Service Manual

ManualsBrandsToro ManualsVehiclesWorkman 4200 with Bed

(Serial No. 240000001 and Above)

PART NO. 03126SL (Rev.D)

Service Manual

Workman

3000/4000 Series

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 3000/4000 Series vehicles.

REFER TO THE OPERATOR’S MANUAL FOR OPER-

ATING, MAINTENANCE AND ADJUSTMENT

INSTRUCTIONS. Spaceis provided in Chapter 2 of this

book to insert the Operator’s Manuals and Parts C ata-

logs for your vehicle. Replacement Operator’s Manuals

are available on the internet at www.toro.com.

TheToroCompany reserves the right to change product

specifications or this publication without notice.

This safety symbol means DANGER, WARNING,

or CAUTION, PERSONAL SAFETY INSTRUC-

TION. When you see this symbol, carefully read

the instructions that follow. Failure to obey the

instructions may result in personal injury.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing, or re-

pair of the machine.

IMPORTANT: The IMPORTANT notice w ill give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

E The Toro Company -- 2003, 2004, 2006, 2007, 2011

Summary of content (306 pages)

PAGE 1
PART NO. 03126SL (Rev.D) Service Manual (Serial No. 240000001 and Above) WorkmanR 3000/4000 Series 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 3000/4000 Series vehicles. 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 vehicle.
PAGE 2
This page is intentionally blank.
PAGE 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 6 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . .
PAGE 4
This page is intentionally blank.
PAGE 5
Chapter 10 -- Front Wheel Drive (4WD) Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -- 2 General Information . . . . . . . . . . . . . . . . . . . . . . . 10 -- 3 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 10 -- 4 Chapter 11 -- Electrical Schematics Vehicle Electrical Schematics . . . . . . . . . . . . . . . 11 -- 3 Wire Harness Drawings . . . . . . . . . . . . . . . . . . . 11 -- 10 Workman 3000/4000 Series Rev.
PAGE 6
This page is intentionally blank.
PAGE 7
Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using Bed Safety Support . . . . . . . . . . . . . . . . . . . .
PAGE 8
Safety Instructions The Workman 3000/4000 series vehicles are designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention are partially dependent upon the design and configuration of the vehicle, 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 vehicle.
PAGE 9
1. Sit on the seat when starting and operating the vehicle. 4. Do not touch engine, radiator, muffler or exhaust pipe while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. 2. Before starting the engine: 5. Before getting off the seat: A. Sit on operator’s seat and engage the parking brake. B. Disengage PTO (if so equipped) and return hand throttle lever to OFF position (if so equipped). A. Stop movement of the vehicle. B. Lower bed. C.
PAGE 10
Maintenance and Service 1. Before servicing or making adjustments, turn all accessories off, put traction pedal in neutral, stop engine, set parking brake, and remove key from the switch. 2. Make sure vehicle is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store the vehicle or fuel container inside where there is an open flame, such as near a water heater or furnace. 4.
PAGE 11
Safety Jacking Vehicle WARNING When changing attachments, tires or performing other service, use the correct blocks, hoists and jacks. Always chock or block the wheels and use jack stands or solid wood blocks to support the vehicle. If the vehicle is not properly supported by blocks or jack stands, the vehicle may move or fall resulting in personal injury. 1 Figure 1 1. Do not start engine while vehicle is on jack, because engine vibration or wheel movement could cause vehicle to slip off jack. 1.
PAGE 12
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 vehicle, 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.
PAGE 13
Chapter 2 Product Records and Maintenance Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
PAGE 14
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 -- 2 Rev.
PAGE 15
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.
PAGE 16
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series Fasteners) 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 +
PAGE 17
Thread Size 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 1.5 38 + 4 ft–lb 52 + 5 N–m 53 + 5 ft–lb 72 + 7 N–m M12 X 1.
PAGE 18
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.
PAGE 19
Maintenance Workman 3000/4000 Series Page 2 – 7 Product Records and Maintenance Maintenance procedures and recommended service intervals for the Workman 3000/4000 are covered in the Operator’s Manual. Refer to that publication when performing regular equipment maintenance. Several maintenance procedures have break–in intervals identified in the Operator’s Manual. Refer to the Engine Operator’s Manual for additional engine specific maintenance procedures.
PAGE 20
This page is intentionally blank.
PAGE 21
Chapter 3 Briggs/Daihatsu Gasoline Engine Table of Contents Briggs/Daihatsu Gasoline Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Adding Oil to Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Speed Adjustment . . . . . . . . . . . . . . . . . .
PAGE 22
Specifications Item Description Make / Designation Briggs & Stratton/Daihatsu, 4–stroke, Liquid Cooled, OHV Gasoline Number of Cylinders 3 Bore x Stroke mm (in.) 72 x 78 (2.834 x 3.07) Total Displacement cc (cu. in.) 952 (58.1) Compression Ratio 8.6:1 Firing Order 1 (front) – 2 – 3 Dry Weight (approximate) kg (lb.) 62 (137) Carburetor Single barrel, float feed, 12 VDC shut–off solenoid Fuel Pump 12 VDC Fuel Unleaded, regular grade (87 octane minimum) Fuel Tank Capacity liter (U.S. gal.
PAGE 23
General Information Adding Oil to Engine Briggs/Daihatsu Gasoline Engine When adding oil to the engine, maintain clearance between the oil fill device and the oil fill opening in the valve cover (Fig. 1). This clearance is necessary to allow venting when adding engine oil which will prevent oil from running into the breather tube and intake system.
PAGE 24
Adjustments Engine Speed Adjustment 1. Park vehicle on a level surface, engage parking brake and place gear shift lever in neutral. 2 1 2. Raise the bed or remove attachment(s) to allow access to engine. If bed is raised, place safety support on lift cylinder (see Operator’s Manual). 3 3. Stop engine and remove key from the ignition switch. 4. Make sure governor spring is assembled to bellcrank on throttle bracket and outer most slot in engine governor lever (Fig. 2). 5.
PAGE 25
8. Using a tachometer, check low idle speed. Low idle speed should be 1100 + 50 RPM. If low idle is incorrect, repeat idle stop screw adjustment (step 5). If low idle is still incorrect, adjust the idle speed screw on the carburetor to obtain 1100 + 50 RPM (Fig. 6). 7 6 5 4 8 10.After engine speed adjustments are complete, lower the bed or install attachment(s). 3 1 2 Figure 5 1. 2. 3. 4. Throttle bracket High idle stop screw Idle stop screw Governor spring 5. 6. 7. 8.
PAGE 26
Service and Repairs Radiator 20 21 26 1 25 22 16 FRONT 24 19 18 RIGHT 23 17 15 14 13 12 2 3 11 10 4 5 6 7 8 9 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. Hydraulic pump Carriage screw (4 used) Fan hub/pulley Fan shroud Lower radiator hose Hose clamp Radiator Lock nut (4 used) Cap screw (4 used) Briggs/Daihatsu Gasoline Engine 10. 11. 12. 13. 14. 15. 16. 17. 18.
PAGE 27
Removal (Fig. 5) Installation (Fig. 5) 1. Park vehicle on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. Allow engine to cool. 1. Remove plugs from radiator and hoses placed during the removal procedure. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder (see Operator’s Manual). 3. Lift and remove the radiator screen from front of radiator. 2. Position radiator to the frame.
PAGE 28
Pump Driveshaft Service 11 18 RIGHT 14 9 12 FRONT 14 11 12 13 10 100 to 130 in–lb (11.3 to 14.7 N–m) 15 17 16 13 8 7 3 9 6 6 ANTISIEZE LUBRICANT 5 1 15 4 2 Figure 6 1. 2. 3. 4. 5. 6. Lock nut Flat washer Woodruff key Pump drive belt Pulley Bearing Briggs/Daihatsu Gasoline Engine 7. 8. 9. 10. 11. 12. Bearing spacer Shaft Lock nut (6 used) Frame support bracket Cap screw (4 used) Coupling spacer (4 used) Page 3 – 8 13. 14. 15. 16. 17. 18.
PAGE 29
Removal (Fig. 6) Installation (Fig. 6) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. 1. To install bearings (Item 6) into frame support bracket: A. Install pulley side bearing into support bracket by pressing on bearing outer race until bearing contacts shoulder in support bracket. 2. Disassemble driveshaft using Figure 6 as a guide. 3. Do not reuse bearings (Item 6) if they have been removed from frame support bracket.
PAGE 30
Fuel Tank 6 7 8 9 5 4 2 10 3 11 13 12 Sender Ground Wire Thread Sealant 1 27 14 24 18 17 19 15 20 RIGHT 26 21 16 23 22 FRONT 25 13 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Fuel tank Fuel tank cap Gasket Fuel sender Lock washer (5 used) Screw (5 used) Hex nut Lock washer Wire harness Spacer Fuel fitting Hose clamp Fuel hose (to fuel filter) Clamp Flange nut (2 used) Flange nut (2 used) Rear fuel tank support Cap screw (2 used) 19. 20. 21. 22. 23.
PAGE 31
Fuel Tank Removal (Fig. 7) Fuel Tank Installation (Fig. 7) 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 1. Check felt straps (item 23) and replace if worn or damaged. 3. Disconnect negative battery cable first and then positive battery cable. Remove battery from vehicle (see Operator’s Manual). IMPORTANT: Review safety information regarding fuel handling in the Operator’s Manual and Chapter 2 – Safety.
PAGE 32
Air Cleaner System 1 3 4 2 RIGHT 13 14 5 FRONT 6 8 2 12 11 7 10 VACUATOR DIRECTION 8 9 Figure 8 1. 2. 3. 4. 5. Engine Hose clamp Air intake hose Radiator hose Air inlet hood Briggs/Daihatsu Gasoline Engine 6. 7. 8. 9. 10. Air cleaner hose Air cleaner assembly Flange nut (2 used) Clamp Mounting band Page 3 – 12 11. 12. 13. 14.
PAGE 33
Removal (Fig. 8) 1 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder (see Operator’s Manual). 3 3. Remove air cleaner components as needed using Figures 8 and 9 as guides. 4 1. Reassemble air cleaner system using Figures 8 and 9 as guides.
PAGE 34
Exhaust System 11 14 15 13 1 12 16 11 2 10 4 9 7 8 Loctite #242 17 3 5 3 RIGHT 6 FRONT Figure 10 1. 2. 3. 4. 5. 6. Engine Stud (4 used) Exhaust gasket Hex nut (4 used) Exhaust manifold Socket head screw (4 used) Briggs/Daihatsu Gasoline Engine 7. 8. 9. 10. 11. 12. Cap screw (2 used) Flange nut (4 used) Cap screw Hardened washer Flange nut (4 used) Carriage bolt (2 used) Page 3 – 14 13. 14. 15. 16. 17.
PAGE 35
Removal (Fig. 10) Installation (Fig. 10) 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 1. Replace any removed gaskets. 3. Remove exhaust system components as needed using Figure 10 as a guide. 3. Using Figure 10 as a guide, fit all exhaust components to vehicle before tightening any fasteners. When securing exhaust, tighten fasteners in the following order: A.
PAGE 36
Engine 12 13 11 32 6 10 7 14 9 8 4 33 3 2 5 1 16 15 17 18 19 20 21 27 RIGHT 22 FRONT 23 26 31 29 24 25 28 30 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Engine Hex nut Lock washer Flat washer Wire harness alternator lead Fuel hose Hose clamp Hose clamp Air intake hose Throttle bracket Lock nut Briggs/Daihatsu Gasoline Engine 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
PAGE 37
Engine Removal (Fig. 11) 1 2 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 3 5 2. Raise or remove the bed or other attachment(s) to gain access to engine. If bed is raised, place safety support on lift cylinder (see Operator’s Manual). 3 4 4 3. Disconnect negative (–) and then positive (+) battery cables at the battery. 6 7 4. Remove exhaust manifold from vehicle (see Exhaust System Removal in this section).
PAGE 38
11. Remove any clamps and cable ties used to attach wiring harness, hoses or cables to the engine. 2 3 1 12.On 4WD vehicles, remove differential drive shaft (see Differential Driveshaft in the Service and Repairs section of Chapter 10 – Front Wheel Drive (4WD)). 2 13.Put blocking under transaxle for support. 14.Attach hoist or block and tackle to engine for support. 15.Loosen and remove two (2) locknuts (Item 9) and cap screws (Item 1) that secure engine mount to engine support (Fig. 13).
PAGE 39
Briggs/Daihatsu Gasoline Engine This page is intentionally blank.
PAGE 40
Engine Throttle Bracket 5 4 6 2 7 3 8 2 9 11 10 12 1 17 16 15 13 14 RIGHT FRONT Figure 17 1. 2. 3. 4. 5. 6. Engine Jam nut Return spring Lock nut Ball joint Accelerator cable Briggs/Daihatsu Gasoline Engine 7. 8. 9. 10. 11. 12. Lock washer (3 used) Flange head screw (3 used) Grease fitting Shoulder bolt Bellcrank Governor spring Page 3 – 20 Rev. B 13. 14. 15. 16. 17.
