Form No.
Revision History Revision Date -- 2014 A 02/2018 Updated Electrical, Chassis and Electrical Drawing chapters. Added revision history. B 03/2019 Updated Electrical chapter. C 05/2020 Updated Electrical Drawings. D 06/2021 Updated Electrical Drawings. © THE TORO COMPANY 2021 Description Initial Issue. This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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Part No. 14208SL (Rev. D) Service Manual WorkmanR HD Series HD Models 07369 S/N 313000001 & Up, HD/HDX/HDX--D Models with Kohler and Kubota Gasoline & Diesel 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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Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2 General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 6 Service and Repairs . . . . . . . . . . . . . . . . . . . . . . .
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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 Drawing Designations . . . . . . . . . . . . . 11 -- 2 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . 11 -- 3 Wire Harness 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 . . . . . . . . . .
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.
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.
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.
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.
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.
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 . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners) Thread Size Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in−lb in−lb N−cm 10 + 2 13 + 2 147 + 23 # 6 − 32 UNC # 6 − 40 UNF # 8 − 32 UNC 13 + 2 25 + 5 # 10 − 24 UNC 30 + 5 SAE Grade 8 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 5 or Stronger Nuts) in−lb N−cm in−lb N−cm 15 + 2 169 + 23 23 + 3
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.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Square Head Hex Socket 1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb 5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb 3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb 1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb 7/16 − 20 UNF Grade 5 65 + 10 ft−lb 88 + 14 N−m 1/2 − 20 UNF Grade 5 80 + 10 ft−lb 108 + 14 N−m M12 X 1.25 Class 8.
Chapter 3 Kubota EFI Gasoline Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . Kubota Workshop and Diagnostics Manuals . . . . Kubota Gasoline Engine . . . . . . . . . . . . . . . . . . . . . Kubota Gasoline Engine Electronic Control Unit (ECU) . . . . . . . . . . . . . .
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Specifications Item Description Kubota, Vertical, 4−Cycle, 3 Cylinder, Liquid Cooled, Gasoline Engine Bore 2.93 in (74.5 mm) Stroke 2.90 in. (73.6 mm) Total Displacement 58.68 cu. In. (962 cc) Compression Ratio 9.2:1 Ignition Timing 31_ BTDC @ 3600 rpm Ignition System Full Transistor Battery Ignition Type Firing Order 1−2−3 Spark Plug Type/Gap NGK BKR6E 0.028 to 0.031 in. (0.7 to 0.8 mm) Intake & Exhaust Valve Clearance (check when engine is cold) 0.0065 + 0.0001 in. (0.165 + 0.
Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the Kubota EFI gasoline engine used in the Workman HDX. Service and repair parts for Kubota gasoline engines are supplied through your local Toro Distributor. If a parts list is not available, be sure to provide your distributor with the Toro model and serial number. Most repairs and adjustments require tools which are commonly available in many service shops.
Kubota Gasoline Engine Electronic Control Unit (ECU) The Kubota gasoline engine that powers your Workman HDX uses an electronic control unit (ECU) for engine management. All wire harness electrical connectors should be plugged into the ECU before the machine ignition switch is moved from the OFF position to either the ON or START position. If the engine ECU identifies that an engine problem exists, the check engine light on the Operator’s Control Panel will illuminate.
Service and Repairs Air Cleaner System 5 6 3 4 2 1 7 8 VACUATOR DIRECTION 9 RIGHT FRONT Figure 4 1. Air cleaner assembly 2. Hose clamp 3. Air inlet hood Kubota EFI Gasoline Engine 4. Hose clamp 5. Air intake hose 6. Hose clamp Page 3 − 6 7. Flange nut (2) 8. Mounting bracket 9.
Check Air Filter, Dust Cup, & Burp Valve 1 The air cleaner body, air filter, dust cup, and burp valve should be checked daily, prior to operation. 2 3 IMPORTANT: Any leaks in the air cleaner system will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during operation. 5 1. Park machine on a level surface, lower cutting units, stop engine, engage parking brake, and remove key from the ignition switch. Unlatch and raise hood. 2.
Exhaust System 28 RIGHT 27 29 FRONT 26 20 25 23 6 13 24 20 21 2 19 3 22 17 4 1 18 22 to 26 ft−lb (30 to 35 N−m) 28 to 36 ft−lb (38 to 49 N−m) 5 23 10 22 to 26 ft−lb (30 to 35 N−m) 16 15 6 7 6 8 14 9 22 to 26 ft−lb (30 to 35 N−m) 10 11 11 12 13 8 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Oxygen sensor Lock washer (4) Hex nut (4) Exhaust tube Stud (4) Exhaust gasket (3) Catalytic converter Flange head screw Heat shield mount Flange nut (8) Kubota EFI Gasoline Engine 11. 12. 13.
Removal Installation 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. A. Hex nuts that secure exhaust tube to engine. Torque from 22−26 ft−lbs (30 to 35 N−m). 3. Note position of exhaust system heat shields and mounting brackets before removal. Remove exhaust system components as needed (Fig. 7). B. Hex nuts that secure catalytic converter to exhaust tube.
Fuel System 175 to 200 in−lb (20 to 22 N−m) 20 12 2 1 11 TO ENGINE 8 17 18 3 22 4 19 15 5 13 9 21 6 10 16 TO PURGE PORT 8 7 RIGHT FRONT 14 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. Fuel hose (to engine) Hose clamp Fuel hose (to vacuum valve) Vacuum check valve Fuel hose (to engine) Filter hose Canister filter Fuel hose (tank to canister) 9. 10. 11. 12. 13. 14. 15. Flange nut (2) Fuel tank Fuel cap Fuel pump/sender assembly Carbon cannister Support tube Retainer plate 16. 17. 18. 19. 20. 21.
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. 3 Kubuta EFI Gasoline Engine CAUTION The fuel supply hose will contain pressurized fuel. Be careful when disconnecting supply hose.
Fuel Pump Removal (Fig. 8) 1 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. 2 3 2. Install bed support on bed lift cylinder to prevent bed from lowering. 3. Disconnect vehicle wire harness connectors from fuel pump/sender assembly on fuel tank. 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.
Carbon Canister 2 3 4 5 TO FUEL TANK 6 7 TO PURGE PORT AT ENGINE Carbon Canister Removal Figure 11 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. 1. 2. 3. 4. Carbon canister Fuel hose Vacuum check valve Fuel hose (to engine) 5. 6. 7. 8. Fuel hose (to tank) Filter hose Canister filter Canister mount DANGER Gasoline is flammable. Use caution when storing or handling it.
Radiator 9 1 RIGHT 5 6 FRONT 7 8 10 11 Thread Sealant 13 4 12 7 3 2 30 28 23 17 24 7 22 14 17 8 14 21 15 25 15 5 15 17 16 15 17 19 18 12 17 20 26 29 7 Thread Sealant 18 27 Figure 12 1. 2. 3. 4. 5. 6. 7. 8. 9. Radiator guard (industrial) Radiator screen Swell latch (4) Flange head screw (4 − industrial) Flange head screw (4) Flat Washer Hose clamp Hose (radiator to reservoir) Flange head screw (2 − industrial) Kubota EFI Gasoline Engine 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
Removal (Fig. 12) Installation (Fig. 12) 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 (Fig. 13) 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.
Engine 26 RIGHT 28 FRONT 27 23 25 29 23 24 15 to 20 ft−lb (20 to 27 N−m) 22 18 14 16 13 15 12 21 11 9 19 10 20 17 16 8 7 14 ANTI−SEIZE LUBRICANT 6 1 LOCTITE #242 15 to 20 ft−lb (20 to 27 N−m) 2 3 4 5 Figure 14 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Gear pump O−ring Hydraulic fitting Hose clamp Suction hose (from transaxle) O−ring Hose (to lift valve) O−ring Hydraulic fitting Flange nut (4) Kubota EFI Gasoline Engine 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Engine Removal (Fig. 14) 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. Disconnect negative (−) and then positive (+) battery cables at the battery. 4. Remove exhaust tube from vehicle (see Exhaust System Removal in this section). 7 5.
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.
14.Fill radiator with coolant (see vehicle Operator’s Manual). Engine Installation (Fig. 14) 1. Install pressure plate and clutch disc if removed (see Installing Clutch Disc and Cover in Chapter 6 − Drive Train). 2. If coupler assembly was removed, assemble coupler to engine pulley. Apply Loctite #242 (or equivalent) to threads of flange head screws that secure coupler to engine pulley. Torque fasteners to 15 to 20 ft−lb (20 to 27 N−m). 15.Connect wire harness connectors to engine components.
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Chapter 4 Kubota Diesel Engine Table of Contents Workman HDX−D Page 4 − 1 Kubota Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Adjust Accelerator Cable . . . . . . . . . . . . . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Kubota water−cooled, Diesel, Model D902−E3B Number of Cylinders 3 Bore x Stroke 2.83” x 2.9” (72mm x 73.6mm) Total Displacement 54.8 in3 (898 cc) Compression Ratio 24.
General Information Information about specifications, maintenance, troubleshooting, testing and repair of the diesel engine used in the Workman HDX−D is included in this chapter and the Kubota Workshop Manual, Diesel Engine, SM−E3B Series. Service and repair parts for Kubota engines are supplied through your local local Toro distributor. If no parts list is available, be sure to provide your distributor with the Toro model and serial number.
Adjustments Adjust Accelerator Cable 1. Position the machine on a level surface, stop the engine, and engage the parking brake. 2. Check position of the engine speed control lever on fuel injection pump. The speed control lever should be contacting the high speed stop screw when the accelerator pedal arm is .200” to .350” (5.08 mm to 8.89 mm) above the floor plate (Fig. 1). 3. If necessary, throttle control can be adjusted by loosening cable jam nuts and repositioning throttle cable as necessary.
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Service and Repairs Air Cleaner System 5 4 STANDARD MODELS 6 RIGHT 3 FRONT 2 1 9 8 VACUATOR DIRECTION 7 10 5 4 INDUSTRIAL MODELS 3 2 5 11 5 12 9 13 7 1 14 10 8 Figure 4 1. 2. 3. 4. 5. Air cleaner assembly Hose clamp Air inlet hood Air intake hose Hose clamp Kubota Diesel Engine 6. 7. 8. 9. 10. Kubota diesel engine Mounting bracket Flange nut (2) Hose clamp Flange head screw (2) Page 4 − 6 11. 12. 13. 14.
Air Cleaner Removal 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. Raise or remove the bed or other attachment(s) if necessary. If bed is raised, place safety support on lift cylinder. 3. Remove air cleaner components as needed. 7. Carefully slide the primary filter over the safety filter. Ensure that it is fully seated by pushing on the outer rim of the filter while installing it. 8. Install the air cleaner cover.
