PART NO. 93808SL, Rev. G Service Manual (Serial No. Below 240000000) Workman� 3000/4000 Series For Vehicles with Liquid Cooled Engines S/N 220000001 – 239999999 Preface Use this book along with the Toro Operator’s Manual and Parts Catalog for the specific model and serial number of the machine, and the Briggs–Daihatsu 3LC Gas or Diesel Engine Repair Manual: Toro Part No. 99048SL (Gas) or 01091SL (Diesel).
Workman 3000/4000 Series
Safety Table Of Contents Chapter 1 – Safety Chapter 5 – Kohler Command Series Air Cooled Gas Engine Briggs–Daihatsu Gas Engine (Workman S/N 220000001 & Up – See Part No. 99048SL Briggs–Daihatsu 3LC Gas Engine Repair Manual) Chapter 4 – Mitsubishi Diesel Engine (Workman S/N Below 220000001) General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 – 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 – 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . .
Workman 3000/4000 Series
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 3 Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 – 4 Chapter 11 – Liquid Propane Gas Conversion Kit (For Mitsubishi Engine only) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 – 2 General Information . . . . . . . . . . . . . . . . . . . . . . . 11 – 3 Special Tools . . . . . . . . . . .
Workman 3000/4000 Series
Safety Table of Contents 1 1 1 2 Maintenance and Service . . . . . . . . . . . . . . . . . . . . . 3 Jacking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Using Bed Safety Support . . . . . . . . . . . . . . . . . . . . 5 The WORKMAN 3000 Series vehicles are designed and tested to offer safe service when operated and main tained properly.
4. Never allow children to operate the vehicle or adults to operate it without proper instructions. Only trained and authorized persons should operate this vehicle. Make sure all operators are physically and mentally ca pable of operating the vehicle. Anyone who operates the vehicle should have a motor vehicle license. 5. This vehicle is designed to carry Only You, the opera tor, and One Passenger in the seat provided by the manufacturer. Never carry any other passengers on the vehicle. 11.
K. Never operate vehicle in or near an area where there is dust or fumes in the air which are explosive. The electrical and exhaust systems of the vehicle can produce sparks capable of igniting explosive materials. D. Use extra caution when operating vehicle on wet surfaces, at higher speeds or with a full load. Stop ping time will increase with a full load. Shift into a lower gear before starting up or down a hill. L.
28. To reduce potential fire hazard, keep the engine area free of excessive grease, grass, leaves and accu mulation of dirt. 29. If the engine must be running to perform a mainte nance adjustment, keep hands, feet, clothing, and any parts of the body away from the engine and any moving parts. Keep everyone away. 30. Do not over–speed engine by changing governor settings. Maximum engine speed is 3650 RPM.
Safety Using Bed Safety Support Many of the procedures shown in this manual require raising and lowering the bed. The following precautions must be taken or serious injury or death could result. 1 WARNING Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition switch. Any load material must be removed from bed or other attachment before working under raised bed.
Safety Page 1 – 6 Workman 3000 Series
Chapter 2 Table of Contents 1 2 2 2 TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3 Capscrew Markings and Torque Values – U.S. . . 3 Capscrew Markings and Torque Values – Metric . 3 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 QUICK REFERENCE MAINTENANCE AID . . . . . . . 9 OPERATION AND SERVICE HISTORY REPORT . 11 Record information about your Workman vehicle on the OPERATION AND SERVICE HISTORY REPORT form.
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Workman 3000/4000 Series
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 spe cified 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 Ser vice Manual.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size 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 – 32 UNC # 6 – 40 UNF # 8 – 32 UNC 13 + 2 25 + 5 # 10 – 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs, & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in–lb N–cm in–lb N–cm 15 + 2 170 + 20 23 + 2 260 +
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Reg lar Height N ts Regular Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Reg lar Height N ts Regular 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 Recommended Torque 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 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.
Lubrication WARNING Product Records and Maintenance Before servicing or making adjustments to the machine, stop engine, set parking brake, and remove key from the ignition switch. Any load material must be removed from the bed or other attachment before working un der it. Always place the safety support on an extended lift cylinder to hold up the bed. GREASING BEARINGS AND BUSHINGS The vehicle has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
Figure 6 Figure 4 Figure 7 Figure 5 Figure 8 IMPORTANT Heavy Duty Operation If vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently.
Product Records and Maintenance 15 SAE 10W–30 SG, SH or SJ 15 SAE 10W–30 SG, SH or SJ DEXTRON III ATF 93–2195 NOTE: Two wheel drive chart shown. Workman 3000/4000 Series Page 2 – 9 Rev.
15 See Note Below NOTE: Four wheel drive chart shown. Use SAE 10W–30 CD, CE, CF, or CF–4 engine oil. Product Records and Maintenance Page 2 – 10 Rev.
Product Records and Maintenance EQUIPMENT OPERATION AND SERVICE HISTORY REPORT FOR WORKMAN� 3100 AND 3120 VEHICLES TORO Model and Serial Number: _____________–___________ Engine Numbers: _________________________ Transaxle Numbers: _________________________ Date Purchased: _________________________ Purchased From: _________________________ Warranty Expires___________ _________________________ _________________________ Contacts: Parts _________________________ Phone___________________ Service
WORKMAN� 3100 and 3120 Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Check Battery Fluid Level Check Battery Cable Connections Lubricate Engine Prefilter Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800hrs A Level Service � Change Engine Oil and Filter Lubricate All Grease Fittings Remove Engine Shrouds and Clean Fins Inspect Condition and Wear of Tires B Level Service � Check Cable Adjustments � Check Pump Drive
WORKMAN� 3100 and 3120 Daily Maintenance Check List Unit Designation:_____________ TORO ID#________–_________ Daily Maintenance Check For Week Of _________________ Maintenance Check Item � MON TUES WED THURS FRI SAT SUN ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs.
Product Records and Maintenance Page 2 – 14 Rev. D Workman 3000/4000 Series A B C D Other Service to perform (circle): __________________–__________________ TORO I.D.
Product Records and Maintenance EQUIPMENT OPERATION AND SERVICE HISTORY REPORT FOR WORKMAN� 3200, 3210, 3220, AND 4200 VEHICLES TORO Model and Serial Number: _____________–___________ Engine Numbers: _________________________ Transaxle/Differential Numbers: _________________________ Date Purchased: _________________________ Purchased From: _________________________ Warranty Expires___________ _________________________ _________________________ Contacts: Parts _________________________ Phone__
WORKMAN� 3200, 3210, 3220, and 4200 Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Check Battery Fluid Level Check Battery Cable Connections Check Dust Cup and Baffle Every 50hrs A Level Service Every 100hrs Every 200hrs Every 400hrs Every 800hrs Lubricate All Grease Fittings Inspect Condition and Wear of Tires Check Front Differential Oil Level (4WD) � Change Engine Oil and Filter Inspect Cooling System Hoses Check Governor Oil L
WORKMAN� 3200, 3210, 3220, and 4200 Daily Maintenance Checklist Daily Maintenance Check For Week Of _________________ Maintenance Check Item � MON TUES WED THURS FRI SAT SUN ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs.
Product Records and Maintenance Page 2 – 18 Rev. D Workman 3000/4000 Series A B C D Other Service to perform (circle): __________________–__________________ TORO I.D.
Product Records and Maintenance EQUIPMENT OPERATION AND SERVICE HISTORY REPORT FOR WORKMAN� 3300–D, 3310–D, 3320–D, AND 4300–D VEHICLES TORO Model and Serial Number: _____________–___________ Engine Numbers: _________________________ Transaxle/Differential Numbers: _________________________ Date Purchased: _________________________ Purchased From: _________________________ Warranty Expires___________ _________________________ _________________________ Contacts: Parts _________________________
WORKMAN� 3300–D, 3310–D, 3320–D, and 4300–D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Check Battery Fluid Level Check Battery Cable Connections Check Dust Cup and Baffle Every 50hrs A Level Service Every 100hrs Every 200hrs Every 400hrs Every 800hrs Lubricate All Grease Fittings Inspect Condition and Wear of Tires Check Front Differential Oil Level (4WD) � Change Engine Oil and Filter Inspect Cooling System Hoses B Level Ser
WORKMAN� 3300–D, 3310–D, 3320–D, and 4300–D Daily Maintenance Checklist Daily Maintenance Check For Week Of _________________ Maintenance Check Item � MON TUES WED THURS FRI SAT SUN ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs.
Product Records and Maintenance Page 2 – 22 Rev. D Workman 3000/4000 Series R A B C D Other Service to perform (circle): __________________–__________________ TORO I.D.
Product Records and Maintenance EQUIPMENT OPERATION AND SERVICE HISTORY REPORT for WORKMAN� 3420–LP VEHICLE TORO Model and Serial Number: _____________–___________ Engine Numbers: _________________________ Transaxle/Differential Numbers: _________________________ Date Purchased: _________________________ Purchased From: _________________________ Warranty Expires___________ _________________________ _________________________ Contacts: Parts _________________________ Phone___________________ S
WORKMAN� 3420–LP Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Check Battery Fluid Level Check Battery Cable Connections Check Dust Cup and Baffle Every 50hrs A Level Service Every 100hrs Every 200hrs Every 400hrs Every 800hrs Lubricate All Grease Fittings Inspect Condition and Wear of Tires � Change Engine Oil and Filter Inspect Cooling System Hoses Check Governor Oil Level B Level Service � Check Cable Adjustments � Check Alt
WORKMAN� 3420–LP Daily Maintenance Checklist Daily Maintenance Check For Week Of _________________ Maintenance Check Item � MON TUES WED THURS FRI SAT SUN ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs.
Product Records and Maintenance Page 2 – 26 Rev. D Workman 3000/4000 Series A B C D Other Service to perform (circle): __________________–__________________ TORO I.D.
Chapter 3 Mitsubishi Engine (Workman S/N Below 220000001) Liquid Cooled Gas Engine GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuel System . . . . . . . . . . . . . . . . . . . . .
General Information Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section. The use of some specialized test equipment is explained, how ever, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at a engine repair facility. If no parts list is available be sure to provide your Distributor with the TORO Model Number and Serial Number.
Specifications General Item Specification Make/Designation Mitsubishi 3G83–051TV, In–line slant (60�), over head camshaft 3 Cylinder Bore 65 mm (2.559 in.) Piston Stroke 66 mm (2.598 in.) Total Displacement 657 cc (40.09 cu. in.) Compression Ratio 9.
Engine Item Standard Specification Limit Compression kPa (psi) Minimum 960 (137) Compression pressure difference between cylinders kPa (psi) Maximum 100 (14) Cylinder Head Overall height mm (in.) Flatness of gasket surface mm (in.) Oversize rework of valve seat hole mm (in.) Intake 0.3 (.012) oversize 0.6 (.024) oversize Exhaust 0.3 (.012) oversize 0.6 (.024) oversize Oversize rework of valve guide hole (both intake and exhaust) mm (in.) 0.05 (.002) oversize 0.25 (.010) oversize 0.50 (.
Engine (cont.) Item Standard Specification Limit Valves Exhaust Face angle Thickness of valve head (margin) mm (in.) Intake Exhaust 100.6 (3.960) 100.8 (3.968) 6.565 – 6.580 (.2585 – .2591) 6.530 – 6.550 (.2571 – .2579) 45� – 45.5� 1.0 (.039) 1.3 (.051) 0.5 (.020) 0.8 (.031) Valve Stem to Guide Clearance mm (in.) Intake Exhaust 0.02 – 0.05 (.0008 – .0020) 0.050 – 0.085 (.0020 – .0033) 0.10 (.0039) 0.15 (.0059) Valve Guides Length mm (in.) Intake Exhaust Service size mm (in.) 44 (1.73) 49.5 (1.
Engine (cont.) Item Standard Specification Limit Piston O.D. mm (in.) Clearance (piston to cylinder) mm (in.) Ring groove width mm (in.) No. 1 No. 2 Oil Service size mm (in.) 64.97 – 65.00 (2.5579 – 2.5591) 0.02 – 0.04 (.0008 – .0016) 1.22 – 1.24 (.0480 – .0488) 1.21 – 1.23 (.0476 – .0484) 2.815 – 2.835 (.1108 – .1116) 0.25 (.010), 0.50 (.020), 0.75 (.030), 1.00 (.039) oversize Piston Ring End gap mm (in.) No. 1 No. 2 Oil Side clearance mm (in.) No. 1 No. 2 0.15 – 0.30 (.0059 – .0118) 0.35 – 0.50 (.
Engine (cont.) Item Standard Specification Limit Crankshaft Journal O.D. mm (in.) Pin. O.D. mm (in.) Cylindricity of journal and pin mm (in.) Concentricity of journal and pin mm (in.) Oil clearance of journal mm (in.) Oil clearance of pin Undersize rework dimension of journal mm (in.) 0.25 U.S. 0.50 U.S. 0.75 U.S. Undersize rework dimension of pin mm (in.) 0.25 U.S. 0.50 U.S. 0.75 U.S. 0.05 – 0.25 (.0020 – .0098) 39.98 – 40.00 (1.5740 – 1.5748) 35.98 – 36.00 (1.4165 – 1.4173) Less than 0.005 (.
Lubrication System Item Standard Specification Limit Engine oil Capacity API Service Class 3.2 liter (3.4 U.S. qt.) including oil filter SJ or SJ/CF Viscosity 10� C to 40� C (14� F to 104� F) Above 68� F (20� C) SAE 10W–30 SAE 30 or 10W–30 Oil Pump Type Drive gear side clearance mm (in.) Driven gear side clearance mm (in.) Gear 0.07 – 0.13 (.0028 – .0051) 0.06 – 0.12 (.0024 – .0047) Fuel System Item Standard Specification Limit Carburetor Type Identification mark Maker model no.
Electrical System Item Standard Specification Limit Alternator Nominal Output 12V – 40A Slip ring O.D. mm (in.) Rotor coil resistance ohms Brush length mm (in.) Regulated voltage volts at 25� C (77� F) 14.4 (.567) 2.8 – 3.0 10.5 (.413) 14.2 – 14.8 14.0 (.551) 4.5 (.177) Type Nominal Output Free running characteristics Terminal voltage volts Current Amps Speed RPM Commutator runout mm (in.) Commutator diameter mm (in.) Undercut depth mm (in.) Brush length mm (in.
Tightening Torques The Mitsubishi 3G83 engine has many bolts and capscrews of special materials and sizes. It is very important that special care be used to replace all bolts and capscrews in their proper location during assembly of the enItem gine. The torque specifications in American Standard and Metric as listed below MUST be followed in order to have the assembled engine conform to the original specifications.
Tightening Torques (cont.
Special Tools Order special tools from TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (Commercial Products). Some tools may be listed in the Workman 3200 Parts Catalog. Tools may also be available from a local supplier. Filter Cleaner Filter cleaner. Mix with water and use solution to wash the Donaldson air cleaner element. Figure 1 Pin Used with End Yoke Holder (Fig. 3) for supporting sprocket when camshaft sprocket bolt is loosened or tightened. Mitsubishi Motors Part No.
Flywheel Stopper Stopper for locking crankshaft pulley, sprocket and fly wheel during removal. MD998608 Figure 4 Valve Spring Compressor Use for compression of valve spring during removal and installation. Mitsubishi Motors Part No. MD999597 Figure 5 Valve Stem Seal Installer Use for installation of valve stem seals. Mitsubishi Motors Part No. MD998302 Figure 6 Workman 3000/4000 Series Page 3 – 13 Liquid Cooled Gas Engine Liquid Cooled Gas Engine Mitsubishi Motors Part No.
Oil Pan Gasket Cutter User for Removing oil pan to break oil pan seal. Mitsubishi Motors Part No. MD998727 Figure 7 Balancer Shaft Bearing Remover Use to pull out counterbalance shaft front and rear bearing. Mitsubishi Motors Part No. MD999593 Figure 8 Balancer Shaft Front Bearing Installer Use for press fitting counterbalance shaft front bearing. Mitsubishi Motors Part No.
Balancer Shaft Rear Bearing Installer Use for press fitting counterbalance shaft rear bearing. MD999592 Figure 10 Crankshaft Front Oil Seal Installer Use for installing crankshaft front oil seal. Mitsubishi Motors Part No. MD999570 Figure 11 Camshaft Oil Seal Installer Use for installation of camshaft oil seal. Mitsubishi Motors Part No. MD999569 Figure 12 Workman 3000/4000 Series Page 3 – 15 Liquid Cooled Gas Engine Liquid Cooled Gas Engine Mitsubishi Motors Part No.
Crankshaft Rear Oil Seal Installer Use for installation of crankshaft rear oil seal. Mitsubishi Motors Part No. MD998376 Figure 13 Piston Pin Setting Base Use with Push Rod and Guide Pin Set (Fig. 14) to pull out and press in piston pin. Mitsubishi Motors Part No. MD999583 Figure 14 Push Rod and Guide Pin Set Use with Piston Pin Setting Base (Fig. 13) to pull out and press in piston pin. Mitsubishi Motors Part No.
Inspection and Adjustments Valve Clearance IMPORTANT: After adjusting timing belt tension, ad just valve clearance. Tiiming belt cover A 1. Warm up the engine until coolant is at 80� to 95� C (176� to 203� F). 3. Remove timing belt cover. Figure 16 4. Turn crankshaft clockwise to align triangular mark on camshaft sprocket with timing mark on timing belt rear cover to set No. 1 cylinder on compression top dead center. Timing mark IMPORTANT: Turn crankshaft only in clockwise direction. Figure 17 5.
6. If valve clearance is not at standard value, loosen rocker arm locknut and use a feeler gauge to adjust clearance while turning adjusting screw. 7. Hold screwdriver so adjusting screw will not turn and tighten locknut to specified torque. Adjusting screw torque 8 – 10 Nm (5.8 – 7.2 ft–lb) Figure 19 8. Turn crankshaft a further 240� in clockwise direction and align round mark on camshaft sprocket with timing mark on timing belt rear cover to set No. 3 cylinder on compression top dead center.
Timing Belt Tension 1. Remove alternator drive belt. Timing belt cover A 2. Remove timing belt cover. 3. Remove access cover. Access cover 4. Turn crankshaft clockwise (right turn) to check that timing belt is okay over it’s entire length. Figure 22 5. Turn crankshaft clockwise to align timing mark on camshaft sprocket and timing belt rear cover. Timing mark Figure 23 6. Loosen tensioner nut by one (1) or two (2) turns and allow spring force to tension belt. Tensioner nut Figure 24 7.
Idle Speed 1. Make sure engine is warm (coolant temperature 80 – 95�C (176 – 203�F), all lights and accessories are OFF and transmission is in NEUTRAL. 2. If vehicle is not equipped with a tachometer, connect an electronic tachometer: CONNECTOR END VIEW A. Insert a paper clip into ignition coil primary 3–pin connector (terminal 1) from harness side. B. Connect tachometer to paper clip. Figure 26 3. Check idle speed. Idle speed 1200 + 100 RPM 4.
CO Concentration (Mixture Adjustment) 1. Make sure engine is warm (coolant temperature 80 – 95�C (176 – 203�F), all lights and accessories are OFF and transmission is in NEUTRAL. 2. Check to make sure that idle speed and ignition timing are the standard values(see Idle Speed and Ignition Timing in this section). MAS Idle speed 1200 + 100 RPM Ignition timing 6� BTDC + 2� Figure 29 3. Check CO and HC concentration for standard values. Standard values CO concentration 1.0 + 0.
Governor / Accelerator Pedal 1. Put vehicle on a level surface, stop engine and engage the parking brake. 0.200” (5 mm) 2. Rotate governor input lever clockwise to put a light tension load on the governor spring. Hold carburetor throttle against wide open throttle stop and adjust ball joint on throttle rod to allow ball joint socket to travel past carburetor throttle stud by 0.200+0.031 in. (5+0.8 mm). Tighten locknuts on throttle rod. Ball joints must move freely through full travel. 2 3 3.
7. Check low idle setting. If low idle is more than setting in step 4, the surge screw was turned too far clockwise. Turn surge screw counterclockwise until the low idle set ting returns to the setting in step 4. Check high idle set ting as instructed in step 6. 8. Stop the engine. NOTE: Engine must NOT be running and return spring must be attached for the next step (Step 9). 4 3 5 6 1 2 Figure 32 1. Governor 2. Oil Check plug 3. Oil fill plug (on top) 4. Governor output lever 5. Surge screw 6.
Carburetor Acceleration Pump Throttle valve Pump nozzle Pump leak jet Outlet check valve Check valve Inlet check valve Diaphragm Lever From float chamber Figure 33 1. Remove air intake hose. 3. Clean the fuel path if fuel is not injected. 2. Check to see that fuel is injected from pump nozzle when throttle valve is opened while keeping the choke valve open. Choke Valve 1. Remove air intake hose. Choke valve 2. Move choke valve with a finger and check for smooth movement without backlash. 3.
Full – Auto – Choke Choke adjusting screw Choke pinion Choke lever Cam follower Fast idle adjusting screw Thermo–wax element Figure 35 1. Remove air intake hose. Choke valve 2. Make sure engine coolant temperature is below 10�C (50�F). 3. Check operation of choke valve under various engine conditions. Engine condition Choke valve operation Before starting Closed Just after starting (Carburetor ID Mark TMB) Slightly opens approx. 1.8 mm (.071 in.
Choke Breaker Opening 1. Inspect after doing Full–Auto–Choke inspection. Choke valve 2. Run engine at idle. Move choke valve in closing direc tion with light finger force until valve resists being moved. Measure clearance between choke valve and choke bore at this point. Choke valve to choke bore clearance (Carburetor ID Mark TMB) 1.8 mm (0.071 mm) Choke valve to choke bore clearance (Carburetor ID Mark TEB) 2.3 mm (0.091 mm) Clearance Figure 37 3.
Fast Idle Choke adjusting screw Choke pinion Choke lever Cam follower Fast idle adjusting screw Thermo–wax element Figure 39 1. Make sure engine coolant temperature is below 10�C (50�F). Fast idle adjusting screw 2. Start the engine. Make sure idle speed during the warm up period changes smoothly as coolant tempera ture increases and becomes stable at the standard speed. Idle speed 1200 + 100 RPM Figure 40 3. If anything abnormal occurs during step 2, adjust fast idle speed.
Troubleshooting Giving Immediate attention to any indication of a problem can prevent major failures, and increase the life of the engine. Never make more that one adjustment at a time, then lo cate the trouble by a process of elimination. Remember the cause is usually SIMPLE, rather than mysterious and complicated. Symptom Possible Causes Engine overheats. Cooling system faulty. – Radiator screen plugged. – Fan belt slipping. – Low coolant level. Incorrect ignition timing.
Symptom Possible Causes Engine will not start or starts too hard (cranks OK). Ignition system problems. Compression too low. No fuel supply to carburetor. Vacuum leaks: – Purge control valve hose. – Vacuum hoses. – Intake manifold. – Carburetor. Engine will not crank. Starting system faulty (see Chapter 8 – Electrical System). Engine dieseling. Incorrect ignition timing. Carburetor problems. Excessive oil consumption. Valve stem seal worn or damaged. Valve step worn. Piston ring worn or damaged.
