Form No.
Revision History Revision Date -- 2016 A 03/2018 Incorporated EFI information and procedures. Added revision history. B 02/2020 Updated torque values. C 05/2020 Updated Chassis and Electrical Drawings chapters. © THE TORO COMPANY 2020 Description Initial Issue. This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. 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.
NOTES _
Part No. 16224SL (Rev. C) Service Manual WorkmanR GTX Gasoline 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 GTX Gasoline vehicle. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts Catalog for your machine into Chapter 2 of this service manual.
This page is intentionally blank.
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2 Jacking and Other Instructions . . . . . . . . . . . . . . . 1 -- 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 6 General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2 Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .
This page is intentionally blank.
Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Supervisor’s Responsibilities . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING AND OTHER INSTRUCTIONS . . . . . . . . Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transporting Vehicle . . . .
Safety Instructions The Workman GTX vehicles are designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
1. Sit on the operator seat when starting and operating the vehicle. 2. When the vehicle is stationary, apply the parking brake to prevent the vehicle from unexpected movement. Make sure to release parking brake before driving the vehicle. 5. Do not touch engine, muffler or exhaust pipe while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. 6. Before getting off the seat: A. Stop movement of the vehicle. B.
Jacking and Other Instructions Jacking Vehicle DANGER POTENTIAL HAZARD • A vehicle that is not properly supported may become unstable. WHAT CAN HAPPEN • The vehicle may move or fall. Personal injury or damage to the machine may result. HOW TO AVOID THE HAZARD • Make sure vehicle is parked on a solid level surface, such as a concrete floor. • Make sure engine is off and key is removed from the key switch before getting off the vehicle.
Transaxle Neutral Position When performing routine maintenance and/or engine testing, the transaxle must be shifted into the neutral position. Safety 2 3 1. Park machine on a level surface, stop engine, set parking brake and remove key from the key switch. 2. Move shift lever to the neutral position (Fig. 3). 3. Make sure transaxle is in the neutral position by rotating the secondary clutch (Fig. 4). The rear tires should not rotate as the secondary clutch is rotated.
Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Workman GTX. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed in the Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 − 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 282 + 30 # 8 − 36 UNF # 10 − 24 UNC 18 + 2 30 + 5 339 + 56 # 10 − 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in−lb 640 + 60 N−cm 78 + 7 in−lb 885 + 80 N−cm M6 X 1.0 96 + 9 in−lb 1018 + 100 N−cm 133 + 13 in−lb 1500 + 150 N−cm M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 27 + 2 ft−lb 36 + 3 N−m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb 5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb 3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb 1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb 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.
Chapter 3 Gasoline Engine Table of Contents Gasoline Engine GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Kohler Command Pro Service Manual . . . . . . . . . 2 Kohler Gasoline Engine . . . . . . . . . . . . . . . . . . . . . . 2 Engine Electronic Control Unit (ECU) (Fuel Injected Engines only) . . . . . . . . . . . . . . . . . 3 Rear Frame Panel Cover . . . . . . . . . . . . . . . . . . . . . 3 SPECIFICATIONS . . .
General Information This Chapter gives information about specifications, maintenance, troubleshooting, testing and repair of the single cylinder Kohler gasoline engines used in the Workman GTX. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman GTX vehicle. The Kohler Owner’s Manual includes information specific to the engine used in your Workman.
Engine Electronic Control Unit (ECU) (Fuel Injected Engines only) Vehicles with a fuel injected engine (Kohler ECH440) use an electronic control unit (ECU) for engine management. The ECU is located at the front of the engine below the valve cover. All wire harness electrical connectors should be plugged into the ECU before the machine ignition switch is moved from the OFF position to either the RUN or START position.
Specifications Item Description Make / Designation 4- cycle, Single Cylinder, OHV, Air Cooled, Gasoline Engine Bore x Stroke 3.5 in x 2.7 in (89 mm x 69 mm) 24.7 in3 (429 cc) Total Displacement Governor Mechanical Idle Speed (no load) 1300 + 50 RPM High Idle (no load) 3700 + 50 RPM Carburetor Float Feed, Single Barrel Fuel Pump Pulsating Crankcase Vacuum Fuel Unleaded regular grade gasoline Fuel Tank Capacity 5.0 U.S. gal (18.
Adjustments Adjust Accelerator Cable NOTE: Workman GTX vehicles use the engine governor to control engine speed. Refer to the Kohler Service Manual for additional governor information. Depressing the accelerator pedal rotates the engine mounted throttle lever which tensions the engine governor spring to increase engine speed. Releasing the accelerator pedal decreases governor spring tension which reduces engine speed. 2 1 NOTE: Two (2) people are needed to complete this procedure.
Service and Repairs Cooling System To ensure proper engine cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. 1 NOTE: Perform this maintenance procedure at the interval specified in the Operator’s Manual. IMPORTANT: The engine that powers the Workman GTX is air- cooled. Operating the engine with dirty or plugged cooling fins or a plugged or dirty blower housing will result in engine overheating and damage. 2 1.
Accelerator Control The Workman GTX accelerator control includes an engine mounted throttle lever that is rotated by the accelerator cable to change engine speed. FRONT 7 Disassembly (Fig. 6) 10 1. Park vehicle on a level surface and engage parking brake. 11 6 5 2 4 3 2. Raise and support the cargo bed. 8 10 3. Make sure that the engine is stopped and the key is removed from key switch. Allow engine to cool. 1 9 Gasoline Engine 4.
Air Cleaner System RIGHT FRONT 1 11 8 10 7 2 9 6 4 3 5 VACUATOR DIRECTION Figure 8 1. 2. 3. 4. Engine Hose clamp Intake hose Hose clamp Gasoline Engine 5. 6. 7. 8. Air cleaner assembly Hose clamp Air inlet hood Mounting bracket Page 3 - 8 9. Flange head screw (2 used) 10. Flange nut (2 used) 11.
Removal (Fig. 8) 1. Park machine on a level surface, stop the engine, engage parking brake and remove the key from the key switch. 2. Raise cargo bed and support with prop rod. 3. Remove rear frame panel cover to allow easier access to air cleaner (see Rear Frame Panel Cover in the General Information section of this chapter). 3 4 CAUTION 2 The engine and exhaust exhaust may be hot. To avoid possible burns, allow engine and exhaust system to cool before working in the engine area. 1 4.
Exhaust System 37 to 44 N- m (27 to 33 ft- lb) 7 3 3 8 4 22 to 27 N- m (16 to 20 ft- lb) 11 17 to 21 N- m (12.6 to 15.4 ft- lb) 10 12 14 16 9 15 37 to 44 N- m (27 to 33 ft- lb) 1 5 6 11 14 15 22 to 27 N- m (16 to 20 ft- lb) 13 2 G247348 Figure 10 1. 2. 3. 4. 5. 6. Engine (carbureted) Engine (EFI) Coupler spring (4 used) Exhaust manifold (carbureted) Exhaust manifold (EFI) Muffler Gasoline Engine 7. 8. 9. 10. 11.
Removal (Fig. 10) Installation (Fig. 10) 1. Park machine on a level surface, stop the engine, engage parking brake and remove the key from the key switch. NOTE: New oxygen sensor threads come pre- coatedwith an anti seize compound. If a previously installed oxygen sensor is used, apply a small amount of antiseize to the threads. 2. Raise cargo bed and support with prop rod. 1. If installing an oxygen sensor, do not allow the tip of the sensor to touch anything as it may become contaminated.
Fuel Lines and Connections CAUTION 7 2 1 3 4 5 Read safety precautions for handling gasoline before working on the fuel system (see Safety Instructions in Chapter 1 - Safety). Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check lines for deterioration, damage, leaks or loose connections. Replace hoses, clamps and connections as necessary.
3 2 1 LOCKED Gasoline Engine 3 UNLOCKED Figure 13 1. Supply hose fitting lock (locked - down) Workman GTX Gasoline 2. Supply hose fitting lock (unlocked - up) 3.
