Toro 07390 Workman HDX-Auto Service Manual Download

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Form No. 15217SL Rev C

Workman

HDX Auto

Original Instructions (EN)

Summary of Contents for 07390 Workman HDX-Auto

Page 1: ...Form No 15217SL Rev C Workman HDX Auto Original Instructions EN...

Page 2: ...ent or the disclosure of its content This document shall not be reproduced by a third party without the express written consent of The Toro Company and or the appropriate affiliated company Revision H...

Page 3: ...lications To do this effectively we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or...

Page 4: ...NOTES _...

Page 5: ...nual 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 publicatio...

Page 6: ...Workman HDX Auto This page is intentionally blank...

Page 7: ...rs 5 10 Chapter 6 Electrical System Electrical Schematics 6 2 Special Tools 6 3 Troubleshooting 6 5 Electrical System Quick Checks 6 7 Component Testing 6 9 Service and Repairs 6 31 Chapter 7 Hydrauli...

Page 8: ...Workman HDX Auto This page is intentionally blank...

Page 9: ...age 1 1 Safety Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 3 Maintenance and Service 4 Jacking Vehicle 5 Using Bed Safety Support 6 SAFETY AND INSTRUCTI...

Page 10: ...and operating the vehicle Become familiar with the controls and know how to stop the vehicle and engine quickly Additional copies of the Operator s Manual are available on the internet at www Toro co...

Page 11: ...dal F Turn ignition key to START Release key when engine starts 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not t...

Page 12: ...ust be running to perform maintenance or an adjustment keep clothing hands feet and other parts of the body away from moving parts Keep by standers away 11 Do not overspeed the engine by changing gove...

Page 13: ...hicle is on jack because engine vibration or wheel movement could cause ve hicle to slip off jack 2 Do not work under vehicle without jack stands sup porting it The vehicle could slip off jack injurin...

Page 14: ...ROPS panel and lower bed 1 Raise bed until lift cylinders are fully extended 2 Remove bed safety support from storage brackets on back of ROPS panel 3 Push bed safety support onto cylinder rod making...

Page 15: ...or s Manual and Parts Catalog for your Workman HDX Auto vehicle at the end of this chapter Refer to Operator s Manual for recommended mainte nance intervals Additionally insert Installation Instruc ti...

Page 16: ...0 09375 Workman HDX Auto Page 2 2 Product Records and Maintenance Equivalents and Conversions...

Page 17: ...d or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Fastener Identification Figure 1 Grade 1 Grade 5 Grade 8 Inch...

Page 18: ...5 58 7 3 8 24 UNF 17 2 18 2 24 3 35 4 47 5 50 6 68 8 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15...

Page 19: ...14 N m M16 X 2 0 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m NOTE Reduce torque values listed in the table above by 25 for lubricated fas...

Page 20: ...in lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5...

Page 21: ...rvice Manual 3 Engine Electronic Control Unit ECU 3 ADJUSTMENTS 4 Adjust Accelerator Control 4 SERVICE AND REPAIRS 5 Accelerator Control 5 Air Cleaner System 6 Fuel Tank 8 Fuel Evaporative Control Sys...

Page 22: ...nted Fuel Unleaded Regular Gasoline Minimum 87 Octane Fuel Tank Capacity 6 5 U S gallons 24 6 liters Governor Mechanical Idle Speed no load 1250 to 1350 RPM High Idle no load 3550 to 3650 RPM Oil Pump...

Page 23: ...he Workman Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Workman HDX Auto ve hicle The Kohler Owner s Manual includes informatio...

Page 24: ...st engine idle speed screw so that idle speed is correct The engine idle speed screw is located on the engine intake manifold throttle body 5 Make sure that transmission lever is in the park posi tion...

Page 25: ...oosen flange nut item 5 in Fig 5 and move throttle lever until ball bearing is in light contact with bellcrank Tighten nut after adjustment 3 Make sure that the engine governor spring is at the end of...

Page 26: ...er Gasoline Engine Air Cleaner System Figure 6 1 Engine 2 Hose clamp 2 3 Intake hose 4 Air cleaner assembly 5 Air inlet hood 6 Mounting bracket 7 Flange head screw 2 8 Flange nut 2 FRONT RIGHT 2 3 6 1...

Page 27: ...stallation Fig 6 IMPORTANT Any leaks in the air filter system will cause serious engine damage Make sure daily that all air cleaner components are in good condition and are properly secured during ass...

Page 28: ...head screw 2 9 Fuel tank cap 10 Fuel pump assembly 11 Carbon canister 12 Hose clamp 2 13 Fuel hose 14 Fresh air filter 15 Vacuum check valve 16 Hose clamp 17 Fuel supply hose 18 Tank vent hose 19 Fue...

Page 29: ...switch Allow engine to cool 4 Disconnect wire harness connector from fuel pump assembly on fuel tank 5 Note routing of fuel hoses for installation purposes Fig 9 Disconnect fuel hoses from fuel pump a...

Page 30: ...he fuel tank on your Workman uses a non vented fuel cap To connect the tank to the evaporative control sys tem a rollover valve is positioned in the top of the tank that allows tank venting through th...

Page 31: ...12 is re moved note direction of arrow on valve body for as sembly purposes IMPORTANT A plugged carbon canister or fresh air filter can cause fuel pressure problems that result in poor engine performa...

Page 32: ...e 16 Hose clamp 17 Fuel supply hose 18 Fuel vent hose 19 Fuel hose 2 20 Fuel pump retainer 21 Gasket FRONT RIGHT DANGER Because gasoline is highly flammable use cau tion when storing or handling it Do...

Page 33: ...ve fuel pump assembly and gasket item 21 from tank Fuel Pump Installation Fig 14 1 Make sure that fuel tank and fuel pump assembly gasket surfaces are thoroughly clean 2 Position gasket item 21 to sea...

Page 34: ...5 7 4 3 4 6 10 11 Figure 16 1 Engine 2 Muffler 3 Carriage screw 4 4 Flange nut 4 5 Muffler bracket 6 Clamp assembly 2 7 Intermediate exhaust pipe 8 Exhaust manifold 9 Flange nut 4 10 Exhaust gasket 2...

Page 35: ...ents as needed us ing Figure 16 as a guide 5 Discard exhaust gaskets and thoroughly clean flange surfaces of exhaust manifold and muffler Installation Fig 16 1 Replace any removed gaskets 2 Using Figu...

Page 36: ...lamp 2 25 Flat washer 26 Cap screw 27 Flange nut 28 Coolant hose 29 Coolant hose 2 FRONT RIGHT 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 24 25 26 27 28 29 7 19 19 19 19 19 13 17 29 1...

Page 37: ...diator using Figure 18 as a guide Make sure that clearance exists between shroud and fan at all points 2 Remove plugs from radiator openings and hoses placed during the removal procedure 3 Position ra...

Page 38: ...head screw 2 6 Flange head screw 7 Tube clamp 2 8 Washer 2 9 Flange nut 10 Hydraulic fitting 11 O ring 12 Hydraulic tube 13 O ring 14 90o hydraulic fitting 15 O ring 16 Hydraulic fitting 17 O ring 18...

