Part No. 02110SL (Rev. D) Service Manual WorkmanR 1100/1110/2100/2110 Preface The purpose of this publication is to provide the service technician with information for troubleshooting, testing, and repair of major systems and components on the Workman 1100, 1110, 2100, and 2110. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE, AND ADJUSTMENT INSTRUCTIONS. Space is provided in Chapter 2 of this book to insert the Operator’s Manuals and Parts Catalogs for your machine.
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Chapter 2 – Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2–1 2–2 2–3 2–7 2–8 Chapter 3 – Briggs & Stratton Gasoline Engine Introduction . . . . . . . . . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Supervisor’s Responsibilities . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . Workman 1100/2100/2110 2 2 2 3 5 JACKING AND OTHER INSTRUCTIONS . . . . . . . . Jack Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Instructions The Workman 1100/2100/2110 was tested and certified by TORO for compliance with the B71.4–1984 specifications of the American National Standards Institute. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, transport, maintenance, and storage of the machine.
4. Never operate vehicle when under the influence of drugs or alcohol. 5. Become familiar with the controls and know how to stop the engine quickly. 6. Keep all shields, safety devices, and decals in place. Repair or replace any shield, safety device, or decal if it is malfunctioning, illegible, or damaged before operating the machine. 7. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes or sneakers.
M. Always watch out for and avoid low overhangs such as tree limbs, door jambs, over head walkways, etc. Make sure there is enough room over head to easily clear the vehicle and your head. C. Watch for holes or other hidden hazards. D. Use extra caution when operating the vehicle on wet surfaces, at higher speeds, or with a full load. Stopping distance will increase with a full load. Slow down before starting up or down a hill. N. If ever unsure about safe operation, stop vehicle and ask your supervisor.
1. Only qualified and authorized personnel should maintain, repair, adjust, or inspect the vehicle. 9. If major repairs are needed or assistance is required, contact an Authorized Toro Distributor. 2. Before servicing or making adjustments to the machine, stop engine, set parking brake, and remove key from the ignition switch to prevent someone from accidentally starting the engine. 10.Make sure of optimum performance and safety. Always use genuine Toro replacement parts and accessories.
Jacking and Other Instructions Jack Vehicle DANGER POTENTIAL HAZARD • A vehicle that is not properly supported may become unstable. WHAT CAN HAPPEN • The vehicle may move or fall. Personal injury or damage to the machine may result. HOW TO AVOID THE HAZARD • Make sure vehicle is parked on a solid level surface, such as a concrete floor. • Make sure engine is off and key is removed from the ignition switch before getting off the vehicle.
In case of emergency, the vehicle can be towed for a short distance. However, Toro does not recommend this as a standard procedure. Towing the vehicle is a two person job. If the vehicle must be moved a considerable distance, transport it on a truck or trailer (see Transport Vehicle). 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. WARNING POTENTIAL HAZARD • Towing at excessive speeds could cause the vehicle to lose control.
Safety and Instruction Decals There are several safety and instruction decals attached to your Workman. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed in the Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series). . . . . . . . . . . . .
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Workman 1100/2100/2110
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Thread Size 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 Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws, and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 5 in–lb 640 + 60 N–cm 78 + 7 in–lb 885 + 80 N–cm M6 X 1.0 96 + 9 in–lb 1018 + 100 N–cm 133 + 13 in–lb 1500 + 150 N–cm M8 X 1.25 19 + 2 ft–lb 26 + 3 N–m 27 + 2 ft–lb 36 + 3 N–m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts 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 Note: Perform this maintenance procedure at the interval specified in the WORKMAN Maintenance Schedule. Lubricate more frequently when using this vehicle for heavy duty operations and after each washing. 1 Product Records and Maintenance Grease Fitting Locations 1. Each tie rod has a grease fitting on each ball joint, the one that secures the tie rod to the Pitman arm (Fig 3) and the joint that secures the tie rod to the front wheel spindle (Fig 4). 2 2.
Drive Clutch Lubrication Note: After every 400 hours of use, or yearly, cleaning and lubrication of the drive clutch is recommended. 2 2 1. Park machine on a level surface, stop engine, and remove key from the ignition switch. Raise and latch cargo bed. 2. Remove the three (3) cap screws that secure the cover to the drive clutch (Fig. 6). Remove the cover from the clutch. 1 2 Figure 6 1. Clutch cover 2.
Chapter 3 Briggs & Stratton Gasoline Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . Fill Fuel Tank and Fuel Safety Precautions . . . . . Check Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjust Starter/Generator Belt . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the V–twin cylinder, gasoline engine used in the Workman 2100 and 2110. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Briggs & Stratton Repair Manual for 4–Cycle, V–Twin Cylinder, OHV Head Engines. The use of some specialized test equipment is ex- Briggs & Stratton Gasoline Engine plained.
Specifications Item Description Make / Designation Briggs and Stratton, 4–cycle, V–Twin Cylinder, OHV, Air Cooled, Gasoline Engine – Model 303440 Horsepower 16 HP @ 3600 RPM Torque kg–m (ft–lb) 4.76 (34.5) @ 2300 RPM Bore x Stroke mm (in.) 68 x 66 (2.68 x 2.60) Total Displacement cc (cu. in.) 480 (29.3) 32.4 (72) Fuel Unleaded regular grade gasoline Fuel Capacity liters (gallons) 26.5 (7.
General Information Fill Fuel Tank and Fuel Safety Precautions The Toro Company strongly recommends the use of fresh, clean, UNLEADED regular grade gasoline in Toro gasoline powered products. Unleaded gasoline burns cleaner, extends engine life, and promotes good starting by reducing the build-up of combustion chamber deposits. Minimum Octane rating of 85. IMPORTANT: Never use gasoline containing METHANOL, gasoline containing more than 10% ethanol, gasoline additives, or white gas.
Check Engine Oil Procedure (Fig. 2) The engine is shipped with oil in the crankcase; however, level of oil must be checked before and after the engine is first started. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2 1 2. Remove dipstick and wipe it with a clean rag. Insert dipstick into tube and make sure it is seated fully. Remove dipstick and check level of oil. Figure 2 1. Dipstick Briggs & Stratton Gasoline Engine 3.
Adjustments Adjust Starter/Generator Belt Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. 4 2 1/4” 3 10 lbs. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Loosen starter generator pivot bolt. 1 3. While pressing the belt at mid–span between the pulleys with 10 lb (44.
Service and Repairs Change Engine Oil Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. 1. Start vehicle and let it run for a few minutes to warm the oil. 2. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1 3. Raise bed and support with prop rod (see Operator’s Manual). Briggs & Stratton Gasoline Engine 4. Disconnect spark plug wires. 2 Figure 7 1.
Service Air Cleaner Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Raise bed and support with prop rod (see Operator’s Manual). 3. Check air cleaner body and hoses for damage which could possibly cause an air leak. Replace air cleaner body if damaged.
Service Drive Belt Inspection 1 Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 3 2. Raise bed and support with prop rod (see Operator’s Manual). Figure 10 1. Drive belt 2. Drive clutch 3. Driven clutch Briggs & Stratton Gasoline Engine 3.
Spark Plugs Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. .030” (.76 mm) Type: Champion RC 12YC (or equivalent) Air Gap: 0.030 inch (0.76 mm) Note: A spark plug usually lasts a long time; however, the plug should be removed and checked whenever the engine malfunctions. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. Figure 12 2.
Clean Debris from Engine Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. IMPORTANT: This engine is air–cooled. Operating the engine with dirty or plugged cooling fins, a blocked rotating screen, or plugged or dirty blower housing will result in overheating and engine damage. 1 1 2. Raise bed and support with prop rod (see Operator’s Manual). IMPORTANT: Never clean engine with pressurized water.
Muffler Removal 1 1. Park machine on a level surface, stop the engine, engage parking brake, and remove the key from the ignition switch. 5 4 2. Raise bed and support with prop rod. CAUTION 8 2 7 6 The muffler and exhaust pipe may be hot. To avoid possible burns, allow engine and exhaust system to cool before working on the muffler. 3. Remove two coupler springs securing the exhaust coupler to the muffler. 4 3 8 Figure 15 1. 2. 3. 4. Engine Muffler Exhaust coupler Coupler spring (4 used) 5. 6.
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Seat Base and Fuel Tank 1 2 3 22 21 5 4 6 7 8 19 14 20 15 17 16 18 9 11 13 10 12 12 1. 2. 3. 4. 5. 6. 7. 8. Seat Seat bracket Cap screw Seat base Fuel hose (to filter) Clamp Stand pipe Bushing 9. 10. 11. 12. 13. 14. 15. Figure 16 Gas cap Fuel tank Web strapping (48 inch) Hex head flange screw Flat washer Fuel gauge Grommet Seat Base Removal (Fig. 16) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2.
6. Remove four hex head flange screws and flat washers securing the front of the seat base to the frame. Remove four hex head flange screws securing the back of the seat base to the frame. IMPORTANT:Make sure shift bracket, shift cables, choke cable, and fuel tank do not catch on the seat base during removal. 7. Lift seat base carefully from the machine. Seat Base Installation IMPORTANT:Make sure shift bracket, shift cables, choke cable, and fuel tank do not catch on the seat base during installation. 2.