Testing Temperature Gauge Sender 1. Lower the coolant level in the engine and remove the temperature gauge sender (see Water Pump, Water Hose, Pipe and Thermostat Removal and Installation). 2. Put the switch in a container of oil with a thermometer and heat the oil. 3. With an Ohm meter connected as shown, the following resistance readings should be indicated. Temperature gauge sender resistance readings 90.5 – 117.5 ohm at 70�C (160�F) 21.3 – 26.
Engine Oil Pressure Switch 1. Turn ignition key switch ON. Oil pressure lamp should be on. If oil pressure light is OFF: 1. Disconnect wire from switch and touch wire to a good ground. If oil pressure light is ON with engine running: 1. Shut off engine immediately. 2. Check switch by disconnecting wire. Light should go out. 3. If light is still on, check for short circuit in wiring. 4. Install test gauge in engine oil pressure switch port. Start engine and check for 30 psi (207 kPa) minimum at 1500 rpm.
Fuel Cut–Off (ETR) Solenoid NOTE: The fuel cut–off solenoid is an energize–to–run (ETR) solenoid. 1. Check that valve makes an operating sound when ignition switch is turned ON. Slow fuel cut solenoid valve Figure 44 2. Start the engine. Let engine run at idle. Make sure en gine stalls when slow fuel cut–off solenoid valve electri cal connector is disconnected. 3. Stop the engine. Measure coil resistance of fuel cut– off solenoid.
Compression Pressure 1. Make sure engine is warm (coolant temperature 80 – 95�C (176 – 203�F), all lights and accessories are OFF and transmission is in NEUTRAL. 2. Remove spark plug caps (3). 3. Remove spark plugs (3). 5. With throttle held open, crank engine and measure compression pressure. Figure 46 Compression pressure 1,250 Kpa (178 psi) at 400 RPM Limit 960 kPa (137 psi) at 400 RPM 6. Measure compression pressure for all cylinders.
Centrifugal Timing Control Device 1. Start engine and run at idle. 2. Remove vacuum hose from vacuum controller. Plug disconnected vacuum hose. Plug disconnected vacuum hose. 3. Increase engine speed gradually and check advance. It is normal if advancing smoothly according to increas ing speed. Symptom Possible cause Excessive advance Worn or damaged governor spring Start up advance too sudden Damaged spring Inadequate advance or slow change in advance.
Vacuum Timing Control Device 1. Start engine and run at idle. 2. Remove vacuum hose from vacuum controller. Plug disconnected vacuum hose. Connect vacuum pump to nipple. 3. Add vacuum on vacuum pump gradually and check advance. Timing should advance smoothly with in creased vacuum.
Crankcase Emission Control System Breather hose Positive crankcase ventilation (PCV) valve Ventilation hose Induction chamber Blowby gas (high load region) Blowby gas and fresh air (low load region) Figure 52 System Inspection 1. Remove ventilation hose from rocker cover where positive crankcase ventilation (PCV) valve is attached. 2. Run engine at idle and put a finger on open end of ventilation hose to check for intake manifold vacuum. 3. If vacuum is not felt on finger, clean or replace PCV valve.
Exhaust Emission Control System Liquid Cooled Gas Engine EGR valve Carburetor Thermo valve Figure 55 1. Remove vacuum hose (green stripe) from carburetor and connect a hand pump to the vacuum hose. Vacuum hose (Green stripe) 2. Plug nipple that vacuum hose was removed from. 3. Perform this test with the engine cold, then again when hot. Apply vacuum to vacuum hose with the en gine idling.
When engine is hot Coolant temperature 80�C (176�F) or higher: Hand vacuum pump p mp Normal condition Engine Vacuum 4 kPa (30 mm Hg, 1.2 in. Hg) of vacuum applied No change Vacuum is maintained 20 kPa (150 mm Hg, 6 in. Hg) of vacuum applied Idling becomes slightly unstable EGR Valve Inspection 1. Remove EGR valve and inspect for sticking, carbon deposits, etc. Clean with a suitable solvent if necessary so valve seats correctly. 2. Connect a hand vacuum pump to EGR valve. 3.
Thermo Valve 1. Disconnect vacuum hose from thermo valve and con nect a hand vacuum pump to thermo valve. Engine coolant temperature Normal condition 40�C (104�F) or less Vacuum leaks 80�C (176�F) or more Vacuum is maintained IMPORTANT: Do use a wrench on plastic part when removing or installing thermo valve. When instal ling, apply a dry sealant (Hermseal H1–M) to threads. Workman 3000/4000 Series Page 3 – 39 Figure 58 Liquid Cooled Gas Engine Liquid Cooled Gas Engine 2.
Ignition Coil Primary Coil Measure resistance of (+) and (–) terminal of ignition coil. Primary coil resistance Secondary terminal + – 1.08 – 1.32 Ohm Secondary Coil Measure resistance between (+) terminal and high volt age terminal of ignition coil. Secondary coil resistance Figure 59 22.1 – 29.
Starter Pinion Gap 1. Disconnect lead wire from terminal ”M” of magnetic switch. 2. Connect 12 volt battery between terminal ”50” and starter body (connect positive terminal of battery to ter minal ”50”. Figure 60 3. Pinion should move out and stop. Measure clearance (pinion gap) between pinion and pinion stop nut. If there is axial play, push back pinion and measure again. Pinion gap 2.2 mm (.087 in.) or less Pinion stop nut 4. Pinion gap is not adjustable.
Starter No–Load Test 1. Connect a 12 volt battery, ammeter and voltmeter to the starter as shown. 2. Starter motor should turn smooth and steady when battery is connected with a maximum resistance value. Adjust variable resistance so voltmeter indicates stan dard value. If current and RPM are out of specification after this adjustment, troubleshoot according to test re sults below. Variable resistor Ammeter A Starter motor Battery V Voltmeter 12V Standard value Terminal voltage 11.
Magnetic Switch Pull–In Test 1. Disconnect the wire from terminal ”M”. 2. Connect a 12 volt battery to the magnetic switch terminals ”50” and ”M”. The pinion must protrude. IMPORTANT: Lead wire must be disconnected from terminal ”M” for this test. Figure 63 Magnetic Switch Hold–In Test 1. Disconnect the wire from terminal ”M”. 2. Connect a 12 volt battery to the magnetic switch terminal ”50” and the body of the magnetic switch. Pull out the pinion fully.
Alternator Regulated Voltage 1. Disconnect battery ground (–) cable. 2. Install an ammeter between the positive (+) terminal of the battery and terminal ”B” of the alternator. Ignition Switch Alternator L 3. Connect a voltmeter between alternator ”L” and ground. G B 4. Connect the battery ground (–) cable. 5. Note that the voltmeter shows 0 volts when the ignition key switch is in the OFF position.
Alternator Current Output 1. Disconnect the battery ground (–) cable. Load 2. Install an ammeter between the positive (+) terminal of the battery and terminal ”B” of the alternator. Ignition Switch 3. Ground alternator terminal ”B” through a voltmeter. Battery 5. Check to make sure voltmeter reads battery voltage. If voltmeter reads 0 V, check for open circuit between al ternator ”B” terminal and battery (–) terminal, a blow fus ible link or poor grounding.
Preparation for Engine Repair 1. Before cleaning and disassembly, carefully check for problems that cannot be found after the engine has been cleaned or disassembled (e.g. oil leaks from cracked components, gaskets or loose fittings, damaged air cleaner or breather hoses that could cause cylinder wear, etc.). Make a note of any problems that you find. 2. Clean or wash the engine exterior thoroughly before disassembly. IMPORTANT: To prevent possible damage to en gine, do not spray water on a hot engine. 3.
External Engine Component Repair Belt Replacement and Adjustment Governor and Alternator Belt Replacement 1 4 1. Loosen idler pulley mounting nut and move pulley to remove governor belt tension. 2 3. Remove two (2) capscrews securing drive shaft cou pler to engine crankshaft pulley, then move drive shaft out of the way so belt(s) can be removed. Liquid Cooled Gas Engine 2. If removing alternator belt, loosen the two (2) alterna tor mounting bolts and pivot alternator to remove belt tension. 3 5 4.
Timing Belt Replacement 24 10 – 12 Nm (7 – 9 ft–lb) 3 10 – 12 Nm (7 – 9 ft–lb) 12 2 17 80 – 100 Nm (58 – 72 ft–lb) 16 13 15 5 6 4 14 11 22 – 30 Nm (16 – 22 ft–lb) 7 23 18 15 – 18 Nm (11 – 13 ft–lb) 20 19 22 10 1 8 50 – 57 Nm (36 – 41 ft–lb) 21 9 135 – 145 Nm (98 – 105 ft–lb) Figure 70 1. Crankshaft pulley 2. Timing belt cover A 3. Gasket 4. Timing belt cover B 5. Gasket 6. Gasket 7. Access cover 8. Timing belt cover C 9. Gasket 10. Gasket 11. Tensioner nut 12. Timing belt 13.
Timing Belt Removal Timing mark 1. Turn crankshaft clockwise to align timing mark on camshaft sprocket and timing belt rear cover. IMPORTANT: Always turn crankshaft clockwise (right turn). Liquid Cooled Gas Engine Figure 71 2. Remove plug on left side of cylinder block and insert a 8 mm (.31 in.) diameter rod to lock counterbalance shaft. IMPORTANT: Be sure to use an inserting rod with a diameter of 8 mm (.31 in.) Figure 72 3. Loosen timing belt tensioner nut. 4.
Camshaft Sprocket Removal 1. Prevent camshaft from turning and remove camshaft sprocket bolt. End yoke holder tool MB990767 Figure 75 Oil Pump Sprocket Removal Oil pump sprocket 1. Remove plug on left side of cylinder block and insert a 8 mm (.31 in.) diameter rod to lock counterbalance shaft. 2. Remove oil pump sprocket flange nut. Rod Figure 76 Flywheel Crankshaft Bolt Removal 1. Use special tool to prevent flywheel from turning and remove crankshaft bolt.
Timing Belt Inspection Inspect all sections of timing belt closely. Replace the belt if any of the following conditions are found: 1. Hardening of rubber on rear surface (rear surface is glossy, no mark is left when scratched and has no elas ticity). 2. Cracks in rubber on rear surface. 3. Cracked and peeling canvas. Crack Crack 4. Cracks at base of teeth. 5. Cracks in rear surface of belt. Side surface crack Cracks at base of teeth Figure 79 Corners are rounded 6.
Flange Installation Crankshaft sprocket 1. Install flange as shown in the illustration before instal ling crankshaft sprocket. Adaptor Flange Figure 82 Crankshaft Sprocket Installation Flywheel 1. Install crankshaft sprocket. 2. Install special tool to prevent flywheel from turning. Tighten the crankshaft bolt to a torque of 135 – 145 Nm (98 – 105 ft–lb). Figure 83 Oil Pump Sprocket Installation Oil pump sprocket 1. Insert a 8 mm (.31 in.
Timing Belt Tensioner Installation Timing belt tensioner 1. Install tensioner spring and timing belt tensioner. 2. Hook tensioner spring onto bent section of timing belt tensioner bracket and onto cylinder block stopper pin. 3. Put timing belt tensioner as close as possible to water pump and tighten tensioner nut to temporarily secure in position. Tensioner spring Timing Belt Installation 1. Align triangle mark on camshaft sprocket with mark on timing belt rear cover. Camshaft sprocket 2.
5. Install timing belt first onto crankshaft sprocket, then oil pump sprocket and camshaft sprocket in that order. IMPORTANT: Install belt so there is no looseness on tension side of timing belt. The rod should not be re moved until timing belt is completely installed. 6. Apply counterclockwise force to camshaft sprocket to apply tension to tension side of belt. 7. Make sure all timing marks are lined up, then loosen tensioner nut 1 to 2 turns and allow spring force to ten sion belt. Figure 89 8.
Water Pump, Hose, Pipe and Thermostat Removal and Installation 1 10 – 13 Nm (7 – 9 ft–lb) 20 – 30 Nm (14 – 22 ft–lb) 2 10 – 12 Nm (7 – 9 ft–lb) 4 3 5 6 Before disassembling: 9 10 2. Remove alternator. Before assembling: 12 1. Install alternator. 7 2. Install timing belt. 11 12 – 15 Nm (9 – 11 ft–lb) 8 14 8 – 10 Nm (6 – 7 ft–lb) 13 Figure 92 1. Water outlet fitting 2. Water outlet fitting gasket 3. Thermostat 4. Coolant temp. gauge sender 5. Thermo valve 6. O–ring 7. Water hose 8.
Water Pump Installation Thread diameter x length mm (in.) Bolts used to secure water pump are different sizes. Make sure different size bolts are installed in the correct locations. Tighten bolts evenly to a torque of 8 – 10 Nm (6 – 7 ft–lb). 6 x 35 (.24 x 1.38) 6 x 18 (.24 x .71) Figure 94 Water Pipe Installation Fit water pipe O–ring in groove provided at water pipe end as shown in illustration. Wet outer diameter of O– ring with anti–freeze before inserting water pipe.
Governor Removal and Installation 9 10 11 10 4 5 9 6 21 23 2 1 20 22 21 8 7 12 13 24 30 14 19 18 25 15 29 17 28 26 27 16 Figure 96 1. Accelerator cable 2. Jam nut 3. Flange nut 4. High idle stop bracket 5. Jam nut 6. Capscrew 7. Capscrew 8. Lockwasher 9. Ball joint 10. Jam nut 11. Linkage rod 12. Capscrew 13. Lockwasher 14. Governor bracket 15. Carriage bolt 16. Capscrew 17. Lockwasher 18. Flange nut 19. Pulley 20. Locknut 21. Locknut 22. Throttle lever 23. Extension spring 24.
Electrical System Repairs Spark Plug Replacement Spark plug type Champion RN 16Y NGK BPR 4ES Spark plug air gap 1 mm (.040 in.) 1. Clean area around spark plugs to prevent foreign ma terial from falling into cylinder when spark plug is re moved. 2. Pull spark plug wires off spark plugs and remove plugs from cylinder head. Spark plug wire removal Figure 97 NOTE: When disconnecting spark plug wires, be sure to hold cable cap and not wire.
Alternator Removal and Installation 20 – 25 Nm (15 – 18 ft–lb) 2 Liquid Cooled Gas Engine 1 50 – 70 Nm (36 – 51 ft–lb) Figure 99 1. Drive belt 2. Alternator Remove and install alternator as shown in illustration.
Alternator Service 11 12 10 15 14 13 1 5 3 2 4 6 7 8 9 Figure 100 1. Alternator pulley 2. Space collar 3. ”B” terminal 4. Rear end cover 5. Brush holder assembly 6. Seal ring 7. IC regulator 8. Rectifier 9. Rear end frame 10. Bearing cover 11. Rear bearing 12. Rotor assembly 13. Drive end frame and stator assembly 14. Front bearing 15. Retainer plate Disassemble and assemble parts as shown in illustra tion above.
2. Use a puller to remove rear end frame as shown. Hold lightly in a soft face vice to prevent damage 3. Use a puller to remove the bearing. Puller Press at the center Figure 103 4. Put drive end frame on a pair of blocks as shown and use a press to remove rotor assembly.
Alternator Inspection 1. Check for continuity of rotor coil. Check for continuity between slip rings. Measure resistance of rotor. If resis tance is low, it indicates a short circuit. If there is no conti nuity or a short circuit, replace the rotor assembly. Resistance standard value 2.8 – 3.0 Ohms Figure 105 2. Check rotor coil for ground. Make sure there is no continuity between slip ring and core. If there is continu ity, replace the rotor assembly. Figure 106 3. Check stator for continuity.
5. Check the rectifier for continuity. If there is continuity in only one direction of the diode, it is good. Liquid Cooled Gas Engine Figure 109 B B 6. Measure the brush length from end of brush holder. If it is more than the limit value, replace the brush holder. Brush length Standard value Limit 10.5 mm (.413 in.) 4.5 mm (.177 in.) P1 P2 P3 E E P1 P3 P2 Figure 110 Figure 111 Reassembly of Alternator Assembly alternator in reverse order of disassembly.
Starter Removal and Installation 2 8 – 10 Nm (6 – 7 ft–lb) 1 43 – 55 Nm (31 – 40 ft–lb) 3 Figure 113 1. Connector 2. Battery (+) cable connection 3. Starter motor Remove and install starter as shown in illustration.
Starter Service 1 2 15 14 Liquid Cooled Gas Engine 12 13 11 10 9 4 6 8 3 5 7 Figure 114 1. Magnetic switch 2. Boot 3. Rear bracket assembly 4. Insulator 5. Brush spring 6. Brush holder 7. Yoke assembly 8. Front bracket assembly 9. Plate washer 10. Drive lever 11. Pinion stop nut 12. Snap ring 13. Pinion stop nut 14. Overrunning clutch 15. Armature Disassemble and assemble parts as shown in illustra tion above.
Snap ring 3. To remove overrunning clutch, expand pinion stop nut as shown and remove front side. Remove snap ring, then remove rear side of pinion stop nut and overrun ning clutch. Starter Motor Parts Cleaning 1. Do not immerse parts in solvent for cleaning. Immer sion of yoke, field coil assembly or armature in solvent causes damage to the insulation. Wipe these parts with a cloth to clean if necessary. 2. Do not immerse drive unit in cleaning solvent.
Segment 3. Check depth of undercuts between segments. Undercut Mica Liquid Cooled Gas Engine Figure 121 4. Check for continuity between brush and yoke as shown. Replace the field coil if there is no continuity. Figure 122 5. Make sure pinion on overrunning clutch locks when it is turned counterclockwise and moves smoothly when it is turned clockwise. Check pinion for wear and dam age. Figure 123 6. Check surface of brushes where they contact com mutator. If surface is too rough, replace brush.
Growler 7. Put the armature on a growler. While applying a thin iron piece in parallel with armature, turn armature slowly. Armature is okay if iron piece is not attracted or does not vibrate. NOTE: Clean armature surface thoroughly be fore doing growler test. Figure 125 Armature coil Commutator 8. Check insulation between commutator segments and armature coil core. There should be no continuity. Figure 126 9. Check for continuity between commutator segments. There should be no continuity.
Liquid Cooled Gas Engine Distributor Removal and Installation 10 – 13 Nm (7 – 9 ft–lb) Figure 129 1. Vacuum hose connection 2. Harness connector 3. Spark plug cable connection 4. High tension cable connection 5. Distributor Remove and install distributor as shown in illustration.
Distributor Service 5 4 2 3 1 9 8 11 12 10 6 7 Figure 130 1. Distributor cap 2. Packing 3. Rotor 4. Cover 5. Signal rotor 6. Lead cable 7. Pick–up assembly 8. Lead cable 9. Vacuum control 10. Breaker plate 11. O–ring 12. Housing assembly Disassemble and assemble parts as shown in illustra tion above. Also use the following instructions for specif ic points of disassembly, inspection and reassembly. Distributor Inspection 1. Check cap for cracks or other damage. 2.
Distributor Installation Tiiming belt cover A 1. Remove timing belt cover A. 2. Turn crankshaft clockwise and align mating marks on camshaft sprocket and rear timing belt cover to bring No. 1 cylinder to top dead center on compression stroke. Rotation Rear timing belt cover Mating mark Camshaft sprocket Figure 134 3. Align mating marks on distributor housing and cou pling. Figure 135 4. Install distributor to engine while aligning stud with elongated hole on distributor flange.
Fuel System Repairs Carburetor Removal and Installation 15 – 20 Nm (11 – 14 ft–lb) 1 2 3 4 5 3G80031 Figure 137 1. Bolt 2. Carburetor assembly 3. Gasket 4. Insulator 5. Gasket Remove and install carburetor as shown in illustration.
Carburetor Service 20 21 3.5 Nm (2.5 ft–lb) *47 1 22 *48 *49 *50 23 24 45 46 2 51 4 Liquid Cooled Gas Engine SEE NOTE BELOW 3 5 7 35 34 32 33 44 6 43 0.8 Nm (0.6 ft–lb) 2 Nm (1.6 ft–lb) 3.5 Nm (2.5 ft–lb) 1213 19 16 40 39 10 38 37 36 42 15 0.8 Nm (0.6 ft–lb) 31 14 18 17 9 27 8 6 Nm (4 ft–lb) 2 Nm (1.6 ft–lb) 29 25 3G80030 Figure 139 18. Diaphragm 19. Spring 20. Clip 21. Clip 22. Piston cover 23. Spring 24. Piston valve assembly 25. Float chamber body 26. O–ring 27.
1. After removing retainer (Item 2), remove FCSV from mixing body by pulling out with a pliers as shown. DO NOT pull on lead wire of FCSV. Be careful not to loose the O–ring (Item 4). 2. After removing float chamber body, remove retainer (Item 27), weight (Item 28) and ball (Item 29). These parts are very small. Be careful not to lose them. 3. Use a pliers to remove needle valve seat (Item 34) as shown. Figure 140 4.
5. Check float operation. Check float and lever for de formation and damage. 6. Check operation of throttle valve, choke valve and linkage. If they do not operate with light force, wash well and apply engine oil sparingly to the shaft(s). 7. Check float chamber body and mixing body for dam age and cracks. Liquid Cooled Gas Engine 8. Check fuel cut solenoid valve (FCSV). The FCSV should operate with a click when battery voltage is ap plied. Figure 142 9.
2. Adjust float level. A. Lightly push up float until it stops, then measure clearance between needle valve and float lever. Needle valve to float lever clearance 1.45 mm (.057 in.) Figure 145 B. If clearance is out of specification, adjust by bending float lever as shown. Figure 146 Retainer 3. Install ball, weight and retainer in correct sequence and location as shown. Weight Ball Figure 147 4.
Carburetor Inspection and Adjustment After Reassembly 1. After installing mixture adjusting screw (MAS) set ini tially by turning clockwise until seated – DO NOT over tighten – then back out 2 full turns counterclockwise. MAS Liquid Cooled Gas Engine Figure 149 2. Make sure alignment mark (engraved) on cam lever is lined up with center of cam follower. Alignment mark Figure 150 3. Measure throttle valve to throttle bore clearance. Throttle valve to throttle bore clearance 0.3 mm (.012 in.
5. Use light pressure with a finger to fully close choke valve. Measure clearance between choke valve and choke bore when throttle valve is fully opened. Choke valve to choke bore clearance 1.45 mm (0.57 mm) Figure 153 If clearance is out of specification, adjust by moving choke shaft end. Choke shaft end Valve clearance Remarks Lower Larger Engine becomes more difficult to start and tends to stall Raise Smaller Carbon tends to accumulate on spark plugs Choke shaft end Figure 154 6.
Removing and Installing the Engine Liquid Cooled Gas Engine Removing the Engine Figure 156 1. Put machine on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Remove the bed or other attachment(s). Allow engine and radiator to cool. CAUTION DO NOT open radiator cap or drain coolant if engine or radiator is hot. Pressurized, hot coolant can escape and cause burns. 2. Disconnect positive (+) and negative (–) battery cables from battery. 3.
9. Disconnect and label electrical leads that attach to engine and engine accessories. crews securing lower sheet metal clutch cover to engine and bell housing. 10. Remove hydraulic pump drive shaft (connected to engine crankshaft pulley). 16. Remove two (2) capscrews and locknuts securing engine mount to frame. 11. Disconnect throttle cable from governor lever on en gine. Remove throttle cable from bracket. 17. Remove capscrews securing clutch bell housing to engine. 12.