Exhaust System 9 RIGHT 8 2 10 FRONT 13 7 8 1 6 11 3 4 8 12 5 3 14 Figure 6 1. 2. 3. 4. 5. Engine Muffler Exhaust gasket Hex nut Exhaust tube Kubota Diesel Engine 6. 7. 8. 9. 10. Flange head screw Transaxle Flange nut Flange head screw Mount plate Page 4 − 8 11. 12. 13. 14.
Removal (Fig. 6) Installation (Fig. 6) 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.Fit all exhaust components to vehicle before tightening any fasteners. When securing exhaust, tighten fasteners in the following order: A. Hex nuts that secure exhaust tube to engine. 3.
Fuel System 175 to 200 in−lb (20 to 22 N−m) 6 5 7 1 8 3 9 4 10 2 11 12 14 16 15 24 13 22 19 RIGHT 8 8 21 23 8 11 Thread Sealant FRONT 17 18 25 8 19 14 20 Thread Sealant Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel tank cap Grommet Rollover valve Fuel hose (vent) Fuel sender Fuel sender nut Gasket Hose clamp Fuel hose (return from engine) 10. 11. 12. 13. 14. 15. 16. 17.
Fuel Tank Removal (Fig. 7) 3 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 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 connector from fuel sender on fuel tank. 4 4. Note routing of fuel hoses for installation purposes (Fig. 8). Disconnect fuel hoses from fuel sender and rollover valve.
Radiator 9 13 1 RIGHT FRONT 5 6 7 8 Thread Sealant 10 11 31 4 2 Thread Sealant 33 12 7 3 32 30 28 23 17 24 7 22 14 17 8 14 21 15 25 15 5 15 17 16 15 17 19 29 18 12 17 20 26 7 18 Thread Sealant 27 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Radiator guard (industrial) Radiator screen Swell latch (4) Flange head screw (4 − industrial) Flange head screw (4) Flat Washer Hose clamp Hose (radiator to reservoir) Flange head screw (2 − industrial) Clip (2) Kubota Diesel Engine 11.
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 (Fig. 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.
Engine 26 27 28 RIGHT FRONT 25 29 23 30 24 15 to 20 ft−lb (20 to 27 N−m) 23 22 18 14 16 13 15 12 21 11 9 19 10 20 17 16 8 7 14 ANTI−SEIZE LUBRICANT 6 1 LOCTITE #242 15 to 20 ft−lb (20 to 27 N−m) 2 3 4 5 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Gear pump O−ring Hydraulic fitting Hose clamp Suction hose (from transaxle) O−ring Hose (to lift valve) O−ring Hydraulic fitting Flange nut (4) Kubota Diesel Engine 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Engine Removal (Fig. 11) 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. 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. Disconnect negative (−) and then positive (+) battery cables at the battery. 4. Remove exhaust tube from vehicle (see Exhaust System Removal in this section). 2 7 7.
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.
14.Fill radiator with coolant (see vehicle Operator’s Manual). 15.Connect wire harness connectors to engine components. Secure wire harness to machine with cable ties in locations noted during engine removal. 3. If engine mount was removed, secure mount to engine with seven (7) flange head screws. Do not install the screw used to secure the ground connections to the engine at this time. A. Positive (+) battery cable, fusible link harness and harness ring terminal from starter solenoid stud (Fig. 12). 4.
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Chapter 5 Kohler Air Cooled Gasoline Engine Table of Contents Kohler Air Cooled Gasoline Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5 Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exhaust System . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Kohler, CH680−3025, 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.
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.
Exhaust System 15 RIGHT 5 10 14 FRONT 13 5 6 11 8 6 5 5 12 4 7 3 9 2 1 Figure 2 1. 2. 3. 4. 5. Flange head screw (4) Exhaust manifold Hex nut (4) Exhaust gasket (2) Flange nut (9) Kohler Air Cooled Gasoline Engine 6. 7. 8. 9. 10. Flange head screw (3) Flange head screw Bracket Muffler gasket Muffler Page 5 − 6 11. 12. 13. 14. 15.
Removal (Fig. 2) Installation (Fig. 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. 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. Fit all exhaust components to vehicle before tightening any fasteners (Fig. 2). When securing exhaust, tighten fasteners in the following order: A. Hex nuts that secure manifold to engine.
Fuel System 20 175 to 200 in−lb (20 to 22 N−m) 16 15 17 1 8 11 13 TO FILTER 2 12 3 18 4 19 20 9 5 29 23 FROM TANK 1 6 TO PURGE PORT 21 8 7 25 2 27 TO ENGINE 10 24 26 28 2 22 RIGHT FRONT Figure 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Fuel hose (to filter) Hose clamp Fuel hose Vacuum check valve Fuel hose (engine purge) Filter hose Canister filter Fuel hose (tank vent) Flange nut (2) Fuel tank 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Fuel Tank Removal (Fig. 3) 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. 4). Disconnect fuel hoses from fuel sender and rollover valve.
Carbon Canister 2 3 4 TO FUEL TANK TO PURGE PORT AT ENGINE 5 6 7 Carbon Canister Removal Figure 5 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. 1. 2. 3. 4. Carbon canister Fuel hose Vacuum check valve Fuel hose (to engine) 5. 6. 7. 8. Fuel hose (to tank) Filter hose Canister filter Canister mount DANGER Gasoline is flammable. Use caution when storing or handling it.
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Engine 19 46 11 47 13 12 15 9 26 16 33 39 24 5 23 7 10 14 38 8 6 28 29 17 48 30 31 32 25 27 21 Antiseize Lubricant 22 20 35 to 40 ft−lb (48 to 55 N−m) 18 4 3 45 Antiseize Lubricant 41 2 37 40 34 RIGHT 42 43 FRONT 1 36 44 Figure 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Engine Removal (Fig. 6) 2 3 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. 5 3. Disconnect negative (−) and then positive (+) battery cables at the battery. 4. Disconnect positive cable and fusible link harness from starter solenoid stud on engine. 6 4 5.
7. Secure engine to engine mount with four (4) flange nuts and flange head screws. Flywheel and Pilot Bearing Inspection 1. Inspect flywheel surface for stepped wear, streaking or seizure and replace if necessary. Check flywheel runout and replace if runout exceeds 0.005 in. (0.13 mm). 8. Connect choke cable to choke lever on engine (Fig. 8). 2. Check pilot bearing for smooth rolling and noise. Check (sealed) bearing for grease leakage. Replace bearing if necessary.
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 . . . . . . . . . . . . . . . . . . . .
Specifications Item Specification Transaxle Oil Dexron III ATF Transaxle Oil Capacity Drive Train 7.5 U.S. quart (7.
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.
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.
Adjustments Power−Take−Off (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.
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.
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.
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.
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.
Service and Repairs Shift Cable Replacement 1 2 3 18 19 4 Loctite #271 7 6 5 9 8 7 10 8 6 11 11 10 17 16 15 12 4 13 RIGHT 135 to 165 in−lb (15 to 18 N−m) 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) 14. 15. 16. 17. 18. 19.
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.
Driveshaft 13 17 19 1 16 8 35 to 40 ft−lb (48 to 55 N−m) 18 6 15 14 170 to 180 ft−lb (231 to 244 N−m) STAKED 19 Antiseize Lubricant 9 12 4 10 40 to 45 ft−lb (55 to 61 N−m) 13 19 5 2 3 7 35 to 40 ft−lb (48 to 55 N−m) RIGHT FRONT Loctite #271 Antiseize Lubricant 11 80 to 90 ft−lb (109 to 122 N−m) Figure 7 1. 2. 3. 4. 5. 6. 7. Rear axle Wheel hub assembly (2) Brake rotor (2) Brake caliper (LH shown) Flange nut (2) Parking brake caliper (LH shown) Splined shaft (2) Drive Train 8. 9.
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 Chapter 7 - Chassis in this manual). 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.
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.
Power−Take−Off (PTO) Removal & 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.
Transaxle 2 6 9 3 RIGHT 7 14 FRONT 5 4 8 3 9 2 11 1 12 19 18 17 15 13 10 16 Figure 12 1. 2. 3. 4. 5. 6. 7. Transaxle assembly Snubbing washer (4) Isolation mount assembly (2) Transaxle mount (2) Flange nut (4) Cap screw (2) Flange head screw (4) Drive Train 8. 9. 10. 11. 12. 13. Shift arm Lock nut (3) Shift cable mount bracket Shift lever (2) Differential lock lever Strainer Page 6 − 16 14. 15. 16. 17. 18. 19.
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 Chapter 8 − Electrical System in this manual). 2 3 3. Remove drain plug from bottom of transaxle and allow oil to drain into a suitable drain pan.
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) Bell housing Oil seal Cap screw (6) 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.
Clutch Disassembly and Inspection (Fig. 19) 1. Insert clutch alignment tool (see Special Tools in this chapter) 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 1 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. Remove extension spring. 2. Loosen and remove flange head screws and remove bell housing assembly from transaxle. 2 3. Thoroughly clean outside surface of transaxle. Figure 24 1. Extension 4. Loosen flange head screws and remove fork shaft case from center plate.
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, shims and snap ring from center plate. 3 4 1 2 Figure 27 1. Seal cap 2. Shims 3. Shim 4. Snap ring 8. 4WD UNITS ONLY: remove front drive shaft and 41T gear from the gear case. Remove bearings from gear case and center plate (Fig. 28 and Fig. 29). 1 4 3 2 Figure 28 1. Front drive shaft 2. 41T gear 3. Bearing (gear case) 4.
10.Remove main shaft assembly together with fork shaft assembly from transaxle case. 2 1 Figure 30 1. Main shaft assembly 11. Remove, all at the same time, reduction shaft assembly, 2nd−3rd shift assembly, countershaft assembly and High−Low shift assembly. 2. Fork shaft assembly 2 4 1 3 Figure 31 1. Reduction shaft assembly 2. 2nd−3rd shaft assembly 3. Countershaft assembly 4. High−Low shift assembly 12.Loosen flange head screws and remove L.H. axle shaft assembly and shims from L.H.
13.Remove roll pin from differential lock lever. Remove lever from shaft. Loosen and remove five (5) flange head screws. Remove L.H. side cover from transaxle case. 2 14.Inspect side cover for cracks or damage and replace if necessary. 1 3 Figure 33 1. Lever 2. Flange head screw (5) 3. L.H. Side cover 15.Loosen and remove four (4) flange head screws. Remove R.H. axle shaft assembly from transaxle case. 1 2 Figure 34 2. R.H. Axle shaft assy. Drive Train 1. Flange head screw (4) 16.
17.Remove washer from inside of transaxle case. NOTE: Washer may stick to fork shaft when removed in step 16. 1 Figure 36 1. Washer 18.To remove shift arms: 1 A. Loosen and remove nut. Remove 2nd−3rd shift arm together with shift arm plate, spring, lock nut, washer and cap screw. 3 B. Loosen and remove lock nut from both 1st−Rev. shift arm and High−Low shift arm (not shown). Remove shift arms. 2 7 6 4 5 8 9 C. Loosen cap screws (Fig. 38) and remove keeper plates. D. Remove oil seals.