Engine 35 1 42 41 2 3 4 5 44 40 39 37 6 43 38 36 9 7 34 10 8 35 11 33 12 31 32 13 14 15 30 16 19 17 18 29 20 27 28 21 22 26 23 24 25 Figure 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Hose clamp Air intake hose Cable bracket Cable clamp Cap screw Threaded insert Washer Cap screw Nut Torque arm Flat washer (2 used) Lock washer (2 used) Cap screw (2 used) Starter V–belt Cap screw (4 used) Briggs & Stratton Gasoline Engine 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Engine Removal (Fig. 19) 1 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 3 2. Remove cargo bed to gain access to the engine. 4 3. Disconnect negative (black) cable from the battery. Then, disconnect positive (red) cable from the battery. 2 1. Carburetor 2. Throttle cable 4. Disconnect the following components: Figure 20 3. Choke cable 4. Cable bracket A. Choke and throttle cables from the carburetor and cable bracket (Fig. 20). B.
4. Connect the following electrical components: CAUTION A. Connect ground cable from the engine at starter/ generator terminal A1 (Fig. 22). One person should operate the chain fall or hoist while the other person guides the engine out of the frame. B. Connect engine harness connector to the main harness connector. 5. Install torque arm to the engine and transaxle. 12.Remove engine from the engine mount. A. Attach a short section of chain between both engine lift tabs. B.
Chapter 4 Kohler Gasoline Engine Table of Contents 2 3 4 4 5 6 6 6 7 7 Service Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Service Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Replace Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Clean Debris from Engine . . . . . . . . . . . . . . . . . . . 10 Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the Kohler gasoline engine used in the Workman 1100 and 1110. specialized test equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Most repairs and adjustments require tools which are commonly available in many service shops.
Specifications Item Description Make / Designation Kohler, 4–cycle, Single Cylinder, OHV, Air Cooled, Gasoline Engine – Model CH12 PA–941521 Horsepower 12 HP @ 3600 RPM Torque N–m (ft–lb) 22.6 (16.7) @ 2000 RPM Bore x Stroke mm (in.) 85 x 63 (3.35 x 2.48) Total Displacement cc (cu. in.) 357 (21.8) Dry Weight (approximate) kg (lb.) 31.9 (70.5) Fuel Unleaded regular grade gasoline 26.5 (7.
General Information Fill Fuel Tank and Fuel Safety Precautions The Toro Company strongly recommends the use of fresh, clean, UNLEADED regular grade gasoline in Toro gasoline powered products. Unleaded gasoline burns cleaner, extends engine life, and promotes good starting by reducing the build-up of combustion chamber deposits. Minimum Octane rating of 87. IMPORTANT: Never use gasoline containing METHANOL, gasoline containing more than 10% ethanol, gasoline additives, or white gas.
Check Engine Oil Procedure (Fig. 2) The engine is shipped with oil in the crankcase; however, level of oil must be checked before and after the engine is first started. 1 2 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove dipstick and wipe it with a clean rag. Insert dipstick into tube and make sure it is seated fully. Remove dipstick and check level of oil. 3.
Adjustments Adjust Starter/Generator Belt Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. 2 1/4” 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Lift cargo bed and prop with rod to gain access to the engine. 10 lb 3. Loosen starter/generator pivot bolt. 1 4. Wedge a pry bar between the engine mount and starter.
Service and Repairs Change Engine Oil Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. 1. Start vehicle and let it run for a few minutes to warm the oil. 1 2. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 3. Raise bed and secure it with the prop rod. 4. Disconnect spark plug wire. 5. Remove drain plug and let the oil flow into a drain pan.
Service Air Cleaner Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Raise bed and secure with prop. 3. Check air cleaner body and hoses for damage which could possibly cause an air leak. Replace air cleaner body if damaged.
Service Drive Belt Inspection Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 1 2 3 2. Raise bed and secure with prop rod. 3. Put vehicle transmission in neutral (see Set Neutral Lock Assembly in Chapter 1 – Safety). 4. Rotate and inspect belt for excessive wear or damage. Replace as necessary.
Spark Plug Note: Perform this maintenance procedure at the interval specified in the Operator’s Manual or Chapter 2 – Product Records and Maintenance. Type: Champion RC 14YC (or equivalent) Air Gap: 0.030 inch (0.76 mm) Note: A spark plug usually lasts a long time; however, the plug should be removed and checked whenever the engine malfunctions. 5. Check condition of side electrode, center electrode, and center electrode insulator for damage. 6. Set air gap between center and side electrodes at 0.030” (0.
Muffler Removal 1. Park machine on a level surface, stop the engine, engage parking brake, and remove the key from the ignition switch. 3 2. Raise bed and support with prop rod. 1 3 CAUTION 2 The muffler and exhaust pipe may be hot. To avoid possible burns, allow engine and exhaust system to cool before working on the muffler. 3. Remove springs securing the exhaust coupler to the muffler and exhaust manifold (Fig. 13). 3 1. Exhaust manifold 2. Exhaust coupler Figure 13 3.
Seat Base and Fuel Tank 1 2 3 22 21 5 4 6 7 8 19 14 20 15 17 16 18 9 11 13 10 12 12 1. 2. 3. 4. 5. 6. 7. 8. Seat Seat bracket Cap screw Seat base Fuel hose (to filter) Clamp Stand pipe Bushing 9. 10. 11. 12. 13. 14. 15. Figure 14 Seat Base Removal (Fig. 14) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Flip both seats forward, and remove them from the seat base. Kohler Gasoline Engine 16. 17. 18. 19. 20. 21. 22.
6. Remove four hex head flange screws and flat washers securing the front of the seat base to the frame. Remove four hex head flange screws securing the back of the seat base to the frame. IMPORTANT:Make sure shift bracket, shift cables, choke cable, and fuel tank do not catch on the seat base during removal. 7. Lift seat base carefully from the machine. Seat Base Installation (Fig.
Engine 3 5 36 4 13 45 44 1 43 38 24 37 19 35 14 20 49 50 48 7 17 2 16 29 34 6 8 41 23 30 25 42 28 9 26 27 37 38 32 10 21 18 33 40 12 22 11 15 47 31 46 39 37 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Kohler engine Exhaust spring Intake hose Hose clamp Hose clamp Muffler Exhaust manifold Exhaust coupler Cap screw Lock washer Washer Drive clutch Drive belt Starter V–belt Cap screw Cap screw Fuel filter Kohler Gasoline Engine 18. 19. 20. 21.
Engine Removal (Fig. 17) 1. Park machine on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. 2. Remove cargo bed to gain access to the engine (see Cargo Bed and Tailgate Removal – Chapter 7). 3. Disconnect ground (black) cable from the battery. Then, disconnect positive (red) cable from the battery. IMPORTANT: Make sure all hoses and engine openings are plugged after disconnecting.
Engine Installation (Fig. 17) 7. Install drive belt (see Service Drive Belt). 1. If removed, install engine parts and attachments to the engine. 8. Install muffler and coupler to the exhaust manifold (see Muffler Removal). 9. Connect fuel hose to the fuel pump (Fig. 18). CAUTION 10.Connect the following components: One person should operate the chain fall or hoist while the other person guides the engine into the frame. 2. Install engine to the frame. A.
Chapter 5 Drive Train Table of Contents Driven Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Principles of Operation . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ramp Button Replacement . . . . . . . . . . . . . . . . . Check Driven Clutch Spring Torsion . . . . . . . . . . . Change Transaxle Fluid . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Transaxle Transaxle Fluid Capacity Transaxle Fluid Mechanically governed differential 1.5 quarts (1.4 liters) 10W--30 Motor Oil Clutch System Drive Clutch Driven Clutch Continuously variable transmission type, torque convertor Speed sensing with mechanical fly weights Torque sensing with spring loaded cam Note: Workman 2100 and 2110 vehicles with serial numbers above 240000000 use an engine governor for speed control rather than a transaxle governor.
Special Tools OTC (Owatonna Tool Company) supplies special tools for servicing Toro Commercial Products. The TORO SPECIAL TOOLS AND APPLICATIONS GUIDE shows service tool applications. Some tools may have been supplied with your vehicle or available as TORO parts. Some tools may also be available from a local supplier. Clutch Removal Tool -- TOR4094 This tool is required to remove the drive clutch from the tapered drive shaft of the engine.
Adjustments Adjust Ground Speed (Vehicles With Transaxle Governor) Note: All Workman 1100 and 1110 models are equipped with a transaxle governor. Workman 2100 and 2110 models with serial numbers below 240000000 are also equipped with a transaxle governor. C. If unable to identify the driven clutch RPM, an alternate method to verify ground speed would be to determine the distance that the vehicle will travel in three (3) seconds with the accelerator pedal to the floor.
Adjust Ground Speed (Vehicles Without Transaxle Governor) Note: Workman 2100 and 2110 models with serial numbers above 240000001 are not equipped with a transaxle governor. These models use an engine governor for speed control. 3 2 1 WARNING Vehicles operating at ground speeds greater than the recommended speed will require further distances to fully stop. Do not adjust ground speed greater than specified. 1.
Adjust Shift Cables 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. Raise and latch cargo bed. 1 2. On vehicles with a shift lever neutral position (Fig. 6): A. Set the shift lever into the Neutral position. 3 B. The transaxle select lever assembly should be in a level position. C. Tighten the locknut on one of the shift cables just enough to take up any cable slack. Note: the locknut below the bracket must be held to allow adjustment. 2 D.