Cylinder Head Overhaul Intake and Exhaust Manifold Before Removing 1. Remove oil level dipstick and guide tube. 2. Remove alternator. Liquid Cooled Gas Engine Removal and Installation 7 – 11 Nm (5 – 8 ft–lb) 1 9 – 14 Nm (7 – 10 ft–lb) 8 – 12 Nm (6 – 9 ft–lb) 5 2 6 9 7 8 10 11 3 4 15 – 20 Nm (11 – 14 ft–lb) Figure 157 1. Clip 2. Engine hanger 3. Intake manifold 4. Intake manifold gasket Workman 3000/4000 Series 5. EGR valve 6. EGR valve gasket 7. PCV valve 8. Thermo valve Page 3 – 81 9.
Rocker Arm, Rocker Shaft and Camshaft 2 1 5 – 7 Nm (4 – 5 ft–lb) 3 4 29 – 35 Nm (21 – 25 ft–lb) 29 – 35 Nm (21 – 25 ft–lb) 5 10 – 12 Nm (7 – 9 ft–lb) 8 7 6 Figure 158 1. PCV hose 2. Oil filter cap 3. Rocker cover 4. Rocker cover gasket 5. Rocker arm, rocker shaft assembly 6. Camshaft oil seal 7. Camshaft thrust plate 8. Camshaft Disassemble and assemble parts as shown in illustration above. Also use the following instructions for specific points of disassembly, inspection and reassembly.
Camshaft Inspection 1. Check camshaft journal surfaces for damage or seizure. If journal is seized, check cylinder head for pos sible damage. Also check for clogged oil holes in cylinder head. Journal Liquid Cooled Gas Engine Figure 159 2. Check camshaft surface for irregular wear or dam age. Measure cam height (diameter of cam length). If cam height is at the limit, replace the camshaft. Cam Standard Value mm (in.) Limit mm (in.) No.1 No. 2 No. 3 35.09 (1.3815) 35.07 (1.3807) 35.06 (1.3803) 34.
3. Apply engine oil to lip of camshaft oil seal. Use seal installer tool to drive seal into cylinder head. Figure 163 4. Install rocker shaft so illustrated portion is located to ward the front (there is a chamfer and the oil hole is closer to the shaft end than the bolt hole). Chamfer Bolt hole 5. Tighten rocker arm shaft attaching bolts (4 bolts) a little at a time and evenly. Tighten bolts to the specified torque.
Rocker Arms and Rocker Shaft 9 6 10 3 7 Liquid Cooled Gas Engine 8 – 10 Nm (6 – 7 ft–lb) 8 5 4 1 2 Figure 165 1. Rocker arm (intake) 2. Wave washer 3. Rocker arm (exhaust) 4. Rocker arm (intake) 5. Wave washer 6. Rocker arm (exhaust) 7. Rocker arm (intake) 8. Wave washer 9. Rocker arm (exhaust) 10. Rocker shaft Disassemble and assemble parts as shown in illustra tion above. Also use the following instructions for specif ic points of disassembly, inspection and reassembly.
Cylinder Head and Valves Cold engine 60 – 70 Nm (43 – 51 ft–lb) 1 2 10 11 4 12 5 14 15 17 6 8 9 20 16 19 18 13 7 3 Figure 168 1. Cylinder head bolt 2. Cylinder head assembly 3. Cylinder head gasket 4. Valve spring retainer lock 5. Valve spring retainer 6. Valve spring 7. Intake valve 8. Valve stem seal 9. Valve spring seat 10. Valve spring retainer lock 11. Valve spring retainer 12. Valve spring 13. Exhaust valve 14. Valve stem seal 15. Valve spring seat 16. Intake valve guide 17.
Cylinder Head Removal and Disassembly 1. Loosen bolts in order as shown and remove cylinder head assembly. Liquid Cooled Gas Engine Figure 169 2. Use a valve spring compressor tool to compress valve spring. Remove retainer lock. Remove valve spring retainer, valve spring, valve spring seat and valve. NOTE: Keep removed parts in order according to cylin der number and intake/exhaust. Figure 170 3. Use a pliers to remove valve stem seal. DO NOT reuse stem seals. Cylinder Head Inspection Figure 171 1.
3. Check valve seat for proper contact with valve. If it is not concentric, recondition valve seat. Check valve mar gin. Replace if margin is at limit. Contact with valve seat (to be at center of valve face) Margin Figure 173 2� 4. Measure free height of spring and replace if it is not within limit specification. 5. Check valve spring for squareness and replace if limit is exceeded. Free length Figure 174 6. Measure clearance between valve guide and valve stem.
Cylinder Head Reassembly and Installation Valve spring seat Valve stem seal Liquid Cooled Gas Engine 1. Install valve spring seat. Use stem seal installer tool to install new stem seal to valve guide. DO NOT reuse valve stem seals. Figure 177 2. Install valve spring with enamel coated side toward rocker arm side. Enamel coating side Spring retainer Stem seal Spring seat Figure 178 3. Put valve spring retainer on top of spring and use valve spring compressor tool to compress valve spring.
4. Make sure cylinder head and cylinder block gasket surface is clean. Put new cylinder head gasket on top of cylinder block with identification mark ”66N” facing up. Indentification mark Figure 180 5. Tighten cylinder head bolts firmly in three steps. Tighten bolts in order as shown. Intake side 6 A. Tighten each bolt to 20 – 30 Nm (14 – 22 ft–lb) in order shown. B. Tighten each bolt to 40 – 50 Nm (29 – 36 ft–lb) in order shown. C. Fully tighten (cold) to 60 – 70 Nm (43 – 51 ft–lb) in order shown.
Cylinder Block Overhaul Front Case, Counterbalance Shaft and Oil Pan 10 – 12 Nm (7 – 9 ft–lb) 13 12 11 8 – 10 Nm (6 – 7 ft–lb) Liquid Cooled Gas Engine 16 14 9 15 10 3 5 20 8 – 10 Nm (6 – 7 ft–lb) 19 18 17 34 – 40 Nm (25 – 29 ft–lb) 8 7 2 35 – 43 Nm (25 – 33 ft–lb) 6 8 – 10 Nm (6 – 7 ft–lb) 1 10 – 12 Nm (7 – 9 ft–lb) 4 Figure 182 1. Drain plug 2. Drain plug gasket 3. Oil pan 4. Oil pump cover 5. Oil pump cover gasket 6. Oil pump drive gear 7. Flange bolt 8. Oil pump driven gear 9.
2. Remove plug on left side of cylinder block and insert a 8 mm (.32 in.) rod to lock counterbalance shaft. Re move flange bolt securing oil pump drive gear. Remove oil pump drive gear. Rod Figure 184 3. Remove rear cover. Use special tool to drive out counterbalance shaft front bearing from cylinder block. Figure 185 4. Use special tool to drive out counterbalance shaft rear bearing from cylinder block. Figure 186 Front Case, Counterbalance Shaft and Oil Pan Inspection 1.
2. Check counterbalance shaft to bearing oil clearance. Replace bearing and/or counterbalance shaft if worn or damaged. Front 0.035 – 0.068 mm (.0014 – .0026 in.) Rear 0.035 – 0.071 mm (.0014 – .0028 in.) 3. Check front case oil holes for clogging and clean if necessary. Check front case and replace if cracked or damaged. Liquid Cooled Gas Engine 4. Check front oil seal for wear, damage or hardening. Replace front oil seal if necessary.
3. Install crankshaft front oil seal: A. Apply engine oil to crankshaft front oil seal lip in ner circumference. B. Use special tool to install oil seal into front case. Figure 191 4. Install front case assembly with a new gasket. Make sure bolts of different lengths are installed in the correct location. Tighten bolts evenly to specified torque. IMPORTANT: Apply engine oil to inner circumfer ence of oil seal lip before installing front case as sembly.
7. Align timing marks on oil pump drive gears, then install drive gears in cylinder block. Timing mark Oil pump cover 8. Insert a new oil pump cover gasket into groove of oil pump cover. Gasket should be inserted so flat side is to ward oil pump cover. Coil pump cover gasket Figure 196 9. Install oil pan: A. Use a scraper and/or wire brush to remove all sealant from oil pan and cylinder block mating sur face. Figure 197 B. Apply a 4 mm (.16 in.
Piston and Connecting Rod 7 8 9 11 10 6 12 4 5 3 2 20 – 23 Nm (14 – 17 ft–lb) 1 Figure 199 1. Nut 2. Connecting rod cap 3. Connecting rod assembly 4. Piston and connecting rod 5. Connecting rod bearing 6. Bolt 7. No. 1 piston ring 8. No. 2 piston ring 9. Oil ring 10. Piston pin 11. Piston 12. Connecting rod Disassemble and assemble parts as shown in illustra tion above. Also use the following instructions for specif ic points of disassembly, inspection and reassembly.
2. Disassemble piston pin, piston and connecting rod: A. Insert special tool. Push rod and Guide B, into piston pin. Set piston and connecting rod assembly on base. Make sure front mark (arrow) stamped on piston top surface faces up. Push rod Front mark Guide B Base Liquid Cooled Gas Engine Figure 201 B. Use a press to drive out piston pin. Keep disas sembled piston, pin and connecting rod together ac cording to cylinder number.
8. Visually check surface of connecting rod bearing. Re place bearing if uneven, streaked, damaged or seized. When streaks or seizure are excessive, check the crankshaft. If crankshaft is damaged, replace crank shaft or machine to next undersize. 9. Measure inner diameter of connecting rod bearing and outer diameter of crankshaft pin. If the gap (oil clear ance) exceeds the limit, replace the bearing and/or crankshaft or machine crankshaft to next undersize. Use bearings to match undersize crankshaft.
3. Use a ring expander to Install No. 2 and No. 1 piston rings. Pay attention to difference in shape between No. 1 and No. 2 rings. Install rings with marks facing up (to wards top of piston). Piston ring No. 1 Piston ring No. 2 Figure 210 4. Apply an ample amount of engine oil to piston outside surfaces, piston rings and oil ring. Position piston rings and oil ring (side rails and spacer) end gaps as shown. Side rail No. 1 Piston pin Side rail No. 2 Spacer Figure 211 5.
6. Use a ring compressor tool to compress the piston rings and carefully insert piston and connecting rod as sembly into cylinder. Figure 213 7. Install connecting rod bearing cap, aligning it with mark made during disassembly. If connecting rod is new and has no alignment mark, install it so notches for lock ing bearing are on the same side as shown. Cylinder No. Stopper notch Figure 214 8. Check connecting rod thrust clearance. Replace con necting rod if thrust clearance exceeds the limit.
34 – 40 Nm (24 – 29 ft–lb) Liquid Cooled Gas Engine Oil Pump 5 3 1 8 – 10 Nm (6 – 7 ft–lb) 6 4 2 8 – 10 Nm (6 – 7 ft–lb) Figure 216 1. Oil pump cover 2. Oil pump oil seal 3. Oil pump cover gasket 4. Oil pump drive gear 5. Flange bolt 6. Oil pump driven gear Disassemble and assemble parts as shown in illustra tion above. Also use the following instructions for specif ic points of disassembly, inspection and reassembly. Rod Removing Oil Pump 1. Remove plug on left side of cylinder block.
Oil Pump Inspection 1. Fit oil pump gear into cylinder block, then use a feeler gauge to check clearance with body at points shown. Driven gear Drive gear A 0.410 – 0.675 mm (.0161 – .0266 in.) B 0.130 – 0.175 mm (.0051 – .0069 in.) C 0.440 – 0.175 mm (.0173 – .0276 in.) D 0.150 – 0.195 mm (.0059 – .0077 in.) A B C D Figure 218 2. Use a straight edge and feeler gauge to check side clearance at points shown. Driven gear Side clearance Side clearance Driven gear 0.06 – 0.12 mm (.0024 – .
3. Align timing marks, then install oil pump drive gear. Timing mark 4. Install a new oil pump cover gasket into groove of oil pump cover. Install gasket with flat side toward oil pump cover. Oil pump cover Coil pump cover gasket Figure 223 5. Press oil seal into oil pump cover so it is flush with the surface.
Crankshaft and Flywheel 3 4 2 8 – 12 Nm (6 – 9 ft–lb) 1 70 – 80 Nm (51 – 58 ft–lb) 35 – 55 Nm (25 – 40 ft–lb) 10 – 12 Nm (7 – 9 ft–lb) 7 8 – 12 Nm (6 – 9 ft–lb) 5 6 15 8 13 14 12 11 10 9 50 – 55 Nm (36 – 40 ft–lb) Figure 225 1. Flywheel bolt 2. Ball bearing 3. Flywheel assembly 4. Rear plate 5. Bell housing cover 6. Oil seal case 7. Oil seal 8. Oil seal gasket 9. Bearing cap bolt 10. Bearing cap Disassemble and assemble parts as shown in illustration above.
Crankshaft Inspection 1. Inspect crankshaft journal and pin areas for streaking or seizure. Measure outside diameter of journal and in side diameter of main bearing. If clearance exceeds the limit replace main bearing. If installing new bearing does not reduce clearance to within service limit, crankshaft must be reground and undersize bearings installed. Standard value 0.021 – 0.045 mm (.0008 – .0018 in.) Limit 0.1 mm (.004 in.) Liquid Cooled Gas Engine Figure 227 Figure 228 1.5 mm (.059 in.
NOTE: Crankshaft oil clearance can be measured by using a plastic gauge as follows: Plastic gauge A. Remove oil, grease and any other foreign materi al from crankshaft journal and bearing inner sur face. B. Install the crankshaft. Figure 230 C. Cut plastic gauge to same length as width of bearing and put it on journal in parallel with its axis. D. Gently put main bearing cap over plastic gauge and tighten bolts to the specified torque.
Flywheel and Ring Gear Inspection Ring gear 1. Check ring gear teeth for wear or damage and re place ring gear if necessary. If ring gear teeth are dam aged or broken, check starter motor pinion. To replace ring gear, strike ring gear at several points on out circum ference. Install ring gear, then heat ring gear to 260 – 280�C (500 – 536�F) for shrink fit. Flywheel Ring gear 2. Inspect flywheel clutch disk surface for stepped wear, streaking or seizure and replace if necessary.
3. When installing bearing cap, note cap No. and arrow mark. Tighten capscrews to the specified torque. Make sure crankshaft turns freely. Arrow mark indicating front of engine Cap No. Front Figure 236 4. Push crankshaft rearward, then insert a feeler gauge in gap between crankshaft journal side surface and thrust bearing end surface to measure end play. Standard value 0.05 – 0.25 mm (.0020 – .0098 in.) Limit 0.3 mm (.012 in.) Figure 237 5. Use special tool to press oil seal into oil seal case. 6.
Cylinder Block 9 3 12 11 Liquid Cooled Gas Engine 7 8 – 12 Nm (6 – 9 ft–lb) 35 – 45 Nm (25 – 33 ft–lb) 1 10 12 2 35 – 45 Nm (25 – 33 ft–lb) 6 5 4 15 – 22 Nm 11 – 16 ft–lb) 8 Figure 240 1. Taper plug 2. Dowel pin 3. Plug 4. Taper plug 5. Water drain plug 6. Stud 7. Dowel pin 8. Knock bushing 9. Knock bushing 10. Taper plug 11. Sealing cap 12. Sealing cap 13. Cylinder block Disassemble and assemble parts as shown in illustra tion above.
3. Use a cylinder gauge to measure inside diameter of cylinder in six (6) locations as shown. Calculate differ ence between maximum and minimum values (cylin dricity). If there is excessive wear or damage, rebore or replace cylinder block. 12 mm (.47 in.) Standard value Cylindricity 0.01 mm (.0004 in.) or less Cylinder diameter 65.00 – 65.03 mm (2.5591 – 2.5602 in.) 12 mm (.47 in.) Limit Cylindricity Figure 241 .02 mm (.0008 in.) 4.
Lubrication System Repair Oil Screen, Dipstick and Oil Filter 19 – 28 Nm (14 – 20 ft–lb) 6 7 15 – 22 Nm (11 – 16 ft–lb) 5 9 – 14 Nm (7 – 10 ft–lb) Liquid Cooled Gas Engine 10 4 1 10 – 12 Nm (7 – 9 ft–lb) 2 9 8 3 15 – 22 Nm (11 – 15 ft–lb) Figure 243 1. Oil level gauge 2. Oil level gauge guide 3. O–ring 4. Oil filter 5. Oil filter bracket stay 6. Oil filter bracket 7. Oil filter bracket gasket 8. Oil screen 9. Oil screen gasket 10.
Liquid Cooled Gas Engine Page 3 – 112 Workman 3000/4000 Series
Chapter 4 Mitsubishi Engine (Workman S/N Below 220000001) Liquid Cooled Diesel Engine GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Lubrication System . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Special Tools section. The use of some specialized test equipment is explained, how ever, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at a qualified diesel engine repair facility. The engine is manufactured by Mitsubishi Heavy Indus tries Limited.
Specifications Refer to the specifications listed in this section when performing tests on the engine or examining parts for wear. Some specifications are included in the service procedures later in this chapter. Figure 2a Figure 2b Liquid Cooled Diesel Engine The illustrations (Figs. 2a and 2b) will give information about the general construction of the engine.
General Item Specification __________________________________________________________________________________________ Make/Designation Mitsubishi L3Ca-62TG or L3Ea-62TG, overhead valve, vertical in-line, 4 cycle diesel ________________________________________________________________________________________________________________________________________________________ Combustion Chamber Swirl chamber type _________________________________________________________________________________________________
Engine Item Standard Specification Repair Limit Service Limit ___________________________________________________________________________________________ Governor Mechanical/Centrifugal ________________________________________________________________________________________________________________________________________________________ High Idle (no load) ± 50 rpm 3600 rpm _________________________________________________________________________________________________________________________________
Engine (cont.) Item Standard Specification Repair Limit Service Limit __________________________________________________________________________________________ Piston Type Material Piston Outside Diameter (skirt end) L3Ca-62TG L3Ea-62TG Piston to Cylinder Wall Clearance Oversize Protrusion from cylinder block top surface Solid Aluminum alloy 70 mm (2.756 in.) 76 mm (2.992 in.) 0.2 mm (0.008 in.) 0.25, 0.50 mm (0.01, 0.02 in.) 0.9 mm (0.035 in.
Engine (cont.) Item Standard Specification Repair Limit Service Limit ___________________________________________________________________________________________ Camshafts Drive System Front Journal Journal to Cylinder Block Hole Clearance Cam Lobe Major Diameter (both intake and exhaust) Cam Lobe Major Diameter (pump cam) Gear Ball bearing 27.37 mm (1.078 in.) 0.15 mm (0.006 in.) – 1.0 mm (– 0.0433 in.) 30 mm (1.224 in.) – 0.7 mm (– 0.028 in.
Fuel System Item Standard Specification Repair Limit Service Limit __________________________________________________________________________________________ Fuel Pump Delivery Rate 225 cc (13.73 in3) or more (15 sec., 12V) ________________________________________________________________________________________________________________________________________________________ Fuel Injection Pump Model Injection Timing (B.T.D.C.) ND-PFR-NC 19o ± 1.
Electrical System Item Standard Specification Repair Limit Service Limit ___________________________________________________________________________________________ Starter Solenoid shift type 1.6 kW - 12V Clockwise as viewed from pinion side 11.5V 100A or less 3000 rpm or more 7.7 V 300A (0.98 kg/m (6.7 ft-lb) or more) 980 rpm or more 17 mm (0.67 in.) 3 kg (6.6 lb.) 38.7 mm (1.52 in.) 0.5 mm (0.02 in.) 0.5 - 2.0 mm (0.02 - 0.08 in.) 0.5 (0.02 in.) or less 11.5V 0.7 kg/m (5 ft lb) 6 mm (0.24 in.) – 1.
Tightening Torque The Mitsubishi diesel engine has many bolts and capscrews of special materials and sizes. It is very important that special care be used to replace all bolts and capscrews in their proper location during assembly of the engine. The torque specifications in American Standard and Metric as listed below MUST be followed in order to have the assembled engine conform to the original specifications.
Special Tools Order special tools from TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (Commercial Products). Some tools may be available from a local supplier. Filter Cleaner Figure 3 Diesel Engine Compression Test Kit Diesel engine compression test kit (Fig. 5). 0-1000 PSI Gauge allows testing of diesel engines to check general operating condition of engine. Includes case, guage with hose, glow plug hole adapters and instructions. Figure 5 Piston Pin Tool Piston pin tool (Fig.
Nozzle Tester Nozzle tester (Fig. 7). Tests condition and opening pressure of fuel injector nozzles. Figure 7 Nozzle Tester Adapter Nozzle tester adapter (Fig.8) is required to test the fuel injection nozzles.
Adjustments Valve Clearance Check the valve clearance after the first 50 hours of operation and every 600 hours of operation after that. 1. The engine must be cold when the valve clearance is checked. 2. Remove the air breather hose from the rocker cover. 3. Remove the rocker cover nuts and washers. Remove the rocker cover. Figure 9 Liquid Cooled Diesel Engine 4. Tighten the cylinder head bolts to the proper torque. The rocker assembly must be removed before tighten ing the cylinder head bolts.
Engine Speed Adjustments Adjustments to the engine speed settings are not nor mally necessary unless the throttle linkage, injection pump, or governor mechanism have been repaired, rebuilt, replaced or are not operating correctly. If your machine is not equipped with the optional ta chometer, use a vibration-type tachometer to set engine speed. WARNING Engine must be running to do these adjust ments.
Accelerator Pedal Adjustment If engine throttle lever does not contact high idle stop when accelerator pedal is fully depressed, an adjust ment to the accelerator cable is required. 2 1 1. Put vehicle into position on a level surface, stop engine and engage parking brake. 3 NOTE: Engine must NOT be running and return spring must be attached. 2. Adjust ball joint on accelerator cable to allow 0.100 0.250 inch clearance between accelerator pedal and top of diamond tread floor plate, when a 25 lb.
Liquid Cooled Diesel Engine Page 4 - 16 Workman 3300-D/4300-D
Liquid Cooled Diesel Engine Workman 3300-D/4300-D Page 4 - 17 Liquid Cooled Diesel Engine
Testing Glow Plug Test CAUTION Be careful while handling or testing glow plugs. Glow plugs become extremely hot. Ac cidental contact with the heated plug tip could cause personal injury. 1. Disconnect the wire lead(s) to the glow plug. 2. Remove the glow plug. 3. Inspect the glow plug for signs of a burnt glow plug end tube. Figure 15 NOTE: If the metal of the glow plug end is melted, it is a sign of cylinder overheating. (See Engine Overheats in the Troubleshooting section of this chapter.) 4.
Compression Test Normal cylinder compression is 28 kg/cm2 (398 psi) at 280 rpm (normal cranking speed). The engine should be warm - coolant temperature of 50o C (120o F). IMPORTANT: DO NOT put oil into the combustion chamber before performing a compression test. Damage may result because of “hydraulic” forces acting upon the piston and connecting rod. 1. Remove the glow plug lead wires and glow plugs from all three cylinders. 2. Insert the compression gauge adapter into the glow plug hole.
