Toro Workman HDX Manuals

Manuals and User Guides for Toro Workman HDX. We have 7 Toro Workman HDX manuals available for free PDF download: Service Manual, Operator's Manual, Installation Instructions Manual

Toro Workman HDX 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

Toro Workman HDX Operator's Manual (68 pages)

Brand: Toro | Category: Utility Vehicle | Size: 2.71 MB

Table of Contents
3
Safety
4
- General Safety
  4
- Safety and Instructional Decals
  5
Setup
12
Product Overview
14
- Controls
  14
- Specifications
  19
- Attachments/Accessories
  19
- Before Operation
  20
  - Before Operation Safety
    20
  - Performing Daily Maintenance
    20
  - Checking the Tire Pressure
    20
  - Adding Fuel
    21
  - Breaking in a New Machine
    21
  - Checking the Safety-Interlock System
    22
- During Operation
  22
  - During Operation Safety
    22
  - Operating the Cargo Bed
    24
  - Starting the Engine
    25
  - Engaging the 4-Wheel Drive
    25
  - Driving the Machine
    25
  - Stopping the Machine
    26
  - Shutting off the Engine
    26
  - Using the Differential Lock
    26
  - Using the Hydraulic Control
    26
- After Operation
  28
  - After Operation Safety
    28
  - Transporting the Machine
    28
  - Towing the Machine
    29
  - Towing a Trailer
    29
Maintenance
30
- Recommended Maintenance Schedule(S)
  30
  - Maintaining the Machine under Special Operating Conditions
    32
- Pre-Maintenance Procedures
  32
  - Maintenance Safety
    32
  - Preparing the Machine for Maintenance
    32
  - Using the Bed Support
    33
  - Removing the Full Bed
    34
  - Installing the Full Bed
    34
  - Raising the Machine
    35
  - Removing and Installing the Hood
    36
- Lubrication
  37
  - Greasing the Bearings and Bushings
    37
- Engine Maintenance
  39
  - Engine Safety
    39
  - Servicing the Air Cleaner
    39
  - Servicing the Engine Oil
    40
  - Replacing the Spark Plugs
    42
- Fuel System Maintenance
  42
  - Replacing the Fuel Filter
    42
  - Inspecting Fuel Lines and Connections
    43
- Electrical System Maintenance
  43
  - Electrical System Safety
    43
  - Servicing the Fuses
    43
  - Jump-Starting the Machine
    44
  - Servicing the Battery
    45
- Drive System Maintenance
  45
- Cooling System Maintenance
  49
- Brake Maintenance
  51
- Belt Maintenance
  54
  - Adjusting the Alternator Belt
    54
- Controls System Maintenance
  54
- Hydraulic System Maintenance
  56
- Cleaning
  61
  - Washing the Machine
    61
Storage
62
- Storage Safety
  62
- Storing the Machine
  62
Troubleshooting
63

Toro Workman HDX Operator's Manual (56 pages)

Brand: Toro | Category: Utility Vehicle | Size: 3.19 MB

Table of Contents
2
Introduction
2
Safety
4
- Safe Operating Practices
  4
- Supervisor's Responsibilities
  4
- Before Operating
  4
- Operation
  5
- Maintenance
  6
- Sound Pressure
  6
- Vibration
  6
- Safety and Instructional Decals
  7
1 Installing the Steering Wheel (TC Models Only)

12
2 Installing the ROPS (TC Models Only)