Service and Repairs Clutch System Operation 1 3 A B 4 6 C 7 Drive Train v 9 8 5 2 Figure 7 1. 2. 3. Drive clutch Driven clutch Moveable sheave (drive clutch) 4. 5. 6. Fixed sheave (drive clutch) Moveable sheave (driven clutch) Button 7. 8. 9. Ramp (fixed cam) Spring Fixed sheave (driven clutch) Two Clutch System (Fig. 4) Power is transferred from the engine to the transaxle by a variable clutch system that consists of two clutches connected by a drive belt.
Drive Clutch 2 1 3 4 5 6 v 7 8 9 Figure 8 1. 2. 3. Fixed sheave Moveable sheave Spider assembly 4. 5. 6. 7. 8. 9. Cover Washer Plastic cap Spring Cam weight Roller Principles of Operation (Fig. 8) The operation of the drive clutch is affected by engine shaft speed. With the engine not turning, the drive belt rests low within the clutch sheaves as the pressure of the spring holds the sheaves apart.
Removal 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 4 2. Remove drive belt from the drive clutch (see Service Drive Belt in Engine Chapter). 5 6 7 3 2 3. Remove starter/generator V–belt from the engine pulley (see Replace Starter/Generator Belt in Engine Chapter). 1 8 4. Remove plastic cap carefully from the drive clutch. 25 to 30 ft–lb (34 to 41 N–m) 5. Remove cap screw and washer securing the drive clutch to the engine tapered shaft.
100 ft–lb (136 N–m) 11 1 5 75 to 100 in–lb 7 4 (8.5 to 11.3 N–m) 2 3 10 8 12 6 9 v Figure 10 1. 2. 3. 4. 5. 6. 7. 8. Fixed sheave Spring Washer Spider assembly 9. 10. 11. 12. Cap screw Plastic cap Cover Moveable sheave Roller kit Cam weight Nut Pilot bolt Disassembly (Fig. 10) IMPORTANT: Do not pry off cover, damage may result. Cover should pop off. 6. Using spider removal spanner tool (TOR4098: see Special Tools), remove spider from the fixed sheave post (Fig. 11). 1.
Inspection 1. Inspect the tapered ends of the crankshaft and primary fixed sheave for scratches. If either is severely scratched, replace component. If scratches are minor, burnish the component with emery cloth. 2 2. Check the surface of the cam weights. If worn, replace all cam weights as a set (Fig. 14). 1 3. Check the rollers. If binding or uneven wear is found, replace all rollers as a set (Fig. 15). 4. Clean pilot bolts and roller pins with 800 -- 1000 grit abrasive paper.
Driven Clutch Principles of Operation (Fig. 17) The operation of the driven clutch is affected by transaxle load. When the vehicle is stopped, the drive belt is held at the outer diameter of the clutch sheaves from the pressure of the spring pushing the moveable sheave against the fixed sheave and away from the fixed cam. Three sets of buttons on the moveable sheave provide a low friction surface on which the sheave can slide on the ramp of the fixed cam.
4. Secure driven clutch to the transaxle input shaft with cap screw, washer, and spacer (if equipped). A. For machines that have a 5/16” -- 18 cap screw, torque cap screw from 25 to 30 ft--lb (34 to 41 N--m). B. For machines that have a 3/8” -- 16 cap screw, torque cap screw from 39 to 47 ft--lb (53 to 64 N--m). 5. Install drive belt to the driven clutch (see Service Drive Belt in Service and Repairs section of Engine Chapter). 6.
Check Driven Clutch Spring Torsion 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 1 2. Place transaxle in gear to prevent the fixed sheave from moving. 2 3. Remove drive belt from the driven clutch (see Service Drive Belt in Engine Chapter). 4 IMPORTANT: Use protective strips of soft metal when clamping the moveable sheave with locking pliers to prevent damage to the sheave. 3 4. Clamp moveable sheave with locking pliers. Figure 18 5.
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Transaxle Removal 5 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 3 2. Remove cargo box from the frame (see Cargo Box Removal in Chapter 7 – Chassis, Wheels, and Brakes). 3. Remove drive belt from the driven clutch (see Service Drive Belt in Engine Chapter). 1 4 4. Remove tie wraps securing both battery cables to the passenger side axle tube. 5. Remove governor and cable brackets from the transaxle as follows (Fig. 21). A.
10.Remove both flange lock nuts, flat washers, isolation mounts, and cap screws securing the engine mount to the rear frame (Fig. 23). 11. Remove four flange lock nuts and hex head flange screws securing the transaxle to the engine mount (Fig. 24). 12.Lower engine mount enough to allow the transaxle and driven clutch to be removed from the rear of the vehicle. 7. Secure both battery cables to the passenger side axle tube with tie wraps. 8.
Transaxle Service 69 56 55 52 57 75 52 55 74 25 to 31 ft–lb (34 to 42 N–m) 50 76 73 72 35 29 67 53 8 65 70 3 4 5 13 70 6 71 2 58 24 12 to 16 in–lb (1.4 to 1.
Figure 26 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. Case (LH) Oil seal Oil seal Snap ring Spacer Selector shaft Oil seal Flange bolt Oil check plug Gasket Oil drain plug Gasket Oil filler plug Case (RH) Oil seal Governor shaft Governor fork Stopper Screw and washer Input shaft Governor base Lock pin Governor plate unit Ball bearing Governor sleeve Ball bearing 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71.
2 1 Figure 28 1. Bolt (steel ball, spring & gasket) 2. Selector shaft C. Remove bolt near the selector shaft. Remove spring and steel ball. Replace gasket if damaged. 2 1 Figure 29 1. Input shaft 2. Oil seal D. Wrap vinyl tape around the splined portion of the input shaft. This should protect the oil seal from being damaged.
3 1 2 Figure 30 1. Flange bolts 2. Axle bracket 3. Axle case E. Remove three flange bolts securing the axle bracket and axle case to each case. Separate bracket from each axle case. Drive Train 2 1 Figure 31 1. Flange bolt 2. Flange nut F. With the input shaft side down, loosen and remove flange bolts and nuts securing the case (RH) and case (LH) together.
1 2 Figure 32 1. Case (RH) 2. Governor boss G. Hold the case (RH) and lift up while lightly tapping the governor boss with a plastic hammer. IMPORTANT: Make sure not to hit the governor boss too hard when separating the cases, the boss may get damaged. Do not pry open the two cases with a screw driver, damage may result to the sealing surfaces. 2. Remove input shaft, center shaft, and differential assemblies. 2 1 Figure 33 1. Gasket 2. Pipe knock A. Remove gasket and pipe knocks.
3 4 1 2 Figure 34 1. Counter shaft 2. Spacer 3. Needle bearing 4. Gear 34 Drive Train B. Pull out counter shaft. Remove spacer, needle bearing, gear 34, and spacer. 1 2 4 3 2 Figure 35 1. Counter shaft 2. Spacer 3. Needle bearing 4. Gear 34 C. Replace counter shaft if it has abnormal wear, cracks, or damage. E. Replace needle bearing if needles are bent, do not rotate freely, or do not remain in the bearing cage. D. Replace spacer if either one is cracked or bent. F.
1 3 4 2 Figure 36 1. Differential assembly 2. Input shaft assembly 3. Center shaft assembly 4. Shift shaft G. Lift up differential assembly, center shaft assembly, and input shaft assembly at the same time. First, remove input shaft assembly. Then, remove center shaft assembly with the shift shaft and differential assembly. IMPORTANT: Make sure not to damage the oil seal when removing the input shaft.
2 4 1 3 Figure 38 1. Snap ring 2. Axle case 3. Axle shaft 4. Ball bearing C. Ball bearing roller balls must be free of deformation and scoring. Ball bearing must spin freely and have minimum axial play. Replace ball bearing as necessary. IMPORTANT: Do not reuse snap ring. Discard and replace ring with new one. B. Remove snap ring from the axle case. Remove axle shaft from case. IMPORTANT: When replacing ball bearings, both ball bearings must be replaced as a set. Drive Train 4.
1 2 Figure 40 1. Ball bearing 2. Input shaft IMPORTANT: Do not reuse ball bearings that have been removed. B. Remove ball bearing from the input shaft with a bearing puller. 1 2 Figure 41 1. Governor plate assembly 2. Governor base IMPORTANT: Make sure not to damage the screw heads when removing screws. Each screw is secured with an adhesive. Drive Train C. Remove screws securing the governor plate assembly to the governor base.
1 4 2 6 3 5 Figure 42 1. Input shaft 2. Ball bearing 3. Governor plate (weight) 4. Governor sleeve 5. Lock pin 6. Screw F. Replace governor plate if cracked, bent, or any weight is missing. Weights must swing freely. D. Replace input shaft if worn or damaged. Gear teeth that are cracked, broken, chipped or missing are not acceptable. G. Replace governor sleeve if cracked or worn. E. Ball bearing roller balls must be free of deformation and scoring.
8 5 3 8 2 1 7 6 4 9 1 Figure 44 1. 2. 3. 4. 5. Gear 55 Gear 47 Gear (small) Ball bearing Ball bearing 6. 7. 8. 9. B. Remove gears, pin clutch, collars, and spacer from the input shaft. C. Replace gears if worn or damaged. Cracked, broken, missing, or chipped gear teeth are not acceptable. D. Replace center shaft if worn or damaged. Splines that are cracked, broken, chipped or missing are not acceptable. Drive Train Pin clutch Center shaft Collar Spacer E.
