Toro Workman HD Series Manuals

Manuals and User Guides for Toro Workman HD Series. We have 2 Toro Workman HD Series manuals available for free PDF download: Service Manual

Toro Workman HD Series Service Manual (328 pages)

Brand: Toro | Category: Utility Vehicle | Size: 16.15 MB

This Page Is Intentionally Blank.

3
- Table of Contents
  3
Chapter 1 Safety

7
- Safety Instructions
  7
- Safety Instructions
  8
  - Before Operating
    8
  - While Operating
    9
  - Maintenance and Service
    10
  - Jacking Vehicle
    11
  - Using Bed Safety Support
    12
- Safety and Instruction Decals
  12
- Chapter 2 - Product Records and Maintenance
  
  13
  - Product Records
    13
  - Equivalents and Conversions
    14
  - Torque Specifications
    15
- Chapter 3 - Kubota EFI Gasoline Engine
  
  18
- Chapter 4 - Kubota Diesel Engine
  
  18
  - Specifications
    18
Chapter 3 Kubota Efi Gasoline Engine

19
- Chapter 7 - Chassis
  
  19
  - General Information
    19
    
    Specifications
    21
    
    Introduction
    22
  - Adjustments
    22
    
    Kubota Gasoline Engine
    22
    
    Kubota Workshop and Diagnostics Manuals
    22
    
    Kubota Gasoline Engine Electronic Control Unit (ECU)
    23
    
    Air Cleaner System
    24
  - Service and Repairs
    24
    
    Exhaust System
    26
    
    Fuel System
    28
    
    Fuel Tank
    29
    
    Carbon Canister
    31
    
    Radiator
    32
    
    Engine
    34
Chapter 4 Kubota Diesel Engine

39
- Specifications
  40
- General Information
  41
  - Operator's Manual
    41
- Special Tools
  41
  - Adjust Accelerator Cable
    42
  - Service and Repairs
    44
    
    Air Cleaner System
    44
    
    Exhaust System
    46
    
    Fuel System
    48
    
    Fuel Sender
    49
    
    Fuel Tank
    49
    
    Radiator
    50
    
    Engine
    52
Chapter 5 Kohler Air Cooled Gasoline Engine

57
- General Information
  59
  - Operator's Manual
    59
- Service and Repairs
  61
  - Cooling System
    61
  - Exhaust System
    62
  - Fuel System
    64
    
    Fuel Sender
    65
    
    Fuel Tank
    65
    
    Carbon Canister
    66
  - Engine
    68
    
    Flywheel and Pilot Bearing Inspection
    70
Chapter 6 Drive Train

71
- Troubleshooting
  71
  - Drive Train Operation
    73
  - Operator's Manual
    73
  - Clutch Alignment Tool
    74
- Special Tools
  74
  - Power−Take−Off (PTO) Cable Adjustment (if Equipped)
    75
  - Clutch
    76
- Troubleshooting
  76
  - Transaxle
    78
  - Service and Repairs
    80
  - Shift Cable Replacement
    80
  - Driveshaft
    83
  - Driveshaft Cross and Bearing Service
    84
  - Transaxle
    86
    
    Transaxle Removal
    87
    
    Transaxle Installation
    88
  - Clutch Service
    90
  - Transaxle Service
    93
    
    Transaxle Disassembly
    93
    
    Transaxle Inspection
    105
    
    Transaxle Assembly
    109
  - Power Take−Off (PTO) Service (if Equipped)
    126
    
    Disassembly
    126
    
    Inspection
    131
    
    Assembly
    132
Chapter 7 Chassis

139
- General Information
  141
  - Operator's Manual
    141
  - Tire Pressure
    141
- Troubleshooting
  143
  - Suspension and Steering
    143
  - Brakes
    144
  - Wheel Assembly
    146
  - Brake System
    148
  - Brake Caliper Service
    150
  - Bleed Brake System
    152
  - Parking Brake Caliper Service
    153
- Brake Master Cylinder
  154
- Brake Master Cylinder Service
  156
- Parking Brake Cable
  158
- Wheel Hub
  160
- Steering Assembly
  162
- Steering Assembly
  163
- Front Control Arms
  166
- Front Compression Spring Service
  168
- Front Shock Absorber
  170
- Rear Shock Absorber
  171
- Rear Leaf Spring
  172
- Front Wheel Alignment
  174
- Steering Wheel
  175
- Seat Base
  176
- Hood
  178
Chapter 8 Electrical System

179
- Electrical Schematics
  180
- Troubleshooting
  182
- Electrical System Quick Checks
  184
  - Battery Test (Open Circuit Test)
    184
    
