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Toro Workman HD Series User Manual

Toro Workman HD Series
328 pages
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Part No. 14208SL
Service Manual
Workman
R
HD Series
HD Model 07369 S/N 314000001 & Up,
HDX/HDX- D Models with Kubota Gasoline & Diesel Engines
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Workman HD, HDX and HDX- D vehicles.
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE AND ADJUSTMENT
INSTRUCTIONS. For reference, insert a copy of the
Operators Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator’s Manual and Parts Catalog are avail-
able on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
EThe Toro Company - 2014

Table of Contents

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Toro Workman HD Series Specifications

General IconGeneral
BrandToro
ModelWorkman HD Series
CategoryUtility Vehicle
LanguageEnglish

Summary

Chapter 1 Safety

Safety Instructions

Provides essential safety guidelines for operating and maintaining the Workman HD series vehicles.

Before Operating

Details crucial checks and procedures to follow before starting and operating the vehicle.

While Operating

Outlines safe practices and precautions to be observed while the vehicle is in operation.

Chapter 3 Kubota EFI Gasoline Engine

Kubota EFI Gasoline Engine Service and Repairs

Details procedures for servicing and repairing the engine's air cleaner system.

Chapter 4 Kubota Diesel Engine

Kubota Diesel Engine Service and Repairs

Covers service and repair procedures for the diesel engine's air cleaner system.

Chapter 5 Kohler Air Cooled Gasoline Engine

Kohler Air Cooled Gasoline Engine Service and Repairs

Details procedures for servicing and repairing the engine's cooling system.

Engine Removal and Installation

Details the procedures for removing and installing the engine, including associated systems and components.

Chapter 6 Drive Train

Drive Train Troubleshooting

Provides a guide to diagnosing common problems related to the clutch system.

Clutch Troubleshooting

Lists common clutch problems and their possible causes, such as slipping, rough operation, or noise.

Transaxle Troubleshooting

Diagnoses common transaxle issues like noisy operation, difficult shifting, or sticking in gear.

Drive Train Service and Repairs

Details the procedures for replacing the shift cable, including removal and installation steps.

Shift Cable Replacement

Provides instructions for removing and installing the shift cable for proper transmission control.

Transaxle Service

Details the procedures for transaxle removal, installation, disassembly, inspection, and assembly.

Transaxle Removal

Provides detailed steps for safely removing the transaxle from the vehicle.

Transaxle Installation

Outlines the procedure for correctly installing the transaxle, including torque specifications.

Clutch Service

Covers procedures for servicing the clutch, including release mechanism inspection and assembly.

Clutch Disassembly and Inspection

Details the process of disassembling and inspecting clutch components for wear or damage.

Transaxle Disassembly

Step-by-step guide for disassembling the transaxle, starting with the extension and bell housing.

Transaxle Inspection

Outlines inspection procedures for various transaxle components like synchronizers, gears, and shafts.

Chapter 7 Chassis

Chassis Troubleshooting

Helps diagnose common suspension and steering problems like front or rear end noise and excessive play.

Suspension and Steering Troubleshooting

Lists possible causes for issues such as front end noise, excessive steering play, and instability (wander).

Brake System Troubleshooting

Diagnoses common brake problems including pedal issues, pulling, dragging, and fading.

Chassis Service and Repairs

Details procedures for servicing the wheel assembly, including removal and installation of wheels and hubs.

Wheel Assembly Service

Covers the removal and installation procedures for wheels, brake rotors, and calipers.

Brake System Service

Details the procedures for removing and installing brake calipers and connecting brake lines.

Brake Caliper Service

Provides instructions for disassembling, inspecting, and assembling the brake caliper components.

Bleed Brake System

Explains the procedure for bleeding the brake system to remove air and ensure proper brake operation.

Brake Master Cylinder Service

Covers the removal, installation, disassembly, and assembly of the brake master cylinder.

Brake Master Cylinder Service Procedures

Details the disassembly, inspection, and assembly procedures for the brake master cylinder.

Parking Brake Cable Service

Provides instructions for removing and installing the parking brake cable and its related components.

Wheel Hub Service

Covers removal, installation, and inspection of wheel hub assemblies, including spindle nuts and studs.

Steering Assembly Service

Details the removal, installation, and disassembly/assembly of steering components like tie rods and knuckles.

