain secondary piston assembly, then install flange seal and reservoir. Chassis Page 5 − 20 Workman HDX Auto...
  • Page 123 This page is intentionally blank. Workman HDX Auto Page 5 − 21 Chassis...

  • Page 124: Parking Brake Cable

    3. Remove knobs from control levers and then remove center console control plate to gain access to parking brake cable in console. Figure 14 1. Parking brake lever 3. Set screw 2. Knob Chassis Page 5 − 22 Workman HDX Auto...
  • Page 125 5. Install control lever knobs. 6. Remove bed support from cargo bed lift cylinder and lower bed. 7. Adjust parking brake (see Parking Brake in the Ad- justments section of this chapter). Workman HDX Auto Page 5 − 23 Chassis...

  • Page 126: Parking Brake Caliper

    3. Jack up and support rear of vehicle (see Jacking Ve- hicle in the Safety Instructions section of Chapter 1 − Safety). Figure 18 1. Parking brake lever 3. Set screw 2. Knob Chassis Page 5 − 24 Workman HDX Auto...
  • Page 127 C. Secure driveshaft and parking brake rotor to rear differential with four (4) socket head screws. Torque screws from 23 to 27 ft−lb (32 to 36 N−m). Workman HDX Auto Page 5 − 25 Chassis...

  • Page 128: Wheel Hub

    NOTE: If vehicle is equipped with optional four wheel drive kit, see CV Axle Assembly in the Service and Re- pairs section of Chapter 8 − Four Wheel Drive (Optional Kit) for front wheel hub removal and installation proce- dure. Chassis Page 5 − 26 Workman HDX Auto...
  • Page 129 6. If front wheel hub replacement is necessary, remove cap screw (item 12), washers (items 11 and 10) and lock nut (item 9) from wheel hub assembly so that these com- ponents can be installed on replacement hub. Workman HDX Auto Page 5 − 27 Chassis...

  • Page 130: Steering Assembly

    20. Center link 31. Snap ring (2) 10. Lock nut (2) 21. Flat washer (2) 32. Cap screw (2) 11. Tie rod assembly (2) 22. Cap screw (2) 33. Lock nut (2) Chassis Page 5 − 28 Workman HDX Auto...
  • Page 131 Discard spindle nut after removal. 1. Pivot mount 5. Thrust washer (2) 2. Flange bushing (2) 6. Pitman arm 3. Flange bushing (2) 7. Idler arm 4. Wave washer (2) 8. Spindle nut (2) Workman HDX Auto Page 5 − 29 Chassis...
  • Page 132 Install cotter pin. C. Install tie rods to center link (see below). D. Install seat base to vehicle (see Seat Base in this section). Chassis Page 5 − 30 Workman HDX Auto...
  • Page 133 This page is intentionally blank. Workman HDX Auto Page 5 − 31 Chassis...

  • Page 134: Front Control Arms

    8. Lock nut (8) 13. Ball joint seal 4. RH lower control arm 9. Cap screw (2) 14. Knuckle (LH shown) 5. Cap screw (4) 10. Flange bushing (2 used per arm) 15. Retaining ring Chassis Page 5 − 32 Workman HDX Auto...
  • Page 135 4. Remove control arm from vehicle frame. 5. Disassemble control arm as needed. A. Remove retaining ring and press ball joint out of control arm. B. Press flange bushings from control arm. Workman HDX Auto Page 5 − 33 Chassis...

  • Page 136: Front Compression Spring Service

    5. Stabilizer link 8. LH control arm tower 2. Compression spring (2) 6. Lock nut 9. Spring pivot sleeve 3. Flange nut 7. Cap screw 10. RH control arm tower 4. Cap screw Chassis Page 5 − 34 Workman HDX Auto...
  • Page 137 1. Control arm tower 3. Spring cradle 2. Spring tool rod 4. Compression spring and stabilizer links. Assembly (Fig. 25) 1. Reverse the disassembly procedure to install com- pression springs. Workman HDX Auto Page 5 − 35 Chassis...

  • Page 138: Front Shock Absorber

    5. Outer washer (0.563” ID) 11. Frame stud lower end of shock absorber onto cap screw. Install se- 6. Lock nut cond washer onto cap screw and secure shock end with lock nut. Chassis Page 5 − 36 Workman HDX Auto...

  • Page 139: Rear Shock Absorber

    1. Rubber bushing (4) 6. Spacer 2. Flat washer (0.563” ID) 7. Flat washer (0.445” ID) 3. Shock absorber 8. Cap screw 4. Flat washer (0.656” ID) 9. Flange nut 5. Lock nut Workman HDX Auto Page 5 − 37 Chassis...

  • Page 140: Rear Leaf Spring

    7. Remove two (2) lock nuts (item 14) and flange head of Chapter 1 − Safety). screws (item 4) securing spring mount (item 2) to frame rail, then remove leaf spring assembly. 3. Remove rear wheels (see Wheel Assembly in this section). Chassis Page 5 − 38 Workman HDX Auto...
  • Page 141 80 to 90 ft−lb (109 to 122 NOTE: During leaf spring installation, make sure axle N−m). and spring plate are centered on leaf spring knob. Workman HDX Auto Page 5 − 39 Chassis...