12
- Setup
  12
3 Checking the Fluid Levels

13
- Product Overview
  13
  - Controls
    13
    
    Brake Pedal
    14
    
    Gear Shift Lever
    14
    
    Parking Brake
    14
    
    Differential Lock
    14
    
    Light Switch
    15
    
    Oil Pressure Warning Light
    15
    
    Ignition Switch
    15
    
    Hour Meter
    15
    
    Fuel Gauge
    16
  - Specifications
    17
  - Attachments/Accessories
    17
- Operation
  17
  - Checking the Engine Oil Level
    17
  - Adding Fuel
    18
  - Checking the Cooling System
    19
  - Checking the Transaxle/Hydraulic Fluid Level
    20
  - Checking the High Flow Hydraulic Fluid (TC Models Only)
    20
  - Checking the Front Differential Oil Level (Four-Wheel Drive Models Only)
    21
  - Checking the Torque of the Wheel Nuts
    21
  - Checking the Tire Pressure
    21
  - Checking the Brake Fluid
    22
  - Pre-Starting Checks
    22
  - Starting the Engine
    22
  - Driving the Vehicle
    23
  - Stopping the Vehicle
    23
  - Stopping the Engine
    23
  - Breaking in a New Vehicle
    23
  - Checking the Interlock System
    23
  - Operating Characteristics
    24
  - Passengers
    24
  - Speed
    25
  - Turning
    25
  - Braking
    25
  - Tip Overs
    25
  - Hills
    26
  - Loading and Dumping
    26
  - Using the Differential Lock
    27
  - Four Wheel Drive (Four-Wheel Drive Models Only)
    27
  - Transporting the Vehicle
    27
  - Towing the Vehicle
    28
  - Towing a Trailer with the Vehicle
    28
  - Hydraulic Control
    28
- Maintenance
  30
- Storage
  52
- Schematics
  53

Toro Workman HDX Operator's Manual (60 pages)

Brand: Toro | Category: Utility Vehicle | Size: 2.89 MB

Table of Contents
3
Safety
4
- Safe Operating Practices
  4
- Sound Pressure
  7
- Vibration
  7
- Safety and Instructional Decals
  8
1 Installing the Steering Wheel

13
2 Installing the Rollover-Protection System (ROPS)

13
- Setup
  13
3 Checking the Fluid Levels

14
- Product Overview
  15
  - Controls
    15
    
    Parking Brake
    16
    
    Ignition Switch
    16
    
    Hour Meter
    17
    
    Fuel Gauge
    17
    
    Light Switch
    17
    
    Horn Button
    17
  - Specifications
    18
  - Attachments/Accessories
    18
- Operation
  19
  - Operating the Cargo Box
    19
  - Checking the Engine-Oil Level
    20
  - Responding to a Check-Engine Light
    21
  - Adding Fuel
    21
  - Checking the Coolant Level
    22
  - Checking the Transaxle/Hydraulic-Fluid Level
    23
  - Checking the High Flow Hydraulic-Fluid Level
    24
  - Checking the Front-Differential-Oil Level
    25
  - Checking the Torque of the Wheel Nuts
    25
  - Checking the Tire Pressure
    25
  - Checking the Brake-Fluid Level
    25
  - Starting the Engine
    26
  - Driving the Machine
    26
  - Stopping the Machine
    27
  - Shutting off the Engine
    27
  - Breaking in a New Machine
    27
  - Checking the Safety-Interlock System
    27
  - Ensuring Passenger Safety
    28
  - Ensuring Proper Speed
    28
  - Ensuring Proper Turning
    28
  - Ensuring Proper Braking
    28
  - Preventing Tip Overs
    29
  - Operating on Hills
    29
  - Loading and Dumping
    29
  - Using the Differential Lock
    30
  - Using 4-Wheel Drive
    30
  - Transporting the Machine
    31
  - Towing the Machine
    31
  - Towing a Trailer with the Machine
    31
  - Using the Hydraulic Control
    32
- Maintenance
  34
  - Recommended Maintenance Schedule(S)
    34
    
