Toro Workman HD, HDX, HDX-D (HD S.N 313000001 and up, HDX, HDX-D with Kubota & Kohler Engine) Service Repair Manual

Manuals: Service Repair Manual

Table of Content – Workman HD, HDX, HDX-D (HD S.N 313000001 and up, HDX, HDX-D with Kubota & Kohler Engine)

Title Page
Revision History
Reader Comments
Preface

Table Of Contents (Page 1)

Table of Contents (Page 2)

1 – Safety
Safety Instructions
Before Operating
While Operating
Maintenance and Service
Jacking Vehicle
Using Bed Safety Support
Safety and Instruction Decals
2 – Product Records and Maintenance
Product Records
Maintenance
Equivalents and Conversions
Torque Specifications
Fastener Identification
Using a Torque Wrench with an Offset Wrench
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners)
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Other Torque Specifications
Conversion Factors
3 – Kubota EFI Gasoline Engine
Specifications
Introduction
Traction Unit Operator’s Manuals
Kubota Workshop and Diagnostics Manuals
Kubota Gasoline Engine
Kubota Gasoline Engine Electronic Control Unit (ECU)
Service and Repairs
Air Cleaner System
Exhaust System
Fuel System
Radiator
Engine
KUBOTA WORKSHOP MANUAL, GASOLINE ENGINE, WG972-G-E3F
KUBOTA DIAGNOSTICS MANUAL, GASOLINE ENGINE, WG972-G-E3F
4 – Kubota Diesel Engine
Specifications
General Information
Operator’s Manual
Adjustments
Adjust Accelerator Cable
Service and Repairs
Air Cleaner System
Exhaust System
Fuel System
Radiator
Engine
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE, SM-E3B SERIES
5 – Kohler Air Cooled Gasoline Engine
Specifications
General Information
Operator’s Manual
Service and Repairs
Cooling System
Exhaust System
Fuel System
Engine
KOHLER COMMAND ENGINE Service Repair Manual
6 – Drive Train
Specifications
General Information
Drive Train Operation
Operator’s Manual
Special Tools
Adjustments
Power-Take-Off (PTO) Cable Adjustment (If Equipped)
Troubleshooting
Clutch
Transaxle
Service and Repairs
Shift Cable Replacement
Driveshaft
Driveshaft Cross and Bearing Service
Power-Take-Off (PTO) Removal & Installation (If Equipped)
Transaxle
Clutch Service
Transaxle Service
Transaxle Disassembly
Transaxle Inspection
Transaxle Assembly
Power Take-Off (PTO) Service (If Equipped)
Disassembly
Inspection
Assembly
7 – Chassis
Specifications
General Information
Operator’s Manual
Tire Pressure
Special Tools
Troubleshooting
Suspension and Steering
Brakes
Service and Repairs
Wheel Assembly
Brake System
Brake Caliper Service
Bleed Brake System
Parking Brake Caliper Service
Brake Master Cylinder
Brake Master Cylinder Service
Parking Brake Cable
Wheel Hub
Steering Assembly
Front Control Arms
Front Compression Spring Service
Front Shock Absorber
Rear Shock Absorber
Rear Leaf Spring
Front Wheel Alignment
Steering Wheel
Seat Base
Hood

Windshield Wiper Assembly (Machines with Operator Cab)1. Flange- head screw (10 each)2. Sealing washer (10 each)3. Cab roof4. Bulb trim seal5. Console foam6. Fuse block mount7. Wiper motor8. Wiper motor bracket9. Roof console10. Clip