Page 39: ...uring adapter removal thoroughly clean exterior of filter adapter hoses and fittings 5 Remove oil filter adapter components as needed us ing Figures 19 and 20 as guides Installation Fig 19 1 Install r...

Page 40: ...2 Set screw 2 23 Socket head screw 2 24 Flange head screw 2 25 Oil filter assembly 26 Washer head screw 2 27 Flange nut 28 Washer 2 29 Tube clamp 2 30 Flange head screw 31 Hydraulic tube 32 Hydraulic...

Page 41: ...Train 10 Remove hydraulic pump from machine see Gear Pump Vehicles with Standard Hydraulics or Gear Pump Vehicles with High Flow Hydraulics in the Ser vice and Repairs section of Chapter 7 Hydraulic...

Page 42: ...as sis One person should operate hoist and a second per son should help guide engine out of chassis Move engine toward the rear of the machine before lifting to al low engine crankshaft to clear spann...

Page 43: ...g 24 IMPORTANT Make sure to not damage the engine fuel hose hydraulic lines electrical harness engine coolant pipes spanner plate or other parts while in stalling the engine 5 Use lift or hoist to car...

Page 44: ...nnect radiator hoses to engine and secure hoses with hose clamps Fill cooling system see Radiator in this section 16 Secure wire harness hoses and cables to the engine with clamps and cable ties in lo...

Page 45: ...trol System 14 Speed Control System 16 Speed Limiter Assembly 18 Speed Limiter Cover Service 20 CVT Enclosure Cover 22 CVT Drive Belt 24 Primary and Secondary Clutches 26 Primary Clutch Service 28 Sec...

Page 46: ...Fluid Capacity 16 fluid ounces 470 milliliter System Capacity approximate Transmission Two Speed Forward Drive and Low Reverse Neutral and Park Transmission Oil Dexron VI Transmission Fluid Transmiss...

Page 47: ...s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Workman vehicle Refer to the Opera tor s Manual for additional inform...

Page 48: ...o limit the maximum ground speed of the machine for operations that require a constant speed like spraying and topdressing The speed range lever mounted to the seat base console Fig 2 is used to selec...

Page 49: ...s transferred from the engine to the transmission by a variable clutch system that consists of two 2 clutches connected by a drive belt The primary clutch is mounted to the engine crankshaft and respo...

Page 50: ...moveable sheave away from the stationary sheave The drive belt disengages from the primary clutch sheaves at a point where the force of the spring is greater than that of the clutch weights Speed Cont...

Page 51: ...eable sheave of the secondary clutch to move away from the stationary sheave against the pressure of the secondary clutch spring As the belt tightens and the secondary clutch sheaves open up the drive...

Page 52: ...transmission input shaft An adapter is required to allow the clutch removal tool to be used to remove the secondary clutch Clutch Removal Tool TOR6032 Secondary Clutch Adapter TOR6033 1 Clutch removal...

Page 53: ...h sheaves are worn or damaged Vehicle creeps at low idle Engine low idle speed is excessive Primary clutch has accumulation of dirt or debris preventing full back shifting Primary and secondary clutch...

Page 54: ...detent star and or detent pawl are worn or damaged Transmission sliding gear s is are tight on shaft or splines Transmission gear teeth damaged Transmission shift forks are worn or damaged Damaged or...

Page 55: ...nuts on shift cable item 6 in Fig 11 to al low full range of motion between PARK and DRIVE at transmission lever If necessary additional cable adjust ment can be made with jam nuts on cable clevis it...

Page 56: ...ve key from the ignition switch 2 Remove knobs from control levers then remove shift and control plates from seat base Fig 13 3 Remove two 2 screws item 7 and cable clamp item 6 that secure shift cabl...

Page 57: ...e properly routed to transmission se cure cable to shift lever and bracket on engine transmis sion mount A Install clevis pin and hair pin to secure shift cable to shift lever on transmission B Secure...

Page 58: ...trol plate to seat base console Lift control plate from seat base to access the speed control system reservoir Fig 16 IMPORTANT Use DOT 3 brake fluid in the speed control system 4 Bleed speed control...

Page 59: ...Workman HDX Auto Page 4 15 Drive Train This page is intentionally blank Safety Product Records Drive Train...

Page 60: ...Disassembly Fig 17 1 Park vehicle on a level surface shut engine off re move key from ignition switch and apply parking brake 2 Move speed range lever to the transport T position to remove pressure i...

Page 61: ...ue banjo bolt from 108 to 132 in lb 12 3 to 14 9 N m during assembly 2 If hydraulic system was opened during disassembly bleed speed control system see Bleed Speed Control System in this section IMPOR...

Page 62: ...21 The speed limiter assembly is used on the Workman Au to vehicle to adjust the maximum opening of the primary clutch moveable sheave The vehicle speed range can easily be adjusted with the speed ra...

Page 63: ...x 6 flange head screws item 8 that secure the speed limiter assembly item 9 to the primary clutch B Separate speed limiter assembly item 9 with at tached hydraulic hose from primary clutch C Carefully...

Page 64: ...ed Limiter Cover Service 1 Speed control hose 2 Button head screw 3 3 Retainer 4 Banjo washer 5 Rotary union 6 O ring 2 7 Speed limiter control cover 8 U cup 9 Quad ring 10 Hydraulic piston 11 Sleeve...

Page 65: ...nt grooves 2 Lubricate piston with clean DOT 3 brake fluid 3 Place piston installation tool see Special Tools in this chapter in bore of speed limiter control cover Using fin ger pressure slide lubric...

Page 66: ...njo washer 9 Flange head screw 6 10 Speed limiter assembly 11 Compression spring 12 Compression spring 13 Speed control hose 14 CVT enclosure cover 15 Washer head screw 9 16 Washer head screw 2 17 Spa...

Page 67: ...item 16 Note that two 2 longer screws are installed on the air intake end of the cover Fig 27 5 Separate CVT enclosure cover from spanner plate and remove from vehicle Installation Fig 26 1 Position C...

Page 68: ...o washer 9 Flange head screw 6 10 Speed limiter assembly 11 Compression spring 12 Compression spring 13 Speed control hose 14 CVT enclosure cover 15 Washer head screw 9 16 Washer head screw 2 17 Spann...

Page 69: ...belt from primary clutch and then from secondary clutch Installation Fig 28 1 Use 1 open end wrench or equivalent in opening of secondary clutch Fig 29 to pry clutch sheaves apart 2 Place drive belt...

Page 70: ...ring 12 Speed control hose 13 CVT enclosure cover 14 Washer head screw 9 15 Washer head screw 2 16 Spanner plate 17 Socket head screw 18 Flat washer 19 CVT fan 20 Fan stiffener 21 Washer head screw 4...

Page 71: ...secondary clutch if necessary A Remove cap screw item 22 lock washer item 23 and flat washer item 24 that secure secondary clutch to transmission input shaft B Remove secondary clutch from transmissi...

Page 72: ...ve Train Primary Clutch Service 1 Spider assembly 2 Shoulder screw 3 3 Lock nut 3 4 Clutch weight 3 5 Moveable sheave 6 Cap 7 Thrust washer 2 8 Bearing 9 Stationary sheave Figure 31 2 3 6 8 9 1 5 7 4...