19.If PTO cover is on transaxle, remove cap screws and nut with washer. Separate PTO cover from transaxle case. Inspect PTO cover for cracks or damage and replace if necessary. 2 3 1 Figure 39 1. Cap screw (5) 2. Nut 3. PTO cover 20.Remove oil cap and O−ring from transaxle case if necessary. 1 2 21.Remove air breather if necessary. Figure 40 1. Oil cap 2. Air breather 22.Loosen flange head screws and remove upper cover from transaxle case. 2 1 Figure 41 1.
23.Disassemble main shaft assembly: 3 4 7 8 10 13 16 14 A. Use a bearing puller to remove bearing from main shaft. B. Remove snap ring and washer. Measure thickness of washer. Replace washer if it is less than 0.0709 in. (1.8 mm) thick. C. Remove needle bearings and gear (item 4). Inspect needle bearings and replace if necessary. 19 D. Remove synchro ring. 1 2 5 6 9 11 12 18 17 15 Figure 42 E. Remove snap ring. F. Remove shifter together with spring, hub and keys. G. Remove key (item 9). H.
24.Disassemble reduction shaft assembly: 1 A. Use a bearing puller to remove bearing from reduction shaft. 5 3 15 14 13 10 7 B. Remove gear, helical gear, collar and gear. C. Use a bearing puller to remove bearing. D. Remove washer, needle bearing and gear. E. Remove spacer. F. Remove snap ring. 4 2 18 17 16 G. Remove shifter together with spring, hub and keys. 12 11 8 6 9 H. Remove key. Figure 44 J. Remove gear, needle bearing and thrust washer.
25.Disassemble reverse shaft assembly: A. Use a bearing puller to remove bearing from reverse shaft. B. Remove gear. C. Use a bearing puller to remove bearing from reverse shaft. 3 4 2 1 Figure 46 1. Bearing 2. Gear 3. Bearing 4. Reverse shaft 12 14 6 8 9 4 1 2 26.Disassemble countershaft assembly: A. Use a bearing puller to remove bearing from countershaft. B. Remove thrust washer. C. 4WD UNITS ONLY: remove the gear that drives the front drive shaft. D.
27.Disassemble fork shaft assemblies: A. Remove lock pin from 2nd−3rd fork shaft assembly. B. Note or mark mating shafts and forks for assembly. C. Remove shift fork from fork shaft. D. Remove lock pin from 1st−R fork shaft assembly. Figure 49 1. Lock pin 2. Shift fork E. Remove shift fork from fork shaft. 3. Fork shaft 28.Disassemble Hi−Lo fork shaft assembly: 5 A. Remove shift fork, steel ball and spring from Hi− Lo shift fork assembly. 1 B. Remove E−ring. 4 3 2 Figure 50 4. E−ring 5.
29.Disassemble differential gear assembly: 1 5 SLIT 11 8 4 A. Use a bearing puller to remove bearing (item 1) from differential case. B. Remove snap ring. 2 C. Use a bearing puller to remove bearing and slider. D. Loosen screws from ring gear. E. Remove ring gear from differential case and remove dowel pins. F. Drive lock pin out of pinion shaft. G. Remove pinion shaft from differential case. H. Remove differential pinions and liners. 12 15 7 6 9 10 14 13 3 I. Remove L.H. side gear, R.H.
30.Disassemble differential fork shaft assembly: LOCK PIN A. Remove O−ring from fork shaft. ARM B. Remove snap ring, washer and spring. C. Remove fork. D. Remove lock pin if necessary. 6 5 4 3 2 1 7 Figure 53 1. 2. 3. 4. O−ring Snap ring Washer Spring 5. Fork 6. Lock pin 7. Fork shaft 31.Disassemble L.H. axle shaft: 4 A. Remove O−ring from differential carrier. 2 1 8 3 B. Remove snap ring. C. Remove L.H. axle shaft assembly. D. Remove snap ring and washer. E.
Transaxle Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. 3. Inspect synchronizer ring: A. Inspect the chamfer for excessive wear or damage. B. Inspect inner tapered area for excessive wear or damage. 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.
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. 2 3 E. The shifter should move freely on the hub. 1 F. Measure the clearance between shifter groove and fork. Replace shift fork, if the clearance exceeds 0.039 in. (1.0 mm). CLEARANCE 4 Figure 57 1. Shifter 2. Key (3) 3. Spring 4. Fork 7.
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. UNDAMAGED GROOVE Figure 60 DAMAGED GROOVE EDGES Figure 61 10.Inspect reduction shaft for wear or damage. If O.D. of outer needle bearing area is less than 0.864 in. (21.95 mm) or inner needle bearing area is less than 0.982 in. (24.95 mm), replace the reduction shaft. 1 3 2 Figure 62 1. Reduction shaft 2. Outer bearing area 11.
12.Inspect differential: 2 A. Inspect pinion shaft for excessive wear or damage. If O.D. is less than 0.707 in. (17.95 mm), replace the pinion shaft. 4 1 B. Measure thickness of pinion liners. If thickness is less than 0.035 in. (0.9 mm), replace the pinion liners. 5 3 3 5 C. Measure thickness of side gear liners. If thickness is less than 0.043 in. (1.1 mm), replace the side gear liners. 4 2 D. Inspect the gear contact condition between spiral bevel pinion and ring gear. Figure 64 1.
Transaxle Assembly 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: 4 A. Install new oil seal into differential carrier. 2 1 8 3 B. Use a press to install bearing onto L.H. axle shaft. C. Install washer and snap ring. D. Install L.H. axle shaft assembly into differential carrier. E. Install snap ring. L.H.
5. Assemble differential gears: 1 5 SLIT 11 8 4 A. Apply moly disulfide grease on pinion liners, holes of pinion gears, side gear liners and hubs of side gears. 2 B. Install side gear liners, side gears, pinion liners and pinion gears. C. Rotate side gears until holes of pinion gears and liners align with holes of differential case. D. Insert pinion shaft. Grease the shaft to aid assembly. E. Assemble lock pin (Fig. 69). Drive the pin to the approximate center location of the pinion mate shaft.
6. Assemble Hi−Lo fork shaft: 5 A. Install E−ring onto fork shaft. 1 B. Insert spring and steel ball into fork. 4 C. Insert fork shaft into fork. Put moly disulfide grease onto the shaft before installing. 3 2 Figure 70 1. Shift fork 2. Steel ball 3. Spring 4. E−ring 5. Hi−Lo fork shaft 7. Assemble R−1 and 2−3 fork shaft: A. Insert R−1 fork shaft into R−1 fork. B. Drive lock pin into fork and fork shaft. Pay attention to direction of slit in lock pin. C. Insert 2−3 fork shaft into 2−3 fork. D.
8. Assemble countershaft: 12 14 6 8 9 4 1 2 A. Use a press to install new bearings (item 15) onto countershaft. B. Install collar and snap ring. C. Install washer and gear. Apply moly disulfide grease into bushing of countershaft gear before installing. Oil groove on washer must face the gear. D. Install collar−spline and snap ring. E. Install shifter onto collar−spline. H. Install washer and snap ring. Oil groove on washer must face the gear. I.
9. Assemble synchro hub: 2 1 A. Install keys into grooves of hub. Figure 74 1. Key (3) 2. Hub B. Install shifter onto hub. 1 2 Figure 75 1. Shifter 2. Hub C. Insert springs into hub. Pay attention to direction of spring. Figure 76 1. Key (3) 2. Hub 3.
10.Assemble reduction shaft: 1 A. Install thrust washer (item 17), needle bearings and gear onto reduction shaft. 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 onto gear. Apply clean Dexron III transmission oil on cone face of gear before installing synchro ring. C. Insert key onto reduction shaft. D. Install synchro hub sub−assembly. 4 2 18 17 16 E. Install snap ring.
11. Assemble reverse shaft: A. Install gear onto reverse shaft. B. Use a press to install bearings. 3 4 2 1 Figure 80 1. Bearing 2. Gear 12.Assemble main shaft: 3. Bearing 4. Reverse shaft 3 4 7 8 10 13 16 14 A. Install gears and snap ring. B. Install gear. C. Use a press to install bearing. D. Install washer and needle bearings onto main shaft. Apply moly disulfide grease onto washer and needle bearings before installing. Oil groove on washer must face the gear.
13.Assemble shift arms: A. Install new oil seals into transaxle case. Apply multi−purpose grease on lips of oil seals before installing. 3 B. Install keeper plates and tighten flange head screws to a torque from 11 to 13 ft−lb (15 to 17 N−m). 1 2 11 to 13 ft−lb (15 to 17 N−m) C. Apply Loctite #680 (or equivalent) to threads and tapers of shift fork arms. D. Install shift arms. Install shift arm assembly. E. Install lock nuts.
16.Assemble reduction shaft and countershaft together with R−1 fork shaft and Hi−Lo fork shaft. Figure 86 17.Insert reduction shaft and countershaft assembly into transaxle case. Insert heads of shift arms into grooves of forks when installing them. Figure 87 18.Assemble main shaft together with 2−3 fork shaft. Figure 88 19.Insert main shaft and 2−3 fork shaft assembly into transaxle case. Insert head of shift arm into groove of fork while installing.
20.Install reverse shaft into transaxle case. Rotate main shaft and reverse shaft gears to mesh gears when installing. 1 2 Figure 90 1. Reverse shaft 21.4WD UNITS ONLY: Install bearing to gear case and center plate. Install front drive shaft and 41T gear to the gear case. 2. Bearing (gear case) 1 4 3 2 Figure 91 3. Bearing (gear case) 4. Bearing (center plate) 22.Install center plate: 18.5 to 22 ft−lb (24.5 to 29.5 N−m) A. Insert dowel pins into transaxle case. B.
NOTE: The thickest shim of the shim set should be positioned against the snap ring. 23.Insert tabbed shim against the bearing. Insert shim set against the tabbed shim. Use thickest shims in set possible, that will permit installation of the snap ring. 3 4 1 2 Figure 93 1. Seal cap 2. Shims 24.Install snap ring into the groove of the bearing housing. 3. Snap ring 4. Shim 5 3 1 6 4 2 Figure 94 1. Countershaft 2. Bearing 3. Shims 4. Snap ring 5. Center plate 6.
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).
B. Insert steel balls and springs into the grooves. 2 3 1 Figure 99 1. Spindle 2. Spring (2) C. Apply silicone sealant to mating surface of fork shaft case. 3. Ball (2) 3 D. Install fork shaft case. Install and tighten flange head screws to a torque from 18.5 to 22 ft−lb (24.5 to 29.5 N−m). 2 2 E. Check operation of shifters and detent. 1 18.5 to 22 ft−lb (24.5 to 29.5 N−m) 2 Figure 100 1. Flange head screw (1) 2. Flange head screw (3) 3. Fork shaft case 28.