PAGE 41
Disassembly (Fig. 17) 1. Remove throttle bracket components from engine as needed using Figures 17, 18 and 19 as guides. NOT EQUIPPED WITH GOVERNOR SPRING ADJUSTING ROD 4 Assembly (Fig. 17) 1. Install removed throttle bracket components to engine using Figures 17, 18 and 19 as guides. 6 2 3 3. Lubricate bellcrank grease fitting after assembly. 4. Check engine speed (both idle and high idle) and adjust if necessary (see Engine Speed Adjustment in Adjustments section of this chapter) 5.
PAGE 42
This page is intentionally blank.
PAGE 43
Chapter 4 Briggs/Daihatsu Diesel Engine Table of Contents Briggs/Daihatsu Diesel Engine INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Adding Oil to Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Adjust Engine Speed . . . . . . . . . . . . . . . . . . . . .
PAGE 44
Specifications Item Description Make / Designation Briggs & Stratton/Daihatsu, 4–stroke, Liquid Cooled, OHV Diesel Number of Cylinders 3 Bore x Stroke mm (in.) 72 x 78 (2.834 x 3.07) Total Displacement cc (cu. in.) 952 (58.1) Compression Ratio 24.0:1 Firing Order 1 (front) – 2 – 3 Dry Weight (approximate) kg (lb.) 78 (172) Fuel Grade No.
PAGE 45
General Information Adding Oil to Engine Briggs/Daihatsu Diesel Engine When adding oil to the engine, maintain clearance between the oil fill device and the oil fill opening in the valve cover (Fig. 1). This clearance is necessary to allow venting when adding engine oil which will prevent oil from running into the breather tube and intake system.
PAGE 46
Adjustments Adjust Engine Speed 1. Park vehicle on a level surface, engage parking brake and place gear shift lever in neutral. 3 2 1 2. Raise the bed or remove attachment(s) to allow access to engine. If bed is raised, place safety support on lift cylinder (see Operator’s Manual). 3. Allow engine to reach operating temperature before checking or adjusting engine speed. 4. With engine running at idle speed, use a tachometer to check that engine is operating at 1500 + 50 RPM. 5.
PAGE 47
Briggs/Daihatsu Diesel Engine This page is intentionally blank.
PAGE 48
Service and Repairs Radiator 20 21 26 1 25 22 16 FRONT 24 19 18 RIGHT 23 17 15 14 13 12 2 3 11 10 4 5 6 7 8 9 Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. Hydraulic pump Carriage screw (4 used) Fan hub/pulley Fan shroud Lower radiator hose Hose clamp Radiator Lock nut (4 used) Cap screw (4 used) Briggs/Daihatsu Diesel Engine 10. 11. 12. 13. 14. 15. 16. 17. 18.
PAGE 49
Removal (Fig. 4) Installation (Fig. 4) 1. Park vehicle on a level surface, stop engine, engage parking brake, and remove key from the ignition switch. Allow engine to cool. 1. Remove plugs from radiator and hoses placed during the removal procedure. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder (see Operator’s Manual). 3. Lift and remove the radiator screen from front of radiator. 2. Position radiator to the frame.
PAGE 50
Pump Driveshaft Service 11 18 RIGHT 14 9 12 FRONT 14 11 12 13 10 100 to 130 in–lb (11.3 to 14.7 N–m) 15 17 16 13 8 7 3 9 6 6 ANTISIEZE LUBRICANT 5 1 15 4 2 Figure 5 1. 2. 3. 4. 5. 6. Lock nut Flat washer Woodruff key Pump drive belt Pulley Bearing Briggs/Daihatsu Diesel Engine 7. 8. 9. 10. 11. 12. Bearing spacer Shaft Lock nut (6 used) Frame support bracket Cap screw (4 used) Coupling spacer (4 used) Page 4 – 8 13. 14. 15. 16. 17. 18.
PAGE 51
Removal (Fig. 5) Installation (Fig. 5) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. 1. To install bearings (Item 6) into frame support bracket: A. Install pulley side bearing into support bracket by pressing on bearing outer race until bearing contacts shoulder in support bracket. 2. Disassemble driveshaft using Figure 5 as a guide. 3. Do not reuse bearings (Item 6) if they have been removed from frame support bracket.
PAGE 52
Fuel Tank 6 7 8 RIGHT 10 9 Sender Ground Wire 5 FRONT 4 13 11 3 12 19 2 20 13 18 29 Thread Sealant 14 1 17 22 30 29 21 23 24 28 25 16 32 15 27 31 33 26 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
PAGE 53
Fuel Tank Removal (Fig. 6) Fuel Tank Installation (Fig. 6) 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 1. Check felt straps (item 27) and replace if worn or damaged. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder (see Operator’s Manual). 3. Disconnect negative battery cable first and then positive battery cable.
PAGE 54
Air Cleaner System 1 3 4 2 RIGHT 13 14 5 FRONT 6 8 2 12 11 7 10 VACUATOR DIRECTION 8 9 Figure 7 1. 2. 3. 4. 5. Engine Hose clamp Air intake hose Radiator hose Air inlet hood Briggs/Daihatsu Diesel Engine 6. 7. 8. 9. 10. Air cleaner hose Air cleaner assembly Flange nut (2 used) Clamp Mounting band Page 4 – 12 11. 12. 13. 14.
PAGE 55
Removal (Fig. 7) 1 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder (see Operator’s Manual). 3 3. Remove air cleaner components as needed using Figure 7 and 8 as guides. 4 Installation (Fig. 7) Figure 8 1. Plug 2. Upper housing 3. Element 4. Gasket 5. Lower housing 6. Vacuator valve 2.
PAGE 56
Exhaust System 11 14 15 13 1 12 16 11 2 10 4 9 7 8 Loctite #242 17 3 5 3 RIGHT 6 FRONT Figure 9 1. 2. 3. 4. 5. 6. Engine Stud (4 used) Exhaust gasket Hex nut (4 used) Exhaust manifold Socket head screw (4 used) Briggs/Daihatsu Diesel Engine 7. 8. 9. 10. 11. 12. Cap screw (2 used) Flange nut (4 used) Cap screw Hardened washer Flange nut (4 used) Carriage bolt (2 used) Page 4 – 14 13. 14. 15. 16. 17.
PAGE 57
Removal (Fig. 10) Installation (Fig. 10) 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 1. Replace any removed gaskets. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder (see Operator’s Manual). 3. Remove exhaust system components as needed using Figure 10 as a guide. 2.
PAGE 58
Engine 25 21 27 22 23 24 26 28 29 30 20 19 31 18 1 17 16 2 15 14 9 RIGHT FRONT 13 3 5 7 12 10 11 8 6 5 4 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Engine Fusible link harness Positive battery cable Wire harness solenoid lead Lock washer Hex nut Hose clamp Lower radiator hose Hex nut Engine cover Cap screw Briggs/Daihatsu Diesel Engine 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
PAGE 59
Engine Removal (Fig. 10) 1 2 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 3 5 2. Raise or remove the bed or other attachment(s) to gain access to engine. If bed is raised, place safety support on lift cylinder (see Operator’s Manual). 3 4 4 3. Disconnect negative (–) and then positive (+) battery cables at the battery. 6 7 4. Remove exhaust manifold from vehicle (see Exhaust System Removal in this section).
PAGE 60
11. Remove any clamps and cable ties used to attach wiring harness, hoses or cables to the engine. 2 3 1 12.On 4WD vehicles, remove differential drive shaft (see Differential Driveshaft in the Service and Repairs section of Chapter 10 – Front Wheel Drive (4WD)). 2 13.Put blocking under transaxle for support. 14.Attach hoist or block and tackle to engine for support. 15.Loosen and remove two (2) locknuts (Item 9) and cap screws (Item 1) that secure engine mount to engine support (Fig. 13).
PAGE 61
Briggs/Daihatsu Diesel Engine This page is intentionally blank.
PAGE 62
Engine Throttle Bracket 8 7 9 7 6 10 5 4 3 1 12 11 2 13 5 14 15 5 16 RIGHT FRONT Figure 14 1. 2. 3. 4. 5. 6. Engine Lock nut Cap screw Cap screw Lock nut Lock nut 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Ball joint Jam nut Threaded rod Accelerator cable Return spring Shoulder bolt Grease fitting Throttle bellcrank Throttle bracket Engine mount Disassembly (Fig. 14) Assembly (Fig. 14) 1. Remove throttle bracket components from engine as needed using Figure 14 as a guide. 1.
PAGE 63
Chapter 5 Kohler Gasoline Engine Table of Contents INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . .
PAGE 64
Specifications Item Description Make / Designation Kohler, CH23S, 4–stroke, V–Twin Air Cooled, OHV Number of Cylinders 2 Bore x Stroke 80 mm x 67 mm (3.15” x 2.64”) Total Displacement 674 cc (41.1 cu. in.) Compression Ratio 8.5:1 Dry Weight (approximate) 41 kg (90 lb.) Fuel Unleaded, Regular Gasoline (Minimum 87 Octane) Fuel Tank Capacity 26 liters (7 U.S. gal.
PAGE 65
Service and Repairs Cooling System To ensure proper engine cooling, make sure the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. 1 NOTE: Perform this maintenance procedure at the interval specified in the Operator’s Manual. 3 IMPORTANT: The engine that powers the Workman 3100 is air–cooled.
PAGE 66
Fuel Tank 6 7 8 9 5 4 2 10 3 11 13 12 Sender Ground Wire Thread Sealant 1 14 24 26 17 18 19 15 20 RIGHT 21 16 23 FRONT 22 25 13 Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Fuel tank Fuel tank cap Gasket Fuel sender Lock washer (5 used) Screw (5 used) Hex nut Lock washer Wire harness Spacer Fuel fitting Hose clamp Fuel line Clamp Flange nut (2 used) Flange nut (2 used) Rear fuel tank support Cap screw (2 used) 19. 20. 21. 22. 23. 24. 25. 26.
PAGE 67
Fuel Tank Removal (Fig. 2) Fuel Tank Installation (Fig. 2) 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 1. Check felt straps (item 23) and replace if worn or damaged. IMPORTANT: Review safety information regarding fuel handling in the Operator’s Manual and Chapter 2 – Safety. 3. Disconnect negative battery cable first and then positive battery cable. Remove battery from vehicle (see Operator’s Manual).
PAGE 68
Exhaust System 15 5 16 14 13 12 5 17 12 11 10 6 Loctite #242 5 18 8 4 7 RIGHT 3 FRONT 2 9 1 Figure 3 1. 2. 3. 4. 5. 6. Socket head screw (4 used) Exhaust manifold Hex nut (3 used) Exhaust gasket (2 used) Flange nut Screw Kohler Gasoline Engine 7. 8. 9. 10. 11. 12. Cap screw Bracket Muffler gasket Flange nut (4 used) Cap screw Hardened washer Page 5 – 6 13. 14. 15. 16. 17. 18.
PAGE 69
Removal (Fig. 3) 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 3. Using Figure 3 as a guide, fit all exhaust components to vehicle before tightening any fasteners. When securing exhaust, tighten fasteners in the following order: A. Hex nuts (item 3) that secure manifold to engine. B. Cap screw (item 11) with washers (item 12) that secures muffler to transaxle. 2. Raise or remove the bed or other attachment(s).
PAGE 70
Engine 26 Anti–seize Lubricant 15 14 16 13 17 18 12 23 25 24 22 11 27 21 10 9 7 19 28 8 29 7 30 6 31 5 32 20 33 43 35 to 41 ft–lb (47 to 56 N–m) Anti–seize Lubricant 35 4 34 3 36 2 37 1 38 RIGHT FRONT 42 41 39 40 Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Lock nut Flat washer Pulley Woodruff key Flange nut Cap screw Jam nut Cap screw Throttle bracket Lock nut Throttle lever Spring Accelerator cable ball joint Socket head screw Shoulder bolt 16. 17. 18.
PAGE 71
5. Disconnect fuel line from fuel pump on engine. Plug end of fuel line to prevent contamination and fuel spillage. Position disconnected fuel line away from engine. 2 3 6. Disconnect and label electrical leads that attach to engine and engine accessories. 4 5 1 7. Loosen fasteners that secure hydraulic pump to engine mount (Fig. 5). Rotate pump to allow drive belt (Item 42) to be removed from pump and engine pulley. 6 8. Disconnect accelerator cable from throttle lever on engine.
PAGE 72
Engine Installation (Fig. 4) 5. If shoulder bolt (Item 15) was removed, apply anti– seize lubricant to bolt shoulder before installing. 1. Install flywheel (Item 33) and/or pilot bearing (Item 30) if removed. Torque socket head cap screw (Item 31) from 35 to 41 ft–lb (47 to 56 N–m) to secure flywheel to engine crankshaft. 2. If pressure plate and clutch disc were removed, see Installing Clutch Disc and Cover in the Repairs section of Chapter 6 Drive Train. 3.
PAGE 73
Chapter 6 Drive Train Table of Contents Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 74
General Information Workman 3000/4000 Series vehicles are equipped with a Toro designed transaxle with 3 forward speeds, 1 reverse speed and a differential lock. Hi–Lo range gives an effective 6 forward and 2 reverse speeds. Optional PTO 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.
PAGE 75
Specifications Item Specification Transaxle Oil Dexron III ATF 8 quart U.S. (7.
PAGE 76
Special Tools Order special tools from your Toro Distributor. Clutch Alignment Tool Use clutch alignment tool (Part No. TOR6002) to align clutch friction disk to engine flywheel before tightening pressure plate cap screws. Figure 2 Drive Train Page 6 -- 4 Rev.
PAGE 77
Adjustments PTO Cable Adjustment 1. Remove clevis pin securing PTO cable to PTO lever arm. 4 3 2. Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in PTO lever arm. 3. Reinstall clevis pin and tighten jam nut after adjustment. 2 1 Figure 3 3. Clevis pin 4. Clevis jam nut Drive Train 1. PTO lever arm 2.