Page 73: ...lace the screws 3 Check the contact surface of the clutch weights Fig 4 If surface is worn or damaged replace all three 3 clutch weights as a set 4 Check the rollers in the spider assembly for binding...

Page 74: ...N m Disassembly Fig 35 1 For clutch assembly purposes use a marker to make alignment marks on the cam assembly moveable sheave and stationary sheave Fig 36 2 Remove cam assembly from secondary clutch...

Page 75: ...Assembly Fig 35 IMPORTANT For proper clutch operation DO NOT lubricate clutch components during assembly IMPORTANT When assembling the secondary clutch check the marker lines made during clutch disas...

Page 76: ...2 per caliper 6 Spindle nut 2 7 Flange head screw 4 per hub 8 Wheel bearing hub 2 9 Rear axle 10 CV axle assembly 2 11 O ring 2 12 Rear differential 13 Inboard boot 2 14 Outboard boot 2 Figure 38 FRON...

Page 77: ...listed in Wheel Hub in the Service and Repairs section of Chapter 5 Chassis 3 Remove rear wheel bearing hub item 8 from axle see Wheel Hub in the Service and Repairs section of Chapter 5 Chassis IMPOR...

Page 78: ...nter axle D Fill CV joint with approximately 1 5 oz 44 ml of Shell Gadus 1452 or equivalent low friction CV joint grease E Align CV joint with center axle splines and slide against spring clip on shaf...

Page 79: ...Workman HDX Auto Page 4 35 Drive Train This page is intentionally blank Safety Product Records Drive Train...

Page 80: ...t head screw 4 5 Parking brake rotor 6 Parking brake caliper 7 Flange head screw 2 8 Lock nut 2 9 Brake mount plate 10 Spacer 11 Parking brake cable 12 Clevis pin 13 Hair pin 14 Retaining ring 15 Engi...

Page 81: ...e sure that mounting holes in parking brake rotor and differential input shaft are aligned 3 Make sure that flange of driveshaft is thoroughly cleaned before installation Also clean rotor thoroughly a...

Page 82: ...ly a coating of grease to bearing bores of end yoke slip yoke or flange yoke and driveshaft yoke Also apply grease to bearings and seal of bearing assembly Make sure that all bearing rollers are prop...

Page 83: ...Workman HDX Auto Page 4 39 Drive Train This page is intentionally blank Safety Product Records Drive Train...

Page 84: ...13 Hair pin 14 Retaining ring 15 Engine transmission mount 16 Flange head screw 14 17 Breather 18 O ring 2 19 CV axle 2 20 LH rear differential mount 21 RH rear differential mount 22 Solenoid control...

Page 85: ...IMPORTANT Make sure to not damage the oil seal on the rear differential with the pry bars when removing the CV axle assemblies B Use two small pry bars 180o apart to carefully leverage the CV axle out...

Page 86: ...Rear CV Constant Velocity Axles in this section Make sure that flange head screws that secure wheel hub to rear axle are torqued from 35 to 40 ft lb 48 to 55 N m 7 Install rear brake rotor brake calip...

Page 87: ...Workman HDX Auto Page 4 43 Drive Train This page is intentionally blank Safety Product Records Drive Train...

Page 88: ...b 265 to 291 N m 490 to 510 ft lb 665 to 691 N m 20 ft lb 27 N m 10 to 14 ft lb Loctite 680 Loctite 680 38 14 to 19 N m 24 27 Thread Locker High Strength Red Retaining Compound Retaining Compound Appl...

Page 89: ...emove bearings item 12 and 13 from the output cover and or differential housing Discard bearings after removal 14 If necessary remove expansion plugs item 24 from output gears 15 If necessary remove c...

Page 90: ...3 If bearing item 29 was removed from differential housing install new bearing onto housing fully to shoul der of housing Press only on inner race of bearing dur ing installation 4 Make sure that exp...

Page 91: ...case to output cover A Support output cover on work bench with the shift fork facing up B Place shim item 11 and then engagement dog item 2 on cover centered on bearing Make sure that shift fork engag...

Page 92: ...her 22 Spanner plate 23 Flange head screw 5 24 Air inlet housing 25 Driveshaft 26 Engine transmission mount 27 Flange head screw 2 28 Flange nut 2 Figure 52 FRONT RIGHT 2 3 8 9 11 11 13 1 5 14 15 16 1...

Page 93: ...engine and transmission C Carefully remove spanner plate from vehicle 6 Disconnect wire harness connectors from rotary switch and speed sensor on front of transmission Fig 53 7 Remove hairpin and clev...

Page 94: ...spanner plate so that the mounting holes align Secure spanner plate to trans mission with five 5 flange head screws Fig 23 5 Secure the transmission in place by fully tightening the two 2 flange nuts...

Page 95: ...Workman HDX Auto Page 4 51 Drive Train This page is intentionally blank Safety Product Records Drive Train...

Page 96: ...35 Front output shaft 36 Helical gear 88T 37 Reverse shaft 38 Rear output shaft 39 Shift lever 40 Shift shaft rail 41 Vent tube 42 Park shift dog 43 Shift shaft 44 Shift collar 45 Shift fork 2 46 Spr...

Page 97: ...bly components for as sembly purposes Fig 57 7 Remove shift assembly components from rear gear case noting the following for assembly purposes A End of compression spring Fig 55 item 22 fits around pi...

Page 98: ...tion of two 2 dowel pins Fig 55 item 10 and remove pins from gear case 1 Rear gear case 2 Front gear case 3 Dowel pin location 2 Figure 59 2 1 3 3 10 Carefully rotate shift drum Fig 55 item 29 to sepa...

Page 99: ...ds and splines on shift drum shaft Replace shift drum if worn or damaged 18 Inspect shift forks Fig 55 item 45 for any evidence of wear or damage Also inspect shift shaft rail Fig 55 item 40 for evide...

Page 100: ...s The input shaft seal Fig 55 item 59 should be installed fully into the front gear case so that the seal shoulder is flush to the case After seal installation apply a light coating of multi pur pose...

Page 101: ...oth slide sector gear Fig 55 item 30 onto lower end of shift shaft Lower shaft with gear into rear case and align the identifica tion marks on the two 2 sector gears Fig 68 C Slide spacer and then det...

Page 102: ...Noting location of missing tooth slide shift lever item 39 onto shift shaft Secure lever with lock nut Torque lock nut from 12 to 18 ft lb 17 to 24 N m 19 If speed sensor Fig 55 item 55 was removed a...

Page 103: ...t 9 SERVICE AND REPAIRS 10 Wheel Assembly 10 Brake System 12 Brake Caliper Service 14 Bleed Brake System 16 Brake Master Cylinder 18 Brake Master Cylinder Service 20 Parking Brake Cable 22 Parking Bra...

Page 104: ...cation Front tire 20 x 9 12 6 ply Maximum front tire pressure 32 PSI 220 kPa Front wheel alignment 0 0 120 in 0 3 mm Rear tire 24 x 12 12 6 ply Maximum rear tire pressure 18 PSI 124 kPa Wheel nut torq...

Page 105: ...determined by the payload carried A The lower the tire pressure the less the compac tion and tire marks are minimized Lower pressure should not be used for heavy payloads at higher speeds Tire damage...