Chapter 8 Electrical System

Electrical System Troubleshooting

Provides a table of common electrical problems and their possible causes.

Verify Interlock System Operation

Explains how to test the clutch, hydraulic lift, and PTO interlock switches for proper function.

Electrical Component Testing

Defines electrical component operations and provides test procedures for various components.

Clutch Switch Testing

Details testing procedures for the clutch proximity switch and the 4WD clutch switch.

Brake Switch Testing

Explains how to test brake switches for continuity, covering both 2WD and 4WD units.

Hydraulic Lift Lever Interlock Switch Test

Describes testing the interlock switch for continuity based on lift lever position.

Electrical System Service and Repairs

Covers battery storage, care, and service procedures, including testing and charging.

Battery Service Procedures

Covers battery removal, installation, inspection, and maintenance for optimal performance and life.

Battery Testing Methods

Explains how to perform hydrometer and load tests to assess battery condition and voltage.

Chapter 9 Hydraulic System

Hydraulic System Troubleshooting

Provides a guide to diagnosing common hydraulic problems like leaks, noise, overheating, and slow operation.

Steering Inoperative or Sluggish Diagnosis

Diagnoses steering issues related to engine RPM, oil level, binding components, or pump problems.

Hydraulic System Testing Procedures

Provides essential precautions, procedures, and equipment requirements for hydraulic system testing.

Precautions For Hydraulic Testing

Details critical safety warnings and procedures, including pressure relief and handling of hot oil.

Primary Hydraulic System Gear Pump Flow Test (Workman HDX/HDX-D)

Provides procedure for testing the primary gear pump flow and relief pressure on HDX/HDX-D models.

Primary Hydraulic System Gear Pump Flow Test (Workman HD)

Details the procedure for testing the primary gear pump flow on Workman HD vehicles.

Primary Hydraulic System Relief Valve Pressure Test

Explains how to test the relief valve pressure integrated into the steering control valve.

Steering Control Valve and Steering Cylinder Test

Details testing procedures for the steering control valve and steering cylinder for proper operation.

Procedure for Steering Control Valve and Steering Cylinder Test

Provides steps to test steering performance and diagnose issues with the steering cylinder.

Lift Cylinder Internal Leakage Test

Describes the procedure to test the lift cylinder for internal leaks.

Procedure for Lift Cylinder Internal Leakage Test

Outlines the steps to test the lift cylinder for internal oil leakage.

High Flow Hydraulic System Gear Pump and Relief Pressure Tests

Details testing the high flow gear pump flow and relief valve pressure.

Procedure for High Flow Hydraulics System Gear Pump Flow and Relief Pressure Tests

Provides steps for testing high flow pump flow and relief pressure, including safety precautions.

Hydraulic System Service and Repairs

Covers general precautions for removing/installing components and checking hydraulic lines/hoses.

General Precautions for Hydraulic Component Service

Provides essential safety precautions and cleaning procedures before and after hydraulic work.

Primary Hydraulic System Gear Pump Service (Workman HDX/HDX-D)

Details the removal, installation, and service procedures for the primary gear pump on HDX/HDX-D models.

Primary Hydraulic System Gear Pump Service (Workman HD)

Provides procedures for removing, installing, and servicing the gear pump on Workman HD vehicles.

High Flow Hydraulic System Gear Pump Service

Details the service procedures for the two-section gear pump used in the high flow hydraulics kit.

Lift Valve Service

Covers removal, installation, disassembly, inspection, and assembly of the lift valve.

Steering Control Valve Service

Covers removal, installation, and testing of the steering control valve.

Steering Cylinder Service

Covers removal, installation, disassembly, inspection, and assembly of the steering cylinder.

Lift Cylinder Service

Covers removal, installation, disassembly, inspection, and assembly of the lift cylinder.

Chapter 10 Front Wheel Drive (4WD)

Front Wheel Drive (4WD) Service and Repairs

Covers procedures for servicing the CV axle assembly, including removal, installation, and inspection.

CV Axle Assembly Service

Details removal, installation, and assembly of the CV axle assembly.

Inspect CV Axle Boot and Test CV Axle

Provides procedures for inspecting the CV axle boot and testing the CV axle joint for problems.

Front Differential Service

Covers removal, installation, and service procedures for the front differential assembly.

Front Differential Service Procedures

Details the disassembly, inspection, and assembly procedures for the front differential.

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