6. Disassemble differential case assembly. 1 2 3 Figure 45 1. Bolt 2. Gear 62 3. Differential case A. Remove bolts securing gear 62 to the differential case. 4 1 4 Drive Train 3 2 Figure 46 1. Spring pin 2. Differential case 3. Pinion shaft 4. Pinion gear Note: The spring pin can be punched out from the hole on the opposite side of gear 62. C. Remove pinion shaft and gears from the case. Separate gears from shaft. B. Remove spring pin from the differential case.
4 5 3 2 6 8 1 7 Figure 47 1. 2. 3. 4. Side gear Pinion gear Gear 34 Ball bearing 5. 6. 7. 8. Differential case Pinion shaft Spring pin Bolt D. Replace gears if worn or damaged. Cracked, broken, missing, or chipped gear teeth are not acceptable. F. Replace case if machined areas where the side and pinion gears mesh are scored or if the pinion shaft fits loosely in its bore. E. Ball bearing roller balls must be free of deformation and scoring.
7. Disassemble governor fork and shaft. 3 4 2 1 Figure 48 3. Governor fork 4. Case (RH) IMPORTANT: Make sure not to damage the screw heads when removing screws. Each screw is secured with an adhesive. A. Remove both screws and washers securing the stopper and governor fork to the case (RH). Remove stopper and fork from the case. Drive Train 1. Screw 2. Stopper 1 3 2 Figure 49 1. Governor shaft 2. Boss 3.
2 5 6 4 1 3 Figure 50 1. Ball bearing 2. Case (RH) 3. Governor shaft 4. Governor fork 5. Stopper 6. Screws D. Remove ball bearing from the case. Ball bearing roller balls must be free of deformation and scoring. Ball bearing must spin freely and have minimum axial play. Replace ball bearing as necessary. Drive Train E. Replace governor shaft if cracked, bent, or excessively worn. F. Replace governor fork or stopper if bent or deformed.
Assembly 1. Assemble input shaft assembly. 4 1 3 12 to 16 in–lb (1.4 to 1.8 N–m) 2 Figure 51 1. Governor plate 2. Governor base 3. Screw 4. Governor sleeve A. Secure governor plate unit to the governor base with screws. Torque screws from 12 to 16 in–lb (1.4 to 1.8 N–m). Drive Train IMPORTANT: To prevent the screws that secure the governor plate to the governor from loosening, apply Loctite Blue No. 242 or equivalent to the screw threads. 1 2 Figure 52 1. Ball bearing 2.
1 2 Figure 53 1. Governor sleeve 2. Input shaft C. Apply molybdenum disulfide grease to the inside of the governor sleeve. Slide sleeve onto the input shaft. 1 2 Figure 54 1. Pivot point 2. Governor plate D. Make sure to apply molybdenum disulfide grease to the pivot points of the weights on the governor plate unit.
2. Assemble the center shaft assembly. 3 4 1 7 8 6 9 5 5 2 136.8 to 137.1 mm Figure 55 Note: Before assembling, apply molybdenum disulfide grease to the inside of gears 47 and 55. A. Slide pin clutch onto the centershaft. Install gears 47 and 55 onto shaft noting correct orientation of gears. Slide collars, small gear, and spacer onto the center shaft. 1 2 Figure 56 1. Ball bearing 2. Ball bearing B. Press ball bearings onto the center shaft using a bearing press.
C. Make sure distance from one ball bearing outer edge to the other ball bearing outer edge is 136.8 to 137.1 mm (Fig. 55). Figure 57 D. The center shaft should appear as above when assembled. 3. Assemble differential assembly. 5 6 2 1 4 8 9 3 3 7 1 123.3 to 124.0 mm Figure 58 1. 2. 3. 4. 5. Drive Train Pinion gear (greased surface) Pinion shaft Side gear (greased surface) Differential case Gear 62 6. 7. 8. 9.
A. Apply molybdenum disulfide grease to the inside of both pinion gears where they contact the pinion shaft. Apply molybdenum disulfide grease to the out- side of both side gears where they contact the differential case and gear 62. 1 4 3 2 Figure 59 1. Side gear 2. Pinion gear 3. Pinion shaft 4. Differential case B. Install side gear, both pinion gears, and pinion shaft into the differential case. Drive Train 1 2 Figure 60 1. Spring pin 2. Differential case C.
3 1 2 4 Figure 61 1. Side gear 2. Pinion gear 3. Gear 62 4. Differential case D. Install remaining side gear to the pinion gears. E. Secure gear 62 to the differential case with bolts. Torque bolts from 40 to 45 ft–lb (54 to 61 N–m) in a criss–cross pattern. 40 to 45 ft–lb (54 to 61 N–m) Figure 62 IMPORTANT: The length from the outer most side of each ball bearing must be from 123.3 to 124.0 mm (Fig. 58). G. The differential assembly should appear as above when assembled. F.
4. Assemble governor fork. 2 1 Figure 63 1. Ball bearing 2. Case (bore) A. Install ball bearing into the bore of the case (RH). Drive Train 1 2 Figure 64 1. Governor shaft 2. IMPORTANT: Make sure not to damage the oil seal when installing the governor shaft into the governor boss. Boss B. Lubricate governor shaft with molybdenum disulfide grease before installing. C. Install governor shaft into the boss.
3 4 2 1 Figure 65 1. Screw 2. Stopper 3. 4. Governor fork Case (RH) D. Secure stopper and governor fork to the governor shaft with both screws. IMPORTANT: To prevent the screws that secure the governor fork and stopper to the governor shaft from loosening, apply Loctite Blue No. 242 or equivalent to the screw threads. 12 to 16 in–lbs (1.4 to 1.8 N–m) 0.5 mm 3 2 1 Figure 66 1. Governor fork 2. Governor shaft (greased surface) E. Adjust governor fork center to the center of the ball bearing hole.
5. Install axle case to case (RH and LH). 2 3 1 Figure 67 1. Axle shaft 2. Snap ring 3. Ball bearing IMPORTANT: Do not reuse snap ring. Replace snap ring with new one. 1 3 Drive Train 25 to 31 ft–lb (34 to 42 N–m) A. Insert axle shaft with snap rings, collar, and ball bearings into the axle case. Install snap ring to the axle case. 2 Figure 68 1. Axle case 2. Case 3. Flange bolt IMPORTANT: Make sure to install the axle case to the proper side of the case.
6. Install input shaft, center shaft, and differential assemblies to the case. 1 2 Figure 69 1. Shift shaft 2. Clutch groove A. Insert fork of the shift shaft to the clutch groove of the center shaft assembly. 4 1 3 2 Figure 70 1. Center shaft assembly 2. Shift shaft 3. Input shaft 4. Differential assembly B. Replace oil seals for the input and selector shafts on the case (LH) if cracked, nicked, or distorted such that they would not hold a proper seal.
1 2 Figure 71 1. Fork (selector shaft) 2. Pin (shift shaft) D. Make sure the selector shaft fork is contacting the pin on the shift shaft. Drive Train 1 2 Figure 72 1. Spacer 2. Boss (counter shaft) E. Place spacer on the counter shaft boss of the case (LH) so the oil groove faces up.
2 3 1 Figure 73 1. Gear 34 2. Counter shaft 3. Spacer F. Apply molybdenum disulfide grease to the inside of gear 34 and the contact surface between the case and the counter shaft. G. Place gear 34 onto the spacer. Make sure not to drop the spacer. Insert needle bearing into gear. Insert counter shaft with remaining spacer through the needle bearing, gear 34, and into the spacer and case. 7. Assemble case (LH and RH). 2 1 2 Figure 74 1. Case (sealing surface) 2. Pipe knock A.
1 2 15 to 18 ft–lb (21 to 25 N–m) Figure 75 1. Governor shaft 2. Bolt C. Install case (RH) so each shaft fits properly into the case. Note: When installing case (RH) to the case (LH), hold governor shaft so the ball bearing will not drop off. Keep the gasket sealing surfaces of the cases as horizontal to each other as possible. If the sealing surfaces do not join to each other, tap the case lightly with a plastic hammer. Drive Train D. Secure case (RH) to case (LH) with bolts.
12 to 15 ft–lb (16 to 20 N–m) 2 1 Figure 77 1. Cable bracket 2. Bolt (steel ball, spring, & gasket) H. Fill transaxle with 1.5 quarts (1.4 liters) of new 10W–30 motor oil. F. Install cable bracket to the transaxle. G. Install steel ball, spring, gasket, and bolt. Torque bolt from 12 to 15 ft–lb (16 to 20 N–m).
Chapter 6 Electrical System Table of Contents SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter/Generator . . . . . . . . . . . . . . . . . . . . . . . . . . Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starter/Generator Service . . . . . . . . . . . . . . . . . . . Brush and Brush Spring Service . . . . . . . .
Electrical Schematics The electrical schematics and other electrical drawings for the Workman 1100, 1110, 2100, and 2110 are located in Chapter 8 – Electrical Diagrams. Electrical System Page 6 – 2 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. Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this vehicle (see Wiring Schematics in Chapter 8). 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 vehicle has any interlock switches by–passed, they must be reconnected for proper troubleshooting and safety.