Page 106: ...age 5 4 Chassis Special Tools Compression Spring Tool Use to remove and install the two 2 front suspension compression springs Quantity Item 2 1 2 x 20 threaded steel rods 4 1 2 nuts 4 1 2 flat washer...

Page 107: ...ear shock absorbers Worn leaf spring bushings Rear differential or CV axle problem see Chapter 4 Drive Train Excessive steering play Loose or worn front wheel bearings Loose or worn steering linkage W...

Page 108: ...Broken or weak rear leaf spring Incorrect front wheel alignment Damaged or bent suspension or steering component Worn or damaged brake components Brakes Problem Possible Causes Brake pedal goes to fl...

Page 109: ...adjustment Weak or broken parking brake return spring Binding brake pedal Sticking brake caliper s Sticking brake master cylinder Saturated brake pads Scored or bent brake rotors Hard brake pedal Inco...

Page 110: ...ment 2 With the pitman arm centered measure center to center distance at axle height between the front wheels at both front and rear of the wheels Fig 3 The front and rear measurements should be equal...

Page 111: ...Workman HDX Auto Page 5 9 Chassis This page is intentionally blank Chassis...

Page 112: ...el hub assembly 4 Lug nut 5 per wheel 5 Brake caliper 6 Flange head screw 2 per caliper 7 Front knuckle LH shown 8 Rear wheel assembly 9 Rear axle Figure 4 5 4 6 1 2 3 80 to 90 ft lb 109 to 122 N m 35...

Page 113: ...then remove wheel assembly from vehicle Installation Fig 4 1 Install wheel Secure with five 5 lug nuts 2 Lower vehicle to ground WARNING Failure to maintain proper wheel lug nut torque could result i...

Page 114: ...er 6 Flange head screw 2 per caliper 7 Front knuckle LH shown 8 Bleed screw 9 Rear wheel assembly 10 Rear axle Figure 6 FRONT RIGHT 5 3 9 2 4 80 to 90 ft lb 109 to 122 N m 35 to 40 ft lb 48 to 55 N m...

Page 115: ...t brake line to caliper Fig 7 A Position brake line to caliper B Place banjo washer on each side of brake line fit ting C Install banjo bolt through brake line fitting and banjo washers and then threa...

Page 116: ...e Caliper Service 1 Bolt 2 2 Caliper body 3 O ring 4 4 Caliper bracket 5 Square seal 2 6 Dust seal 2 7 Piston 2 8 Brake pad 2 9 Caliper anvil Figure 8 2 3 6 8 1 5 7 4 37 to 44 N m 27 to 33 ft lb BAF 1...

Page 117: ...ns or complete brake caliper assembly if necessary 3 Check that pins on caliper bracket are not worn or damaged Wear on the pins will prevent smooth brake operation Assembly Fig 8 1 If caliper body wa...

Page 118: ...alve of left rear brake until pedal fades to floor then close bleed er valve 5 Repeat procedure until a continuous flow of brake fluid with no air bubbles is released from bleeder valve Make sure flui...

Page 119: ...Workman HDX Auto Page 5 17 Chassis This page is intentionally blank Chassis...

Page 120: ...ster Cylinder 1 Brake master cylinder 2 Flange head screw 2 3 Clevis pin 4 Grease fitting 5 Brake pedal 6 Flange bushing 7 Flange nut 8 Flange nut 2 9 Cotter pin 10 Shoulder screw 11 Brake shaft Figur...

Page 121: ...o vehicle frame 6 Remove master cylinder from vehicle Installation Fig 10 1 Position master cylinder to vehicle frame and secure with two 2 flange head screws and flange nuts 2 Remove plugs from brake...

Page 122: ...grooves and passageways with com pressed air Make sure cylinder bore and component pieces are thoroughly clean 2 Check cylinder bore pistons and springs for damage or excessive wear Replace brake cyl...

Page 123: ...Workman HDX Auto Page 5 21 Chassis This page is intentionally blank Chassis...

Page 124: ...5 1 4 2 7 6 3 Removal Fig 13 1 Park vehicle on a level surface raise and support ve hicle cargo bed if installed shut engine off and engage the parking brake Remove key from the ignition switch 2 Rem...

Page 125: ...e and work towards front 2 Install brake cable end to brake equalizer on parking brake lever Secure brake cable to lever support assem bly with retaining ring 3 Connect parking brake cable to parking...

Page 126: ...2 to 36 N m Grease FRONT RIGHT Disassembly Fig 17 1 Park vehicle on a level surface raise and support ve hicle cargo bed if installed shut engine off and engage the parking brake Remove key from the i...

Page 127: ...differential and drive shaft are thoroughly cleaned before installing brake rotor Also clean rotor thoroughly B Position brake rotor and driveshaft flange to dif ferential IMPORTANT Socket head screw...

Page 128: ...embly 18 O ring 5 3 2 4 80 to 90 ft lb 109 to 122 N m 35 to 40 ft lb 48 to 55 N m 6 5 4 6 1 2 3 80 to 90 ft lb 109 to 122 N m 35 to 40 ft lb 48 to 55 N m 7 8 8 54 to 66 in lb 6 2 to 7 4 N m 54 to 66 i...

Page 129: ...embly is necessary Wheel hubs are not rebuildable 6 If front wheel hub replacement is necessary remove cap screw item 12 washers items 11 and 10 and lock nut item 9 from wheel hub assembly so that the...

Page 130: ...assembly 20 Center link 21 Flat washer 2 22 Cap screw 2 23 Flange head screw 12 24 Washer 2 25 Grease fitting 2 26 Ball bearing 2 27 Flange nut 2 28 Flange head bolt 2 29 Flange nut 2 30 Cap screw 2...

Page 131: ...cylinder ball joint to steering linkage Sepa rate steering cylinder from steering linkage D Remove fasteners items 27 28 32 and 33 that secure steering linkage and center link assembly to frame Remove...

Page 132: ...tted hex nut from 80 to 90 ft lb 109 to 122 N m If necessary tighten nut further until slot in nut aligns with hole in ball joint stud Install cotter pin C Install tie rods to center link see below D...

Page 133: ...Workman HDX Auto Page 5 31 Chassis This page is intentionally blank Chassis...

Page 134: ...ew 4 6 Flange nut 4 7 Flange head screw 6 8 Lock nut 8 9 Cap screw 2 10 Flange bushing 2 used per arm 11 Ball joint 12 Grease fitting 13 Ball joint seal 14 Knuckle LH shown 15 Retaining ring Figure 24...

Page 135: ...ontrol arm from vehicle frame 5 Disassemble control arm as needed A Remove retaining ring and press ball joint out of control arm B Press flange bushings from control arm Installation Fig 24 1 Assembl...

Page 136: ...ssion Spring Service 1 Spring cradle 2 2 Compression spring 2 3 Flange nut 4 Cap screw 5 Stabilizer link 6 Lock nut 7 Cap screw 8 LH control arm tower 9 Spring pivot sleeve 10 RH control arm tower Fig...

Page 137: ...em 7 that secure spring cradles to control arm towers can be removed Fig 27 5 Install a compression spring tool rod see Special Tools through holes in each spring cradle item 1 then install nuts and w...