  • Page 142: Steering Wheel

    Torque hex nut from 20 to 25 ft−lb (28 to 33 N−m). 4. Install steering wheel cover. Figure 32 1. Steering wheel 4. Steering control valve 2. Flat washer 5. Frame 3. Hex nut Chassis Page 5 − 40 Workman HDX Auto...
  • Page 143 This page is intentionally blank. Workman HDX Auto Page 5 − 41 Chassis...

  • Page 144: Seat Base

    4. Remove six (6) carriage screws and flange nuts that secure ROPS cover to ROPS frame. Remove cover 2. Loosen hose clamps and remove CVT intake hose from vehicle (Fig. 35). from ROPS cover and CVT enclosure cover (Fig. 34). Chassis Page 5 − 42 Workman HDX Auto...
  • Page 145 8. Install CVT intake hose to ROPS cover and CVT en- closure cover (Fig. 34). Secure intake hose with hose clamps. 9. Lower bed (if installed). Figure 36 1. Control plate 3. Speed range lever 2. Screw (6) 4. Hydraulic lift lever Workman HDX Auto Page 5 − 43 Chassis...

  • Page 146: Hood

    4. Pivot the top of hood forward and unplug the wire harness connectors from the head lights. 5. Remove hood from vehicle. Chassis Page 5 − 44 Workman HDX Auto...

  • Page 147: Windshield Wiper Assembly (Machines With Operator Cab)

    7. Wiper motor 16. Wiper arm 25. Flange nut (2 each) 8. Wiper motor bracket 17. Wiper stud nut (2 each) 26. Washer- head screw (3 each) 9. Roof console 18. Lock washer Workman HDX Auto Page 5 - 45 Chassis...
  • Page 148 A. Ensure that the wiper motor electrical connector is secured to the cab wire harness. B. Position the console foam. Secure the roof to the cab frame with the 10 clips, 10 sealing washers, and 10 flange- head screws. Chassis Page 5 - 46 Workman HDX Auto...
  • Page 149 ........Workman HDX Auto Page 6 − 1...

  • Page 150: General Information

    Manual for additional information when servicing the vehicle. Electrical Drawings The electrical schematics and other electrical drawings for Workman HDX Auto vehicles are located in Chapter 9 − Electrical Drawings. Electrical System Page 6 − 2 Workman HDX Auto...

  • Page 151: Special Tools

    The digital multimeter can test electrical components and circuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
  • Page 152 Apply terminal protector to the connection af- ter the battery cable, ring terminal or fork terminal has been secured. Toro Part Number: 107−0392 Figure 4 Spark Tester The spark tester can be used to test magneto ignitions on gasoline engines.

  • Page 153: Troubleshooting

    Starter cranks, but should not, with hydraulic lift lever Lift lever interlock switch is out of adjustment. out of the neutral position. Lift lever interlock switch or circuit wiring is faulty. Workman HDX Auto Page 6 − 5 Electrical System...
  • Page 154 Fan fuse (30 Amp) is faulty. Fusible link is faulty. Fan relay or circuit wiring is faulty. Excessive temperature output from engine controller has not energized fan relay (see Kohler Aegis Service Manual). Electrical System Page 6 − 6 Workman HDX Auto...

  • Page 155: Charging System Test

    NOTE: Depending upon the condition of the battery charge and battery temperature, the charging system voltage will increase at different rates as the battery charges. Workman HDX Auto Page 6 − 7 Electrical System...

  • Page 156: Verify Interlock System Operation

    2. Without depressing the brake pedal, rotate ignition switch to START position. 3. If engine cranks or starts, there is a malfunction in the interlock system that must be repaired before operating vehicle. Electrical System Page 6 − 8 Workman HDX Auto...

  • Page 157: Component Testing

    6. After testing, connect wire harness electrical connec- tor to the ignition switch. 7. Install hood if it was removed (see Hood in the Ser- vice and Repairs section of Chapter 5 − Chassis). Workman HDX Auto Page 6 − 9 Electrical System...

  • Page 158: Gauge Cluster

    If the oil level was low, but adding oil does not cause the light to go out when the engine is restarted, turn the engine off immediately and contact your Toro distributor for assistance. Speedometer The speedometer displays the vehicle ground speed.

  • Page 159: Fuses

    1. Make sure that ignition switch is OFF and key is re- moved from switch. 2. Remove fuse from fuse block for testing. 3. Fuse should have continuity across the terminals. Figure 10 Workman HDX Auto Page 6 − 11 Electrical System...

  • Page 160: Headlight Switch

    6. After testing, connect wire harness electrical connec- tor to the headlight switch. 7. Install hood if it was removed (see Hood in the Ser- vice and Repairs section of Chapter 5 − Chassis). Electrical System Page 6 − 12 Workman HDX Auto...

  • Page 161: Rear Differential Lock Switch

    (see Hood in the Service and Repairs section of Chapter 5 − Chassis). Figure 14 3. Locate rear differential lock switch on dash and dis- connect wire harness electrical connector from the switch. Workman HDX Auto Page 6 − 13 Electrical System...