29.Install differential gear assembly together with fork shaft onto transaxle case. Figure 102 1 2 Figure 103 1. Differential gear assy. 2. Fork shaft 18.5 to 22 ft−lb (24.5 to 29.5 N−m) A. Insert 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 104 Drive Train Page 6 − 52 Workman HD Series Drive Train 30.
31.Install R.H. axle shaft assembly: 18.5 to 22 ft−lb (24.5 to 29.5 N−m) 1 A. Apply silicone sealant onto mating surface of seal cover. B. Install axle shaft assembly and secure with four (4) flange head screws. Torque screws from 18.5 to 22 ft−lb (24.5 to 29.5 N−m). 2 Figure 105 1. Flange head screw (4) 2. Axle shaft assembly 32.Install L.H. axle shaft assembly: A. Thoroughly clean mating surface of differential carrier and side cover. 1 B. Insert selected shims into housing of side cover.
33.Measure backlash of ring gear through window on transaxle case. Using a dial indicator, check ring gear backlash in three equally spaced points. Backlash should be 0.0031 to 0.0071 in. (0.08 to 0.18 mm) and must not vary more than 0.0019 in. (0.05 mm) at the points checked. If backlash is not in this range, replace shim set in end of differential carrier: A. If less than target range, decrease total thickness of shim set until correct backlash is achieved. B.
36.Apply multi−purpose grease to O−ring and insert O− ring into groove of transaxle case. Install cover and secure with nut, lockwasher and cap screws. Torque fasteners from 11 to 13 ft−lb (15 to 17 N−m). 2 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. 3 1 11 to 13 ft−lb (15 to 17 N−m) Figure 111 1. Cap screw (5) 2. Nut 37.
Power Take−Off (PTO) Service (If Equipped) 34 35 33 3 18 to 22 ft−lb (24.5 to 29.5 N−m) 2 32 1 31 17 30 29 2 25 28 3 24 27 26 4 17 11 5 3 6 22 8 21 23 7 20 19 9 10 17 11 12 13 14 15 18 16 Figure 113 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. PTO cover Cap screw (4) Lock washer (7) Cap screw (3) 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.
6. Remove PTO output shaft assembly from PTO housing. Remove oil seal from PTO cover. 1 Figure 114 1. Output shaft assembly 7. Remove intermediate shaft assembly from PTO housing. Remove intermediate gear. Remove bearing from housing if necessary. 1 2 2. Intermediate gear 3 Figure 116 3. Bearing Workman HD Series Page 6 − 57 Drive Train Drive Train Figure 115 1. Intermediate shaft assy.
8. Remove PTO input shaft from PTO housing: Moly disulfide grease A. Shift PTO to ”ON” position. B. Remove retaining rings from PTO housing. C. Slide input shaft assembly toward PTO shaft. D. Remove bearing (item 4). E. Slide input shaft away from PTO shaft. F. Remove bearing. G. Remove thrust washer and gear by sliding input shaft toward PTO shaft. H. Release shift arm from shifter block. I. Remove input shaft assembly. Figure 117 1. 2. 3. 4. 5.
10.Disassemble PTO intermediate shaft: 1 A. Use a bearing puller to remove bearing if necessary. Figure 120 1. Bearing 11. Disassemble PTO output shaft: A. Use a bearing puller to remove bearing. B. Remove gear and retaining ring. C. Remove retaining ring and thrust washer. D. Use a bearing puller to remove bearing if necessary. Figure 121 1. 2. 3. 4. Bearing Gear Retaining ring Retaining ring 5. Thrust washer 6. Bearing 7. Output shaft Drive Train 5 4 6 2 7 3 1 Figure 122 1. 2. 3. 4.
12.Disassemble shift arm: A. Remove lock pins from shift arm. 1 B. Remove O−rings. Figure 123 1.
Inspection 1. Thoroughly clean and dry all parts. CLEARANCE 2. Use emery cloth to remove nicks and burrs from all parts. 3. Measure clearance between groove on shift collar and shifter block. Replace shifter block if clearance exceeds 0.039 in. (1.0 mm). Figure 124 4. Measure I.D. of input shaft bushing. Replace bushing if I.D. exceeds 0.673 in. (17.10 mm). 1 Figure 125 1. Input shaft bushing Drive Train 5. Measure O.D. of bushing area on input shaft. Replace shaft if O.D. is less than 0.667 in. (16.
34 35 33 3 18 to 22 ft−lb (24.5 to 29.5 N−m) 2 32 1 31 17 30 29 2 25 28 3 24 27 26 4 17 11 5 3 6 22 8 21 23 7 20 19 9 10 17 11 12 13 14 15 18 16 Figure 128 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. PTO cover Cap screw (4) Lock washer (7) Cap screw (3) 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.
3. Assemble shift arm: A. Apply moly disulfide grease to new O−rings and install onto shift arm. 2 B. Apply moly disulfide grease to arm pin and shaft. 3 C. Install shift arm into PTO housing. 1 D. Install shift lever onto shift arm. E. Drive spring pins into shift lever and shift arm. Pay attention to direction of slit in spring pins. Figure 129 1. O−ring (2) 2. Spring pin (2) 3.
4. Assemble PTO output shaft: 5 A. If bearing was removed, use a press to install bearing onto output shaft. 6 4 B. Install washer and retaining ring. C. Install retaining ring and gear. 2 7 D. Use a press to install bearing. 3 1 Figure 132 1. 2. 3. 4. Bearing Gear Retaining ring Retaining ring 1. 2. 3. 4. Bearing Gear Retaining ring Retaining ring 5. Thrust washer 6. Bearing 7. Output shaft Figure 133 5. Use a press to install bearing onto intermediate shaft. 5. Thrust washer 6. Bearing 7.
6. Assemble PTO input shaft: A. Insert spring and steel balls into hole. B. Insert shift collar onto input shaft. 1 2 C. Move shift collar to ”ON” position. 3 2 Figure 135 3. Spring Drive Train 1. Shift collar 2.
7. Install PTO input shaft sub−assembly: MOLY DISULFATE GREASE A. Insert shifter block 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 on the shifter block. C. Install gear with bushing and thrust washer onto input shaft after sliding the assembly toward PTO shaft. Apply moly disulfide grease to bushing of gear and thrust washer before installing. D. Slide bearings onto input shaft. E.
8. Install PTO intermediate shaft sub−assembly: A. If removed during disassembly, insert bearing into PTO housing. B. Put gear on mating gear. C. Move gear until bores of gear and bearing line up. D. Insert intermediate shaft sub−assembly. Apply grease to intermediate shaft to aid assembly. 3 Figure 140 3. Bearing 2 1 Figure 141 2. Gear Drive Train 1. Intermediate shaft sub−assembly 9. Insert PTO shaft assembly into bearing housing of PTO housing. 1 Figure 142 1.
10.Install PTO cover: A. Insert new oil seal into PTO cover. Apply multi− purpose grease to lip of oil seal. B. Insert 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). 11. Install PTO to transaxle (see PTO Removal and Installation in this chapter). Drive Train Page 6 − 68 18.5 to 22 ft−lb (24.5 to 29.
Chapter 7 Chassis Table of Contents Brake Master Cylinder Service . . . . . . . . . . . . . . . Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Front Control Arms . . . . . . . . . . . . . . . . . . . . . . . . . Front Compression Spring Service . . . . . . . . . . . Front Shock Absorber . . . . . . . . . . . . . . . . . . . . . .
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. (0 + 3 mm) Rear tire 24” x 12” − 12, 6 ply Model 07383 = 24” x 13” − 12, 6 ply Model 07379 (Industrial) = 23” x 10.
General Information Operator’s Manual The vehicle 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. Maximum tire pressures will reduce turf compaction, tire marks, and create the best tire footprint. 3.
Special Tools Compression Spring Tool Use to remove and install the front suspension compression springs.
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).
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.
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.
Service and Repairs Wheel Assembly 6 12 9 35 to 40 ft−lb (48 to 55 N−m) 8 10 7 6 35 to 40 ft−lb (48 to 55 N−m) 5 6 3 3 5 2 1 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 per wheel) Chassis 5. 6. 7. 8. Brake caliper Flange head screw Parking brake caliper (LH) Parking brake bracket (LH) Page 7 − 8 9. 10. 11. 12.
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 Chapter 1 − Safety in this manual). 4 1 2 3. Remove lug nuts and then remove wheel assembly from vehicle. Installation (Fig. 2) 3 5 1. Install wheel. Secure with five (5) lug nuts. 2. Lower vehicle to ground.
Brake System 6 12 9 8 35 to 40 ft−lb (48 to 55 N−m) 13 10 7 6 35 to 40 ft−lb (48 to 55 N−m) 5 6 3 3 5 2 1 11 4 2 80 to 90 ft−lb (109 to 122 N−m) 4 RIGHT FRONT 80 to 90 ft−lb (109 to 122 N−m) Figure 4 1. 2. 3. 4. 5. Front wheel assembly Brake rotor Wheel hub assembly Lug nut (5 per wheel) Brake caliper Chassis 6. 7. 8. 9. Flange head screw Parking brake caliper (LH shown) Parking brake bracket (LH shown) Parking brake return spring Page 7 − 10 10. 11. 12. 13.
5. Lower machine to ground. Disassembly (Fig. 4) 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - Safety. 2. Chock wheels not being jacked up. For brake that is to be serviced, jack wheel off the ground and place appropriate jack stand beneath the frame to support vehicle.
Brake Caliper Service 9 White Lithium Grease 4 27 to 33 ft−lb (37 to 44 N−m) 3 8 7 1 6 5 BAF−12 Assembly Lube 2 Figure 6 1. Bolt (2) 2. Caliper body 3. O−ring (4) Chassis 4. Caliper bracket 5. Square seal (2) 6. Dust seal (2) Page 7 − 12 7. Piston (2) 8. Brake pad (2) 9.
Disassembly (Fig. 6) Assembly (Fig. 6) 1. Remove two (2) bolts that secure brake caliper assembly. 1. If caliper body was disassembled, install components in caliper body: 2. Remove caliper anvil and then slide brake pads from pins on caliper bracket. A. Apply hydraulic brake cylinder assembly lube (BAF−12 or equivalent) to square seals and pistons before installation. 3. Slide caliper body assembly from caliper bracket. 4. If necessary, remove remaining components from caliper body: B.
Bleed Brake System 1. Remove hood to access brake master cylinder (see Hood in this section). Make sure that brake fluid level is correct. 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. Bleeder valve 3. Have a second person pump brake pedal several times, then hold pedal down firmly. 4.
Parking Brake Caliper Service Disassembly (Fig. 8) 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. 8) 7 1. If removed, install cam lever into caliper body and then place pivot pins into lever holes.