Page 138: ...f new shock absorber Insert spacer into ram lower end of shock absorber 2 Install inner washer item 3 onto frame stud above control arm 3 Install upper end of shock absorber onto frame stud Secure sho...

Page 139: ...s being replaced or bushings are worn insert two 2 new rubber bush ings into each end of shock absorber Insert spacer into ram lower end of shock absorber 2 Install washer item 4 onto shock absorber m...

Page 140: ...th sides of the ve hicle Removal Fig 31 1 Park vehicle on a level surface shut engine off re move key from ignition switch and apply parking brake 2 Jack up and support rear of vehicle with jack stand...

Page 141: ...shackle al ready placed in leaf spring Install flange nuts item 5 to spring shackles and tighten finger tight NOTE During leaf spring installation make sure axle and spring plate are centered on leaf...

Page 142: ...teering wheel from control valve If necessary use suitable puller to remove steering wheel Installation Fig 32 1 Apply antiseize lubricant to taper and spline on steer ing control valve shaft 2 Slide...

Page 143: ...Workman HDX Auto Page 5 41 Chassis This page is intentionally blank Chassis...

Page 144: ...3 Socket head screw 8 Figure 33 18 19 15 17 16 20 13 12 14 11 10 3 6 8 9 5 1 4 2 7 23 21 12 22 12 in lb maximum 1 3 N m FRONT RIGHT Removal Fig 33 1 Park vehicle on a level surface raise and support b...

Page 145: ...e control plate to seat base with removed screws Torque screws a maximum of 12 in lb 1 3 N m Make sure that lift lever can be moved in con trol plate slot to allow correct operation of lift lock 4 Plu...

Page 146: ...od to release the lower mounting tabs from the frame slots 3 Pivot the bottom of the hood upward until the top mounting tabs can be pulled from the frame slots 4 Pivot the top of hood forward and unpl...

Page 147: ...rame 12 Seal washer 2 each 13 Cup cover 2 each 14 Wiper acorn nut 15 Wiper blade 16 Wiper arm 17 Wiper stud nut 2 each 18 Lock washer 19 Stud cover 20 Wiper nut 2 each 21 Cup cover 2 each 22 Seal wash...

Page 148: ...ove the roof B Remove the console foam 5 Remove the wiper motor components as shown in Figure 38 Installation Fig 38 1 Locate the nuts on the studs at the dimensions shown before assembling the wiper...

Page 149: ...Brake Switch 14 Parking Brake Switch 15 Hydraulic Lift Lever Interlock Switch 16 High Flow Hydraulics Switch Vehicles with High Flow Hydraulics 17 Front Differential Interrupter Switch Vehicles with 4...

Page 150: ...arding the operation general maintenance and maintenance intervals for your Workman vehicle Refer to the Opera tor s Manual for additional information when servicing the vehicle Electrical Drawings Th...

Page 151: ...ess current can cause damage to circuits not designed to carry it Figure 1 Dielectric Gel Dielectric gel should be used to prevent corrosion of un sealed connection terminals To ensure complete coat i...

Page 152: ...ls to reduce corrosion problems Apply terminal protector to the connection af ter the battery cable ring terminal or fork terminal has been secured Toro Part Number 107 0392 Figure 4 Spark Tester The...

Page 153: ...neutral position when attempting to start instruct operator Fuse A1 10 amp is faulty Battery cables are loose or corroded Ground connection s is loose or corroded Battery is discharged Fusible link is...

Page 154: ...ter cranks but engine will not start Fuel tank is empty Fuse B1 10 Amp is faulty Wiring to interlock components is loose corroded or damaged see electrical schematic and wire harness drawings in Chapt...

Page 155: ...89 v or lower 0 charged Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if a charging system has an output but not its capacity Use a...

Page 156: ...Make sure that hydraulic lift lever is in neutral position 2 Without depressing the brake pedal rotate ignition switch to START position 3 If engine cranks or starts there is a malfunction in the inte...

Page 157: ...ne apply parking brake and remove key from ignition switch 2 To ease access to ignition switch remove hood of ve hicle see Hood in the Service and Repairs section of Chapter 5 Chassis 3 Locate ignitio...

Page 158: ...s the vehicle ground speed Speed is shown in miles per hour MPH but can be con verted to kilometers per hour KPH by changing the sta tus of the wire harness MPH KPH shunt Engine Coolant Temperature Ga...

Page 159: ...speedometer and engine tachometer Fourth Row Position D2 15 amp Protects power sup ply circuit for headlights and rear lights Fourth Row Position D1 30 amp Protects power sup ply circuit for horn NOT...

Page 160: ...e of a multimeter ohms setting the headlight switch functions may be tested to determine whether continuity exists between the various terminals for each switch position The switch terminals are marke...

Page 161: ...vehicle ignition key in the RUN or START position the rear dif ferential relay will be energized opening the circuit and de energizing the rear differential solenoid and locking the differential This...

Page 162: ...brake Locate the brake switch Fig 15 2 To ease access to brake switch remove hood of vehi cle see Hood in the Service and Repairs section of Chapter 5 Chassis 3 Disconnect the wire harness connector f...

Page 163: ...rake applied Testing 1 Park vehicle on a level surface shut engine off re move key from ignition switch and apply parking brake Locate the parking brake switch Fig 16 2 Remove seat base to gain access...

Page 164: ...inuity zero ohms when the lift lever is in the neutral position and there should not be continu ity infinite ohms when the lever is not in the neutral position 6 Replace lift lever interlock switch if...

Page 165: ...high flow hydraulics switch on dash and dis connect wire harness electrical connector from the switch 4 With the use of a multimeter ohms setting the switch functions may be tested to determine wheth...

Page 166: ...he connector termi nals 5 When the switch plunger is extended accelerator pedal is depressed there should be continuity closed between the switch terminals 6 When the switch plunger is depressed accel...

Page 167: ...ll resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are te...

Page 168: ...elay will be de energized to ensure that front wheel drive is disengaged The start and fan relays are attached to the relay bracket under the right side of the bed near the engine Fig 25 The other rel...

Page 169: ...lied and removed from terminal 85 7 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 8 Connect multimeter ohms setting leads to relay ter minals 30 and 87A Apply 12 VDC to term...

Page 170: ...sembly location Testing 1 Park vehicle on a level surface engage parking brake Stop the engine and remove key from ignition switch Allow engine to cool 2 Locate diode assembly that is to be tested A F...

Page 171: ...battery cable from battery ter minal and then disconnect positive cable from battery see Battery Service in the Service and Repairs section of this chapter 4 Locate and unplug fusible link connector...

Page 172: ...er if circuit wiring and gauge are acceptable 4 Remove fuel pump assembly from the fuel tank see Fuel Pump in the Service and Repairs section of Chapter 3 Kohler Gasoline Engine Clean all fuel from t...

Page 173: ...m lowering CAUTION The fuel supply hose will contain pressurized fuel Be careful when disconnecting fuel supply hose Wipe up any spilled fuel before starting the engine 3 Disconnect fuel supply hose f...

Page 174: ...re to prevent personal injury or fire NOTE Prior to taking resistance readings with a digital multimeter short the meter test leads together The me ter will display a small resistance value usually 0...

