Toro Workman HDX--D Manuals

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

Toro Workman HDX--D 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--D Operator's Manual (60 pages)

Utility Vehicle with Bed

Brand: Toro | Category: Utility Vehicle | Size: 2.86 MB

Introduction
2
Table of Contents
3
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 Activating and Charging the Battery

13
- Only)
  13
4 Checking Fluid Levels

14
- Product Overview
  15
  - Controls
    15
    
    Ignition Switch
    16
    
    Parking Brake
    16
    
    Hour Meter
    16
    
    Fuel Gauge
    17
    
    Light Switch
    17
    
    Oil Pressure Warning Light
    17
  - Specifications
    18
  - Attachments/Accessories
    18
- Operation
  19
  - Checking the Engine Oil Level
    19
  - Adding Fuel
    19
  - Checking the Coolant Level
    21
  - Checking the Transaxle/Hydraulic Fluid Level
    22
  - Checking the High Flow Hydraulic Fluid (TC Models Only)
    22
  - Checking the Front Differential Oil Level (Four-Wheel Drive Models Only)
    23
  - Checking the Torque of the Wheel Nuts
    23
  - Checking the Tire Pressure
    23
  - Checking the Brake Fluid
    23
  - Pre-Starting Checks
    24
  - Starting the Engine
    24
  - Driving the Vehicle
    24
  - Stopping the Vehicle
    25
  - Stopping the Engine
    25
  - New Vehicle Break-In
    25
  - Checking the Interlock System
    25
  - Operating Characteristics
    25
  - Passengers
    26
  - Speed
    27
  - Turning
    27
  - Braking
    27
  - Tip Overs
    27
  - Hills
    27
  - Loading and Dumping
    28
  - Using the Differential Lock
    28
  - Four Wheel Drive (Four-Wheel Drive Models Only)
    29
  - Transporting the Vehicle
    29
  - Towing the Vehicle
    29
  - Towing a Trailer with the Vehicle
    30
  - Hydraulic Control
    30
- Maintenance
  32
- Storage
  54
- Schematics
  55

Toro Workman HDX--D Operator's Manual (60 pages)

Utility Vehicle with Bed

Brand: Toro | Category: Utility Vehicle | Size: 2.57 MB

Table of Contents
3
Safety
4
- Operation
  4
- Sound Pressure
  6
- Vibration
  6
- Safety and Instructional Decals
  7
1 Installing the Steering Wheel (TC Models Only)

12
2 Installing the Rollover Protection System (ROPS)

12
- Setup
  12
3 Checking the Fluid Levels

13
- Product Overview
  14
  - Controls
    14
    
    Accelerator Pedal
    14
    
    Differential Lock
    14
    
    Brake Pedal
    14
    
    Parking Brake
    15
    
    Hour Meter
    16
    
    Light Switch
    16
    
    Fuel Gauge
    16
    
    Oil Pressure Warning Light
    16
  - Specifications
    17
  - Attachments/Accessories
    17
- Operation
  18
- Maintenance
  32
  - Recommended Maintenance Schedule(S)
    32
    
    Operating in Adverse Conditions
    33
  - Premaintenance Procedures
    34
    
    Using the Bed Support
    34
    
    Removing the Full Bed
    35
    
    Installing the Full Bed
    35
  - Raising the Machine
    36
  - Removing the Hood
    37
  - Installing the Hood
    37
- Lubrication
  38
  - Greasing the Bearings and Bushings
    38
- Engine Maintenance
  40
  - Servicing the Air Cleaner
    40
  - Changing the Engine Oil and Filter
    40
- Fuel System Maintenance
  41
  - Checking the Fuel Lines and Connections
    41
  - Servicing the Fuel Filter/Water Separator
    41
- Electrical System Maintenance
  42
  - Servicing the Fuses
    42
  - Jump Starting the Machine
    43
  - Servicing the Battery
    44
- Drive System Maintenance
  44
- Cooling System Maintenance
  47
  - Removing Debris from the Cooling System
    47
  - Changing the Engine Coolant
    47
- Brake Maintenance
  48
  - Adjusting the Parking Brake
    48
  - Adjusting the Brake Pedal
    49
- Belt Maintenance
  50
  - Adjusting the Alternator Belt
    50
- Controls System Maintenance
  50
- Hydraulic System Maintenance
  52
- Cleaning
  55
  - Washing the Machine
    55
- Storage
  55