Nozzle Tests There are several tests to examine the condition of the injection nozzles. These tests require the use of a nozzle tester and nozzle tester adapter. (See the Spe cial Tools section of this chapter.) DANGER The nozzle tester forces fuel from the nozzle under extremely high pressure. Always point the nozzle tip away from yourself and any other personnel. Contact with the fuel stream, even though it appears to be a mist can cause fuel to penetrate clothing and skin.
amount of fuel may be present due to a previous chat tering test - this would be normal. If the fuel accumulates and drips down during the test (about ten seconds) the nozzle assembly is defective and must be replaced. Spray Test For proper combustion, the nozzle must effectively at omize the injected fuel. 1. Operate the pump handle at a rate of 20 - 30 strokes per minute. 2. Observe the injector nozzle spray. The spray pattern should be finely atomized in a broad, straight stream (Fig. 19).
Injection Pump Test Calibration of fuel delivery volumes, pressure and dis tribution between pump barrels should be performed by a professional diesel engine service shop. Special test fixtures and equipment are required. D. Push accelerator pedlal to the floor. Turn the ignition key to the START position to crank the engine. Observe the nozzle. It is possible to determine if the fuel injection pump requires service through a process of elimination using other fuel system tests.
Injection Timing Test Injection timing can be adjusted by installing shims under the pump body. The timing is important because it determines when the fuel enters the combustion chamber. The most accurate method of timing is done with an electronic diesel timing tester (available from major tool supply companies). The following method is an initial setting for starting the machine. 1. Remove the number one injection pipe from both the pump and nozzle.
Fuel Pump Test 1. Turn the ignition switch to the ON position. Test for pump operation by listening for the pump oscillating sound, or by feeling for vibration which indicates the pump is operating. 2. If no pumping action occurs when the ignition switch is turned on, connect a 12 volt DC battery directly to the pump (Fig. 22). If the pump now operates, check for an electrical failure of the pump circuit, eg. fuses, connec tions, wires, etc. 3.
Fuel Stop (ETR) Solenoid The Workman 3300-D/4300-D has an energize-to-run (ETR) fuel stop solenoid. The solenoid will stop injector pump fuel delivery with any electrical failure in the RUN circuit. 1 1. Disconnect the wire connector and remove the fuel stop solenoid from the engine. 3 2. Connect a 12 volt battery so the positive (+) battery terminal is connected to terminals A (hold) and B (pull) (Fig. 22). Connect the negative (–) battery terminal to solenoid terminal C (common).
Engine Oil Pressure Switch The switch is normally closed (NC) and opens with pressure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on. If bulb is not on: 1 1. Disconnect wire from switch and touch wire to a good ground. 2. If lamp comes on, replace switch. 3. If lamp does not come on check lamp and/or wiring between lamp and switch for continuity. Figure 26 1. Engine oil pressure switch If lamp is on with engine running: 1.
Temperature Gauge Sender 1. Lower the coolant level in the engine and remove the temperature gauge sender. 1 2. Put the switch in a container of oil with a thermometer and heat the oil. 3. With an Ohm meter connected as shown, the follow ing resistance readings should be indicated. 90.5 - 117.5 ohm at 160o F (70o C) 21.3 - 26.3 ohm at 207o F (115o C) Figure 27 CAUTION 1. Temperature gauge sender Liquid Cooled Diesel Engine Handle hot oil with special care to prevent personal injury or fire.
Checking Starter Pinion Gap 1. Install 12 volt battery between the “S” terminal and the starter body. The pinion should protrude and stop. IMPORTANT: Never apply battery voltage to the starter for longer than 10 seconds. 2. Lightly push the pinion back and measure the return stroke (called pinion gap). 3. If the pinion gap is not within standard range of 0.5 2.0 mm (0.02 - 0.08 in.), adjust it by increasing or decreasing the number of packings on the magnetic switch.
Magnetic Switch (Solenoid) Attraction Test 1. Disconnect the wire from terminal “M” (Fig. 31). 2. Connect a 12 volt battery to the magnetic switch terminals “S” and “M”. The pinion must protrude. IMPORTANT: Never apply battery voltage to the starter for longer than 10 seconds. Figure 31 Liquid Cooled Diesel Engine Magnetic Switch (Solenoid) Holding Test 1. Disconnect the wire from terminal “M”. 2. Connect a 12 volt battery to the magnetic switch terminal “S” and the starter body.
Alternator Regulated Voltage Test 1. Install an ammeter between the positive (+) terminal of the battery and terminal “B” of the alternator. 2. Ground alternator terminal “L” through a voltmeter. 3. Note that the voltmeter shows 0 volts when the ignition key switch is in the OFF position. The voltmeter will show voltage lower than battery voltage when the ignition key switch is in the ON position (engine not running). 4. Start the engine. 5.
Preparation for Engine Repair 2. Clean or wash the engine exterior thoroughly before disassembly. engine oil to disassembled parts, as necessary to pre vent rust. 5. Keep the work area clean; dirt causes engine failures. 6. Be very careful when working on fuel system compo nents. Cover the work area with clean paper. Store components of the nozzles or injector pump in clean fuel oil. Do not allow components to strike each other or other objects.
External Engine Component Repair Belt Replacement and Adjustment Alternator Belt 1. Loosen bolt securing alternator brace to engine and bolt securing alternator to brace (Fig. 36). 2 2. Remove two capscrews securing drive shaft coupler to engine crankshaft pulley. 1 3. Move drive shaft out of the way so belt can be removed and new one installed. 4. Install new belt. 5. Connect drive shaft coupler to engine crankshaft pulley with two capscrews and washers. 6.
Thermostat Removal and Installation 1. Lower the coolant level to below the thermostat. 2. Loosen the hose clamp and disconnect the hose from the water outlet fitting. 7. Fill the cooling system to the proper level with a 50/50 solution of clean, soft water and ethylene glycol anti freeze (See Checking the Cooling System and Chang ing Coolant in the Maintenance section of this book.). 3. Remove the water outlet fitting and gasket (Fig. 38). 4.
Electrical System Repairs Alternator Removal and Installation 1. Disconnect the negative (–) cable from the battery. 2. Disconnect the wire from terminal “B” on the back of the alternator. 3. Disconnect the alternator wiring harness connector. 4. Loosen alternator brace bolt and alternator support bolt (Fig. 40). Push the alternator toward the engine and remove the belt. 5. Remove the alternator. 6. Reverse steps 1 - 5 to install the alternator.
Replacing and/or Adjusting Engine Stop Solenoid An improperly adjusted stop solenoid can result in fail ure of the engine to stop when the key switch is turned off or could cause injection pump damage or malfunc tion. 7. Hold the solenoid body to prevent it from turning and tighten the nut against the engine to secure the adjust ment. Do not over tighten the nut. If the nut is over tightened, the solenoid may become distorted and will not operate correctly. Removing the Stop Solenoid 1.
Glow Plug Replacement Replace the glow plug(s) if they do not operate correctly. (See Glow Plug Test in the Testing section of this chapter.) 3. Remove the glow plug. 4. Install a new glow plug. Tighten the glow plug to a torque of 11-14.5 ft-lb (1.5-2 KgM). 1. Remove the nut and lead wire. 5. Install the lead wire and nuts. 2. Clean the area around the glow plug. This will prevent dirt or other contamination from falling through the glow plug hole into the cylinder.
Starter Service Disassembly and Inspection 1. Remove the starter from the engine (see Starter Removal and Installation). 7. Unscrew the bolts and remove the center bracket. As the bracket is removed, washers for pinion shaft end play adjustment will come off. 2. Disconnect wire from magnetic switch terminal “M”. 8. Pull out the reduction gear lever and lever spring from the front bracket. 3. Loosen two screws securing the magnetic switch. Remove the magnetic switch. 9.
Break and short circuit Wear and chipping One-way mechanism Bearing: Play, noise, and rough rotation Insulation Break and short circuit Bearing: Play, noise, and rough rotation Figure 47 10. Check the magnetic switch for continuity between terminals “S” and “M” and between terminals “S” and body. If there is continuity (or zero ohm is indicated), replace the magnetic switch.
11. Put the armature on a growler tester to check for a shorted armature. A burned commutator bar is an indi cation of a shorted armature. With the growler turned on, put a thin strip of steel or a hacksaw blade on the armature as it is slowly rotated. If the metal strip vibrates over a winding, that winding is short circuited. Short circuited windings are sometimes caused by metal in the commutator bridging the gap from on commutator bar to the next.
Assembly and Adjustment of Starter 1. Reverse steps 1 - 10 under Disassembly and Inspec tion and also following the following instructions: Adjusting Washer Gear Washer 2. Set the pinion shaft end play (thrust gap) to 0.5 mm (0.02 in.) or less by inserting an adjusting washer be tween the center bracket and reduction gear. A. Fit the pinion shaft, reduction gear washer and snap ring to the center bracket. B. Measure end play by moving the pinion shaft in and out. If end play exceeds 0.5 mm (0.02 in.
Alternator Service 4. Put the rotor in a vise. Remove pulley nut and pull off the pulley and spacer. Disassembly and Inspection 1. Remove the alternator from the engine (see Alterna tor Removal and Installation). 5. Pull the rotor assembly from the front bracket. 2. Remove the three through bolts. 6. Unsolder the stator core lead wires. Remove the stator assembly. 3. Use a solder iron to heat the rear bracket around the rear bearing to 120 - 140o F (50 - 60o C).
Deformation and damage Break and short circuit Wear and roughness Wear Crack and damage Break and short circuit Wear to limit line Figure 54 9. Check each diode in the rectifier for conduction. Connect an ohm meter across the lead wire and diode case. The diode is normal if its resistance is large in one direction and small in the reverse direction. If there is equal resistance in both directions the diode is dam aged. Replace the rectifier assembly if a diode is dam aged. Figure 55 10.
11. Check for continuity between a slip ring and shaft (core). Replace the field coil if there is continuity. Figure 57 Liquid Cooled Diesel Engine 12. Check for continuity between lead wires of the stator coil. Replace the stator coil if there is no continuity. Figure 58 13. Check for continuity between each lead wire and stator core. Replace the stator coil if there is continuity.
Assembly of Alternator 1. Reverse steps 1 - 8 under Disassembly and Inspec tion and also following the following instructions: 2. The rear bearing has an eccentric groove. Install the snap ring so its projection fits in the deepest part of the groove. 3. When installing a new rear bearing, press fit the bearing with its groove facing the slip ring side. 4. Heat the rear bracket when press fitting the rear bearing into the bracket.
Governor System Repairs Governor Operation governor weights, thus maintaining constant engine speed. When the speed control lever is pulled toward high speed, the governor spring is pulled. The spring pulls on the governor lever to move the governor control rack and increase the fuel injection rate. As engine speed increases, the governor weight centrifugal force also increases until it is balanced with the governor spring force, thus maintaining a constant engine speed.
Governor Inspection A governor failure can cause engine starting failure, loss of engine speed control, or engine surging (hunting). Before removal and disassembly of the engine the following inspections are recommended: 3. Push the tie rod forward only with only enough force to overcome the spring pressure and operate the speed control lever (or throttle lever). You should feel the governor lever, under spring tension, move the tie rod and control rack as the lever is operated. 1.
Governor Service 1. Remove the tie rod cover (Fig. 33). 2. Remove the tie rod clip and disconnect the tie rod from the injection pump control rack. 3. Disconnect the governor spring from the tension lever. 4. Remove the cover assembly. 5. Removing the levers: A. To remove the levers, pull out the grooved pins from the governor lever, stop lever and speed control lever. Figure 35 B. Loosen the bolts securing the levers and shafts. Liquid Cooled Diesel Engine 6. Installing the levers: A.
Installation of Torque Spring Set IMPORTANT: Torque spring set adjustment has been done and sealed at the factory. Do not remove, disassemble or adjust this device unless necessary. The torque spring set adjustment is very sensitive. Improper adjustment can vary fuel delivery to under power or over fuel the engine. 1. Engage the parking brake. Make sure the high speed set bolt is adjusted to the correct engine speed of 3600 ±50rpm (See Adjusting Engine Speed). NOTE: Specified rpm is with no load on engine.
Assembly of Torque Spring Set If the torque spring set has been disassembled or parts replaced, reassemble and adjust the torque spring set using the following procedure. IMPORTANT: The torque spring set has been ad justed and sealed at the factory. Do not remove, disassemble or adjust this device unless necessary. The torque spring set adjustment is very sensitive. Improper adjustment can vary fuel delivery to under power or over fuel the engine. 1. Assemble the torque spring set as shown in Figure 37. 2.
Fuel System Repairs When cleaning the engine, DO NOT spray water onto a hot injection pump. This could cause the fuel pump to seize and be damaged. When working on the fuel system, ALWAYS make sure that the equipment and work area is clean. The close tolerance parts of the fuel system can be easily dam aged by dirt. Wash fuel system parts in clean fresh diesel fuel. If parts are removed for a period of time, store them in contain ers of clean diesel fuel to prevent corrosion. Bleeding the Fuel System 1.
Bleeding Air From the Injectors This procedure should only be used if the fuel system has been purged of air. (See Bleeding the Fuel System in this section of the book.) 1. Loosen the pipe connection at the number one nozzle and holder assembly on the cylinder head (Fig. 41). 1 2. Push accelerator pedal to the floor. 3. Turn the ignition key to the START position to crank the engine and pump fuel to the nozzles.
5. Carefully remove the spring retainer from the end of the plunger tube (Fig. 43). Remove the washer, o-ring, valve, plunger spring and plunger. IMPORTANT: Be careful not to bend or deform the plunger tube while disassembling the fuel pump. If the plunger tube is bent, the fuel pump plunger will bind and the pump will need to be replaced. 6. Install the plunger (valve side out), plunger spring, valve, o-ring, washer and spring retainer. Make sure the plunger operates freely. 7.
3. Remove the tappet roller and stopper pin. Remove the tappet and adjusting shim. Injection Pump Disassembly IMPORTANT: Do not mix the delivery valves, deliv ery valve seats, plungers or plunger barrels from one cylinder to another. These are parts are “matched sets”. Handle these parts carefully. Place the parts in a container of clean diesel fuel to pre vent corrosion. 1. Remove the stopper holder. Remove the delivery valve holder (Fig. 46). 2. Remove the valve spring, delivery valve and o-ring.
Injection Pump Inspection Inspect the injection pump parts for proper operation, wear, corrosion, seizure, etc. (Fig. 47). Replace worn or damaged parts. Injection Pump Assembly 1. Insert the plunger barrel into the housing. 2. Install the delivery valve seat, gasket, delivery valve and valve spring. Install the o-ring on the delivery valve holder. Temporarily tighten the delivery valve holder. 3. Insert the control rack. Insert the sleeve. Align the match mark on the rack with that on the pinion (sleeve).
Nozzle Service IMPORTANT: When servicing the injection nozzles make sure that the engine and fuel delivery pipes are clean to prevent dirt from entering cylinder or nozzle. Do not mix components of one nozzle with the other. Nozzle Removal and Disassembly 1. Disconnect the injection pipes and fuel return pipe. 2. Remove the injector nozzle from the cylinder head. NOTE: Further disassembly of the nozzle is not required for the nozzle to be tested. (See Nozzle Tests in the Testing section of this chapter.
Nozzle Inspection and Cleaning 1. Clean the inside and outside of the retaining nut in clean diesel fuel or kerosene to remove carbon or fuel deposits. Inspect the lower seating surface for rust or damage. The sealing area may be restored with emery cloth. 2. Remove carbon or lacquer deposits from the nozzle by cleaning in clean diesel fuel or kerosene. Stubborn deposits can be removed with a brass wire brush. IMPORTANT: Do not use a steel brush, steel wool, etc.
Removing and Installing the Engine Liquid Cooled Diesel Engine Removing the Engine Figure 52 1. Put machine on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Remove the bed or other attachment(s). Allow engine and radiator to cool. 4. Disconnect coolant and radiator hoses from engine. 2. Disconnect positive (+) and negative (–) battery ca bles from battery. 6. Disconnect air intake hose from engine. 5.
12. Remove clamps and wire ties where wiring harness, hydraulic hoses or cables are attached to the engine. 16. Remove capscrews securing clutch bell housing to engine. 13. Put blocking under transaxle for support. 17. Use a hoist or block and tackle to remove engine from chassis. One person should operate hoist or block and tackle and the other person should help guide engine out of chassis. Move engine forward before lifting to disengage transaxle input shaft from clutch. 14.
Cylinder Head Overhaul Cylinder Head Removal 1. If the engine will not be removed from the vehicle, lower the coolant level in the engine. Loosen the hose clamp and remove the upper radiator hose from the thermostat housing. Disconnect the coolant bypass hose from the thermostat housing. 2. Remove plug from left side of cylinder block to drain the coolant from head and cylinder block. 3. Remove the muffler. 4.
Cylinder Head Service 1. Use a valve lifter tool to compress the valve spring (Fig. 61). To remove each valve retainer, depress the retainer against the valve spring and remove the re tainer lock (Fig. 62). Remove the valve retainer, spring and valve. Keep each valve and other parts for each cylinder separate so they can be reinstalled in the same cylinder. 2. Examine each valve for burning, pitting, heavy carbon deposits or wear.
8. Use a straight edge and feeler gauge to check the flatness of the cylinder head lower surface (Fig. 63). Be sure to check the surface variation crosswise, length wise, and diagonally. If the variation in surface flatness exceeds (0.05 mm) 0.002 in. , the cylinder head or cylinder block must be replaced or resurfaced. Figure 63 Valve Guides Liquid Cooled Diesel Engine 1. Use a micrometer and a small hole gauge to check the valve guide to valve stem clearance.
Valves 1. Carefully clean each valve with a wire wheel to remove all carbon deposits. 2. Check the valve face and valve stem for excessive wear, damage, cracks or deformation. If any of these conditions exist, the valve must be replaced. It is possi ble to reface the valve if the valve head thickness (margin width) is not less than the service limit (Fig.65). If the margin of the resurfaced valve is less than the service limit, replace the valve. Minimum valve head thickness (margin width): 0.5 mm (0.
Valve Springs 1. Check the valve springs for rust, pitting, cracks or other damage. 2. Check the squareness of the valve spring by putting it upright on a level surface. Any spring that is 3o or more out of square must be replaced. 3. Measure the spring free length. Any spring that has a free length of 39.3 mm (1.55 in.) or less must be replaced. 4. Over a period of time, valve springs can lose some of their tension. The spring must be replaced if the tension is less than the service limit. (Fig.
Cylinder Head Assembly and Installation 1. Install the thermostat housing. Use a new gasket. valve springs and valve retainers. Compress the spring with a valve lifter, then install the retainer lock. 2. Install the intake and exhaust manifolds. Use new gaskets. 3. Make sure the valve guides are properly installed (Fig. 64). 4. Install new valve stem seals onto the valve guides (Fig. 70). DO NOT install used seals. 5.
8. Make sure that the cylinder head and cylinder block surfaces are clean. Put a new gasket on the cylinder head. Insert dowel pins into two cylinder head bolt holes to assist in mounting the head onto the block. Carefully put the cylinder head into position on the cylinder block. Remove the dowel pins. Insert the cylinder head bolts. IMPORTANT: Do not put any sealant on the cylinder head gasket. 9. Tighten the cylinder head bolts in the order shown in Figure 71.
Cylinder Block Overhaul NOTE: The engine must be removed from the vehicle chassis and put in an engine stand. (See Removing and Installing The Engine.) Gear Case and Oil Pump 1. Remove the crankshaft pulley. 2. Remove the fuel injection pump. (See Injection Pump Service in the Fuel System Repairs section of this chapter.) 3. Disconnect the governor spring from the tension lever. Remove the governor cover assembly from the gear case. (See the Governor System Repairs section of this chapter.) 4.
Liquid Cooled Diesel Engine 7. Check removed parts for wear or damage (Fig. 73). Replace parts as necessary.
8. Check the governor parts for wear or damage (Fig 74). Replace parts as necessary. A. Remove the expansion plug (Fig 75). Be careful to not scratch the gear case. B. Pull out the grooved pin. C. Remove the shaft, spring and levers. D. If necessary replace the governor bushings (Fig. 76). E. Install the shaft, spring and levers. Press fit the expansion plug into the hole in the gear case. Figure 74 9. Reverse steps 1 - 6 to reassemble the gear case. Use new gaskets when assembling the gear case.
Timing Gears and Camshafts 1. Remove the cylinder head (see Cylinder Head Re moval in the Cylinder Head Overhaul section of this chapter). 2. Remove the gear case (see Gear Case and Oil Pump in this section). 3. Remove the snap ring and remove the idle gear (Fig. 77). 4. To remove the injection pump camshaft: A. Remove the governor weight assembly (Fig. 33). B. Remove camshaft rear cover. Figure 77 C. Remove the stopper bolt (Fig. 78). Liquid Cooled Diesel Engine D.
6. Check the gears for incorrect tooth contact, wear and damage. Replace any gears that are badly worn or damaged. 7. Inspect the camshaft parts (Fig. 80). Replace any parts that are worn or damaged. Major diameter of cam: Injection pump cam: 29.3 - 30 mm (1.154 - 1.181 in.) Valve cam: 26.37 - 27.37 mm (1.038 - 1.078 in.) Maximum idle gear bushing to shaft clearance: 0.2 mm (0.008 in.) Push rod bend: within 0.3 mm (0.012 in.) Maximum backlash between gears in mesh: 0.3 mm (0.012 in.
8. Before installing the camshafts and timing gears, turn the crankshaft to set the No. 1 cylinder to top dead center (TDC) of the compression stroke. Reverse steps 1 - 5 to install the camshafts and timing gears (Fig. 81). Figure 81 Liquid Cooled Diesel Engine 9. With the crankshaft set to No. 1 cylinder TDC, install the idle gear so the timing marks on all the gears are in alignment (Fig. 82).
Piston and Connecting Rod 1. Remove the cylinder head (see Cylinder Head Re moval in the Cylinder Head Overhaul section of this chapter). 2. Remove the oil pan and gasket. 3. Remove the oil screen NOTE: Before removing the pistons, mark the number of the cylinder onto the top of each piston and on the side face of each connecting rod (on the large end). When the piston and connecting rod is removed be careful to prevent damage to the piston or bearing surfaces. 4.
8. Measure the piston outside diameter (Fig. 84). (See Cylinder Block in this section). Maximum piston to cylinder wall clearance: 0.3 mm (0.012 in.) Figure 84 9. Use a thickness gauge to check the piston ring side clearance (Fig. 85). Liquid Cooled Diesel Engine If the piston ring side clearance exceeds the service limit, the ring must be replaced. If the clearance still does not meet specifications with a new ring the piston must be replaced. (See the Specifications section of this chapter.
11. To remove the piston from the connecting rod press the piston pin from each piston. Use the piston setting tool (Fig. 87). IMPORTANT: Do not attempt to remove the piston pins by driving then out with a hammer. A stuck piston pin, requiring excessive pressure to remove, should be replaced. 12. Check for bending or distortion of the connecting rod. The service limit for bend and distortion is 0.15 mm (0.006 in.). Replace the connecting rod if damaged or out of specification. 13.
15.Install the piston rings. Each piston ring has different shape. Make sure they are installed in the proper posi tion and with the ring gaps in the directions as illustrated (Fig. 90). 17. Install the connecting rod bearings and end caps. Make sure the notches on the bearings and connecting rod are aligned. Tighten the end cap retaining bolts to a torque of 3.2 - 3.5 KgM ( 23 - 25 ft-lb). Liquid Cooled Diesel Engine 16.
Crankshaft 1. Perform steps 1 - 5 under Piston and Connecting Rod in this section. 2. Remove the flywheel. 3. Remove the rear oil seal case. 4. Remove the main bearing caps (Fig. 91). Keep each set of bearings together with its bearing cap. 5. Remove the crankshaft. 6. Inspect the removed parts. Repair or replace any worn or damaged parts (Fig. 92).