Page 175: ...Remove speed sensor from transaxle IMPORTANT Incorrect jumper wire connections during testing can damage the sensor 5 Using a 12 VDC battery a multimeter a 1K ohm re sistor and appropriate jumper wir...

Page 176: ...ltimeter short the meter test leads together The meter may display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtr...

Page 177: ...itch functions to determine if continuity exists be tween the various terminals for each switch position Check the continuity between the switch terminals The windshield wiper washer switch terminals...

Page 178: ...Workman HDX Auto Page 6 30 Electrical System This page is intentionally blank...

Page 179: ...lt if the gases are inhaled Unplug battery charger from electrical outlet before connecting or dis connecting charger leads to or from battery posts CAUTION IMPORTANT Do not remove battery fill caps w...

Page 180: ...ve cable NOTE Before connecting the negative cable to the battery connect a digital multimeter set to DC Amps between the negative battery post and the negative cable connector The reading should be l...

Page 181: ...ischarge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform...

Page 182: ...s 126 to 170 5 5 hrs 5 amps 11 hrs 5 amps 16 5 hrs 5 amps 22 hrs 5 amps 171 to 250 5 8 hrs 6 amps 11 5 hrs 6 amps 17 3 hrs 6 amps 23 hrs 6 amps above 250 6 hrs 10 amps 12 hrs 10 amps 18 hrs 10 amps 24...

Page 183: ...apter 7 Chassis 3 If bulb removal is necessary loosen the bulb from the headlight by rotating it 1 4 turn counter clockwise Then grasp bulb base and remove bulb from the head light 4 If necessary remo...

Page 184: ...Workman HDX Auto Page 6 36 Electrical System Tail Lights Disassemble and assemble tail light using Fig 45 as a guide 1 Screw 2 2 Lens 3 Bulb 4 Tail light assembly Figure 45 1 2 3 4...

Page 185: ...Cylinder Internal Leakage 24 High Flow Hydraulics Gear Pump Flow and System Relief Pressure 26 SERVICE AND REPAIRS 28 General Precautions for Removing and Installing Hydraulic System Components 28 Che...

Page 186: ...eutral Ball checks to maintain load Hydraulic Oil Mobil M15 Reservoir System Capacity 8 U S quart 7 5 Liter Hydraulic Filter Spin on cartridge type 100 mesh strainer in hydraulic reservoir High Flow H...

Page 187: ...e correct hydraulic oil level is used 1 Hydraulic reservoir 2 Reservoir cap 3 Dipstick Figure 1 1 2 3 Relieving Hydraulic System Pressure Before disconnecting or performing any work on the hy draulic...

Page 188: ...e hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the other wrench See Hydraulic Hose and Tube Installation in this section If the ho...

Page 189: ...in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate me...

Page 190: ...cords and Maintenance to determine necessary conversion in formation 5 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is t...

Page 191: ...ith a wrench and use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 6 This tightening process will require the use of an offset wrench e g crowfoot wren...

Page 192: ...2WD 4 89 STROKE IN 4WD 1 00 ROD CONTROL T E 100 MESH 1 FLOWS SHOWN ARE CALCULATED AT HIGH IDLE AND 95 PUMP EFFICIENCY UNLESS OTHERWISE NOTED EXTEND 0 519 in3 rev GEAR PUMP T COOLER DISCONNECT COUPLING...

Page 193: ...Workman HDX Auto Page 7 9 Hydraulic System This page is intentionally blank Hydraulic System...

Page 194: ...44 CIR T E STEERING CYLINDER NO PISTON MOVEMENT NEUTRAL POSITION STEERING CONTROL VALVE 1800 PSI P R L 2 44 CIR T E STEERING CYLINDER PISTON MOVEMENT LEFT TURN STEERING CONTROL VALVE 1800 PSI P R L 2...

Page 195: ...ough the top of the spool Flow entering the steering control valve at the P port passes through the rotary meter and is directed out the L port Pressure retracts the steering cylinder for a left turn...

Page 196: ...of the lift valve to the barrel end of the lift cylinders Hydraulic pressure against the cylinder pistons extends the cylin der shafts At the same time the lift valve spool cam pin opens the return di...

Page 197: ...il in the reservoir for correct system operation High Flow Circuit OFF Fig 11 When the rocker switch is in the OFF position the hy draulic manifold solenoid operated relief valve SVRV is not energized...

Page 198: ...mber TOR47009 Figure 12 Hydraulic Tester Pressure and Flow This tester requires O ring Face Seal ORFS adapter fittings for use on this machine see Hydraulic Test Fit ting Kit in this section 1 INLET H...

Page 199: ...seal and port seal hydraulic connections It is recommended that O rings be replaced whenever a hydraulic connec tion is loosened Toro Part Number 117 2727 Figure 15 Male Coupler For High Flow Hydrauli...

Page 200: ...s are missing or damaged Squealing noise Hydraulic lift valve is being held in raise or lower position hydraulic oil flowing over relief valve Hydraulic oil is overheating Oil level in reservoir is in...

Page 201: ...rface with a heavily loaded stationary vehicle hydraulic circuit pressure to steering control valve may be near relief pressure Engine RPM is low Oil level in reservoir is low Steering components e g...

Page 202: ...are interchanged Oil level in reservoir is low Engine RPM is low Excessive load is applied to attachment Gear pump key is sheared or missing NOTE Entire hydraulic system is affected Gear pump flow or...

Page 203: ...2 people One person should be in the seat to oper ate the machine and the other should monitor testing equipment and record test results 1 Thoroughly clean the vehicle before disconnecting or disassem...

Page 204: ...IT 7 7 GPM 3600 1100 RPM UNIT STEERING TO RAISE OIL 2000 PSI QUICK B A SVRV TESTER Figure 17 NOTE This test procedure is for the single section gear pump used on vehicles with standard hydraulics If v...

Page 205: ...flow is fully restricted 6 Fully depress and hold accelerator pedal Check that engine speed is 3600 RPM Verify engine speed with a phototac 7 While watching tester pressure gauges slowly close flow co...

Page 206: ...0 PSI P R L 2 44 CIR 4 9 GPM 25 PSI ENGINE LIFT VALVE 0 33 in3 rev GEAR PUMP CONTROL T E 100 MESH EXTEND 0 519 in3 rev GEAR PUMP T COOLER DISCONNECT COUPLINGS OPTIONAL HIGH FLOW KIT 7 7 GPM 3600 1100...

Page 207: ...face B With the engine running turn the steering wheel to the right clockwise until the steering cylinder rod is fully extended C Turn engine off and engage the parking brake D Read Precautions for Hy...

Page 208: ...1800 PSI P R L 2 44 CIR 4 9 GPM 25 PSI ENGINE LIFT VALVE 0 33 in3 rev GEAR PUMP CONTROL T E 100 MESH 0 519 in3 rev GEAR PUMP T COOLER DISCONNECT COUPLINGS OPTIONAL HIGH FLOW KIT 7 7 GPM 3600 1100 RPM...

Page 209: ...sconnect hydraulic hose from base end of lift cylin der that is to be tested and install a steel plug with O ring seal in the hose Fig 21 Clean any remaining oil from cylinder port 5 Start engine and...

