Service Manual

ManualsBrandsToro ManualsVehiclesIndustrial Workman HDX-D Utility Vehicle with Bed

Part No. 09173SL (Rev. B)

Service Manual

Workman

HD Series

HD Models with S/N Below 314000000,

HD/HDX/HDX- D Models with Briggs/Daihatsu Gasoline & Dies

el and Kohler Engines

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 HD, HDX and HDX- D vehicles.

REFER TO THE OPERATOR’S MANUAL FOR OPER-

ATING, MAINTENANCE AND ADJUSTMENT

INSTRUCTIONS. For reference, insert a copy of the

Operator’s Manual and Parts Catalog for your machine

into Chapter 2 of this service manual. Additional copies

of the Operator’s Manual and Parts Catalog are avail-

able on the internet at www.Toro.com.

The Toro Company reserves the right to change product

specifications or this 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 no tice will give im-

portant instructions which must be followed to pre-

vent damage to systems or components on the

machine.

E The Toro Company - 2009, 2011, 2015

Summary of content (318 pages)

PAGE 1
Part No. 09173SL (Rev. B) Service Manual WorkmanR HD Series HD Models with S/N Below 314000000, HD/HDX/HDX- D Models with Briggs/Daihatsu Gasoline & Diesel and Kohler Engines 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 HD, HDX and HDX- D vehicles. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS.
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Chapter 2 -- Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 2 ----- 1 1 2 3 Chapter 3 -- Briggs/Daihatsu Gasoline Engine Chapter 7 -- Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . .
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Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -- 2 General Information . . . . . . . . . . . . . . . . . . . . . . . 10 -- 3 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 10 -- 4 HILLIARD FRONT DRIVE DIFFERENTIAL PARTS and SERVICE MANUAL Chapter 11 -- Electrical Drawings Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 11 -- 3 Workman HD Circuit Drawings . . . . . . . . . . . . . . 11 -- 6 Workman HDX Circuit Drawings . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Using Bed Safety Support . . . . . . . . . . . . . . . . . . . . SAFETY AND INSTRUCTION DECALS . . . . . . . . . .
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Safety Instructions The Workman HD 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. Improper use or maintenance of the vehicle can result in injury or death.
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1. Sit on the operator seat when starting and operating the vehicle. 2. When starting the engine: A. Sit on operator’s seat and engage the parking brake. 4. Do not touch engine, exhaust system components, transaxle or radiator (if equipped), while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. 5. Before getting off the seat: A. Stop movement of the vehicle. B. Disengage PTO (if so equipped) and return hand throttle lever to OFF position (if so equipped). B.
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Maintenance and Service 1. Before servicing or making adjustments, turn all accessories off, put traction pedal in neutral, stop engine, engage parking brake and remove key from the ignition 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.
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Safety Jacking Vehicle WARNING When changing attachments, tires or performing other service, use correct jacks, hoists and jack stands. Always chock or block the wheels and use jack stands to support the vehicle. If the vehicle is not properly supported by jack stands, the vehicle may move or fall resulting in personal injury. 1 1. Do not start engine while vehicle is on jack, because engine vibration or wheel movement could cause vehicle to slip off jack. Figure 1 1. Front jacking point 2.
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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. WARNING 1 Before servicing or making adjustments to the vehicle, stop engine, engage parking brake and remove key from ignition switch. Any load material must be removed from bed or other attachment before working under raised bed.
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Chapter 2 Product Records and Maintenance Product Records and Maintenance Table of Contents PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . .
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Equivalents and Conversions 0.
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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.
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or
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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 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.5 38 + 4 ft--lb 52 + 5 N--m 54 + 6 ft--lb 73 + 8 N--m M12 X 1.
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Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
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Chapter 3 Briggs/Daihatsu Gasoline Engine Table of Contents Workman HDX Page 3 -- 1 Rev. A Briggs/Daihatsu Gasoline Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adding Oil to Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine Electronic Controller . . . . . . . . . . . . . . . . . . 4 ADJUSTMENTS . . . . . . . . . . .
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Specifications Item Description Make / Designation Briggs & Stratton/Daihatsu, 4--stroke, Liquid Cooled, OHV Gasoline Number of Cylinders 3 Bore x Stroke 2.834 in x 3.07 in (72 mm x 78 mm) Total Displacement 58.1 in3 (952 cc) Compression Ratio 8.6:1 Firing Order 1 (front) -- 2 -- 3 Fuel System Electronic fuel injection Fuel Pump 12 VDC, fuel tank mounted Fuel Unleaded, regular grade (87 octane minimum) Fuel Tank Capacity 6.5 U.S. gallons (24.
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General Information General engine maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and assembly is identified in the Briggs & Stratton/Daihatsu Repair Manual that is included at the end of this section. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Briggs & Stratton/Daihatsu Repair Manual. The use of some specialized test equipment is explained.
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Engine Electronic Controller The engine that is used in the Workman HDX uses an electronic controller for engine management and also to provide inputs for the gauge cluster on the machine. All wire harness connections should be plugged into the controller and engine electrical components before the vehicle ignition switch is moved from the OFF position to either the ON or START position.
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Adjustments Engine Speed Adjustment 1. Park vehicle on a level surface, engage parking brake and place gear shift lever in neutral. 4 2. Raise the bed or remove attachment(s) to allow access to engine. If bed is raised, place safety support on lift cylinder. 1 Briggs/Daihatsu Gasoline Engine 2 3. Stop engine and remove key from the ignition switch. 4. Make sure governor spring is assembled to governor link rod on throttle bracket and center slot in engine governor lever (Fig. 2). 5.
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Engine Diagnostics Check Engine Light The Workman HDX is equipped with a check engine light that indicates if the engine electronic controller is functioning correctly. The check engine light is located on the dash panel (Fig. 4). When the ignition switch is moved to the ON position and the engine electronic controller is functioning properly, the check engine light will be illuminated for approximately three (3) seconds and then will turn off. The light should remain off during normal vehicle operation.
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Component Failure 0 -- 2 Engine speed sensor 0 -- 9 Intake manifold pressure sensor 1 -- 2 Water temperature sensor 1 -- 3 Intake air temperature sensor 1 -- 7 Oxygen sensor 2 -- 4 Battery voltage 3 -- 3 Cylinder #1 fuel injector 3 -- 4 Cylinder #2 fuel injector 3 -- 5 Cylinder #3 fuel injector 3 -- 7 Cylinder #1 ignition coil 3 -- 8 Cylinder #2 ignition coil 3 -- 9 Cylinder #3 ignition coil 4 -- 1 Fuel pump relay 4 -- 5 Oxygen heater 5 -- 8 75 ohm resister (or circuit wiring)
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Service and Repairs Air Cleaner System 2 1 3 5 2 6 7 8 4 RIGHT FRONT 9 VACUATOR DIRECTION Figure 6 1. Engine 2. Hose clamp (4 used) 3. Air intake hose Briggs/Daihatsu Gasoline Engine 4. Mounting bracket 5. Air inlet hood 6. Air cleaner hose Page 3 -- 8 7. Air cleaner assembly 8. Flange nut (2 used) 9.
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Removal (Fig. 6) 1 1. Park 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. 3. Remove air cleaner components as needed using Figures 6 and 7 as guides. 3 IMPORTANT: Any leaks in the air filter system will cause serious engine damage.
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Fuel Tank 175 to 200 in--lb (20 to 22 N--m) 19 11 2 10 2 1 7 16 TO ENGINE 17 3 21 18 14 8 3 4 12 20 5 7 15 TO PURGE PORT 6 9 RIGHT FRONT 13 Figure 8 1. 2. 3. 4. 5. 6. 7. Fuel supply hose Hose clamp Fuel hose (2 used) Vacuum check valve Fuel hose Fuel filter Fuel hose 8. 9. 10. 11. 12. 13. 14. Flange nut (2 used) Fuel tank Fuel cap Fuel pump/sender assembly Carbon cannister Support tube Retainer plate 15. 16. 17. 18. 19. 20. 21.
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Fuel Tank Removal (Fig. 8) 2 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 1 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 3. Disconnect wire harness connectors from fuel pump and sender on fuel tank. CAUTION The fuel supply hose will contain pressurized fuel. Be careful when disconnecting supply hose. Wipe up any spilled fuel before starting the engine.
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Fuel Pump 175 to 200 in--lb (20 to 22 N--m) 6 11 2 10 2 1 13 3 TO ENGINE 8 4 5 12 7 TO PURGE PORT 9 RIGHT FRONT Figure 10 1. 2. 3. 4. 5. Fuel supply hose Hose clamp Rollover valve Fuel filter Gasket Briggs/Daihatsu Gasoline Engine 6. 7. 8. 9. Cap Washer head screw (2 used) Grommet Fuel tank Page 3 -- 12 10. 11. 12. 13.
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Fuel Pump Removal (Fig. 10) 1. Park vehicle on a level surface, raise bed and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 3 2 2. Install bed support on bed lift cylinder to prevent bed from lowering. 1 CAUTION The fuel supply hose will contain pressurized fuel. Be careful when disconnecting fuel supply hose. Wipe up any spilled fuel before starting the engine. Figure 11 1. Fuel pump/sender 2. Fuel supply hose 3. Pump/sender harness 4.
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Exhaust System 9 8 2 10 RIGHT FRONT 13 7 8 6 1 11 3 4 8 12 5 3 14 Figure 12 1. 2. 3. 4. 5. Engine Muffler Exhaust gasket (2 used) Hex nut (4 used) Exhaust tube Briggs/Daihatsu Gasoline Engine 6. 7. 8. 9. 10. Flange head screw (2 used) Transaxle Flange nut (8 used) Flange head screw (2 used) Mount plate Page 3 -- 14 11. 12. 13. 14.
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Installation (Fig. 12) 1. Park 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. 2. Using Figure 12 as a guide, fit all exhaust components to vehicle before tightening any fasteners. When securing exhaust, tighten fasteners in the following order: 3.
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Radiator 9 13 19 8 RIGHT 6 1 FRONT 16 14 13 19 10 20 15 11 14 11 13 18 5 8 3 5 13 11 12 7 4 2 6 17 Figure 13 1. 2. 3. 4. 5. 6. 7. Radiator assembly Coolant reservoir Upper radiator hose Lower radiator hose Hose clamp (4 used) Hose (radiator to coolant reservoir) Hose Briggs/Daihatsu Gasoline Engine 8. 9. 10. 11. 12. 13. 14. Hose clamp (3 used) Radiator screen Radiator mount Flange nut (4 used) Flange head screw Flange head screw (4 used) Clip (2 used) Page 3 -- 16 15. 16. 17.
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Removal (Fig. 13) Installation (Fig. 13) 1. Park vehicle on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Allow engine and radiator to cool. 1. If radiator assembly was disassembled, install components to radiator using Figure 14 as a guide. Make sure that clearance exists between shroud and fan at all points. 3. Unlatch and remove radiator screen from front of radiator. 4.
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Engine 32 31 29 30 RIGHT FRONT 25 21 25 to 30 ft--lb (33 to 40 N--m) 33 26 LOCTITE #242 28 20 14 25 to 30 ft--lb (33 to 40 N--m) 37 13 14 19 22 18 15 19 16 18 22 17 11 10 26 17 12 9 34 23 8 20 24 27 16 LOCTITE #242 14 16 7 37 25 to 30 ft--lb (33 to 40 N--m) 6 1 2 35 3 4 36 5 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
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Engine Removal (Fig. 15) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 1 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. 3 4. Remove exhaust tube (item 28) from vehicle (see Exhaust System Removal in this section). 4 5 5. Loosen hose clamp (item 31) that secures air intake hose (item 32) to engine. Remove intake hose from engine.
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8. Disconnect accelerator cable ball joint from throttle lever (see Engine Throttle Bracket Disassembly in this section). Position accelerator cable away from engine. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene--glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly labeled container away from children and pets. 9. Remove the radiator cap.
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1. If pressure plate and clutch disc were removed, see Installing Clutch Disc and Cover in the Service and Repairs section of Chapter 6 -- Drive Train. 2. If coupler assembly was removed, assemble coupler to engine flywheel using Figure 15 as a guide. Apply Loctite #242 (or equivalent) to threads of flange head screws (item 14) that secure rubber coupler to engine pulley. Torque fasteners to values identified in Figure 15. 3.
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Engine Throttle Bracket 2 9 16 10 5 4 13 6 14 1 12 11 2 15 3 8 7 RIGHT FRONT Figure 19 1. 2. 3. 4. 5. 6. Engine Jam nut (2 used) Governor spring Lock nut Ball joint Accelerator cable Briggs/Daihatsu Gasoline Engine 7. 8. 9. 10. 11. Flange nut Flange head screw Grease fitting Shoulder bolt Bellcrank Page 3 -- 22 12. 13. 14. 15. 16.