  • Page 162: Brake Switch

    6. After switch testing is completed, connect the wire harness connector to the brake switch. 7. Install hood if it was removed (see Hood in the Ser- vice and Repairs section of Chapter 5 − Chassis). Electrical System Page 6 − 14 Workman HDX Auto...

  • Page 163: Parking Brake Switch

    6. After switch testing is completed, connect the wire harness connector to the parking brake switch. 7. Install seat base to machine (see Seat Base in the Service and Repairs section of Chapter 5 − Chassis). Workman HDX Auto Page 6 − 15 Electrical System...

  • Page 164: Hydraulic Lift Lever Interlock Switch

    Adjust interlock switch position by loosening lock nut and 1. Lift lever 4. Switch plate moving switch for proper operation (Fig. 19). Tighten 2. Switch 5. Lock nut lock nut after adjustment. 3. Carriage screw Electrical System Page 6 − 16 Workman HDX Auto...

  • Page 165: High Flow Hydraulics Switch (Vehicles With High Flow Hydraulics)

    6. After testing, connect wire harness electrical connec- tor to the high flow hydraulics switch. 7. Install hood if it was removed (see Hood in the Ser- vice and Repairs section of Chapter 5 − Chassis). Workman HDX Auto Page 6 − 17 Electrical System...

  • Page 166: Front Differential Interrupter Switch (Vehicles With 4Wd)

    Make sure that the flange of the accelerator pedal is against the stop. The plunger of the switch should be bottomed out in the switch. If necessary, loosen switch fasteners and reposition switch. Tighten fasteners after adjustment. Electrical System Page 6 − 18 Workman HDX Auto...

  • Page 167: Main Power Relay (Four Terminals)

    7. After testing is complete, install main power relay to relay bracket and connect wire harness connector to relay. 8. Remove bed support from cargo bed lift cylinder and lower bed. Workman HDX Auto Page 6 − 19 Electrical System...

  • Page 168: Relays With Five (5) Terminals

    Relays with Five (5) Terminals Workman HDX Auto vehicles use a number of relays that have five (5) terminals: FRONT The start relay ensures that the hydraulic lift lever is in neutral before the engine starter solenoid can be ener- gized.
  • Page 169 9. Disconnect voltage and multimeter leads from the relay terminals. 10.Replace relay if testing determines that relay is faulty. 11. After testing is complete, secure relay to machine and connect wire harness connector to relay. Workman HDX Auto Page 6 − 21 Electrical System...

  • Page 170: Diode Assemblies

    (see Hood in the Service and Repairs section of Chapter 5 − Chassis). 3. Remove cable tie that secures diode to wire harness. Unplug the diode from the wire harness for testing. Electrical System Page 6 − 22 Workman HDX Auto...

  • Page 171: Fusible Link

    Fusible Link A Workman HDX Auto vehicle uses three (3) fusible links for circuit protection. These fusible links are located in a harness that connects the engine starter motor B+ termi- nal to the vehicle rear wire harness (Fig. 29). If any of these links should fail, current to the protected circuit will cease.

  • Page 172: Fuel Gauge Sender

    Fuel Gauge Sender The fuel gauge sender on Workman HDX Auto vehicles 7. After testing, install pump assembly into fuel tank and is included with the fuel pump assembly that fits into the secure with gasket and fuel pump cap (see Fuel Pump fuel tank (Fig.

  • Page 173: Fuel Pump

    Fuel Pump The fuel pump used on Workman HDX Auto vehicles is 5. While monitoring fuel pressure gauge, turn ignition a positive displacement electric pump that provides switch to RUN so that engine relay and fuel pump are en- pressurized fuel to the engine fuel rail in a return-less ergized.

  • Page 174: Temperature Sender

    COOLANT TEMP TEMP SENDER RESISTANCE 100F (38C) 460 ohms (approximate) 160F (71C) 140 ohms (approximate) Figure 36 200F (93C) 54 to 78 ohms 220F (105C) 50 ohms (approximate) Electrical System Page 6 − 26 Workman HDX Auto...

  • Page 175: Speed Sensor

    11. Remove bed support from cargo bed lift cylinder and 1. Speed sensor 4. Red striped wire 2. Sensor tip 5. Gray striped wire lower bed. 3. Sensor connector 6. Black wire Workman HDX Auto Page 6 − 27 Electrical System...

  • Page 176: Hydraulic Solenoid Valve Coil

    2. Carefully slide coil from valve. 3. When installing coil on cartridge valve, torque nut to 5 ft−lb (6.8 N−m). Figure 40 1. Nut 3. Manifold body 2. Solenoid coil Electrical System Page 6 − 28 Workman HDX Auto...

  • Page 177: Windshield Washer/Wiper Switch (Machines With Operator Cab)

    6. If the windshield wiper/washer switch testing is cor- rect and a circuit problem still exists, check the wire har- ness; refer to the Chapter 9 − Electrical Drawings. Workman HDX Auto Page 6 − 29 Electrical System...
  • Page 178 This page is intentionally blank. Electrical System Page 6 − 30 Workman HDX Auto...