Fuel Tank and Fuel Pumps 10 13 15 14 16 8 9 11 12 7 2 7 90 to 110 in- lb (10.2 to 12.4 N- m) 6 1 18 to 22 in- lb (2 to 2.5 N- m) 4 11.7 to 14.3 ft- lb (16 to 19 N- m) 5 3 RIGHT FRONT Figure 14 1. 2. 3. 4. 5. 6. Fuel tank Washer head screw Fuel tank mount Fuel tank bracket LH seat base side Fuel supply hose 7. 8. 9. 10. 11. 12. Hose clamp (2 used) Pulse pump Washer head screw (2 used) Flange nut (2 used) Carbon canister (EVAP system) Pulse hose 13. Pulse line filter 14.
Fuel Pumps (Fig. 14) A pulse style fuel pump is used with both the carbureted and the fuel injected engines to lift fuel from the fuel tank. Pumping action within the pulse pump is created by alternating positive and negative pressures within the crankcase through a pulse line. Check valves inside the pulse pump prevent fuel from going backward through the pump. 2 6 4 3 The pulse pump is not serviceable and difficult to test accurately.
Fuel Evaporative Control System CARBURETED ENGINE 1 5 4 3 6 9 10 11 12 7 8 2 FUEL INJECTED ENGINE (EFI) 6 13 14 12 4 5 11 3 16 17 10 9 7 8 15 2 G247513 Figure 16 1. 2. 3. 4. 5. 6. Engine (carbureted) Fuel tank Rollover valve EVAP hose Carbon canister Carbon canister bracket Gasoline Engine 7. 8. 9. 10. 11. 12. EVAP hose Fresh air filter CV cartridge EVAP hose Orifice adapter EVAP hose (to engine) Page 3 - 16 13. 14. 15. 16. 17.
The fuel tank on the Workman GTX vehicle uses a nonvented fuel cap. To connect the tank to the evaporative control system, a rollover valve is positioned in the top of the tank that allows tank venting through the carbon canister. The EVAP system also includes an in- line check valve (CV cartridge) that is inserted in the hose between the carbon canister and the carburetor EVAP fitting. Evaporative control system components for Workman GTX vehicles are shown in Figure 16.
Engine 25 to 31 ft- lb (34 to 42 N- m) 200 to 230 in- lb (23 to 25 N- m) 39 to 47 ft- lb (53 to 63 N- m) 12 11 12.6 to 15.
IMPORTANT: Torque tighten the fasteners based on the fastener grade. Make sure to use the correct torque; refer to Figure 18. 5 6 Engine Removal (Fig. 18) 1. Park machine on a level surface, stop the engine, engage parking brake and remove the key from the key switch. 4 2. Disconnect ground (black) cable from the battery. Then, disconnect positive (red) cable from the battery. 3. Raise cargo bed and support with prop rod. 3 4.
10.Disconnect the engine from the machine wire harness: A. For machines with carbureted engines, disconnect the engine magneto electrical connector at the rear of the engine. B. For machines with electronic fuel injected (EFI) engines, disconnect the engine wire harness connector secured to the left side of the swing arm under the air cleaner assembly. 11.
9. Install exhaust manifold and intermediate pipe to engine and muffler (see Exhaust System in this section). 10.Connect hoses to carbureted engines (Fig. 19): A. Connect the EVAP hose at the carburetor. B. Install the R- clamp with the disconnected hoses to the throttle bracket. C. Connect the pulse hose at the pulse line filter. D. Connect the fuel supply hose at the carburetor. 11. Connect hoses to electronic fuel injected (EFI) engines (Fig. 20): A. Connect the EVAP hose at the throttle body. B.
This page is intentionally blank.
Chapter 4 Drive Train Table of Contents Workman GTX Gasoline Page 4 − 1 Drive Train GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DRIVE TRAIN OPERATION . . . . . . . . . . . . . . . . . . . . 4 Clutch System Operation . . . . . . . . . . . . . . . . . . . . . 4 Primary Clutch Operation . . . . . . . . . . . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Operator’s Manual for additional information when servicing the vehicle.
Specifications Item Description Transaxle Transaxle Fluid Transaxle Fluid Capacity SAE 80W−90 gear oil (API GL−1/MT−1) 1.7 U.S. quarts (1.
Drive Train Operation Clutch System Operation LOW ENGINE SPEED LIGHT LOAD FULL ENGINE SPEED DECREASING LOAD 5 7 FULL ENGINE SPEED INCREASING LOAD 2 6 A B C 8 v 3 1 4 Figure 1 1. Primary clutch 2. Secondary clutch 3. Moveable sheave (primary clutch) 4. Stationary sheave (primary clutch) 5. Moveable sheave (driven clutch) 6. Spring Power is transferred from the engine to the transaxle by a variable clutch system that consists of two (2) clutches connected by a drive belt.
Primary Clutch Operation The operation of the primary clutch is affected by engine shaft speed. When the engine is off and not turning, the drive belt rests low within the primary clutch sheaves as the clutch sheaves are spaced apart. As the engine is started and increases in speed, the clutch rollers move outward as they spin about the engine drive shaft. The outward movement of the rollers against the spider assembly forces the moveable sheave closer to the stationary sheave.
Special Tools Order special tools from your Toro Distributor. Primary Clutch Removal Tool This tool is required to remove the primary clutch from the tapered drive shaft of the engine. It is placed in the threaded hole of the stationary clutch sheave after the clutch holding cap screw is removed. Toro Part Number: TOR6039 Figure 4 Primary Clutch Spider Removal Tool Kit This kit is required to remove the primary clutch spider from the post of the stationary sheave.
Troubleshooting Clutch ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Service and Repairs CVT Drive Belt 7 5 6 3 1 2 4 v 8 RIGHT FRONT 9 Figure 7 1. Engine 2. Starter/generator 3. Starter/generator drive belt Drive Train 4. Starter/generator pulley 5. CVT drive belt 6. Primary clutch Page 4 − 8 7. Secondary clutch 8. Vehicle swing arm 9.
3. Raise and support vehicle cargo bed to allow access to drive system. CAUTION The engine, exhaust system and drive system components may be hot. To avoid possible burns, allow all components to cool before working on drive system components. 4. While rotating the secondary clutch, route CVT drive belt from the secondary clutch sheaves. 5. Remove drive belt from from the primary clutch and vehicle. Drive Belt Removal (Fig. 7) Drive Belt Installation (Fig. 7) 1.
Primary and Secondary Clutches 10 39 to 47 ft−lb (53 to 63 N−m) 11 9 5 7 8 6 3 17 to 22 ft−lb (24 to 29 N−m) 1 2 Antiseize Lubricant 4 v 12 RIGHT FRONT 13 Figure 8 1. 2. 3. 4. 5. Engine Starter/generator Starter/generator drive belt Starter/generator pulley CVT drive belt 6. 7. 8. 9. Primary clutch Cap screw Flat washer Secondary clutch 10. 11. 12. 13. Cap screw Stepped washer Vehicle swing arm Transaxle assembly Removal (Fig.
E. Install starter/generator belt to the primary clutch and starter/generator pulleys. Tension the belt by rotating the starter/generator away from the engine. Torque fasteners that secure starter/generator from 200 to 230 in−lb (23 to 25 N−m) to secure starter/ generator. When properly adjusted, the belt should deflect 1/4 inch (6 mm) with 10 lb (4.5 kg) of force on the center of the belt. 5. If necessary, remove primary clutch from engine drive shaft: A.
Primary Clutch Service 2 132 to 168 in−lb (15.0 to 18.9 N−m) 9 8 1 6 4 3 13 132 to 168 in−lb (15.0 to 18.9 N−m) 12 11 10 190 to 220 ft−lb (258 to 298 N−m) 7 5 v Figure 11 1. 2. 3. 4. 5. Washer head screw (4 used) Starter/generator pulley Washer head screw (3 used) Dust cover Compression spring 6. 7. 8. 9. Shim (2 used) Spider Shim Roller (6 used) Primary Clutch Disassembly (Fig. 11) IMPORTANT: During clutch disassembly, note location of shims (items 6 and 8) for assembly purposes.