PAGE 78
Troubleshooting Clutch Problem 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.
PAGE 79
Clutch (Continued) Problem Possible Causes Clutch drags or does not release. Control cable loose or out of adjustment. Bent or broken clutch diaphragm spring tip. Damaged or distorted clutch disc. Worn or rusted clutch disc spline. Damaged pressure plate or flywheel. Damaged release bearing. 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.
PAGE 80
Transaxle Problem 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. Excessive wear of differential side gear liners and pinion liners. Excessive wear of splined slider on axle drive joints. Difficult shifting. Clutch not releasing. Shift cable out of adjustment. Shift cable damaged. Shifter cap screw loose (at operator station). Loose shift lever on transaxle.
PAGE 81
Transaxle (Continued) Problem Possible Causes Transaxle slips out of gear. Shift linkage out of adjustment. Gear loose on shaft. Gear teeth worn. Excessive end play in gears. Lack of spring pressure on shift fork detent ball. Badly worn bearings. Overheating of transaxle. Oil level too high. Excessive hydraulic load. Drive Train See Chapter 9 – Hydraulic System.
PAGE 82
Service and Repairs Shift Cable Replacement 1 2 19 4 3 18 6 7 5 8 9 7 10 8 6 11 11 10 17 16 15 12 4 RIGHT FRONT 180 to 210 in–lb (20.3 to 23.7 N–m) 13 14 Figure 4 1. 2. 3. 4. 5. 6. 7. Shift knob Jam nut Boot seal Shift cable Shift pin Jam nut Cotter pin Drive Train 8. 9. 10. 11. 12. 13. Clevis pin Shift lever Shift link Cable clevis Cap screw Lower shift boot Page 6 – 10 14. 15. 16. 17. 18. 19.
PAGE 83
Removal (Fig. 4) 1. Remove knobs from control levers, then remove center console shift boot and control plate (Fig. 5). 2. Remove three screws (Item 18) and cable clamp (Item 19) that secure shift cables to lever support. 3. Remove cotter pin and clevis pin that secure shift cable clevis to shift link (Item 10) on shifter in operator platform. 4. Loosen jam nut that retains clevis to shift cable and remove clevis from cable. 1 2 5. Remove shift cable from transaxle shift lever (Fig. 7): A.
PAGE 84
Stub Axle and Drive Shaft Service 25 40 to 60 ft–lb (54 to 81 N–m) 29 28 16 24 8 23 27 12 22 26 11 Loctite #680 10 21 35 to 42 ft–lb (47 to 57 N–m) 220 to 250 ft–lb (298 to 339 N–m) 9 7 6 20 15 19 18 45 to 65 ft–lb (61 to 88 N–m) 17 13 RIGHT 4 5 14 200 to 250 in–lb (22.6 to 28.3 N–m) 8 2 1 ACCESS HOLE FRONT 3 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
PAGE 85
7. Carefully slide stub axle from axle housing. Assembly (Fig. 8) 8. If required, slide driveshaft from transaxle. 1. If driveshaft was removed from transaxle, apply anti– seize lubricant to transaxle shaft. Slide driveshaft clamp end onto splined transaxle shaft. A. Remove brake assembly from axle housing (see Brake Service in Service and Repairs Section of Chapter 7 – Chassis). B. Remove three (3) cap screws with washers that secure axle housing to vehicle frame. Remove axle housing.
PAGE 86
Drive Shaft Universal Joint Service 1. Remove drive shaft from vehicle (see Stub Axle and Drive Shaft Service). 2. Remove snap rings (Item 1). IMPORTANT: Yokes must be supported when removing and installing bearings to prevent bending. 3. While supporting yoke, use a press to remove cross and bearings (Item 2). 7 6 4. To install new cross and bearings: 5 A. Apply a coating of grease to bearing bores. 4 B. Press one bearing partially into yoke (Item 3). 2 3 C. Insert cross into yoke and bearing.
PAGE 87
P.T.O. Removal and Installation (If Equipped) 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. 3 2. Disconnect and label electrical lead that attaches to PTO switch. 2 1 3. Disconnect hydraulic hose from fitting on PTO. Put labels on hydraulic hoses for proper reassembly. Put caps or plugs on all open hoses or fittings to prevent contamination. Label hoses and fittings for proper reinstallation. 4.
PAGE 88
Transaxle 2 6 3 5 7 8 4 3 9 10 2 11 1 12 Loctite #242 13 RIGHT 14 Loctite #242 FRONT 15 Figure 13 1. 2. 3. 4. 5. Transaxle assembly Snubbing washer (4 used) Isolation mount assembly (2 used) Transaxle mount (2 used) Lock nut (4 used) Drive Train 6. 7. 8. 9. 10. Cap screw (2 used) Cap screw (4 used) Shift arm Nut (3 used) Hardened washer (3 used) Page 6 – 16 11. 12. 13. 14. 15.
PAGE 89
Removal 1. Put vehicle on a level surface. Stop the engine and remove key from ignition switch. Remove the bed or other attachment(s). Allow engine and radiator to cool. 1 3 2. Disconnect negative (–) battery cable from battery first. Then disconnect positive (+) battery cable from battery. 2 3. Remove drain plug from bottom of transaxle (Fig. 14) and allow oil to drain into a drain pan. Install drain plug. 4. Note orientation of 90o fitting connected to strainer on side of transaxle.
PAGE 90
16.Put blocking under engine for support. Support transaxle with a floor jack or suspend transaxle from vehicle frame rails. 17.Remove transaxle isolation mounts and mount brackets (Fig. 17). 18.Remove drive shaft clamp bolts, then slide transaxle side–to–side to disconnect each drive shaft from axle shafts on transaxle. 1 20.Carefully pull transaxle back to disengage transaxle input shaft from clutch. Use floor jack to lower transaxle and slide out rear of vehicle under the frame. 2 2 19.
PAGE 91
Drive Train This page is intentionally blank.
PAGE 92
Clutch Service Silicone sealant (Workman 3100 only) 5 RIGHT 8 14 FRONT 9 5 to 7 ft–lb (7 to 9 N–m) 12 11 6 10 13 7 2 4 6 1 9 3 Figure 20 1. 2. 3. 4. 5. Spring pin Throw out bearing Release guide Clutch release fork Clutch release shaft 6. 7. 8. 9. 10. 11. 12. 13. 14. Bushing Spring pin (2 used) Bell housing Oil seal Cap screw (6 used) Lock washer (6 used) Pressure plate Clutch disc Spring 5. During assembly, apply anti–seize lubricant to the following: Clutch Release Mechanism (Fig.
PAGE 93
Clutch Disassembly and Inspection (Fig. 20) 1. Insert clutch alignment tool (see Special Tools) in flywheel pilot bearing hole to keep clutch disk from falling off (Fig. 21). 3. Install pressure plate. Install and tighten six cap screws and lock washers a little at a time, working in a diagonal sequence. Torque screws from 5 to 7 ft--lb (7 to 9 N--m). Remove alignment tool from flywheel bearing. 2. Loosen pressure plate screws (Item 10) in a diagonal sequence. Clutch Alignment Tool 3.
PAGE 94
Transaxle Service 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 cap screws (Item 2) and remove bell housing assembly from transaxle. 2 3. Thoroughly clean outside surface of transaxle. Figure 25 4. Loosen cap screws (Item 1) and remove fork shaft case (Item 2) from center plate.
PAGE 95
7. Loosen cap screws and separate center plate from transaxle case. Note dowel pins in transaxle case. Remove seal cap (Item 1), shims (Item 2 and 4) and snap ring (Item 3) from center plate. 3 4 1 2 Figure 28 8. On 4WD units, remove front drive shaft and 41T gear from the gear case. Remove bearings from gear case (see Item 2 of Fig. 30) and center plate. FRONT DRIVE SHAFT BEARING (CENTER PLATE) BEARING (GEAR CASE) 41T GEAR Figure 29 Drive Train 9. Remove reverse shaft (Item 1) from transaxle case.
PAGE 96
11. Remove, all at the same time, reduction shaft assembly (Item 1), 2nd–3rd shift assembly (Item 2), countershaft assembly (Item 3) and High–Low shift assembly (Item 4). 2 4 1 3 Figure 32 12.Loosen cap screws (Item 1) and remove L.H. axle shaft assembly (Item 2) and shims (Item 3) from L.H. side cover (Item 4) still attached to transaxle. Figure 33 13.Remove roll pin from differential lock lever. Remove lever (Item 1) from shaft. Loosen cap screws (Item 2) and remove L.H.
PAGE 97
16.Remove differential gear assembly (Item 1) together with fork shaft assembly (Item 2). 1 2 Figure 36 17.Remove washer (Item 1) from inside of transaxle case. NOTE: Washer may stick to fork shaft when removed in step 16.
PAGE 98
18.To remove shift arms: 1 2 A. Loosen and remove nut (Item 1). Remove washer (Item 2) and 2nd–3rd shift arm (Item 3) together with shift arm plate (Item 4), spring (Item 5), locknut (Item 6), washer (Item 7) and cap screw (Item 8). B. Loosen and remove locknut (Item 9) and washer (Item 10) from both 1st–Rev. shift arm (Item 11) and High–Low shift arm (not shown). Remove shift arms. 4 6 8 7 5 3 9 10 11 C. Loosen cap screws (Fig. 39, Item 12) and remove keeper plates (Item 13). D.
PAGE 99
20.Remove oil cap (Item 1) and O–ring from transaxle case if necessary. 1 21.Remove air breather (Item 2) if necessary. 2 Figure 41 22.Loosen cap screws (Item 1) and remove upper cover (Item 2) from transaxle case.
PAGE 100
23.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 .0709 in. (1.8 mm) thick. C. Remove 2 needle bearings (Item 5) and gear (Item 4). Inspect needle bearings and replace if necessary. D. Remove synchro ring (Item 6). Figure 43 E. Remove snap ring (Item 7). F. Remove shifter (Item 8) together with spring, hub and 3 keys. G. Remove key (Item 9).
PAGE 101
24.Disassemble reduction shaft assembly: 1 A. Use a bearing puller to remove bearing (Item 1) from reduction shaft. 5 3 15 14 13 10 7 B. Remove gear (Item 2), helical gear (Item 3), collar (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). 4 2 18 E. Remove spacer (Item 10). 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.
PAGE 102
25.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 47 26.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).
PAGE 103
27.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 50 28.Disassemble Hi–Lo fork shaft assembly: 5 1 A. Remove shift fork (Item 1), steel ball (Item 2) and spring (Item 3) from Hi–Lo shift fork assembly. 4 B. Remove E–ring (Item 4). 3 2 Figure 51 29.Disassemble differential gear assembly: A.
PAGE 104
30.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 54 31.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.
PAGE 105
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. C. Measure the clearance between synchronizer ring and synchro gear in three equally spaced points. If clearance is less than .0195 in. (0.5 mm) replace the synchronizer ring. 4. Inspect synchro gears: Figure 56 A.
PAGE 106
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 exceeds .039 in. (1.0 mm). Figure 58 7. Inspect main shaft: A. Inspect main shaft for worn or damaged surface. If O.D.
PAGE 107
9. Inspect center plate for cracks and damage. Replace center plate if the snap ring groove has more than 15% of its edges damaged due to nicks, rounding, cracks, or dents (Fig. 61 and 62).
PAGE 108
10.Inspect reduction shaft for wear or damage. If O.D. of needle bearing area is less than .864 in. (21.95 mm) or .982 in. (24.95 mm), replace the reduction shaft. Figure 63 11. Inspect countershaft for wear or damage. If O.D. of inner portion is less than 1.100 in. (27.95 mm) or 71T gear portion is less than 1.179 in. (29.95 mm), replace the countershaft. Figure 64 12.Inspect differential: A. Inspect pinion shaft for excessive wear or damage. If O.D. is less than .707 in. (17.
PAGE 109
Assembly NOTE: Item numbers in figures are shown in reverse order 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 surfaces 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. C.
PAGE 110
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.
PAGE 111
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 72 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.
PAGE 112
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 inner (Item 6).
PAGE 113
9. Assemble synchro hub: A. Install 3 keys (Item 1) into grooves of hub (Item 2). 1 2 Figure 76 B. Install shifter (Item 1) onto hub (Item 2). 1 2 Figure 77 Drive Train C. Insert 2 springs (Item 3) into hub. Pay attention to direction of spring.
PAGE 114
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 15 14 13 10 7 B. Install synchro ring (Item 14) onto gear (Item 15). Apply Dexron III transmission oil on cone face of gear before installing synchro ring. C. Insert key (Item 13) onto reduction shaft. 4 2 18 17 16 12 11 8 6 D.
PAGE 115
11. Assemble reverse shaft: A. Install gear (Item 2) onto reverse shaft. B. Use a press to install bearings (Item 3 and 1). Figure 82 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. Figure 83 E.
PAGE 116
13.Assemble shift arms: A. Install 3 new oil seals (Item 14) onto transaxle case. Apply multi–purpose grease on lips of oil seals before installing. B. Install 3 keeper plates (Item 13) and tighten 3 cap screws (Item 12) to a torque from 11 to 13 ft–lb (15 to 17 N–m). 1 2 200 to 280 in–lb (22.6 to 31.6 N–m) 200 to 280 in–lb (22.6 to 31.6 N–m) 8 7 5 4 6 3 9 10 11 Apply Loctite 680 to threads and tapers 9 10 11 C. Apply Loctite #680 (or equivalent) to threads and tapers of shift fork arms. D.