General Run Problems Problem Possible Causes Battery does not charge. Wiring to the charging circuit (see Wiring Schematics) components is loose, corroded, or damaged. Voltage regulator and/or starter/generator is faulty. Battery is dead. Engine kills during operation. Wiring to the run circuit (see Wiring Schematics) components became broken or disconnected. RPM shutdown module is faulty (Workman 2100 and 2110). Electrical System Engine or fuel system is malfunctioning (see Engine Chapter).
Electrical System Quick Checks Battery Test Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100o F. The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (–) meter lead the the negative battery post. 12.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check on the switch). NOTE: See the Briggs and Stratton Repair Manual for 4 Cycle, V–Twin Cylinder, OHV Head Engines or the Kohler Service Manual for Command Pro CS Series Engines for additional component testing information.
Hour Meter IMPORTANT: Make sure to observe polarity on the hour meter terminals when testing. Damage to the meter may result from an improper connection. 1. Isolate hour meter from the circuit. QUARTZ 2. Connect positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. 00000 RUNNING: INDICATOR WINDOW 1 – 10 HOURS 3. Connect negative (–) terminal of the voltage source to the other terminal of the hour meter.
Starter Solenoid NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually 0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from the measured value of the component you are testing. 1 1. Make sure engine is off. Disconnect battery. Disconnect solenoid electrical connections. 2 2.
Starter/Generator & Voltage Regulator 1. Place machine in the NEUTRAL position (see Operator’s Manual). Set parking brake. 7. Reconnect green wire connector from the regulator and test voltage regulator: 2. Raise bed and secure with prop rod. Gain access to electric components by removing the electrical cover. A. Set multimeter to VDC. Connect red (+) probe of the multimeter into the green wire connection. Connect black (–) probe of the multimeter to a known good ground. 3.
Starter/Generator Testing of starter/generator field and armature windings is difficult with the starter/generator still mounted in the Workman. Follow the procedures for Starter Generator & Voltage Regulator Component Testing prior to removing the starter generator for further testing and repairs. Starter generator resistance tests are as follows: NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together.
Accelerator Switch The accelerator switch is a four terminal, two circuit switch. When the accelerator pedal is pushed, the switch allows current flow to the start/run solenoid, hour meter, and engine oil indicator and provides an open circuit to the engine ignition system. With the accelerator pedal released, the switch provides a grounding circuit for the engine ignition system and prevents current flow to the start/run solenoid, hour meter, and engine oil indicator. 2 1 END VIEW 6 4 3 Testing 1.
Diode Assembly The diode D1 (Fig. 15) is used to protect the ignition switch from voltage spikes that can occur when the starter solenoid is de–energized. The diode plugs into the wiring harness. 2 Testing The diode can be tested using a digital multimeter (diode test or ohms setting) and the table to the right. 3 1 Figure 15 1. Diode 2. Male terminal 3.
Oil Pressure Switch (Workman 2100/2110) The oil pressure switch is located on the mounting adapter for the oil filter. It is a normally closed switch and opens with pressure. 1 Oil pressure switch testing 1. Turn the ignition switch to ON. The oil indicator light should be on. 2. If the light is not on, disconnect the wire from the oil pressure switch and ground the wire to the engine block. 3. If the light comes on, the oil pressure switch is bad. 4.
Service and Repairs NOTE: For more component testing information, see the Briggs and Stratton Vanguard Service and Repair Manual for 4–Cycle, V–Twin Cylinder, OHV Engines or the Kohler Service Manual for Command Pro CS Series Engines. Headlights Specification: GE Headlight #H7610 1. Set parking brake, turn ignition off, and remove key. 2. Reach beneath dash and push headlight out of the hood. 3. Remove screws attaching the wire harness to the headlight. 4. Remove rubber seal from around the headlight.
Starter/Generator Removal WORKMAN 2100/2110 1. Park vehicle on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 4 2 3 6 2. Raise bed and secure with prop rod to gain access to the starter/generator. NOTE: Place all fasteners back onto starter/generator terminals after disconnecting wires to prevent loss of fasteners. 3. Label all wires on the starter/generator. Disconnect all wires from the starter/generator. 4.
Installation 1 9 1. Install pulley to the starter/generator shaft (Fig. 21). 10 A. Position spacer and woodruff key onto the shaft. Place pulley onto the shaft. B. Secure pulley to the shaft with spring washer and nut. Torque nut from 15 to 25 ft–lb (20 to 34 N–m). 8 2 7 6 4 15 to 25 ft lbs (20 to 34 N–m) 2. Position starter/generator to the engine mount. A. Insert pivot bolt through the engine mount, starter/generator front bracket, pivot, and starter/generator rear bracket. B.
Starter/Generator Service 8 16 21 7 22 24 23 19 20 WIRING DIAGRAM MOTOR 17 18 F2 13 FIELD(STATOR) F1 ARMATURE (ROTOR) A2 DF REG. 12 A1 9 14 1 6 3 2 15 to 25 ft–lb (20 to 34 N–m) 10 11 4 5 95.5 to 104 in–lb (10.8 to 11.8 N–m) 35 to 43 in–lb (4.0 to 4.9 N–m) 15 26 8 23 24 1 2 16 17 14 7 9 27 5 10 11 3 1. 2. 3. 4. 5. 6. 7. 8. Yoke Armature kit Ball bearing Bearing retainer Ball bearing Spacer Through bolt & flat washer Brush cover Electrical System Figure 22 9.
Brush and Brush Spring Service (Fig. 22) IMPORTANT: When removing or installing the commutator end cover, make sure brushes do not contact the commutator. Damage to the brushes may result. 10.Slide brushes into holders. Secure brushes by positioning brush springs into the notch at the end of the brushes (Fig. 25). 11. Install brush covers to the commutator end cover. 1. Remove brush covers from the commutator end cover.
6. Clean and inspect commutator. Armature and Field Coil Service (Fig. 22) A. Remove carbon dust, dirt, and oil from the commutator. IMPORTANT: When removing the commutator end cover, make sure brushes do not contact the commutator. Damage to the brushes may result. B. Lightly remove slight roughness, burning, or glazing of the commutator with 400 grit (or finer) sandpaper. Clean commutator after sanding. 1. Remove brush covers from the commutator end cover.
I. Position commutator end cover carefully to the commutator and yoke. Align end cover to the yoke with the locating pin. IMPORTANT: Do not remove field coils unless they are to be replaced. 10.To remove field coils (Fig. 27): J. Secure both end covers to the yoke with both through bolts and flat washers. Torque bolts from 95.5 to 104 in–lbs (10.8 to 11.8 N–m). A. Remove nuts from threaded terminal, and slide insulator and terminal out of yoke. B.
Rework Starter/Generator (Fig. 22) NOTE: Rework to the starter/generator must be performed by a properly trained technician using the correct tools and equipment for testing and reworking electrical motors and generators. It may be more economically feasible to replace the starter/generator than have it reworked. Detail Specification Minimum commutator diameter 1.575 inches (40mm) Commutator concentricity to the shaft 0.0003 inch (0.008 mm) Commutator machining limit per cut 0.005 inch (0.
Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. FILLER CAPS CAP TUBES CORRECT WATER LEVEL COVER SEAL WARNING Electrolyte Specific Gravity Fully charged: 1.265 corrected to 80oF (26.7oC) Discharged: less than 1.240 Battery Specifications BCI Group Size UI: 300 Amp Cranking Performance at 0o F (–17.8oC) Reserve Capacity at 25 Amps and 80oF (26.
IMPORTANT: Before cleaning the battery, tape or block the vent holes to the filler caps and make sure the caps are on tightly. C. Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap, overcharging, loose terminal post, or overfilling. Also, check the battery case for dirt and oil. Clean the battery with a solution of baking soda and water, then rinse it with clean water. D. Check that the cover seal is not broken away.
IMPORTANT: To prevent possible electrical problems, install only a fully charged battery. Battery Charge Level Specific Gravity Open Circuit Voltage 100% 1.265 12.68 75% 1.225 12.45 50% 1.190 12.24 25% 1.155 12.06 0% 1.120 11.89 1. Make sure the ignition switch and all accessories are off. 2. Make sure the battery base is clean and repainted if necessary. 3. Make sure battery cables, battery connections, and the battery hold down strap are in good condition. 4.
4. Charge the battery following the manufacturer’s instructions. 5. Occasionally check the temperature of the battery electrolyte. If the temperature exceeds 125oF (51.6oC) or the electrolyte is violently gassing or spewing, the charging rate must be lowered or temporarily stopped. 6. Three hours prior to the end of the charging, measure the specific gravity of a battery cell once per hour. The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0.
Chapter 7 Chassis, Wheels, and Brakes Table of Contents A--arm and Frame Pivot Yoke . . . . . . . . . . . . . . . . 22 Rear Wheels and Brakes (Workman 1100 and 2100) . . . . . . . . . . . . . . . . . 26 Rear Brake Service (Workman 1100 and 2100) . 28 Parking Brake (Workman 1110 and 2110) . . . . . . 30 Rear Wheels and Brakes (Workman 1110 and 2110) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Rear Brake Service (Workman 1110 and 2110) .
Specifications Item Description Workman 1100 front tire (20 x 10 – 8, 4 ply) pressure 6 to 12 PSI (0.41 to 0.83 bar) Workman 1100 rear tire (22.5 x 10 – 8, 4 ply) pressure 8 to 22 PSI (0.55 to 1.52 bar) Workman 2100 front tire (22.5 x 10 – 8, 4 ply) pressure 8 to 22 PSI (0.55 to 1.52 bar) Workman 2100 rear tire (25 x 12 – 9, 4 ply) pressure 8 to 22 PSI (0.55 to 1.52 bar) Workman 1110 and 2110 front tire (22 x 9.5 – 10, 4 ply) pressure 8 to 22 PSI (0.55 to 1.