Brake Master Cylinder 2 1 10 11 6 9 3 4 5 6 8 7 12 RIGHT FRONT 13 Figure 9 1. 2. 3. 4. 5. Brake master cylinder Flange head screw (2) Clevis pin Grease fitting Brake pedal Chassis 6. 7. 8. 9. Flange bushing Flange nut Flange nut (2) Cotter pin Page 7 − 16 10. 11. 12. 13.
Removal (Fig. 9) 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.
Brake Master Cylinder Service Disassembly (Fig. 11) 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 13 7 5 8 14 9 2 15 10 11 12 1 9 6 8 16 17 RIGHT FRONT Figure 12 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. 12) Socket head screw (3) Cable clamp Parking brake cable Retaining ring (2) Lever support assembly 5. Disconnect brake cable from parking brake caliper on rear axle (Fig.
7. Remove retaining ring that secures brake cable to lever support assembly. 1 3 4 8. Disconnect brake cable from cable equalizer bracket (Fig. 14). 2 9. Note routing of parking brake cable and location of cable ties to secure brake cable to vehicle frame. Remove brake cable from vehicle. 5 Installation (Fig. 12) 6 1. Route new brake cable in same location as before and secure with cable ties. Start from rear of vehicle and work towards front. 2.
Wheel Hub RIGHT 12 35 to 40 ft- lb (48 to 55 N- m) 13 6 FRONT 9 170 to 180 ft- lb (231 to 244 N- m) STAKED 8 10 6 35 to 40 ft- lb (48 to 55 N- m) 7 17 5 6 19 3 14 18 15 2 22 16 5 1 21 3 6 Antiseize lubricant 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 15 1. 2. 3. 4. 5. 6. 7. 8.
Removal (Fig. 15) Installation (Fig. 15) 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, washers and lock nut to new hub. Torque lock nut from 170 to 180 ft- lb (231 to 244 N- m). 2. Jack up and support rear of vehicle (see Jacking Vehicle in Chapter 1 - Safety in this manual). Make sure that vehicle is supported with jack stands. 3.
Steering Assembly 80 to 90 ft−lb (109 to 122 N−m) 28 6 30 27 9 17 19 25 15 1 33 3 2 35 to 40 ft−lb (48 to 55 N−m) 12 18 32 12 16 8 23 14 11 35 to 40 ft−lb (48 to 55 N−m) 3 20 26 24 21 11 22 5 13 1 31 29 14 12 7 23 RIGHT 35 to 40 ft−lb (48 to 55 N−m) 40 to 50 ft−lb (55 to 67 N−m) 10 2 FRONT 170 to 180 ft−lb (231 to 244 N−m) 80 to 90 ft−lb (109 to 122 N−m) 4 Figure 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Disassembly (Fig. 16) 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 from vehicle (Fig. 17): 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. D.
Assembly (Fig. 16) 3. To install tie rod to vehicle: 1. If steering linkage and center link is disassembled (Fig. 17 and 18). A. If flange bushings (Fig. 18) were removed from pivot mount, make sure that new bushings are pressed fully into the pivot mount. B. Fill pivot mount cavities with grease. A. If tie rod was separated, make sure that jam nut is on inner tie rod threads. Thread outer tie rod end onto inner tie rod the same number of revolutions as the old one took to remove. B.
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Front Control Arms 1 10 12 15 11 3 12 13 40 to 50 ft−lb (55 to 67 N−m) 7 6 5 14 12 4 7 70 to 80 ft−lb (94 to 109 N−m) 8 13 7 9 RIGHT 11 7 FRONT 10 15 2 12 Figure 19 1. 2. 3. 4. 5. LH upper control arm LH lower control arm RH upper control arm RH lower control arm Cap screw (4) Chassis 6. 7. 8. 9. 10. Flange nut (4) Flange head screw (6) Lock nut (8) Cap screw (2) Flange bushing (2 per arm) Page 7 − 28 11. 12. 13. 14. 15.
Removal (Fig. 19) Installation (Fig. 19) 1. Assemble control arm. WARNING 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. If servicing upper control arm, remove front compression springs (see Front Compression Spring Service in this section).
Front Compression Spring Service 2 10 4 1 6 5 3 9 11 4 8 7 12 RIGHT FRONT Figure 20 1. 2. 3. 4. Spring cradle (2) Compression spring (2) 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.
Disassembly (Fig. 20) 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 Chapter 1 − Safety). Remove front wheels. 4. Remove front shock absorbers (see Front Shock Absorber Removal in this section). WARNING Figure 21 1. Shock absorber 2.
Front Shock Absorber Removal (Figs. 23 and 24) 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. 23 and 24) 1 1. If necessary (e.g.
Rear Shock Absorber Removal (Fig. 26) 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 1 3. Remove cap screw, flat washer and flange nut that secure bottom of shock absorber to axle. Figure 25 4.
Rear Leaf Spring 5 12 10 3 8 12 5 14 10 7 5 13 12 9 1 11 12 4 2 12 6 RIGHT See tightening procedure in text FRONT Figure 27 1. 2. 3. 4. 5. Washer (4 per plate) Spring mount (LH shown) Rear frame Flange head screw Flange nut 6. 7. 8. 9. 10. Rear axle Axle bumper (2) Lock nut Bolt (4 per plate) Spring shackle (2 per spring) IMPORTANT: For proper vehicle performance, always replace the springs on both sides of the vehicle. 11. 12. 13. 14.
8. Remove flange nut that secures spring mount to leaf spring and remove mount from spring. 9. Remove rubber bushings from leaf spring and frame side rails. Installation (Fig. 27) 1. Make sure that four (4) rubber bushings are positioned in leaf spring and two (2) rubber bushings are fitted in frame side rail. 2. Insert one (1) spring shackle, from inside/out, into rear of leaf spring. Insert spring mount, from outside/in, to front of leaf spring and secure, finger tight, with flange nut. 3.
Front Wheel Alignment 1. Rotate steering wheel to center the pitman arm with the vehicle to ensure correct front wheel alignment measurement. FRONT OF VEHICLE 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. 28). The front and rear measurements should be equal with a tolerance of 0.120” (3 mm). Rotate tires and make a second measurement. 3.
Steering Wheel Removal (Fig. 29) 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. 29) 1.
Seat Base 2 17 12 in−lb (1.3 N−m) 1 16 4 19 18 22 5 21 20 3 9 14 13 12 13 8 15 6 9 7 RIGHT 10 FRONT 11 Figure 30 1. 2. 3. 4. 5. 6. 7. 8. LH (operator) seat RH (passenger) seat Socket head screw (8) Washer head screw (12) Shift boot Carriage bolt (8) Seat bracket (4) Seat base Chassis 9. 10. 11. 12. 13. 14. 15. Flange nut (9) U−clip nut (8) Rubber bumper (2) Mudflap (2) Flat washer (8) Flange head screw (4) Flange nut (4) Page 7 − 38 16. 17. 18. 19. 20. 21. 22.
Removal (Fig. 30) 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. 31). 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.
Hood 8 1 8 2 7 8 3 8 5 RIGHT FRONT 4 6 Figure 32 1. Hood 2. Clip (3 per headlight) 3. Headlight (2) 4. Bumper 5. Bumper bracket 6. Cover 7. Operator frame 8. Hood attachment tab Removal (Fig. 32) Installation (Fig. 32) 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. 2.
Windshield Wiper Assembly (Machines with Operator Cab) 1 2 3 26 4 5 6 20 to 22 N m (177 to 194 in-- lb) 16 25 5 to 6 N m (45 to 53 in-- lb) 7 8 24 22 23 21 19 20 17 18 12 14 13 9 7 to 8 N m (62 to 70 in-- lb) 15 10 Chassis 11 Figure 33 1. 2. 3. 4. 5. 6. 7. 8. 9. Flange- head screw (10 each) Sealing washer (10 each) Cab roof Bulb trim seal Console foam Fuse block mount Wiper motor Wiper motor bracket Roof console Workman HD Series 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 33) 1. Park the machine on a level surface, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the wiper blade (item 15 in Fig. 33) from the wiper arm. 3.05 mm (0.12 inch) 3.05 mm (0.12 inch) 3. If necessary, remove the wiper arm as follows: A. Disconnect the washer hose from the wiper arm. B. Lift the cap at the top of the wiper arm and remove the wiper stud nut that secure the wiper arm to the wiper motor. C.
Chapter 8 Electrical System Table of Contents Fuel Gauge Sender (Workman HD & HDX−D) . . 22 Fuel Pump (Workman HDX) . . . . . . . . . . . . . . . . . . 23 Fuel Pump (Workman HDX−D) . . . . . . . . . . . . . . . 24 Temperature Sender (Workman HDX and HDX−D) . . . . . . . . . . . . . . . 25 Electric Fan Thermal Switch (Workman HDX and HDX−D) . . . . . . . . . . . . . . . 26 Speed Sensor (Workman HDX and HDX−D) . . . . 27 Glow Controller (Workman HDX−D) . . . . . . . . . . .
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.
Battery Terminal Protector Aerosol spray that should be used on battery terminals, ring terminals, and fork terminals to reduce corrosion problems. Apply battery terminal protector to the connection after the battery cable, ring terminal, or fork terminal has been secured.
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.
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 cranks, but should not, with 1/3 Area Platform Lift (if equipped) and parking brake engaged. Parking brake proximity switch is faulty. Starter solenoid clicks, but starter will not crank. (If solenoid clicks, problem is not in interlock system.
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 60F to 100F (16C to 38C). The ignition key should be in the OFF position and all accessories turned off.
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.
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).
Gauge Cluster Hourmeter The hourmeter should move 1/10 of an hour for every six minutes that the ignition switch is in the ON position. 5 1 7 6 2 Fuel Level Gauge The fuel level gauge displays the approximate amount of fuel remaining in the fuel tank. Additionally, a red LED will illuminate when the fuel tank is low and the LED will flash when the tank is near empty.
Fuses The fuse blocks are located below the center of the dash panel. LEFT RIGHT Identification and Function (Fig. 8) Top Row LH: Protects ignition power supply. TOP ROW 10A 15A SECOND 10A 10A Second Row LH: Protects main (switched) power supply. THIRD 10A Second Row RH: Protects power supply for hazard lights (if equipped). FOURTH 15A Top Row RH: Protects power supply for light system (headlights, running lights and brake lights).
Headlight Switch This headlight switch allows the headlights to be turned on and off and is located on the dash (Fig. 9). 1 Testing The headlight switch terminals are marked as shown (Fig. 10). 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.
Clutch Switch(s) A proximity switch is attached to the frame under the dash of all units (Fig. 11). 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.
Brake Switch(s) The brake switch is is attached to the frame under the dash (Fig. 12). A switch with one set of normally closed terminals is used on 2WD units. A switch with one set of normally closed terminals and one set of normally open terminals is used on 4WD units (Fig. 13). 2 When the brakes are not applied, the brake pedal presses the brake switch plunger to open the normally closed terminals.