PAGE 117
16.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 88 Drive Train Figure 89 17.Install main shaft together with 2–3 fork shaft. Insert head of shift arm into groove of fork while installing.
PAGE 118
18.Install reverse shaft (Item 1). Rotate main shaft and reverse shaft gears to mesh gears when installing. 1 2 Figure 92 19.On 4WD vehicles, install bearing to gear case (see Item 2 of Fig. 92) and center plate. Install front drive shaft and 41T gear to the gear case. FRONT DRIVE SHAFT BEARING (CENTER PLATE) BEARING (GEAR CASE) 41T GEAR Figure 93 20.Install center plate: A. Insert 2 dowel pins into transaxle case. B. Apply silicone sealant onto mating surface of center plate. C.
PAGE 119
NOTE: The thickest shim of the shim set (Item 2) should be positioned against the snap ring (Fig. 95). 21.Insert tabbed shim (Item 4) against the bearing. Insert shim set (Item 2) against the tabbed shim. Use thickest shims in set possible, that will permit installation of the snap ring. (Fig. 95 and 96). 3 4 1 2 Figure 95 5 22.Install snap ring into the groove of the bearing housing (Fig. 96 and 97). 3 1 6 4 2 Figure 96 4. Snap ring 5. Center plate 6. Sealing cap Drive Train 1. Countershaft 2.
PAGE 120
23.Measure countershaft end play. Rotate one of the axle shafts back and forth to take up all back lash. Rotating the shaft in one direction will pull the shaft and bearing 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 0.000 to 0.0039 in. (0.00 to 0.10 mm) (Fig. 98).
PAGE 121
25.Install fork shaft case: A. Insert spindle (Item 1) between fork shafts. 1 Figure 100 B. Insert 2 steel balls (Item 2) and 2 springs (Item 1) into the grooves. 1 2 Figure 101 C. Apply silicone sealant to mating surface of fork shaft case. 2 Drive Train D. Install fork shaft case (Item 2). Tighten cap screws (Item 1) to a torque from 18.5 to 22 ft–lb (24.5 to 29.5 N–m). Check operation of shifters and detent. 1 Figure 102 26.Insert a washer (Item 1) into housing of transaxle case.
PAGE 122
27.Install differential gear assembly (Item 1) together with fork shaft (Item 2) onto transaxle case. Figure 104 1 2 Figure 105 28.Install side cover: A. Insert 2 dowel pins onto transaxle case. B. Apply silicone sealant onto mating surface of side cover. C. Install side cover. Tighten cap screws to a torque from 18.5 to 22 ft–lb (24.5 to 29.5 N–m). Figure 106 29.Install R.H. axle shaft assembly: A. Apply silicone sealant onto mating surface of seal cover. B.
PAGE 123
30.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 inserted against the bearing. 2 Figure 108 C. Install axle shaft assembly and tighten cap screws (Item 1) to a torque from 18.5 to 22 ft–lb (24.5 to 29.5 N–m). 1 Figure 109 Drive Train 31.Measure backlash of ring gear through window on transaxle case.
PAGE 124
32.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 111 33.Apply silicone sealant to mating surface of upper cover (Item 2). Pay attention to direction of cover and install. Tighten cap screws (Item 1) to a torque from 18.5 to 22 ft–lb (24.5 to 29.5 N–m).
PAGE 125
34.Apply multi–purpose grease to O–ring and insert O– ring into groove of transaxle case. If installing P.T.O., insert 2 dowel pins in transaxle case. Install P.T.O. or cover. Tighten nut with lockwasher (Item 2) and cap screws (Item 1) to a torque from 11 to 13 ft–lb (15 to 17 N–m). 2 3 1 Figure 113 35.Install bell housing and secure with cap screws (Item 2). Tighten cap screws to a torque from 18.5 to 22 ft–lb (24.5 to 29.5 N–m). 1 36.Install extension spring (Item 1).
PAGE 126
Power Take–Off (P.T.O.) Service 33 34 35 3 32 28 26 29 30 1 31 17 25 2 3 24 27 11 18 to 22 ft–lb (24.5 to 29.5 N–m) 2 4 17 5 3 6 22 21 8 7 9 20 23 19 17 12 11 10 13 14 18 16 15 Figure 115 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. PTO cover Cap screw (4 used) Lock washer (7 used) Cap screw (3 used) O–ring Shift arm Shifter block Spring Ball Retaining ring Bearing Input shaft 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
PAGE 127
5. Remove PTO output shaft assembly (Item 1) from PTO housing. Remove oil seal from PTO cover. 1 Figure 117 6. Remove intermediate shaft assembly (Item 1) from PTO housing. Remove intermediate gear (Item 2). Remove bearing (Item 3) from housing if necessary.
PAGE 128
7. Remove PTO input shaft from PTO housing: A. Shift PTO to ”ON” position. B. Remove 2 retaining rings (Items 1 and 2) from PTO housing. C. Slide input shaft assembly (Item 3) toward PTO shaft side. D. Remove bearing (Item 4). E. Slide input shaft toward other side. F. Remove bearing (Item 5). G. Remove thrust washer (Item 6) and gear (Item 7), sliding input shaft toward PTO shaft side. Figure 120 H. Release shift arm (Item 8) from shifter block (Item 9). 8 I. Remove input shaft assembly.
PAGE 129
9. Disassemble PTO intermediate shaft: A. Use a bearing puller to remove bearing (Item 1) if necessary. 1 Figure 123 10.Disassemble PTO output shaft: A. Use a bearing puller to remove bearing (Item 1). B. Remove gear (Item 2) and retaining ring (Item 3). C. Remove retaining ring (Item 4) and thrust washer Item 5). D. Use a bearing puller to remove bearing (Item 6) if necessary. Figure 124 4 Drive Train 5 6 7 3 1 2 Figure 125 11. Disassemble shift arm: A. Remove two (2) lock pins from shift arm.
PAGE 130
Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. 3. Measure clearance between groove on shift collar and shifter block. Replace shifter block if clearance exceeds .039 in. (1.0 mm). Figure 127 4. Measure I.D. of input shaft bushing (Item 1). Replace bushing if I.D. exceeds .673 in. (17.10 mm). 1 Figure 128 5. Measure O.D. of bushing area on input shaft. Replace shaft if O.D. is less than .667 in. (16.95 mm).
PAGE 131
Assembly (Fig. 115) NOTE: Item numbers in figures are shown in reverse order of assembly; for example, when reassembling, install Item 1 last. 1. Clean gasket material from mating surfaces of housing and cover. 3 2 1 IMPORTANT: Be careful not to damage mating surfaces when removing gasket material. 2. Make sure all parts are free of dirt and dust. 3. Assemble shift arm: Figure 131 A. Install two (2) new O–rings (Item 1) onto shift arm. Apply moly disulfide grease to O–rings before installing. B.
PAGE 132
4. Assemble PTO output shaft: 5 6 4 A. If bearing (Item 6) was removed, use a press to install bearing onto output shaft. B. Install washer (Item 5) and retaining ring (Item 4). C. Install retaining ring (Item 3) and gear (Item 2). 7 D. Use a press to install bearing (Item 1). 3 1 2 Figure 134 Figure 135 5. Use a press to install bearing (Item 1) onto intermediate shaft. 1 Figure 136 6. Assemble PTO input shaft: A. Insert spring (Item 3) and two (2) steel balls (Item 2) into hole. 2 1 B.
PAGE 133
7. Install PTO input shaft sub–assembly: 7 A. Insert shifter block (Item 9) onto pin of shift arm. Apply moly disulfide grease onto both sides of block before installing. B. Put shift collar of PTO input shaft sub–assembly (Item 3) on the shifter block. C. Install gear (Item 7) with bushing and thrust washer (Item 6) onto input shaft after sliding the assembly toward PTO shaft side. Apply moly disulfide grease to bushing of gear and thrust washer before installing. 3 6 5 4 Figure 138 D.
PAGE 134
8. Install PTO intermediate shaft sub–assembly: A. If removed during disassembly, insert bearing (Item 3) into PTO housing. 3 Figure 142 B. Put gear (Item 2) on mating gear. C. Move gear until bores of gear and bearing line up. D. Insert intermediate shaft sub–assembly (Item 1). Apply grease to intermediate shaft to aid assembly. 2 1 Figure 143 9. Insert PTO shaft assembly (Item 1) into bearing housing of PTO housing.
PAGE 135
10.Install PTO cover: A. Insert new oil seal into PTO cover. Apply multi– purpose grease to lip of oil seal. B. Insert two (2) alignment pins into PTO housing. C. Apply silicone sealant onto mating surface of PTO cover. D. Install PTO cover. Tighten cap screws and nut with lockwasher to a torque from 18 to 22 ft–lb (24.5 to 29.5 N–m). Figure 145 Drive Train 11. Install PTO to transaxle (see PTO Removal and Installation in this chapter).
PAGE 136
This page is intentionally blank.
PAGE 137
Chapter 7 Chassis Table of Contents Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . Brake Master Cylinder Service . . . . . . . . . . . . . . . Parking Brake Cable Replacement . . . . . . . . . . . Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Arm Ball Joint Replacement . . . . . . . . . . Tie Rod End Replacement . . . . . . . . . . . . . . . . . . Front Wheel Alignment . . . . . . . . . . . . . . . . . . . . . Front Compression Spring Service . . . . . .
PAGE 138
Specifications Item Specification Front wheel toe–in 0 to 0.125 in. (0 to 3 mm) Front tire 20” x 10” – 10, 4 ply Maximum front tire pressure 20 PSI Rear tire 24” x 12” – 12, 6 ply Maximum rear tire pressure 18 PSI Wheel nut torque 45 to 65 ft–lb (61 to 88 N–m) Brake fluid DOT 3 Tire Pressure 1. Tire pressure needed is determined by the payload carried. 2. The lower the air pressure, the less the compaction, and tire marks are minimized.
PAGE 139
Special Tools Compression Spring Tool Use to remove and install the two (2) front suspension compression springs. Qty.
PAGE 140
Troubleshooting Suspension and Steering Problem Possible Causes Front end noise. Loose or worn front wheel bearings. Worn front shock absorbers. Worn stabilizer link bushings. Loose steering components (e.g. tie rods, steering cylinder). Worn control arm bushings. Tire pressure low (4WD vehicles). Worn tires (4WD vehicles). Rear end noise. Worn or brinelled rear wheel bearings. Worn rear shock absorbers. Worn leaf spring bushings. Clutch, drive shaft or transaxle problem (see Chapter 6 – Drive Train).
PAGE 141
Suspension and Steering (Continued) Problem Possible Causes 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). Damaged or binding steering cylinder. Worn or damaged steering control valve. 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.
PAGE 142
Brakes Problem Possible Causes Brake pedal goes to floor. Incorrectly adjusted brakes. Low brake fluid level. Air in brake system. Leaking wheel cylinder(s). Loose or broken brake lines. Leaking or worn brake master cylinder. Excessively worn brake shoes or drums. Spongy brake pedal. Air in brake system. Excessively worn or cracked brake drums. Broken or worn brake pedal pivot bushing. Brakes pulling. Incorrect tire pressure. Contaminated brake linings. Front end out of alignment.
PAGE 143
Brakes (Continued) Problem Possible Causes Dragging brakes. Improper brake or parking brake adjustment. Parking brake engaged. Weak or broken brake shoe return spring. Binding brake pedal. Sticking brake master cylinder. Saturated brake linings. Bent or out of round brake drums. 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.
PAGE 144
Service and Repairs Wheel Installation 1. Mount wheel and evenly tighten wheel nuts to a torque from 45 to 65 ft–lb (61 to 88 N–m). WARNING Failure to maintain proper wheel nut torque could result in failure or loss of wheel and may result in personal injury. Torque front and rear wheel nuts from 45 to 65 ft–lb (61 to 88 N–m) at intervals recommended in Operator’s Manual. Figure 2 1. Wheel assembly Chassis Page 7 – 8 2.
PAGE 145
Chassis This page is intentionally blank.
PAGE 146
Front Wheel Assembly (2 Wheel Drive) 3 5 1 45 to 65 ft–lb (61 to 88 N–m) 6 Loctite #680 2 8 40 to 60 ft–lb (54 to 81 N–m) 10 4 9 11 12 See tightening procedure in text 13 17 18 19 20 7 RIGHT 14 ACCESS HOLE 15 16 FRONT Figure 3 1. 2. 3. 4. 5. 6. 7. Dust cap Cotter pin Nut retainer Jam nut Tab washer Wheel nut (5 used per wheel) Wheel assembly 8. 9. 10. 11. 12. 13. 14.
PAGE 147
4. Carefully slide wheel hub with inner bearing cone and seal onto spindle. Fill cavity of wheel hub 50% full with grease. 8. Adjust brake shoes: A. Align access hole in brake drum with adjuster bolt on adjuster assembly. 5. Pack outer bearing cone with grease and insert it into wheel hub over spindle. Install tab washer over bearing and secure hub to spindle with jam nut. DO NOT tighten jam nut. 6. While rotating wheel hub, tighten jam nut to a torque from 75 to 180 in–lb (8.5 to 20.3 N–m).
PAGE 148
Rear Wheel Assembly 25 40 to 60 ft–lb (54 to 81 N–m) 16 24 8 23 12 11 22 Loctite #680 10 26 220 to 250 ft–lb (298 to 339 N–m) 9 7 21 6 15 20 19 18 FRONT 45 to 65 ft–lb (61 to 88 N–m) 17 13 RIGHT 4 5 14 200 to 250 in–lb (22.6 to 28.3 N–m) 8 2 1 ACCESS HOLE 3 Figure 4 1. 2. 3. 4. 5. 6. 7. 8. 9. Flange nut Wheel nut (5 used per wheel) Wheel assembly Brake drum Stub axle Lock washer (5 used per wheel) Hex bolt (5 used per wheel) Bearing Bearing spacer 10. 11. 12. 13. 14. 15. 16.
PAGE 149