Toro Workman HDX--D Operator's Manual (68 pages)

Brand: Toro | Category: Utility Vehicle | Size: 2.88 MB

Table of Contents
3
Safety
4
General Safety
4
Safety and Instructional Decals
5
Setup
12
Installing the Steering Wheel
12
Installing the Roll Bar
13
Checking the Fluid Levels and Tire Pressure
13
Burnishing the Brakes
13
Product Overview
14
Controls
14
Specifications
20
Attachments/Accessories
20
Before Operation
21
Before Operation Safety
21
Performing Daily Maintenance
21
Checking the Tire Pressure
21
Adding Fuel
22
Breaking in a New Machine
22
Checking the Safety-Interlock System
23
During Operation
23
During Operation Safety
23
Operating the Cargo Bed
25
Starting the Engine
26
Engaging the 4-Wheel Drive
26
Driving the Machine
27
Stopping the Machine
27
Shutting off the Engine
27
Using the Differential Lock
27
Using the Hydraulic Control
28
After Operation
30
After Operation Safety
30
Hauling the Machine
30
Towing the Machine
30
Towing a Trailer
31
Maintenance
32
Maintenance Safety
32
Recommended Maintenance Schedule(S)
33
Maintaining the Machine under Special Operating Conditions
35
Pre-Maintenance Procedures
35
Preparing the Machine for Maintenance
35
Using the Bed Support
35
Removing the Full Bed
36
Installing the Full Bed
37
Raising the Machine
38
Removing and Installing the Hood
38
Lubrication
39
Greasing the Bearings and Bushings
39
Engine Maintenance
41
Engine Safety
41
Servicing the Air Cleaner
41
Servicing the Engine Oil
42
Fuel System Maintenance
44
Servicing the Fuel Filter/Water Separator
44
Inspecting Fuel Lines and Connections
44
Electrical System Maintenance
45
Electrical System Safety
45
Servicing the Fuses
45
Jump-Starting the Machine
45
Servicing the Battery
46
Drive System Maintenance
47
Checking the Front Differential-Oil Level
47
Changing the Front Differential Oil
47
Inspecting the Constant-Velocity Boot
47
Adjusting the Shift Cables
48
Adjusting the High-Low Cable
48
Adjusting Differential-Lock Cable
48
Inspecting the Tires
49
Checking the Front Wheel Alignment
49
Torquing the Wheel Lug Nuts
50
Cooling System Maintenance
51
Cooling System Safety
51
Checking the Engine-Coolant Level
51
Removing Debris from the Cooling System
52
Changing the Engine Coolant
52
Brake Maintenance
53
Checking the Brake-Fluid Level
53
Adjusting the Parking Brake
53
Adjusting the Brake Pedal
54
Belt Maintenance
55
Adjusting the Alternator Belt
55
Controls System Maintenance
56
Adjusting the Clutch Pedal
56
Adjusting the Accelerator Pedal
57
Hydraulic System Maintenance
57
Hydraulic System Safety
57
Servicing the Transaxle/Hydraulic System
57
Servicing the High-Flow Hydraulic System
60
Raising the Cargo Bed in an Emergency
61
Cleaning
63
Washing the Machine
63
Storage
64
Storage Safety
64
Storing the Machine
64
Troubleshooting
65

Toro Workman HDX--D Operator's Manual (56 pages)