    Operating in Adverse Conditions
    35
  - Premaintenance Procedures
    36
    
    Using the Bed Support
    36
    
    Removing the Full Bed
    37
    
    Installing the Full Bed
    37
    
    Raising the Machine
    38
    
    Removing the Hood
    39
  - Installing the Hood
    39
- Lubrication
  40
  - Greasing the Bearings and Bushings
    40
- Engine Maintenance
  42
- Fuel System Maintenance
  44
  - Replacing the Fuel Filter
    44
  - Inspecting the Fuel Lines and Connections
    44
- Electrical System Maintenance
  45
  - Servicing the Fuses
    45
  - Jump Starting the Machine
    45
  - Servicing the Battery
    46
- Drive System Maintenance
  47
- Cooling System Maintenance
  49
  - Removing Debris from the Cooling System
    49
  - Changing the Engine Coolant
    50
- Brake Maintenance
  51
  - Adjusting the Parking Brake
    51
  - Adjusting the Brake Pedal
    51
- Belt Maintenance
  52
  - Adjusting the Alternator Belt
    52
- Controls System Maintenance
  53
  - Adjusting the Clutch Pedal
    53
  - Converting the Speedometer
    53
- Hydraulic System Maintenance
  54
- Cleaning
  57
  - Washing the Machine
    57
- Storage
  57

Toro Workman HDX Operator's Manual (60 pages)

Brand: Toro | Category: Utility Vehicle | Size: 3.4 MB

Introduction
2
Table of Contents
3
Safety
4
- Safe Operating Practices
  4
- Sound Pressure
  7
- Vibration
  7
- Safety and Instructional Decals
  8
1 Installing the Steering Wheel (TC Models Only)

13
2 Installing the Rollover Protection System (ROPS)-TC Models Only

13
- Setup
  13
3 Checking the Fluid Levels

14
- Product Overview
  15
  - Controls
    15
    
    Parking Brake
    16
    
    Ignition Switch
    16
    
    Hour Meter
    17
    
    Fuel Gauge
    17
    
    Light Switch
    17
  - Specifications
    18
  - Attachments/Accessories
    18
- Operation
  19
- Maintenance
  34
  - Recommended Maintenance Schedule(S)
    34
    
    Operating in Adverse Conditions
    35
  - Premaintenance Procedures
    36
    
    Using the Bed Support
    36
  - Removing the Full Bed
    37
  - Installing the Full Bed
    37
  - Raising the Machine
    38
  - Removing the Hood
    39
  - Installing the Hood
    39
- Lubrication
  40
  - Greasing the Bearings and Bushings
    40
- Engine Maintenance
  42
- Fuel System Maintenance
  44
  - Replacing the Fuel Filter
    44
  - Inspecting the Fuel Lines and Connections
    44
- Electrical System Maintenance
  45
  - Servicing the Fuses
    45
  - Jump Starting the Machine
    45
  - Servicing the Battery
    46
- Drive System Maintenance
  47
- Cooling System Maintenance
  49
  - Removing Debris from the Cooling System
    49
  - Changing the Engine Coolant
    50
- Brake Maintenance
  51
  - Adjusting the Parking Brake
    51
  - Adjusting the Brake Pedal
    51
- Belt Maintenance
  52
  - Adjusting the Alternator Belt
    52
- Controls System Maintenance
  53
  - Adjusting the Clutch Pedal
    53
  - Converting the Speedometer
    53
- Hydraulic System Maintenance
  54
- Cleaning
  57
  - Washing the Machine
    57
- Storage
  57

Toro Workman HDX Operator's Manual (68 pages)