6. Measure the crankshaft for “run-out” (bend). Mount the crankshaft in a pair of V-blocks (or live centers) and use a dial indicator to measure the run-out in the crank shaft (Fig. 103). The maximum allowable crankshaft run-out is 0.05 mm (0.002 in.). 7. Check the crank journals and crankpins for damage, out of round wear or tapering wear. The diameter of each crankpin or main journal should be measured at two places, “1" and ”2", in two directions, “A” and “B” (Fig. 104). Main journal diameter: 42.
10. Reverse steps 1 - 5 to install the crankshaft (Fig. 97). When installing the No. 1 and No. 4 bearing caps, apply sealant (Permatex No. 2 or equivalent) to the upper surface that meets with the cylinder block. 11. Use a dial indicator to measure the crankshaft end play. If end play exceeds specifications, replace all the main bearings. Crankshaft end play: 0.05 - 0.175 mm (0.002 - 0.007 in.) 12. Apply sealant (Permatex No. 2 or equivalent) to the outside surface of the side seals.
Cylinder Block Before cleaning check the cylinder block for coolant leaks, oil leaks or damage. Clean all parts to remove dirt, oil, carbon deposits and water scale. Check the cylinder block for cracks or other damage. Check the water jacket for water scale and rust. Replace the cylinder block if necessary. Measure each cylinder bore size in six locations (Fig. 98). The cylinder must be rebored and over-sized piston and rings installed if the diameter exceeds the standard by 0.2 mm (0.0079 in.).
Liquid Cooled Diesel Engine Page 4 - 80 Workman 3300-D/4300-D
Chapter 5 Air Cooled Gas Engine Table of Contents 2 3 3 3 4 4 Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . Choke Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Accelerator Adjustment . . . . . . . . . . . . . . . . . . . . . . . REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Removal and Installation . . . . . . . . . . . . . . . KOHLER ENGINE SERVICE MANUAL 4 5 5 6 6 Air Cooled Gas Engine SPECIFICATIONS . . . . . . . .
Specifications Item Specification Make / Designation Serial Number Below 220000000 Serial Number Above 220000000 Kohler Air Cooled, Gasoline Engine CH 22S Spec. No. 66513 CH 23S Spec. No. 76548 Bore/Stroke Serial Number Below 220000000 Serial Number Above 220000000 3.03 in. / 2.64 in. (77 mm / 67 mm) 3.15 in. / 2.64 in. (80 mm / 67 mm) Displacement Serial Number Below 220000000 Serial Number Above 220000000 38.1 cu. in. (624 cc) 41.1 cu. in. (674 cc) Crankcase oil capacity 2 U.S. qt. (1.
General Information Removing Debris From Engine To ensure proper cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. To clean, remove the blower housing and other cooling shrouds and clean the cooling fins and external surfaces as necessary. Make sure cooling shrouds are reinstalled after cleaning.
Adjustments Belt Adjustment 1. Park machine on a level surface, stop engine and engage parking brake. 1 2. Check tension by depressing belt at mid span of crankshaft and pump pulleys with 22 lbs. (10 Kg) of force. A new belt should deflect .48 – .58 in. (12 – 15 mm). A used belt should deflect .55 –.65 in. (14 – 17 mm) If deflection is out of specification, go to next step. If deflection is within specification, no adjustment is necessary. 3. To adjust belt tension: A.
Choke Adjustment 1. Park machine on a level surface, stop engine and engage parking brake. 2. Loosen cable clamp screw securing choke cable to engine. 3. Push choke control knob down to OFF position. 4. Push choke cable firmly toward operator’s side of vehicle and tighten cable clamp screw. 2 1 Figure 5 1. Choke cable 2. Cable clamp Accelerator Adjustment 1. Park machine on a level surface, stop engine and engage parking brake.
Repairs Engine Removal and Installation 35 – 41 ft–lb (47 – 56 Nm) 14 13 12 16 20 7 15 11 18 17 19 10 1 3 4 9 2 8 6 5 Never–seez Figure 7 1. Battery Positive (+) cable 2. Hydraulic pump drive belt 3. Locknut 4. Flat washer 5. Capscrew 6. Lockwasher 7. Engine 8. Locknut 9. Flat washer 10. Pulley 11. Woodruff key 12. Pilot bearing 13. Socket head screw 14. Washer 15. Flywheel 16. Woodruff key 17. Capscrew 18. Lockwasher 19. Flat washer 20. Clutch adapter 5.
11. Attach hoist or block and tackle to engine for support. Pilot bearing 12. Remove four (4) locknuts (Item 3), flat washers (Item 4), capscrews (Item 5) and lockwashers (Item 6) securing engine to frame. 35 – 41 ft–lb (47 – 56 Nm) 13. Remove capscrews securing clutch bell housing to engine. 14. Use a hoist or block and tackle to remove engine from chassis. One person should operate hoist or block and tackle and the other person should help guide engine out of chassis.
Air Cooled Gas Engine (Rev.
Chapter 6 Drive Train Table of Contents TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 9 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Control Cable Replacement . . . . . . . . . . . . . . . . . . 12 Stub Axle and Drive Shaft Service . . . . . . . . . . . . 13 Drive Shaft Universal Joint Service . . . . . . . . . . . 15 P.T.O. Removal and Installation . . . . . . . . . . . . . . 16 Transaxle Removal and Installation . . . . . . . . . . .
General Information Workman 3000/4000 Series vehicles are equipped with a Toro designed transaxle with 3 forward speeds, 1 reverse and a differential lock. Hi–Lo range gives an effective 6 forward and 2 reverse speeds. The transaxle is a constant mesh, collar shift transmission with synchronizers for gears 1, 2 and 3. Reverse and High–Low range must be shifted with the vehicle stationary. An optional top mounted PTO operates at 540 RPM.
Specifications General Specifications Item Specification Clutch pedal free play 19 mm (.75 in.) min. Transaxle countershaft end play 0.00 – 0.10 mm (.000 – .0039 in.) 0.08 – 0.18 mm (.0031 – .0071 in.) with max. variation of 0.05 mm (.0019 in.) at three different points checked Transaxle ring gear backlash Liquid gasket (transaxle case gasket) Three–Bond 1216 or Loctite 599 Transaxle oil Dexron III ATF Oil capacity (Fig. 2) 7.5 qt. U.S. (7.1 liter) system capacity Drive Train 1 Figure 2 1.
Special Tools Drive Shaft Yoke Flange Nut Wrench A modified 1–1/8� box end wrench is required to remove and install flange nut securing drive shaft yoke to stub axle on early production machines. NOTE: If your ma chine has a half yoke on the stub axle, this modified tool is not necessary. Recommended Tool: Snap–On Part No. GOEX36B Figure 3 Stub Axle Removal Tool Use this tool with modified box end wrench shown above to remove flange nut securing drive shaft yoke to stub axle.
Stub Axle Use an extra stub axle (Toro P/N 87–8740) with washer (Toro P/N 87–3060) and flange lock nut (Toro P/N 32128–53) as a tool to install stub axle. Attach this tool to the wheel studs on the stub axle. Secure tool with wheel nuts. Use a 1–1/8� six point socket, torque wrench, and modified 1–1/8� combination wrench to tighten stub axle flange nut to a torque of 300 – 340 Nm (220 – 250 ft–lb).
Adjustments Clutch Pedal Adjustment 1. Loosen jam nuts securing clutch cable to bracket on bell housing. NOTE: Ball joint may be removed and rotated, if addi tional adjustment is required. 2. Disconnect return spring from clutch lever. 3. Adjust jam nuts/or ball joint until bottom rear edge of clutch pedal is “A” from top of floor plate diamond pat tern, when an 4 lb. force is applied to pedal. Vehicle Dimension “A” Workman 3200 / 3100 95 + 3 mm (3.75� + .12�) Workman 3300–D 108 + 3 mm (4.25� + .
Shift Cable Adjustment 1st–Rev. / 2nd–3rd Cable Adjustments 2 1. Move shift lever to neutral. 2. Remove clevis pins securing shift cables 1st–Rev. and 2nd–3rd cables to transaxle shift arms. 3. Loosen clevis jam nuts and adjust each clevis so cable free play is equal forward and backward relative to hole in transaxle shift arm (with transaxle lever free play taken up in same direction). 3 1 4 4. Reinstall clevis pins and tighten jam nuts after adjust ments have been made. 5.
Differential Lock Cable Adjustment Note: On units without a Differential Lock lever, do not perform this adjustment. 2 1. Move differential lock lever to OFF position. 2. Loosen jam nuts securing differential lock cable to bracket on transaxle. 3. Adjust jam nuts to obtain 0.9 + 0.6 mm (.035� + .025�) gap between spring hook and O.D. of hole in transaxle lever. 1 3 0.9 ± 0.6 mm (.035� ± .025�) 4. Tighten jam nuts after adjustment has been made. Figure 15 1. Differential lock cable 2.
Troubleshooting Clutch Symptom Possible Causes Clutch slips. Excessive wear of clutch disc facing. Clutch pedal out of adjustment. Hardening of clutch disc facing, or adhesion of oil. Weak or broken clutch diaphragm spring. Damaged pressure plate or flywheel. Clutch operation erratic or rough. Improper installation of clutch cover assembly. Damaged clutch disc. Excessive wear of clutch disc facing. Weak or broken clutch torsion spring. Damaged or broken clutch pressure plate.
Clutch (continued) Symptom Possible Causes Clutch chatters. Worn or damaged clutch disc facing. Oil adhered to clutch disc facing. Uneven height of diaphragm spring. Weak or damaged clutch torsion spring. Damaged pressure plate or flywheel. Damaged release bearing. Transaxle Symptom Possible Causes Noisy operation. Low oil level in transaxle. Damaged or worn bearings. Gears worn, scuffed or broken. Excessive end play in countershaft. Gears loose on shaft.
Transaxle (continued) Symptom Possible Causes Gears make clashing noise when shifting. Shifting too fast. Excessive wear of synchro rings. Excessive wear of differential side gear liners and pinion liners. Damaged synchro springs and/or keys. Main gear needle bearings worn or damaged. Excessive wear of drive shaft(s). Transaxle sticks in gear. Clutch not releasing. Shift fork detent ball stuck. Shift linkage damaged, loose or out of adjustment. Sliding gears tight on shaft splines.
Repairs Shifter Cable Replacement d 4 20 – 24 Nm (15 – 18 ft–lb) 6 5 2 3 1 5 2 1 6 9 10 7 2nd–3rd High–Low First–Rev Figure 17 NOTE: Before removing cable(s), note routing and location of cable ties. 9.5 mm (.375 in.) 1. Before installing cables adjust clevis (Item 1) on 1st– Rev and 2nd–3rd cables as shown Figure 18. 2. Connect shift cables to shift links (Item 6) on shifter in operator platform by inserting both clevis pins (Item 5) from the passenger side, then install cotter pins. 3.
Stub Axle and Drive Shaft Service 300 – 340 Nm (220 – 250 ft–lb) 47 – 57 Nm (35 – 42 ft–lb) 4 5 6 9 3 2 Loctite 271 10 11 Drive Shaft with Half Yoke 8 7 1 Half yoke 60 – 75 Nm (45 – 55 ft–lb) Figure 19 5. Washer 6. Stub axle 7. Bearing with thin spacer 8. Spacer 9. Locknut 10. Seal 11. Bearing Drive Train 1. Wheel nut 2. Wheel and tire 3. Brake drum 4. Flange nut NOTE: Later production machines have a half yoke on the stub axle. See inset in Figure 19. Stub Axle and Driveshaft Removal 1.
6. Install stub axle removal tool onto wheel studs. 7. Loosen flange lock (Item 4) nut by turning counter clockwise. 8. Remove stub axle (Item 6). 9. To remove driveshaft, loosen locknuts (Item 9) , then remove bolts securing driveshaft at splined axle shaft of transaxle. Slide driveshaft outward and remove from transaxle. Installation 1. If driveshaft was removed, install drive shaft clamp end onto splined axle shaft. Tighten clamp bolts to a torque of 47 – 57 Nm (35 – 42 ft–lb). Figure 21 2.
Drive Shaft Universal Joint Service 1. Remove drive shaft from machine (see Stub Axle and Drive Shaft Service). 2. Remove snap rings (Item 1). IMPORTANT: Yokes must be supported when re moving and installing bearings to prevent bending. 3. Use a press to remove cross and bearings (Item 2). 7) 6) 5) 4. To install new cross and bearings: 4) A. Apply a coating of grease to bearing bores. 2) B. Press one bearing partially into yoke (Item 3). 3) C. Insert cross into yoke and bearing. 1) D.
P.T.O. Removal and Installation PTO Removal 1. Remove clevis pin to disconnect PTO control cable clevis from shift arm on PTO. Do not loosen jam nuts to remove cable from support bracket. 2. Disconnect and label electrical lead that attaches to PTO switch. 2 1 3. Disconnect hydraulic hose from fitting on PTO. Put la bels on hydraulic hoses for proper reassembly. Put caps or plugs on all open hoses or fittings to prevent contami nation. Label hoses and fittings for proper reinstallation. 4.
Transaxle Removal and Installation Transaxle Removal 1. Put machine on a level surface. Stop the engine and remove key from ignition switch. Remove the bed or oth er attachment(s). Allow engine and radiator to cool. 2. Disconnect positive (+) and negative (–) battery cables from battery. 3. Remove drain plug from bottom of transaxle and allow oil to drain into a drain pan. Install drain plug. 1 Figure 27 1. Drain plug 4.
4 1 5 2 4 3 Figure 29 (Workman 3200 shown) 1. PTO 2. Drive shaft coupler 3. Control cable support bracket 4. Drive shaft assembly 5. Mount bracket 6. Remove hydraulic filter assembly and bracket. 11. Disconnect shifter control cables from levers on transaxle and PTO (see Shift Cable Adjustment). Do not loosen jam nuts to remove cables from support bracket. 7. Remove starter assembly from bell housing (Work man 3200 only). 12.
16. Block front wheels. Jack–up rear of machine under rear axle and install jack stands so transaxle can be re moved by sliding out under rear axle. 17. Put blocking under engine for support. Support transaxle with a floor jack or suspend transaxle from vehicle frame rails. NOTE: PTO hole cover has a threaded boss where you can attach a bracket or ring for supporting the transaxle. 2 18. Remove transaxle isolation mounts and mount brackets. 19.
Clutch Service 5 Silicone sealant (Workman 3100 only) 9 7 – 9 Nm (5 – 7 ft–lb) 12 11 6 10 13 4 2 1 6 9 3 Never–Seez (if bearing has metal inside diameter) Figure 31 Clutch Release Mechanism 8 1. Remove transaxle. 2. Inspect main shaft of transaxle for wear or damaged splines. 3. Remove roll pin (Item 1), then remove release bearing (Item 2). Inspect release bearing and replace if it is loose on the sleeve, if it appears burned or is worn.
Clutch Disassembly and Inspection Special tool (or transaxle main shaft 1. Insert special tool (or transaxle main shaft) in flywheel pilot bearing hole to keep disk from falling off. 2. Loosen clutch cover capscrews (Item 10) in a diagonal sequence. 3. Remove capscrews, washers (Item 11) and clutch cover (Item 12), then pull out the special tool and remove clutch disk (Item 13). Figure 33 4. Inspect diaphragm spring end of cover for wear and uneven height.
Transaxle Service Transaxle Disassembly NOTE: Item numbers in figures are shown in order of disassembly; for example, remove Item 1 first, then Item 2, etc. Reassemble in reverse order; for example, install Item 1 last. 1 1. Remove extension spring (Item 1). 2. Loosen capscrews (Item 2) and remove bell housing assembly from transaxle. 2 3. Thoroughly clean outside surface of transaxle. Figure 37 4. Loosen capscrews (Item 1) and remove fork shaft case (Item 2) from center plate.
IMPORTANT:Make sure to note the type of shim set removed from the center plate. Early versions of the centerplate have either four shims (Item 2) without tabs or one thick shim (Item 4) with a tab (Fig. 40). Newer versions of the center plate have one tabbed shim (Item 4) with three tabless shims (Item 2) (Fig. 41). 7. Loosen capscrews and separate center plate from transaxle case. Note dowel pins in transaxle case.
10. Remove main shaft assembly (Item 1) together with fork shaft assembly (Item 2) from transaxle case. 2 1 Figure 44 11. Remove, all at the same time, reduction shaft as sembly (Item 1), 2nd–3rd shift assembly (Item 2), coun tershaft assembly (Item 3) and High–Low shift assembly (Item 4). 2 4 1 3 Figure 45 12. Loosen capscrews (Item 1) and remove L.H. axle shaft assembly (Item 2) and shims (Item 3) from side cover. Figure 46 13. Remove roll pin from arm. Remove arm (Item 1) from fork shaft.
15. Loosen capscrews and remove R.H. axle shaft assembly from transaxle case. 1 2 Figure 48 16. Remove differential gear assembly (Item 1) together with fork shaft assembly (Item 2). 1 2 Figure 49 Drive Train 17. Remove washer (Item 1) from inside of transaxle case. NOTE: Washer may stick to fork shaft when re moved in step 15.
18. To remove shift arms (Transaxle Model KT40): 2 A. Loosen shift arm clamp bolt (Item 1) with a 3/16� Allen wrench. 8 4 B. Loosen nut (Item 2), then remove 2nd–3rd shift arm (Item 3) together with shift arm plate (Item 4), spring (Item 5), locknut (Item 6), washer (Item 7) and capscrew (Item 8). 7 5 6 3 3 1 C. Loosen locknut (Item 9) and remove washer (Item 10). Remove 1st–Rev. shift arm (Item 11) and High–Low shift arm (not shown). 9 10 11 4 D.
20. Loosen capscrews (Item 1) and remove nut (Item 2) with washer. Separate P.T.O. cover (Item 3) or P.T.O. and O–ring from transaxle case. Inspect P.T.O. cover for cracks or damage and replace if necessary. 2 3 1 Figure 54 21. Remove oil cap (Item 1) and O–ring from transaxle case if necessary. 1 2 22. Remove air breather (Item 2) if necessary. Figure 55 Drive Train 23. Loosen capscrews (Item 1) and remove upper cover (Item 2) from transaxle case.
24. Disassemble main shaft assembly: A. Use a bearing puller to remove bearing (Item 1) from main shaft. B. Remove snap ring (Item 2) and washer (Item 3). Measure thickness of washer. Replace washer if it is less than 1.8 mm (.0709 in.) thick. C. Remove 2 needle bearings (Item 5) and gear (Item 4). Inspect needle bearings and replace if nec essary. D. Remove synchro ring (Item 6). Figure 57 E. Remove snap ring (Item 7). F. Remove shifter (Item 8) together with spring, hub and 3 keys. G.
25. Disassemble reduction shaft assembly: 1 A. Use a bearing puller to remove bearing (Item 1) from reduction shaft. 5 3 14 13 10 15 7 B. Remove gear (Item 2), helical gear (Item 3), col lar (Item 4) and gear (Item 5). C. Use a bearing puller to remove bearing (Item 6). D. Remove washer (Item 7), needle bearing (Item 9) and gear (Item 8). 18 E. Remove spacer (Item 10). 2 4 17 16 F. Remove snap ring (Item 11). 12 11 8 6 9 G. Remove shifter (Item 12) together with spring, hub and 3 keys.
26. Disassemble reverse shaft assembly: A. Use a bearing puller to remove bearing (Item 1) from reverse shaft. B. Remove gear (Item 2). C. Use a bearing puller to remove bearing (Item 3) from reverse shaft. Figure 61 27. Disassemble countershaft assembly: A. Use a bearing puller to remove bearing (Item 1) from countershaft. B. Remove thrust washer (Item 2) and snap ring (Item 3). C. Remove thrust washer (Item 4) and gear (Item 5). D. Remove inner (Item 6) and thrust washer (Item 7).
28. Disassemble fork shaft assemblies: A. Remove lock pin (Item 1) from 2nd–3rd fork shaft assembly. B. Remove shift fork (Item 2) from fork shaft. C. Remove lock pin (Item 1) from 1st–R fork shaft assembly. D. Remove fork (Item 2) from fork shaft. Figure 64 29. Disassemble Hi–Lo fork shaft assembly: 5 1 A. Remove shift fork (Item 1), steel ball (Item 2) ad spring (Item 3) from Hi–Lo shift fork assembly. 4 B. Remove E–ring (Item 4). 3 2 Figure 65 30. Disassemble differential gear assembly: A.
31. Disassemble differential fork shaft assembly: A. Remove O–ring (Item 1) from fork shaft. B. Remove snap ring (Item 2), washer (Item 3) and spring (Item 4). C. Remove fork (Item 5). D. Remove lock pin (Item 6) if necessary. Figure 68 32. Disassemble axle shaft assemblies: A. Remove O–ring (Item 1) from differential carrier. B. Remove snap ring (Item 2). C. Remove L.H. axle shaft assembly (Item 3). D. Remove snap ring (Item 4) and washer (Item 5). E.
Transaxle Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. 3. Inspect synchronizer ring: A. Inspect the chamfer for excessive wear or damage. B. Inspect inner tapered area for excessive wear or damage. Figure 70 C. Measure the clearance between synchronizer ring and synchro gear in three equally spaced points. If clearance is less than 0.5 mm (.0195 in.) replace the synchronizer ring. 4.
6. Inspect hub, shifter, synchro key and synchro spring: A. Inspect hub for worn or damaged spline. B. Inspect shifter for chipping or damaged chamfer. C. Inspect synchro keys for wear or damage. D. Inspect synchro springs for wear or damage. E. The shifter should move freely on the hub. F. Measure the clearance between shifter groove and fork. Replace shift fork, if the clearance ex ceeds 1.0 mm (.039 in.) Figure 72 7. Inspect main shaft: A. Inspect main shaft for worn or damaged surface. If O.D.
10. Inspect center plate for cracks and damage. Re place center plate if the snap ring groove has more than 15% of its edges damaged due to nicks, rounding, cracks, or dents (Fig. 76 and 77). UNDAMAGED GROOVE Figure 76 DAMAGED GROOVE EDGES Drive Train Figure 77 Workman 3000/4000 Series Page 6 – 35 Rev.
11. Inspect reduction shaft: A. Inspect reduction shaft for wear or damage. If O.D. of needle bearing area is less than 21.95 mm (.864 in.) or 24.95 mm (.982 in.), replace the reduc tion shaft. Figure 78 12. Inspect countershaft: A. Inspect countershaft for wear or damage. If O.D. of inner portion is less than 27.95 mm (1.100 in.) or 71T gear portion is less than 29.95 mm (1.179 in.), replace the countershaft Figure 79 13. Inspect differential: A. Inspect pinion shaft for excessive wear or dam age.
Transaxle Reassembly NOTE: Item numbers in figures are shown in reverse or der of assembly; for example, when reassembling, install Item 1 last. 1. Clean gasket material from all mating surfaces before reassembling. Make sure all parts are clean and free of dirt and dust. IMPORTANT: Be careful not to damage mating sur faces when removing gasket material. 2. Assemble L.H. axle shaft: A. Install new oil seal (Item 7) into differential carrier. B. Use a press to install bearing (Item 6) onto L.H. axle shaft.