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Disassembly (Fig. 19) 1. Remove throttle bracket components from engine as needed using Figures 19 and 20 as guides. 5 3 Assembly (Fig. 19) 2 1 1. Install removed throttle bracket components to engine using Figures 19 and 20 as guides. 4 2. If removed, attach governor spring to governor link rod and center slot in engine governor lever (Fig. 21). 4. Check engine speed (both idle and high idle) and adjust if necessary (see Engine Speed Adjustment in Adjustments section of this chapter) 5.
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EFI System Overview The electronic fuel injection system controls two aspects of engine operation: the amount of fuel delivered to the engine and the amount of ignition timing advance. The end result is seamless engine performance while maintaining exhaust emission standards and maximum fuel economy. The ECU (Electronic Control Unit) collects information from various EFI system components to determine the amount of compensation added to the base injection time frame in the ECU’s memory.
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Engine Coolant Temperature Sensor When the coolant temperature reaches about 140o F (60o C), the engine is considered to be at sufficient operating temperature to turn on the ”closed loop” function. This allows the engine to run at a much leaner air fuel ratio for economy and exhaust catalyst performance. This sensor is a NTC (negative temperature coefficient) type. At cold temperatures the NTC type sensor’s resistance is very high, but reduces as coolant temperature increases.
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Fuel Injector The fuel injector is an electromagnetic device that operates when voltage is delivered from the ECU for a predetermined amount of time. When energized, the injector opens and allows fuel to travel through the injector. The open injector allows a fine mist of highly atomized fuel to be sprayed at the back of the intake valve through the intake port. The longer the voltage is applied, the longer the injector will stay open. The length of time the injector is open is called the duty cycle.
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Ignition Coil The ignition coils have 12v DC current applied to them when the ignition key is ON to energize the coil windings. The ECU will trigger the coils to apply voltage to the spark plug when appropriate. Ignition--timing advance is controlled by the ECU which varies the point when the spark is initiated at the plug in relation to where the piston is located in degrees before top dead center. Dynamic ignition timing advance offers optimal torque and economy for any given RPM and engine load.
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This page is intentionally blank. Briggs/Daihatsu Gasoline Engine Page 3 -- 28 Rev.
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Chapter 4 Briggs/Daihatsu Diesel Engine Table of Contents Workman HDX--D Page 4 -- 1 Briggs/Daihatsu Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Adding Oil to Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Adjust Engine Speed . . . . . . .
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Specifications Item Description Make / Designation Briggs & Stratton/Daihatsu, 4--stroke, Liquid Cooled, OHV Diesel Number of Cylinders 3 Bore x Stroke 2.834 in x 3.07 in (72 mm x 78 mm) Total Displacement 58.1 in3 (952 cc) Compression Ratio 24.0:1 Firing Order 1 (front) -- 2 -- 3 Fuel Diesel or Biodiesel (up to B20) Fuel with low or ultra low sulfur content Fuel Injection Pump Bosch VE (Distributor type) Fuel Injector Nozzle Bosch throttle type Fuel Tank Capacity 6.5 U.S.
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General Information This Chapter gives information about specifications and repair of the Briggs and Stratton/Daihatsu 3LC diesel engine used in the Workman HDX--D. General engine maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and assembly is identified in the Briggs & Stratton/Daihatsu Repair Manual that is included at the end of this section.
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Adjustments Adjust Engine Speed 1. Park vehicle on a level surface, engage parking brake and place gear shift lever in neutral. 2 2. Raise the bed or remove attachment(s) to allow access to engine. If bed is raised, place safety support on lift cylinder. 3 1 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.
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Briggs/Daihatsu Diesel Engine This page is intentionally blank.
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Service and Repairs Air Cleaner System 5 6 7 3 5 2 4 10 1 8 9 RIGHT FRONT VACUATOR DIRECTION Figure 4 1. 2. 3. 4. Mounting bracket Air cleaner hose Air inlet hood Air cleaner assembly Briggs/Daihatsu Diesel Engine 5. Hose clamp (4 used) 6. Engine 7. Air intake hose Page 4 -- 6 8. Frame 9. Flange head screw (2 used) 10.
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Removal (Fig. 4) 1 1. Park 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. 3. Remove air cleaner components as needed using Figure 4 and 5 as guides. 3 4 Installation (Fig. 4) IMPORTANT: Any leaks in the air filter system will cause serious engine damage.
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Fuel Tank 3 175 to 200 in--lb (20 to 22 N--m) 16 13 2 9 15 FROM 12 ENGINE 1 8 13 5 4 10 18 7 19 20 14 10 4 11 7 6 4 RIGHT FRONT Thread Sealant TO ENGINE 17 Figure 6 1. 2. 3. 4. 5. 6. 7. Fuel hose Gasket Fuel sender cap Hose clamp (4 used) Fitting (2 used) Fuel filter/water separator Washer head screw (4 used) 8. 9. 10. 11. 12. 13. 14.
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Fuel Tank Removal (Fig. 6) 1 1. Park 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. 3. Disconnect wire harness connector from fuel sender on fuel tank. 3 4. Note routing of fuel hoses for installation purposes (Fig. 7). Disconnect fuel hoses from fuel sender and rollover valve.
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Exhaust System RIGHT 9 8 FRONT 2 10 13 7 8 6 1 11 3 4 8 12 5 3 14 Figure 8 1. 2. 3. 4. 5. Engine Muffler Exhaust gasket (2 used) Hex nut (4 used) Exhaust tube Briggs/Daihatsu Diesel Engine 6. 7. 8. 9. 10. Flange head screw (2 used) Transaxle Flange nut (8 used) Flange head screw (2 used) Mount plate Page 4 -- 10 11. 12. 13. 14.
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Removal (Fig. 8) Installation (Fig. 8) 1. Park 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. 2. Using Figure 8 as a guide, fit all exhaust components to vehicle before tightening any fasteners. When securing exhaust, tighten fasteners in the following order: A.
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Radiator 9 13 19 8 RIGHT 6 1 FRONT 16 14 13 15 10 19 11 14 11 13 18 5 8 3 5 13 11 12 7 4 2 6 17 Figure 9 1. 2. 3. 4. 5. 6. 7. Radiator assembly Coolant reservoir Upper radiator hose Lower radiator hose Hose clamp (4 used) Hose (radiator to coolant reservoir) Hose Briggs/Daihatsu Diesel Engine 8. 9. 10. 11. 12. 13. Hose clamp (3 used) Radiator screen Radiator mount Flange nut (4 used) Flange head screw Flange head screw (4 used) Page 4 -- 12 14. 15. 16. 17. 18. 19.
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Removal (Fig. 9) Installation (Fig. 9) 1. Park vehicle on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Allow engine and radiator to cool. 1. If radiator assembly was disassembled, install components to radiator using Figure 10 as a guide. Make sure that clearance exists between shroud and fan at all points. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 3.
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Engine 32 31 RIGHT FRONT 33 25 25 to 30 ft--lb (33 to 40 N--m) 30 29 34 21 28 26 LOCTITE #242 20 14 25 to 30 ft--lb (33 to 40 N--m) 37 13 18 22 17 11 10 23 8 27 19 16 12 9 26 17 15 14 18 19 22 20 16 24 14 LOCTITE #242 16 7 37 25 to 30 ft--lb (33 to 40 N--m) 6 1 2 35 3 4 36 5 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
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Engine Removal (Fig. 11) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 1 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. 2 3. Disconnect negative (--) and then positive (+) battery cables at the battery. 3 4. Remove exhaust tube (item 28) from vehicle (see Exhaust System Removal in this section). 5 5.
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CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. Ethylene--glycol antifreeze is poisonous. Dispose of coolant properly or store it in a properly labeled container away from children and pets. 9. Remove the radiator cap. Drain radiator into a suitable container by disconnecting lower radiator hose from the radiator. 10.Loosen hose clamps and remove upper and lower radiator hoses from engine.
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4. If gear pump was removed, install gear pump to engine mount (see Gear Pump Installation in the Service and Repairs section of Chapter 9 -- Hydraulic System). 5. Install two (2) dowel pins in bell housing bores (Fig. 14). 6. Make sure that snubbing washer is positioned on top of both engine mounts (Fig. 13). 7. Use lift or hoist to install engine to chassis. One person should operate hoist and second person should help guide engine to machine.
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Engine Throttle Bracket 7 8 12 6 9 8 2 3 7 4 2 5 7 1 13 10 11 RIGHT FRONT Figure 15 1. 2. 3. 4. 5. Engine Lock nut Cap screw Throttle bracket Flange nut 6. 7. 8. 9. Throttle bellcrank Ball joint Jam nut Threaded rod 10. 11. 12. 13. Accelerator cable Return spring Shoulder bolt Grease fitting Disassembly (Fig. 15) Assembly (Fig. 15) 1. Remove throttle bracket components from engine as needed using Figure 15 as a guide. 1.
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Chapter 5 Kohler Gasoline Engine Table of Contents Kohler Gasoline Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Make / Designation Kohler, CH23S, 4--stroke, V--Twin Air Cooled, OHV Number of Cylinders 2 Bore x Stroke 3.15 in x 2.64 in (80 mm x 67 mm) Total Displacement 41.1 in3 (674 cc) Compression Ratio 8.5:1 Governor Mechanical Idle Speed (no load) 1200 + 100 RPM High Idle (no load) 3600 + 50 RPM Oil Pump Gear driven trochoid type Engine Oil See Operator’s Manual Crankcase Oil Capacity 2 U.S. quarts (1.
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General Information This Chapter gives information about specifications and repair of the Kohler engine used in the Workman HD. General engine maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and assembly is identified in the Kohler Command Engine Service Manual that is included at the end of this section. Most repairs and adjustments require tools which are commonly available in many service shops.
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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 3 NOTE: Perform this maintenance procedure at the interval specified in the Operator’s Manual. IMPORTANT: The engine that powers the Workman HD vehicle is air--cooled.
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Fuel Tank 20 175 to 200 in--lb (20 to 22 N--m) 21 10 11 29 TO PURGE PORT 8 23 17 1 27 18 22 1 19 28 14 26 12 15 6 3 4 7 9 3 23 5 25 24 16 2 3 RIGHT FRONT TO ENGINE 13 Figure 2 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Fuel hose (fuel supply) Fuel hose Hose clamp (3 used) Fuel filter R--clamp Flange nut Flange head screw (2 used) Cap Fuel tank Fuel tank cap 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
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Fuel Tank Removal (Fig. 2) 1 1. Park 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. 3. Disconnect wire harness connector from fuel sender on fuel tank. 3 4. Note routing of fuel hoses for installation purposes (Fig. 3). Disconnect fuel hoses from fuel sender and rollover valve.
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Exhaust System 15 RIGHT 5 10 14 FRONT 13 5 6 11 8 6 5 5 12 4 7 3 9 2 1 Figure 4 1. 2. 3. 4. 5. Flange head screw (4 used) Exhaust manifold Hex nut (4 used) Exhaust gasket (2 used) Flange nut (9 used) Kohler Gasoline Engine 6. 7. 8. 9. 10. Flange head screw (3 used) Flange head screw Bracket Muffler gasket Muffler Page 5 -- 8 11. 12. 13. 14. 15.
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Removal (Fig. 4) Installation (Fig. 4) 1. Park 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. 2. Using Figure 4 as a guide, fit all exhaust components to vehicle before tightening any fasteners. When securing exhaust, tighten fasteners in the following order: A.
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Engine 19 46 47 RIGHT 13 FRONT 15 11 12 26 9 33 16 39 24 35 23 10 5 7 38 30 14 32 8 6 28 29 48 31 25 17 27 21 Antiseize Lubricant 20 18 4 35 to 40 ft--lb (48 to 55 N--m) 45 3 37 2 34 1 22 41 42 40 36 Antiseize Lubricant 43 44 Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
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Engine Removal (Fig. 5) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2 3 1 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 5 3. Disconnect negative (--) and then positive (+) battery cables at the battery. 2 4 4. Disconnect positive cable (item 37) and fusible link harness (item 41) from starter solenoid stud on engine. 6 5.
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2. Check pilot bearing (item 23) for smooth rolling and noise. Check (sealed) bearing for grease leakage. Replace bearing if necessary. Remove pilot bearing from flywheel by backing out socket head screw (item 22) that attaches flywheel to crankshaft. Do not reuse bearing if it has been removed. Engine Installation (Fig. 5) 1. Install flywheel (item 20) and/or pilot bearing (item 23) if removed. Torque socket head screw (item 22) from 35 to 40 ft--lb (48 to 55 N--m) to secure flywheel to engine crankshaft.
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Chapter 6 Drive Train Table of Contents Workman HD Series Page 6 -- 1 Drive Train SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Drive Train Operation . . . . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Clutch Alignment Tool . . . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Specification Transaxle Oil Dexron III ATF Transaxle Oil Capacity Drive Train 8 U.S. quart (7.
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General Information Drive Train Operation Workman HD 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.