  • Page 179: Service And Repairs

    A. Clean battery by washing entire case with a solu- tion of baking soda and water. Rinse with clear water. B. Coat battery posts and cable connectors with Bat- tery Terminal Protector (Toro Part No. 107−0392) or petroleum jelly to prevent corrosion. Workman HDX Auto Page 6 −...

  • Page 180: Battery Service

    6. Coat battery posts and cable connectors with Battery Terminal Protector (Toro Part No. 107−0392) or petro- leum jelly to prevent corrosion. 7. Make sure that battery retainer secures battery in place.
  • Page 181 12.4 VDC, charge the battery. B. If the battery has been charged, apply a 150 amp load for fifteen (15) seconds to remove the surface charge. Use a battery load tester following the manufacturer’s instructions. Workman HDX Auto Page 6 − 33 Electrical System...
  • Page 182 0.003 change in specific gravity for three (3) consecutive read- ings. 8. If battery filler caps are removable, check the electro- lyte level in each cell. Adjust electrolyte level if needed. Electrical System Page 6 − 34 Workman HDX Auto...

  • Page 183: Headlights

    2. If bulb was removed from headlight, align tabs on bulb with notches in headlight opening. Insert bulb into back of headlight without touching the clear bulb sur- face. Secure bulb to headlight by rotating it 1/4 turn clockwise. Workman HDX Auto Page 6 − 35 Electrical System...

  • Page 184: Tail Lights

    Tail Lights Disassemble and assemble tail light using Fig. 45 as a guide. Figure 45 1. Screw (2) 3. Bulb 2. Lens 4. Tail light assembly Electrical System Page 6 − 36 Workman HDX Auto...
  • Page 185 ....... DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Workman HDX Auto Page 7 − 1 Hydraulic System...

  • Page 186: Specifications

    Rear section displacement (per revolution) 0.519 in (8.5 cc) High Flow Hydraulics System Relief Pressure 2000 PSI (137 Bar) High Flow Hydraulics Hydraulic Filter Spin−on cartridge type 100 mesh strainer in reservoir Hydraulic System Page 7 − 2 Workman HDX Auto...

  • Page 187: General Information

    (1) or two (2) seconds after the bed contacts the After all hydraulic system pressures have been relieved, frame to ensure that system pressure is fully relieved. remove key from ignition switch. Workman HDX Auto Page 7 − 3 Hydraulic System...

  • Page 188: Hydraulic Hoses

    Installation in this section). If the hose has an elbow at one end, tighten the swivel nut on that end before tight- ening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).

  • Page 189: Hydraulic Hose And Tube Installation

    85 to 105 ft−lb (116 to 142 N−m) 1 7/16 − 12 110 to 136 ft−lb (150 to 184 N−m) 1 11/16 − 12 140 to 172 ft−lb (190 to 233 N−m) Figure 4 Workman HDX Auto Page 7 − 5 Hydraulic System...

  • Page 190: Hydraulic Fitting Installation

    202 to 248 ft−lb (274 to 336 N−m) 121 to 149 ft−lb (165 to 202 N−m) 1 5/8 − 12 247 to 303 ft−lb (335 to 410 N−m) 149 to 183 ft−lb (202 to 248 N−m) Figure 6 Hydraulic System Page 7 − 6 Workman HDX Auto...
  • Page 191 1.00 + 0.25 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 0.25 16 (1 in.) 1.50 + 0.25 Workman HDX Auto Page 7 − 7 Hydraulic System...

  • Page 192: Hydraulic Schematic

    Hydraulic Schematic Hydraulic System Page 7 − 8 Workman HDX Auto...
  • Page 193 This page is intentionally blank. Workman HDX Auto Page 7 − 9 Hydraulic System...

  • Page 194: Hydraulic Circuit Operation

    Hydraulic Circuit Operation Figure 9 Hydraulic System Page 7 − 10 Workman HDX Auto...

  • Page 195: Steering Circuit

    Fluid leaving the steering cylinder flows back through the spool valve, then out the T port and returns to the hy- draulic reservoir. The steering control valve returns to the neutral position when turning is completed. Workman HDX Auto Page 7 − 11 Hydraulic System...

  • Page 196: Raise And Lower Bed

    LIFT CYLINDERS (2) PISTON MOVEMENT LIFT CYLINDERS (2) PISTON MOVEMENT LIFT VALVE LIFT VALVE (IN LOWER POSITION) (IN RAISE POSITION) LOWER BED RAISE BED Figure 10 Hydraulic System Page 7 − 12 Workman HDX Auto...

  • Page 197: High Flow Hydraulic Circuit

    High Flow Hydraulic Circuit On Workman HDX Auto vehicles that are equipped with High Flow Circuit OFF (Fig. 11) high flow hydraulics, a second gear pump section is di- When the rocker switch is in the OFF position, the hy- rectly coupled to the standard gear pump.

  • Page 198: Special Tools

    Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
  • Page 199 Hydraulic Test Fitting Kit This kit includes a variety of O−ring Face Seal fittings to TORO TEST FITTING KIT enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.