8 – Electrical System
Electrical Schematics
Special Tools
Troubleshooting
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Charging System Test
Glow Plug System Test (Workman HDX-D)
Verify Interlock System Operation
Component Testing
Ignition (Key) Switch
Gauge Cluster
Fuses
Headlight Switch
Clutch Switch(s)
Brake Switch(s)
Hydraulic Lift Lever Interlock Switch
3rd – High Lockout Key Switch
Transaxle Switches
Power Relay (Four Terminals)
Relay (Five Terminals)
Fusible Link
Diodes
Electronic Throttle Control (Workman HDX)
Fuel Run, Stop Solenoid (Workman HDX-D)
Fuel Gauge Sender (Workman HD & HDX-D)
Fuel Pump, Sender (Workman HDX)
Fuel Pump (Workman HDX-D)
Temperature Sender (Workman HDX and HDX-D)
Electric Fan Thermal Switch (Workman HDX-D)
Speed Sensor
Glow Controller (Workman HDX-D)
High Flow Hydraulics Kit Switch (High Flow Hydraulics Kit)
Hydraulic Solenoid Valve Coil (High Flow Hydraulics Kit)
Rear PTO Switch (Optional Kit)
Interlock Switch (1, 3 Area Lift Platform Kit)
Windshield Washer, Wiper Switch (Machines with Operator Cab)
Diode Assembly (Machines with Operator Cab)
Service and Repairs
Battery Storage
Battery Care
Battery Service
Headlights
Tail Lamps
9 – Hydraulic System
Specifications
General Information
Operator’s Manual
Hydraulic Hoses
Hydraulic Hose and Tube Installation (O-Ring Face Seal Fitting)
Hydraulic Fitting Installation (SAE Straight Thread O-Ring Fitting into Component Port)
Special Tools
Hydraulic Schematics
Primary Hydraulic System Schematic
High Flow Hydraulic System Schematic
Hydraulic Circuit Operation
Steering Circuit
Raise and Lower Bed
High Flow Hydraulic Circuit
Troubleshooting
Testing
Primary Hydraulic System Gear Pump Flow Test (Workman HDX and HDX-D)
Primary Hydraulic System Gear Pump Flow Test (Workman HD)
Primary Hydraulic System Relief Valve Pressure Test
Steering Control Valve and Steering Cylinder Test
Lift Cylinder Internal Leakage Test
High Flow Hydraulic System Gear Pump Flow and Relief Pressure Tests
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Primary Hydraulic System Gear Pump (Workman HDX and HDX-D)
Primary Hydraulic System Gear Pump (Workman HD)
Primary Hydraulic System Gear Pump Service
High Flow Hydraulic System Gear Pump Service
Lift Valve
Lift Valve Service
Steering Control Valve
Steering Control Valve Service
Steering Cylinder
Steering Cylinder Service
Lift Cylinder
Lift Cylinder Service
Hydraulic Manifold (High Flow Hydraulics Kit)
DANFOSS STEERING UNIT TYPE OSPM Service Repair Manual
10 – Front Wheel Drive (4WD)
Specifications
General Information
Operator’s Manual
Service and Repairs
Constant Velocity (CV) Axle Assembly
Inspect CV Axle Boot and Test CV Axle
Differential Driveshaft
Driveshaft Cross and Bearing Service
Front Differential
Front Differential Service
Front Differential Disassembly
Front Differential Assembly
HILLIARD FRONT DRIVE DIFFERENTIAL PARTS and Service Repair Manual
11 – Electrical Drawings
Electrical Drawing Designations
Workman HD (Serial Numbers313000001 to 404350000)
Workman HD (Serial NumbersAbove 404350001)
Workman HDX (Serial Numbers313000001 to 401400000)
Workman HDX (Serial Numbers401400001 to 404350000)
Workman HDX (Serial NumbersAbove 404350001)
Workman HDX–D (Serial Numbers313000000 to 314000000)
Workman HDX–D (Serial Numbers314000001 to 401420000)
Workman HDX–D (Serial Numbers401420001 to 404350000)
Workman HDX–D (Serial NumbersAbove 404350001)
Front Wire Harness: Workman HD (SerialNumbers 313000000 to 314000000)
Front Wire Harness: Workman HD (SerialNumbers 314000001 to 401406000)
Front Wire Harness: Workman HD (SerialNumbers 401406001 to 404350000)
Front Wire Harness: Workman HD (Serial Numbers 404350001 to 409080000)
Front Wire Harness Drawing(Serial Number above 409080000)
Rear Wire Harness Drawing
Serial Number below 409080000)
Rear Wire Harness Drawing(Serial Number above 409080000)
Front Wire Harness: Workman HDX (SerialNumbers 313000001 to 314000000)
Front Wire Harness: Workman HDX (SerialNumbers 314000001 to 316000000)
Front Wire Harness: Workman HDX (SerialNumbers 316000001 to 316999999)
Front Wire Harness: Workman HDX (SerialNumbers 400000000 to 401400000)
Front Wire Harness: Workman HDX (SerialNumbers 401400001 to 404350000)
Front Wire Harness: Workman HDX (SerialNumbers 404350001 to 409100000)
Front Wire Harness Drawing(Serial Number above 409100000)
Rear Wire Harness: Workman HDX (SerialNumbers 313000001 to 315000500)
Rear Wire Harness: Workman HDX (SerialNumbers 315000501 to 316999999)
Rear Wire Harness: Workman HDX (SerialNumbers 400000000 to 401420000)
Rear Wire Harness: Workman HDX (SerialNumbers 401420001 to 409100000)
Rear Wire Harness Drawing(Serial Number above 409100000)
Front Wire Harness: Workman HDX–D (SerialNumber 313000000 to 314000000)
Front Wire Harness: Workman HDX–D (SerialNumber 314000001 to 316000000)
Front Wire Harness: Workman HDX–D (SerialNumber 316000001 to 400000000)
Front Wire Harness: Workman HDX–D (SerialNumber 400000001 to 401420000)
Front Wire Harness: Workman HDX–D (SerialNumber 401420001 to 404350000)
Front Wire Harness: Workman HDX–D (SerialNumber 4043500001 to 408000000)
Workman HDX–D Front Wire Harness Drawing(Serial Number above 408000000)
Rear Wire Harness: Workman HDX–D (SerialNumbers 313000000 to 400000000)
Rear Wire Harness: Workman HDX–D (SerialNumbers 400000001 to 401420000)
Rear Wire Harness: Workman HDX–D (SerialNumbers 401420001 to 408000000)
Workman HDX–D Rear Wire Harness Drawing(Serial Number above 408000000)
Front Wire Harness:Workman HDX–D (Industrial)
Rear Wire Harness:Workman HDX–D (Industrial)
Heater Kit–Wire Harness DrawingWorkman HD Series