5. Assemble differential gears: A. Apply moly disulfide grease on pinion liners (Item 11), holes of pinion gears (Item 10), side gear liners (Item 14) and hubs of side gears (Item 13, 12). B. Install side gear liners (Item 14), side gears (Item 13, 12), pinion liners (Item 11) and pinion gears (Item 10). C. Rotate side gears until holes of pinion gears and liners line up with holes of differential case (Item 1). D. Insert pinion shaft (Item 9). Grease the shaft to aid assembly. E.
6. Assemble Hi–Lo fork shaft: 5 A. Install E–ring (Item 4) onto fork shaft (Item 5). 1 B. Insert spring (Item 3) and steel ball (Item 2) into fork (Item 1). C. Insert fork shaft into fork. Put moly disulfide grease onto the shaft before installing. 7. Assemble R–1 and 2–3 fork shaft: 4 3 2 Figure 87 A. Insert R–1 fork shaft (Item 2) into R–1 fork (Item 3). B. Drive lock pin (Item 1) into fork and fork shaft. Pay attention to direction of slit in lock pin. C.
8. Assemble countershaft: A. Use a press to install 2 new bearings (Item 15) onto countershaft. B. Install collar (Item 14) and snap ring (Item 13). C. Install washer (Item 12) and gear (Item 11). Apply moly disulfide grease into bushing of countershaft gear before installing. Oil groove on washer must face the gear. D. Install collar–spline (Item 10) and snap ring (Item 8). E. Install shifter (Item 9) onto collar–spline. F. Install snap ring (Item 8), washer (Item 7) and in ner (Item 6).
9. Assemble synchro hub: A. Install 3 keys (Item 1) into grooves of hub (Item 2). 1 2 Figure 91 B. Install shifter (Item 1) onto hub (Item 2). 1 2 Figure 92 Drive Train C. Insert 2 springs (Item 3) into hub. Pay attention to direction of spring.
10. Assemble reduction shaft: 1 A. Install washer(s) (Item 17), 2 needle bearings (Item 16) and gear (Item 15) onto reduction shaft (Item 18). Apply moly disulfide grease to washer and needle bearings before installing. Oil groove on washer must face the gear. 5 3 14 13 10 15 7 B. Install synchro ring (Item 14) onto gear (Item 15). Apply Dexron II transmission oil on cone face of gear before installing synchro ring. C. Insert key (Item 13) onto reduction shaft. 2 18 4 17 16 12 11 8 6 D.
11. Assemble reverse shaft: A. Install gear (Item 2) onto reverse shaft. B. Use a press to install bearings (Item 3, 1 ). Figure 97 12. Assemble main shaft: A. Install gear (Item 18), gear (Item 17) and snap ring (Item 16). B. Install gear (Item 15). C. Use a press to install bearing (Item 14). D. Install washer (Item 13) and 2 needle bearings (Item 12) onto main shaft. Apply moly disulfide grease onto washer and needle bearings before installing. Oil groove on washer must face the gear. E.
13. Assemble shift arms (Transaxle Model KT40): 2 A. Install 3 new oil seals (Item 14) onto transaxle case. Apply multi–purpose grease on lips of oil seals before installing. 8 4 7 5 6 B. Install 3 keeper plates (Item 13) and tighten 3 capscrews (Item 12) to a torque of 15 – 17 Nm (11 – 13 ft–lb). 3 3 1 IMPORTANT: This sequence for installing the shift arms must be followed in sequence.
15. Install oil cap (Item 1) with O–ring. Apply multi–purpose grease to O–ring. 1 2 16. Install air breather (Item 2). Use sealing tape on threads of air breather.
17. Install reduction shaft and countershaft together with R–1 fork shaft and Hi–Lo fork shaft. Insert heads of shift arms into grooves of forks when installing them. Figure 104 Figure 105 18. Install main shaft together with 2–3 fork shaft. Insert head of shift arm into groove of fork while installing.
19. Install reverse shaft (Item 1). Rotate main shaft and reverse shaft gears to mesh gears when installing. 1 2 Figure 108 20. On 4WD units, install bearing to gear case and cen ter plate. Install front drive shaft and 41T gear to the gear case (see Item 2 of Fig. 103). FRONT DRIVE SHAFT 41T GEAR BEARING (GEAR CASE) BEARING (CENTER PLATE) Figure 109 21. Install center plate: A. Insert 2 dowel pins into transaxle case. Drive Train B. Apply silicone sealant onto mating surface of center plate. C.
IMPORTANT:On early versions of the center plate, use one thick, tabbed shim (Item 2) (Fig. 111). 22. Insert shim (Item 2) against the bearing. Use thickest shim possible that will permit installation of the snap ring. (Fig. 111 and 113). 2 Figure 111 IMPORTANT:On newer versions of the center plate, use one tabbed shim (Item 4) with three tabless shims (Item 2) (Fig. 112). Note: The thickest shim of the shim set (Item 2) should be positioned against the snap ring (Fig. 112). 3 4 1 2 23.
25. Measure countershaft end play. Rotate one of the axle shafts back and forth to take up all back lash. Rotat ing the shaft in one direction will pull the shaft and bear ing away from the snap ring. Rotate axle shaft in this direction, then measure space between the snap ring and shim (set) with a feeler gauge. Make sure shim (set) is held against the bearing during the measurement. End play should be 0.00 to 0.0039 inch (0.0 to 0.10 mm) (Fig. 115).
27. Install fork shaft case: A. Apply silicone sealant to mating surface of fork shaft case. B. Insert spindle (Item 1) between fork shafts. 1 Figure 117 C. Insert 2 steel balls (Item 2) and 2 springs (Item 1) into the grooves. 1 2 Figure 118 D. Install fork shaft case (Item 2). Tighten caps crews (Item 1) to a torque of 24.5 – 29.5 Nm (18.5 – 22 ft–lb). Check operation of shifters and detent. 2 1 Figure 119 28. Insert a washer (Item 1) into housing of transaxle case.
29. Install differential gear assembly (Item 1) together with fork shaft (Item 2) onto transaxle case. Figure 121 1 2 Figure 122 30. Install side cover: A. Insert 2 dowel pins onto transaxle case. Drive Train B. Apply silicone sealant onto mating surface of side cover. C. Install side cover. Tighten capscrews to a torque of 24.5 – 29.5 Nm (18.5 – 22 ft–lb). Figure 123 31. Install R.H. axle shaft assembly: A. Apply silicone sealant onto mating surface of seal cover. 1 B.
32. Install L.H. axle shaft assembly: A. Thoroughly clean mating surface of differential carrier and side cover (Item 1). 1 B. Insert selected shims (Item 2) into housing of side cover. NOTE: The thickest shim should be in serted against the bearing. 2 Figure 125 C. Install axle shaft assembly and tighten caps crews (Item 1) to a torque of 24.5 – 29.5 Nm (18.5 – 22 ft–lb). 1 Figure 126 33. Measure backlash of ring gear through window on transaxle case.
34. Install differential lock arm (Item 1) onto fork shaft. Insert lock pin into fork shaft and arm. Pay attention to direction of slit in lock pin. 1 Figure 128 35. Apply silicone sealant to mating surface of upper cover (Item 2). Pay attention to direction of cover and install. Tighten capscrews (Item 1) to a torque of 24.5 – 29.5 Nm (18.5 – 22 ft–lb).
36. Apply multi–purpose grease to O–ring and insert O– ring into groove of transaxle case. If installing P.T.O., in sert 2 dowel pins in transaxle case. Install P.T.O. or cover. Tighten capscrews and nut with lockwasher to a torque of 15 – 17 Nm (11 – 13 ft–lb). 2 3 1 Figure 130 37. Install bell housing and secure with capscrews (Item 2). Tighten capscrews to a torque of 24.5 – 29.5 Nm (18.5 – 22 ft–lb). 1 38. Install extension spring (Item 1).
P.T.O. Service Figure 132 Drive Train Power Take–Off (PTO) Disassembly NOTE: Item numbers in figures are shown in order of dis assembly; for example, remove Item 1 first, then Item 2, etc. Reassemble in reverse order; for example, install Item 1 last. 1. Thoroughly clean outside surface of PTO case. 2. Loosen capscrews and nut. Separate PTO cover from PTO case.
3. Remove PTO shaft assembly (Item 1) from PTO case. Remove oil seal from PTO cover. 1 Figure 134 4. Remove idle shaft assembly (Item 1) from PTO case. Remove idle gear (Item 2). Remove bearing (Item 3) if necessary.
5. Remove PTO drive shaft: C. Shift PTO to ”ON” position. D. Remove 2 snap rings (Item 1, 2) from PTO case. E. Slide drive shaft assembly (Item 3) toward PTO shaft side. F. Remove bearing (Item 4). G. Slide drive shaft toward other side. H. Remove bearing (Item 5). I. Remove washer (Item 6) and gear (Item 7), sliding drive shaft toward PTO shaft side. Figure 137 J. Release shift arm (Item 8) from block (Item 9). 8 K. Remove drive shaft assembly. 6 3 7 Drive Train Figure 138 6.
7. Disassemble PTO idle shaft: A. Use a bearing puller to remove bearing (Item 1) if necessary. 1 Figure 140 8. Disassemble PTO shaft: A. Use a bearing puller to remove bearing (Item 1). B. Remove gear (Item 2) and snap ring (Item 3). C. Remove snap ring (Item 4) and washer Item 5). D. Use a bearing puller to remove bearing (Item 6) if necessary. Figure 141 5 6 4 5 3 1 2 Figure 142 9. Disassemble shift arm: A. Remove 2 lock pins from shift arm. B. Remove 2 O–rings (Item 1).
Power Take–Off (PTO) Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. 3. Measure clearance between shifter groove and shifter block. Replace shifter block if clearance exceeds 1.0 mm (.039 in.). Figure 144 4. Measure I.D. of bushing (Item 1). Replace bushing if I.D. exceeds 17.10 mm (.673 in.). 1 Figure 145 Drive Train 5. Measure O.D. of bushing area on shaft. Replace shaft if O.D. is less than 16.95 mm (.667 in.).
Power Take–Off (PTO) Reassembly NOTE: Item numbers in figures are shown in reverse or der of assembly; for example, when reassembling, install Item 1 last. 1. Clean gasket material from mating surfaces of case and cover. 3 2 1 IMPORTANT: Be careful not to damage mating sur faces when removing gasket material. 2. Make sure all parts should be free of dirt and dust. 3. Assemble shift arm: Figure 148 A. Install 2 new O–rings (Item 1) onto shift arm.
4. Assemble PTO shaft: 5 6 4 A. Use a press to install bearing (Item 6) onto PTO shaft. B. Install washer (Item 5) and snap ring (Item 4). C. Install snap ring (Item 3) and gear (Item 2). 5 D. Use a press to install bearing (Item 1). 3 1 2 Figure 151 Figure 152 Drive Train 5. Use a press to install bearing (Item 1) onto idle shaft. 1 Figure 153 6. PTO drive shaft sub–assembly: A. Insert spring (Item 3) and 2 steel balls (Item 2) into hole. 2 1 B.
7. Install PTO drive shaft sub–assembly: 7 6 A. Insert block (Item 9) into pin of shift arm. Apply moly disulfide grease onto both sides of block before installing. B. Put shifter of PTO drive shaft sub–assembly (Item 3) on the block. 3 5 4 C. Install gear (Item 7) with bushing and washer (Item 6) onto drive shaft after sliding the assembly toward PTO shaft side. Apply moly disulfide grease to bushing of gear and washer before installing. Figure 155 D.
8. Install PTO idle shaft sub–assembly: A. Insert bearing (Item 3) into PTO case. 3 Figure 159 B. Put gear (Item 2) on mating gear. C. Move gear until holes of gearing and bearing line up. D. Insert idle shaft sub–assembly (Item 1). Apply grease to idle shaft to aid assembly. 2 1 Figure 160 Drive Train 9. Insert PTO shaft assembly (Item 1) into bearing hous ing of PTO case.
10. Install PTO cover: A. Insert new oil seal into PTO cover. Apply multi– purpose grease to lip of oil seal. B. Insert 2 dowel pins onto PTO case. C. Apply silicone sealant onto mating surface of PTO cover. D. Install PTO cover. Tighten capscrews and nut with lockwasher to a torque of 24.5 – 29.5 Nm (18.5 – 22 Nm).
Chapter 7 Steering, Brakes and Suspension Table of Contents Bleeding the Brakes . . . . . . . . . . . . . . . . . . . . . . . . Master Brake Cylinder Service . . . . . . . . . . . . . . . Parking Brake Cable Replacement . . . . . . . . . . . . Steering Wheel Installation . . . . . . . . . . . . . . . . . . Steering Linkage Service . . . . . . . . . . . . . . . . . . . . Front Shock Absorber Replacement . . . . . . . . . . Rear Shock Absorber Replacement . . . . . . . . . . .
Specifications Item Specification Front wheel toe–in 0 to 0.125 in. (0 – 3 mm) Front tire pressure 20� x 10� – 10, 4 ply (Std. on all turf models) 175/80 D13 (Std on industrial models) 20 PSI (138 kPa) max. 35 PSI (241 kPa) max. Rear tire pressure 23� x 10.5� – 12, 6 ply (Std. on Workman 3100) 24� x 13� – 12, 6 ply (Std. on all other turf models) 205/75 D14 (Std. on industrial models) 32 PSI (220 kPa) max. 18 PSI (124 kPa) max. 50 PSI (345 kPa) max.
Special Tools Compression Spring Tool Use to remove and install the two (2) front suspension compression springs. Qty.
Adjustments Brake Pedal Adjustment 1. Loosen jam nut on link rod ball joint. 2. Rotate rod until gap between brake pedal and up stop is 0.020 to 0.080 inch (0.5 to 2 mm). 3. Tighten jam nut after making adjustment. 1 CAUTION Worn or misadjusted brakes may result in personal injury. If brake pedal travels to with in 11/2� (38 mm) of the vehicle floor board, the brakes must be adjusted or repaired. Figure 2 1. Link rod ball joint 3 2 1 Figure 3 1. Brake pedal 2. Clutch pedal 3.
Parking Brake Adjustment 1. Loosen set screw securing knob to parking brake lever. 2 2. Rotate knob until a force of 55 to 65 lbs. (25 to 29 kg) is required to actuate lever. 3. Tighten set screw after making adjustment. 1 3 Figure 4 1. Parking brake lever 2. Knob 3. Set screw Front Wheel Toe–In 1. Measure center to center distance (at axle height) at front and rear of steering tires. Front measurement must be equal to the rear measurement + 1/8 in. (3 mm). 2.
Troubleshooting Suspension and Steering Problem Possible Cause Front end noise. Loose or worn front wheel bearings. Worn shock absorbers. Worn stabilizer link bushings. Loose steering gear. Worn control arm bushings. Rear end noise. Worn or brinelled rear wheel bearings. Worn shock absorbers. Worn leaf spring bushings. Clutch, drive shaft or transaxle problem (see Chap ter 6 – Drive Train). Excessive steering play. Loose or worn front wheel bearings. Loose or worn steering linkage.
Suspension and Steering (continued) Problem Possible Cause Hard steering. Loose worn or glazed hydraulic pump drive belt. Binding or damaged steering linkage. Low or uneven tire pressure. Low hydraulic pressure (see Chapter 9 – Hydraulic System). Worn or damaged steering gear. Incorrect front wheel alignment. Vehicle pulls to one side when not braking. Low or uneven tire pressure. Broken or weak rear leaf spring. Incorrect front wheel alignment. Damaged or bent suspension or steering component.
Brakes (continued) Problem Possible Cause Brakes pulling. Incorrect tire pressure. Contaminated brake linings. Front end out of alignment. Incorrect brake adjustment. Distorted brake shoes. Restricted brake lines or hoses. Broken rear spring. Unmatched tires on same axle. Squealing brakes. Glazed brake lining. Saturated brake lining. Weak or broken shoe return spring. Weak or broken shoe retaining spring. Distorted brake shoes. Bent support plate. Dust in brake drums and brakes. Scored brake drums.
Brakes (continued) Problem Possible Cause Hard brake pedal. Incorrect brake lining material. Restricted brake lines or hoses. Brake pedal linkage binding. Wheel locks. Contaminated brake linings. Loose or damaged brake linings. Wheel cylinder sticking. Incorrect wheel bearing adjustment. Brakes fade. Overheated brake drums. Saturated brake linings. Surge at slow speeds. Chatter at fast speeds. Bent or out of round brake drums. Shoe lock. Machining grooves in contact face of brake drums.
Repairs Wheel Installation 1. Mount wheel and evenly tighten nuts to a torque of 45 – 55 ft–lb (61 – 75 Nm). WARNING Failure to maintain proper torque could result in failure of loss of wheel and may result in personal injury. Torque front and rear wheel nuts to 45 – 55 ft–lb (61 – 75 Nm) after 1 – 4 hours of operation and again after 10 hours of operation and every 200 hours thereafter. Figure 7 1. Wheel 2.
Front Wheel Bearing Service 4 6 7 2 1 3 5 8 10 12 13 11 9 Figure 8 6. Slotted nut 7. Washer 8. Wheel hub. 9. Seal 10. Bearing cone 11. Bearing cone 12. Bearing cup 13. Bearing cup 1. Partially loosen lug nuts (Item 1), then jack up and support front of vehicle. Remove lug nuts then remove wheel (Item 2) and brake drum (Item 3). 6. Carefully slide wheel hub (Item 8) with inner bearing and seal onto spindle. Fill cavity of wheel hub 50% full with wheel bearing grease. 2. Remove dust cup (Item 4).
Brake Service 13 11 9 6 12 1 3 10 Star wheel 8 7 2 5 4 Figure 9 1. Upper spring 2. Adjuster spring 3. Lower spring 4. Hold down washer 5. Hold down spring 6. Hold down pin 7. Brake shoe and lining 8. Pawl 9. Brake shoe and lining 10. Adjuster assembly 11. Parking brake lever 12. Wheel cylinder 13. Backing plate Brake Drum Inspection CAUTION Worn or misadjusted brakes may result in personal injury.
3. After a brake drum is machined, wipe braking surface diameter with a cloth soaked in denatured alcohol. If one brake drum is machined, the other should also be ma chine to the same diameter to maintain equal braking forces. then remove brake shoe assemblies (Item 7–8, 9) and adjuster assembly (Item 10). 2. Loosen set screw on parking brake control lever knob (Fig. 14). Turn knob on parking brake lever counter clockwise all the way to loosen cable adjustment. Brake Lining and Spring Inspection 2.
Brake Cylinder Service Disassembly 1. Disassemble brakes as described in Brake Service. 2. Disconnect brake line from brake cylinder. Put a cap on brake line to prevent contamination of system and brake fluid leakage. 5) 6) 2) 7) 1) 3) 4) 3. Remove two (2) capscrews and lockwashers secur ing brake cylinder to backing plate (Fig. 12). Remove brake cylinder assembly. 4. Remove dust covers (Fig. 11, Item 1), pistons (Item 2), seals (Item 3) and spring (Item 4). Discard dust cov ers and seals.
Bleeding the Brakes 1. Connect a suitable transparent hose to bleeder valve on right rear wheel cylinder and submerge other end in a glass container partially filled with clean brake fluid. 2. Have a helper pump brake pedal several times, then hold pedal down firmly. 3. With pedal firmly depressed, open bleeder valve of right rear brake until pedal fades to floor, then close bleeder valve. Bleeder valve 4.
Master Brake Cylinder Service Note: Unlike older versions (Fig. 12) of the master cylinder, newer versions (Fig. 13) have the reservoir attached to the cylinder. 4 5 Disassembly 6 1. Remove pipe adapter (Item 1), if installed, and adapter or flange seal (Item 2). Push in on the push rod so the stop pin (Item 3) can can be removed. 7 8 11 9 2. Disconnect lower end of the dust cover (Item 6) from the housing. 3.
Parking Brake Cable Replacement 1. Loosen set screw on parking brake control lever knob (Fig. 14). Turn knob on parking brake lever counterclockwise all the way to loosen cable adjustment. Brake equalizer plate 2. Remove knobs from transmission shifter and other control levers, then remove center console plate assembly. Remove seats and skirt assembly to get access to parking brake cables (Fig. 15): A. Remove seats. B. Remove lower bolts on seat frame bracket. Setscrew Parking brake cables C.
Steering Wheel Installation 1. Slide foam seal, steering wheel and washer onto steering shaft. 4 2 1 2. Secure steering wheel to shaft with jam nut and tighten to a torque of 10 – 15 ft–lb (13 – 20 Nm). 5 3 3. Install cap to steering wheel. Figure 17 1. Foam seal 2. Steering wheel 3. Washer 4. Jam nut 5.
Front Shock Absorber Replacement 1. Remove lower and upper locknuts, then remove shock absorber and washers. 7 2. Insert two (2) new rubber bushings (Item 1) into each end of new shock absorber. Insert spacer (Item 2) into ram (lower) end of shock absorber. 6 3. Install large washer (Item 3) onto stud above control arm. 4. Install new shock absorber (Item 4) with ram end down and secure upper end with small flat washer (Item 5) and locknut (Item 6). 5.
Rear Shock Absorber Replacement 1. Remove lower and upper locknuts, then remove shock absorber and washers. 2. Insert two (2) new rubber bushings (Item 1) into each end of new shock absorber. 2 1 3. Install one large washer (Item 2) onto each shock ab sorber mounting stud. 4 5 4. Install new shock absorber (Item 3) with ram end down and secure each end with with a large washer (Item 4) and locknut (Item 5). 3 2 5 1 4 Figure 21 1. Rubber bushing 2. Large washer 3. Shock absorber 4. Large washer 5.
Ball Joint Replacement 3 5 6 7 2 80 – 90 ft–lb (108 – 122 Nm) 1 7 6 4 50 – 60 ft–lb (68 – 81 Nm) 5 Figure 23 1. Cotter pin 2. Slotted nut 3. Upper control arm 4. Lower control arm 5. Snap ring 6. Ball joint 7. Boot 4. Remove snap ring (Item 5). Press ball joint (Item 6) out of control arm. Removal Installation FRONT SUSPENSION IS SPRING LOADED! To prevent possible personal injury, use special tool to remove compression springs before disassembling the front suspension. 1.
Tie Rod End Replacement Removal 1. Loosen jam nut (Item 1) 2. Remove cotter pin (Item 2) from affected rod end. Re move slotted nut (Item 3). 3. Use a suitable puller to disconnect rod end (Item 4) from spindle or steering arm. 4. When removing rod end (Item 4) from tie rod (Item 5), count the number of revolutions it takes to remove so new tie rod end can be installed without changing the toe–in adjustment. Figure 24 Installation 1. Install new rod end (Item 4) to tie rod.
Front Compression Spring Removal and Installation COMPRESSION SPRING TOOL TOP VIEW 20� Control arm tower (4) 1/2� flat washers 5� Compression spring tool rod (2) 1/2� steel rods Spring cradle 5� 8 (4) 1/2� nuts Compression spring 9 6 1 7 Install compression spring tool rods with extended portion on opposite ends so capscrews (Item 7) securing spring cradles to control arm tower can be removed. Extended portion should be on nut side of capscrew. 5 2 4 3 Figure 26 4. Capscrew 5.