  • Page 200: Troubleshooting

    Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Hydraulic System Page 7 − 16 Workman HDX Auto...
  • Page 201 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Workman HDX Auto Page 7 − 17...
  • Page 202 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Hydraulic System Page 7 − 18 Workman HDX Auto...

  • Page 203: Testing

    All testing should be performed by two (2) people. One person should be in the seat to oper- ate the machine and the other should monitor testing equipment and record test results. Workman HDX Auto Page 7 − 19 Hydraulic System...

  • Page 204: Gear Pump Flow And System Relief Pressure

    High Flow Hy- draulics Gear Pump Flow and Relief Pressure Test for testing of the rear pump section. FRONT Figure 18 1. Gear pump 3. Suction hose 2. Pressure hose Hydraulic System Page 7 − 20 Workman HDX Auto...
  • Page 205 6. Fully depress and hold accelerator pedal. Check that engine speed is 3600 RPM. Verify engine speed with a phototac. Workman HDX Auto Page 7 − 21 Hydraulic System...

  • Page 206: Steering Control Valve And Steering Cylinder

    STEERING COOLER SVRV CONTROL UNIT 1800 PSI OPTIONAL HIGH FLOW KIT 4.9 GPM LIFT VALVE EXTEND TO RAISE GEAR PUMP 0.33 in3/rev ENGINE 3600 / 1100 RPM 100 MESH Figure 19 Hydraulic System Page 7 − 22 Workman HDX Auto...
  • Page 207 D. Read Precautions for Hydraulic Testing in this section. E. Clean and remove hydraulic hose from the fitting on the rod end of the steering cylinder. Plug the end of the disconnected hose (Fig. 19). Workman HDX Auto Page 7 − 23 Hydraulic System...

  • Page 208: Lift Cylinder Internal Leakage

    COOLER SVRV CONTROL UNIT 1800 PSI OPTIONAL HIGH FLOW KIT 4.9 GPM LIFT VALVE (IN LOWER POSITION) GEAR PUMP 0.33 in3/rev PLUG ENGINE 3600 / 1100 RPM 100 MESH Figure 20 Hydraulic System Page 7 − 24 Workman HDX Auto...
  • Page 209 6. If any oil comes out of open cylinder port, cylinder has an internal leak. Repair or replace cylinder. 7. When testing is complete, reconnect hose that was disconnected in step 3. 8. Repeat test for second lift cylinder if necessary. Workman HDX Auto Page 7 − 25 Hydraulic System...

  • Page 210: High Flow Hydraulics Gear Pump Flow And System Relief Pressure

    LEFT on vehicles with this system, refer to the Gear Pump FRONT Flow and System Relief Pressure Test in this section. Figure 23 1. Pressure coupler (lower) 2. Return coupler (upper) Hydraulic System Page 7 − 26 Workman HDX Auto...
  • Page 211 1500 PSI (103.4 bar) is obtained on gauge. Verify that engine speed contin- ues to be 3600 RPM. Record flow meter reading. Workman HDX Auto Page 7 − 27 Hydraulic System...

  • Page 212: Service And Repairs

    5. Note the position of hydraulic fittings (especially el- bow fittings) on hydraulic components before removal. Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes. Hydraulic System Page 7 − 28 Workman HDX Auto...

  • Page 213: Check Hydraulic Lines And Hoses

    If fluid is in- jected into the skin, it must be surgically re- moved within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. Workman HDX Auto Page 7 − 29 Hydraulic System...

  • Page 214: Hydraulic Reservoir

    15. Cap screw 22. Flange nut (2) 8. O−ring The hydraulic reservoir on all Workman HDX Auto vehi- NOTE: Refer to your Operator’s Manual for checking cles is the same. Vehicles with standard hydraulics use hydraulic fluid level in the reservoir.
  • Page 215 Figure 25 1. Hydraulic reservoir 7. Fitting 2. O−ring 8. Hose clamp (3) 3. Strainer 9. Hydraulic hose 4. O−ring 10. Hydraulic hose 5. Tee fitting 11. Gear pump 6. O−ring Workman HDX Auto Page 7 − 31 Hydraulic System...

  • Page 216: Gear Pump (Vehicles With Standard Hydraulics)

    HDX Auto vehicles is a single gear pump. If your vehicle is equipped with High Flow Hydraulics, a second pump section is added to the standard gear pump (see Gear Pump (Vehicles with High Flow Hydraulics) in this sec- tion). Hydraulic System Page 7 − 32 Workman HDX Auto...
  • Page 217 5. Rubber coupler 3. Align pump shaft to pump hub. Slide pump shaft into hub until pump flange holes align with holes in mount. Take care to not damage the pump coupling. Workman HDX Auto Page 7 − 33 Hydraulic System...