Chassis This page is intentionally blank.
PAGE 150
Brake Service 2 49 to 97 in–lb (5.5 to 11 N–m) 8 1 7 13 26 25 5 4 3 11 6 9 12 10 10 24 12 11 14 16 17 18 21 13 15 27 19 20 23 22 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. Cap screw and lock washer (2 used) Backing plate Plug Bleed screw Bleed screw cap Brake cylinder body Parking brake lever Pin Spring Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18. L–type seal Piston Dust cover Brake shoe Upper shoe spring Lower shoe spring Female push rod Bolt adjuster Adjuster sleeve Page 7 – 14 19.
PAGE 151
B. Replace drums if they are cracked or heat spotted. Disassembly (Fig. 5 and 6) 1. Partially loosen wheel nuts then jack up and support vehicle (see Jacking Instructions in Operator’s Manual). Remove wheel nuts and then remove wheel. NOTE: It may be necessary to back off adjuster to remove brake drum. To back off adjuster, rotate brake drum until access hole lines up with bolt adjuster on adjuster assembly. Use a hooked piece of wire to pull pawl away from bolt adjuster, then turn bolt adjuster. 3.
PAGE 152
4. Inspect upper shoe spring (14), lower shoe spring (15) and adjuster spring (20). A. Replace if springs show signs of overheating as indicated by a slight blue color. Over heated springs lose their tension and could cause brake linings to wear out prematurely. B. Replace sagging, bent or externally damaged springs. 5. Inspect backing plate (2). A. Replace if shoe contact surfaces have grooves that may restrict shoe movement and can not be removed by sanding lightly with emery cloth. B.
PAGE 153
Wheel Brake Cylinder Service Disassembly 1. Disassemble brakes as described in Brake Service. 5 2. If brake line is still attached to brake cylinder, disconnect brake line from cylinder. Put a cap on brake line to prevent contamination of system and brake fluid leakage. 6 7 1 4 1 3. Remove two (2) cap screws and lock washers that secure brake cylinder to brake backing plate. Remove brake cylinder assembly. 3 2 4. Remove dust covers, pistons, L–type seals and spring from brake cylinder body (Fig.
PAGE 154
Bleeding the Brakes 1. Connect a suitable transparent hose to bleeder valve on right rear wheel cylinder and submerge other end of hose 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.
PAGE 155
Chassis This page is intentionally blank.
PAGE 156
Brake Master Cylinder 2 RIGHT 1 FRONT 3 4 5 6 Figure 9 1. Brake master cylinder 2. Cap screw (2 used) 3. Clevis pin 4. Cotter pin 5. Flange nut (2 used) 6. Brake pedal Removal (Fig. 9) Installation (Fig. 9) 1. Remove cotter pin from the clevis pin that connects master cylinder to brake pedal. 1. Position master cylinder to vehicle frame and secure with two (2) cap screws and flange nuts. 2. Clean hydraulic brake line area of master cylinder to prevent contamination.
PAGE 157
Brake Master Cylinder Service Disassembly (Fig. 10) 4 1. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 5 2. Disconnect lower end of the dust cover from the housing. 6 3. Push in on the push rod and remove circlip, then remove push rod with dust cover and clevis. Remove retainer washer. 4. Remove primary piston assembly and secondary piston assembly from cylinder housing. 7 11 8 9 12 10 Inspection 1.
PAGE 158
Parking Brake Cable Replacement 7. Install center console control plate and control lever knobs. Removal (Fig. 11) 1. Remove brake handle from parking brake lever. Loosen set screw on parking brake control lever knob. Turn knob on parking brake lever counterclockwise all the way to loosen brake cable adjustment. 8. Adjust parking brake lever (see Operator’s Manual) and check operation of brakes before using the vehicle. 8 2.
PAGE 159
Steering Wheel Removal (Fig. 14) 3 1 1. Carefully remove steering wheel cover from steering wheel. 2 2. Remove hex nut and lock washer that secure steering wheel to steering control valve. 5 20 to 26 ft–lb (28 to 35 N–m) 3. Pull steering wheel from control valve. Installation (Fig. 14) 4 1. Apply anti–seize lubricant to shaft of control valve. Anti–seize Lubricant 2. Slide steering wheel onto control valve shaft. 3. Secure steering wheel with lock washer and hex nut.
PAGE 160
Control Arm Ball Joint Replacement 8 3 5 6 7 9 12 2 80 to 90 ft–lb (108 to 122 N–m) 1 10 9 7 11 6 4 RIGHT FRONT 11 5 8 9 10 Figure 15 1. 2. 3. 4. Cotter pin Slotted hex nut Upper control arm (RH shown) Lower control arm (RH shown) 5. 6. 7. 8. Flange bushing Cap screw Lock nut Spindle (RH, 2WD shown) Installation (Fig. 15) Removal (Fig. 15) 1. Press new ball joint into control arm. Install snap ring to secure ball joint.
PAGE 161
Tie Rod End Replacement 9 8 1 45 to 55 ft--lb (61 to 75 N--m) 7 2 3 4 5 RIGHT FRONT 50 ft--lb (68 N--m) 2 6 45 to 55 ft--lb (61 to 75 N--m) Figure 16 4. Tie rod 5. Jam nut (LH thread) 6. Tie rod end (LH thread) 7. Pitman arm 8. Steering cylinder 9. Spindle (RH shown) Removal (Fig. 16) Installation (Fig. 16) 1. Loosen jam nut that secures affected tie rod end to tie rod. 1. Install new tie rod end to tie rod. Thread in the same number of revolutions as the old one took to remove. 2.
PAGE 162
Front Wheel Alignment 1. Before inspecting or adjusting front wheel alignment, check that when fully retracted, the steering cylinder has a length as shown in Figure 17. If the retracted cylinder length is incorrect, see Steering Cylinder Installation in Service and Repair section of Chapter 9 -- Hydraulic System for steering cylinder ball joint installation procedure. CYLINDER LENGTH WHEN FULLY RETRACTED 2.
PAGE 163
Front Compression Spring Service COMPRESSION SPRING TOOL TOP VIEW 20I Control arm tower (4) 1/2I flat washers 5I Compression spring tool rod (2) 1/2I steel rods 8 Spring cradle 5I (4) 1/2I nuts Compression spring 9 1 6 7 Install compression spring tool rods with extended portion on opposite ends so cap screws (Item 7) securing spring cradles to control arm tower can be removed. Extended portion should be on nut side of cap screw. 5 2 4 3 Figure 19 7. Cap screw 8. Control arm tower 9.
PAGE 164
Front Shock Absorber Replacement 1. Remove lower and upper lock nuts, then remove shock absorber and washers. Note that washers on upper end of shock absorber are different. Washers on lower end of shock are identical. 10 2. Insert two (2) new rubber bushings into each end of new shock absorber. Insert spacer into ram (lower) end of shock absorber. 7 6 5 3. Install inner washer onto stud above control arm. 1 4.
PAGE 165
Rear Shock Absorber Replacement 1. Remove lower and upper lock nuts, then remove shock absorber and washers from vehicle. 2 2. Insert two (2) new rubber bushings into each end of new shock absorber. 1 4 5 3. Install one large washer onto each shock absorber mounting stud. 3 4. Install new shock absorber with ram end down. Secure each end with with large washer and lock nut. 2 5 1 4 Figure 23 1. Rubber bushing 2. Large washer 3. Shock absorber 4. Large washer 5.
PAGE 166
Rear Leaf Spring Replacement 1 2 3 3 2 12 1 1 4 5 7 6 8 9 13 RIGHT 10 11 FRONT 3 See tightening procedure in text 14 Figure 25 1. 2. 3. 4. 5. Lock nut Spring shackle Rubber bushing Axle bumper Hex nut 6. 7. 8. 9. 10. Lock nut (4 used per spring) Washer (4 used per spring) Spring plate Leaf spring Flange head screw (2 per mount) 11. 12. 13. 14.
PAGE 167
Installation (Fig. 25) 1. Before installing new leaf spring, insert four (4) rubber bushings (Item 3) 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 2), from inside/ out, into rear of leaf spring. Insert spring mount (Item 11), from outside/in, to front of leaf spring and secure, finger tight, with lock nut. 3. Install leaf spring assembly to frame.
PAGE 168
Seat Base 1 6 4 2 5 3 11 10 8 9 7 RIGHT FRONT Figure 27 1. 2. 3. 4. Passenger seat Screw (6 used) Control plate Hose to radiator Chassis 5. 6. 7. 8. Coolant reservoir Operator seat Lock nut Flat washer Page 7 – 32 9. Cap screw 10. Seat base 11.
PAGE 169
Removal (Fig. 27) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. 2. Remove ROPS from vehicle (Fig. 28) 3. Remove knobs from control levers, then remove center console control plate assembly. 1 5 4. Remove four (4) socket head screws that secure each seat to vehicle. Lift both seats from vehicle. 5. Remove cap screw, flat washer and lock nut that secure each front corner of seat base to frame. 2 4 6.
PAGE 170
This page is intentionally blank.
PAGE 171
Chapter 8 Electrical System Table of Contents Start Relay (Kohler Engine) . . . . . . . . . . . . . . . . . . 11 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Indicator Lights and Gauges . . . . . . . . . . . . . . . . . . 12 High Temperature Shutdown Switch (Briggs/ Daihatsu Gas and Diesel Engine) . . . . . . . . . . . 13 Fuel Gauge Sender . . . . . . . . . . . . . . . . . . . . . . . . . 14 Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 172
Electrical Schematics The electrical schematics for the Workman are located in Chapter 11 -- Electrical Schematics. Special Tools Order special tools from your Toro Distributor. 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.
PAGE 173
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this vehicle (see Vehicle Electrical Schematics in Chapter 11). 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.
PAGE 174
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. Rear PTO switch (if equipped) faulty. Rear PTO switch (if equipped) wiring loose, corroded or damaged.
PAGE 175
Electrical System Quick Checks Battery Test (Open Circuit 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 (16o to 38o C). The ignition key should be in the OFF position and all accessories turned off.
PAGE 176
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 (all models), the hydraulic lift lever is in the neutral position (TC models) and rear PTO (if so equipped) is disengaged. 1. Sit on operator’s seat and engage parking brake. Move shift lever to NEUTRAL position. Disengage rear PTO (if so equipped). 2. Move hydraulic lift lever out of neutral position.
PAGE 177
Component 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.
PAGE 178
Clutch Switch The clutch switch is normally open and closes when the clutch pedal is depressed. The clutch switch is attached to a bracket on the left side of the clutch bell housing (Fig. 6). 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.
PAGE 179
Transaxle Lockout Switches 2–3 Lockout Switch 1 The transaxle 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.
PAGE 180
Start (Briggs/Daihatsu Gas and Diesel Engine) and Fuel Pump (Briggs/Daihatsu Gas Engine) Relay The start relay used on Workman vehicles with a Briggs/ Daihatsu gasoline or diesel engine and the fuel pump relay on Workman vehicles with a Briggs/Daihatsu gasoline engine are identical. These relays are attached to the frame near the hydraulic oil filter. Testing NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together.
PAGE 181
Glow Relay (Briggs/Daihatsu Diesel Engine) On Workman vehicles with a diesel engine, the glow relay is attached to the the hydraulic oil filter bracket. Two styles of glow relays have been used on the Workman. On machines with serial numbers below 260000000, two of the four relay connections are secured with screws (Fig. 11). On machines with serial numbers above 260000000, the glow relay is attached to the wire harness with a four wire connector (Fig. 12). 86 87 85 30 1.
PAGE 182
Battery Use a digital multi meter to measure the voltage between the battery terminals. If the voltage is less than 12.3 Volts DC, the battery should be charged. NOTE: Regulated battery voltage will increase to approximately 13.5 Volts when the engine is running. 1 Figure 13 1.
PAGE 183
High Temperature Shutdown Switch (Briggs/Daihatsu Gas and Diesel Engine) The high temperature shutdown switch is threaded into the thermostat housing (Fig. 15). There is a blue wire attached to the switch. 1 2 Testing CAUTION Make sure engine is cool before removing the temperature switch. 1. Lower coolant level in the engine and remove the temperature shutdown switch. 2. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 16). Figure 15 1. Temp. shutdown switch 2.
PAGE 184
Fuel Gauge Sender Disconnect wire and remove the fuel gauge sender from the fuel tank. 1 CAUTION Make sure sending unit is completely dry (no fuel on it) before testing. Perform test away from the tank to prevent an explosion or fire from sparks. Install an ohm meter between the terminal and base. With arm completely down (empty position), resistance should be 240–260 ohms. With arm completely up (full position), resistance should be 29–34 ohms. Figure 17 1.
PAGE 185