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Special Tools Order special tools from your Toro Distributor. Clutch Alignment Tool Use clutch alignment tool to align clutch friction disk to engine flywheel before tightening pressure plate cap screws.
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Adjustments PTO Cable Adjustment (If Equipped) 1. Remove clevis pin that secures PTO cable to PTO lever arm. 3 4 2. Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in PTO lever arm. 3. Tighten jam nut making sure that holes in clevis and lever arm still align. 2 1 4. Secure PTO cable clevis to PTO lever arm with clevis pin. Figure 3 3. Clevis pin 4. Clevis jam nut Drive Train 1. PTO lever arm 2.
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Troubleshooting Clutch Problem Possible Causes Clutch slips. Clutch pedal out of adjustment. Excessive wear of clutch disc facing. 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.
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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.
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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.
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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.
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Service and Repairs Shift Cable Replacement 1 2 19 4 3 18 6 7 5 9 8 7 10 8 6 11 11 10 17 16 15 12 4 13 RIGHT 14 FRONT Figure 4 1. 2. 3. 4. 5. 6. 7. Shift knob Jam nut Boot seal Shift cable Shift pin Jam nut Hair pin 8. 9. 10. 11. 12. 13. Clevis pin Shift lever Shift link Cable clevis Cap screw Lower shift boot Shift Cable Removal (Fig. 4) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake.
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6. Remove shift cable from transaxle shift lever (Fig. 6): A. Remove hair pin and clevis pin that secure shift cable to shift lever on transaxle. 2 B. Loosen jam nuts on bulkhead fitting of cable. C. Disconnect cable from shift lever. 7. Note routing of shift cable and location of cable ties used to secure cable to vehicle. Slide shift cable from lower shift boot and remove cable from vehicle. 1 Shift Cable Installation (Fig. 4) 1. Route shift cable in same location as noted during cable removal.
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Driveshaft 13 17 35 to 40 ft- lb (48 to 55 N- m) 19 1 16 8 18 170 to 180 ft- lb (231 to 244 N- m) STAKED 6 15 14 Antiseize Lubricant 40 to 45 ft- lb (55 to 61 N- m) 19 35 to 40 ft- lb (48 to 55 N- m) 9 12 19 4 10 13 2 5 7 3 Loctite #271 RIGHT FRONT Antiseize Lubricant 80 to 90 ft- lb (109 to 122 N- m) 11 Figure 7 1. 2. 3. 4. 5. 6. 7.
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Removal (Fig. 7) 1. Park vehicle on a level surface, shut engine off and remove key from ignition switch. 3 2. For driveshaft to be serviced, remove wheel, brake caliper, brake rotor and wheel hub (see Wheel Hub Removal in the Service and Repairs section of Chapter 7 -- Chassis). 2 3. Loosen and remove flange nuts, cap screws and hardened washers that secure driveshaft to transaxle shaft (Fig. 8). 1 4. Slide driveshaft from transaxle shaft and remove from vehicle. 5.
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Driveshaft Cross and Bearing Service 1. Remove driveshaft from vehicle (see Driveshaft Removal in this section). 5. Lubricate grease fittings until grease purges from bearing cups. Make sure to grease all cross fittings. IMPORTANT: When placing yoke in vise, clamp lightly on the solid part of the yoke to prevent yoke damage. Also, the use of a vise with soft jaws is recommended. 6. Make sure that assembled joint moves without binding.
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PTO Removal and Installation (If Equipped) PTO Removal 2 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 3 2. Remove clevis pin to disconnect PTO control cable clevis from lever arm on PTO. Do not loosen jam nuts to remove cable from support bracket. 1 3. Disconnect wire harness connector that attaches to PTO switch. 4. Disconnect hydraulic hose from fitting on PTO.
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Transaxle RIGHT 2 6 9 3 7 14 FRONT 5 4 8 3 9 2 11 1 19 18 12 17 15 13 10 16 Figure 12 1. 2. 3. 4. 5. 6. 7. Transaxle assembly Snubbing washer (4 used) Isolation mount assembly (2 used) Transaxle mount (2 used) Flange nut (4 used) Cap screw (2 used) Flange head screw (4 used) Drive Train 8. 9. 10. 11. 12. 13. Shift arm Lock nut (3 used) Shift cable mount bracket Shift lever (2 used) Differential lock lever Strainer Page 6 -- 16 14. 15. 16. 17. 18. 19.
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Transaxle Removal (Fig. 12) 1. Park vehicle on a level surface. Stop the engine and remove key from ignition switch. Remove the bed or other attachment(s). Allow transaxle and engine to cool. 1 2. Disconnect negative (--) battery cable from battery first. Then disconnect positive (+) battery cable from battery (see Battery Service in the Service and Repairs section of Chapter 8 -- Electrical System). 2 3 3. Remove drain plug from bottom of transaxle and allow oil to drain into a suitable drain pan.
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16.Put blocking under engine for support. Support transaxle with a floor jack or suspend transaxle from vehicle frame rails. 1 1 17.Remove isolation mount assemblies and transaxle mounts (Fig. 16). 18.Remove driveshaft clamp bolts, then slide transaxle side--to--side to disconnect each driveshaft from axle shafts on transaxle. 19.Remove cap screws securing clutch bell housing to engine. Note location of washers and harness brackets. 2 2 20.
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Clutch Service RIGHT 8 5 FRONT 14 9 6 5 to 7 ft--lb (7 to 9 N--m) 10 11 2 Antiseize lubricant 12 13 7 6 1 4 9 3 Antiseize lubricant Figure 19 1. 2. 3. 4. 5. Spring pin Throw out bearing Release guide Clutch release fork Clutch release shaft 6. 7. 8. 9. 10. Bushing Spring pin (2 used) Bell housing Oil seal Cap screw (6 used) NOTE: To perform the following clutch service procedures, the transaxle needs to be removed from vehicle (See Transaxle Removal in this section). 11. 12. 13. 14.
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Clutch Disassembly and Inspection (Fig. 19) 1. Insert clutch alignment tool (see Special Tools) in engine flywheel pilot bearing hole to keep clutch disk from falling off (Fig. 20). 3. Install pressure plate. Install and tighten six (6) 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 after pressure plate is installed. 2.
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Transaxle Service Transaxle Disassembly NOTE: Item numbers in figures are shown in order of disassembly; for example, remove item 1 first, then item 2, etc. assemble transaxle in reverse order; for example, install item 1 last. 1 1. Remove extension spring (item 1). 2. Loosen and remove nine (9) flange head screws (item 2) and remove bell housing assembly from transaxle. 2 3. Thoroughly clean outside surface of transaxle. Figure 24 3 4.
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7. Loosen and remove fifteen (15) flange head screws and separate center plate from transaxle case. Note dowel pins in transaxle case. Remove seal cap (item 1), shims (items 2 and 4) and snap ring (item 3) from center plate. 3 4 1 2 Figure 27 8. On 4WD units, remove front drive shaft and 41T gear from the gear case. Remove bearings from gear case (Fig. 29, item 2) and center plate. FRONT DRIVE SHAFT BEARING (CENTER PLATE) BEARING (GEAR CASE) 41T GEAR Figure 28 Drive Train 9.
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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 31 12.Loosen five (5) flange head 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 32 2 13.Remove roll pin from differential lock lever. Remove lever (item 1) from shaft.
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16.Remove differential gear assembly (item 1) together with fork shaft assembly (item 2). 1 2 Figure 35 17.Remove washer (item 1) from inside of transaxle case. NOTE: Washer may stick to fork shaft when removed in step 16.
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18.To remove shift arms: 1 3 A. Loosen and remove nut (item 1). Remove 2nd--3rd shift arm (item 2) together with shift arm plate (item 3), spring (item 4), locknut (item 5), washer (item 6) and cap screw (item 7). 5 2 B. Loosen and remove locknut (item 8) from both 1st--Rev. shift arm (item 9) and High--Low shift arm (not shown). Remove shift arms. 7 6 4 8 9 C. Loosen cap screws (Fig. 38, item 10) and remove keeper plates (item 11). D. Remove oil seals (item 12). E.
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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 40 22.Loosen four (4) flange head screws (item 1) and remove upper cover (item 2) from transaxle case.
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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 0.0709 in. (1.8 mm) thick. C. Remove two (2) needle bearings (item 5) and gear (item 4). Inspect needle bearings and replace if necessary. D. Remove synchro ring (item 6). Figure 42 E. Remove snap ring (item 7). F. Remove shifter (item 8) together with spring, hub and three (3) keys. G.
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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). E. Remove spacer (item 10). 4 2 18 17 16 F. Remove snap ring (item 11). 12 11 8 6 9 G.
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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 46 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).
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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 49 28.Disassemble Hi--Lo fork shaft assembly: 1 A. Remove shift fork (item 1), steel ball (item 2) and spring (item 3) from Hi--Lo shift fork assembly. 5 4 B. Remove E--ring (item 4). 3 2 Figure 50 29.Disassemble differential gear assembly: A.
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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 53 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.
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Transaxle Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. 3. Inspect synchronizer ring: A. Inspect the chamfer for excessive wear or damage. B. Inspect inner tapered area for excessive wear or damage. C. Measure the clearance between synchronizer ring and synchro gear in three equally spaced points. If clearance is less than 0.0195 in. (0.5 mm) replace the synchronizer ring. 4. Inspect synchro gears: Figure 55 A.
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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 0.039 in. (1.0 mm). Figure 57 7. Inspect main shaft: A. Inspect main shaft for worn or damaged surface. If O.D.
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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 (Figs. 60 and 61).
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10.Inspect reduction shaft for wear or damage. If O.D. of needle bearing area is less than 0.864 in. (21.95 mm) or 0.982 in. (24.95 mm), replace the reduction shaft. Figure 62 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 63 12.Inspect differential: A. Inspect pinion shaft for excessive wear or damage. If O.D. is less than 0.707 in. (17.
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Transaxle Assembly NOTE: Item numbers in figures are shown in reverse order of assembly; for example, when assembling, 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.
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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 and 12). B. Install side gear liners (item 14), side gears (items 13 and 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.
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6. Assemble Hi--Lo fork shaft: A. Install E--ring (item 4) onto fork shaft (item 5). 1 5 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 71 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.
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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).
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9. Assemble synchro hub: 2 A. Install 3 keys (item 1) into grooves of hub (item 2). 1 Figure 75 B. Install shifter (item 1) onto hub (item 2). 1 2 Figure 76 Drive Train C. Insert two (2) springs (item 3) into hub. Pay attention to direction of spring.
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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 clean Dexron III transmission oil on cone face of gear before installing synchro ring. C. Insert key (item 13) onto reduction shaft. 4 2 18 D.
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11. Assemble reverse shaft: A. Install gear (item 2) onto reverse shaft. B. Use a press to install bearings (item 3 and 1). Figure 81 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 82 E.
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13.Assemble shift arms: A. Install three (3) new oil seals (item 12) into transaxle case. Apply multi--purpose grease on lips of oil seals before installing. B. Install three (3) keeper plates (item 11) and tighten three (3) flange head screws (item 10) to a torque from 11 to 13 ft--lb (15 to 17 N--m). 230 to 240 in--lb (26 to 27 N--m) 1 230 to 240 in--lb (26 to 27 N--m) 7 6 4 3 5 2 8 Apply Loctite #680 to threads and tapers 8 9 9 C.
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16.Assemble reduction shaft and countershaft together with R--1 fork shaft and Hi--Lo fork shaft. Figure 87 17.Insert reduction shaft and countershaft assembly into transaxle case. Insert heads of shift arms into grooves of forks when installing them. Drive Train Figure 88 18.Assemble main shaft together with 2--3 fork shaft. Figure 89 19.Insert main shaft and 2--3 fork shaft assembly into transaxle case. Insert head of shift arm into groove of fork while installing.
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20.Install reverse shaft (item 1) into transaxle case. Rotate main shaft and reverse shaft gears to mesh gears when installing. 1 2 Figure 91 21.On 4WD vehicles, install bearing to gear case (see item 2 of Fig. 91) and center plate. Install front drive shaft and 41T gear to the gear case. BEARING (CENTER PLATE) FRONT DRIVE SHAFT BEARING (GEAR CASE) 41T GEAR Figure 92 22.Install center plate: A. Insert two (2) dowel pins into transaxle case. B.