  • Page 218: Gear Pump Service (Vehicles With Standard Hydraulics)

    High Flow Hydraulics Gear Pump Service later MARKER LINE in this section. NOTE: The Workman HDX Auto gear pump includes a rear flange that will allow the installation of a second pump section for the High Flow Hydraulics system.
  • Page 219 Apply a light coating of petroleum jelly to the exposed side of the front cover. C. Inspect gear face edge for sharpness. Sharp edges of gears will mill into wear plates and, thus, must be replaced. Workman HDX Auto Page 7 − 35 Hydraulic System...
  • Page 220 If any binding is noted, disassemble the pressure should be sufficient to engage the dowel pins. pump and check for assembly problems. 11. Install two (2) dowel pins into body. Hydraulic System Page 7 − 36 Workman HDX Auto...
  • Page 221 This page is intentionally blank. Workman HDX Auto Page 7 − 37 Hydraulic System...

  • Page 222: Gear Pump (Vehicles With High Flow Hydraulics)

    23. Hydraulic manifold 8. Hydraulic hose 16. Square key NOTE: Workman HDX automatic vehicles equipped with High Flow Hydraulics use a two (2) section gear pump as shown in Figure 31. Hydraulic System Page 7 − 38 Workman HDX Auto...
  • Page 223 5. Rubber coupler 3. Align pump shaft to pump hub. Slide pump shaft into hub until pump flange holes align with holes in mount. Take care to not damage the pump coupling. Workman HDX Auto Page 7 − 39 Hydraulic System...

  • Page 224: Gear Pump Service (Vehicles With High Flow Hydraulics)

    21. Rear cover 31. Front flange 11. Front pump section body The gear pump assembly used on Workman HDX Auto vehicles equipped with High Flow Hydraulics is shown in Figure 33. When servicing this gear pump, follow the procedure for Gear Pump Service (Vehicles with Stan- dard Hydraulics) in this section and the following: 1.
  • Page 225 This page is intentionally blank. Workman HDX Auto Page 7 − 41 Hydraulic System...

  • Page 226: Lift Valve

    19. Flange head screw (2) 6. Hyd. tube (return to hydraulic filter) 13. 90 hydraulic fitting 20. Hyd. tube (pressure supply) 7. Flange nut (2) 14. Hyd. tube (to male quick fitting) Hydraulic System Page 7 − 42 Workman HDX Auto...
  • Page 227 Tighten fittings (see Hy- Figure 35 draulic Fitting Installation in the General Information 1. Lift lever 3. Retainer pin section of this chapter). 2. Link 4. Lift valve Workman HDX Auto Page 7 − 43 Hydraulic System...

  • Page 228: Lift Valve Service

    2. Coat all O−rings and spool with clean hydraulic oil be- fore installation into valve body. Assemble components in reverse order of disassembly. Install spool into valve body before inserting cam pins, balls, springs and hex cap plugs. Hydraulic System Page 7 − 44 Workman HDX Auto...
  • Page 229 This page is intentionally blank. Workman HDX Auto Page 7 − 45 Hydraulic System...

  • Page 230: Steering Control Valve

    2. Remove steering wheel (see Steering Wheel in the Chassis). Service and Repairs section of Chapter 7 − Chassis). 3. Remove cable ties that secure steering hose cover to hydraulic hoses. Remove cover from hoses. Hydraulic System Page 7 − 46 Workman HDX Auto...
  • Page 231 7. Start the engine, operate at idle speed and rotate the steering wheel in both directions until air is out of hydrau- lic system. 8. Stop the engine and check oil level in reservoir. Fill reservoir if necessary. Workman HDX Auto Page 7 − 47 Hydraulic System...

  • Page 232: Steering Control Valve Service

    15. Inner gearwheel 22. Spring set 8. Ball NOTE: For service of the steering control valve, see the Sauer/Danfoss Steering Unit Type OSPM Service Manual at the end of this chapter. Hydraulic System Page 7 − 48 Workman HDX Auto...
  • Page 233 This page is intentionally blank. Workman HDX Auto Page 7 − 49 Hydraulic System...

  • Page 234: Steering Cylinder

    20. Center link 31. Snap ring (2) 10. Lock nut (2) 21. Flat washer (2) 32. Cap screw (2) 11. Tie rod assembly 22. Cap screw (2) 33. Lock nut (2) Hydraulic System Page 7 − 50 Workman HDX Auto...
  • Page 235 3. Hydraulic fitting 7. Hydraulic hose tings (see Hydraulic Fitting Installation in the General 4. O−ring Information section of this chapter). 2. Install steering cylinder to vehicle using Figure 19 as a guide. Workman HDX Auto Page 7 − 51 Hydraulic System...

  • Page 236: Steering Cylinder Service

    9. Remove and discard seals, O−rings and wear ring from piston and heads. B. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening. Hydraulic System Page 7 − 52 Workman HDX Auto...
  • Page 237 3. Install piston (item 5) with new seals and back−ups onto rear shaft. IMPORTANT: When installing roll pin into front and rear shafts, make sure that shaft surfaces are not damaged. Workman HDX Auto Page 7 − 53 Hydraulic System...