Industrial Utility Vehicle with Bed

Brand: Toro | Category: Utility Vehicle | Size: 2.83 MB

Introduction
2
Table of Contents
3
Safety
4
- Safe Operating Practices
  4
- Supervisor's Responsibilities
  4
- Before Operating
  4
- Operation
  5
- Maintenance
  6
- Sound Pressure
  6
- Vibration
  6
- Sound Level Certification
  7
- Safety and Instructional Decals
  8
Setup
13
- Checking the Fluid Levels
  13
Product Overview
14
- Controls
  14
  - Hour Meter
    15
  - Oil Pressure Warning Light
    15
  - Ignition Switch
    15
  - Horn Button
    16
  - Fuel Gauge
    16
- Specifications
  17
- Attachments/Accessories
  17
Operation
18
- Checking the Engine Oil Level
  18
- Adding Fuel
  19
- Checking the Coolant Level
  20
- Checking the Transaxle/Hydraulic Fluid Level
  20
- Checking the High Flow Hydraulic Fluid (if so Equipped)
  21
- Checking the Front Differential Oil Level (Four Wheel Drive Models Only)
  21
- Checking the Torque of the Wheel Nuts
  22
- Checking the Tire Pressure
  22
- Checking the Brake Fluid
  22
- Pre-Starting Checks
  23
- Starting the Engine
  23
- Driving the Vehicle
  23
- Stopping the Vehicle
  24
- Stopping the Engine
  24
- New Vehicle Break-In
  24
- Checking the Interlock System
  24
- Operating Characteristics
  25
- Passengers
  25
- Speed
  26
- Turning
  26
- Braking
  26
- Tip Overs
  26
- Hills
  27
- Loading and Dumping
  27
- Four Wheel Drive (Four Wheel Drive Models Only)
  28
- Transporting the Vehicle
  28
- Towing the Vehicle
  28
- Towing a Trailer with the Vehicle
  29
Maintenance
30
Storage
50
Schematics
51

Toro Workman HDX--D Operator's Manual (56 pages)

Industrial Utility Vehicle with Bed

Brand: Toro | Category: Utility Vehicle | Size: 2.53 MB

Introduction
2
Table of Contents
4
Safety
5
- Safe Operating Practices
  5
- Supervisor's Responsibilities
  5
- Before Operating
  5
- Operation
  6
- Maintenance
  7
- Sound Pressure
  7
- Vibration
  7
- Sound Level Certification
  7
- Safety and Instructional Decals
  8
Setup
13
- Checking the Fluid Levels
  13
Product Overview
14
- Controls
  14
  - Oil Pressure Warning Light
    15
  - Ignition Switch
    15
  - Hour Meter
    15
  - Fuel Gauge
    16
  - Horn Button
    16
- Specifications
  17
- Attachments/Accessories
  17
Operation
17
- Checking the Engine-Oil Level
  17
- Adding Fuel
  18
- Checking the Coolant Level
  19
- Checking the Transaxle/Hydraulic Fluid Level
  19
- Checking the High-Flow Hydraulic Fluid (if so Equipped)
  20
- Checking the Front-Differential-Oil Level (Four-Wheel-Drive Models Only)
  20
- Checking the Torque of the Wheel Nuts
  21
- Checking the Tire Pressure
  21
- Checking the Brake Fluid
  21
- Pre-Starting Checks
  22
- Starting the Engine
  22
- Driving the Vehicle
  22
- Stopping the Vehicle
  23
- Stopping the Engine
  23
- Break-In New Vehicle
  23
- Checking the Interlock System
  23
- Operating Characteristics
  23
- Passengers
  24
- Speed
  24
- Turning the Vehicle
  25
- Braking the Vehicle
  25
- Preventing Tip Overs
  25
- Operating the Vehicle on Hills
  25
- Loading Onto and Dumping from the Vehicle
  26
- Four Wheel Drive (Four-Wheel-Drive Models Only)
  26
- Transporting the Vehicle
  26
- Towing the Vehicle
  27
- Towing a Trailer with the Vehicle
  27
Maintenance
28
Storage
49
Schematics
50