Troubleshooting Suspension and Steering ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Suspension and Steering (continued) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Problem Possible Cause Steering
Brakes ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ
Brakes (continued) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ
Adjustments Adjust Brakes (Workman 1100 and 2100, Serial Number Below 230000000) CAUTION Before and after adjusting the brakes, always check the brakes in a wide open area that is flat and free of other persons and obstructions. 1. While driving the machine, depress brake pedal. Both wheels should lock equally. 2. Park machine on a level surface. Make sure engine is off. Remove key from ignition switch.
Adjust Brakes (Workman 1100 and 2100, Serial Number Above 230000000) The recommended brake pedal travel is from 1” to 1 1/2” (25.4 to 38.1 mm) with a 75 to 100 pound (34 to 45.4 kg) input force to the brake pedal. 1 Adjustment Procedure (Fig. 2) 2 1. Park vehicle on a level surface, turn on/off switch OFF and remove key from the on/off switch. 3 4 2. Depress brake pedal lightly (10 to 15 pound input force) until resistance is achieved.
Adjust Parking Brake (Workman 1110 and 2110) 1. Pry the rubber cover off of the parking brake. 2. Loosen the set screw securing the knob to the parking brake lever (Fig. 3). 1 3. Rotate the knob until a force of 30–35 lb. (133–156 N) is required to actuate the lever. 2 4. Tighten the set screw and install the rubber cover. 3 Figure 3 1. Parking brake lever 2. Brake knob 3. Set screw Check Front Ride Height 1. Adjust tire pressures to 12 psi before checking front ride height. 2.
Adjust Front Ride Height 1. If front ride height adjustment is needed, park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 1 2 WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 4 2. Jack front end of the vehicle off the ground. 3 2 3. Remove travel limiting bolt (Fig. 5). 4. Loosen centering bolts (front and rear) in the A–arm (Fig. 5). 5. Remove ride height adjustment bolt (Fig. 6).
Adjust Front Wheel Toe–in Note: Adjust front wheel ride height before checking or adjusting front wheel toe–in. 6 1. Adjust tire pressures to 12 psi before checking front wheel toe–in. 1 5 2. With a 175 to 225 lb (79 to 102 kg) operator in the driver’s seat, drive vehicle back and forth a few times on a level surface to relax suspension. 3. Stop vehicle. With operator still in driver’s seat and wheels pointed straight ahead, measure the front wheel toe–in. 4.
This page is intentionally blank. Chassis, Wheels, and Brakes (Rev.
Service and Repairs Check Tire Pressure See Specifications for tire pressure range for front and rear tires. paction and tire marks are minimized. Lower pressure should not be used for heavy payloads at high speeds. The air pressure needed is determined by the payload carried. The lower the air pressure, the less the com- Higher pressures should be used for heavier payloads at higher speeds. Do not exceed the maximum tire pressure.
Upper Steering 14 2 3 13 Antiseize lubricant 1 10 15 13 to 17 ft--lb (18 to 23 N--m) 11 12 10 4 9 8 7 6 Antiseize lubricant 4 5 16 1. 2. 3. 4. 5. 6. Nut Lock washer Steering wheel Flanged lock nut Steering gearbox Cap screw 7. 8. 9. 10. 11. Figure 10 Washer Steering shaft Cap screw Upper steering bushing Carriage screw Removal 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 2.
5. Remove four flange lock nuts and carriage screws securing the steering column to the mounting plate on the frame. 6. Remove dust cover from the steering shaft. Replace cover if damaged. Slide steering shaft out of the steering column. 7. Disconnect both tie rods from the Pitman arm on the steering gearbox (see Lower Steering and Front Wheel Removal). 8. Remove flange lock nuts and cap screws securing the steering gearbox to the tower plate on the front frame. Remove gearbox from the tower plate.
Steering Gearbox 27 to 33 ft–lb (37 to 44 N–m) 9 90 to 110 in–lb (10.2 to 12.4 N–m) 8 3 6 2 18 17 15 10 16 7 14 6 1 11 175 to 225 in–lb (20 to 25 N–m) 10 12 4 5 19 13 Matchmark before disassembly Figure 11 1. 2. 3. 4. 5. 6. 7. Gasket Hex washer head screw Seal Sector gear Flat washer Ball bearing Output shaft spacer 8. 9. 10. 11. 12. 13. Chassis, Wheels, and Brakes (Rev.
Disassembly IMPORTANT:Do not reuse flange head screw with patch lock after it has been removed. 1. Remove flange head screw with patch lock and stepped washer from Pitman arm. Discard flange head screw. 2. Remove cap screw and flat washer from pinion gear shaft. 3. Remove hex washer head screws securing the housing cover and gasket to the steering housing. Remove cover and gasket from the housing. Replace gasket if damaged. 4. Inspect gears.
Lower Steering and Front Wheels (Workman 1100 and 2100) 15 16 17 18 19 13 20 to 25 ft–lb (27 to 34 N–m) 13 20 24 25 26 12 13 26 24 9 24 11 Antiseize lubricant 23 22 14 20 to 25 ft–lb (27 to 34 N–m) 135 to 165 ft–lb (183 to 224 N–m) 7 21 1 2 8 13 7 6 RIGHT 24 FRONT 75 to 100 ft–lb (102 to 136 N–m) 5 11 4 10 3 Thread locking compound Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. Tire Front wheel Plastic dust cap Cap screw Large flat washer Flat washer Bearing Spacer Spindle (LH) 10.
2. Install tire and front wheel as follows: Installation A. Place antiseize lubricant on spindle shaft. 1. Install spindle as follows: A. Position king pin sleeve into the pivot hub of the A–arm. Spacer must extend through the bottom of the hub. B. Place thrust washer onto the bottom of the king pin sleeve. Then position spindle over the hub, king pin sleeve, and thrust washer. B. Slide tire and wheel assembly onto the shaft with the valve stem facing out.
Lower Steering and Front Wheels (Workman 1110 and 2110) 36 28 27 30 29 25 26 33 21 34 32 31 35 20 36 23 25 20 to 25 ft–lb (27 to 34 N–m) 24 24 19 40 21 Thread locking Compound 16 22 39 38 20 to 25 ft–lb (27 to 34 N–m) 14 13 18 12 10 17 18 ft–lb (24 N–m) 45 to 65 ft–lb (61 to 88 N–m) 9 8 7 37 5 11 15 75 to 100 ft–lb (102 to 136 N–m) RIGHT 6 4 FRONT 3 2 1 Figure 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
D. Insert tie rod ball joints down through the spindle and up through the Pitman arm. Secure with castle nuts. 3. Remove lug nuts and pull wheel assembly from machine. 4. Remove brake caliper from spindle (see Front Brake Caliper). Position caliper away from wheel hub and spindle. E. Torque castle nuts from 20 to 25 ft–lb (27 to 34 N–m) to secure ball joint while aligning castle nut slot with hole in ball joint stud. If necessary to align holes, castle nut torque may be slightly more than specification.
A–arm and Frame Pivot Yoke 1 23 240 to 290 ft–lb (325 to 393 N–m) 2 3 34 5 31 32 30 1 4 6 5 29 27 26 24 23 7 12 33 28 35 8 10 9 11 13 14 27 25 15 22 18 24 19 23 27 20 21 RIGHT 16 FRONT 17 27 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Flange lock nut Light duty hitch Flange head screw Decal Decal Rear frame Retaining ring Decal R–clamp Flange head screw Flange nut Flat washer Chassis, Wheels, and Brakes (Rev. B) 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
A–arm Removal (Fig. 14 and 15) 1 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. WARNING 4 Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 3 2. Chock wheels not being jacked up. Jack front wheel off the ground and place blocks beneath the frame. 3. Remove front wheel and spindle from A–arm (see Lower Steering and Front Wheel Removal). 4.
Pivot Yoke Removal (Fig. 14 and 17) 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 2. Remove cargo bed from the rear frame (see Cargo Bed and Tailgate Removal). 3. Remove seat base from the front frame (see Seat Base Removal in Engine Chapter). 3. Secure pivot yoke to the rear frame with four cap screws and flat washers. 4. Install seat base to the front frame (see Seat Base Installation in Engine Chapter). 5.
Chassis, Wheels, and Brakes This page is intentionally blank. Workman 1100/1110/2100/2110 Page 7 – 25 Chassis, Wheels, and Brakes (Rev.
Rear Wheels and Brakes (Workman 1100 and 2100) 13 11 20 ft–lb (27 N–m) 9 12 8 7 120 to 200 ft–lb (163 to 271 N–m) 2 6 14 45 to 65 ft–lb (61 to 88 N–m) 4 Antiseize Lubricant 15 3 16 10 5 1 RIGHT FRONT 1. 2. 3. 4. 5. 6. Lug nut Wheel assembly Wheel hub Brake drum Cotter pin Castle nut Chassis, Wheels, and Brakes (Rev. B) 7. 8. 9. 10. 11. Figure 18 Lock washer Spacer Cap screw Brake cable Clevis pin Page 7 – 26 Rev. A 12. 13. 14. 15. 16.