Primary Clutch Inspection NOTE: If primary clutch wear or damage occurs, clutch replacement may be necessary. Refer to your parts catalog to identify individual primary clutch components that are available. 2 1. Inspect the tapered ends of the engine crankshaft and stationary sheave of primary clutch. If either is severely damaged, replace component as damage to the taper will allow loosening of the clutch during vehicle operation. 1 2. Check all of the rollers, button plugs and primary buttons.
Secondary Clutch Service 1. Use secondary clutch press tool (see Special Tools in this chapter) to compress the compression spring enough to allow removal of the retaining ring (item 7) that secures internal clutch components. 2 3 2. Remove retaining ring. 4 3. Carefully, release clutch press tool to allow the spring to extend fully. 6 4. Remove outer spring retainer, spring and inner spring retainer from clutch. 1 5.
Drive Train This page is intentionally blank.
Transaxle Shift Cable 11 8 10 5 3 9 2 7 6 90 to 110 in−lb (10.2 to 12.4 N−m) v 4 1 RIGHT FRONT Figure 14 1. 2. 3. 4. Swing arm Engine Spanner bar Transaxle assembly 5. 6. 7. 8. Shift arm Flange head screw Flange nut Ball joint 9. Lock nut 10. Shift cable 11. Shift cable jam nut 4. Disconnect shift cable from transaxle (Fig. 14): Removal 1. Park machine on a level surface, stop engine, set parking brake and remove key from the key switch. A.
5. Disconnect shift cable from shift lever (Fig. 16): A. Remove ball joint from shift lever assembly. Then, remove ball joint from end of shift cable. B. Remove shift cable jam nut on the left side of the parking brake mount and pull cable from brake mount. 6. After shift cable adjustments have been made, install dash (see Dash in the Service and Repairs section of Chapter 6 − Chassis). 7. Lower and secure cargo bed. 1 6. Note routing of shift cable through front frame for assembly purposes. 2 7.
Transaxle 7 8 39 to 47 ft- lb (53 to 63 N- m) 6 4 25 to 31 ft- lb (34 to 42 N- m) 200 to 230 in- lb (23 to 25 N- m) 10 77 to 95 ft- lb (105 to 128 N- m) 9 5 1 11 Antiseize Lubricant 13 11 14 v 12 RIGHT FRONT Grade 8 2 Grade 5 12 3 Figure 17 1. 2. 3. 4. 5. Engine Transaxle assembly Swing arm CVT drive belt Primary clutch 6. 7. 8. 9. 10.
4. Remove secondary clutch from transaxle input shaft (see Primary and Secondary Clutches in this section). 5. Remove muffler from vehicle (see Exhaust System in the Service and Repairs section of Chapter 3 − Gasoline Engine). 6. Separate shift lever from transaxle and position it away from transaxle (Fig. 18). A. Remove flange head screw and flange nut that secure the shift lever to the transaxle selector shaft. 11.
7. Install muffler to vehicle (see Exhaust System in the Service and Repairs section of Chapter 3 − Gasoline Engine). 8. Install both rear wheel hubs and wheels to the vehicle (see Rear Wheel and Hubs in the Service and Repairs section of Chapter 7 − Chassis). 9. Check that forward, neutral and reverse positions engage as shift lever is moved to each position. If necessary, adjust shift cable at spanner bar so that all positions engage. Drive Train 10.Lower vehicle to ground. 11.
Drive Train This page is intentionally blank.
Transaxle Service 16 to 19 ft−lb (21 to 25 N−m) 44 41 39 16 12 to 15 ft−lb (16 to 20 N−m) 26 to 31 ft−lb (35 to 42 N−m) 17 29 28 22 42 18 48 23 47 5 6 25 4 26 3 45 28 24 16 2 8 13 46 20 21 1 27 19 16 to 19 ft−lb (21 to 25 N−m) 13 38 35 31 19 33 37 7 36 31 32 38 12 34 9 30 43 10 15 2 48 11 40 to 45 ft−lb (54 to 61 N−m) 40 15 14 26 to 31 ft−lb (35 to 42 N−m) 41 44 16 to 19 ft−lb (21 to 26 N−m) Figure 19 Drive Train Page 4 − 22 Workman GTX Gasoline
Figure 19 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Case (LH) Oil seal (2 used) Steel ball Spring Gasket Bolt Case (RH) Selector shaft Oil seal Snap ring Spacer Oil seal Pipe knock (2 used) Oil drain plug (2 used) Gasket (2 used) Ball bearing (2 used) 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32.
6. For assembly purposes, note location of pipe knocks (item 13 in Fig. 19) in the cases. Remove pipe knocks from cases. 5 3 7. Individually, remove counter shaft, differential, center shaft (with shift shaft) and input shaft assemblies from RH case (Fig. 22). 2 4 1 Figure 22 1. 2. 3. Counter shaft Differential Center shaft 4. 5. IMPORTANT: When disassembling transaxle shaft assemblies, discard all bearings that have been removed and replace with new bearings during assembly.
10.Disassemble differential case assembly (Fig. 25): 9 7 A. Remove bearings from the differential case assembly. Discard removed bearings. 5 3 B. Remove six (6) bolts securing gear 60 to the differential case and remove gear from case. C. Remove pin from the differential case. Discard pin and replace it during assembly. 2 8 D. Remove pinion shaft, side gears and pinion gears from the case. 6 5 11. Disassemble input shaft assembly (Fig. 26): A. Remove bearings from the input shaft assembly.
Transaxle Inspection 5 1. Thoroughly clean and dry all internal transaxle parts. 2 2. Use emery cloth to remove nicks and burrs from all transaxle components. 3. Inspect all gear teeth for roughness, material transfer or other damage. Cracked, broken, missing or chipped gear teeth are not acceptable. Replace gears if worn or damaged. 6 1 4. Inspect splines on input and center shafts. If cracked, broken, chipped or missing splines are found on either shaft, replace shaft. 5. Inspect I.D.
Transaxle Assembly (Fig. 19) 2 1. Clean sealant material from transaxle RH and LH case mating surfaces before transaxle assembly. Make sure all transaxle parts are clean. 1 2. Replace all removed bearings and seals during transaxle assembly. 3 IMPORTANT: When pressing bearings onto transaxle shafts, make sure to press bearing only on the inner race to prevent damaging the bearing. 3. Press new bearings onto the input shaft (Fig. 30). Make sure bearings are pressed fully to the shaft shoulder.
6. Assemble center shaft assembly (Fig. 33): 8 A. With mating holes for pin clutch engagement toward pin clutch location, install gear 51 onto center shaft. 5 B. Install spacer onto shaft and then press new bearing onto center shaft. Make sure that bearing is pressed fully to the shaft shoulder. 3 10 9 7 C. Install pin clutch onto splines of center shaft. D. With mating holes for pin clutch engagement facing pin clutch location, install gear 52 onto center shaft. E.
14.Install axle cases to transaxle cases (RH and LH): 10.Install LH case to RH case assembly: A. Make sure gasket sealing surfaces of both cases are clean. IMPORTANT: Make sure to install the axle cases to the correct side of the transaxle case assembly. The right side of the transaxle case uses the longer axle case and the left side takes the shorter axle case. Use marks made during disassembly when installing axle cases. B. Install both pipe knocks to the supported RH case. C.
This page is intentionally blank.
Chapter 5 Electrical System Table of Contents Workman GTX Gasoline SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 26 Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Battery Specifications . . . . . . . . . . . . . . . . . . . . . 26 Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Battery Inspection and Maintenance . . . . . . . . 27 Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . 27 Battery Testing . . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman GTX vehicle. Refer to the Operator’s Manual for additional information when servicing the vehicle. Engine Electronic Control Unit (ECU) (Fuel Injected Engines only) Vehicles with a fuel injected engine (Kohler ECH440) use an electronic control unit (ECU) for engine management.