  • Page 238: Lift Cylinder

    9. Frame engine support 2. O−ring 6. Lift cylinder (LH shown) 10. Frame rail (LH shown) 3. 90 hydraulic fitting 7. Hydraulic hose 11. Clevis pin 4. O−ring 8. Cotter pin 12. Lynch pin Hydraulic System Page 7 − 54 Workman HDX Auto...
  • Page 239 6. Remove lift cylinder from vehicle. 7. If hydraulic fittings are to be removed from lift cylin- der, mark fitting orientation to allow correct assembly. Remove fittings from cylinder and discard O−rings. Workman HDX Auto Page 7 − 55 Hydraulic System...

  • Page 240: Lift Cylinder Service

    C. Rotate the head counter−clockwise to remove re- scoring, pitting or wear. taining ring from barrel and head. 4. Replace lift cylinder if internal components are found to be worn or damaged. Hydraulic System Page 7 − 56 Workman HDX Auto...
  • Page 241 C. Apply silicone sealer to tube access slot. B. Slide head and piston onto the shaft. C. Secure piston to shaft with lock nut. Torque lock nut from 60 to 75 ft−lb (81 to 102 N−m). Workman HDX Auto Page 7 − 57 Hydraulic System...

  • Page 242: Hydraulic Manifold (Vehicles With High Flow Hydraulics)

    Flow Hydraulics use a hydraulic manifold mounted sole- noid valve to engage the accessory hydraulic circuit. The hydraulic manifold is attached to the vehicle above the hydraulic oil filter assembly (Fig. 47). Hydraulic System Page 7 − 58 Workman HDX Auto...
  • Page 243 B. If valve sealing surfaces appear pitted or dam- to the sealing surfaces, damaged threads or contamina- aged, the hydraulic system may be overheating or tion. there may be water in the system. Workman HDX Auto Page 7 − 59 Hydraulic System...
  • Page 244 5 ft−lb (6.8 N−m). Over−tightening may damage the solenoid or cause the valve to mal- function. 8. If hydraulic problems still exist with vehicle, remove cartridge valve and clean again or replace valve. Hydraulic System Page 7 − 60 Workman HDX Auto...
  • Page 245 Front Differential Assembly ....HILLIARD FRONT DRIVE SYSTEM DIFFERENTIAL PARTS and SERVICE MANUAL Workman HDX Auto Page 8 − 1 Four Wheel Drive (Optional Kit)

  • Page 246: Specifications

    Description Front Differential (Optional Kit) Ring and Pinion with Dual Bi−Directional Clutches Front Differential Oil Mobil 424 Front Differential Oil Capacity 6 fluid ounces (180 milliliter) system capacity Four Wheel Drive (Optional Kit) Page 8 − 2 Workman HDX Auto...

  • Page 247: General Information

    The Automatic on Demand front wheel drive feature on front differential sense the rear wheels slipping and en- Workman HDX Auto vehicles equipped with the optional gage the front wheel drive instantaneously to deliver four wheel drive kit does not require operator activation.

  • Page 248: Cv (Constant Velocity) Axle Assembly

    12. Brake caliper (LH shown) 19. Inboard boot (1 per axle) 6. Cap screw 13. Brake rotor (2) 20. Outboard boot (1 per axle) 7. Lock nut 14. Slotted hex nut (2) Four Wheel Drive (Optional Kit) Page 8 − 4 Workman HDX Auto...

  • Page 249: Test Cv Axle

    CV axle out of the differential (Fig. 2). 9. Make sure that wheel lug nuts are properly tight- ened. 7. Pull CV axle through opening in knuckle and remove from vehicle. Workman HDX Auto Page 8 − 5 Four Wheel Drive (Optional Kit)

  • Page 250: Cv Axle Boots

    F. Use a soft brass or plastic hammer against the outboard joint housing and carefully drive the joint onto the center shaft until spring clip is seated. Four Wheel Drive (Optional Kit) Page 8 − 6 Workman HDX Auto...
  • Page 251 This page is intentionally blank. Workman HDX Auto Page 8 − 7 Four Wheel Drive (Optional Kit)

  • Page 252: Front Differential Driveshaft

    4. Front differential driveshaft 7. Flange head screw (4) 2. Cap screw 5. Front differential assembly 8. Mount (4) 3. Lock nut 6. CV axle assembly (2) 9. Differential plate (2) Four Wheel Drive (Optional Kit) Page 8 − 8 Workman HDX Auto...
  • Page 253 3. Rotate input shaft of front differential until the hole in the input shaft is aligned with the hole in the differential yoke. Workman HDX Auto Page 8 − 9 Four Wheel Drive (Optional Kit)

  • Page 254: Driveshaft Cross And Bearing Service

    E. Thoroughly clean and inspect all components. binding. 3. Install front differential driveshaft to vehicle (see Front Differential Driveshaft in this section). Four Wheel Drive (Optional Kit) Page 8 − 10 Workman HDX Auto...
  • Page 255 This page is intentionally blank. Workman HDX Auto Page 8 − 11 Four Wheel Drive (Optional Kit)

  • Page 256: Front Differential

    10. Axle spacer (2) 16. Knuckle (LH shown) 5. Driveshaft 11. Flange head screw (8) 17. Differential plate (2) 6. Cap screw 12. Brake caliper (LH shown) 18. Mount (4) Four Wheel Drive (Optional Kit) Page 8 − 12 Workman HDX Auto...
  • Page 257 8. Tip differential toward left side (driver side) of ve- hicle. Remove differential assembly toward the right side (passenger side) of the vehicle. Workman HDX Auto Page 8 − 13 Four Wheel Drive (Optional Kit)