    Charging System Test
    184
    
    Glow Plug System Test (Workman HDX−D)
    184
    
    Verify Interlock System Operation
    185
- Component Testing
  186
  - Ignition (Key) Switch
    186
    
    Gauge Cluster
    187
    
    Fuses
    188
    
    Headlight Switch
    189
    
    Clutch Switch(S)
    190
    
    Brake Switch(S)
    191
    
    Hydraulic Lift Lever Interlock Switch
    192
    
    3Rd − High Lockout Key Switch
    193
    
    Transaxle Switches
    194
    
    Power Relay (Four Terminals)
    195
    
    Relay (Five Terminals)
    196
    
    Fusible Link
    197
    
    Diodes
    198
    
    Electronic Throttle Control (Workman HDX)
    198
  - Fuel Run/Stop Solenoid (Workman HDX−D)
    199
  - Fuel Gauge Sender (Workman HD & HDX−D)
    200
  - Fuel Pump (Workman HDX−D)
    202
    
    (Workman HDX and HDX−D)
    203
  - Speed Sensor (Workman HDX and HDX−D)
    205
  - Glow Controller (Workman HDX−D)
    206
    
    High Flow Hydraulics Kit)
    207
  - Rear PTO Switch (Optional Kit)
    209
  - Service and Repairs
    211
  - Battery Storage
    211
  - Battery Care
    211
  - Battery Service
    212
  - Headlights
    215
  - Tail Lamps
    216
Chapter 9 Hydraulic System

217
- Specifications
  219
- General Information
  220
  - Hydraulic Hoses
    220
  - Operator's Manual
    220
  - Hydraulic Hose and Tube Installation
    221
  - Hydraulic Fitting Installation
    222
- Special Tools
  224
- Hydraulic Schematics
  226
  - Primary Hydraulic System Schematic
    226
  - High Flow Hydraulic System Schematic
    227
- Chapter 5 - Kohler Air Cooled Gasoline Engine
  
  228
- Hydraulic Circuit Operation
  228
  - Steering Circuit
    228
    
    Raise and Lower Bed
    229
    
    High Flow Hydraulic Circuit
    230
  - Troubleshooting
    231
  - Testing
    234
    
    Primary Hydraulic System Gear Pump Flow Test (Workman HDX and HDX−D)
    236
    
    Workman Hd
    240
    
    Primary Hydraulic System Relief Valve Pressure Test
    245
    
    Steering Control Valve and Steering Cylinder Test
    246
    
    Lift Cylinder Internal Leakage Test
    248
    
    Gear Pump Flow and Relief Pressure Tests
    250
  - SERVICE and REPAIRS
    253
  - General Precautions for Removing and Installing Hydraulic System Components
    253
  - Check Hydraulic Lines and Hoses
    253
  - Primary Hydraulic System Gear Pump (Workman HDX and HDX−D)
    254
  - Primary Hydraulic System Gear Pump (Workman HD)
    256
  - Primary Hydraulic System Gear Pump Service
    258
  - High Flow Hydraulic System Gear Pump Service
    262
  - Lift Valve
    264
  - Lift Valve Service
    266
  - Steering Control Valve
    268
  - Steering Control Valve Service
    270
  - Steering Cylinder
    272
  - Steering Cylinder Service
    274
  - Lift Cylinder
    276
  - Lift Cylinder Service
    278
  - Hydraulic Manifold (High Flow Hydraulics Kit)
    280
Chapter 10 Front Wheel Drive (4Wd)

283
- Specifications
  284
- General Information
  285
  - Operator's Manual
    285
- SERVICE and REPAIRS
  286
  - Constant Velocity (CV) Axle Assembly
    286
  - Differential Driveshaft
    290
  - Driveshaft Cross and Bearing Service
    292
  - Front Differential
    294
  - Front Differential Service
    296
- Workman HDX/HDX−D
  296
- Front Wheel Drive (4WD)
  297
- Electrical Drawing Designations
  308
- Chapter 11
  
  309
  - Workman HD
    309
  - Workman HDX
    310
  - Workman HDX- D
    311
    
    Workman HDX- D (Industrial)
    324
    
    Workman HDX- D (Industrial)
    325

Toro Workman HD Series Service Manual (318 pages)

Brand: Toro | Category: Utility Vehicle | Size: 32.22 MB

This Page Is Intentionally Blank.