Removal (Fig. 18) 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 5. Torque castle nut to the shaft between 120 to 200 ft– lb (163 to 271 N–m) while aligning nut to hole in shaft. Install cotter pin. 6. Slide brake drum onto wheel hub. 7. Position wheel assembly to the machine with valve stem facing out and secure with five lug nuts.
Rear Brake Service (Workman 1100 and 2100) 9 6 3 5 7 6 6 2 1 2 9 7 7 ROTATION TO EXPAND BRAKE SHOES 4 12 9 18 1 17 17 19 11 7 5 16 15 7 10 14 3 7 7 8 13 1. 2. 3. 4. 5. 6. 7. 8 Backing plate Hold down pin Top shoe–to–shoe spring Bottom shoe–to–shoe spring Auto adjust spring Shoe cup (spring loaded) Brake shoe 1 Figure 20 8. Actuator lever 9. Adjusting screw 10. P TFE coated washer 11. Push rod 12. Shim washer 13. Protective boot Chassis, Wheels, and Brakes (Rev.
Disassembly (Fig. 20) 1. Remove auto adjust spring and shoe–to–shoe springs from brake shoes. 2. Remove hold down pins and shoe cups securing the brake shoes to the backing plate. 3. Inspect backing plate surfaces, which contact with the brake shoes for grooves that may restrict shoe movement. Replace plate if grooves can not be removed by light sanding with emery cloth or other suitable abrasive. Replace plate if cracked, warped, or excessively rusted. 4.
Parking Brake (Workman 1110 and 2110) 11 10 8 2 1 9 7 6 17 16 5 14 4 12 3 15 13 RIGHT FRONT Figure 21 1. 2. 3. 4. 5. 6. Parking brake cover Operator seat Seat base Cable equalizer bracket Parking brake lever Curved washer 7. 8. 9. 10. 11. 12. Chassis, Wheels, and Brakes (Rev. B) Lock nut Flat washer Flange head screw (4 used) Flat washer (2 used) Screw (2 used) Cap screw Page 7 – 30 13. 14. 15. 16. 17.
Disassembly (Fig. 21) Assembly (Fig. 21) 1. Park machine on a level surface, stop engine, and remove key from the ignition switch. Chock wheels to prevent the machine from moving. 1. Secure brake cables to parking brake support and cable equalizer bracket using Figure 21 as a guide. 2. Disconnect both brake cables from rear of machine: A. Remove cotter pin and clevis pin that secures each brake cable end to brake lever. B. Remove retaining ring that secures each brake cable to frame. C.
Rear Wheels and Brakes (Workman 1110 and 2110) 11 20 ft–lb (27 N–m) 8 10 7 120 to 200 ft–lb (163 to 271 N–m) 5 13 1 17 4 12 18 19 RIGHT 6 16 14 15 Antiseize Lubricant 3 20 45 to 65 ft–lb (61 to 88 N–m) FRONT 2 9 Figure 22 1. 2. 3. 4. 5. 6. 7. Wheel assembly Lug nut Castle nut Brake drum Socket head screw Brake assembly (LH shown) Clevis pin 8. 9. 10. 11. 12. 13. 14. Chassis, Wheels, and Brakes (Rev.
Removal (Fig. 22) 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. WARNING IMPORTANT:Do not get antiseize lubricant onto brake shoes. 3. Apply light coat of antiseize lubricant to the transaxle shaft splines. 4. Secure wheel hub to the shaft with washer, spring washer, and castle nut. 5. Torque castle nut from 120 to 200 ft–lb (163 to 271 N–m) while aligning nut to hole in transaxle shaft. 2. Chock wheels not being jacked up.
Rear Brake Service (Workman 1110 and 2110) 110 to 120 in–lb (12.4 to 13.6 N–m) 6 110 to 120 in–lb (12.4 to 13.6 N–m) 3 8 2 9 11 10 7 11 5 10 12 1 13 8 7 110 to 120 in–lb (12.4 to 13.6 N–m) 4 3 12 Figure 23 1. 2. 3. 4. 5. 6. 7. 8. 9. Brake backing plate Washer head screw Brake shoe Lower spring Wheel cylinder Parking brake lever (LH shown) Belleville washer Adjuster lever Dust cover 10. 11. 12. 13. Flat washer Bolt Shoe hold down cup and spring Upper spring 4.
Inspection (Fig. 23) Assembly (Fig. 23) 1. Inspect brake drums. IMPORTANT:Brake shoe lining surfaces must be free of grease, oil, and other foreign matter. 1. Apply a light film of lubricant to the following: A. Ledges on which the brake shoes rest. A. Clean drums with denatured alcohol. Check braking surface diameter in at least three places. If the diameter exceeds 6.320 inches (16.05 cm), replace both brake drums. B.
Front Brake Calipers (Workman 1110 and 2110) 10 9 Thread locking Compound 8 7 2 45 to 65 ft–lb (61 to 88 N–m) 6 13 4 5 3 RIGHT 1 18 ft–lb (24 N–m) 12 FRONT 11 Figure 24 1. 2. 3. 4. 5. LH brake caliper RH brake caliper Lock washer (2 per caliper used) Cap screw (2 per caliper used) Wheel hub assembly 6. 7. 8. 9. Chassis, Wheels, and Brakes (Rev. B) Brake rotor Socket head screw (4 per rotor used) Spindle (LH shown) A–arm (LH shown) Page 7 – 36 10. 11. 12. 13.
Removal Installation 1. Park machine on a level surface, stop engine, set parking brake, and remove key from the ignition switch. 1. Slide brake caliper onto brake rotor. Make sure that rotor is between brake pads. 2. Align caliper mounting holes with spindle. Secure caliper with cap screws and lock washers. Torque screws 18 ft–lb (24 N–m). WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 – Safety. 2. Chock wheels not being jacked up.
Front Brake Caliper Service (Workman 1110 and 2110) (Serial Number Below 240000000) 3 2 4 1 3 12 16 13 8 7 5 9 14 6 10 11 15 1. 2. 3. 4. 5. 6. 72 to 94 in--lb (8.1 to 10.8 N--m) Caliper bracket Caliper housing Rubber spring O--ring Inner brake pad Outer brake pad 7. 8. 9. 10. 11. Figure 25 Piston plug Oval piston Round piston Square seal Gasket 12. 13. 14. 15. 16. Cover (LH shown) Bleeder screw Seat insert Cover screw (4 used) Cap Disassembly (Fig. 25) Inspection 1.
Assembly (Fig. 25) 1. Coat round piston with a small amount of silicone grease and coat square seal with clean brake fluid. 6. Position gasket and cover to housing. Secure cover to housing with four cover screws. Torque screws from 72 to 94 in--lb (8.1 to 10.8 N--m). 2. Install square seal and round piston into cover. 7. If removed, press piston plugs into oval piston and place rubber springs to housing. 3. Insert o--ring into bore of caliper housing. 8. Apply light coat of grease to rubber springs.
Brake Master Cylinder (Workman 1110 and 2110) 1 4 2 5 3 6 7 RIGHT FRONT Figure 26 1. Master cylinder 2. Cap screw 3. Brake pedal 4. Clevis pin 5. Cotter pin 6. Flange head nut 7. Pedal frame Removal Installation 1. Remove front hood from machine. 1. Position master cylinder to pedal frame and secure with cap screws and flange nuts. 2. Remove cotter pin from the clevis pin that connects master cylinder to brake pedal. 3.
Brake Master Cylinder Service (Workman 1110 and 2110) Disassembly (Fig. 27) 1 1. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 2 12 3 2. Disconnect lower end of the dust cover from the housing. 3. Push in on the push rod and remove circlip, then remove push rod with dust cover and clevis. Remove retainer washer. 4 11 4. Remove primary piston assembly and secondary piston assembly from cylinder housing. Inspection 1.
Hydraulic Brake System (Workman 1110 and 2110) 11 13 14 16 16 24 10 19 12 21 17 2 26 5 26 20 4 6 11 18 16 15 11 9 32 7 32 25 23 8 27 RIGHT 31 32 22 18 ft–lb (24 N–m) 28 29 30 25 FRONT Thread locking Compound 3 1 Figure 28 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Brake caliper (LH) Brake caliper (RH) Brake rotor Front brake tube Front brake hose Carriage screw Rear brake tube Carriage screw Rear brake hose bracket Cap screw Thread forming screw 12. 13. 14. 15. 16. 17. 18. 19.
Bleed Brake System (Workman 1110 and 2110) 1. Connect a suitable transparent hose to bleeder valve on wheel cylinder or caliper and submerge other end of hose in a glass container partially filled with clean brake fluid. 5. Repeat steps 1 to 4 for other brake cylinders and calipers. CAUTION 2. Have a helper pump brake pedal several times, then hold pedal down firmly. 3. With pedal firmly depressed, open bleeder valve of brake until pedal fades to floor. Close bleeder valve before releasing pedal. 6.