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NOTE: The thickest shim of the shim set (item 2) should be positioned against the snap ring (Fig. 94). 23.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. 94 and 95). 3 4 1 2 Figure 94 24.Install snap ring into the groove of the bearing housing (Fig. 95 and 96). 5 3 1 6 4 2 Figure 95 4. Snap ring 5. Center plate 6. Sealing cap Drive Train 1. Countershaft 2.
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25.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 from 0.000 to 0.0039 in. (0.00 to 0.10 mm) (Fig. 97).
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27.Install fork shaft case: A. Insert spindle (item 1) between fork shafts. 1 Figure 99 B. Insert two (2) steel balls (item 2) and two (2) springs (item 1) into the grooves. 1 2 Figure 100 C. Apply silicone sealant to mating surface of fork shaft case (item 3). 3 1 1 E. Check operation of shifters and detent. 1 Figure 101 28.Insert a washer (item 1) into housing of transaxle case. Apply moly disulfide grease to washer before installing.
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29.Install differential gear assembly (item 1) together with fork shaft (item 2) onto transaxle case. Figure 103 1 2 Figure 104 30.Install side cover: A. Insert two (2) dowel pins onto transaxle case. B. Apply silicone sealant onto mating surface of side cover. C. Install side cover and secure with ten (10) flange head screws. Torque screws from 18.5 to 22 ft--lb (24.5 to 29.5 N--m). Figure 105 1 31.Install R.H. axle shaft assembly: A. Apply silicone sealant onto mating surface of seal cover. B.
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32.Install L.H. axle shaft assembly: A. Thoroughly clean mating surface of differential carrier and side cover (item 1). 1 B. Insert selected shims (item 2) into housing of side cover. NOTE: The thickest shim should be installed against the bearing. 2 Figure 107 C. Install axle shaft assembly and secure with five (5) flange head screws (item 1). Torque screws from 18.5 to 22 ft--lb (24.5 to 29.5 N--m). 1 Figure 108 Drive Train 33.Measure backlash of ring gear through window on transaxle case.
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34.Install differential lock arm (item 1) onto fork shaft. Insert lock pin into fork shaft and arm. Pay attention to direction of slit in lock pin. 1 Figure 110 35.Apply silicone sealant to mating surface of upper cover (item 2). Pay attention to direction of cover and install. Secure with four (4) flange head screws (item 1). Torque screws from 18.5 to 22 ft--lb (24.5 to 29.5 N--m).
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36.Apply multi--purpose grease to O--ring and insert O-ring into groove of transaxle case. Install cover and secure with nut (item 2) with lockwasher and five (5) cap screws (item 1). Torque fasteners from 11 to 13 ft--lb (15 to 17 N--m). 2 3 NOTE: If equipped with optional PTO, install PTO assembly after the transaxle has been installed in vehicle. Plug transaxle opening to prevent debris entry into transaxle. 1 Figure 112 37.Install bell housing and secure with nine (9) flange head screws (item 2).
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Power Take--Off (PTO) Service (If Equipped) 33 34 35 3 32 28 26 29 30 1 31 17 2 25 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 17 19 11 10 12 13 14 18 16 15 Figure 114 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.
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6. Remove PTO output shaft assembly (item 1) from PTO housing. Remove oil seal from PTO cover. 1 Figure 115 7. Remove intermediate shaft assembly (item 1) from PTO housing. Remove intermediate gear (item 2). Remove bearing (item 3) from housing if necessary.
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8. Remove PTO input shaft from PTO housing: Moly disulfide grease A. Shift PTO to ”ON” position. B. Remove two (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 118 H. Release shift arm (item 8) from shifter block (item 9). 8 I.
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10.Disassemble PTO intermediate shaft: 1 A. Use a bearing puller to remove bearing (item 1) if necessary. Figure 121 11. 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 122 5 2 Drive Train 4 6 7 3 1 Figure 123 12.Disassemble shift arm: 1 A.
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Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. CLEARANCE 3. Measure clearance between groove on shift collar and shifter block. Replace shifter block if clearance exceeds 0.039 in. (1.0 mm). Figure 125 4. Measure I.D. of input shaft bushing (item 1). Replace bushing if I.D. exceeds 0.673 in. (17.10 mm). 1 Figure 126 5. Measure O.D. of bushing area on input shaft. Replace shaft if O.D. is less than 0.667 in. (16.95 mm).
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Assembly (Fig. 114) NOTE: Item numbers in figures are shown in reverse order of assembly; for example, when assembling, install item 1 last. 1. Clean gasket material from mating surfaces of housing and cover. 2 3 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 129 A. Apply moly disulfide grease to two (2) new O-rings (item 1) and install onto shift arm. B.
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4. Assemble PTO output shaft: 5 A. If bearing (item 6) was removed, use a press to install bearing onto output shaft. 6 4 B. Install washer (item 5) and retaining ring (item 4). C. Install retaining ring (item 3) and gear (item 2). 2 D. Use a press to install bearing (item 1). 7 3 1 Figure 132 Figure 133 5. Use a press to install bearing (item 1) onto intermediate shaft. 1 Figure 134 6. Assemble PTO input shaft: A. Insert spring (item 3) and two (2) steel balls (item 2) into hole. 1 2 B.
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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. 6 3 5 4 Figure 136 D.
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8. Install PTO intermediate shaft sub--assembly: A. If removed during disassembly, insert bearing (item 3) into PTO housing. 3 Figure 140 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 141 9. Insert PTO shaft assembly (item 1) into bearing housing of PTO housing.
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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. Secure cover with cap screws, nut and lock washers. Torque fasteners from 18 to 22 ft--lb (24.5 to 29.5 N--m). Figure 143 Drive Train 11. Install PTO to transaxle (see PTO Removal and Installation in this section).
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Chapter 7 Chassis Table of Contents Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . Brake Master Cylinder Service . . . . . . . . . . . . . . . Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . . Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Front Control Arms . . . . . . . . . . . . . . . . . . . . . . . . . Front Compression Spring Service . . . . . . . . . . .
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Specifications Item Specification Front tire 20” x 9” -- 12, 6 ply Maximum front tire pressure 32 PSI (220 kPa) Front wheel alignment 0 + 0.120 in.
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Operator’s Manual for additional information when servicing the vehicle. Tire Pressure 1. Tire pressure should be determined by the payload carried. 2. The lower the tire pressure, the less the compaction and tire marks are minimized. Lower pressure should not be used for heavy payloads at higher speeds.
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Special Tools Compression Spring Tool Use to remove and install the two (2) front suspension compression springs.
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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, driveshaft or transaxle problem (see Chapter 6 -- Drive Train).
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Suspension and Steering (Continued) Problem Possible Causes Hard steering. Loose, worn or glazed hydraulic pump drive belt (Workman HD vehicles). 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.
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Brakes (Continued) Problem Possible Causes Brakes pulling. Incorrect tire pressure. Contaminated brake pads. Front end is out of alignment. Bent or damaged brake rotors. Damaged brake hoses. Parking brake caliper or cable is sticking or damaged. Unmatched tires on same axle. Dragging brakes. Parking brake is engaged or sticking. Improper parking brake adjustment. Weak or broken parking brake return spring. Binding brake pedal. Sticking brake master cylinder. Saturated brake pads.
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Service and Repairs Wheel Assembly 6 12 35 to 40 ft--lb (48 to 55 N--m) 9 8 10 7 35 to 40 ft--lb (48 to 55 N--m) 6 5 6 3 3 5 1 2 11 4 2 80 to 90 ft--lb (109 to 122 N--m) RIGHT 4 FRONT 80 to 90 ft--lb (109 to 122 N--m) Figure 2 1. 2. 3. 4. Front wheel assembly Brake rotor Wheel hub assembly Lug nut (5 used per wheel) Chassis 5. 6. 7. 8. Brake caliper Flange head screw Parking brake caliper (LH shown) Parking brake bracket (LH shown) Page 7 -- 8 9. 10. 11. 12.
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Removal (Fig. 2) 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 2. Partially loosen wheel lug nuts that secure wheel to be removed, then jack up and support vehicle (see Jacking Vehicle in the Safety Instructions section of Chapter 1 -- Safety). 4 1 2 3. Remove lug nuts and then remove wheel assembly from vehicle. 3 Installation (Fig. 2) 5 1. Install wheel. Secure with five (5) lug nuts. 2. Lower vehicle to ground.
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Brake System 12 13 6 35 to 40 ft--lb (48 to 55 N--m) 9 8 10 7 35 to 40 ft--lb (48 to 55 N--m) 6 5 6 3 3 5 1 2 11 4 2 80 to 90 ft--lb (109 to 122 N--m) 4 RIGHT 80 to 90 ft--lb (109 to 122 N--m) FRONT Figure 4 1. 2. 3. 4. 5. Front wheel assembly Brake rotor Wheel hub assembly Lug nut (5 used per wheel) Brake caliper 6. 7. 8. 9. Flange head screw Parking brake caliper (LH shown) Parking brake bracket (LH shown) Parking brake return spring Disassembly (Fig. 4) 1.
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5. On rear axle, remove parking brake assembly from brake rotor: 4. Slide brake caliper onto brake rotor. Make sure that rotor is between brake pads. A. Remove two (2) flange head screws that secure parking brake bracket to rear axle. 5. Align caliper with mounting holes. Secure caliper with two (2) flange head screws. Torque screws from 35 to 40 ft--lb (48 to 55 N--m). B. Raise parking brake bracket assembly (bracket, cable and parking brake caliper) from brake rotor.
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Brake Caliper Service Disassembly (Fig. 5) 3 1. Remove anti--rattle clip from caliper, pins and brake pads. 2 2. Remove pins from caliper by prying with a flat blade screwdriver through loop in pins. 3. Slide brake pads from caliper. For assembly purposes, note orientation of inner and outer pads as the pads are not the same. 4. Replace the brake pads if the friction material is worn to less than 1/32” (0.8 mm).
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Parking Brake Caliper Service Disassembly (Fig. 6) 4 1. Remove carrier side brake pad and pad support from caliper. 5 3 2 2. Remove cam side brake pad and pad support from caliper. 1 3. Replace the brake pads if the friction material is worn to less than 0.135” (3.4 mm). 4. If necessary, remove lever retainer spring, pivot pins and cam lever from caliper body. Assembly (Fig. 6) 7 1. If removed, install cam lever into caliper body and then place pivot pins into lever holes.
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Bleed Brake System 1. Remove hood to access brake master cylinder (see Hood Removal in this section). Make sure that brake fluid level is correct. Bleeder valve 2. Connect a suitable transparent hose to bleeder valve on left rear wheel caliper and submerge other end of hose in a clean glass container partially filled with clean brake fluid. 3. Have a second person pump brake pedal several times, then hold pedal down firmly. 4.
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Brake Master Cylinder 2 10 1 9 2 11 3 4 5 8 6 7 RIGHT FRONT Figure 8 1. 2. 3. 4. Brake master cylinder Flange head screw (2 used) Clevis pin Grease fitting Chassis 5. 6. 7. 8. Brake pedal Flange bushing Flange nut Flange nut (2 used) Page 7 -- 16 9. Cotter pin 10. Shoulder screw 11.
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Removal (Fig. 8) 1 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 2. Remove hood to access brake master cylinder (see Hood Removal in this section). 3. Remove cotter pin from the clevis pin that connects master cylinder to brake pedal. 4. Clean hydraulic brake line area of master cylinder to prevent contamination. Remove both brake lines from master cylinder. Cap ends of brake lines and position them away from master cylinder. 5.
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Brake Master Cylinder Service Disassembly (Fig. 10) 1 1. Thoroughly clean outside of master cylinder before disassembly. 2 12 3 2. Remove reservoir and flange seal. Push in on the push rod (item 8) so the stop pin (item 3) can be removed. 3. Disconnect lower end of the dust cover from the housing. 4 11 4. Push in on the push rod and remove circlip (item 9) from cylinder housing, then remove push rod with dust cover and clevis. Remove retainer washer. 5.
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Parking Brake Cable 6 4 3 3 5 2 7 13 8 9 14 10 1 15 11 12 9 6 8 16 17 RIGHT FRONT Figure 11 1. 2. 3. 4. 5. 6. Parking brake lever handle Parking brake lever Spacer Curved washer Clevis pin Lock nut 7. 8. 9. 10. 11. 12. Bellcrank Cap screw Hair pin Flat washer Cable equalizer bracket Clevis pin Removal (Fig. 11) 1. Park vehicle on a level surface, shut engine off and remove key from ignition switch. 4.
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8. Disconnect brake cable from cable equalizer bracket (Fig. 13). 1 3 4 9. Note routing of parking brake cable and location of cable ties used to secure brake cable to vehicle frame. Remove brake cable from vehicle. 2 Installation (Fig. 11) 5 1. Route new brake cable in same location as before and secure with cable ties. Start from rear of vehicle and work towards front. 6 2. Connect brake cable to parking brake caliper on rear axle (Fig. 12). A.