Rear Frame Panel Cover A panel cover is secured to the top of the rear frame behind the seats to prevent debris entry to the front of the swing arm area. The cover can easily be removed by releasing the latches and lifting the cover from the rear frame. 2 3 1 Figure 1 3. Latch (2 used) Electrical System 1. Rear frame 2.
Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter.
Terminal Protector Aerosol spray that should be used on battery terminals, ring terminals and fork terminals to reduce corrosion problems. Apply terminal protector to the connection after the battery cable, ring terminal or fork terminal has been secured. Toro Part Number: 107−0392 Figure 5 Spark Tester The spark tester can be used to test magneto ignitions on gasoline engines. The spark tester determines if ignition is present.
Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this vehicle (see electrical schematic and wire harness drawings in Chapter 7 − Electrical Drawings).
Starting Problems (continued) Problem Possible Causes Engine starts and runs when the accelerator pedal is depressed but will not start when the key switch is moved to the START position. Key switch or circuit wiring is faulty. Wiring to the start circuit components is loose, corroded or damaged (see electrical schematic and wire harness drawings in Chapter 7 − Electrical Diagrams). One or both of the key start latch relays or circuit wiring is faulty. Diode 2 in wire harness is faulty.
Electrical System Quick Checks Battery Test Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100o F. The key switch should be OFF and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (−) meter lead the negative battery post. 12.45 V 75% charged 12.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the wire harness connector from the key switch before doing a continuity check on the switch). NOTE: For engine electrical component testing information, see the Kohler COMMAND PRO CH260−CH440 Service Manual for machines with carbureted engines and the Kohler COMMAND PRO EFI ECH440 & ECH440LE Service Manual for machines with fuel injected (EFI) engines.
Headlight Switch The headlight switch is located on the dash (Fig. 9). This rocker switch allows the headlights to be turned ON and OFF. 1 Testing 1. Park vehicle on a level surface, shut engine off and engage the parking brake. Remove key from the key switch. 2. Raise hood to allow access to wire harness connections for switches mounted in dash. 3. Disconnect wire harness connector from the headlight switch. 4.
Machine Fuses The fuse blocks for the machine fuses are located beneath the seat base (Fig. 10). Fuses can be removed to check continuity. The test meter should read less than 1 ohm if a fuse is functional. Fuses protect circuits as follows: Bottom fuse in the left fuse block (10 amp) protects the circuit for the USB charge port on the dash. This fuse also provides circuit protection for the optional power point, reverse alarm and parking brake alarm.
USB Charge Port The USB charge port can be used to charge or power electrical devices that use a USB port. The charge port has a 5 VDC output and is mounted to the dash (Fig. 12). If the vehicle wire harness is to be disconnected from the charge port, note the wire harness connections at the charge port for assembly purposes.
Start/Run Solenoid The start/run solenoid provides a current path between the starter/generator and the vehicle electrical circuits. The solenoid is located beneath the seat base near the fuse blocks (Fig. 14). The start/run solenoid is energized when: A. The key switch is in the ON position and the accelerator pedal is depressed. B. The key switch is momentarily held in the START position. The solenoid remains energized when the switch is returned to the ON position. 9.
Electric Fuel Pump (fuel injected engines − EFI) An electric fuel pump assembly is used on Workman GTX machines with a fuel injected gasoline engine. The fuel pump assembly provides pressurized fuel to the fuel injector in a return−less system and includes a regulator to maintain fuel pressure of approximately 40 PSI (276 kPa). The fuel pump is rated for a minimum output of 7.6 oz. (224 ml) per minute. To protect the fuel pump, a special 10−micron fuel filter is included upstream of the electric fuel pump.
6. While monitoring pressure gauge, turn ignition switch to RUN (do not start engine) so that fuel pump is energized. The fuel pressure displayed on the gauge should rise. After pump is de−energized (approximately 6 seconds), turn ignition switch to OFF and then back to RUN (do not start engine) to re−energize the fuel pump. Repeat energizing the fuel pump in this manner until the fuel pressure stabilizes. Fuel pump pressure should be approximately 40 PSI (276 kPa). 8.
Key Start Latch and Magneto/ECU Relays A Workman GTX vehicle uses up to three (3) identical relays that have five (5) terminals. The relays are attached to the dash bracket near the brake master cylinder (Fig. 18). 1 Two relays work together to operate the start latch circuits so that the engine can be started when the key switch is rotated to the START position.
9. Replace relay if testing determines that it is faulty. 10.After relay testing is complete, secure relay to vehicle and connect wire harness connector to relay. Electrical System 11. Lower and secure hood.
Delay Timer (fuel injected engines − EFI) To prevent the engine ECU from switching ON/OFF rapidly when using the accelerator pedal start feature, a delay timer works with the ECU relay to keep the ECU energized for 30 seconds after the engine stops (magneto grounded). The delay timer is attached to the dash bracket near the brake master cylinder (Fig. 20). 1 2 Testing 1. Park vehicle on a level surface, stop engine, engage parking brake and remove key from the key switch.
Accelerator Pedal Switch The accelerator pedal switch is a four (4) terminal, two (2) circuit switch. The switch is used to determine if the accelerator pedal is depressed or not when starting the engine via the accelerator pedal. The switch is attached to the pedal mount next to the brake master cylinder (Fig. 22).
Diode Assemblies Two (2) identical diode assemblies are included in the Workman GTX wire harness. 4 1 The diode D1 is used for circuit protection from voltage spikes that can occur when the start/run solenoid is de− energized. This diode plugs into the wire harness beneath the seat base near the battery. 2 The second diode is used for circuit logic to allow the key switch START position to function. This diode plugs into the wire harness near the relays mounted under the hood.
Starter/Generator & Voltage Regulator Testing 1. Park vehicle on a level surface, stop engine and engage parking brake. Place vehicle shift lever in the NEUTRAL position. 2. To access electrical components: A. Remove seat base assembly with attached seats from vehicle. B. Raise cargo bed and secure with prop rod. C. Remove rear frame panel cover from rear frame (see Rear Frame Panel Cover in the General Information section of this chapter). 3.
8. If battery voltage in step 5 above did not increase to 14.5 VDC and starter/generator tested correctly in step 7 above, test voltage regulator: 1 2 A. Set multimeter to VDC. Connect red (+) multimeter probe to the starter/generator terminal DF (Fig. 27). Connect black (−) multimeter probe to a known good ground. B. Start and run the engine at mid−range RPM. C. The measured voltage should be approximately 2 VDC when the battery is charging and from 6 to 8 VDC when the battery is fully charged.
Starter/Generator Resistance Testing Resistance testing of starter/generator field and armature windings are as follows: NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will 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. Subtract this value from the measured value of the component you are testing. 9.
Parking Brake Alarm Switch (If Equipped) If your Workman is equipped with the optional parking brake alarm, the audio alarm should sound whenever the parking brake is applied. The parking brake alarm switch is attached to the parking brake mount behind the dash (Fig. 30). A normally closed contact in the switch is opened when the parking brake is released. When the parking brake is applied, the switch is in its normally closed state.
Reverse Alarm Switch (If Equipped) The optional reverse alarm switch is a normally open proximity switch that is secured to the spanner bar that is attached to the engine and transaxle (Fig. 32). When vehicle is equipped with the optional reverse alarm, the audio alarm should sound whenever the shift lever is placed in the reverse position. 2 3 The alarm switch is in its normal open position when the dash mounted shift lever is either in the neutral or the forward position.
Service and Repairs NOTE: See the KOHLER Command PRO CH260- CH440 Service Manual for carbureted engines, or the KOHLER Command PRO EFI ECH440 & ECH440LE Service Manual for electronic fuel injected (EFI) engines for engine electrical component testing information. Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended and electrical component failure can be prevented.