Glow Plug Switch (Briggs/Daihatsu Diesel Engine) The glow plug switch is located on the control panel on vehicles powered with a diesel engine. This rocker switch allows the glow plugs to be energized. The switch terminals are marked as shown in Figure 20. The circuitry of the glow plug switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position.
PAGE 186
Diode Assembly (Kohler Engine) The diode assembly on Kohler powered Workman vehicles is used for circuit protection from voltage spikes that occur when the starter solenoid is de–energized. 2 The diode assembly plugs into the vehicle wiring harness (see Workman 3100 electrical schematic in Chapter 11 – Electrical Schematics). 3 1 Testing Figure 22 The diode assembly can be tested using a digital multimeter (diode test or ohms setting) and the table to the right. 1. Diode 2. Male terminal 3.
PAGE 187
Service and Repairs 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. 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 24 1.
PAGE 188
2. If battery filler caps are removable, conduct a hydrometer test of the battery electrolyte. D. If battery filler caps are removable, 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.
PAGE 189
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 nut with two wrenches.
PAGE 190
Headlight Replacement Disassemble and assemble headlight as follows: 1 1. Set parking brake, turn ignition off, and remove key. 2. Reach beneath dash and disconnect the wiring harness connector from the headlight. 3. From beneath the dash, push headlight out of the hood. 4. Remove rubber seal from around the headlight. Discard headlight. 5. Align notch on the inside of the seal with the notch on the new headlight. Slide seal onto the headlight until the seal is firmly in place.
PAGE 191
Chapter 9 Hydraulic System Table of Contents SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . 25 General Precautions for Removing and Installing Hydraulic System Components . . . . . . . . . . . . . 25 Check Hydraulic Lines and Hoses . . . . . . . . . . . . 25 Gear Pump (Vehicles With Liquid Cooled Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Gear Pump (Vehicles With Air Cooled Engine) . 27 Gear Pump Service Barnes Gear Pump) . . . . . .
PAGE 192
This page is intentionally blank.
PAGE 193
Specifications Item Description Hydraulic Pump Positive Displacement Gear Pump Pump Performance 4 GPM (15 LPM) at 1,500 PSI (103.4 Bar) System Relief Pressure 1,800 PSI (124.1 Bar) Lift Control Valve Three position control valve Spring return to neutral Ball checks to maintain load Hydraulic Oil Dexron III ATF Reservoir (Transaxle) 8 U.S. quart (7.
PAGE 194
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 conditions, or mishandling during operation or maintenance. These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these conditions than others. Inspect the hoses frequently for signs of deterioration or damage.
PAGE 195
SAE Straight Thread O–Ring Port – Non–adjustable 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 fitting 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. 5. Tighten the fitting to the correct Flats From Finger Tight (F.F.F.T.). Size 4 (1/4 in.
PAGE 196
Hydraulic System Page 9 – 6 100 MESH STRAINER TRANSAXLE RESERVOIR 10 MICRON RETURN FILTER W/25 PSI BYPASS (6.36 CC/REV) .769 ENGINE SPEED PUMP BARNES .388 IN 3 /REV E T P STEERING UNIT SAUER OSPM – PB 3 3.05 IN /REV (50 CC/REV) 1800 PSI RELIEF R L PARKER VY13 VALVE LIFT CYLINDERS (2) TEXAS HYDRAULICS ROD .750 IN (19.1 MM) BORE 1.50 IN (38.1 MM) STROKE 16.25 IN (41.3 CM) STEERING CYLINDER TEXAS HYDRAULICS ROD .625 IN (15.9 MM) BORE 1.750 IN (44.5 MM) STROKE 5.56 IN (14.1 CM) 2WD 4.47 IN (11.
PAGE 197
Hydraulic System IN TANK SUCTION STRAINER 100 MESH Workman 3000/4000 Series Page 9 – 7 4 GALLON RESERVOIR OIL COOLER RELIEF VALVE 2000 PSI SOLENOID ACTIVATED BYPASS VALVE RETURN FILTER 10 MICRON WITH 25 PSI BYPASS HYDRAULIC GEAR PUMP .610 IN 3 /REV (10 CC/REV) .
PAGE 198
Hydraulic Circuit Operation Steering Circuit Left Turn When a left turn is made with the engine running, the turning of the steering wheel positions the spool valve so that flow goes through the top of the spool. Flow entering the steering control valve at the P port passes through the rotary meter and is directed out the L port. Pressure contracts the steering cylinder for a left turn.
PAGE 199
Raise and Lower Bed The hydraulic gear pump supplies flow for the steering circuit and for raising and lowering the bed. Pump output flows through the steering control valve and then to the lift valve for raising and lowering the bed (flow priority to the steering circuit). Circuit pressure is limited by a relief valve located in the steering control valve. When the control valve lever is released, spring action returns the lift valve spool to the center position and lift cylinder movement is stopped.
PAGE 200
Special Tools Order these tools from your Toro Distributor. Hydraulic Pressure Test Kit (TOR47009) Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on vehicle 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. Use gauges as recommended in Testing section of this chapter.
PAGE 201
Hydraulic Test Fitting Kit (TOR4079) This kit includes a variety of O–ring Face seal fittings to enable connection of test gauges to the hydraulic system. TORO TEST FITTING KIT (NO. TOR4079) The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Figure 11 Male Coupler (For Optional High Flow Hydraulic Kit) (#105–4170) Male coupler that fits into female hydraulic coupler that is included in High Flow Hydraulic Kit.
PAGE 202
Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either of these conditions be noticed, immediately stop the vehicle, turn off the engine, locate the cause of the trouble and correct it before allowing the vehicle to be used again.
PAGE 203
Problem Possible Cause Lift cylinders extend with valve in neutral position. Load checks in hydraulic lift valve are leaking. Lift valve lever is sticking. Lift valve control handle is not in correct location. Hydraulic relief valve stuck or damaged (see TEST NO. 1). Bed drops from raised position with lift valve in centered position. Improperly positioned valve. Lift valve worn or damaged. Internal leakage of lift cylinder(s). Lift cylinder hydraulic lines or fittings leaking.
PAGE 204
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ
PAGE 205
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 Special Tools section in this Chapter.) CAUTION Failure to use gauges with recommended pressure (psi) rating as listed in test procedures could result in damage to gauge and possible personal injury from leaking hot oil.
PAGE 206
TEST NO. 1: Gear Pump Flow and System Relief Pressure STEERING CONTROL L P STEERING CYLINDER T E R TESTER LIFT CYLINDERS GEAR PUMP FILTER STRAINER LIFT VALVE TRANSAXLE RESERVOIR Figure 13 1 2 3 Figure 14 1. Gear pump 2. Pressure hose Hydraulic System 3.
PAGE 207
Procedure for Gear Pump Flow and System Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the vehicle for approximately 10 minutes. 2. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. After turning engine off, operate all hydraulic controls to relieve hydraulic system pressure. 8. While watching tester pressure gauges, slowly close flow control valve on the tester until 1500 PSI (103.
PAGE 208
TEST NO.
PAGE 209
Procedure for Steering Control Valve and Steering Cylinder Test 1. Make sure hydraulic oil is at normal operating temperature by operating the vehicle for approximately 10 minutes. NOTE: This steering test procedure will be affected by incorrect tire pressure, binding of the hydraulic steering cylinder, excessive weight on the vehicle, and/or binding of the steering assembly (e.g. wheel spindles, tie rods). Make sure that these items are checked before proceeding with any hydraulic testing procedure. 2.
PAGE 210
TEST NO.
PAGE 211
Procedure for Lift Cylinder Internal Leakage Test Disconnect and plug this hose 1. Shut off engine and engage parking brake. ANY oil flow or droplets from this fitting indicates internal leak CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning of this section. 2. Remove all pressure from cylinder by fully retracting it (i.e. put hydraulic lift lever in LOWER position).
PAGE 212
TEST NO. 4: High Flow Hydraulic Kit (Optional) Gear Pump Flow and Relief Pressure QUICK DISCONNECT COUPLINGS HYDRAULIC GEAR PUMP .610 IN 3/REV .833 ENGINE SPEED TESTER SOLENOID ACTIVATED BYPASS VALVE (ENERGIZED) RELIEF VALVE 2000 PSI IN TANK SUCTION STRAINER 100 MESH RETURN FILTER 10 MICRON WITH 25 PSI BYPASS 4 GALLON RESERVOIR OIL COOLER Figure 18 2 1 Figure 19 1. Pressure coupler Hydraulic System 2.
PAGE 213
Procedure for High Flow Hydraulic Kit (Optional) Gear Pump Flow and System Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the vehicle for approximately 10 minutes. 2. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. After turning engine off, operate all hydraulic controls to relieve hydraulic system pressure. 3.
PAGE 214
This page is intentionally blank.
PAGE 215
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic system, park vehicle on a level surface, engage parking brake, and stop engine. Remove key from the ignition switch. 1. Check oil level in the transaxle and add correct oil if necessary.
PAGE 216
Gear Pump (Vehicles with Liquid Cooled Engine) 3. Check oil level in transaxle (see Operator’s Manual). Add Dexron III ATF if necessary. Removal (Fig. 20) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage parking brake. 2. Loosen pump drive belt and remove belt from pump pulley (see Operator’s Manual). 4. Start the engine and operate at idle speed until air is out of hydraulic system. 5.
PAGE 217
Gear Pump (Vehicles with Air Cooled Engine) 3. Check oil level in transaxle (see Operator’s Manual). Add Dexron III ATF if necessary. Removal (Fig. 22) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. 4. Start the engine and operate at idle speed until air is out of hydraulic system. 2. Loosen pump drive belt and remove belt from pump pulley (see Operator’s Manual). 5.
PAGE 218
Gear Pump Service (Barnes Gear Pump) 9.5 to 12.5 ft--lb (13 to 17 N--m) 18 17 20 23 12 13 14 15 16 11 19 10 9 8 6 1 2 3 4 4 7 5 4 12 16 11 21 12 22 1. 2. 3. 4. 5. 6. 7. 8. Retaining ring Shaft seal Spacer Crescent ring Square key Drive shaft Shear pin Stator 9. 10. 11. 12. 13. 14. 15. 16.
PAGE 219
Disassembly (Fig. 23) Assembly (Fig. 23) 1. Remove shaft seal (see Shaft Seal Replacement). IMPORTANT: Use caution when using a vise to avoid distorting any pump components. 1. Install one crescent ring (Item 4) on inside portion of driveshaft (Item 6), then install bearing (Item 22) and other crescent ring. Install driveshaft and bearing assembly into stator (Item 8). 2. Secure flange end of pump in a vise with drive shaft (Item 6) facing down. 2.
PAGE 220
Gear Pump Service (Casappa Gear Pump) 4 13 9 3 1 6 14 7 2 16 5 10 12 5 4 17 15 11 220 in--lb (25 N--m) 8 Figure 23.1 1. 2. 3. 4. 5. 6. Retaining ring Shaft seal Front cover Dowel pin O--ring (2 used) Back--up seal 7. 8. 9. 10. 11. 12. Pressure seal Front thrust plate Drive shaft Idler shaft Body Rear thrust plate 13. 14. 15. 16. 17. Pressure seal Back--up seal Rear flange Lock washer (4 used) Screw (4 used) Disassembly (Fig. 23.1) 1.
PAGE 221
IMPORTANT: Make sure to not damage the seal bores when removing the seal from the front cover and rear flange. 3 10.Carefully remove retaining ring and shaft seal from front cover. Discard seal. 2 Inspection 1. Remove any nicks and burrs from all parts with emery cloth. 1 CAUTION 4 Use eye protection such as goggles when using compressed air. Figure 23.3 1. 2. Gear shaft spline Gear shaft 3. 4. Gear teeth Gear face edge 2. Clean all parts with solvent. Dry all parts with compressed air. 2.
PAGE 222
12.Carefully install rear flange onto pump assembly. 15.Remove pump from vise. 13.Install the four (4) screws (item 17) with lock washers and hand tighten. 16.Place a small amount of clean Dexron III ATF in the inlet of the pump and rotate the drive shaft away from the inlet one revolution. If any binding is noted, disassemble the pump and check for assembly problems. IMPORTANT: Prevent damage when clamping the pump into a vise; clamp on the front cover only. Also, use a vise with soft jaws. 14.
PAGE 223
Hydraulic System This page is intentionally blank. Workman 3000/4000 Series Page 9 -- 29.4 Rev.
PAGE 224
Lift Valve 20 17 18 17 5 16 RIGHT 21 19 FRONT 5 12 10 2 15 1 10 11 8 9 14 2 5 3 13 6 4 5 7 Figure 24 1. 2. 3. 4. 5. 6. 7. Lift valve O–ring Tee fitting Hyd. hose (steering circuit return) O–ring Hyd. hose (return to hydraulic filter) Flange nut Hydraulic System 8. 9. 10. 11. 12. 13. 14. Lift lever Clevis pin Hairpin Jam nut Link rod Clevis Hyd. hose (to male quick fitting) Page 9 – 30 15. 16. 17. 18. 19. 20. 21. Hyd.