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 lift lever linkage is positioned close to the interlock switch causing the switch to close.
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 (Fig. 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.
Transaxle Switches 3rd Gear Lockout Switch The transaxle 2−3 Lockout switch is located on the top of the transaxle (Fig. 18). The switch is closed in 1st and 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 1st or 2nd gear, there should be continuity (zero ohms).
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).
Relay (Five Terminals) Workman HD series vehicles use a number of relays that have five (5) terminals: 1 2 3 1 2 The start enable 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 ensures that the hydraulic lift lever is in neutral before the engine starter solenoid can be energized.
4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87 (Fig. 22). Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85. 5. Disconnect voltage from terminal 85 and multimeter lead from terminal 87. 7. Disconnect voltage and multimeter leads from the relay terminals. 8. Replace relay if testing determines that relay is faulty. 9.
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.
Fuel Run/Stop Solenoid (Workman HDX−D) The fuel run/stop solenoid used on the Workman HDX− D (Kubota Diesel engine) must be energized for the diesel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 27). 1 The fuel run/stop solenoid includes two coils for operation, the pull coil and the hold coil. When the ignition switch is turned to START, the solenoid is initially energized and the pull coil retracts the solenoid plunger.
Fuel Gauge Sender (Workman HD & HDX−D) The fuel gauge sender is located in the fuel tank (Fig. 29). The fuel gauge sender on Workman HDX vehicles (Kubota EFI gasoline engine) is included with the fuel pump and fuel filter assembly that fits into the fuel tank. Use the following procedure to test either style sender. 2 FUEL SENDER FROM WORKMAN HD & HDX−D SHOWN 4 1 Testing 1. Park machine on a level surface, raise bed, stop engine, apply parking brake and remove key from ignition switch.
Fuel Pump/Sender (Workman HDX) The electric fuel pump/sender used on Workman HDX vehicles (Kubota EFI gasoline engine) is a combination positive displacement pump that provides pressurized fuel to the engine fuel rail in a return−less system, and a fuel level sending unit. The fuel pump assembly includes a regulator to maintain fuel pressure of approximately 40 PSI (276 kPa).
Fuel Pump (Workman HDX−D) The fuel pump is attached to the left frame rail near the engine. 2 Operational Test 3 1. Park machine on a level surface, lower cutting decks, stop engine, and engage parking brake. Unlatch and raise hood. 1 2. Disconnect electrical connector from the fuel stop/ run solenoid to prevent the engine from starting. 3. Disconnect the fuel hose between the pump and the filter/separator (pump discharge) at the filter separator. 4.
Temperature Sender (Workman HDX and HDX−D) Liquid cooled vehicles have a temperature sender threaded into the water pump housing on the engine (Fig. 34). 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. 2 1 3 Testing 1.
Electric Fan Thermal Switch (Workman HDX−D) The thermal fan switch is threaded into the thermostat housing on the engine (Fig. 36). The fan switch is a normally open switch that closes when the engine coolant temperature reaches 190F to 210F (88C to 99C). 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.
Speed Sensor NOTE: The speed sensor and speedometer are standard equipment on the Workman HDX and HDX−D, and optional equipment on the Workman HD. 2 The speed sensor is attached to the upper transaxle cover (Fig. 38). It uses a magnetically based, Hall Effect integrated circuit to provide a signal to the speedometer. As the differential in the transaxle turns, the sensor accurately senses the movement of the differential ring gear teeth passing by the sensor.
Glow Controller (Workman HDX−D) The controller is located under the instrument panel. NOTE: Refer to Electrical Diagrams − Chapter 11 in this manual when troubleshooting the glow controller. Controller Operation 1. When the ignition switch is placed in the RUN position, the controller energizes the glow plug relay and illuminates the glow lamp for 10 seconds. 2.
High Flow Hydraulics Kit Switch (High Flow Hydraulics Kit) On vehicles equipped with the high flow hydraulics kit, the switch to engage the high flow hydraulic circuit is mounted on the dash (Fig. 41). When the high flow hydraulics kit switch is ON, the solenoid coil on the control manifold is energized to allow hydraulic flow to the attachment. An indicator light on the switch identifies when the switch is ON. 1 Testing 1.
Hydraulic Solenoid Valve Coil (High Flow Hydraulics Kit) Vehicles equipped with the High Flow Hydraulics Kit use a hydraulic solenoid valve coil for system control (Fig. 43). 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. 9 11 7 Testing 3 1. Park machine on a level surface, raise bed, stop engine, apply parking brake and remove key from ignition switch.
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.
Interlock Switch (1/3 Area Lift Platform Kit) A proximity switch is attached to the frame under the dash of units with a 1/3 area lift platform installed. The switch is in its closed position as long as the parking brake is released. When the parking brake is engaged, the brake lever moves away from the switch causing the contacts to open. The switch is used in the starting interlock system to make sure that the lift platform is not in use during engine startup. 1 2 Testing 1.
Windshield Washer/Wiper Switch (Machines with Operator Cab) The windshield washer/wiper switch controls the operation of the windshield wiper and washer pump. The switch is located in the roof console (Fig. 48). 1 2 Testing 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. To access the switch, do as follows: A. Remove the 10 clips, 10 sealing washers, and 10 flange−head screws that secure the roof to the cab frame, and remove the roof. B.
Diode Assembly (Machines with Operator Cab) 1 2 Figure 50 1. Diode 2. Dash panel The electrical system of the HD Workman (Machines with Operator Cab) includes a diode. The maximum current allowed through a diode is 6 A. The diode assembly can be identified by a black color, diode symbol, and Toro Part Number on the end of the diode assembly body (Figure 51).
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.
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. RIGHT FRONT 2 3 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.
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.
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.
Headlights 3. Install hood (see Hood Installation in 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.
Tail Lamps Disassemble and assemble tail lamp as necessary Fig. 54). 1 2 4 3 Figure 54 1. Screw (2) 2. Lens Electrical System Page 8 − 40 3. Bulb 4.
Chapter 9 Hydraulic System Table of Contents SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . . 37 General Precautions for Removing and Installing Hydraulic System Components . . . . . . . . . . . . . . 37 Check Hydraulic Lines and Hoses . . . . . . . . . . . . . 37 Primary Hydraulic System Gear Pump (Workman HDX and HDX−D) . . . . . . . . . . . . . . . 38 Primary Hydraulic System Gear Pump (Workman HD) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Specifications NOTE: Vehicles that are equipped with the High Flow Hydraulics Kit have two (2) independent hydraulic systems. Each of these hydraulic systems include a hydraulic gear pump, reservoir, oil filter and controls. Maintenance, troubleshooting and repair of each hydraulic system need to be performed independently. Item Description Workman HD Hydraulic Pump Primary System (drive section) displacement (per rev.) Positive displacement gear type pump 0.378 in3 (6.
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.
Hydraulic Hose and Tube Installation (O−Ring Face Seal Fitting) 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. 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. 2.
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.
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.
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.
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 10 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.
Hydraulic Schematics 1800 to 1900 PSI STEERING CONTROL VALVE STEERING CYLINDER LIFT CYLINDERS Primary Hydraulic System Schematic Hydraulic System Page 9 − 10 Workman HD Series
Hydraulic System HYDRAULIC MANIFOLD High Flow Hydraulic System Schematic Workman HD Series Page 9 − 11 Hydraulic System
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.
Raise and Lower Bed The hydraulic gear pump supplies flow for the steering circuit and for raising and lowering the bed. Pump output flows through the steering control valve and then to the lift valve for raising and lowering the bed (flow priority to the steering circuit). Circuit pressure is limited by a relief valve located in the steering control valve. When the control valve lever is released, spring action returns the lift valve spool to the center position and lift cylinder movement is stopped.
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.
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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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.
7. To minimize the possibility of damaging components when using tester with pressure and flow capabilities, completely open load valve in hydraulic tester before starting engine. 8. Install fittings finger tight, far enough to insure that they are not cross−threaded, before tightening the fittings with a wrench. 10.Check and adjust the oil level in the hydraulic reservoir after connecting hydraulic test equipment. 11.
Primary Hydraulic System Gear Pump Flow Test (Workman HDX and HDX−D) 1800 to 1900 PSI STEERING CONTROL VALVE TESTER LIFT CYLINDERS Figure 16 NOTE: This test procedure is for the primary hydraulic system gear pump used on Workman HDX and HDX−D vehicles.
Procedure for Primary Hydraulic System Gear Pump Flow (Workman HDX and HDX−D) The primary hydraulic system gear pump is designed to satisfy both steering cylinder and lift cylinder needs simultaneously (at full speed throttle). If unit steering is sluggish or otherwise performs poorly, see Steering Control Valve and Steering Cylinder Test in this chapter. If lift operation is unsatisfactory, check lift control valve and/or lift cylinders.
9. The under load test flow reading (step 7.B) should not drop more than 15% when compared to the no load test flow reading (step 6.A). A difference in flow of more than 15%, or the inability to achieve specified pressure may indicate: A. A restriction in the pump intake line B. The primary hydraulic system gear pump is worn and should be repaired or replaced Hydraulic System 10.Disconnect tester and reconnect hose to pump. 11.
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Primary Hydraulic System Gear Pump Flow Test (Workman HD) 1800 to 1900 PSI STEERING CONTROL VALVE TESTER LIFT CYLINDERS Figure 18 NOTE: This test procedure is for the belt driven primary hydraulic system gear pump used on Workman HD vehicles. FRONT 3 WORKMAN HD PRIMARY HYDRAULIC SYSTEM GEAR PUMP 1 2 Figure 19 1. Gear pump 2. Pressure hose Hydraulic System Page 9 − 24 3.
Procedure for Primary Hydraulic System Gear Pump Flow Test (Workman HD) The primary hydraulic system gear pump is designed to satisfy both steering cylinder and lift cylinder needs simultaneously (at full speed throttle). If unit steering is sluggish or otherwise performs poorly, see Steering Control Valve and Steering Cylinder Test in this chapter. If lift operation is unsatisfactory, check lift control valve and/or lift cylinders. Additional information on these components is available in this chapter.
10.The under load test flow reading (step 7.B) should not drop more than 15% when compared to the no load test flow reading (step 6.A). A difference in flow of more than 15%, or the inability to achieve specified pressure may indicate: D. If pump speed of 2270 RPM cannot be maintained during test, consider that engine performance problems exist. 11. Disconnect tester and reconnect hose to pump. 12.Make sure the hydraulic reservoir (transaxle) is full before returning the vehicle to service. A.