Battery Inspection and Maintenance Battery Installation (Fig. 34) IMPORTANT: To prevent possible electrical problems, install only a fully charged battery. POTENTIAL HAZARD: Battery electrolyte contains sulfuric acid which is a deadly poison and it causes severe burns. WHAT CAN HAPPEN: If you carelessly drink electrolyte you could die or if it gets onto your skin you will be burned. HOW TO AVOID THE HAZARD: Do not drink electrolyte and avoid contact with skin, eyes or clothing.
Battery Testing 1. If the battery design allows removal of battery caps, conduct a hydrometer test of the battery electrolyte: IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer. Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm− up the hydrometer. At the same time take the temperature of the cell. B. Temperature correct each cell reading. For each 10F (5.
Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is readily available. Follow the battery charger manufacturer’s instructions when using a battery charger. NOTE: If the battery design allows removal of battery caps, using specific gravity of the battery cells is the most accurate method of determining battery condition. 1.
Starter/Generator 4 16 3 5 200 to 230 in- lb (23 to 25 N- m) 13 1 8 7 11 12 17 to 22 ft- lb (24 to 29 N- m) 25 to 31 ft- lb (34 to 42 N- m) 200 to 230 in- lb (23 to 25 N- m) 6 14 18 2 9 9 v 17 7 16 to 20 ft- lb (22 to 27 N- m) 15 10 RIGHT FRONT Grade 8 Grade 5 200 to 230 in- lb (23 to 25 N- m) 9 Figure 35 1. 2. 3. 4. 5. 6. Engine Swing arm Primary clutch Secondary clutch Starter/generator belt Starter/generator 7. 8. 9. 10. 11. 12.
NOTE: Place all fasteners back onto starter/generator terminals after disconnecting wires to prevent loss of fasteners. 5. Label all wires on the starter/generator for assembly purposes. Disconnect all wires from the starter/generator. 6. Loosen flange head screws (items 7 and 15) and flange nuts (item 9) that secure starter/generator to bracket. 7. Pivot starter/generator toward engine and remove drive belt from the starter/generator pulley. 8.
Starter/Generator Service 1 4 5 6 2 3 8 11 12 7 9 10 Figure 37 1. 2. 3. 4. Drive head end Bearing Retaining ring Armature assembly Electrical System 5. 6. 7. 8. Frame and field assembly Brush kit Brush spring (4 used) Brush box assembly Page 5 − 32 9. 10. 11. 12.
NOTE: A troubleshooting guide for the Advanced Motors and Drive starter/generator is included at the end of this chapter. Refer to this guide when diagnosing a starter/generator problem on your Workman GTX vehicles. Brush and Brush Spring Service 1. Gain access to brushes by carefully removing rubber plugs from commutator end head of starter/generator. Figure 38 Electrical System 2. Check the length of the brush that extends from the top of the brush box. If the brush is less than 0.140” (3.
4. Pull drive head end along with attached armature from the frame housing. Figure 41 5. Position the motor so the commutator end head is facing upwards and remove the two (2) screws that secure the commutator end head. Lift commutator end head from frame housing. 6. Locate and retrieve wave washer from between armature and commutator end head. IMPORTANT: Use clean, dry, lint−free rags when cleaning the starter/generator.
9. Remove nut, lock washer, flat washer and fiber washer from A1 and A2 terminals on commutator end head. Figure 43 10.Remove two (2) screws that secure the brush box to the commutator end head. Carefully remove brush box from the commutator end head. Electrical System Figure 44 11. Remove brush assemblies from the brush box. Minimum brush length is 0.375 in (9.5 mm) Maximum brush length is 0.
12.Assembly new brushes to the brush plate. A. First, insert the brush with the short lead into one of the brush holders. Then rotate the brush plate 180o to insert the brush with the longer lead. Repeat for second brush assembly. B. Be sure that terminal insulator is positioned on each terminal bolt after assembly. Also, be sure to have the brush springs against the side of the brushes so the brushes do not go into the brush box fully. Figure 46 13.Verify the correct position of the brushes.
15.Secure A1 and A2 terminals to commutator end head with fiber washer, flat washer, lock washer and nut on each terminal. Torque nuts from 40 to 50 in−lb (4.6 to 5.6 N−m). Figure 49 16.Secure commutator end head assembly to frame housing with two (2) screws. Use marks placed on end head and housing to properly orientate head. Torque screws from 49 to 66 in−lb (5.6 to 7.4 N−m). Electrical System Figure 50 17.
18.Make sure that brushes are pushed back in brush holders so they will not interfere with armature installation. 19.Position wave washer into bearing bore in commutator end head. Figure 52 20.Carefully lower the armature and drive end head assembly into the frame housing making sure that armature bearing is inserted into bearing bore in commutator end head. 21.Use marks placed on drive end head and housing to properly orientate head. Secure drive end head to frame housing with two (2) screws.
23.Install rubber plugs to the commutator end head. 24.Make sure that the armature rotates freely after assembly. Figure 55 Starter/Generator Specifications NOTE: Rework to the starter/generator must be performed by a properly trained technician using the correct tools and equipment for testing and reworking electrical motors and generators. It may be more economically feasible to replace the starter/generator than have it reworked. Detail Specification Armature Resistance at 75F (24C) 0.
This page is intentionally blank.
Chapter 6 Chassis Table of Contents Front Brake Caliper Service . . . . . . . . . . . . . . . . . Rear Brake Calipers . . . . . . . . . . . . . . . . . . . . . . . . Rear Brake Caliper Service . . . . . . . . . . . . . . . . . . Parking Brake Cables and Lever Assembly . . . . Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . Brake Master Cylinder Service . . . . . . . . . . . . . . . Bleed Brake System . . . . . . . . . . . . . . . . . . . . . . . . Steering Assembly . . . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman GTX vehicle. Refer to the Operator’s Manual for additional information when servicing the vehicle. Thread Forming Fasteners Numerous thread forming fasteners are used to secure Workman GTX frame components.
Specifications Item Description Front and Rear Tires Pressure Range 205/65 -- 10 24 to 30 PSI (165 to 207 kPa) Wheel Lug Nut Torque (all wheels) 75 to 95 ft--lb (102 to 128 N--m) Front Wheel Toe--In 0 + 0.
Special Tools Order special tools from your Toro Distributor. Spanner Wrench Use spanner wrench to rotate collar on front suspension strut and rear shock absorber. Collar rotation may be necessary to accommodate installed accessories or heavier vehicle loads. Make sure that vehicle is jacked up off the ground to allow spring to be at full extension before using spanner wrench.
Tools for Frame Extension Kit Use this tool kit (shown in Fig. 4) when installing or servicing the vehicle frame extension kit. The installed kit is shown in Figure 5. 7 4 1 When the front and rear frame components are separated, the rear frame of the machine can be supported with the legs included in this tool kit. The legs attach to the rear frame with two (2) flange head screws and nuts for each leg.
Troubleshooting Suspension and Steering Problem Possible Cause Front end is noisy. Front wheel lug nuts are loose. Front wheel bearings are loose or worn. Front suspension struts are loose or worn. Front end components (e.g. tie--rod, spindle, A--arm) are loose or worn. Steering rack assembly is damaged or worn. Rear end is noisy. Rear wheel lug nuts are loose. Rear suspension shocks are loose or worn. Rear wheel bearings are loose or worn. Rear end components (e.g.
Suspension and Steering (continued) Problem Possible Cause Front end shimmies. Front wheel lug nuts are loose. Front wheel alignment (toe--in) is incorrect. Front wheel bearings are loose or worn. Tie rod ends are loose or worn. Steering shaft bearings or joints are loose or worn. Bushings in spindle or A--arm are loose or worn. Steering is hard. Tire pressure is low or uneven between tires. Steering components are binding or damaged. Front wheel alignment (toe--in) is incorrect.
Brakes (continued) Problem Possible Cause Brakes pull to either side. Tire pressure is incorrect or uneven between tires. Brake pads are worn or contaminated. Front wheel alignment (toe--in) is incorrect. Brake rotors are bent or damaged. Tires on same axle are unmatched. Brakes squeal. Brake pads are worn or contaminated. Brake components are dirty. Brake rotors are scored or bent. Brakes drag. Parking brake is applied or incorrectly adjusted. Brake pedal is binding. Parking brake cable is binding.