PAGE 225
Removal (Fig. 24) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. 2. Remove seat base from vehicle (see Seat Base Removal in the Service and Repairs section of Chapter 7 – Chassis). 1 2 3 4 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
PAGE 226
Lift Valve Service Disassembly (Fig. 26) 1. After removing lift valve from vehicle, wash valve in solvent and dry thoroughly. 2. Carefully mount lift valve in a vise so that mounting pads are against jaws of vise. Lift valve spool retaining ring (Item 14) should be facing up. 8 3. Remove two (2) hex cap plugs (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); remove these parts.
PAGE 227
Hydraulic System This page is intentionally blank.
PAGE 228
Steering Control Valve 1 RIGHT 20 to 26 ft--lb (28 to 35 N--m) 2 10 3 FRONT 12 11 CONTROL VALVE PORTS Anti--seize Lubricant 13 4 9 FRONT OF VEHICLE 8 5 6 7 20 19 14 15 1. 2. 3. 4. 5. 6. 7. 16 17 18 Hex nut Lock washer Steering wheel Steering control valve Hyd hose (to control valve P port) Hyd hose (to control valve E port) Hyd hose (to control valve T port) 8. 9. 10. 11. 12. 13. 14.
PAGE 229
7. Start the engine, operate at idle speed and rotate the steering wheel in both directions until air is out of hydraulic system. CAUTION Before performing any service or repair on hydraulic system components, relieve system pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the ignition switch, rotate the steering wheel in both directions, lower or support the bed and operate other hydraulic accessories. 8.
PAGE 230
Steering Control Valve Service 8 9 7 6 10 5 4 3 2 11 1 12 22 13 14 15 21 13 16 20 13 17 18 20 to 24 ft–lb (27 to 33 N–m) 19 Figure 30 1. 2. 3. 4. 5. 6. 7. 8. Sleeve Cross pin Ring Spool Bearing assembly Shaft seal Ball stop Ball 9. 10. 11. 12. 13. 14. 15. Dust seal ring Housing Cardan shaft Spacer O–ring Distribution plate Inner gearwheel 16. 17. 18. 19. 20. 21. 22.
PAGE 231
Hydraulic System This page is intentionally blank.
PAGE 232
Steering Cylinder 14 12 15 1 2 3 3 13 4 7 12 11 8 5 6 10 9 RIGHT FRONT Figure 31 1. 2. 3. 4. 5. Steering cylinder Retaining ring Grease fitting 90o hydraulic fitting Hyd. hose (from steering valve R) Hydraulic System 6. 7. 8. 9. 10. Hyd. hose (from steering valve L) 45o hydraulic fitting Jam nut Pitman arm Slotted hex nut Page 9 – 38 11. 12. 13. 14. 15.
PAGE 233
Removal (Fig. 31) 50 ft--lb (68 N--m) 1. Park vehicle on a level surface, shut engine off and engage the parking brake. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 7 8 4 CAUTION 1 Before performing any service or repair on hydraulic system components, relieve system pressure to avoid injury from pressurized hydraulic oil.
PAGE 234
Steering Cylinder Service 10 9 8 7 11 30 to 36 ft–lb (41 to 49 N–m) 6 2 3 4 5 1 12 13 14 Figure 34 1. 2. 3. 4. 5. Lock nut Wear ring Seal O–ring Piston 6. 7. 8. 9. 10. 11. 12. 13. 14. Head O–ring Back–up ring Retaining ring Seal Wiper Barrel Shaft O–ring Disassembly (Fig. 34) 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 exterior with cleaning solvent and dry thoroughly.
PAGE 235
Inspection 1. Inspect head (Item 6), piston (Item 5) and shaft (Item 13) for excessive scoring, pitting or wear. Replace any worn or damaged parts. Spanner wrench 2. Inspect inside of barrel for scoring, pitting or out–of– round and replace if worn or damaged. Assembly (Fig. 34) 1. Use a new seal kit to replace all seals, o–rings, wear ring and wiper to piston and head. Apply clean Dexron III ATF to all seal kit components before installing.
PAGE 236
Lift Cylinder 12 1 11 RIGHT FRONT 10 2 4 8 3 3 2 4 9 7 6 5 Figure 37 1. 2. 3. 4. Box frame O–ring Hydraulic fitting O–ring Hydraulic System 5. 6. 7. 8. Hydraulic hose Lift cylinder (LH shown) Hydraulic hose Cotter pin Page 9 – 42 9. 10. 11. 12.
PAGE 237
Removal (Fig. 37) Installation (Fig. 37) 1. Park vehicle on a level surface, lower bed until clevis pins that secure lift cylinder to bed are loose in the bed slots. Shut engine off and engage the parking brake. 1. Make sure that lift cylinder is fully retracted. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2. Position lift cylinder to vehicle.
PAGE 238
Lift Cylinder Service 60 to 75 ft–lb (81 to 102 N–m) 8 9 7 11 10 6 3 4 2 5 1 12 13 14 Figure 38 1. 2. 3. 4. 5. Lock nut Wear ring Seal O–ring Piston 6. 7. 8. 9. 10. 11. 12. 13. 14. Head O–ring Back–up seal Retaining ring Seal Wiper Barrel Shaft O–ring Disassembly (Fig. 38) 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 exterior with cleaning solvent and dry thoroughly.
PAGE 239
Inspection 1. Inspect head (Item 6), piston (Item 5) and shaft (Item 13) for excessive scoring, pitting or wear. Replace any worn or damaged parts. Spanner wrench 2. Inspect inside of barrel for scoring, pitting or out–of– round and replace if worn or damaged. Assembly (Fig. 38) 1. Use a new seal kit to replace all seals, o–rings, wear ring and wiper to piston and head. Apply clean Dexron III ATF to all seal kit components before installing.
PAGE 240
Hydraulic Manifold (Optional High Flow Hydraulic Kit) Removal (Fig. 41) 1. Park vehicle on a level surface, raise bed, shut engine off and engage the parking brake. RIGHT FRONT 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. 2 6 1 7 3 4 CAUTION 5 4 3 Before performing any service or repair on hydraulic system components, relieve system pressure to avoid injury from pressurized hydraulic oil.
PAGE 241
4. Visually inspect the port in the manifold for damage to the sealing surfaces, damaged threads, and contamination. 5. Visually inspect cartridge valve for damaged sealing surfaces and contamination. A. Contamination may cause valves to stick or hang up. Contamination can become lodged in small valve orifices or seal areas causing malfunction. B. If valve sealing surfaces appear pitted or damaged, the hydraulic system may be overheating or there may be water in the system. 7.
PAGE 242
This page is intentionally blank.
PAGE 243
Front Wheel Drive (4WD) Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . . 4 Front Wheel and Axle Housing Assembly . . . . . . 4 Front Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Front Brake Service . . . . . . . . . . . . . . . . . . . . . . . . 10 Inspect Constant Velocity (CV) Joint Boot and Test CV Joint . .
PAGE 244
Specifications Item Description Front Differential 5.
PAGE 245
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.
PAGE 246
Service and Repairs Front Wheel and Axle Housing Assembly 1 45 to 65 ft–lb (61 to 88 N–m) 40 to 60 ft–lb (54 to 81 N–m) 2 LOCTITE #680 3 4 22 SMALL SPACER 5 21 6 7 8 9 170 to 200 ft–lb (230 to 271 N–m) 10 11 12 13 16 CUP 20 ACCESS HOLE 19 CONE 18 15 23 RIGHT 17 24 16 LOCTITE #271 25 FRONT 14 26 27 24 28 APPLY GREASE TO SPLINES Figure 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
PAGE 247
4 8. Remove cotter pin and slotted hex nut from the tie rod end assembly. Separate tie rod end from the axle housing. 9 80 to 90 ft–lb (108 to 122 N–m) 1 9. Remove axle housing as follows (Fig. 2): A. Remove cotter pin and slotted hex nut from the upper ball joint. Separate upper ball joint from the axle housing. 3 5 2 B. Remove cap screw (6) and lock nut (5) from axle housing. 8 6 9 C. Remove cotter pin and slotted hex nut from the lower ball joint.
PAGE 248
IMPORTANT: Bearing cones and bearing cups are part of a matched bearing set; these parts are not interchangeable. Use one matched bearing set per axle housing. 10.Connect tie rod end to the axle housing with slotted hex nut. Torque slotted hex nut from 45 to 55 ft–lb (61 to 74 N–m). If necessary to install cotter pin, tighten nut further and secure assembly with cotter pin.. 2. If a bearing cup was removed from the axle housing, press new bearing cup(s) into each end of the axle housing.
PAGE 249
Front Wheel Drive (4WD) This page is intentionally blank.
PAGE 250
Front Brake 1 45 to 65 ft–lb (61 to 88 N–m) 40 to 60 ft–lb (54 to 81 N–m) 2 LOCTITE #680 3 4 23 SMALL SPACER 5 22 6 8 7 9 11 10 170 to 200 ft–lb (230 to 271 N–m) 12 14 13 15 17 21 20 ACCESS HOLE 16 19 18 17 RIGHT LOCTITE #271 FRONT APPLY GREASE TO SPLINES Figure 5 1. 2. 3. 4. 5. 6. 7. 8. Wheel nut (5 used per wheel) Wheel and tire assembly Brake drum Stub axle Lock washer (5 used per wheel) Hex bolt (5 used per wheel) Brake cable clip Cap screw (4 used per brake) 9. 10. 11.
PAGE 251
1. If the brake assembly was removed from the axle housing, install brake assembly as follows: IMPORTANT:Hex flange nut (23) should be replaced whenever it is removed. A. Secure brake assembly to the axle housing with four cap screws and lock washers. 6. Apply Loctite #271 (or equivalent) to the threads of the CV joint. Install hardened washer and new hex flange nut to the CV joint threads. Torque flange nut from 170 to 200 ft–lb (230 to 271 N–m).
PAGE 252
Front Brake Service 2 49 to 97 in–lb (5.5 to 11 N–m) 8 1 7 13 26 25 5 4 3 11 6 9 12 10 10 24 12 11 14 16 17 18 21 13 15 27 19 20 23 22 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. Cap screw and lock washer (2 used) Back plate Plug Bleed screw Bleed screw cap Brake cylinder body Parking brake lever Pin Spring 10. 11. 12. 13. 14. 15. 16. 17. 18. L–type seal Piston Dust cover Brake shoe Upper shoe spring Lower shoe spring Female push rod Bolt adjuster Adjuster sleeve 19. 20. 21. 22. 23. 24.
PAGE 253
Front Wheel Drive (4WD) Inspect Constant Velocity (CV) Joint Boot and Test CV Joint Inspect CV Joint Boot Inspect CV joint boot after every 200 hours of operation. A torn boot is the most common cause of CV joint failures. NOTE: A worn and noisy CV joint with the boot in good condition and filled with grease is not uncommon. Potholes, curb contact, or collision damage can chip bearing components and initiate worn conditions. 1.
PAGE 254
Constant Velocity (CV) Joint 1 45 to 65 ft–lb (61 to 88 N–m) 2 3 4 22 5 21 6 7 8 9 10 11 170 to 200 ft–lb (230 to 271 N–m) 12 13 16 CUP 20 CONE 19 14 18 15 23 RIGHT 17 24 LOCTITE #271 25 FRONT 16 26 27 APPLY GREASE TO SPLINES 24 28 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
PAGE 255
LEVERAGE POINT 1. Remove wheel, stub axle and axle housing from the CV joint and front suspension (see Front Wheel And Axle Housing Assembly in this section). 2 IMPORTANT: Make sure not to damage the oil seal on the front differential with the pry bars when removing the CV joints. 1 2. Use two small pry bars (180o apart) to leverage the CV joint out of the front differential. Use even pressure on both pry bars (Fig. 9).
PAGE 256
Front Differential 1 RIGHT 2 4 FRONT 3 15 25 24 7 22 19 4 38 7 9 8 35 16 16 6 14 2 17 18 6 28 4 4 18 18 29 13 1 19 17 34 15 11 10 12 32 26 17 37 5 33 18 36 6 21 23 27 30 20 31 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Grease fitting Retaining ring Upper control arm Flange bushing Slotted hex nut Lock nut Ball joint seal Lower ball joint Brake hose retainer Cap screw Brake hose bracket Lock nut R–clamp Front Wheel Drive (4WD) 14. 15. 16. 17. 18. 19. 20.
PAGE 257
1. Park vehicle on a level surface. Make sure engine is off. Set parking brake and block rear wheels. 2. Drain front differential oil into a suitable container 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 (see Constant Velocity (CV) Joint Assembly Removal). 4. Remove differential drive shaft from the front differential flange (see Differential Drive Shaft Removal). 5.
PAGE 258
Front Differential Service 75 to 90 ft–lb (102 to 122 N–m) 15 to 20 ft–lb (20 to 27 N–m) 20 to 25 ft–lb (27 to 33 N–m) 16 14 30 to 45 ft–lb (41 to 61 N–m) 12 15 19 13 20 22 23 21 24 BEARING CAP 11 1 2 3 7 6 4 5 18 17 10 9 BEARING CRADLE 8 29 30 BEARING CAP 25 28 6 7 26 58 to 65 ft–lb (79 to 88 N–m) 32 34 27 33 31 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
PAGE 259
Front Wheel Drive (4WD) Disassembly (Fig. 11) 1. Remove flange (19) from the pinion shaft (8) by removing lock nut (18) and washer (17) from the threaded end of the shaft. Use a bearing puller if necessary to remove the coupler flange (Fig. 12). 2. Secure carrier assembly (15) so that pinion gear shaft (8) is facing up. Remove eight cap screws (16) securing the front housing to the carrier assembly. 3.
PAGE 260
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. 16). 7. Support differential case (27) in a vise. Drive pinion shaft (25) from the differential case using a long drift punch (Fig. 17). PUNCH 8.
PAGE 261
Front Wheel Drive (4WD) NOTE: Remove bearing cones (29) from the differential 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. 20). IMPORTANT: Make sure shims (21) are kept after they are removed from the carrier assembly (15). 11.
PAGE 262