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Wheel Hub RIGHT 12 35 to 40 ft- lb (48 to 55 N- m) 6 13 170 to 180 ft- lb (231 to 244 N- m) STAKED 9 FRONT 8 10 7 35 to 40 ft- lb (48 to 55 N- m) 6 17 5 6 19 3 14 18 2 22 15 5 1 21 3 16 6 2 35 to 40 ft- lb (48 to 55 N- m) 6 11 4 20 35 to 40 ft- lb (48 to 55 N- m) 80 to 90 ft- lb (109 to 122 N- m) 4 170 to 180 ft- lb (231 to 244 N- m) 80 to 90 ft- lb (109 to 122 N- m) Figure 14 1. 2. 3. 4. 5. 6. 7. 8.
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Removal (Fig. 14) Installation (Fig. 14) 1. Park vehicle on a level surface, shut engine off and remove key from ignition switch. 1. If front wheel hub is being replaced, install cap screw (item 22), washers (items 18 and 21) and lock nut (item 20) to new hub. Torque lock nut from 170 to 180 ft- lb (231 to 244 N- m). 2. For wheel hub to be serviced, remove wheel, brake caliper and brake rotor (see Brake System Disassembly in this section).
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Steering Assembly 40 to 50 ft--lb (55 to 67 N--m) 6 80 to 90 ft--lb (109 to 122 N--m) 19 27 30 17 33 25 15 3 2 1 9 12 14 28 18 16 23 8 11 3 21 22 26 24 35 to 40 ft--lb (48 to 55 N--m) 11 5 13 1 12 31 14 29 FRONT 12 32 20 RIGHT 35 to 40 ft--lb (48 to 55 N--m) 7 23 35 to 40 ft--lb (48 to 55 N--m) 40 to 50 ft--lb (55 to 67 N--m) 170 to 180 ft--lb (231 to 244 N--m) 10 2 80 to 90 ft--lb (109 to 122 N--m) 4 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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Disassembly (Fig. 15) 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 45 to 55 ft- lb (61 to 74 N- m) 70 to 80 ft- lb (94 to 109 N- m) 1 2 2. To remove tie rod (item 11) from vehicle (Fig. 16): 3 4 A. Remove cotter pin and slotted hex nut that secure outer tie rod ball joint stud to knuckle. 5 B. Use puller to separate ball joint from knuckle. Loctite #271 C. Unscrew inner tie rod end from center link and remove tie rod from vehicle.
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Assembly (Fig. 15) 3. To install tie rod (item 11) to vehicle: 1. If steering linkage and center link assembly was disassembled, use Figures 15 and 17 as guides for assembly. A. If flange bushings (items 2 and 3 in Fig. 17) were removed from pivot mount, make sure that new bushings are pressed fully into the pivot mount. B. Torque spindle nut (item 8 in Fig. 17) to 85 ft- lb (115 N- m). Deform spindle nut into slot in idler arm or pitman arm after torquing nut. C.
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Front Control Arms 10 1 12 15 11 3 12 13 7 5 14 12 40 to 50 ft--lb (55 to 67 N--m) 4 8 7 6 9 70 to 80 ft--lb (94 to 109 N--m) 13 7 11 RIGHT 10 2 15 FRONT 12 Figure 18 1. 2. 3. 4. 5. LH upper control arm LH lower control arm RH upper control arm RH lower control arm Cap screw (4 used) Chassis 6. 7. 8. 9. 10. Flange nut (4 used) Flange head screw (6 used) Lock nut (8 used) Cap screw (2 used) Flange bushing (2 used per arm) Page 7 -- 28 11. 12. 13. 14. 15.
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Removal (Fig. 18) Installation (Fig. 18) 1. Assemble control arm. WARNING A. Press ball joint into control arm and secure with retaining ring. Make sure that grease fitting is in ball joint. FRONT SUSPENSION IS SPRING LOADED! To prevent possible personal injury, use special tool to remove compression springs before disassembling the front suspension. 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 2.
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Front Compression Spring Service 2 10 4 1 6 5 3 9 4 8 7 11 12 RIGHT FRONT Figure 19 1. 2. 3. 4. Spring cradle (2 used) Compression spring (2 used) Flange nut Cap screw Chassis 5. Stabilizer link 6. Lock nut 7. Cap screw Page 7 -- 30 8. LH control arm tower 9. Spring pivot sleeve 10.
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Disassembly (Fig. 19) 2 4 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 4 2. Remove seat base to gain access to front suspension assembly (see Seat Base Removal in this section). 3 1 3. Jack up front of vehicle and secure with jack stands (see Jacking Vehicle in the Safety Instructions section of Chapter 1 -- Safety). Remove front wheels. 4. Remove front shock absorbers (see Front Shock Absorber Removal in this section).
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Front Shock Absorber Removal (Figs. 22 and 23) 10 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 7 2. 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. 6 5 Installation (Figs. 22 and 23) 1 1. If necessary (e.g.
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Rear Shock Absorber Removal (Fig. 25) 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. NOTE: The three (3) flat washers used to retain shock absorber to vehicle are different. Note location of each washer during removal. 2. Remove lock nut and flat washer that secure top of shock absorber to frame. 1 3. Remove cap screw, flat washer and flange nut that secure bottom of shock absorber to axle. 1 Figure 24 4.
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Rear Leaf Spring 5 12 3 8 10 12 5 14 10 7 5 13 12 1 9 11 12 4 2 12 6 See tightening procedure in text RIGHT FRONT Figure 26 1. 2. 3. 4. 5. Washer (4 used per plate) Spring mount (LH shown) Rear frame Flange head screw Flange nut 6. 7. 8. 9. 10. Rear axle Axle bumper (2 used) Lock nut Bolt (4 used per plate) Spring shackle (2 used per spring) IMPORTANT: For proper vehicle performance, always replace the springs on both sides of the vehicle. 11. 12. 13. 14.
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7. Remove two (2) lock nuts (item 14) and flange head screws (item 4) securing spring mount (item 2) to frame rail, then remove leaf spring assembly. 8. Remove flange nut that secures spring mount to leaf spring and remove mount from spring. 9. Remove rubber bushings (item 12) from leaf spring and frame side rails. NOTE: During leaf spring installation, make sure axle and spring plate are centered on leaf spring knob. 5.
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Front Wheel Alignment 1. Rotate steering wheel to center the pitman arm with the vehicle to ensure correct front wheel alignment measurement. 2. With the pitman arm centered, measure center to center distance (at axle height) between the front wheels at both front and rear of the wheels (Fig. 27). The front and rear measurements should be equal with a tolerance of 0.120” (3 mm). Rotate tires and make a second measurement. 3.
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Steering Wheel Removal (Fig. 28) 1 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 3 2 RIGHT FRONT 2. Carefully remove steering wheel cover from steering wheel. 5 20 to 25 ft--lb (28 to 33 N--m) 3. Remove hex nut and flat washer that secure steering wheel to steering control valve. 4. Pull steering wheel from control valve. If necessary, use suitable puller to remove steering wheel. 4 Antiseize Lubricant Installation (Fig. 28) 1.
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Seat Base 2 12 in--lb (maximum) (1.3 N--m) 17 3 1 16 4 19 18 22 5 21 20 23 9 14 13 12 8 15 13 6 9 7 RIGHT 10 FRONT 11 Figure 29 1. 2. 3. 4. 5. 6. 7. 8. LH (operator) seat RH (passenger) seat Washer head screw (12 used) Shift boot plate Shift boot Carriage bolt (8 used) Seat bracket (4 used) Seat base Chassis 9. 10. 11. 12. 13. 14. 15. 16.
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Removal (Fig. 29) 1 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and apply the parking brake. Remove key from ignition switch. 4 2 2 2. Remove six (6) carriage screws and flange nuts that secure ROPS cover to ROPS frame. Remove cover from vehicle (Fig. 30). 3. Remove knobs from control levers, then remove center console control plate assembly. 2 3 3 3 2 4. Remove four (4) socket head screws that secure each seat to vehicle. Lift both seats from vehicle.
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Hood 8 1 8 2 7 8 3 8 5 4 RIGHT 6 FRONT Figure 31 1. Hood 2. Clip (3 used per headlight) 3. Headlight (2 used) 4. Bumper 5. Bumper bracket 6. Cover 7. Operator frame 8. Hood attachment tab Removal (Fig. 31) Installation (Fig. 31) 1. Park vehicle on a level surface, shut engine off and apply the parking brake. Remove key from ignition switch. 1. Position hood to operator frame. 2. Grasp hood at headlight openings and carefully pull hood away from operator frame. 3.
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Chapter 8 Electrical System Table of Contents Temperature Sender (Workman HDX and HDX--D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermal Fan Switch (Workman HDX and HDX--D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed Sensor (Workman HDX and HDX--D) . . . Glow Plug Timer (Workman HDX--D) . . . . . . . . . . Delay Timer (Vehicles with 4WD) . . . . . . . . . . . . . High Flow Hydraulics Kit Switch (Vehicles with High Flow Hydraulics Kit) . . . . . . . . .
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Electrical Schematics The electrical schematics and other electrical drawings for Workman HD series vehicles are located in Chapter 11 - Electrical Drawings. Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Digital Multimeter The digital multimeter can test electrical components and circuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally.
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Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply battery terminal protector after the battery cable has been secured to the battery terminal. Toro Part Number: 107--0392 Figure 4 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally.
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Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this vehicle (see electrical schematics and drawings in Chapter 11 -- Electrical Drawings). 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.
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Condition Possible Cause Starter cranks, but should not, with hydraulic lift lever out of the neutral position. Lift lever interlock switch out of adjustment. Starter cranks, but should not, with rear PTO (if equipped) engaged. Rear PTO switch faulty. Starter solenoid clicks, but starter will not crank. (If solenoid clicks, problem is not in interlock system.) Low battery charge. Lift lever interlock switch faulty. Loose or corroded battery cables or ground.
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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 60oF to 100oF (16oC to 38oC). The ignition key should be in the OFF position and all accessories turned off.
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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 (all models) and rear PTO (if equipped) is disengaged. To verify operation of hydraulic lift lever interlock switch: 1. Sit on operator’s seat and engage parking brake. Move shift lever to NEUTRAL position. Disengage rear PTO (if equipped). 2.
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Component Testing This section will define electrical component operation and supply test procedures that can be performed on those components. NOTE: Electrical troubleshooting of any 12 volt power connection can also be performed through voltage drop tests without disconnecting the component. For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the clutch switch connector before doing a continuity check on the switch).
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Gauge Cluster Hourmeter Tachometer (Workman HDX and HDX--D) The hourmeter should move 1/10 of an hour for every six minutes that the ignition switch is in the ON position. The tachometer on Workman HDX and HDX--D vehicles displays the engine speed. NOTE: The tachometer is optional on Workman HD vehicles. Fuel Level Gauge The fuel level gauge displays the approximate amount of fuel remaining in the fuel tank.
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Fuses The fuse blocks are located below the center of the dash panel. LEFT RIGHT Identification and Function (Fig. 9) Top Row LH: Protects ignition power supply. Top Row RH: Protects power supply for light system (headlights, running lights and brake lights). TOP ROW 10A 15A SECOND 10A 10A THIRD 10A FOURTH 15A Second Row LH: Protects main power supply. Second Row RH: Protects power supply for hazard lights (if equipped).
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Headlight Switch This headlight switch allows the headlights to be turned on and off and is located on the dash (Fig. 10).. 1 Testing The headlight switch terminals are marked as shown in Figure 11. The circuitry of the headlight 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 switch position.
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Clutch Switch The clutch switch is a normally open proximity switch that is attached to the frame under the dash (Fig. 13). The switch is in its normal open position as long as the clutch pedal is released (clutch engaged). When the clutch pedal is depressed (clutch disengaged), the pedal is positioned close to the clutch switch causing the switch to close. The closed clutch switch is used in the starting interlock system to make sure that the drive system is disengaged during engine starting.
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Hydraulic Lift Lever Interlock Switch The lift lever interlock switch is a normally open proximity switch that is attached to the control lever support (Fig. 14). The interlock switch is in its normal open position whenever the hydraulic lift lever is moved away from the neutral position. When the lift lever is in the neutral position, the retainer pin that attaches the lift lever link to the lift valve is positioned close to the interlock switch causing the switch to close.
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3rd -- High Lockout Key Switch The 3rd -- High lockout key switch has two positions: SLOW (turtle) and FAST (rabbit). This switch is located on the dash (Fig. 16). 1 Testing 2 The switch terminals are identified as shown in Figure 17. The circuit wiring of the 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 switch terminals for each switch position.
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Transaxle Switches 2--3 Lockout Switch The transaxle 2--3 Lockout switch is located on the top of the transaxle (Fig. 18). The switch is closed in 2nd gear and open in 3rd gear. 1 To test the switch, disconnect the wire harness connector from the switch. Use a multimeter (ohms setting) to test for continuity across the two (2) switch terminals. With the engine off and the transaxle shifter in 2nd gear, there should be continuity (zero ohms).