Page 210: ...COUPLINGS OPTIONAL HIGH FLOW KIT 7 7 GPM 3600 1100 RPM UNIT STEERING TO RAISE OIL 2000 PSI QUICK B A SVRV TESTER Figure 22 NOTE This test procedure is for the rear gear pump section on Workman vehicle...

Page 211: ...th high flow hydraulics switch still in the ON posi tion watch tester pressure gauges while slowly closing flow control valve on the tester until 1500 PSI 103 4 bar is obtained on gauge Verify that en...

Page 212: ...stem contamination 4 Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hy...

Page 213: ...ng under pressure can have sufficient force to penetrate the skin and cause serious injury If fluid is in jected into the skin it must be surgically re moved within a few hours by a doctor familiar wi...

Page 214: ...22 Flange nut 2 Figure 24 FRONT RIGHT 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 11 21 TO OIL FILTER 90 to 110 ft lb 123 to 149 N m 55 to 60 ft lb 75 to 81 N m HYDRAULIC RESERVOIR FOR ST...

Page 215: ...from hydrau lic reservoir using Figure 24 or 25 as a guide Discard and replace any removed O rings Hydraulic Reservoir Inspection 1 Clean hydraulic reservoir and strainer with solvent 2 Inspect hydra...

Page 216: ...ange head screw 4 14 Pump mount 15 Square key 16 Barbed fitting with O ring 17 Strainer 18 O ring 2 3 6 8 9 10 13 1 5 7 12 16 17 18 4 11 TO OIL FILTER 90 to 110 ft lb 123 to 149 N m 55 to 60 ft lb 75...

Page 217: ...onto fittings Install fittings into pump openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor m...

Page 218: ...lics Gear Pump Service later in this section NOTE The Workman HDX Auto gear pump includes a rear flange that will allow the installation of a second pump section for the High Flow Hydraulics system Di...

Page 219: ...Scoring rough surfaces or wear on gear shafts indi cates need for replacement B Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be replaced C Inspect gear...

Page 220: ...10 Gently slide the body onto the assembly Firm hand pressure should be sufficient to engage the dowel pins 11 Install two 2 dowel pins into body 12 Align marker line on the body and rear flange IMPO...

Page 221: ...Workman HDX Auto Page 7 37 Hydraulic System This page is intentionally blank Hydraulic System...

Page 222: ...O ring 12 Gear pump 13 Flange nut 4 14 Flange head screw 4 15 Pump mount 16 Square key 17 45o hydraulic fitting 2 18 Hydraulic fitting 19 O ring 20 Tee fitting 21 O ring 22 Oil filter assembly 23 Hydr...

Page 223: ...onto fittings Install fittings into pump openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor m...

Page 224: ...26 Thrust plate 27 Idler shaft 28 Drive shaft 29 Rear pump section body 30 Thrust plate 31 Front flange Figure 33 HIGH FLOW HYDRAULICS KIT GEAR PUMP 1 2 6 7 8 9 19 22 23 11 13 14 15 3 4 5 10 16 17 18...

Page 225: ...Workman HDX Auto Page 7 41 Hydraulic System This page is intentionally blank Hydraulic System...

Page 226: ...lter 7 Flange nut 2 8 Lift lever 9 Clevis pin 10 Hairpin 11 Retainer pin 12 Link 13 90o hydraulic fitting 14 Hyd tube to male quick fitting 15 Hyd tube to female quick fitting 16 90o hydraulic fitting...

Page 227: ...lve and discard O rings Installation Fig 34 1 If fittings were removed from lift valve lubricate and place new O rings onto fittings Install fittings into valve openings using marks made during the re...

Page 228: ...m valve body IMPORTANT When removing O rings from valve body be very careful to not scratch valve bore fin ish 5 Use a hooked scribe or thin screwdriver to remove O rings item 9 from inside bore of va...

Page 229: ...Workman HDX Auto Page 7 45 Hydraulic System This page is intentionally blank Hydraulic System...

Page 230: ...18 Hyd hose to steer cyl shaft end 19 Hyd hose to steer cyl barrel end Figure 37 FRONT RIGHT 1 2 3 4 5 6 7 8 9 10 11 12 13 19 Antiseize Lubricant 20 to 25 ft lb 28 to 33 N m 14 15 16 17 18 Removal Fig...

Page 231: ...es 38 and 39 see Hydraulic Hose and Tube Installation in the General Information section of this chapter Make sure that hoses are not twisted while tightening 2 Position steering control valve to vehi...

Page 232: ...ring 14 Distribution plate 15 Inner gearwheel 16 Outer gearwheel 17 End cover 18 O ring 5 19 Screw fitting ports L R T 20 Screw fitting ports P and E 21 P port check ball 22 Spring set Figure 40 1 2 3...

Page 233: ...Workman HDX Auto Page 7 49 Hydraulic System This page is intentionally blank Hydraulic System...

Page 234: ...nkage assembly 20 Center link 21 Flat washer 2 22 Cap screw 2 23 Flange head screw 12 24 Washer 2 25 Grease fitting 2 26 Ball bearing 2 27 Flange nut 2 28 Flange head bolt 2 29 Flange nut 2 30 Cap scr...

Page 235: ...Fig 42 Installation Fig 41 1 If fittings were removed from steering cylinder lubri cate and place new O rings onto fittings Install fittings into cylinder openings using marks made during the re moval...

Page 236: ...oth heads in barrel A Use a spanner wrench to rotate head clockwise until the edge of the retaining ring appears in the bar rel opening B Insert a screwdriver under the beveled edge of the retaining r...

Page 237: ...s onto rear shaft IMPORTANT When installing roll pin into front and rear shafts make sure that shaft surfaces are not damaged 4 Slide front shaft onto rear shaft and align roll pin holes in shafts Ins...

Page 238: ...r 1 Bed frame 2 O ring 3 90o hydraulic fitting 4 O ring 5 Hydraulic hose 6 Lift cylinder LH shown 7 Hydraulic hose 8 Cotter pin 9 Frame engine support 10 Frame rail LH shown 11 Clevis pin 12 Lynch pin...

Page 239: ...ft cylinder to frame engine support 6 Remove lift cylinder from vehicle 7 If hydraulic fittings are to be removed from lift cylin der mark fitting orientation to allow correct assembly Remove fittings...

Page 240: ...Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening C Rotate the head counter clockwise to remove re taining ring from barrel and head 5 E...

Page 241: ...lide head and piston onto the shaft C Secure piston to shaft with lock nut Torque lock nut from 60 to 75 ft lb 81 to 102 N m 4 Lubricate head and piston with clean hydraulic oil Slide shaft assembly c...

Page 242: ...ic hose 7 Cap screw 2 8 Oil filter assembly 9 Tee fitting 10 O ring 11 Engine mount assembly Figure 46 FRONT RIGHT 2 3 6 8 9 10 1 5 7 4 3 9 11 Workman HDX automatic vehicles equipped with High Flow Hy...

Page 243: ...ve fittings from manifold and discard O rings Valve Cartridge Service Fig 46 1 Make sure the entire outer surface of the manifold is clean before removing the cartridge valve 2 Remove nut securing sol...

Page 244: ...carefully into manifold port The valve should go in easily without binding C Using a deep socket torque cartridge valve 25 ft lb 34 N m D Slide solenoid coil onto the cartridge valve Install nut and t...