Adjustments Adjust Parking Brake Checking Parking Brake (Fig. 7) 8. Adjust other rear wheel using steps 4 to 7 above. 1. Apply parking brake with brake lever on dash. 9. Check parking brake adjustment as described in Checking Parking Brake on this page. Make additional parking brake adjustments if necessary. 2. There should be tension felt when applying the parking brake within 4 ” to 6 ” (11.4 to 16.
Adjust Front Wheel Toe--in 1. Adjust tire pressures from 24 to 30 PSI (165 to 207 kPa) before checking front wheel toe--in. 2. Either have an operator on the vehicle operator’s seat or add weight to the driver’s seat equal to the average operator who will run the vehicle. The operator or weight must remain on the seat for the duration of the front wheel toe--in adjustment procedure. 1 2 3.
Service and Repairs Check Tire Pressure The tire pressure range for front and rear tires is 24 to 30 PSI (165 to 207 kPa). The air pressure needed is determined by the payload carried. Lower air pressure will provide less compaction, a smoother ride and fewer tire marks. Lower pressure should not be used for heavy payloads at higher speeds. Higher pressures should be used for heavier payloads at higher speeds. Do not exceed the maximum tire pressure.
Front Wheels and Hubs Lifted suspension models 18 14 18 17 See text for tightening procedure 12 2 14 5 4 10 6 8 9 7 35 to 40 ft−lb (48 to 54 N−m) Medium Strength Thread Locker RIGHT 3 1 75 to 95 ft−lb (102 to 128 N−m) 16 15 13 9 to 11 ft−lb (13 to 14 N−m) 12 11 2 FRONT 1 Figure 11 1. 2. 3. 4. 5. 6. Front wheel assembly Lug nut (4 per wheel) Front brake caliper (LH shown) Socket head screw (2 per caliper) Front brake line Banjo bolt and washers 7. 8. 9. 10. 11. 12.
6. Remove the cotter pin, retainer, jam nut and tab washer. Slide the front wheel hub from the spindle shaft. 7. Pull the seal out of the wheel hub. Discard seal. 8. Remove the bearing cones from both sides of the wheel hub. Clean the bearings in solvent. Make sure the bearings are in good operating condition. Clean the inside of the wheel hub. Check the bearing cups for wear, pitting or other damage. Replace worn or damaged parts. 9.
Rear Wheels and Hubs 13 17 Lifted suspension models 1 12 220 to 240 ft−lb (299 to 325 N−m) 11 35 to 40 ft−lb (48 to 54 N−m) Medium Strength Thread Locker 9 4 10 2 5 8 3 13 6 7 75 to 95 ft−lb (102 to 128 N−m) 1 17 12 14 16 Antiseize Lubricant 15 RIGHT 11 9 to 11 ft−lb (13 to 14 N−m) 10 2 FRONT 220 to 240 ft−lb (299 to 325 N−m) Figure 13 1. 2. 3. 4. 5. 6.
4. Install the wheel hub to the transaxle shaft: 1. Park vehicle on a level surface, stop engine and remove key from the key switch. Do not apply parking brake. A. Install hardened spacer, wheel hub and then thrust washer onto the transaxle shaft. B. Secure wheel hub assembly with slotted hex nut. Torque slotted hex nut from 220 to 240 ft--lb (299 to 325 N--m). Make sure that slot in nut aligns with hole in transaxle shaft to allow installation of cotter pin.
Front Brake Calipers RIGHT 9 to 11 ft--lb (13 to 14 N--m) 4 FRONT 5 6 7 8 10 2 3 54 to 66 in--lb (6.1 to 7.4 N--m) 9 11 35 to 40 ft--lb (48 to 54 N--m) Medium Strength Thread Locker 1 108 to 132 in--lb (12.3 to 14.9 N--m) Figure 14 1. 2. 3. 4. LH brake caliper RH brake caliper Socket head screw (2 per caliper) Wheel hub assembly (2 used) Chassis 5. 6. 7. 8. Brake rotor (2 used) Socket head screw (4 per rotor) Spindle (RH shown) Front brake line Page 6 -- 16 9. Banjo bolt 10.
4. Connect brake line to front brake caliper (Fig. 15): Disassembly (Fig. 14) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the key switch. A. Position brake line to caliper. B. Place banjo washer on each side of brake line fitting. WARNING C. Install banjo bolt through brake line fitting and banjo washers and then thread into caliper. Torque banjo bolt from 108 to 132 in--lb (12.3 to 14.9 N--m).
Front Brake Caliper Service 9 White Lithium Grease 4 27 to 33 ft--lb (37 to 44 N--m) 3 8 7 6 1 5 BAF--12 Assembly Lube 2 Figure 16 1. Bolt (2 used) 2. Caliper body 3. O--ring (4 used) Chassis 4. Caliper bracket 5. Square seal (2 used) 6. Dust seal (used) Page 6 -- 18 7. Piston (2 used) 8. Brake pad (2 used) 9.
Disassembly (Fig. 16) Assembly (Fig. 16) 1. Remove two (2) bolts that secure brake caliper body to the caliper anvil. 1. If caliper body was disassembled, install components in caliper body: 2. Remove caliper anvil and then slide brake pads from pins on caliper bracket. A. Apply hydraulic brake cylinder assembly lube (BAF--12 or equivalent) to square seals, dust seals and piston before installation. 3. Slide caliper body assembly from caliper bracket. 4.
Rear Brake Calipers 108 to 132 in--lb (12.3 to 14.9 N--m) 35 to 40 ft--lb (48 to 54 N--m) Medium Strength Thread Locker 2 4 54 to 66 in--lb (6.1 to 7.4 N--m) 5 10 1 9 3 8 16 17 15 7 6 RIGHT 12 9 to 11 ft--lb (13 to 14 N--m) FRONT 220 to 240 ft--lb (299 to 325 N--m) 11 14 13 Figure 17 1. 2. 3. 4. 5. 6. LH rear brake caliper assembly RH rear brake caliper assembly Transaxle assembly Rear swing arm Socket head screw (2 per caliper) Parking brake cable (2 used) 7. 8. 9. 10. 11. 12.
5. Disconnect brake line from rear brake caliper: C. Rotate brake lever on caliper toward front of vehicle and hold lever in place. Then, insert cable into caliper bracket and slowly release brake lever to align cable conduit with caliper bracket. A. Clean brake line area of brake caliper to prevent contamination of brake system. B. Remove banjo bolt that secures brake line fitting to caliper. 3 C. Carefully separate brake line from caliper.
Rear Brake Caliper Service 2 1 30 to 35 ft--lb (41 to 47 N--m) 3 5 4 108 to 132 in--lb (12.3 to 14.9 N--m) Figure 19 1. Brake caliper assembly (LH shown) 2. Caliper slide pin (2 used) 3. Anti--rattle spring (2 used) 4. Brake pad assembly 5. Bleed screw NOTE: Replacement parts for the rear caliper assembly are limited to the brake pad assembly and bleed screw. If any other caliper components are damaged or worn, replace the caliper assembly.
Disassembly (Fig. 19) 1. Remove two (2) caliper slide pins that secure brake pads to the caliper assembly. 2 2. Slide brake pads with attached anti--rattle springs from caliper. 3. Remove anti--rattle springs from brake pads. 4. Clean caliper components with brake cleaner. 3 Inspection 1. Check brake pads for uneven wear that might indicate binding in the caliper assembly. Replace the brake pads if the friction material is worn to less than 1/16” (1.6 mm).