3
- Table of Contents
  3
- Safety Instructions 1
  7
- Chapter 1 -- Safety
  
  8
  - Safety Instructions
    8
    
    Before Operating
    8
    
    While Operating
    9
    
    Maintenance and Service
    10
    
    Jacking Vehicle
    11
  - Safety and Instruction Decals
    12
    
    Using Bed Safety Support
    12
- Chapter 2 -- Product Records and Maintenance
  
  13
  - Maintenance
    13
  - Product Records
    13
  - Equivalents and Conversions
    14
  - Torque Specifications
    15
Chapter 3 Briggs/Daihatsu Gasoline Engine

19
- General Information 3
  19
- Specifications
  20
- General Information
  21
  - Special Tools 6
    21
- Adjustments
  23
- Engine Diagnostics
  24
- Service and Repairs
  26
  - Fuel Pump
    30
  - Engine
    36
    
    Engine Removal
    37
    
    Engine Installation
    39
    
    Engine Throttle Bracket
    40
- EFI System
  42
  - Overview
    42
    
    EFI System Components
    42
    
    EFI Troubleshooting
    45
    
    Troubleshooting 6
    45
Chapter 4 Briggs/Daihatsu Diesel Engine

47
- Engines
  47
- Service and Repairs 6
  47
- Specifications
  48
- General Information
  49
  - Adding Oil to Engine
    49
  - Operator's Manual
    49
  - Special Tools 7
    49
- Adjustments
  50
  - Adjust Engine Speed
    50
- Service and Repairs
  52
  - Air Cleaner System
    52
  - Fuel Tank
    54
  - Exhaust System
    56
  - Radiator
    58
  - Engine
    60
  - Engine Removal
    61
  - Engine Installation
    62
  - Briggs/Daihatsu Diesel Engine
    64
  - Engine Throttle Bracket
    64
  - Workman HDX--D
    64
- Chapter 5 -- Kohler Gasoline Engine
  
  65
  - General Information
    65
  - Kohler Command Engine Service Manual
    65
- Chapter 6 -- Drive Train
  
  66
  - Service and Repairs
    65
  - Specifications
    65
  - Specifications
    66
  - General Information
    67
Chapter 6 Drive Train

77
- Adjustments
  77
- Troubleshooting
  77
- Chapter 7 -- Chassis
  
  78
  - Specifications
    78
  - General Information
    79
    
    Drive Train Operation
    79
    
    Operator's Manual
    79
  - Special Tools
    80
    
    Clutch Alignment Tool
    80
    
    PTO Cable Adjustment
    81
  - Troubleshooting
    82
    
    Clutch
    82
    
    Transaxle
    84
  - Service and Repairs
    86
    
    Shift Cable Replacement
    86
    
    Driveshaft
    88
    
    Driveshaft Cross and Bearing Service
    90
    
    PTO Removal and Installation (if Equipped)
    91
    
    Transaxle
    92
    
    Transaxle Removal
    93
    
    Transaxle Installation
    94
    
    Clutch Service
    96
    
    Transaxle Disassembly
    98
    
    Transaxle Service
    98
    
    Transaxle Inspection
    109
    
    Transaxle Assembly
    113
Chapter 7 Chassis

141
- Specifications
  142
- General Information
  143
  - Operator's Manual
    143
  - Tire Pressure
    143
- Special Tools
  144
  - Compression Spring Tool
    144
- Troubleshooting
  145
  - Suspension and Steering
    145
  - Brakes
    146
- Service and Repairs
  148
  - Wheel Assembly
    148
  - Brake System
    150
  - Brake Caliper Service
    152
  - Parking Brake Caliper Service
    153
  - Bleed Brake System
    154
- Brake Master Cylinder
  156
- Brake Master Cylinder Service
  158
- Parking Brake Cable
  160
- Wheel Hub
  162
- Steering Assembly
  164
- Front Control Arms
  168
- Front Compression Spring Service
  170
- Front Shock Absorber
  172
- Rear Shock Absorber
  173
- Rear Leaf Spring
  174
- Front Wheel Alignment
  176
- Steering Wheel
  177
- Seat Base
  178
- Hood
  180
Chapter 8 Electrical System

181
- Electrical Schematics 8
  181
- Electrical Schematics
  182
- Special Tools
  182
- Troubleshooting
  184
- Electrical System Quick Checks
  186
  - Battery Test (Open Circuit Test)
    186
    
    Charging System Test
    186
    
    Glow Plug System Test (Workman HDX--D)
    186
    
    Verify Interlock System Operation
    187
- Component Testing
  188
  - Ignition (Key) Switch
    188
    