Toro Workman HDX--D Operator's Manual (48 pages)

Industrial Utility Vehicle with Bed

Brand: Toro | Category: Utility Vehicle | Size: 2.32 MB

Introduction
2
Table of Contents
3
Safety
4
- Safe Operating Practices
  4
- Supervisor's Responsibilities
  4
- Before Operating
  4
- Operation
  4
- Maintenance
  5
- Safety and Instructional Decals
  7
Setup
11
- Checking the Fluid Levels
  11
Product Overview
12
- Controls
  12
  - Hour Meter
    13
  - Ignition Switch
    13
  - Fuel Gauge
    14
  - Horn Button
    14
- Specifications
  15
- Attachments/Accessories
  15
Operation
15
- Checking the Engine-Oil Level
  15
- Adding Fuel
  16
- Checking the Coolant Level
  17
- Checking the Transaxle/Hydraulic-Fluid Level
  17
- Checking the Torque of the Wheel Nuts
  18
- Checking the Tire Pressure
  18
- Checking the Brake-Fluid Level
  18
- Pre-Starting Checks
  19
- Starting the Engine
  19
- Driving the Vehicle
  20
- Stopping the Vehicle
  20
- Stopping the Engine
  20
- Breaking-In a New Vehicle
  20
- Checking the Interlock System
  20
- Operating Characteristics
  21
- Ensuring Passenger Safety
  21
- Ensuring Proper Speed
  22
- Ensuring Proper Turning
  22
- Ensuring Proper Braking
  22
- Preventing Tip Overs
  22
- Operating the Vehicle on Hills
  23
- Loading Onto and Dumping from the Vehicle
  23
- Transporting the Machine
  24
- Towing the Machine
  24
- Towing a Trailer with the Machine
  24
Maintenance
25
- Recommended Maintenance Schedule(S)
  25
  - Using the Machine During Heavy-Duty Operation
    26
- Premaintenance Procedures
  26
  - Removing the Full Bed
    26
  - Installing the Full Bed
    27
  - Raising the Machine
    27
  - Removing the Hood
    28
  - Installing the Hood
    28
- Lubrication
  29
  - Greasing Bearings and Bushings
    29
- Engine Maintenance
  30
  - Servicing the Air Cleaner
    30
- Changing the Engine Oil and Filter
  31
Fuel System Maintenance
32
- Fuel Lines and Connections
  32
- Servicing the Water Separator/Fuel Filter
  32
Electrical System Maintenance
33
- Servicing the Battery
  33
- Jump Starting the Vehicle
  33
- Fuses
  34
Drive System Maintenance
35
Cooling System Maintenance
36
- Removing Debris from the Cooling System
  36
- Changing the Engine Coolant
  37
Brake Maintenance
38
- Adjusting the Parking Brake
  38
- Adjusting the Brake Pedal
  38
Belt Maintenance
39
- Adjusting the Alternator Belt
  39
Controls System Maintenance
40
Hydraulic System Maintenance
42
- Changing the Hydraulic Fluid and Cleaning the Strainer
  42
- Replacing the Hydraulic Filter
  43
Cleaning
43
- Washing the Machine
  43
Storage
44

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Toro Workman HDX--D Manuals

Toro Workman HDX--D 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--D Operator's Manual (60 pages)

Table of Contents

1 Installing the Steering Wheel(TC Models Only)

2 Installing the ROPS(TC Models Only)

3 Activating and Charging the Battery

4 Checking Fluid Levels

Toro Workman HDX--D Operator's Manual (60 pages)

Table of Contents

1 Installing the Steering Wheel (TC Models Only)

2 Installing the Rollover Protection System (ROPS)

3 Checking the Fluid Levels

Toro Workman HDX--D Operator's Manual (68 pages)

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