Parking Brake Cables and Lever Assembly FRONT RIGHT 14 13 200 to 230 in--lb (23 to 25 N--m) 12 40 to 45 in--lb (4.5 to 5 N--m) 12 4 5 2 8 9 6 3 10 3 11 1 7 Figure 21 1. 2. 3. 4. 5. Parking brake lever Clevis pin Hair pin (2 used) Parking brake link Clevis pin 6. 7. 8. 9. 10. Cable equalizer bracket Button head screw (2 used) Flange nut (2 used) Parking brake mount Parking brake cable (2 used) 11. 12. 13. 14.
Disassembly (Fig. 21) 1. Park vehicle on a level surface, stop engine and remove key from the key switch. Chock wheels to prevent the vehicle from moving. 3. Secure brake cables to parking brake lever assembly: A. Insert both brake cable ends through parking brake mount and then through jam nuts. 2. Disconnect both parking brake cables from rear brake calipers (Fig. 22): B. Insert both cable ends into cable equalizer bracket. A. Make sure that parking brake is released. C.
Brake Master Cylinder RIGHT FRONT 7 3 2 4 1 5 9 8 6 75 to 85 in--lb (8.5 to 9.6 N--m) Figure 23 1. Master cylinder 2. Hair pin 3. Clevis pin Chassis 4. Brake pedal 5. Pedal mount 6. Flange nut (2 used) Page 6 -- 26 7. Flange head screw (2 used) 8. Front brake line 9.
Removal (Fig. 23) 1 1. Park machine on a level surface, stop engine, set parking brake and remove key from the key switch. 2. Raise front hood to gain access to master cylinder. 3. Remove hair pin from the clevis pin that connects master cylinder to brake pedal. IMPORTANT: To prevent contamination of the brake system, make sure to clean master cylinder components before disassembly. 4. Clean hydraulic brake line area of master cylinder to prevent contamination. Remove both brake lines from master cylinder.
Brake Master Cylinder Service Disassembly (Fig. 25) 1. Thoroughly clean outside of master cylinder before disassembly. 2. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 1 2 12 3 3. Disconnect lower end of the dust cover from the housing. 4. Push in on the push rod and remove circlip, then remove push rod with dust cover and clevis. Remove retainer washer. 4 11 5. Remove primary piston assembly and secondary piston assembly from cylinder housing.
Bleed Brake System IMPORTANT: To prevent contamination of the brake system, make sure to clean components before disassembly. 1. Park machine on a level surface, stop engine and remove key from the key switch. Do not apply parking brake. 2 1. Connect a suitable transparent hose to bleeder valve on front or rear brake caliper. Submerge other end of hose in a glass container partially filled with clean brake fluid. 1 54 to 66 in--lb (6.1 to 7.4 N--m) 2.
Steering Assembly 11 FRONT 16 to 20 ft--lb (21.5 to 27 N--m) 13 12 14 7 3 RIGHT 2 10 3 4 9 5 6 1 8 16 15 16 to 20 ft--lb (21.5 to 27 N--m) 45 to 55 ft--lb (61 to 75 N--m) Figure 28 1. 2. 3. 4. 5. 6. Steering rack assembly Steering column Bearing (2 used) Steering shaft Lock washer Cap screw 7. 8. 9. 10. 11. Dust cover Washer head screw (4 used) Carriage bolt (4 used) Flange nut (4 used) Steering wheel Disassembly (Fig. 28) 1.
9. Lift up on steering column assembly, slide lower steering shaft joint from the steering rack assembly input shaft and remove steering column from vehicle. A. Install steering wheel onto steering shaft. Leave steering wheel loose on shaft. B. Rotate the steering wheel until the distance from the steering rack boot to the tie rod is equal on both sides of vehicle indicating that the front wheels are centered. 10.Remove dust cover from the steering shaft. Replace cover if damaged. 11.
Steering Rack Assembly Service 6 5 4 45 to 50 ft--lb (61 to 75 N--m) 7 2 8 3 Medium Strength Thread Locker 1 34 to 42 ft--lb (47 to 57 N--m) Figure 30 1. Tie rod end (2 used) 2. Jam nut (2 used) 3. Tie rod track (2 used) 4. Bellows clamp (2 used) 5. Bellows (2 used) 6. Bellows clamp (2 used) 7. Input shaft seal 8. Steering rack assembly NOTE: Check parts catalog to identify individual components that are available for the steering rack assembly on your Workman GTX vehicle.
Disassembly (Fig. 30) 1. For assembly purposes, measure the distance from shoulder on the tie rod track to the location of the tie rod end (Fig. 31). This will help to adjust front wheel toe--in during assembly of steering rack. 2. Loosen jam nut that secures tie rod end to tie rod track. Remove tie rod end and jam nut from end of tie rod track. 3. Remove clamps that secure bellows to the tie rod track and steering rack housing. Remove bellows from steering rack assembly. 4.
Shift Lever Assembly 20 21 22 16 15 12 14 19 13 18 5 3 1 21 17 11 10 4 6 2 9 8 7 FRONT RIGHT Figure 33 1. 2. 3. 4. 5. 6. 7. 8. Steering column Carriage screw (4 used) Flange nut (4 used) Pedal mount assembly Shift cable Extension spring Detent arm Bearing Chassis 9. Lock nut 10. Shoulder screw 11. Flange nut 12. Ball joint 13. Lock nut 14. Shift arm 15. Slotted roll pin Page 6 -- 34 16. 17. 18. 19. 20. 21. 22.
Disassembly (Fig. 33) 3 1. Park vehicle on a level surface, stop engine, set parking brake and remove key from the key switch. 2. Raise front hood to gain access to the steering components. 1 3. Remove dash and position it toward the front of the vehicle to allow access to the shift lever assembly (see Dash in this section). It is not necessary to remove choke cable from dash. 2 4. Disassemble shift lever as necessary using Figures 33 and 22 as guides. Assembly (Fig. 33) 1.
Front Suspension 200 to 230 in--lb (23 to 25 N--m) 200 to 230 in--lb (23 to 25 N--m) 22 80 to 90 ft--lb (109 to 122 N--m) 23 17 18 45 to 55 ft--lb (61 to 75 N--m) 23 27 to 33 ft--lb (37 to 44 N--m) 45 to 55 ft--lb (61 to 75 N--m) 24 27 to 33 ft--lb (37 to 44 N--m) 13 25 14 20 9 14 26 27 19 16 21 7 FRONT 4 14 15 RIGHT 2 8 45 to 55 ft--lb (61 to 75 N--m) 12 27 to 33 ft--lb (37 to 44 N--m) 6 10 11 Grade 8 5 Grade 5 3 1 Figure 35 1. 2. 3. 4. 5. 6. 7. 8. 9.
4. Remove front wheel assembly and wheel hub from vehicle (see Front Wheels and Hubs in this section). 5. Remove spindle assembly from vehicle: A. Remove cotter pin and slotted hex nut securing steering rack tie rod ball joint stud to the spindle. Separate ball joint from the spindle. 2. If suspension strut assembly was removed from vehicle, position the top of the strut assembly to the front frame and secure with flange head screw and lock nut. Torque screw from 80 to 90 ft--lb (109 to 122 N--m). 3.
Rear Suspension 12 5 Lifted suspension models 7 4 27 to 33 ft−lb (37 to 44 N−m) 6 77 to 95 ft− lb (104 to 128 N--m) 27 to 33 ft−lb (37 to 44 N−m) 1 2 13 16 6 6 15 9 5 6 7 9 77 to 95 ft−lb (104 to 128 N−m) 17 3 27 to 33 ft−lb (37 to 44 N−m) 11 10 11 8 7 5 14 4 7 RIGHT 4 9 77 to 95 ft−lb (104 to 128 N−m) 77 to 95 ft− lb (104 to 128 N−m) 6 18 FRONT 77 to 95 ft−lb (104 to 128 N−m) 7 5 Figure 37 1. 2. 3. 4. 5. 6.
3. Chock front wheels. Use a jack to raise rear wheels off the ground. Support vehicle with appropriate jack stands beneath the rear frame. 2. Install rear shock absorber(s) if it was removed (Fig. 38): A. Position shock absorber(s) to rear frame and swing arm brackets. 4. Support transaxle from below to prevent the transaxle and swing arm from moving during rear suspension disassembly. CAUTION B. Secure shock absorber(s) to vehicle with flange head screws and lock nuts.