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Power Relay (Four Terminals) The main power relay is used to provide electrical power to the majority of the Workman circuits. When the ignition key is in either the ON or START position, the main power relay is energized. The main power relay is attached to the relay bracket under the right side of the bed near the rear axle (Fig. 19). Besides the main power relay, Workman HDX--D vehicles (diesel engine) use an additional power relay to supply electrical power to the glow plugs.
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Relay (Five Terminals) Workman HD series vehicles use a number of relays that have five (5) terminals: The clutch relay on Workman HD, HDX and HDX--D vehicles ensures that the clutch pedal is depressed before the engine starter can be engaged. The start relay on Workman HD, HDX and HDX--D vehicles is used to energize the starter solenoid so that the engine can be started. 4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87 (Fig. 22). Ground terminal 86 and apply +12 VDC to terminal 85.
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Diodes A diode is used for starting circuit protection from voltage spikes that occur when the starter solenoid is de--energized. 2 1 If a vehicle is equipped with the optional High Flow Hydraulics Kit, an additional diode is used for circuit protection from voltage spikes that occur when the Kit hydraulic solenoid is de--energized. 3 If a vehicle is equipped with the optional light kit that includes flashers, two (2) additional diodes are used for flasher circuit logic.
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Fusible Link A Workman HD series vehicle uses three (3) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the vehicle wire harness (Fig. 24). If any of these links should fail, current to the protected circuit will cease. Refer to electrical schematics and wire harness drawings in Chapter 11 -- Electrical Drawings for additional fusible link information. 1 2 Testing 1.
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Fuel Gauge Sender The fuel gauge sender is located in the fuel tank (Fig. 26). The fuel gauge sender on Workman HDX vehicles (liquid cooled gasoline engine) is included with the fuel pump and fuel filter assembly that fits into the fuel tank. 8. After testing, install sender into fuel tank and secure with gasket and fuel sender cap. Secure fuel hoses to fittings on sender and connect fuel sender connector to wire harness. Testing 9. Remove bed support from bed lift cylinder and lower bed. 1.
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Fuel Pump (Workman HDX) The electric fuel pump used on Workman HDX vehicles is a positive displacement pump that provides pressurized fuel to the engine fuel rail in a returnless system. The fuel pump assembly includes a regulator to maintain fuel pressure of approximately 40 PSI (276 kPa). Electrical power for the fuel pump is available when the fuel pump relay is energized by the engine controller and when the transaxle lockout switches are properly positioned (e.g.
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Temperature Sender (Workman HDX and HDX--D) The temperature sender is threaded into the water pump housing on the engine (Fig. 30). The resistance of the temperature sender reduces as the engine coolant temperature increases. This resistance change is used by the instrument cluster to display engine operating temperature. There is a yellow wire attached to the sender. 7. Install switch to the water pump. A. Clean threads of water pump housing and switch thoroughly.
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Thermal Fan Switch (Workman HDX and HDX--D) The thermal fan switch is threaded into the thermostat housing on the engine (Fig. 32). The fan switch is a normally open switch that closes when the engine coolant temperature reaches approximately 198oF (92oC). There is a green wire attached to the switch. When the thermal fan switch closes, the radiator fan is energized. 7. Install fan switch to the water pump. A. Clean threads of water pump housing and switch thoroughly.
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Speed Sensor (Workman HDX and HDX--D) The speed sensor is attached to the upper transaxle cover (Fig. 34). It uses a magnetically based, Hall Effect integrated circuit. As the differential in the transaxle turns, the sensor accurately senses the movement of the differential ring gear teeth passing by the sensor. The red striped connector wire is the sensor positive lead, the black wire is the ground lead and the gray striped wire is the signal output. 2 1 Testing 1.
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Glow Plug Timer (Workman HDX--D) The glow plug timer is attached to the relay bracket under the right side of the bed near the rear axle (Fig. 36). 1 2 NOTE: Refer to electrical schematic and circuit drawings in Chapter 11 -- Electrical Drawings when troubleshooting the glow plug timer. Glow Plug Timer Operation 1. When the ignition switch is initially turned to the ON position, the timer energizes the glow plugs and illuminates the glow lamp for approximately five (5) seconds. 2.
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Delay Timer (Vehicles with 4WD) To delay the re--engagement of the 4WD differential clutch when shifting, the 4WD engage circuit includes a one second delay timer. On some early production vehicles, the delay timer is located near the differential electrical connector. On most vehicles, the delay timer is located behind the dash panel (Fig. 38). 4 1 Testing 1. Turn ignition switch to ON (do not start the engine). 3 2. Press the clutch pedal in to disengage the clutch. 3.
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Hydraulic Solenoid Valve Coil (Vehicles with High Flow Hydraulics Kit) Vehicles equipped with the High Flow Hydraulics Kit use a hydraulic solenoid valve coil for system control (Fig. 41). When the solenoid coil is energized, hydraulic valve shift occurs to provide hydraulic flow for the attachment. Testing of the coil can be done with the coil installed on the hydraulic manifold valve. 9 11 7 Testing 3 1.
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Rear PTO Switch (Optional Kit) On vehicles equipped with the optional rear PTO kit, the rear PTO switch is located in the rear PTO housing mounted on the top of the transaxle. The Rear PTO switch is normally closed and opens when the PTO is engaged. 1 Testing 1. Park machine on a level surface, raise bed, stop engine, apply parking brake and remove key from ignition switch. 2. Install bed support on bed lift cylinder to prevent bed from lowering. 3.
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Service and Repairs NOTE: Refer to the appropriate engine Service Manual for engine electrical component repair information. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery from the machine and charge it fully (see Battery Service). 2. Either store battery on a shelf or on the machine. 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 5.
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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. 2 3 RIGHT FRONT 1 CAUTION 4 When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin and eyes. Always wear safety goggles and a face shield when working with batteries.
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Battery Testing C. Make sure battery terminals are free of corrosion. 1. 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.
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Battery Charging To minimize possible damage to the battery and to allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is available in most shops. Battery Reserve Capacity (Minutes) 75% 50% 25% 0% 80 or less 3.8 hrs @ 3 amps 7.5 hrs @ 3 amps 11.3 hrs @ 3 amps 15 hrs @ 3 amps 81 to 125 5.3 hrs @ 4 amps 10.5 hrs @ 4 amps 15.8 hrs @ 4 amps 21 hrs @ 4 amps 126 to 170 5.
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Headlights 3. Install hood (see Hood Installation in the Service and Repairs section of Chapter 7 -- Chassis). Make sure to connect the wire harness connector to the headlight during hood installation. CAUTION The Workman headlights use a halogen bulb that becomes extremely hot when in operation. Handling a hot headlight bulb can cause severe burns and personal injury. Allow enough time for bulb to cool before handling.
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Tail Lamps Disassemble and assemble tail lamp using Fig. 46 as a guide. 2 1 4 3 Figure 46 1. Screw (2 used) 2. Lens Electrical System Page 8 -- 34 3. Bulb 4.
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Chapter 9 Hydraulic System Table of Contents SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . 31 General Precautions for Removing and Installing Hydraulic System Components . . . . . . . . . . . . . 31 Check Hydraulic Lines and Hoses . . . . . . . . . . . . 31 Gear Pump (Workman HDX and HDX--D) . . . . . 32 Gear Pump (Workman HD) . . . . . . . . . . . . . . . . . . 34 Gear Pump Service . . . . . . . . . . . . . . . . . . . . . . . . .
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Specifications Item Description Hydraulic Pump (Workman HDX and HDX--D) Displacement (per revolution) Casappa positive displacement gear type pump 0.325 in3 (5.3 cc) Hydraulic Pump (Workman HD) Displacement (per revolution) Casappa positive displacement gear type pump 0.378 in3 (6.
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General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Operator’s Manual for additional information when servicing the vehicle. 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 and maintenance.
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Hydraulic Hose and Tube Installation (O--Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. C. Use a second wrench to tighten the nut to the correct Flats From Wrench Resistance (F.F.W.R.). The markings on the nut and fitting body will verify that the connection has been properly tightened. 2.
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Hydraulic Fitting Installation (SAE Straight Thread O--Ring Fitting into Component Port) Non--Adjustable Fitting (Fig. 4) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate method of assembly is the Flats From Finger Tight (F.F.F.T.) method. 2.
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Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is recommended that the O--ring be replaced any time the connection is opened. Lock Nut 3. Lightly lubricate the O--ring with clean hydraulic oil. Fitting threads should be clean with no lubricant applied. Back--up Washer 4. Turn back the lock nut as far as possible.
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Hydraulic Schematics STEERING CONTROL VALVE STEERING CYLINDER LIFT CYLINDERS Vehicle Hydraulic Schematic Hydraulic System Page 9 -- 8 Workman HD Series
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Hydraulic System HYDRAULIC MANIFOLD High Flow Hydraulics Kit (If Equipped) Schematic Workman HD Series Page 9 -- 9 Hydraulic System
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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.
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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.
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High Flow Hydraulic Circuit On Workman HDX and HDX--D vehicles that are equipped with the high flow hydraulics kit, a second gear pump is directly coupled to the standard gear pump. This second gear pump provides hydraulic system flow for the high flow circuit that is designed to power hydraulic attachments. A manifold equipped with a solenoid operated relief valve (SVRV) is used to control the circuit and when energized, also provides circuit relief.
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Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings. Contains one each: 1000 PSI (70 Bar), 5000 PSI (350 Bar) and 10000 PSI (700 Bar) gauges. Use gauges as recommended in Testing section of this chapter.
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Hydraulic Test Fitting Kit This kit includes a variety of O--ring Face Seal fittings to enable you to connect test gauges into the system. TORO TEST FITTING KIT The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. Toro Part Number: TOR4079 Figure 13 O--ring Kit The kit includes O--rings in a variety of sizes for face seal and port seal hydraulic connections. It is recommended that O--rings be replaced whenever a hydraulic connection is loosened.
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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.
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Problem Possible Cause Bed does not lift or lifts very slowly. Excessive load in bed. Oil level in transaxle is low. Engine RPM is low. Incorrect oil in system (see oil recommendations in Operator’s Manual). Lift cylinder pivots or bed pivots are binding or damaged. Hydraulic pump drive belt is loose (Workman HD vehicles). Lift cylinder(s) is (are) worn or damaged. Gear pump key is sheared or missing (NOTE: Entire hydraulic system is affected).
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Problem Possible Cause Difficulty in connecting or disconnecting quick couplers. Hydraulic pressure is not relieved (coupler under pressure -- engine running). Hydraulic lift valve is not in neutral (centered) position. Hydraulic attachment does not function. Quick couplers are not fully engaged. Quick couplers are interchanged. Oil level in transaxle is low. Engine RPM is low. Excessive load is applied to attachment.
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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). 1. Thoroughly clean the vehicle before disconnecting or disassembling any hydraulic components. Always keep in mind the need for cleanliness when working on hydraulic equipment. Contamination will cause excessive wear of hydraulic components. 2.
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Gear Pump Flow and System Relief Pressure (Workman HDX and HDX--D) STEERING CONTROL VALVE TESTER LIFT CYLINDERS Figure 16 NOTE: This test procedure is for the single gear pump used on Workman HDX and HDX--D vehicles. If vehicle is equipped with the High Flow Hydraulics Kit, use this test for the front pump section and refer to the High Flow Hydraulics Kit Gear Pump Flow and Relief Pressure Test for testing of the rear pump section. 1 WORKMAN HDX and HDX--D GEAR PUMP 3 2 FRONT Figure 17 1.