Brand: Toro | Category: Utility Vehicle | Size: 2.9 MB

Table of Contents
3
Safety
4
General Safety
4
Safety and Instructional Decals
5
Setup
11
Installing the Roll Bar
11
Checking the Fluid Levels and Tire Pressure
12
Burnishing the Brakes
12
Product Overview
13
Controls
13
Specifications
19
Attachments/Accessories
19
Before Operation
20
Before Operation Safety
20
Performing Daily Maintenance
20
Checking the Tire Pressure
20
Adding Fuel
21
Breaking in a New Machine
21
Checking the Safety-Interlock System
22
During Operation
22
During Operation Safety
22
Operating the Cargo Bed
24
Starting the Engine
25
Engaging the 4-Wheel Drive
25
Driving the Machine
25
Stopping the Machine
26
Shutting off the Engine
26
Using the Differential Lock
26
Using the Hydraulic Control
26
After Operation
28
After Operation Safety
28
Hauling the Machine
29
Towing the Machine
29
Towing a Trailer
29
Maintenance
30
Maintenance Safety
30
Recommended Maintenance Schedule(S)
31
Maintaining the Machine under Special Operating Conditions
33
Pre-Maintenance Procedures
33
Preparing the Machine for Maintenance
33
Using the Bed Support
33
Removing the Full Bed
34
Installing the Full Bed
35
Raising the Machine
36
Removing and Installing the Hood
36
Lubrication
37
Greasing the Bearings and Bushings
37
Engine Maintenance
39
Engine Safety
39
Servicing the Air Cleaner
39
Servicing the Engine Oil
40
Replacing the Spark Plugs
42
Fuel System Maintenance
43
Replacing the Fuel Filter
43
Inspecting Fuel Lines and Connections
43
Electrical System Maintenance
44
Electrical System Safety
44
Servicing the Fuses
44
Jump-Starting the Machine
44
Servicing the Battery
45
Drive System Maintenance
46
Checking the Front Differential-Oil Level
46
Changing the Front Differential Oil
46
Inspecting the Constant-Velocity Boot
47
Adjusting the Shift Cables
47
Adjusting the High-Low Cable
47
Adjusting Differential-Lock Cable
47
Inspecting the Tires
48
Checking the Front Wheel Alignment
48
Torquing the Wheel Lug Nuts
49
Cooling System Maintenance
50
Cooling System Safety
50
Checking the Engine-Coolant Level
50
Removing Debris from the Cooling System
51
Changing the Engine Coolant
51
Brake Maintenance
52
Checking the Brake-Fluid Level
52
Adjusting the Parking Brake
52
Adjusting the Brake Pedal
53
Belt Maintenance
54
Adjusting the Alternator Belt
54
Controls System Maintenance
55
Adjusting the Clutch Pedal
55
Adjusting the Accelerator Pedal
56
Hydraulic System Maintenance
56
Hydraulic System Safety
56
Servicing the Transaxle/Hydraulic System
56
Servicing the High-Flow Hydraulic System
59
Raising the Cargo Bed in an Emergency
60
Cleaning
62
Washing the Machine
62
Storage
63
Storage Safety
63
Storing the Machine
63
Troubleshooting
64

Toro Workman HDX Installation Instructions Manual (24 pages)

Brand: Toro | Category: Utility Vehicle | Size: 3.45 MB

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Toro Workman HDX Manuals

Toro Workman HDX 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

Chapter 6 Drive Train

Chapter 7 -- Chassis

Chapter 7 Chassis

Chapter 8 Electrical System

Chapter 9 Hydraulic System

Chapter 10 Front Wheel Drive (4Wd)

Toro Workman HDX Operator's Manual (68 pages)

Table of Contents

Toro Workman HDX Operator's Manual (56 pages)

Table of Contents

1 Installing the Steering Wheel (TC Models Only)

2 Installing the ROPS (TC Models Only)

3 Checking the Fluid Levels

Toro Workman HDX Operator's Manual (60 pages)

Table of Contents

1 Installing the Steering Wheel

2 Installing the Rollover-Protection System (ROPS)

3 Checking the Fluid Levels

Toro Workman HDX Operator's Manual (60 pages)

Table of Contents

1 Installing the Steering Wheel (TC Models Only)

2 Installing the Rollover Protection System (ROPS)-TC Models Only

3 Checking the Fluid Levels

Toro Workman HDX Operator's Manual (68 pages)

Table of Contents

Toro Workman HDX Installation Instructions Manual (24 pages)

Table of Contents

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