Swing Arm Mount Assembly 140 to 160 ft--lb (190 to 216 N--m) RIGHT FRONT 4 3 27 to 33 ft--lb (37 to 44 N--m) 5 9 1 6 2 7 8 10 Figure 40 1. 2. 3. 4. Front frame Swing arm Cap screw Upper plate Chassis 5. Isolator (upper portion) 6. Isolator (lower portion) 7. Snubbing washer Page 6 -- 40 8. Rear suspension mount 9. Cap screw (2 used) 10.
Removal (Fig. 40) Installation (Fig. 40) 1. Park vehicle on a level surface, stop engine and remove key from the key switch. Make sure to set the parking brake. 1. If rear suspension mount was removed, position mount to front frame and secure with two (2) cap screws, washers and flange nuts. Torque cap screws from 27 to 33 ft--lb (37 to 44 N--m). 2. Raise and support cargo bed with prop rod. 3. Chock the front and rear of both front tires to prevent the vehicle from moving.
Seat Base 8 18 to 22 in--lb (2.1 to 2.4 N--m) 40 to 45 in--lb (4.6 to 5.0 N--m) 20 1 90 to 110 in--lb (10.2 to 12.4 N--m) 18 16 21 17 5 7 40 to 45 in--lb (4.6 to 5.0 N--m) 14 15 19 12 4 6 13 16 16 6 10 18 to 22 in--lb (2.1 to 2.4 N--m) 11 23 16 15 22 2 12 9 3 17 12 RIGHT 17 90 to 110 in--lb (10.2 to 12.4 N--m) FRONT Figure 41 1. 2. 3. 4. 5. 6. 7. 8.
Disassembly (Fig. 41) 1. Park vehicle on a level surface, stop engine, engage parking brake and remove key from the key switch. 40 to 45 in--lb (4.6 to 5.0 N--m) 1 2. Remove seat base assembly with attached seats from vehicle. 11 3 3. If right hand seat base side is to be removed from vehicle (Fig. 42): 4 5 7 A. Remove battery from vehicle (see Battery Service in the Service and Repairs section of Chapter 5 -- Electrical System). 2 18 to 22 in--lb (2.1 to 2.4 N--m) B.
Dash 40 to 45 in--lb (4.6 to 5.0 N--m) 90 to 100 in--lb (10.2 to 11.3 N--m) 13 2 15 12 13 2 16 9 13 5 1 3 10 40 to 45 in--lb (4.6 to 5.0 N--m) 14 5 4 6 11 5 40 to 45 in--lb (4.6 to 5.0 N--m) 18 to 22 in--lb (2.1 to 2.4 N--m) 18 to 22 in--lb (2.1 to 2.4 N--m) 8 FRONT 7 RIGHT Figure 44 1. 2. 3. 4. 5. 6. Dash Washer head screw (10 used) Foot board Screw (2 used) Washer head screw (10 used) Foot board cover Chassis 7. 8. 9. 10. 11.
Removal (Fig. 44) Installation (Fig. 44) 1. Park vehicle on a level surface, stop engine, apply parking brake and remove key from the key switch. NOTE: Do not fully tighten fasteners securing dash until all fasteners are in place. 2. Raise hood to allow access to wire harness connections to switches mounted in dash. 1. If choke cable was removed, install choke cable to dash and engine. 3. Disconnect wire harness connectors from all switches and power ports on dash. 2.
Front Fenders, Hood and Bumper 7 7 to 13 in--lb (0.8 to 1.4 N--m) 20 10 19 18 11 8 9 13 18 to 22 in--lb (2.1 to 2.4 N--m) 4 18 to 22 in--lb (2.1 to 2.4 N--m) 3 2 21 1 22 40 to 45 in--lb (4.6 to 5.0 N--m) 17 14 5 RIGHT 200 to 230 in--lb (23 to 25 N--m) 6 12 15 FRONT 16 25 24 40 to 45 in--lb (4.6 to 5.0 N--m) 23 Figure 45 1. 2. 3. 4. 5. 6. 7. 8. 9.
Installation (Fig. 45) 1. Park vehicle on a level surface, stop engine, set parking brake and remove key from the key switch. NOTE: Do not fully tighten fasteners securing body components until all fasteners are in place. 2. Remove front fenders, hood or front bumper using Figure 45 as a guide. 1. Install removed body components using Figure 45 as a guide. During assembly, use fastener torque specifications that are identified in Figure 45. Chassis Removal (Fig.
Cargo Bed 2 RIGHT FRONT 5 6 12 3 133 to 147 in--lb (15 to 16 N--m) 10 4 8 9 11 3 7 1 8 140 to 170 in--lb (16 to 19 N--m) 4 27 to 33 ft--lb (37 to 44 N--m) Figure 46 1. 2. 3. 4. Cap screw (2 used) Cargo bed assembly Flange head screw Bed latch striker (2 used) Chassis 5. 6. 7. 8. Prop rod RH cargo bed support LH cargo bed support Flange head screw (6 used) Page 6 -- 48 9. 10. 11. 12.
Disassembly 1. Park vehicle on a level surface, stop engine, set parking brake and remove key from the key switch. 133 to 147 in--lb (15 to 16 N--m) 90 to 110 in--lb (10.2 to 12.4 N--m) 2. Make sure that cargo bed is empty. 4 3 6 10 2 3. If necessary, remove cargo bed from vehicle (Fig. 46): A. Raise cargo bed and support bed so that prop rod assembly can be removed from bottom of bed. 11 9 B.
This page is intentionally blank.
Chapter 7 Electrical Drawings Table of Contents Workman GTX Gasoline Page 7 -- 1 Electrical Drawings ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 ELECTRICAL SCHEMATICS Electrical Schematic (carbureted engine) Machine serial number below 401400000 . . . . 3 Electrical Schematic (carbureted engine) Machine serial numbers 401400001 to 403448000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Electrical Schematic (carbureted engine) Machine serial numbers above 403448001 . . .
Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE PK PINK R or RD RED T or TN TAN VIO VIOLET W or WH WHITE Y or YE YELLOW Numerous harness wires used on Workman GTX vehicles include a line with an alternate color.
6 5 4 3 2 1 122--0226 REV. A D D C C B B Workman GTX Gasoline Models 07042 and 07152 (carbureted engine) Machine serial number below 401400000 Electrical Schematic A A All relays and solenoids are shown as de-- energized. All ground wires are black.
6 5 4 3 2 1 122--1144 REV. A D D C C B B A Workman GTX Gasoline (carbureted engine) Machine serial number 401400001 to 403448000 Electrical Schematic A All relays and solenoids are shown as de-- energized. All ground wires are black.
122--1470 Rev.
6 5 4 3 2 1 122--1029 REV. B D D C C B B Workman GTX Gasoline (EFI engine) Machine Serial Numbers Below 403446000 Electrical Schematic A All relays and solenoids are shown as de-- energized. All ground wires are black.
122--1472 Rev.
6 5 4 3 2 1 122--1029 REV.
6 5 4 3 2 1 122--1029 REV.
6 5 4 3 2 1 122--1029 REV.
6 5 4 3 2 1 122--0225 REV.
6 5 4 3 2 1 122--0225 REV.
6 5 4 3 2 1 122--1143 REV.
6 5 4 3 2 1 122--1143 REV.
122--1471 Rev.
122--1471 Rev.
6 5 4 3 2 1 122--1030 REV.
6 5 4 3 2 1 122--1030 REV.
122--1473 Rev.
122--1473 Rev.
6 5 4 3 2 1 122--0730 REV.
6 5 4 3 2 1 122--0818 REV.
6 5 4 3 2 1 122--0785 REV.
6 5 4 3 2 1 122--0739 REV.
6 5 4 3 2 1 122--3995 REV.