  • Page 258: Front Differential Service

    19. Roller cage assembly 30. Drain plug 9. Bushing 20. Output hub (2) 31. Fill plug 10. Oil seal (2) 21. Gear shim 32. Vent 11. Oil seal 22. Roller (14) Four Wheel Drive (Optional Kit) Page 8 − 14 Workman HDX Auto...
  • Page 259 (Fig. 11). If the bushing is excessively worn, the gear case must be replaced. The bushing is not serviced sep- arately. Figure 11 1. Pinion bushing 2. Gear case Workman HDX Auto Page 8 − 15 Four Wheel Drive (Optional Kit)
  • Page 260 8. Lift the roller cage assembly from the center of the ring gear (Fig. 14). Note: the rollers are loose in the cage and may fall out when removed. Figure 14 1. Roller cage assembly 2. Roller Four Wheel Drive (Optional Kit) Page 8 − 16 Workman HDX Auto...
  • Page 261 Take care to not damage the oil seal in the gear case during hub removal. Figure 17 1. Drift 3. Oil seal 2. Gear case Workman HDX Auto Page 8 − 17 Four Wheel Drive (Optional Kit)
  • Page 262 1. Output hub 2. Armature plate NOTE: For additional front differential information, see the Hilliard Front Drive System Differential Parts and Service Manual at the end of this chapter. Four Wheel Drive (Optional Kit) Page 8 − 18 Workman HDX Auto...
  • Page 263 (Fig. 23). Make sure that retaining ring is fully seated into groove in cover plate. Figure 23 1. Output hub 2. Gear spacer Workman HDX Auto Page 8 − 19 Four Wheel Drive (Optional Kit)
  • Page 264 Place the rollers into the roller cage slots and press them out toward the ring gear bore. Figure 26 1. Roller cage assembly 3. Torsion spring 2. Ring gear notch Four Wheel Drive (Optional Kit) Page 8 − 20 Workman HDX Auto...
  • Page 265 This proper backlash should be achieved by the time that the set screw has been turned counter−clockwise one (1) complete rotation. Figure 29 1. Cover plate 2. Set screw Workman HDX Auto Page 8 − 21 Four Wheel Drive (Optional Kit)
  • Page 266 This page is intentionally blank. Four Wheel Drive (Optional Kit) Page 8 − 22 Workman HDX Auto...
  • Page 267 ......Heater Kit--Wire Harness Drawing ... . . Workman HDX Auto Page 9 - - 1 Electrical Drawings...

  • Page 268: Electrical Drawing Designations

    WHITE Y or YE YELLOW Numerous harness wires used on Toro machines in- clude a line with an alternate color. These wires are iden- tified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g.

  • Page 269: Vehicle Electrical Schematic

    122--0090 REV. B Workman HDX Auto Vehicle Electrical Schematic (Serial Numbers 314000001 to 403430000) All relays and solenoids are shown as de- - energized. Page 9 - - 3...

  • Page 270: Numbers Above 403430001)

    122--1466 Rev. A Workman HDX Auto Vehicle Electrical Schematic (Serial Numbers Above 403430001) (All relays and solenoids are shown as de energized.) − Page 9 - - 4...
  • Page 271 122--0088 REV. D Workman HDX Auto Front Wire Harness Drawing (machine serial numbers below 316000000) Page 9 - - 5...

  • Page 272: Below 316000000)

    122--0088 REV. D Workman HDX Auto Front Wire Harness Diagram (machine serial numbers below 316000000) Page 9 - - 6...
  • Page 273 122--0823 REV. B Workman HDX Auto Front Wire Harness Drawing (machine serial numbers 316000001 to 403430000) Page 9 - - 7...

  • Page 274: 316000001 To 403430000)

    122--0823 REV. B Workman HDX Auto Front Wire Harness Diagram (machine serial numbers 316000001 to 403430000) Page 9 - - 8...
  • Page 275 122--1449 Rev. A Workman HDX Auto Front Wire Harness Diagram (Serial Numbers Above 403430001) Page 9 - - 9...

  • Page 276: Front Wire Harness

    122--1449 Rev. A Workman HDX Auto Front Wire Harness Diagram (Serial Numbers Above 403430001) Page 9 - - 10...

  • Page 277: Rear Wire Harness

    122--0089 REV. D Workman HDX Auto Rear Wire Harness Drawing Page 9 - - 11...
  • Page 278 122--0089 REV. D Workman HDX Auto Rear Wire Harness Diagram Page 9 - - 12...

  • Page 279: Rear Differential Solenoid Controller Wire Harness

    122--0589 REV. A Workman HDX Auto Rear Differential Solenoid Controller Wire Harness Page 9 - - 13...

  • Page 280: Heater Kit--Wire Harness Drawing

    Drawing No: 120--3996 Rev. C Workman HDX Auto Heater Kit--Wire HArness Drawing Page 9 - - 14...

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