Page 245: ...ons 3 SERVICE AND REPAIRS 4 CV Constant Velocity Axle Assembly 4 Test CV Axle 5 Disassembly 5 Assembly 5 CV Axle Boots 6 Front Differential Driveshaft 8 Driveshaft Cross and Bearing Service 10 Front D...

Page 246: ...ve Optional Kit Specifications Item Description Front Differential Optional Kit Ring and Pinion with Dual Bi Directional Clutches Front Differential Oil Mobil 424 Front Differential Oil Capacity 6 flu...

Page 247: ...sense the rear wheels slipping and en gage the front wheel drive instantaneously to deliver power to the front wheels The front wheel drive system continues to deliver power to the front wheels until...

Page 248: ...assembly 2 10 Axle spacer 2 11 Flange head screw 8 12 Brake caliper LH shown 13 Brake rotor 2 14 Slotted hex nut 2 15 Cotter pin 4 16 Knuckle LH shown 17 Differential plate 2 18 Mount 4 19 Inboard boo...

Page 249: ...heel hub to knuckle Slide wheel hub assembly from CV axle 5 Remove axle spacer item 10 from CV axle IMPORTANT Make sure to not damage the oil seal on the differential with the pry bars when removing t...

Page 250: ...over center axle D Fill CV joint with approximately 1 5 oz 44 ml of Shell Gadus 1452 or equivalent low friction CV joint grease E Align CV joint with center axle splines and slide against spring clip...

Page 251: ...Workman HDX Auto Page 8 7 Four Wheel Drive Optional Kit This page is intentionally blank Four Wheel Drive Optional Kit...

Page 252: ...al Driveshaft 1 Transmission 2 Cap screw 3 Lock nut 4 Front differential driveshaft 5 Front differential assembly 6 CV axle assembly 2 7 Flange head screw 4 8 Mount 4 9 Differential plate 2 Figure 4 F...

Page 253: ...y antiseize lubricant to front differential input shaft and transmission output shaft 2 Position front differential driveshaft to vehicle frame front differential assembly and transmission 3 Rotate in...

Page 254: ...et C Remove yoke from press grasp partially re moved bearing and tap on yoke to completely re move the bearing D Repeat process for remaining bearings E Thoroughly clean and inspect all components Ass...

Page 255: ...Workman HDX Auto Page 8 11 Four Wheel Drive Optional Kit This page is intentionally blank Four Wheel Drive Optional Kit...

Page 256: ...nut 8 Wheel hub assembly 2 9 Tie rod assembly 2 10 Axle spacer 2 11 Flange head screw 8 12 Brake caliper LH shown 13 Brake rotor 2 14 Slotted hex nut 2 15 Cotter pin 4 16 Knuckle LH shown 17 Differen...

Page 257: ...ical harness control cables or other parts while removing the differential 8 Tip differential toward left side driver side of ve hicle Remove differential assembly toward the right side passenger side...

Page 258: ...e assembly 16 Ring gear 17 Gear case 18 Thrust bearing 19 Roller cage assembly 20 Output hub 2 21 Gear shim 22 Roller 14 23 Torsion spring 24 H clip spring 14 25 Thrust button 26 Gear spacer 27 Pinion...

Page 259: ...he cover 3 Remove the pinion gear with bearing from housing by pulling it out of the gear case by hand Fig 10 4 Inspect the inner pinion bushing in the gear case Fig 11 If the bushing is excessively w...

Page 260: ...raight up 7 Remove the thrust bearing from the cover plate and inspect for wear Fig 13 Replace the thrust bearing if the red coating is worn completely off the bearing sur face The thrust bearing is u...

Page 261: ...b from gear case be careful to not damage the seal in the gear case The seal cannot be serviced separately 11 Turn the gear case over Using a hammer and a suit able drift carefully remove the output h...

Page 262: ...tely 16 Turn the cover plate over and place it on blocking or in a vise Using a hammer and suitable drift carefully re move the output hub and bearing from the cover plate by driving the hub down The...

Page 263: ...bushing 3 Press the new output hub bearing assembly into the cover plate assembly The bearing has a slight interfer ence fit to the bore so it should not take much force to install Fig 21 Take care t...

Page 264: ...8 Set the roller cage on a flat surface with the torsion spring end facing up Fig 25 Install nine 9 rollers into the slots on the bottom row of the cage If needed use grease or petroleum jelly to hel...

Page 265: ...five 5 flange head screws Torque screws from 14 to 17 ft lbs 19 to 27 N m 14 Install the pinion gear and then the input cover Fig 28 Secure cover with four 4 flange head screws Torque screws from 14...

Page 266: ...Workman HDX Auto Page 8 22 Four Wheel Drive Optional Kit This page is intentionally blank...

Page 267: ...s 314000001 to 403430000 3 Electrical Schematic Serial Numbers Above 403430001 4 WIRE HARNESS DRAWINGS AND DIAGRAMS Front Wire Harness Serial Numbers Below 316000000 5 Front Wire Harness Serial Number...

Page 268: ...YELLOW Numerous harness wires used on Toro machines in clude a line with an alternate color These wires are iden tified with the wire color and line color with either a or _ separating the color abbre...

Page 269: ...Page 9 3 Vehicle Electrical Schematic Workman HDX Auto All relays and solenoids are shown as de energized 122 0090 REV B D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 Serial Numbers 314000001 to 403430000...

Page 270: ...Page 9 4 Vehicle Electrical Schematic Serial Numbers Above 403430001 All relays and solenoids are shown as de energized Workman HDX Auto 122 1466 Rev A...

Page 271: ...Page 9 5 Front Wire Harness Drawing Workman HDX Auto 122 0088 REV D D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 machine serial numbers below 316000000...

Page 272: ...Page 9 6 Front Wire Harness Diagram Workman HDX Auto 122 0088 REV D D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 machine serial numbers below 316000000...

Page 273: ...Page 9 7 Front Wire Harness Drawing Workman HDX Auto 122 0823 REV B D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 machine serial numbers 316000001 to 403430000...

Page 274: ...Page 9 8 Front Wire Harness Diagram Workman HDX Auto 122 0823 REV B D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 machine serial numbers 316000001 to 403430000...

Page 275: ...Page 9 9 CV Front Wire Harness Diagram Serial Numbers Above 403430001 Workman HDX Auto 122 1449 Rev A...

Page 276: ...Page 9 10 Front Wire Harness Diagram Serial Numbers Above 403430001 Workman HDX Auto 122 1449 Rev A...

Page 277: ...Page 9 11 Rear Wire Harness Drawing Workman HDX Auto 122 0089 REV D D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1...

Page 278: ...Page 9 12 Rear Wire Harness Diagram Workman HDX Auto 122 0089 REV D D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1...

Page 279: ...Page 9 13 Rear Differential Solenoid Workman HDX Auto Controller Wire Harness 122 0589 REV A D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1...

Page 280: ...Page 9 14 Heater Kit Wire HArness Drawing Workman HDX Auto D C B A 6 5 4 3 2 1 D C B 6 5 4 3 2 1 A Drawing No 120 3996 Rev C...

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Toro 07390 Workman HDX-Auto, Service Manual

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