    Gauge Cluster
    189
    
    Fuses
    190
    
    Brake Switch
    191
    
    Headlight Switch
    191
    
    Clutch Switch
    192
    
    Hydraulic Lift Lever Interlock Switch
    193
    
    3Rd -- High Lockout Key Switch
    194
    
    Transaxle Switches
    195
    
    Power Relay (Four Terminals)
    196
    
    Relay (Five Terminals)
    197
    
    Diodes
    198
    
    Fusible Link
    199
    
    Fuel Gauge Sender
    200
    
    Fuel Pump (Workman HDX)
    201
  - Temperature Sender (Workman HDX and HDX--D)
    202
  - Thermal Fan Switch
    202
  - Speed Sensor (Workman HDX and HDX--D)
    204
  - Glow Plug Timer (Workman HDX--D)
    205
  - Delay Timer (Vehicles with 4WD)
    206
  - High Flow Hydraulics Kit Switch
    206
    
    High Flow Hydraulics Kit)
    206
  - Hydraulic Solenoid Valve Coil
    207
  - Rear PTO Switch (Optional Kit)
    208
- Service and Repairs
  209
  - Battery Storage
    209
  - Battery Care
    209
  - Battery Service
    210
    
    Battery Inspection and Maintenance
    210
    
    Battery Removal and Installation
    210
    
    Battery Specifications
    210
    
    Battery Testing
    211
    
    Battery Charging
    212
  - Headlights
    213
  - Tail Lamps
    214
Chapter 9 Hydraulic System

215
- General Information 9
  215
- Specifications
  217
- General Information
  218
  - Operator's Manual
    218
    
    Hydraulic Hoses
    218
    
    Hydraulic Hose and Tube Installation
    219
- Hydraulic Schematics
  222
  - Vehicle Hydraulic Schematic
    222
    
    High Flow Hydraulics Kit (if Equipped) Schematic
    223
- Hydraulic Circuit Operation
  224
  - Steering Circuit
    224
    
    Raise and Lower Bed
    225
    
    High Flow Hydraulic Circuit
    226
- Special Tools
  228
  - Hydraulic Pressure Test Kit
    228
    
    Hydraulic Tester (Pressure and Flow)
    228
    
    Hydraulic Test Fitting Kit
    229
    
    Male Coupler (for High Flow Hydraulics Kit)
    229
    
    O--Ring Kit
    229
  - Troubleshooting
    230
- Testing
  233
  - Gear Pump Flow and System Relief Pressure
    234
    
    WORKMAN HDX and HDX- -D
    234
- Service and Repairs
  245
  - Lift Valve
    256
  - Lift Valve Service
    258
- Sauer/Danfoss Steering Unit Type Ospm Service Manual
  262
  - Steering Control Valve Service
    262
  - Steering Cylinder
    264
  - Hydraulic System
    264
  - Steering Cylinder Service
    266
  - Lift Cylinder
    268
  - Lift Cylinder Service
    270
Chapter 10 Front Wheel Drive (4Wd)

275
- Specifications
  276
- General Information
  277
- SERVICE and REPAIRS
  278
  - CV Axle Assembly
    278
  - Differential Driveshaft
    282
  - Driveshaft Cross and Bearing Service
    284
  - Front Differential
    286
  - Front Differential Service
    288
    
    Front Differential Disassembly
    289
    
    Front Differential Assembly
    293
    
    Rev. a Front Wheel Drive (4WD)
    293

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More Toro Manuals

Toro Workman HD Series Manuals

Toro Workman HD Series Service Manual (328 pages)

Table of Contents

This Page Is Intentionally Blank.

Chapter 1 Safety

Chapter 2 - Product Records and Maintenance

Chapter 3 - Kubota EFI Gasoline Engine

Chapter 4 - Kubota Diesel Engine

Chapter 3 Kubota Efi Gasoline Engine

Chapter 7 - Chassis

Chapter 4 Kubota Diesel Engine

Chapter 5 Kohler Air Cooled Gasoline Engine

Chapter 6 Drive Train

Chapter 7 Chassis

Chapter 8 Electrical System

Chapter 9 Hydraulic System

Chapter 5 - Kohler Air Cooled Gasoline Engine

Chapter 10 Front Wheel Drive (4Wd)

Chapter 11

Toro Workman HD Series Service Manual (318 pages)

Table of Contents

This Page Is Intentionally Blank.

Chapter 1 -- Safety

Chapter 2 -- Product Records and Maintenance

Chapter 3 Briggs/Daihatsu Gasoline Engine

Chapter 4 Briggs/Daihatsu Diesel Engine

Chapter 5 -- Kohler Gasoline Engine

Chapter 6 -- Drive Train