Rear Leaf Spring Replacement 7 11 See special tightening proce dure in installation instructions 6 6 8 1 2 6 7 11 5 12 13 9 11 10 4 3 Figure 28 1. Locknut 2. Washer 3. Carriage bolt 4. Rear axle 5. Clamp plate 6. Locknut 7. Spring shackle 8. Flange head locknut 9. Flange head capscrew 10. Spring mount 11. Rubber bushing 12. Leaf spring 13. Frame rail IMPORTANT: For proper vehicle performance, always replace the springs on both sides of the vehicle. 3.
Installation 1. Before installing new leaf spring, insert four (4) rubber bushings (Item 11) into leaf spring. Insert two (2) rubber bushings into frame side rail. Make sure axle and plate are centered on leaf spring knob 2. Insert one (1) spring shackle (Item 11), from outside/ in, into rear of leaf spring. Insert spring mount (Item 10), from outside/in, to front of leaf spring and secure, finger tight, with locknut. NOTE: Clip is on front end of spring. 3. Install leaf spring assembly to frame.
Steering Gear Service 16) 17) 15) 9) 8) 1) 14) 7) 2) 3) 4) 5) 6) 10) 11) 21) 18) 19) 13) 22) 23) 20) 25) 12) 35) 34) 33) 47) 32) 31) 46) Torque to 180 – 210 ft–lb (244 – 285 Nm) when installing pitman arm 24) 44) 39 45) 40) 44) 39) 30) 29) 28) 27) 26) 38) 43) 37) 42) 41) 36) Figure 30 1. Retaining ring 2. Housing end plug 3. Housing end plug seal 4. Rack piston seal 5. Rack piston o–ring 6. Rack piston end plug 7. Guide ball return 8. Ball return guide clamp 9.
Disassembly 1. Pry retaining ring (Fig. 29, Item 1) out of housing groove with a screwdriver. Ball retainer tool Plug 2. Turn stub shaft (Item 36) to the left until plug (Item 2) on opposite end is forced out of cylinder, then remove seal (Item 3). Socket 3. Remove plug (Item 6) from rack piston (Fig. 30). 4. Remove nut (Fig. 29, Item 16), bolts (Item 17), side cover (Item 15) and gasket (Item 14), then turn adjuster screw right until side cover (Item 15) separates from pit man shaft (Item 13).
10. Disassemble adjuster plug as follows: A. Remove retaining ring (Fig. 29, Item 24), washer (Item 23), seal (Item 22) and bearing (Item 21). Adjuster plug B. Remove bearing retainer (Item 32) by prying at raised area, then remove seal and needle bearing (Fig. 34). Figure 35 11. Remove valve and worm shaft as an assembly with both races and bearing. Separate as follows (Fig. 35): Valve body Worm shaft A. Remove worm shaft (Fig. 29, Item 38) from valve body (Item 20). B. Remove races (Fig.
Assembly 11 1. Lubricate 11 balls (Fig. 37, Item 10) with hydraulic fluid, then install alternately by color into rack piston. Use ball retainer tool to hold balls inside (Fig. 30). Worm flange 7 10 8 9 Figure 38 2. Install balls (Fig. 38, Item 7) in ball guide alternately by color. Retain balls in guide with petroleum jelly. 7 3. Connect ball guide (Fig. 37, Item 7), clamp (Item 8) and screws (Item 9) to rack piston (Item 11). Petroleum jelly 10 4. Lubricate stub shaft (Fig.
Worm Bearing Preload Adjustment 1. Loosen and remove adjuster plug nut (Fig. 29, Item 25) (Fig. 41). Figure 42 2. Turn adjuster plug (Fig. 29, Item 26) clockwise using a spanner wrench until plug and thrust bearing are firmly bottomed in housing (Fig. 42). Spanner wrench Adjuster plug Figure 43 3. Scribe an index mark on the housing even with a hole on adjuster plug. 4. Measure back 3/16 – 1/4 in. (5 – 6 mm) from first index mark and scribe a second index mark (Fig. 43). 5.
Over Center Preload Adjustment Side cover 1. Turn pitman shaft adjuster screw counterclockwise until fully extended, then reverse 1/2 turn clockwise. Stub shaft 2. Rotate stub shaft from stop to stop and count number of turns. 3. Starting at either stop, turn stub shaft halfway back. When gear is centered, flat on stub shaft will face up ward and be parallel with side cover (Fig. 45). 4. Put torque wrench on stub shaft and rotate 45� each side of center.
Steering, Brakes and Suspension Page 7 – 32 Workman 3000 Series
Chapter 8 Electrical System Table of Contents TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . Verify Interlock System Operation . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . Clutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear PTO Switch . . . . . . . . . . . . . .
VEHICLE HARNESS BLACK Page 8 – 2 R/W BLACK BLACK R/W BLACK HI–LO LOCKOUT SWITCH OFF = CLOSED PTO (OPT) CLUTCH SWITCH FUEL SENDER PINK BLUE GRAY PINK RED TAIL/BRAKE LIGHT RED BROWN BLACK BLACK BLACK 85 30 TACH MAG PICKUP (OPT) 87A 86 87 PINK/BLUE FUSIBLE LINK 67–7120 2–3 LOCKOUT SWITCH DIODE 86–7470 BRN/WHT ENGINE HARNESS S R/W R/W BLACK KILL 87A RELAY 86 SHOWN IN 87 IGNITION OFF 85 POSITION 30 RED IGNITION MODULE MAGNET R B SPEED ADVANCE MODULE STARTER RECTIFIER RE
DIODE 86–7470 Page 8 – 3 CARB FUEL PUMP COIL + – R/W Electrical System (Rev. G) Electrical System) B R PINK 87 30 HI–LO LOCKOUT SWITCH 2–3 LOCKOUT SWITCH R/W ALTERNATOR L B STARTER S FUSIBLE LINK R/W 10 GA PINK RED R R/W R/W BLACK BLACK BLACK BLACK RED BLUE BLACK BU/R WHT/BK BLACK WHT/BK WHITE R/BK BLACK BLACK DISTRIBUTOR YEL/BK BLUE YEL/BK WHT/BK BLUE + PINK BLUE 85 87A 86 RED BU/WHT HYD.
TC MODELS ONLY Workman 3200/4200 (Models 07211, 07212, 07218, and 07211TC) Electrical System (Rev.
Page 8 – 5 HOLD RED C B A YEL/BK G B S B R BLACK HI–LO LOCKOUT SWITCH 2–3 LOCKOUT SWITCH R/W 30 85 87A 86 87 BLACK BLUE 86–7470 DIODE PINK ALTERNATOR P L TACH PINK FUSIBLE LINK 67–7120 R/W 10 GA FUEL SENDER TAIL/BRAKE LIGHT IGNITION BROWN RED BU/WHT HYD. SWITCH OFF = CLOSED PTO (OPT) RED GLOW PLUGS CLUTCH SWITCH GRAY YELLOW RED PINK RED STARTER R/W R/W R/W Electrical System (Rev.
PK RD Electrical System (Rev. G) Page 8 – 6 OR X B Y S A START FL3 FL2 OR GY (–) FRAME GROUND VIO L ALTERNATOR R/BK R/W R B PK R/BK ALL MAIN HARNESS GROUND POINTS MARKED AS BLACK WIRE ARE CONNECTED TOGETHER AND TO THE ENGINE GROUND ENGINE GROUND HI LO P16–C NEGATIVE BATTERY CABLE BK BK GY B+ TIE POINT ON STARTER POSITIVE BATTERY CABLE BK OFF RUN I LIGHTS, HORN, BRAKE ACC. RD FUSIBLE LINK HARNESS FL1 GY W PK BATTERY (+) RD R/W RD F 3 15 A F2 7.5 A F4 F 1 7.
”C” CARB FUEL PUMP + – COIL DIODE 86–7470 BLUE ”B” RED R S R PINK ”E” PINK HI–LO LOCKOUT SWITCH 2–3 LOCKOUT SWITCH R/W ALTERNATOR L B STARTER Electrical System BLACK BLACK BLACK BLACK RED BLUE BLACK BU/R WHT/BK BLACK WHT/BK WHITE R/BK BLACK BLACK DISTRIBUTOR YEL/BK R/GN 30 87 87A ”L” ”D” BLACK R/GN RED TIME DELAY 15 SEC.
”C” BLACK FUEL PUMP C B A PULL WHITE HOLD RED BLACK GROUND BLACK BLACK ”A” RED S ”E” ”D” BLACK HI–LO LOCKOUT SWITCH (OPT) 2–3 LOCKOUT SWITCH R/W 30 85 87A 86 87 PINK BLACK R/GN BN/W YELLOW VIOLET GRAY 85 TAIL/BRAKE LIGHT RED RED TIME DELAY 15 SEC. 99–1063 10 AMP FUSE 218–578 FUSE BLOCK 67–7160 ”J” 87 30 PINK 86 87A 85 TEMP SWITCH SHUT DOWN RELAY ”G” ”H” DIODE 87–7470 GN/BK ”F” ”K” 86 87A RUN RELAY 87 BLUE 30 85 ”I” 7.
YELLOW Page 8 – 9 VEHICLE HARNESS S R/W BLACK BLACK BLACK BLACK HI–LO LOCKOUT SWITCH 2–3 LOCKOUT SWITCH R/W 85 87A 86 TACH MAG PICKUP (OPT) 30 87 PINK/BLUE FUSIBLE LINK 67–7120 – R/BK PINK BLUE GRAY PINK RED OFF = CLOSED PTO (OPT) CLUTCH SWITCH TAIL/BRAKE LIGHT RED BROWN Electrical System (Rev.
Page 8 – 10 CARB FUEL PUMP COIL + - DIODE 86-7470 + S R PINK 30 87 86 PINK BLUE 85 87A R/BK HI-LO LOCKOUT SWITCH 2-3 LOCKOUT SWITCH R/W ALTERNATOR L B STARTER R B FUSIBLE LINK R/W 10 GA PINK RED R/W R/W R/W BLACK BLACK BLACK BLACK RED BLUE BLACK BU/R WHT/BK BLACK WHITE R/BK WHT/BK BLACK BLACK DISTRIBUTOR YEL/BK BLUE YEL/BK WHT/BK BLUE - PINK RED BACKUP ALARM BU/WHT OFF = CLOSED PTO (OPT) CLUTCH SWITCH FUEL SENDER PINK TAIL/BRAKE LIGHT BLACK RED TEMP S
BLACK GROUND BLACK BLACK FUEL PUMP RED S R/W 10 GA 87A 86 85 30 BLACK HI–LO LOCKOUT SWITCH 2–3 LOCKOUT SWITCH R/W BLACK BLUE 86–7470 DIODE 87 PINK ALTERNATOR TACH R P L B STARTER G B PINK FUSIBLE LINK 67–7120 BLACK RED RED BROWN TAIL/BRAKE LIGHT FUEL SENDER BU/WHT REVERSE SWITCH OFF = CLOSED PTO (OPT) GREEN GLOW PLUGS CLUTCH SWITCH GRAY YELLOW RED PINK 85 30 7.
STARTER VALVE Workman 3420–LP (Industrial Model 07233) Electrical System (Rev.
Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Some tools may also be available from a local supplier. Continuity Tester Battery powered test lamp which is helpful in testing for continuity of circuits and electrical components when the current is off. Figure 1 Multimeter The meter can test electrical components and circuits for current, resistance, or voltage.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this machine (see Wiring Schematics section of this chapter). 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. If the machine has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety.
Condition Possible Cause Nothing happens when start attempt is made. Clutch pedal not depressed – instruct operator. PTO engaged – instruct operator. Low battery charge. Loose or corroded battery cables. Loose or corroded ground. ”RUN” fuse open. Fusible link open. Clutch cable out of adjustment. Clutch switch out of adjustment or faulty. Clutch switch wiring loose, corroded or damaged. PTO switch faulty. PTO switch wiring loose, corroded or damaged. Faulty ignition key switch.
Verify Interlock System Operation The purpose of the interlock system is to prevent the engine from cranking or starting unless the clutch pedal is depressed or PTO (if so equipped) is disengaged. To verify PTO interlock switch operation: 1. Sit on operator’s seat and engage parking brake. Move shift lever to NEUTRAL position. 2. Engage PTO. CAUTION The interlock switches are for the operator’s protection, so do not bypass them.
Testing This section will define given components, and the tests that can be performed on those components, when those parts are disconnected from the electrical system. Note: Electrical troubleshooting of any 12 Volt power connection can also be performed through voltage drop tests without disconnection of the component. For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g.
Clutch Switch The clutch switch is normally open and closes when the clutch pedal is depressed. Test the switch by disconnecting the wiring connector and connecting a continuity tester across the two terminals. With the engine off, depress the clutch pedal completely – there should be an indication of continuity. Release the clutch pedal – there should be no continuity (see Clutch Pedal Adjustment in Chapter 6 – Drive Train). 1 Figure 6 1.
2–3 and High–Low Lockout Switches 2–3 Lockout Switch 1 The 2–3 Lockout switch is closed in 2nd gear and open in 3rd gear. Test the switch by disconnecting the wiring connector and connecting a continuity tester across the two terminals. With the engine off, move transmission shifter to 2nd gear – there should be an indication of continuity. Move shifter to 3rd gear – there should be no continuity. High–Low Lockout Switch The High–Low Lockout switch is closed in Low range and open in High range.
Battery Use a volt–ohm meter to measure the voltage between the battery terminals. If the voltage is less than 12.3 Volts D.C., the battery should be charged. NOTE: Regulated voltage will increase to approximately 13.5 Volts when the engine is running. 1 Figure 12 1.
Fuel Gauge Sender Disconnect wire and remove the fuel gauge sender from the fuel tank. Install an ohm meter between the terminal and base. 1 With arm completely down (empty position), resistance should be 240–260 ohms. With arm completely up (full position), resistance should be 29–34 ohms. NOTE: Bend float arm, if necessary, to get proper gauge reading for a 1/2 full tank. CAUTION Figure 13 1.
Service and Repairs Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extend. Additionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme caution to avoid slashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin or eyes. Always wear safety goggles and a face shield when working with batteries. 1 Figure 14 1.
2. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center cell. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions. Connect a digital multimeter to the battery terminals. A. Measure the specific gravity of each cell with a hydrometer.
6. Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made. 7. Connect a digital multimeter (set to amps) between the negative battery post and the negative (ground) cable connector. The reading should be less than 0.1 amp. If the reading is 0.1 amp or more, the unit’s electrical system should be tested and repaired. 8. Connect negative (ground) cable connector to the negative battery post. Tighten cap screw and lock nut with two wrenches.
Fuses The fuse block is located under the right side of the dash panel. NOTE: It is not always possible to see if a fuse is faulty. It is recommended that you check for faulty fuses with a continuity tester, not visually. FUSES OPEN LIGHTS & HORN DASH IGNITION –– 15A 7.5A 7.5A 1 Figure 16 Figure 17 1. Fuse block Headlamp Replacement Assemble and disassemble headlamp as shown in illustration. 2 NOTE: Bulb can be replaced without removing headlamp assembly. Be careful when replacing bulb.
Tail Lamp Replacement Assemble and disassemble tail lamp as shown in illustration. The tail lamp uses a standard #1157 12volt bulb. 1 2 4 3 Figure 19 1. Screw 2. Lens Electrical System (Rev. G) Page 8 – 26 3. Bulb #1157 4.
Chapter 9 Hydraulic System Table of Contents TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Test No. 1: Pump Flow and Relief Pressure . . . . Test No. 2: Remote Hydraulics Relief Pressure . Test No. 3: Power Steering Relief Pressure . . . . Test No. 4: Lift Cylinder Internal Leakage . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Removing Hydraulic System Components . . . . .
Specifications Item Description Pump Pump Capacity Pump Relief Pressure (Vehicles with Hydraulic Lift Capabilities) Pump Relief Pressure (Vehicles without Hydraulic Lift Capabilities) Lift Control Valve (Vehicles with Hydraulic Lift Capabilities) 3.5 GPM (13.4 liter/min.
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi tions or mishandling during operation or maintenance. These conditions can cause damage or premature dete rioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
SAE Straight Thread O–Ring Port – Non–adjustable (Fig. 4) 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O–ring seal when this type of fit ting shows signs of leakage. O–Ring 3. Lubricate the O–ring with a light coating of oil. 4. Install the fitting into the port and tighten it down full length until finger tight. Figure 4 5. Tighten the fitting to the correct flats from finger tight (F.F.F.T.). Size 4 (1/4 in.
Hydraulic Schematics Hydraulic System) RETURN FILTER 10 MICRON WITH 25 PSI BYPASS VALVE Base Vehicle Workman 3000/4000 Series Page 9 – 5 Hydraulic System
RETURN FILTER 10 MICRON WITH 25 PSI BYPASS VALVE Vehicle with Optional Remote Hydraulic Kit Hydraulic System Page 9 – 6 Workman 3000/4000 Series
Industrial Models without Hydraulic Lift Capabilities Industrial Workman Models: 07220, 07222, 07230, 07231, 07232, 07233 DISPLACEMENT 3 .388 IN /REV HYDRAULIC PUMP INTERNAL 1000 PSI RELIEF VALVE OPERATING SPEED 0.625 OF ENGINE SPEED POWER ASSISTED STEERING GEAR PITMAN OUTPUT SHAFT WORM SCREW IN TANK SUCTION STRAINER 100 MESH RETURN FILTER 10 MICRON WITH 25 PSI BYPASS VALVE TRANSAXLE RESERVOIR Hydraulic System) MANUAL INPUT FROM STEERING WHEEL Workman 3000/4000 Series Page 9 – 7 Rev.
Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Hydraulic Pressure Test Kit – TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges.
Hydraulic Test Fitting Kit – TOR4079 This kit includes a variety of O–ring Face seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Hydraulic System) Figure 9 Workman 3000/4000 Series Page 9 – 9 Rev.
Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equip ment and a thorough understanding of the complete hy draulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either of these condi tions be noticed, immediately stop the machine, turn off the engine, locate the cause of the trouble, and correct it before allowing the machine to be used again.
Problem Possible Causes Difficulty in connecting or disconnecting quick couplers. Pressure not relieved (coupler under pressure – en gine running). Remote hydraulic valve not in float position. Attachment does not function. Quick couplers not fully engaged. Quick couplers are interchanged. Pump drive belt loose. Sheared key on pump shaft. Hydraulic oil level low. Low engine RPM. Excessive load. Low pump flow or pressure – TEST NO. 1. Remote hydraulics relief valve stuck open damaged – TEST NO. 2.
Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks. (See the Special Tools section in this Chapter.) 1. Thoroughly clean the machine before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2.
TEST NO. 1: Pump Flow and Relief Pressure 1. Make sure hydraulic oil is at normal operating temper ature before performing tests. 2. Raise and support dump box if installed, then engage parking brake and stop the engine. 3. Install tester in series between pump outlet (pressure hose) and dump valve or steering valve on units without dump cylinders. Make sure tester flow control valve is open. 1 2 CAUTION The engine must be running to perform hy draulic tests.
TEST NO. 2: Remote Hydraulics Relief Pressure Install tester in series between pump outlet and dump valve Tester Figure 11 1. Make sure hydraulic oil is at normal operating temperature before performing tests. Remote hydraulics relief pressure 2. Raise and support dump box, if equipped, then en gage parking brake and stop the engine. 1,900 + 100 PSI (13,100 + 690 kPa) If unable to get specified pressure, check for: – Worn or stuck relief valve. – Internal leakage of remote cylinder(s). 3.
TEST NO. 3: Power Steering Relief Pressure(Units with Lift Capabilities Only) Install tester in series between pump outlet and dump valve Tester Figure 13 IMPORTANT:This test can be performed on units with dump cylinders installed. Units without dump cylinders installed do not have a separate relief valve installed for the steering valve. 1. Make sure hydraulic oil is at normal operating temperature before performing tests.
TEST NO. 4: Lift Cylinder Internal Leakage Test. 1. Remove all pressure from cylinder by fully retracting it (e.g. put hydraulic dump lever in LOWER position). 2. Shut of engine and engage parking brake. Disconnect and plug this hose ANY oil flow or droplets from this fitting indicates internal leak 3. Disconnect hose from base end of cylinder and install a steel plug with o–ring seal in the hose. Clean any re maining oil off of cylinder port. 4. Start engine and apply pressure to rod end of cylinder (e.
Service and Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, removing or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. 2. Put caps or plugs on any hydraulic lines or fittings left open or exposed. 3. Put labels on disconnected hydraulic lines and hoses for proper installation after repairs are completed. 2.
Pump Drive Shaft Service (Workman 3200/3300–D) 10 1 100 to 130 in–lb (11.3 to 14.7 N–m) 7 9 8 8 6 Never–seez 5 3 4 2 Figure 16 1. Driveshaft assembly 2. Belt 3. Locknut 4. Washer 5. Pulley 6. Woodruff key 7. Driveshaft 1. Disassemble and reassemble as shown in Figure 16. 2. Do not reuse bearings (Item 8) if removed. Replace with new bearings. 8. Bearing 9. Spacer 10. Support bracket 6.
Pump Removal and Installation (Excluding Models with Air Cooled Engines) Removal 8 1. Loosen fan belt and remove from drive pulley. 11 1 2. Disconnect hydraulic lines from pump (Item 11). Install caps or plugs in hydraulic lines to prevent contamination and leakage of hydraulic oil. Install plugs in pump ports. 130 – 160 in–lb (150 – 184 kgcm) 3. Remove fan mount bracket (Item 1) with pump at tached. 4. Remove parts as shown in illustration. 9 5 6 Installation 12 3 2 1.
Pump Removal and Installation (Models with Air Cooled Engines Only) Removal 5 130 – 160 in–lb (150 – 184 kgcm) 1. Disconnect hydraulic lines from pump (Item 9). Install caps or plugs in hydraulic lines to prevent contamination and leakage of hydraulic oil. Install plugs in pump ports. 9 6 2. Disassemble parts as shown in illustration. 8 Installation 1. Install parts as shown in illustration and using the fol lowing instructions. 2.
Pump Repair 18 17 16 15 9.5 – 12.5 ft–lb (13 – 17 Nm) 14 12 25 13 28 11 20 19 21 22 23 24 10 9 4 8 12 7 6 5 1 2 3 4 4 11 26 12 – 15 ft–lb (16 – 10 Nm) 12 27 Figure 19 1. Retaining ring 2. Oil seal 3. Spacer 4. Crescent ring 5. Square key 6. Driveshaft 7. Shear pin 8. Stator 9. Seal plate 10. Wear plate 11. Gear 12. Bearing 13. Pressure plate 14. Back–up seal 15. Pressure plate seal 16. Dowel pin 17. Gear end housing 18. Socket head capscrew 19. Plug 20. Ball 21. Spring 22.
18 17 16 15 9.5 – 12.5 ft–lb (13 – 17 Nm) 14 12 25 13 28 11 20 19 21 22 23 24 10 9 4 8 12 7 6 5 1 2 3 4 4 11 26 12 – 15 ft–lb (16 – 10 Nm) 12 27 Figure 20 1. Retaining ring 2. Oil seal 3. Spacer 4. Crescent ring 5. Square key 6. Driveshaft 7. Shear pin 8. Stator 9. Seal plate 10. Wear plate 11. Gear 12. Bearing 13. Pressure plate 14. Back–up seal 15. Pressure plate seal 16. Dowel pin 17. Gear end housing 18. Socket head capscrew 19. Plug Relief Valve Service 4. Clean and dry all parts.
