Toro Workman HDX Auto Service Repair Manual

Table of Content – Workman HDX Auto

Title Page
Revision History
Reader Comments
Preface
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
Decimal and Millimeter Equivalents
U.S. to Metric 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 – Kohler Gasoline Engine
Specifications
General Information
Operator’s Manual
Kohler Aegis Service Repair Manual
Engine Electronic Control Unit (ECU)
Adjustments
Adjust Accelerator Control
Service and Repairs
Accelerator Control
Air Cleaner System
Fuel Tank
Fuel Evaporative Control System
Fuel Pump
Exhaust System
Radiator
Oil Filter Assembly
Engine
KOHLER AEGIS Service Repair Manual
4 – Drive Train
Specifications
General Information
Operator’s Manual
Drive Train Operation
Drive Train Operation
Clutch System Operation
Primary Clutch Operation
Secondary Clutch Operation
Special Tools
Clutch Removal Tools
Piston Installation Tool
Secondary Clutch Press Tool
Troubleshooting
Clutch
Transmission
Adjustments
Shift Cable Adjustment
Service and Repairs
Shift Cable
Bleed Speed Control System
Speed Control System
Speed Limiter Assembly
Speed Limiter Cover Service
CVT Enclosure Cover
CVT Drive Belt
Primary and Secondary Clutches
Primary Clutch Service
Secondary Clutch Service
Rear CV (Constant Velocity) Axles
Rear Driveshaft
Rear Driveshaft Cross and Bearing Service
Rear Differential
Rear Differential Service
Transmission
Transmission Service
5 – Chassis
Specifications
General Information
Operator’s Manual
Tire Pressure
Special Tools
Compression Spring Tool
Troubleshooting
Suspension and Steering
Brakes
Adjustments
Parking Brake Adjustment
Front Wheel Alignment
Service and Repairs
Wheel Assembly
Brake System
Brake Caliper Service
Bleed Brake System
Brake Master Cylinder
Brake Master Cylinder Service
Parking Brake Cable
Parking Brake Caliper
Wheel Hub
Steering Assembly
Front Control Arms
Front Compression Spring Service
Front Shock Absorber
Rear Shock Absorber
Rear Leaf Spring
Steering Wheel
Seat Base
Hood
Windshield Wiper Assembly (Machines with Operator Cab)
6 – Electrical System
General Information
Operator’s Manual
Electrical Drawings
Special Tools
Digital Multimeter
Dielectric Gel
Battery Hydrometer
Battery Terminal Protector
Spark Tester
Troubleshooting
Electrical System Quick Checks
Battery Test (Open Circuit Test)
Charging System Test
Verify Interlock System Operation
Component Testing
Ignition (Key) Switch
Gauge Cluster
Fuses
Headlight Switch
Rear Differential Lock Switch
Brake Switch
Parking Brake Switch
Hydraulic Lift Lever Interlock Switch
High Flow Hydraulics Switch (Vehicles with High Flow Hydraulics)
Front Differential Interrupter Switch (Vehicles with 4WD)
Main Power Relay (Four Terminals)
Relays with Five (5) Terminals
Diode Assemblies
Fusible Link
Fuel Gauge Sender
Fuel Pump
Temperature Sender
Speed Sensor
Hydraulic Solenoid Valve Coil (Vehicles with High Flow Hydraulics Kit)
Windshield Washer, Wiper Switch (Machines with Operator Cab)
Service and Repairs
Battery Storage
Battery Care
Battery Service
Headlights
Tail Lights
7 – Hydraulic System
Specifications
General Information
Operator’s Manual
Check Hydraulic Oil
Relieving Hydraulic System Pressure
Hydraulic Hoses
Hydraulic Hose and Tube Installation (O-Ring Face Seal Fitting)
Hydraulic Fitting Installation (SAE Straight Thread O-Ring Fitting into Component Port)
Hydraulic Schematic
Hydraulic Circuit Operation
Steering Circuit
Raise and Lower Bed
High Flow Hydraulic Circuit
Special Tools
Hydraulic Pressure Test Kit
Hydraulic Tester (Pressure and Flow)
Hydraulic Test Fitting Kit
O-ring Kit
Male Coupler (For High Flow Hydraulics)
Troubleshooting
Testing
Gear Pump Flow and System Relief Pressure
Steering Control Valve and Steering Cylinder
Lift Cylinder Internal Leakage
High Flow Hydraulics Gear Pump Flow and System Relief Pressure
Service and Repairs
General Precautions for Removing and Installing Hydraulic System Components
Check Hydraulic Lines and Hoses
Hydraulic Reservoir
Gear Pump (Vehicles with Standard Hydraulics)
Gear Pump Service (Vehicles with Standard Hydraulics)
Gear Pump (Vehicles with High Flow Hydraulics)
Gear Pump Service (Vehicles with High Flow Hydraulics)
Lift Valve
Lift Valve Service
Steering Control Valve
Steering Control Valve Service
Steering Cylinder
Steering Cylinder Service
Lift Cylinder
Lift Cylinder Service
Hydraulic Manifold (Vehicles with High Flow Hydraulics)
DANFOSS STEERING UNIT TYPE OSPMService Repair Manual
8 – Four Wheel Drive (Optional Kit)
Specifications
General Information
Front Wheel Drive Operation
Installation Instructions
Service and Repairs
CV (Constant Velocity) Axle Assembly
Front Differential Driveshaft
Driveshaft Cross and Bearing Service
Front Differential
Front Differential Service
HILLIARD FRONT DRIVE SYSTEM DIFFERENTIALPARTS and Service Repair Manual
9 – Electrical Drawings
Electrical Drawing Designations
Wire Color
Wire Size
Electrical Schematic (SerialNumbers 314000001 to 403430000)
Electrical Schematic (SerialNumbers Above 403430001)
Front Wire Harness (Serial NumbersBelow 316000000)
Front Wire Harness (Serial Numbers316000001 to 403430000)
Front Wire Harness (Serial NumbersAbove 403430001)
Rear Wire Harness
Rear Differential Solenoid ControllerWire Harness
Heater Kit–Wire Harness Drawing