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Procedure for Gear Pump Flow and System Relief Pressure Test (Workman HDX and HDX--D) 1. Make sure hydraulic oil is at normal operating temperature by operating the vehicle for approximately ten (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. CAUTION 7.
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Gear Pump Flow and System Relief Pressure (Workman HD) STEERING CONTROL VALVE TESTER LIFT CYLINDERS Figure 18 NOTE: This test procedure is for the belt driven gear pump used on Workman HD vehicles. FRONT WORKMAN HD GEAR PUMP 3 1 2 Figure 19 1. Gear pump 2. Pressure hose Hydraulic System Page 9 -- 22 3.
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Procedure for Gear Pump Flow and System Relief Pressure Test (Workman HD) 1. Make sure hydraulic oil is at normal operating temperature by operating the vehicle for approximately ten (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. Make sure that gear pump drive belt is adjusted properly (see Operator’s Manual). 8.
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Steering Control Valve and Steering Cylinder (ROTATED FOR RIGHT TURN) PLUG STEERING CYLINDER STEERING CONTROL VALVE LIFT CYLINDERS Figure 20 Hydraulic System Page 9 -- 24 Workman HD Series
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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 ten (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.
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Lift Cylinder Internal Leakage STEERING CYLINDER STEERING CONTROL VALVE (IN LOWER POSITION) LIFT CYLINDERS PLUG Figure 21 Hydraulic System Page 9 -- 26 Workman HD Series
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Procedure for Lift Cylinder Internal Leakage Test 1. Shut off engine and engage parking brake. Disconnect and plug this hose 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).
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High Flow Hydraulics Kit (If Equipped) Gear Pump Flow and Relief Pressure TESTER HYDRAULIC MANIFOLD (SOLENOID ENERGIZED) Figure 23 NOTE: This test procedure is for the rear gear pump section on Workman HDX and HDX--D vehicles that are equipped with the High Flow Hydraulics Kit. For testing the front pump section on vehicles with this kit, refer to the Gear Pump Flow and System Relief Pressure (Workman HDX and HDX--D) Test. 2 1 LEFT FRONT Figure 24 1.
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Procedure for High Flow Hydraulics Kit (If Equipped) Gear Pump Flow and System Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the vehicle for approximately ten (10) minutes. 2. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and apply the parking brake. After turning engine off, operate all hydraulic controls to relieve hydraulic system pressure. CAUTION 7.
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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.
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Gear Pump (Workman HDX and HDX--D) 25 to 30 ft--lb (33 to 40 N--m) RIGHT LOCTITE #242 20 FRONT 13 18 14 25 to 30 ft--lb (33 to 40 N--m) 19 22 17 15 14 19 16 18 12 11 10 9 22 17 23 8 20 16 6 9 8 29 25 to 30 ft--lb (33 to 40 N--m) 1 LOCTITE #242 24 14 7 6 21 16 7 HIGH FLOW GEAR PUMP 25 2 26 2 3 4 4 5 2 5 3 27 2 3 4 28 Figure 25 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
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Removal (Fig. 25) Installation (Fig. 25) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage parking brake. Remove key from the ignition switch. 1. If fittings were removed from gear pump, lubricate and place new O--rings onto fittings. Install fittings into pump openings using marks made during the removal process to properly orientate fittings. Tighten fittings (see Hydraulic Fitting Installation in the General Information section of this chapter). 2.
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Gear Pump (Workman HD) Removal (Fig. 26) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Loosen pump drive belt and remove belt from pump pulley. 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of this chapter section. 3. After installing the pump and connecting hydraulic hoses, install belt and adjust belt tension (see Operator’s Manual).
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Gear Pump Service 130 in--lb (15 N--m) WORKMAN HDX AND HDX--D GEAR PUMP 13 2 1 6 22 14 9 8 4 19 15 11 3 23 7 21 4 12 17 20 220 in--lb (25 N--m) 10 5 16 5 18 4 9 WORKMAN HD GEAR PUMP 3 1 6 13 14 7 2 16 5 10 12 5 4 17 15 11 220 in--lb (25 N--m) 8 1. 2. 3. 4. 5. 6. 7. 8. Retaining ring Shaft seal Front cover Dowel pin O--ring (2 used) Back--up seal Pressure seal Front thrust plate 9. 10. 11. 12. 13. 14. 15. 16.
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Disassembly (Fig. 28) 1. Plug pump ports and clean the outside of the pump thoroughly. After cleaning, remove plugs and drain any oil out of the pump. MARKER LINE 2. Use a marker to make a diagonal line across the front thrust plate, body and rear flange for assembly purposes (Fig. 29). IMPORTANT: Prevent damage when clamping the gear pump in a vise; clamp on the front thrust plate only. Also, use a vise with soft jaws. 3. Clamp front thrust plate of pump in a vise with soft jaws with the shaft end down.
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Assembly (Fig. 28) NOTE: When assembling the pump, check the marker line on each part to make sure the pump components are properly aligned during assembly (Fig. 29). 3 2 1. Lubricate O--rings, pressure seals, back--up seals and thrust plate grooves with a thin coat of petroleum jelly. Lubricate all other internal parts freely with clean Dexron III ATF. 1 2. Install new seal into front cover and rear flange (HDX and HDX--D): 4 A. Press shaft seal into seal bore until it reaches the bottom of the bore.
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Gear Pump Service (Vehicles with High Flow Hydraulics Kit) 220 in--lb (25 N--m) HIGH FLOW HYDRAULICS KIT GEAR PUMP 4 15 12 11 7 3 14 17 9 8 6 13 24 2 4 5 16 18 19 28 10 5 4 21 1 22 23 14 27 20 25 19 18 31 4 14 13 29 30 13 220 in--lb (25 N--m) 26 Figure 31 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Retaining ring Shaft seal Front cover Dowel pin (6 used) O--ring (4 used) Back--up seal Pressure seal Thrust plate Drive shaft Idler shaft Front pump section body Hydraulic System 12.
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The gear pump assembly used on Workman HDX and HDX--D vehicle equipped with the High Flow Hydraulics Kit is shown in Figure 31. When servicing this gear pump, follow the procedure for Gear Pump Service in this section and the following: RIGHT FRONT 1. Use Figure 31 as a guide when servicing pump. 2. Do not mix components from one pump section to the other. 3. The High Flow Kit gear pump supplies oil flow for two circuits and uses two separate reservoirs and oil types (Fig. 32).
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Lift Valve 20 RIGHT 16 FRONT 5 12 11 8 17 19 5 13 2 15 1 14 10 5 9 18 2 17 3 6 4 5 5 7 1. 2. 3. 4. 5. 6. 7. Lift valve O--ring Tee fitting Hyd. tube (steering circuit return) O--ring Hyd. tube (return to hydraulic filter) Flange nut (2 used) Hydraulic System 8. 9. 10. 11. 12. 13. 14. Figure 33 Lift lever Clevis pin Hairpin Retainer pin Link 90o hydraulic fitting Hyd. tube (to male quick fitting) Page 9 -- 42 15. 16. 17. 18. 19. 20. Hyd.
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Removal (Fig. 33) 2. Install lift valve to vehicle using Figure 33 as a guide. 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 3. Replace O--rings on hydraulic hoses and fittings. Remove caps and plugs from hoses and fittings. Connect hydraulic hoses to lift valve (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 2.
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Lift Valve Service Disassembly (Fig. 35) 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.
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Steering Control Valve 1 RIGHT 20 to 25 ft--lb (28 to 33 N--m) 2 10 3 FRONT 11 Antiseize Lubricant 4 8 9 12 13 5 6 19 20 7 14 15 16 17 18 Figure 36 1. 2. 3. 4. 5. 6. 7. Lock nut Flat 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.
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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. FRONT OF VEHICLE 1 5 5. Remove hood to gain access to steering control (see Hood Removal in the Service and Repairs section of Chapter 7 -- Chassis). 6.
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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 39 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.
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Steering Cylinder 40 to 50 ft--lb (55 to 67 N--m) 6 80 to 90 ft--lb (109 to 122 N--m) 19 27 30 17 33 25 15 3 2 1 9 12 14 28 18 16 23 8 11 3 21 22 26 24 35 to 40 ft--lb (48 to 55 N--m) 11 13 5 1 12 31 14 29 FRONT 12 32 20 RIGHT 35 to 40 ft--lb (48 to 55 N--m) 7 23 35 to 40 ft--lb (48 to 55 N--m) 40 to 50 ft--lb (55 to 67 N--m) 170 to 180 ft--lb (231 to 244 N--m) 10 2 80 to 90 ft--lb (109 to 122 N--m) 4 Figure 40 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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Removal (Fig. 40) 1. Park vehicle on a level surface, shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of this chapter section. CAUTION Before performing any service or repair on hydraulic system components, relieve system pressure to avoid injury from pressurized hydraulic oil.
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Steering Cylinder Service 6 1 9 11 8 4 7 3 10 2 4 12 5 14 8 3 9 11 15 13 Figure 42 1. 2. 3. 4. 5. Rear shaft Wear ring Seal O- ring Piston 6. 7. 8. 9. 10. Rear head O- ring Back- up ring Retaining ring Seal Disassembly (Fig. 42) 1. Pump oil out of cylinder into a drain pan by slowly moving piston back and forth. 2. Before disassembling cylinder, plug ports, wash exterior with cleaning solvent and dry thoroughly.
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Inspection 1. Wash all cylinder parts in clean solvent. Dry parts with compressed air. Do not wipe parts dry with paper towels or cloth. Lint in the hydraulic system will cause damage. 4. Slide front shaft onto rear shaft and align roll pin holes in shafts. Install roll pin to secure shafts. IMPORTANT: Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the clevis only. Do not close vise on barrel. 2.
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Lift Cylinder 12 1 RIGHT 11 FRONT 10 2 4 8 3 3 2 4 9 1. 2. 3. 4. Bed frame O--ring 90o hydraulic fitting O--ring Hydraulic System 7 5. 6. 7. 8. Figure 43 Hydraulic hose Lift cylinder (LH shown) Hydraulic hose Cotter pin Page 9 -- 54 6 5 9. 10. 11. 12.
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Removal (Fig. 43) Installation (Fig. 43) 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. Remove key from the ignition switch. 1. If fittings were removed from lift cylinder, lubricate and place new O--rings onto fittings. Install fittings into cylinder openings using marks made during the removal process to properly orientate fittings.
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Lift Cylinder Service 60 to 75 ft--lb (81 to 102 N--m) 7 8 9 10 11 6 3 4 2 5 1 12 13 14 1. 2. 3. 4. 5. Lock nut Wear ring Seal O--ring Piston 6. 7. 8. 9. 10. Figure 44 Head O--ring Back--up seal Retaining ring Seal Disassembly (Fig. 44) 1. Pump oil out of cylinder into a drain pan by slowly moving piston back and forth. 2. Before disassembling cylinder, plug ports, wash exterior with cleaning solvent and dry thoroughly.
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Assembly (Fig. 44) 4. Lubricate head and piston with clean Dexron III ATF. Slide shaft assembly carefully into cylinder barrel. 1. Make sure all parts are clean before assembly. 2. Coat new O--rings, piston seal, wear ring, shaft seal, back--up ring and dust seal with clean Dexron III ATF. IMPORTANT: Prevent damage when clamping the cylinder’s barrel into a vise; clamp on the clevis only. Do not close vise on barrel. A. Install piston seal, O--rings and wear ring to the piston. 5.
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Hydraulic Manifold (High Flow Hydraulics Kit) Removal (Fig. 45) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
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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. CAUTION Use eye protection such as goggles when using compressed air. Installation (Fig. 45) 1.
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Front Wheel Drive (4WD) Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . . 4 CV Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspect CV Boot and Test CV Joint . . . . . . . . . . . . 6 Differential Driveshaft . . . . . . . . . . . . . . . . .
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Specifications Item Description Differential Oil Capacity 8.
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The “Automatic on Demand” four wheel drive feature on 4WD Workman vehicles does not require operator activation. The front differential on 4WD Workman vehicles is an electro--mechanically activated bi--directional overrunning clutch system. The front differential is engaged whenever the ignition switch is in the ON position and the clutch is engaged. No power is delivered to the front wheels until the rear wheels begin to lose traction.
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Service and Repairs CV Axle Assembly ANTISEIZE LUBRICANT 1 8 10 ANTISEIZE LUBRICANT 170 to 180 ft- lb (231 to 244 N- m) STAKED 5 3 7 6 35 to 40 ft- lb (48 to 55 N- m) 9 2 16 11 8 1 4 2 10 15 14 RIGHT 11 FRONT 35 to 40 ft- lb (48 to 55 N- m) 12 13 Figure 1 1. 2. 3. 4. 5. 6. Spindle nut CV axle assembly Differential assembly Flange head screw (4 used) Driveshaft Cap screw 7. 8. 9. 10. 11. Disassembly (Fig. 1) 1.
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6. Install new spindle nut (item 1) onto CV axle. Torque spindle nut from 170 to 180 ft- lb (231 to 244 N- m). After tightening nut, stake nut extension into slot in axle. 5. Remove axle spacer (item 10) from CV axle. 7. Fully tighten flange head screws to secure wheel hub to knuckle. Torque screws from 35 to 40 ft- lb (48 to 55 N- m). IMPORTANT: Make sure to not damage the oil seal on the differential with the pry bars when removing the CV axle. 6.