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Primary Hydraulic System Relief Valve Pressure Test 1800 to 1900 PSI STEERING CONTROL VALVE TEST GAUGE LIFT CYLINDERS Figure 20 WORKMAN HDX and HDX−D PRIMARY HYDRAULIC SYSTEM GEAR PUMP WORKMAN HD PRIMARY HYDRAULIC SYSTEM GEAR PUMP FRONT 3 1 1 3 2 FRONT 2 Figure 21 1. Gear pump 2. Pressure hose Hydraulic System 3. Suction hose Figure 22 1. Gear pump 2. Pressure hose Page 9 − 28 3.
Primary Hydraulic System Relief Valve Pressure Test: 7. Start engine and depress accelerator pedal so engine is running at high idle (3600 RPM). The relief valve for the steering and lift circuits is integrated into the steering control valve. If both steering and lift operations perform poorly, perform the relief valve pressure test and primary hydraulic system gear pump flow test (see Primary Hydraulic System Gear Pump Flow Test in this chapter). 8.
Steering Control Valve and Steering Cylinder Test (ROTATED FOR RIGHT TURN) PLUG 1800 to 1900 PSI STEERING CYLINDER STEERING CONTROL VALVE LIFT CYLINDERS Figure 23 Hydraulic System Page 9 − 30 Workman HD Series
Procedure for Steering Control Valve and Steering Cylinder Test 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. 1. Make sure hydraulic oil is at normal operating temperature by operating the vehicle for approximately ten (10) minutes. 2.
Lift Cylinder Internal Leakage Test 1800 to 1900 PSI STEERING CYLINDER STEERING CONTROL VALVE (IN LOWER POSITION) LIFT CYLINDERS PLUG Figure 24 Hydraulic System Page 9 − 32 Workman HD Series
Procedure for Lift Cylinder Internal Leakage Test Disconnect and plug this hose 1. Shut off engine and engage parking brake. ANY oil flow or droplets from this fitting indicates internal leak CAUTION Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS and Precautions for Hydraulic Testing at the beginning of this section. 2. Remove all pressure from cylinder by fully retracting it (i.e. put hydraulic lift lever in LOWER position).
High Flow Hydraulic System Gear Pump Flow and Relief Pressure Tests TESTER HYDRAULIC MANIFOLD (SOLENOID ENERGIZED) Figure 26 NOTE: This test procedure is for the high flow hydraulic system gear pump and high flow hydraulic system relief valve on Workman HDX and HDX−D vehicles that are equipped with the High Flow Hydraulics Kit.
Procedure for High Flow Hydraulics System Gear Pump Flow and Relief Pressure Tests If both steering and lift operations perform poorly, perform the primary hydraulic system gear pump flow test and relief valve pressure test. This test compares fluid flow at No Load with fluid flow Under Load. A drop in flow under load of more than 15% indicates the gears and wear plates in the pump have worn.
D. System pressure should be approximately 2000 PSI (138 bar) as the relief valve lifts. E. Open tester flow control valve, release accelerator pedal to allow engine to return to low idle, turn High Flow Kit switch OFF and stop engine. Record test results. Hydraulic System 11. If relief pressure is incorrect, inspect for a worn, stuck or damaged relief valve (SVRV) in control manifold (see Hydraulic Manifold (High Flow Hydraulics Kit) in the Service and Repairs section of this chapter). 12.
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.
Primary Hydraulic System Gear Pump (Workman HDX and HDX−D) RIGHT FRONT 15 to 20 ft−lb (20 to 27 N−m) 18 16 14 15 12 13 21 20 11 9 LOCTITE #242 15 to 20 ft−lb (20 to 27 N−m) 19 10 17 16 8 6 9 7 14 ANTI−SEIZE LUBRICANT 6 8 26 1 2 7 HIGH FLOW GEAR PUMP 22 3 4 5 2 23 3 4 5 2 24 2 3 4 25 Figure 28 1. 2. 3. 4. 5. 6. 7. 8. 9. Gear pump O−ring Hydraulic fitting Hose clamp Suction hose (from transaxle) O−ring Hose (to lift valve) O−ring Hydraulic fitting 10. 11. 12. 13. 14. 15. 16.
Removal (Fig. 28) Installation (Fig. 28) 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 this chapter). 2.
Primary Hydraulic System Gear Pump (Workman HD) Removal (Fig. 29) 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.
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Primary Hydraulic System Gear Pump Service 130 in−lb (15 N−m) WORKMAN HDX AND HDX−D PRIMARY HYDRAULIC SYSTEM GEAR PUMP 23 22 19 15 14 13 11 9 3 2 1 6 4 8 7 21 4 18 5 16 20 17 12 220 in−lb (25 N−m) 10 5 WORKMAN HD GEAR PUMP PRIMARY HYDRAULIC SYSTEM GEAR PUMP 14 4 13 9 3 1 6 7 17 16 2 15 5 4 12 11 220 in−lb (25 N−m) 5 10 8 Figure 31 1. 2. 3. 4. 5. 6. 7. 8. Retaining ring Shaft seal Front cover Dowel pin O−ring (2) Back−up seal Pressure seal Front thrust plate 9. 10. 11. 12.
NOTE: The Workman HDX and HDX−D gear pump includes a rear flange that will allow the installation of a second pump section for the High Flow Hydraulics Kit. The Workman HD gear pump does not have this type of rear flange. Inspection MARKER LINE Disassembly (Fig. 31) 1. Plug pump ports and clean the outside of the pump thoroughly. After cleaning, remove plugs and drain any oil out of the pump. 2.
Assembly (Fig. 31) NOTE: When assembling the pump, check the marker line on each part to make sure the pump components are properly aligned during assembly (Fig. 32). 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. B.
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High Flow Hydraulic System Gear Pump Service HIGH FLOW HYDRAULIC SYSTEM GEAR PUMP 220 in−lb (25 N−m) 4 15 12 13 14 265 in−lb (30 N−m) 11 17 9 6 8 7 24 3 2 18 4 19 16 5 28 10 5 4 22 23 21 1 30 13 220 in−lb (25 N−m) 29 27 20 25 19 18 31 4 14 13 14 26 Figure 34 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Retaining ring Shaft seal Front cover Dowel pin (6) O−ring (4) Back−up seal Pressure seal Thrust plate Drive shaft Idler shaft Front pump section body Hydraulic System 12. 13. 14. 15.
The two section gear pump assembly used on Workman HDX and HDX−D vehicle equipped with the High Flow Hydraulics Kit is shown (Fig. 34). The first section of the pump (drive end) is identical in form and function to the Primary Hydraulic System Gear Pump. When servicing this gear pump, follow the procedure for the Primary Hydraulic System Gear Pump Service in this section and observe the following: RIGHT FRONT 1. Do not mix components from one pump section to the other. 1 3 Figure 35 1. Gear pump 2.
Lift Valve 20 RIGHT 16 FRONT 5 17 19 5 13 12 11 8 2 15 1 14 10 5 9 18 2 17 3 6 4 5 5 7 Figure 36 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) Hydraulic System 8. 9. 10. 11. 12. 13. 14. Lift lever Clevis pin Hairpin Retainer pin Link 90 hydraulic fitting Hyd. tube (to male quick fitting) Page 9 − 48 15. 16. 17. 18. 19. 20. Hyd.
Removal (Fig. 36) 1 4 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. Remove seat base from vehicle (see Seat Base Removal in Chapter 7 − Chassis in this manual). 3. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of this chapter section.
Lift Valve Service Disassembly (Fig. 38) 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 should be facing up. 8 3. Remove two (2) hex cap plugs from side of valve body. Inside valve body, behind each hex cap plug, there is a spring, ball and cam pin; remove these parts. 4. Remove retaining ring from spool.
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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 12 9 13 5 6 7 19 20 14 15 16 17 18 Figure 39 1. 2. 3. 4. 5. 6. 7. Lock nut Flat washer Steering wheel Steering control valve Hyd hose (to control valve E port) Hyd hose (to control valve T port) Hyd hose (to control valve P port) 8. 9. 10. 11. 12. 13. 14.
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 Chapter 7 − Chassis in this manual). 6.
Steering Control Valve Service 9 8 7 6 5 10 4 3 2 1 11 12 13 22 14 15 21 13 16 20 13 17 18 20 to 24 ft−lb (27 to 33 N−m) 19 Figure 42 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 80 to 90 ft−lb (109 to 122 N−m) 28 6 30 27 9 17 19 25 15 1 33 3 2 35 to 40 ft−lb (48 to 55 N−m) 12 18 32 12 16 8 23 14 11 35 to 40 ft−lb (48 to 55 N−m) 3 20 26 24 21 11 22 5 13 1 31 29 14 12 7 23 RIGHT 35 to 40 ft−lb (48 to 55 N−m) 40 to 50 ft−lb (55 to 67 N−m) 10 2 FRONT 170 to 180 ft−lb (231 to 244 N−m) 80 to 90 ft−lb (109 to 122 N−m) 4 Figure 43 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Removal (Fig. 43) 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 3. Remove caps and plugs from hoses and fittings. Install new O−rings on hydraulic fittings. Connect hydraulic hoses to steering cylinder (see Hydraulic Hose and Tube Installation in this chapter). 4.
Steering Cylinder Service 6 1 9 11 8 4 7 3 10 2 4 12 5 14 8 3 9 11 15 13 Figure 45 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. 45) 11. 12. 13. 14. 15. Dust seal Barrel Front shaft Roll pin Front head C. Rotate the head counter−clockwise to remove retaining ring from barrel and head. 1. Pump oil out of cylinder into a drain pan by slowly moving piston back and forth. 2.
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 the ⅛” x ⅞” 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.
Lift Cylinder 12 1 RIGHT 11 FRONT 10 2 4 8 3 3 2 4 9 7 6 5 Figure 46 1. 2. 3. 4. Bed frame O−ring 90o hydraulic fitting O−ring Hydraulic System 5. 6. 7. 8. Hydraulic hose Lift cylinder (LH shown) Hydraulic hose Cotter pin Page 9 − 60 9. 10. 11. 12.
Removal (Fig. 46) Installation (Fig. 46) 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.
Lift Cylinder Service 60 to 75 ft−lb (81 to 102 N−m) 7 8 10 9 11 6 4 3 5 2 1 12 13 14 Figure 47 1. 2. 3. 4. 5. Lock nut Wear ring Seal O−ring Piston 6. 7. 8. 9. 10. Head O−ring Back−up seal Retaining ring Seal Disassembly (Fig. 47) 11. 12. 13. 14. Wiper Barrel Shaft O−ring 5. Extract shaft with head and piston by carefully twisting and pulling on the shaft. 1. Pump oil out of cylinder into a drain pan by slowly moving piston back and forth. 2.
Assembly (Fig. 47) 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.
Hydraulic Manifold (High Flow Hydraulics Kit) Removal (Fig. 48) 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.
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. Installation (Fig. 48) 1. If fittings were removed from manifold, lubricate and place new O−rings onto fittings.
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Front Wheel Drive (4WD) Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . . 4 Constant Velocity (CV) Axle Assembly . . . . . . . . . 4 Inspect CV Boot and Test CV Joint . . . . . . . . . . . . 6 Differential Driveshaft . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Differential Oil Capacity 8.