Front Hood 30 2 3 4 1 6 7 8 9 16 26 29 11 18 25 24 23 21 28 27 10 12 15 11 13 14 12 22 11 12 19 20 15 17 32 5 31 RIGHT FRONT 16 11 12 Figure 29 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Decal Power point Cap Ignition switch Ignition key Hole plug Oil light Light switch Hourmeter Decal Hex flange head screw 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Cargo Bed and Tailgate 1 2 3 16 23 6 7 8 9 10 11 4 4 10 5 14 12 13 14 14 35 34 14 19 15 33 22 20 32 17 28 RIGHT 21 18 14 24 FRONT 27 31 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Tailgate rod (RH) Tailgate latch bracket (RH) Tailgate Cap screw Striker plate (LH) Decal Tailgate rod (LH) Screw Tailgate latch bracket (LH) Latch washer Spring Tailgate pivot bracket 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
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Chapter 8 Electrical Diagrams Table of Contents Main Electrical Harness Wiring Diagram: Workman 1100 and 2100 (Serial No. From 230000001 To 230999999) Workman 2110 (Serial No. From 220000001 To 230999999) . . Main Electrical Harness Drawing: Workman 1100, 1110, 2100 and 2110 (Serial No. Above 240000000) . . . . . . . . . . . . . . Main Electrical Harness Wiring Diagram: Workman 1100, 1110, 2100 and 2110 (Serial No. Above 240000000) . . . . . . . . . . . . . .
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Workman 1100 and 1110 Electrical Schematic Solenoid is shown de–energized Page 8 – 3 (Rev.
2 1 VIO GY REVERSE SWITCH .
Workman 2100 and 2110 (Serial Number Over 220000000) Electrical Schematic Solenoid is shown de–energized Page 8 – 5 (Rev.
Start Circuits (Workman 2100 Schematic Shown) Power Current Control Current Indication Current Current Direction Page 8 – 6 (Rev.
Run Circuits (Workman 2100 Schematic Shown) Power Current Control Current Indication Current Current Direction Page 8 – 7 (Rev.
HEADLIGHT (+) J3 RS (–) J4 NEUTRAL SWITCH C P5 1 NO NC 2 3 1 1 (+) 3 2 (–) 8 5 6 3 1 4 1 2 ACCELERATOR P4 4 4 3 OPTIONAL KIT P13 J9 B+ 2 3 POWER POINT P1 2 1 3 3 4 2 FUSES P8 J8 START (+) RUN COIL SOLENOID 2 5 6 LIFT–KIT SW.
NO YELLOW 3 ORANGE P5 P4 NO 2 3 4 VIOLET 1 VIOLET 2 NC 3 4 GRAY 1 BLUE NC BROWN NO BLACK BLACK ORANGE 2 WHITE 1 2 1 BLACK (–) (+) REVERSE SWITCH ACCELERATOR HEAD LIGHT (RIGHT SIDE) J3 J4 ORANGE HEAD LIGHT (LEFT SIDE) J1 J2 BLACK POWER POINT P1 S4 4 LIGHT SWITCH P2 5 6 7 8 BLACK (+) J15 (–) BLUE BLUE BLUE HOURMETER BLACK BLUE BLACK S2 S3 BLACK 1 ENGINE GROUND 2 MAGNETO 3 OIL PRESSURE GREEN 4 ”DF” BROWN BROWN RED 1 + 12 V VIOLET 2 TAIL LIGHT
HEADLIGHT (RH) 1 J3 2 (+) J4 (–) 4 3 REVERSE SWITCH P5 1 3 2 2 POWER POINT P1 (+) 1 2 (–) 7 8 3 6 4 1 4 1 2 FUSE BLOCK P8 4 3 OPTIONAL KIT P13 J9 B+ P11 (+) 4 TO ENGINE HARNESS P3 2 3 LIFT–KIT SWITCH (OPTIONAL) P7 7 4 8 1 5 2 3 6 3 OPTIONAL KIT P14 LIGHT SWITCH P2 J14 FUSE BLOCK (OPTIONAL) HOUR METER (–) VOLTAGE REGULATOR P15 J15 P10 C J16 (–) 2 A P16 4 B 3 P12 LIFT KIT (OPTIONAL) 1 2 5 1 1 2 J7 1 2 1 ACCELERATOR P4 5 6 (+) J8 START/RUN SOLENOID 2 4
LIGHT SWITCH (NO) P2 3 ORANGE S4 REVERSE SWITCH P5 NO NC 2 3 P16 4 A VIOLET VIOLET B J16 C BLUE 1 BLACK 4 ORANGE NC 3 GRAY 2 P4 BLUE BLACK ORANGE BLACK 1 BLACK YELLOW NO (+) BROWN/WHITE 2 2 ORANGE 1 1 WHITE (–) BLACK P1 ACCELERATOR HEAD LIGHT (RIGHT SIDE) J3 J4 VIOLET HEAD LIGHT (LEFT SIDE) J1 J2 POWER POINT BROWN/WHITE BLACK 4 5 6 ORANGE 30 2 85 3 87A 4 87 5 86 P15 RELAY (NOT USED) BROWN 7 1 8 BLACK BLACK BLACK BLACK BLACK BLACK 1 2 ENG
Workman 1100 and 2100 (Serial Number From 220000001 To 220999999) Main Electrical Harness Drawing Page 8 – 12 (Rev.
GRAY VIOLET BLUE BLACK BLACK ORANGE BLACK ORANGE BLACK WHITE VIOLET YELLOW BROWN BLACK BLACK BLACK BLUE BROWN/WHITE ORANGE WHITE/BLUE GREEN BROWN/WHITE BLACK BLACK BLACK BLUE BLUE BLACK BLACK BLACK RED VIOLET GRAY BLACK BLACK BLUE WHITE/BLACK VIOLET PINK PINK YELLOW BLACK VIOLET WHITE BROWN RED RED BLUE BLUE WHITE/BLUE RED/BLACK BLACK YELLOW YELLOW BLUE VIOLET GRAY RED GREEN YELLOW RED/BLACK RED BLUE BLACK BLACK GRAY BLUE WHITE/BLACK RED/BLACK BLACK W
Workman 1100 and 2100 (Serial Number From 230000001 To 230999999) Workman 2110 (Serial Number From 220000001 To 230999999) Main Electrical Harness Drawing Page 8 – 14 (Rev.
P1 J1 J2 J3 P4 J4 P5 BLUE VIOLET ORANGE ORANGE GRAY BLACK ORANGE WHITE/BLUE BROWN/WHITE YELLOW BLACK BLACK P3 GREEN BLACK P2 RED VIOLET P14 GRAY BLACK BLACK WHITE/BLACK F1 J14 BLUE F2 P8 J15 BLACK J18 BLACK F3 VIOLET J17 F4 BLACK BLUE PINK WHITE RED P18 P11 VIOLET BROWN BLACK RED/BLACK BLUE BLACK YELLOW RED BLUE P7 RED/BLACK BLACK P8 BLACK BLUE P6 P19 YELLOW J7 J8 J9 P12 P10 P13 Workman 1100 and 2100 (Serial Number From 230000001 To 230999999) Work
Workman 1100, 1110, 2100 and 2110 (Serial Number Above 240000000) Main Electrical Harness Drawing Page 8 – 16 (Rev.
ORANGE ORANGE YELLOW WHITE VIOLET BLUE GRAY BLACK BLACK BLACK BLACK WHITE/BLUE BROWN/WHITE BLACK BLACK ORANGE BLACK RED GRAY BLACK BLACK BLUE BLACK WHITE WHITE/BLACK GREEN VIOLET VIOLET PINK BLACK BLUE BLACK RED VIOLET BROWN RED/BLACK BLACK BLACK YELLOW RED BLUE YELLOW BLUE BLUE BLACK BLUE RED/BLACK YELLOW Workman 1100, 1110, 2100 and 2110 (Serial Number Above 240000000) Main Electrical Harness Wiring Diagram Page 8 – 17 (Rev.
1 P1 MAIN HARNESS BLACK J1 ENGINE GROUND BROWN J4 MAGNETO WHITE/BLUE J3 OIL LEVEL J2 ”DF” 2 3 4 GREEN J2 ”DF” 3 1 P1 J3 MAIN HARNESS 2 OIL LEVEL 4 J4 MAGNETO J1 ENGINE GROUND Workman 1100 (Serial Number Under 220000000) Engine Electrical Harness Drawing and Wiring Diagram Page 8 – 18 (Rev.
BLACK BROWN BROWN WHITE/BLUE GREEN Workman 1100 (Serial Number From 220000001 To 230999999) Engine Electrical Harness Drawing and Wiring Diagram Page 8 – 19 (Rev.
BLACK BROWN BROWN BROWN/WHITE WHITE/BLUE GREEN Workman 1100 and 1110 (Serial Number Over 240000000) Engine Electrical Harness Drawing and Wiring Diagram Page 8 – 20 (Rev.
FRAME GROUNDJ5 P1 TO MAIN WIRE HARNESS BLACK J4 ENGINE GROUND J1 MAGNETO WHITE/BLUE J3 OIL PRESSURE GREEN J2 ”DF” TERMINAL STARTER GENERATOR BLACK 1 2 BROWN 3 4 J2 ”DF” TERMINAL STARTER GENERATOR J1 MAGNETO 4 3 2 1 P1 J3 TO MAIN WIRE HARNESS OIL PRESSURE SWITCH J5 FRAME GROUND J4 ENGINE GROUND Workman 2100 (Serial Number Under 220000000) Engine Electrical Harness Drawing and Wiring Diagram Page 8 – 21 (Rev.
BLACK BLACK BROWN WHITE/BLUE GREEN BROWN/WHITE Workman 2100 and 2110 (Serial Number Over 220000000) Engine Electrical Harness Drawing and Wiring Diagram Page 8 – 22 (Rev.