4. Check bearing (Item 27) for smooth operation. Re place bearing if loose on shaft or noisy when rotated. Disassembly 1. Remove shaft seal (see Shaft Seal Replacement). 2. Remove relief valve (see Relief Valve Service). 3. Secure flange end of pump (Item 8) in a vise with driveshaft (Item 6) facing down. IMPORTANT: Use caution when using a vise to avoid distorting any parts. 4. Remove four (4) socket head capscrews (Item 18). 5.
Lift Valve Repair 1. After removing control valve, wash valve in solvent and dry thoroughly. 2. Carefully mount control valve in a vise so that control valve mounting pads are against jaws of vise. Control valve spool snap ring (Item 15) should be facing up. 3. Remove hex cap plug (Item 1) from side of valve body. Inside valve body, behind each hex cap plug, there is a spring (Item 3), ball (Item 4) and cam pin (Item 6); re move these parts. 8 4. Remove snap ring (Item 15) from spool (Item 8).
Lift Cylinder Repair 13 1 2 3 4 5 6 8 9 8 9 8 7 10 11 12 Figure 22 1. Barrel 2. Shaft 3. Dust seal 4. Backup ring 5. O–ring seal 6. Head 7. Retaining ring 8. Backup ring 9. O–ring seal 10. O–ring seal 11. Piston 12. Nut 13. Warning decal Disassembly 1. Pump oil out of cylinder into a drain pan by slowly moving piston back and forth. Spanner wrench 2. Before disassembling cylinder, plug ports, wash exte rior with cleaning solvent and dry thoroughly.
13 1 2 3 4 5 6 8 9 8 9 8 7 10 11 12 Figure 24 1. Barrel 2. Shaft 3. Dust seal 4. Backup ring 5. O–ring seal 6. Head 7. Retaining ring 8. Backup ring 9. O–ring seal Inspection 1. Inspect head (Item 6), piston (Item 11) and shaft (Item 1) for excessive scoring, pitting or wear. Replace any worn or damaged parts. 10. O–ring seal 11. Piston 12. Nut 13. Warning decal 4. Install retaining ring (Item 7) to secure assembly in barrel.
Front Wheel Drive – 4WD Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Check Front Differential Oil . . . . . . . . . . . . . . . . . . . 3 REPAIRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Front Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . . 4 Front Wheel Bearing . . . . . . . . . . . . . . . . . . . . . . . . 5 Front Brake . . . . . . . .
Specifications Item Description Front Differential 5.0 to 1 ratio, single reduction Front Brakes Hydraulically operated, self adjusting, 8–inch diameter drum Bidirectional Clutch Front Wheell Drive Section (4WD) Overrunning type Page 10 – 2 Rev.
The “Automatic on Demand” four wheel drive feature, on this vehicle, does not require operator activation. The front wheel drive is not engaged (no power delivered to front wheels) until the rear wheels begin to lose traction. The bidirectional clutch senses the rear wheels slipping, engages the front wheel drive, and delivers power to the front wheels.
Repairs Front Wheel Assembly 1 32 36 31 35 2 3 SMALL SPACER 4 5 6 7 8 9 34 10 11 12 33 WHEEL 13 ACCESS HOLE 14 14 30 29 16 17 28 15 CUP 20 CONE 26 25 24 26 23 22 21 27 17 16 Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Lug nut Lock washer Cap screw Brake cable clip Brake assembly Cap screw Lock washer Brake tube Cap screw Flat washer Retainer Brake hose bracket Front Wheell Drive Section (4WD) 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.
Front Wheel Drive Section (4WD) Front Wheel Bearing Disassembly (Fig. 2) 4 1. Park machine on a level surface. Make sure engine is off. Set parking brake and block rear wheels. 9 2. Partially loosen lug nuts (1). Jack up and secure front wheel off the ground (see Jacking Vehicle in Chap ter 1 – Safety). Remove lug nuts and wheel from the brake drum (32). 3 1 3. Remove brake drum (32) from the cap screws (3) and stub axle (31). 4.
2. If ball joint seals are torn or cracked, replace seals and lubricate ball joints (Fig. 3). 3. Replace worn or cross–threaded cap screws (3) or lug nuts (1). IMPORTANT:If the cotter pin does not align, tighten slotted hex nut until the key hole is aligned. Make sure cotter pin has a 0.002 inch (0.005 cm) clearance from the CV joint boot. B. Connect upper ball joint to the axle housing. Install slotted hex nut and cotter pin to the ball joint. 4. Replace large spacer (30) if worn or damaged.
Front Wheel Drive Section (4WD) Workman 4000 Series Page 10 – 7 Rev.
Front Brake 2 1 8 7 13 26 5 4 3 25 11 6 9 12 10 10 24 11 12 14 16 17 18 21 15 27 19 13 20 22 23 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. Cap screw and lock washer Back plate Plug Bleed screw Bleed screw cap Cylinder body Operating lever Pin Spring 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. L–type seal Piston Dust cover Brake shoe Upper shoe spring Lower shoe spring Female push rod Bolt adjuster Adjuster sleeve Removal (Fig. 2) 1.
7 1 Note: The front brake assembly may be disas sembled as necessary for inspection and repairs. 1. Remove upper shoe spring (14), adjuster spring (20), and then lower shoe spring (15). 4 Note: The adjuster assembly (27) consists of the fe male push rod (16), bolt adjuster (17), and adjuster sleeve (18). 8 6 2 3 2. Remove hold down washers (22) and hold down springs (23) from the hold down pins (26). Remove brake shoes (13), pawl (19), and adjuster assembly (27).
6. Inspect female push rod (16), bolt adjuster (17), and adjuster sleeve (18) for rust, corrosion, bending, and fa tigue. Replace parts as necessary. 6. Install adjuster assembly (27) in the slots on the brake shoes (13). Install pawl (19) into brake shoe and onto top of bolt adjuster (17). Note: The brake cylinder assembly consists of the fol lowing: bleed screw (4), bleed screw cap (5), body (6), spring (9), L–type seals (10), pistons (11), and dust cov ers (12) 7.
Front Wheel Drive Section (4WD) Inspect Constant Velocity (CV) Joint Boot and Test CV Joint Inspecting Boot Inspect CV joint boot after every 200 hours of operation. A torn boot is the most common cause of CV joint fail ures. Note: A worn and noisy CV joint with the boot in good condition and filled with grease is not uncommon. Pot holes, curb contact, or collision damage can chip bear ing components and initiate worn conditions. 1.
Constant Velocity (CV) Joint BOOT CLAMPS RETAINING RING 4 BALL INNER RACE BOOT 2 CAGE 2 5 SNAP RING 1 OUTER RACE 3 Figure 9 1. Outboard boot kit 2. Inboard boot kit 5. Outboard joint and shaft 3. Circular clip 4. Inboard joint assembly Removal (Fig. 2) LEVERAGE POINT 1. Remove wheel, stub axle (31) and axle housing (28) from the CV joint (15) and front suspension (see Front Wheel Bearing Service Disassembly).
RETAINING RING Note: The inboard and outboard joints are similar in construction. The principle difference is the inboard joint’s outer race has internal ball tracks that are longer, which allow the shaft of the outboard joint to plunge into the inboard joint. Also, the inboard joint does not come with a shaft. The same Assembly and Disassembly instructions can be used for both joints. OUTER RACE 1. Unlock boot clamps securing the boot to the outer race. Slide boot away from the outer race. 2.
Inspection 1. Clean all parts thoroughly of dirt, grease, and de bris. Note: If any single part of either the outboard or in board joint is defective, the complete inboard or out board joint must be replaced 2. Inspect cage for worn windows; balls should be able to snap in. Replace joint if cage is cracked, distorted, or windows are worn (Fig. 15). 3. Inspect balls for damage and wear.
Change front differential oil every 800 hours. 1 1. Position vehicle on a level surface. stop engine and engage parking brake. Remove key from ignition switch. 2. Clean area around drain plug on the side of the dif ferential. Place drain pan under the drain plug. 3. Remove drain plug and let oil flow into the drain pan. Reinstall and tighten plug when the oil stops draining. 4. Clean area around the fill/check plug on side of dif ferential. 5.
Front Suspension Control Arm Assembly 1 2 4 3 19 18 17 35 7 15 4 16 5 6 17 18 16 21 22 23 24 26 20 19 15 7 34 33 8 9 10 11 12 13 14 28 18 17 29 18 32 2 6 27 4 1 6 30 31 4 Figure 20 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Grease fitting Retaining ring Upper control arm Flange bushing slotted hex nut Lock nut Ball joint seal Lower ball joint Retainer Cap screw Brake hose bracket Lock nut Front Wheell Drive Section (4WD) 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.
Front Wheel Drive Section (4WD) Front Differential Installation (Fig. 20) Removal (Fig. 20) 1. Park machine on a level surface. Make sure engine is off. Set parking brake and block rear wheels. CAUTION 2. Drain front differential (20) oil into a suitable contain er by removing the drain plug from its bottom. Install drain plug when draining is complete. 3. Remove both CV inboard joint assemblies from the front differential (20) (see CV Joint Assembly Removal). 4.
17 18 16 14 12 15 19 13 20 22 23 21 24 BEARING CAP 11 1 2 3 7 6 4 5 10 9 BEARING CRADLE 8 29 30 BEARING CAP 25 28 6 7 26 32 34 31 27 33 Figure 21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Vent Front housing Alignment pin Thrust washer Side bevel gear Pinion gear shaft Thrust washer Pinion gear Bearing cone Bearing cup Cap screw Plug Front Wheell Drive Section (4WD) 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
Front Wheel Drive Section (4WD) Disassembly (Fig. 21) 1. Remove flange (19) from the pinion shaft (8) by re moving lock nut (18) and washer (17) from the threaded end of the shaft. Use a bearing puller if necessary to re move the coupler flange (Fig. 22). 2. Secure carrier assembly (15) so that pinion gear shaft (8) is facing up. Remove eight cap screws (16) se curing the front housing to the carrier assembly. Figure 22 3.
IMPORTANT:When using a hammer and punch to remove the roll pin (28) and pinion shaft (25), be careful not to damage any gear teeth. 6. Drive roll pin (28) from the pinion shaft (25) using a long thin drift punch (Fig. 26). PUNCH Figure 26 7. Support differential case (27) in a vise. Drive pinion shaft (25) from the differential case using a long drift punch (Fig. 27). Figure 27 8.
Front Wheel Drive Section (4WD) Note: Remove bearing cones (29) from the differen tial case only if they need replacing (see Inspection). Retain shims (31) for reassembly of new bearing cones. 10. Remove bearing cone (29) from the differential case (27) with a puller. Make sure puller is inserted into the indentations on the differential case (Fig. 30). Figure 30 IMPORTANT:Make sure shims (21) are kept after they are removed from the carrier assembly (15). 11.
IMPORTANT:Make sure shims (14) are kept after they are removed from the carrier assembly (15). Note: Remove bearing cup (10) from the carrier hous ing (15) only if it needs replacing (see Inspection). 14. Pull bearing cup (10) and shims (14) from the carrier assembly (15) (Fig. 34). Figure 34 Note: Remove needle bearing (34) from the front housing (2) only if it needs replacing (see Inspection). 15. Remove oil seal (33). Press needle bearing (34) from the front housing (2) (Fig. 35).
Front Wheel Drive Section (4WD) 3. Inspect differential case (27) in the area where the bevel side gears (5) and pinion gear shafts (6) mesh. Replace case if machined areas are scored or if the pin ion shaft (25) fits loosely in its bore (Fig. 38). Figure 38 IMPORTANT:The ring gear (32) and pinion gear (8) must be replaced as a matched set. 4. Inspect bevel side gears (5), pinion gear shafts (6), pinion gear (8), and ring gear (32) for abnormal wear or damage. Replace any gear that is worn or damaged.
Assembly (Fig. 21) RING GEAR (32) PINION SHAFT (25) PINION GEAR (6) CAP SCREW (26) THRUST WASHER (7) DIFFERENTIAL CASE (27) THRUST WASHER (4) SIDE BEVEL GEAR (5) SHIM (31) CAP SCREW (11) BEARING CAP BEARING CRADLE BEARING CONE (29) BEARING CUP (30) 3.
Front Wheel Drive Section (4WD) The ring gear (32) and pinon gear (8) are supplied as a matched set. Both gears are etched for verification with matching numbers. If a new gear set is being used, verify that the matching numbers are the same on both the ring and pinion gear before assembling the front dif ferential (Fig. 43). SHIMMING DIMENSION MATCHING NUMBERS The distance from the center line of the ring gear to the bottom of the pinion gear teeth is 3.750 inches (5.525 cm).
2. If the bearing cup (23) was removed, press new bearing cup into the carrier assembly (15) (Fig. 45). Figure 45 3. If the bearing cup (10) was removed, place shims (14) into the carrier assembly (15). Press new bearing cup into the assembly (Fig. 46). 4. If a new carrier assembly (15) is being installed, pro ceed as follows: A. Press bearing cup (10) into the assembly with out any shims (14). B. Place pinion gear (8) with bearing cone (9) installed into the carrier assembly and bearing cup. C.
Front Wheel Drive Section (4WD) 6. Verify bearing preload and pinion gear shaft (8) rota tion as follows: A. Install coupler flange (19), washer (17), and lock nut (18) to the shaft of the pinion gear. Torque lock nut from 75 to 90 ft–lb (10.3 to 12.4 kg–m). B. The torque required to rotate the shaft of the pin ion gear should be from 7 to 12 in–lb (8 to 14 kg–cm) (Fig. 49). C.
IMPORTANT:When bearing cones (29) are removed removed from the differential case (27) they should replaced with new ones. When installing new bear ing cones to the differential case, use original shims (31) or new shims of the same thickness. 8. Press bearing cone (29) onto the differential case (27) (Fig. 53). Figure 53 9. Position ring gear (32) to the differential case (27). Secure ring gear to the case with five cap screws (26) in a criss–cross pattern so the gear is pulled evenly into place.
Front Wheel Drive - 4WD 12. Check backlash of ring gear (32) with a dial indicator at three equally spaced positions (Fig. 57). A. Backlash should be from 0.002 to 0.006 inch (0.051 to 0.152 mm) and should not vary more than 0.002 inch (0.051 mm). B. If backlash does not meet specifications, move shims (31) from one side of the differential case (27) to the other until the correct backlash is attained. 13.
17. Make sure both plugs (12) and O–rings (13) are installed. Verify that plugs are torqued between 20 to 25 ft–lb (2.8 to 3.5 kg–m). FILL PLUG DRAIN PLUG Figure 61 Ring to Pinion Gear Engagement When replacing the ring and pinion gear set, final position of pinion is verified by using the gear contact pattern method as described in the following procedure. Note: engagement contact of original production ring and pinion gear may differ slightly from gear pattern shown.
Heel Heel Toe High backlash is corrected by moving the ring gear closer to the pinion. Low backlash is corrected by moving the ring gear away from the pinion. These corrections are made by switching shims from one side of the differential case to the other. Example 1: Backlash correct. Thicker pinion position shims required (Fig. 64). RING GEAR COAST SIDE RING GEAR DRIVE SIDE Toe Figure 64 Heel Toe Example 2: Backlash correct. Thinner pinion position shims required (Fig. 65).
Front Wheel Drive Section – 4WD (Rev.
Front Wheel Drive - 4WD Differential Drive Shaft 7 4 2 5 2 3 1 6 SNAP RING SNAP RING 3 Figure 67 1. Flange yoke 2. Cross and bearing kit 3. Tube yoke 4. Slip yoke 5. Grease fitting 6. Seal 7. Socket head screw Removal 1. Park machine on a level surface. Make sure engine is off. Set parking brake and block rear wheels. 2. Jack up and secure front wheels off the ground (see Jacking Vehicle in Chapter 1 – Safety).
Bidirectional Clutch 14 13 CAGE AND ROLLER ASSEMBLY 10 11 12 9 8 7 4 6 19 5 2 3 15 4 1 18 16 17 Figure 70 1. 2. 3. 4. 5. 6. 7. Clutch shaft Seal plug Retaining ring Ball bearing Housing and race Garter gear Roller 8. 9. 10. 11. 12. 13. Cam Thrust bearing Thrust washer Spring Cage Oil seal Removal (Fig. 70) 1. Park machine on a level surface. Make sure engine is off. Set parking brake and block rear wheels. 2. Remove drain plug from the transaxle. Drain all oil into a suitable container.
Front Wheel Drive - 4WD Inspection (Fig. 70) 1. Replace cage (12) if it is bent, cracked, or broken. Corrosion that can not be cleaned up with light polishing is not acceptable. 2. Replace spring (11) if flattened or distorted. 3. Replace thrust washer (10) if flat surfaces are pitted, gouged, or distorted. 4. Replace thrust bearing (9) if bent, distorted, or the needles do not spin freely. Figure 71 5. Replace rollers (7) or cam (8) if any of the following conditions occur: A.
Assembly (Fig. 70) 1. Clean all parts thoroughly of all dirt and debris to prevent damage to the bidirectional clutch and transaxle. 2. Place garter spring around the cage and into the groove (Fig. 75). 1 2 3. Place thrust bearing, thrust washer, and spring onto the cam (Fig. 76). 4. Insert cam with thrust bearing, thrust washer, and spring into the cage (Fig. 77). Note: Figure 75 1. Garter spring Rollers must be replaced as a complete set. 3 5. Insert rollers into the slots of the cage.
6. Insert seal plug (2) into the housing and race (5) using a driver. 7. Secure clutch shaft to housing and race (5) with lock washers (16) and hex socket head screws (17). 9. Make sure drain plug is installed properly to the transaxle. Fill transaxle with Dexron III ATF (see Changing Transaxle/Hydraulic Fluid in the Service and Repairs section of Chapter 6 – Drive Train). 10. Install differential drive shaft (18) to clutch shaft (1) and the front differential (see Differential Drive Shaft Installation).
Lubrication WARNING Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition switch. Any load material must be removed from bed or other attachment before working under raised bed. Always place the safety support on extended lift cylinder to hold box up. Figure 78 The differential drive shaft has 3 grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
Chapter 11 (For Mitsubishi Engine only) Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . Precautions for Working on Liquid Propane (LP) Gas Fuel Systems . . . . . . . . . . . . . . . . . . . . . . . . . . Refueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS . . . . . . . . . . . . . . .
Specifications Item Description Engine Mitsubishi 3G83 liquid cooled gasoline (Modified) Ignition Timing (low idle) 11� BTDC + 2� @ 1200 + 100 RPM Ignition Timing (high speed) 22� BTDC + 2� @ 3000 + 100 RPM Spark Plug Gap 0.030 inch (0.762 mm) Fuel Liquid propane gas Fuel Tank 20 lb (9.
General Information CAUTION CAUTION LP gas must be treated with care. This fuel is nat urally odorless and invisible. An identifying odor has been added to LP gas so the presence of the gas can be quickly detected. When escaping LP gas is detected, take the following steps: 1. Shut off tank service valves immediately. 2. Eliminate all possible sources of ignition. 3. Get qualified LP gas personnel to fix the problem.
Refueling LPG gas is stored in a 20 lb fork lift style tank. Acceptable LP Gas mixtures should meet the specifications for Pro pane HD–5 of Gas Producers Association Standard 2140, or the specifications documented in California title 13 CCR 2292.6 or a mixture with a minimum of 90% pro pane by volume that can pass the ASTM D2713 test for moisture content. 1. Park machine on a level surface, stop engine, en gage parking brake, and remove key from the ignition switch. 2.
Special Tools Pressure Test Pressure Gauge Kit Liquid Propane Gas Conversion Kit Use this kit to take various pressure readings for diag nostic tests of the liquid propane (LP) gas fuel system. The kit contains one each of the following: 0 to 160 PSI test gauge, 0 to 5 PSI test gauge, and 0 to 10 inches (H2O) vacuum gauge, vacuum hose, and assorted fit tings. Use gauges as recommended in Testing section of this chapter.
Liquid Propane Conversion Kit 1. 2. 3. 4. 5. 6. 1 Page 11 – 6 Rev. D 7. 8. 9. 10. 11. 12. Figure 3 20 Lb.
Application LP Gas (Liquid) Liquid Propane (LP) Fuel Tank LP Gas (Vapor) LP Gas (Liquid) Vaporizer– Regulator LP gas is stored in the 20–lb. fork lift style fuel tank. The tank has a fuel gauge. LP gas is delivered to the vacuum fuelock–filter through a LP gas hose assembly. The hose has a female quick fitting that attaches to the fuel tank. Both the tank and hose assembly automatically stop fuel flow should a rupture or high fuel flow rate occur in the fuel system.
Troubleshooting With the exception of the fuel system, a gasoline engine converted to run on LP gas operates as a gasoline one. When looking for the source of a engine malfunction, it is important to eliminate all other possible causes that are not associated with the fuel system (see Trouble shooting in Chapter 3 – Liquid Cooled Gas Engine). If the fuel system is not operating properly, take the fol lowing steps to determine the cause: 1.
Testing LP Gas Fuel System (Fig. 5) 6 4 1. Park machine on a level surface, stop engine, en gage parking brake, and remove key from the ignition switch. 5 2. Read carefully Precautions for Working on Liquid Propane Gas Systems before proceeding to any of the tests. 1 3. Make sure there is sufficient LP gas in the tank to run the engine before each test. Test Vacuum Fuelock Filter 1.
Adjustments Adjust LP Fuel System 1. Park machine on a level surface, stop engine, en gage parking brake, and remove key from the ignition switch. 2 2. Read carefully Precautions for Working on Liquid Propane Gas (LP) Fuel Systems before proceeding fur ther. 3. Slowly open valve on propane fuel tank and close. Use leak check or soap solution to check all fittings, valves, couplers, and lines for leaks. No fuel leaks should be present. Any detected fuel leaks must be re paired before engine is started.
Service and Repairs 1. Park machine on a level surface, stop engine, en gage parking brake, and remove key from the ignition switch. 2. Read carefully Precautions for Working on Liquid Propane Gas (LP) Fuel Systems before proceeding fur ther. 3. Clean area around spark plugs so foreign matter cannot fall into cylinder when spark plug is removed. 4. Disconnect spark plug wires off spark plugs. Re move plugs from cylinder head.
Fuel Tank Assembly 1 2 3 4 13 5 12 11 10 9 8 7 6 Figure 9 1. 2. 3. 4. 5. 20 lb. LP gas fuel tank Flange head screw Clip Thread forming screw Tank mount 6. 7. 8. 9. 10. 11. 12. 13. LP gas fuel decal LP gas dash decal Flange nut Lynch pin Flange head screw Lock nut Hose assembly Quick fitting (female) Removal Installation 1. Park machine on a level surface, stop engine, en gage parking brake, and remove key from the ignition switch. 1.
Conversion Kit Assembly 13 12 39 5 7 32 36 6 24 9 10 8 4 4 31 5 11 3 14 1 2 1 30 41 15 10 16 18 38 17 33 24 6 1 34 23 10 35 18 19 20 37 18 22 40 16 25 28 26 27 26 18 18 15 21 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Hose clamp Hose adapter 2–inch rubber elbow Cap screws Lock washer Vapor hose Vaporizer–regulator Elbow Fitting Vacuum hose 1/4–inch NPT nipple fitting 3/8–inch flare to 1/4–inch fitting HOse assembly Support strap 15. 16. 17. 18. 19. 20.
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