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Inspect CV Axle Boot and Test CV Axle Inspect CV Axle Boot A torn CV axle boot is the most common cause of CV axle failures. 2 NOTE: A worn and noisy CV axle joint with the boot in good condition and filled with grease is not uncommon. Potholes, curb contact or collision damage can damage bearing components and initiate worn conditions. 3 1. Look for grease on front suspension components, inner tire sidewall or fender to indicate a possible torn boot.
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Differential Driveshaft 1 RIGHT FRONT 2 3 ANTISEIZE LUBRICANT 6 ANTISEIZE LUBRICANT 5 4 3 2 6 7 1. Transaxle 2. Cap screw 3. Flat washer Front Wheel Drive (4WD) Figure 4 4. Driveshaft 5. Differential assembly Page 10 -- 8 6. CV axle assembly 7.
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Front Wheel Drive (4WD) Removal (Fig. 4) 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 2. Remove cap screw and flat washer that secure the driveshaft yokes to differential input shaft and transaxle output shaft. 1 2 WARNING Support driveshaft to prevent it from dropping and causing personal injury when removing. Figure 5 3. Support driveshaft to prevent it from falling. 1. Driveshaft flange yoke 2. Differential assembly 4.
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Driveshaft Cross and Bearing Service 1 5 2 4 3 5 2 1 5 5 Figure 7 1. Yoke 2. Cross and bearing kit 3. Yoke and shaft 4. Yoke and tube 5. Snap ring Disassembly (Fig. 7) Assembly (Fig. 7) 1. Remove driveshaft from vehicle (see Differential Driveshaft Removal in this section). 1. To install new cross and bearings: IMPORTANT: When placing yoke in vise, clamp lightly on the solid part of the yoke to prevent yoke damage. Also, the use of a vise with soft jaws is recommended. 2.
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Front Wheel Drive (4WD) This page is intentionally blank.
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Front Differential ANTISEIZE LUBRICANT 1 8 ANTISEIZE LUBRICANT 10 ANTISEIZE LUBRICANT 170 to 180 ft- lb (231 to 244 N- m) STAKED 5 3 7 6 35 to 40 ft- lb (48 to 55 N- m) 9 2 16 11 8 1 4 2 10 15 14 RIGHT 11 FRONT 35 to 40 ft- lb (48 to 55 N- m) 12 13 Figure 8 1. 2. 3. 4. 5. 6. Spindle nut CV axle assembly Differential assembly Flange head screw (4 used) Driveshaft Cap screw Front Wheel Drive (4WD) 7. 8. 9. 10. 11.
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1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. Block rear wheels to prevent the vehicle from moving unexpectedly. 2. Secure differential to the frame with four (4) flange head screws (item 4). 3. Install and tighten inner two (2) flange head screws and flange nuts that secure control arm tower to upper control arm (Fig. 9). 2. Drain differential oil into a suitable container by removing the drain plug. Install drain plug after draining. 4.
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Front Differential Service 15 ft--lb (20 N--m) 16 23 14 to 20 ft--lb (19 to 27 N--m) 20 3 7 10 17 27 28 24 5 18 14 to 20 ft--lb (19 to 27 N--m) 30 16 1 34 11 15 33 35 36 37 22 4 21 29 25 13 2 19 5 24 6 26 32 9 31 15 ft--lb (20 N--m) 33 8 12 14 Figure 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. O--ring Set screw O--ring O--ring Bearing (2 used) Armature plate Bearing Bushing Roller cage assembly Vent Plug clip Coil Torsion spring Front Wheel Drive (4WD) 14. 15. 16. 17.
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1. Make sure that the oil is drained from the differential assembly. Front Wheel Drive (4WD) Front Differential Disassembly 2 2. Remove the four (4) flange head screws from the input cover (Fig. 11). Remove the cover. 1 Figure 11 1. Input cover 2. Pinion shaft 3. Remove the pinion shaft from housing by pulling it out of the gear case by hand (Fig. 12). 2 1 Figure 12 1. Pinion shaft 2. Gear case 4. Inspect the inner pinion bushing in the gear case (Fig. 13).
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5. Place the differential assembly on workbench with the cover plate facing up. 1 6. Remove the five (5) flange head screws that secure cover plate to gear case. Note location of plug clip for assembly purposes (Fig. 14). Carefully remove the cover plate from the gear case by lifting straight up. 3 2 Figure 14 1. Cover plate 2. Gear case 3. Plug clip 7. Remove the thrust bearing from the cover plate and inspect for wear (Fig. 15).
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Front Wheel Drive (4WD) 9. Carefully lift the ring gear out of the gear case (Fig. 17). Inspect ring gear teeth for any damage or abnormal wear. 1 2 Figure 17 1. Ring gear 2. Gear case 1 10.Remove the gear spacer from between the gear case and the ring gear (Fig. 18). 2 Figure 18 1. Gear spacer 2. Gear case IMPORTANT: When removing female output hub from gear case, be careful to not damage the seal in the gear case. The seal cannot be serviced separately. 11. Turn the gear case over.
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12.Place the cover plate on the workbench with the male output hub facing up. 13.Using a screwdriver, remove the internal retaining ring from the cover plate (Fig. 20). 1 2 Figure 20 1. Male output hub 2. Retaining ring 14.Remove the gear spacer from the cover plate (Fig. 21). 1 2 Figure 21 1. Male output hub 2. Gear spacer 15.Remove the armature plate from the cover plate (Fig. 22). 1 IMPORTANT: When removing male output hub from cover plate, be careful to not damage the seal in the cover plate.
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1. Be sure that all parts are clean and free of any dirt or debris. Make sure that all residual oil has been removed from differential components. Front Wheel Drive (4WD) Front Differential Assembly 2 2. Check the condition of the square sectioned O--ring located on the cover plate. Make sure that it is clean and free of any cuts or nicks. 1 IMPORTANT: When installing male output hub assembly into cover plate, be careful to not damage the seal in the cover plate. The seal cannot be serviced separately.
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IMPORTANT: When installing female output hub assembly into gear case, be careful to not damage the seal in the gear case. The seal cannot be serviced separately. 2 3 6. Press the new female output hub/bearing assembly into the gear case from the inside. The bearing has a slight interference fit to the bore, so it should not take much force to press in. Take care to not damage the seal during installation of the output hub assembly. 7.
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1 IMPORTANT: When installing the cover plate, make sure that the tangs on the armature plate are properly aligned into the slots on the roller cage. Improper assembly can cause damage to the armature plate and will prevent 4WD from engaging. 12.Place the cover plate onto the gear case assembly. Make sure to line up the tangs on the armature so they will insert into the mating slots on the roller cage. Also, make sure to align the cover plate bolt holes with the threaded holes in the gear case.
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This page is intentionally blank. Front Wheel Drive (4WD) Page 10 -- 22 Rev.
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Chapter 11 Electrical Drawings Electrical Drawings Table of Contents ELECTRICAL SCHEMATICS Workman HD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Workman HDX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Workman HDX--D . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 WORKMAN HD CIRCUIT DRAWINGS Start Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Run Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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3rd -- HIGH LOCKOUT SWITCH (SLOW) (OPTIONAL KIT) (OPTIONAL KIT) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) ELECTRIC BRAKE KIT (OPTIONAL KIT) LEFT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HD Kohler Gasoline Engine Vehicle Electrical Schematic All relays and solenoids are shown as de-- energized.
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3rd -- HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) 1 SECOND TIME DELAY 4 WD VEHICLES ONLY MPH/KPH SHUNT (IF EQUIPPED) ELECTRIC BRAKE KIT (OPTIONAL KIT) (IF EQUIPPED) LEFT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HDX Briggs/Daihatsu Gasoline Engine Vehicle Electrical Schemati
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3rd -- HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) 4 WD VEHICLES ONLY 1 SECOND TIME DELAY MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) ELECTRIC BRAKE KIT (OPTIONAL KIT) LEFT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HDX--D Briggs/Daihatsu Diesel Engine Vehicle Electrical Schemati
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3rd -- HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) (OPTIONAL KIT) (LIFT LEVER IN NEUTRAL) (OPTIONAL KIT) MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) ELECTRIC BRAKE KIT (OPTIONAL KIT) LEFT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HD Start Circuits Ignition Switch in START Position Transmission in Neutral Clutch Pedal Depr
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3rd -- HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) (OPTIONAL KIT) (LIFT LEVER IN NEUTRAL) (OPTIONAL KIT) MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) ELECTRIC BRAKE KIT (OPTIONAL KIT) LEFT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HD Run Circuits Ignition Switch in RUN Position Transmission in Neutral Power Current Control
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3rd -- HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) (LIFT LEVER IN NEUTRAL) (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) 1 SECOND TIME DELAY 4 WD VEHICLES ONLY MPH/KPH SHUNT (IF EQUIPPED) ELECTRIC BRAKE KIT (OPTIONAL KIT) (IF EQUIPPED) LEFT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HDX Start Circuits Ignition Switch in
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3rd -- HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) (OPTIONAL KIT) (LIFT LEVER IN NEUTRAL) (OPTIONAL KIT) (OPTIONAL KIT) 1 SECOND TIME DELAY 4 WD VEHICLES ONLY MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) ELECTRIC BRAKE KIT (OPTIONAL KIT) LEFT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HDX Run Circuits Ignition Switch in RUN
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3rd -- HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) (OPTIONAL KIT) (LIFT LEVER IN NEUTRAL) (OPTIONAL KIT) (OPTIONAL KIT) 4 WD VEHICLES ONLY 1 SECOND TIME DELAY MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) ELECTRIC BRAKE KIT (OPTIONAL KIT) LEFT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HDX--D Glow Plug Circuits Ignition S
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3rd -- HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) (OPTIONAL KIT) (LIFT LEVER IN NEUTRAL) (OPTIONAL KIT) (OPTIONAL KIT) 4 WD VEHICLES ONLY 1 SECOND TIME DELAY MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) ELECTRIC BRAKE KIT (OPTIONAL KIT) LEFT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HDX--D Start Circuits Ignition Switch
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3rd -- HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) (OPTIONAL KIT) (LIFT LEVER IN NEUTRAL) (OPTIONAL KIT) (OPTIONAL KIT) 4 WD VEHICLES ONLY 1 SECOND TIME DELAY MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) ELECTRIC BRAKE KIT (OPTIONAL KIT) LEFT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HDX--D Run Circuits Ignition Switch in
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3RD HIGH LOCKOUT SWITCH Workman HD Series (All Models) Front Wire Harness Drawing Page 11 -- 14
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3RD--HIGH LOCKOUT SWITCH BLACK TAN BLACK TAN GREEN GREEN WHITE/BLACK GREEN RED/BLACK BLACK GRAY TAN PINK RED RED ORANGE PINK RED/BLACK YELLOW TAN ORANGE WHITE RED GREEN BLUE TAN VIOLET GREEN YELLOW BLUE ORANGE BLUE PINK YELLOW GRAY BLACK YELLOW GRAY RED/BLACK TAN BROWN GREEN ORANGE WHITE/BLACK BLACK PINK YELLOW BLACK RED WHITE/BLACK BLACK BLACK GREEN GREEN TAN ORANGE GREEN ORANGE BLACK GREEN VIOLET BROWN GREEN YELLOW BLACK BROWN WHITE/BLACK BLACK GREEN WHITE/BLACK RED GREEN
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LIFT LEVER INTERLOCK SWITCH Workman HD Kohler Gasoline Engine Rear Wire Harness Drawing Page 11 -- 16
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BLACK RED/BLACK RED/BLACK ORANGE RED/BLACK ORANGE BLACK BLUE BLUE BLACK YELLOW RED PINK GRAY GRAY PINK ORANGE WHITE TAN GREEN ORANGE BLUE GRAY RED/BLACK BROWN GREEN ORANGE WHITE/BLACK BLACK BLACK BLACK YELLOW BLACK RED ORANGE WHITE BLACK BLACK RED BLACK BLACK ORANGE BLACK ORANGE BLACK WHITE/BLACK BLACK ORANGE BLACK WHITE/BLACK 3RD--HIGH LOCKOUT GRAY LIFT LEVER INTERLOCK SWITCH Workman HD Kohler Gasoline Engine Rear Wire Harness Diagram Page 11 -- 17
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LIFT LEVER INTERLOCK SWITCH ON EARLY PRODUCTION VEHICLES WITH 4WD, A SMALL WIRE HARNESS IS CONNECTED TO THE P20 HARNESS CONNECTOR FOR THE DELAY TIMER AND DIFFERENTIAL DELAY RELAY. THIS WIRE HARNESS IS DEPICTED BELOW.
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YELLOW BLUE BLUE PINK BLACK BLUE/WHITE GREEN/WHITE GREEN GRAY ORANGE TAN ORANGE ORANGE BLACK ORANGE WHITE ORANGE BLUE GREEN VIOLET BROWN PINK GREEN GREEN GRAY ORANGE ORANGE YELLOW BROWN GREEN ORANGE WHITE/BLACK PINK BLACK BLACK YELLOW BLUE BLACK RED BLACK ORANGE BLACK WHITE/BLACK BLACK WHITE/BLACK ORANGE BLACK 3RD--HIGH LOCKOUT ORANGE RED BLACK YELLOW GRAY RED/BLACK TAN YELLOW GREEN TAN ORANGE GREEN ORANGE WHITE ORANGE PINK BLACK RED/BLACK RED/BLACK ORANGE RED/BLACK OR
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LIFT LEVER INTERLOCK SWITCH ON EARLY PRODUCTION VEHICLES WITH 4WD, A SMALL WIRE HARNESS IS CONNECTED TO THE P20 HARNESS CONNECTOR FOR THE DELAY TIMER AND DIFFERENTIAL DELAY RELAY. THIS WIRE HARNESS IS DEPICTED BELOW.
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ORANGE PINK BLACK RED/BLACK RED/BLACK ORANGE RED/BLACK ORANGE BLUE BLACK BLUE YELLOW RED YELLOW RED BLACK BLACK YELLOW PINK GRAY GRAY ORANGE WHITE BLUE TAN VIOLET GREEN YELLOW ORANGE BLUE PINK YELLOW GRAY RED/BLACK TAN BROWN GREEN ORANGE WHITE/BLACK BLACK BLACK BLACK BLACK YELLOW BLACK RED BLACK PINK GRAY VIOLET RED BLACK BLACK YELLOW BLUE YELLOW PINK ORANGE VIOLET YELLOW BLUE BLACK BLACK BLACK ORANGE BLACK WHITE/BLACK ORANGE BLACK WHITE/BLACK BLACK ORANGE GREEN RED 3RD--
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