IMPORTANT: Make sure shims (14) are kept after they are removed from the carrier assembly (15). NOTE: Remove bearing cup (10) from the carrier housing (15) only if it needs replacing (see Inspection). 14.Pull bearing cup (10) and shims (14) from the carrier assembly (15) (Fig. 24). 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. 25). Figure 24 Inspection (Fig. 11) 1.
PAGE 263
Front Wheel Drive (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 pinion shaft (25) fits loosely in its bore (Fig. 28). 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.
PAGE 264
Assembly (Fig. 11) 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.
PAGE 265
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 differential (Fig. 33). Front Wheel Drive (4WD) 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).
PAGE 266
2. If the bearing cup (23) was removed, press new bearing cup into the carrier assembly (15) (Fig. 35). 3. If the bearing cup (10) was removed, place shims (14) into the carrier assembly (15). Press new bearing cup into the assembly (Fig. 36). 4. If a new carrier assembly (15) is being installed, proceed as follows: A. Press bearing cup (10) into the assembly with out any shims (14). Figure 35 B. Place pinion gear (8) with bearing cone (9) installed into the carrier assembly and bearing cup. C.
PAGE 267
Front Wheel Drive (4WD) 6. Verify bearing preload and pinion gear shaft (8) rotation 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 (102 to 122 N–m). B. The torque required to rotate the shaft of the pinion gear should be from 7 to 12 in–lb (8 to 14 kg–cm) (Fig. 39). C.
PAGE 268
IMPORTANT: When bearing cones (29) are removed removed from the differential case (27) they should replaced with new ones. When installing new bearing 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. 43). 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.
PAGE 269
Front Wheel Drive (4WD) 12.Check backlash of ring gear (32) with a dial indicator at three equally spaced positions (Fig. 47). 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.
PAGE 270
17.Make sure both plugs (12) and O–rings (13) are installed. Verify that plugs are torqued between 20 to 25 ft–lb (27 to 33 N–m). FILL PLUG DRAIN PLUG Figure 51 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.
PAGE 271
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. 54). RING GEAR COAST SIDE RING GEAR DRIVE SIDE Toe Figure 54 Heel Toe Example 2: Backlash correct. Thinner pinion position shims required (Fig. 55).
PAGE 272
Differential Drive Shaft 7 4 2 5 2 3 1 6 SNAP RING SNAP RING 3 Figure 57 1. Flange yoke 2. Cross and bearing kit 3. Tube yoke 4. Slip yoke 5. Grease fitting 6. Seal 7. Socket head screw (6 used) Removal 1. Park vehicle on a level surface. Make sure engine is off. Engage parking brake and block rear wheels. 2. Jack up and secure front wheels off the ground (see Jacking Instructions in Operator’s Manual). 2 WARNING 1 Prevent flange yoke from dropping and causing personal injury when removing.
PAGE 273
Front Wheel Drive (4WD) Drive Shaft Cross and Bearing Service 1. Remove drive shaft from vehicle (see Differential Drive Shaft Removal). 3 2. Remove snap rings that secure bearings. 2 IMPORTANT: Yokes must be supported when removing and installing bearings to prevent damage. 1 3. Use a press to remove cross and bearings from yokes. Thoroughly clean drive shaft yokes. 4 4. To install new cross and bearings: A. Apply a coating of grease to all bearing bores. 3 B.
PAGE 274
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 61 1. 2. 3. 4. 5. 6. 7. Clutch shaft Seal plug Retaining ring Ball bearing Housing and race Garter gear Roller (6 used) 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. Cam Thrust bearing Thrust washer Spring Cage Oil seal Removal (Fig. 61) 1. Park vehicle on a level surface. Make sure engine is off. Engage parking brake and block rear wheels. 2. Remove drain plug from the transaxle.
PAGE 275
Front Wheel Drive (4WD) Inspection (Fig. 61) 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 62 5. Replace rollers (7) or cam (8) if any of the following conditions occur: A.
PAGE 276
Assembly (Fig. 61) 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. 66). 3. Place thrust bearing, thrust washer, and spring onto the cam (Fig. 67). 1 2 4. Insert cam with thrust bearing, thrust washer, and spring into the cage (Fig. 68). NOTE: Rollers must be replaced as a complete set. Figure 66 1. Garter spring 5. Insert rollers into the slots of the cage.
PAGE 277
7. Secure clutch shaft to housing and race (5) with lock washers (16) and hex socket head screws (17). 5. Secure clutch to front drive shaft (19) with retaining ring (3). 9. Make sure drain plug is installed properly to the transaxle. Fill transaxle with Dexron III ATF (see Operators Manual). IMPORTANT: Make sure rubber side of the seal plug (2) faces towards the clutch when installing. 6. Insert seal plug (2) into the housing and race (5) using a driver. Workman 4000 Series 8.
PAGE 278
This page is intentionally blank.
PAGE 279
Chapter 11 Electrical Schematics Electrical Schematics Table of Contents VEHICLE ELECTRICAL SCHEMATICS Workman 3100 Serial Number Below 260000000 . . . . . . . . . . . . . 3 Serial Number Above 260000000 . . . . . . . . . . . . . 4 Workman 3200 and 4200 Serial Number Below 260000000 . . . . . . . . . . . . . 5 Serial Number Above 260000000 . . . . . . . . . . . . . 6 Workman 3300 and 4300 Serial Number Below 260000000 . . . . . . . . . . . . . 7 Serial Number Above 260000000 . . . . . . . . . . . . .
PAGE 280
This page is intentionally blank.
PAGE 281
VIA MATING CONN FACTORY SHUNT REAR HARNESS PK PK 10 A F1 FRONT HARNESS OFF ENGINE B R I RUN CLUTCH SWITCH (ENGAGED) 86 PK 10 A F2 RUN X OR Y 15 A D GY GY OR PK/BU STARTER P101--C C GY PROTECTION DIODE (D2) GY GY 3 4 5 OR F BK 1 2 GY E OR IGNITION SWITCH F3 BK B+ Start START ENABLE HIGH FLOW HYDRAULICS KIT (OFF) A R 85 GY+BK PK/BU PK/BU BK START S 87 PTO KIT (OFF) FACTORY SHUNT VIA MATING CONN R/BK B+ TO POSITIVE BATTERY CABLE 87a 30 PK 8 P101--
PAGE 282
Workman 3100 Kohler Gasoline Engine Vehicle Electrical Schematic Serial Number Above 260000000 All relays and solenoids are shown as de-- energized. Page 11 -- 4 Rev.
PAGE 283
VIA MATING CONN FACTORY SHUNT REAR HARNESS PK F1 FRONT HARNESS OFF 10 A ENGINE B R I RUN CLUTCH SWITCH (ENGAGED) 86 R/BK START S PK F2 10 A RUN X OR Y GY GY OR OR D E F3 VIA MATING CONN FACTORY SHUNT P101--C GY C GY 4 6 8 LIGHTS, HORN, BRAKE W GY+BK R B+ Start STARTER BK 1 GY 2 GY PARKING BRAKE SWITCH (LIFT KIT) HIGH FLOW HYDRAULICS KIT P101--E Y B Y BK PROTECTION DIODE (D2) Y Y 7 BK BRAKE SWITCH 15 A 85 VIA MATING CONN FACTORY SHUNT 1 2 HYD.
PAGE 284
Workman 3200 and 4200 Briggs/Daihatsu Gasoline Engine Vehicle Electrical Schematic Serial Number Above 260000000 All relays and solenoids are shown as de-- energized. Page 11 -- 6 Rev.
PAGE 285
VIA MATING CONN FACTORY SHUNT B+ TO POSITIVE BATTERY CABLE REAR HARNESS W PK 10 A F1 ENGINE B R I RUN START R 10 A F2 PK RUN X OR Y GY GY OR 15 A F4 GY E OR IGNITION SWITCH F3 D BK OR F 1 2 VIA MATING CONN FACTORY SHUNT P101--C C GY 1 GY 4 6 8 W 1 GY 2 GY BED LIFT & REMOTE HYD (CE VEHICLES ONLY) HIGH FLOW HYDRAULICS KIT Y BK BN LIGHT SWITCH W/BK BK W/BK BK AUX LIGHT KIT BK BK OR P101--D P101--G P100--A OR OR OR I FUSIBLE LINK HARNESS PK (+) I
PAGE 286
Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Vehicle Electrical Schematic Serial Number Above 260000000 All relays and solenoids are shown as de-- energized. Page 11 -- 8 Rev.
PAGE 287
This Page Is Intentionally Blank. Page 11 -- 9 Rev.
PAGE 288
SN 280000001 AND UP Workman 3000/4000 Front Wire Harness Drawing Serial Number Below 270999999 Page 11 -- 10 Rev.
PAGE 289
GRAY RED/BLACK RED/WHITE RED/BLACK RED/WHITE WHITE WHITE BROWN WHITE WHITE/BLACK BROWN WHITE YELLOW GRAY GRAY ORANGE BLACK BROWN WHITE/BLACK ORANGE YELLOW RED RED RED WHITE RED ORANGE SN 280000001 AND UP BLACK VIOLET/RED BLACK ORANGE ORANGE BROWN/WHITE GRAY YELLOW BLUE RED/BLACK BROWN WHITE/BLACK GREEN/BLACK ORANGE ORANGE RED GRAY RED/BLACK VIOLET YELLOW RED/WHITE ORANGE BLUE/WHITE BLACK ORANGE ORANGE BLACK ORANGE ORANGE BLACK BLACK WHITE/BLACK BLACK WHITE/BLACK BLACK BLACK G
PAGE 290
Workman 3000/4000 Front Wire Harness Drawing Serial Number Above 280000000 Page 11 -- 12 Rev.
PAGE 291
GRAY RED/BLACK RED/WHITE WHITE WHITE BROWN WHITE WHITE/BLACK BROWN WHITE YELLOW GRAY GRAY ORANGE BLACK BROWN WHITE/BLACK BLACK ORANGE GRAY YELLOW RED RED RED WHITE RED ORANGE BLACK VIOLET/RED BLACK ORANGE ORANGE BROWN/WHITE GRAY YELLOW BLUE RED/BLACK BROWN WHITE/BLACK GREEN/BLACK ORANGE ORANGE RED GRAY RED/BLACK VIOLET YELLOW RED/WHITE ORANGE BLUE/WHITE BLACK ORANGE ORANGE BLACK ORANGE ORANGE BLACK WHITE/BLACK BLACK WHITE/BLACK BLACK BLACK GREEN BLACK ORANGE YELLOW ORANGE ORANG
PAGE 292
21A 19B FUEL SENDER 23A 22A 24A 2B TAIL LIGHT 17B CBA SPLICE ”E” BLACK 16A 17A 18A 19A 34A 30 85 KILL RELAY SPEED PICKUP PLUG 20A 5B B A 87A 86 18B 12A P101 INTERCONNECT FRONT HARNESS START RELAY 33A 86 26A 33B 25A 30 85 87 34B 14B 27A 28A GROUND 5A 6A BA STARTER 4B 32A 13B 32B 14A P102 INTERCONNECT FRONT HARNESS B A 4A BA 7A 1A SPLICE ”C” RED/WHITE 1B 10B 30B 8B 20B SPLICE ”B” BLACK 7B 16B 24B 25B 27B FUSIBLE LINK SPLICE ”A” 6B 15B 29B SPLICE ”D” RED/BLACK 9
PAGE 293
WIRE LIST Workman 3100 Kohler Gasoline Engine Rear Wire Harness Serial Number From 260000001 To 260000400 Page 11 -- 15 Rev.
PAGE 294
Workman 3100 Kohler Gasoline Engine Rear Wire Harness Drawing Serial Number Above 260000400 Page 11 -- 16 Rev.
PAGE 295
RED/BLACK RED/WHITE RED/BLACK RED/WHITE GRAY GRAY GRAY GRAY GRAY GRAY RED BLACK RED PINK GRAY GRAY BLACK PINK RED/BLACK BLACK FUSIBLE LINK BLUE/WHITE RED/WHITE RED/WHITE WHITE BROWN/WHITE BLACK BLACK BROWN WHITE/BLACK BLACK BLACK BLUE PINK BLACK RED/WHITE BLACK BLACK Workman 3100 Kohler Gasoline Engine Rear Wire Harness Diagram Serial Number Above 260000400 Page 11 -- 17 Rev.
PAGE 296
Workman 3200 and 4200 Briggs/Daihatsu Gasoline Engine Rear Wire Harness Drawing Serial Number Below 260000000 Page 11 -- 18 Rev.
PAGE 297
BLUE BLACK YELLOW GRAY GRAY GRAY GRAY WHITE BROWN/WHITE PINK BLACK RED/BLACK RED YELLOW GRAY RED WHITE GREEN/BLACK WHITE BLACK RED BLUE/WHITE PINK BLACK PINK BLACK BLACK BLACK RED/WHITE RED/BLACK BLACK WHITE/BLACK BROWN RED/WHITE RED/BLACK RED/BLACK RED/WHITE RED/WHITE BLACK RED/WHITE RED/WHITE WHITE RED/WHITE RED/WHITE WHITE VIOLET/RED BLACK RED GREEN BLUE/WHITE BLACK BLACK RED/ WHITE RED/ WHITE RED/WHITE BLUE GREEN/WHITE VIOLET ORANGE THIS WIRE (DASHED LINE) INC
PAGE 298
Workman 3200 and 4200 Briggs/Daihatsu Gasoline Engine Rear Wire Harness Drawing Serial Number Above 260000000 Page 11 -- 20 Rev.
PAGE 299
BLUE BLACK YELLOW YELLOW BROWN/WHITE GRAY GRAY GRAY WHITE WHITE BLACK RED/BLACK RED RED PINK RED BLACK RED GRAY GRAY GREEN/BLACK BLACK BLUE/WHITE GRAY GRAY BLACK BLACK PINK RED/WHITE RED/BLACK BLACK WHITE/BLACK BROWN RED/WHITE RED/BLACK RED/WHITE RED/WHITE RED/WHITE WHITE RED/WHITE BLACK RED/BLACK VIOLET/RED RED/WHITE VIOLET BLACK GREEN/WHITE BLUE/WHITE BLACK BLACK RED/WHITE WHITE GREEN ORANGE BLUE RED/WHITE RED/WHITE RED/WHITE BLACK Workman 3200 and 4200 Briggs/Daihatsu
PAGE 300
Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Drawing Serial Number Below 260000000 Page 11 -- 22 Rev.
PAGE 301
BLUE PINK GRAY GRAY RED PINK YELLOW RED/BLACK RED WHITE BLACK GRAY BLACK YELLOW PINK RED BLUE/WHITE PINK BLACK PINK BLACK GREEN/BLACK BLACK BLACK RED RED/BLACK BLACK WHITE/BLACK BROWN RED RED/BLACK RED/BLACK RED BROWN/WHITE VIOLET BLACK GRAY RED BLACK GRAY BLACK VIOLET/RED BLACK RED ORANGE YELLOW Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Diagram Serial Number Below 260000000 Page 11 -- 23 Rev.
PAGE 302
Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Drawing Serial Number From 260000001 To 270999999 Page 11 -- 24 Rev.
PAGE 303
GRAY BLUE BLACK GRAY GRAY BROWN/WHITE GRAY GRAY RED RED/BLACK PINK RED BLACK RED GRAY BLACK GRAY BLUE/WHITE PINK BLACK GREEN/BLACK BLACK BLACK RED RED/BLACK PINK BLACK WHITE/BLACK BROWN RED RED/BLACK BLACK RED BLACK RED BLACK RED/BLACK VIOLET/RED GRAY RED VIOLET GRAY PINK BLACK YELLOW ORANGE Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Diagram Serial Number From 260000001 To 270999999 Page 11 -- 25 Rev.
PAGE 304
Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Drawing Serial Number Above 280000000 Page 11 -- 26 Rev.
PAGE 305
GREEN/BLACK BLUE BLACK YELLOW YELLOW BROWN/WHITE GRAY GRAY GRAY RED RED/BLACK PINK RED BLACK RED GRAY BLACK GRAY BLUE/WHITE PINK BLACK BLACK RED RED/BLACK BLACK WHITE/BLACK BROWN RED RED/BLACK RED BLACK RED BLACK RED/BLACK VIOLET/RED GRAY RED VIOLET GRAY PINK BLACK BLACK YELLOW RED/BLACK PINK ORANGE Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Diagram Serial Number Above 280000000 Page 11 -- 27 Rev.
PAGE 306