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.
Service and Repairs Constant Velocity (CV) Axle Assembly ANTISEIZE LUBRICANT 1 8 10 ANTISEIZE LUBRICANT 170 to 180 ft−lb (231 to 244 N−m) STAKED 5 7 6 35 to 40 ft−lb (48 to 55 N−m) 9 2 16 11 3 8 1 4 2 20 to 26 ft−lb (27 to 35 N−m) 10 15 14 11 RIGHT 35 to 40 ft−lb (48 to 55 N−m) FRONT 12 13 Figure 1 1. 2. 3. 4. 5. 6. Spindle nut CV axle assembly Differential assembly Flange head screw (4) Driveshaft Cap screw 7. 8. 9. 10. 11.
Front Wheel Drive (4WD) 4. Using wheel hub hole to access flange head screws, remove screws that secure wheel hub to knuckle. Slide wheel hub assembly from CV axle. LEVERAGE POINT 5. Remove axle spacer from CV axle. IMPORTANT: Make sure to not damage the oil seal on the differential with the pry bars when removing the CV axle. 6. Use two small pry bars (180 degrees apart) to leverage the CV axle out of the differential. Use even pressure on both pry bars (Fig. 2). 1 2 LEVERAGE POINT 7.
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.
Front Wheel Drive (4WD) This page is intentionally blank.
Differential Driveshaft 1 RIGHT FRONT 2 3 ANTISEIZE LUBRICANT 6 ANTISEIZE LUBRICANT 5 4 3 2 6 7 20 to 26 ft−lb (27 to 35 N−m) Figure 4 1. Transaxle 2. Cap screw 3. Flat washer Front Wheel Drive (4WD) 4. Driveshaft 5. Differential assembly Page 10 − 8 6. CV axle assembly 7.
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.
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. A.
Front Wheel Drive (4WD) This page is intentionally blank.
Front Differential ANTISEIZE LUBRICANT 1 8 10 ANTISEIZE LUBRICANT 170 to 180 ft−lb (231 to 244 N−m) STAKED 5 7 6 35 to 40 ft−lb (48 to 55 N−m) 9 2 16 11 3 8 1 4 2 20 to 26 ft−lb (27 to 35 N−m) 10 15 14 11 RIGHT 35 to 40 ft−lb (48 to 55 N−m) FRONT 12 13 Figure 8 1. 2. 3. 4. 5. 6. Spindle nut CV axle assembly Differential assembly Flange head screw (4) Driveshaft Cap screw Front Wheel Drive (4WD) 7. 8. 9. 10. 11.
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. 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. Apply antiseize lubricant to input shaft of differential.
Front Differential Service 15 ft−lb (20 N−m) 16 23 14 to 20 ft−lb (19 to 27 N−m) 20 3 7 17 10 27 28 24 5 18 35 14 to 20 ft−lb (19 to 27 N−m) 30 15 37 33 36 22 34 4 21 1 29 11 31 16 13 32 25 15 ft−lb (20 N−m) 9 2 19 8 6 33 26 24 12 5 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) Armature plate Bearing Bushing Roller cage assembly Vent Plug clip Coil Torsion spring Front Wheel Drive (4WD) 14. 15. 16. 17. 18. 19. 20. 21.
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. 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. 2 1 Figure 12 1. Pinion shaft 2. Gear case 4. Inspect the inner pinion bushing in the gear case. If the bushing is excessively worn, the gear case must be replaced.
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. 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. Replace the thrust bearing if the red coating is worn completely off the bearing surface.
Front Wheel Drive (4WD) 9. Carefully lift the ring gear out of the gear case. Inspect ring gear teeth for any damage or abnormal wear. 1 2 Figure 17 1. Ring gear 10.Remove the gear spacer from between the gear case and the ring gear. 2. Gear case 1 2 Figure 18 1. Gear spacer Workman HDX/HDX−D Page 10 − 17 2.
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. Using a hammer and a suitable drift, carefully remove the female output hub and bearing by driving it in toward the center of the gear case. The bearing has a slight interference fit to the bore of the gear case. Take care to not damage the oil seal in the gear case during hub removal. 1 3 2 Figure 19 1. Drift 2. Gear case 3.
Front Wheel Drive (4WD) 14.Remove the gear spacer from the cover plate. 1 2 Figure 21 1. Male output hub 2. Gear spacer 15.Remove the armature plate from the cover plate. IMPORTANT: When removing male output hub from cover plate, be careful to not damage the seal in the cover plate. The seal cannot be serviced separately. 1 16.Turn the cover plate over and place it on blocking or in a vise.
Front Differential Assembly 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. 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.
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. Place the gear spacer to the gear case and then install the ring gear into the gear case. 1 Figure 26 1. Gear case 2. Gear spacer 3. Female output hub 8. Set the roller cage on a flat surface with the torsion spring end facing up.
9. Align torsion spring on roller cage with the slot in the ring gear and then carefully lower the cage assembly into the ring gear bore. The torsion spring must align and fit into the notch cut into the ring gear. 1 10.Install remaining nine (9) rollers into the top row of the roller cage assembly. Place the rollers in the roller cage slots and press them out toward the ring gear bore. 3 2 Figure 28 1. Roller cage assembly 2. Ring gear notch 11.
Front Wheel Drive (4WD) 14.Install the pinion shaft and then the input cover. Secure cover with four (4) flange head screws. Torque screws from 14 to 17 ft−lbs (19 to 27 N−m). 2 1 Figure 30 1. Input cover 2. Pinion shaft 15.Remove the oil fill plug and fill the unit with 8.45 oz. (250 ml.) of Mobil 424 hydraulic oil (or equivalent). 16.Adjust differential gear backlash as follows: A. Locate backlash adjustment set screw inside round boss on cover plate. 2 B.
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Chapter 11 Table of Contents ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 ELECTRICAL SCHEMATICS Workman HD (Serial Numbers 313000001 to 404350000) . . . . . . . . . . . . . . . . . . . 3 Workman HD (Serial Numbers Above 404350001) . . . . . . . . . . . . . . . . . . . . . . . . . 4 Workman HDX (Serial Numbers 313000001 to 401400000) . . . . . . . . . . . . . . . . . . . 5 Workman HDX (Serial Numbers 401400001 to 404350000) . . . . . . . . . . . . . . . . . . .
Electrical Drawing Designations The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter. ABBREVIATION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRAY OR ORANGE PK PINK R or RD RED T TAN VIO VIOLET W or WH WHITE Y or YE YELLOW Numerous harness wires used on Workman HD vehicles include a line with an alternate color.
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 (Serial Numbers 313000001 to 404350000) All relays and solenoid
122--1469 Rev.
3RD -- HIGH LOCKOUT (OFF) Workman HDX Kubota EFI Gasoline Engine Vehicle Electrical Schematic (Serial Numbers 313000001 to 401400000) All relays and solenoids are shown as de-- energized.
122--0902 Rev.
122--1467 Rev.
B ( -) L (+) R PK BU ALTERNATOR R BK G B+ Start R FUSIBLE LINK KUBOTA STARTER 98-- 9705 GY GY T 3 2 1 GY 2 GY GY 87 85 OR 86 RELAY R/BK OR R/BK OR OR 6 Y Y BK BK BK BK BK W PK BU GN 87 85 VIO U22 87a 30 FAN T 86 87 85 BU RELAY OR 87a 30 Y OR 86 GN RELAY BK R/BK W PK PK R R/BK BK RELAY 87a 85 30 OR R GN 1 2 OR 3 4 PK 5 6 R/BK 7 8 T STOP - - - - NONE BK RUN - - - - B+C+F; D+E START - - - A+B+C A B C OFF E D RUN Y C
122--0282 Rev.
122--0903 Rev.
122--1468 Rev.
3RD--HIGH LOCKOUT SWITCH 3RD--HIGH LOCKOUT SWITCH Workman HD Kohler Gasoline Engine Front Wire Harness Drawing (Serial Numbers 313000000 to 314000000) Page 11 -- 12
3RD--HIGH LOCKOUT SWITCH TAN BLACK BLACK TAN GREEN ORANGE WHITE/BLACK RED/BLACK TAN PINK BLACK GRAY RED RED ORANGE PINK RED/BLACK YELLOW TAN ORANGE WHITE BLUE TAN VIOLET RED GREEN GREEN YELLOW BLUE ORANGE BLUE YELLOW PINK GRAY BLACK BLACK YELLOW GRAY RED/BLACK TAN BROWN GREEN ORANGE WHITE/BLACK BLACK PINK YELLOW BLACK RED GREEN WHITE/BLACK PINK BLACK GREEN ORANGE YELLOW ORANGE RED BLACK GREEN BLACK BLACK PINK BLUE GREEN ORANGE VIOLET BROWN GREEN TAN BLACK BLACK BLACK
122--0222 Rev.
122--0222 Rev.
122--0822 Rev.
122--0822 Rev.
122--1450 Rev.
122--1450 Rev.
122--2215 Rev.
122--2215 Rev.
LIFT LEVER INTERLOCK SWITCH Workman HD Kohler Gasoline Engine Rear Wire Harness Drawing (Serial Number below 409080000) Page 11 -- 22
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 (Serial Number below 409080000) Page 11 --
122--2216 Rev.
122--2216 Rev.
Workman HDX Kubota EFI Gasoline Engine Front Wire Harness Drawing (Serial Numbers 313000001 to 314000000) Page 11 -- 26
3RD--HIGH LOCKOUT SWITCH VIOLET BLUE TAN BLACK BLACK TAN GREEN ORANGE BLACK YELLOW GREEN WHITE/BLACK GRAY TAN TAN PINK BLACK GRAY RED RED ORANGE PINK RED/BLACK YELLOW TAN BLUE WHITE BLUE ORANGE GREEN TAN VIOLET GREEN YELLOW ORANGE BLUE PINK YELLOW GRAY BLACK BLACK YELLOW GRAY RED/BLACK TAN YELLOW BROWN GREEN ORANGE WHITE/BLACK BLACK BLACK PINK GRAY BROWN RED/BLACK BLACK YELLOW BLACK RED BLACK PINK YELLOW ORANGE RED BLUE GREEN BLACK GREEN ORANGE GREEN BLACK BLUE PINK GREEN ORANG
122--0221 Rev.
122--0221 Rev.
122--0821 Rev.
122--0821 Rev.
122--0861 Rev.
122--0861 Rev.
122--0888 Rev.
122--0888 Rev.
122--1448 Rev.
122--1448 Rev.
122--2209 Rev.
122--2209 Rev.
Workman HDX Kubota EFI Gasoline Engine Rear Wire Harness Drawing (Serial Numbers 313000001 to 315000500) Page 11 -- 40
PINK BLACK BLACK BLUE BLACK BLUE BLACK BLUE BLUE RED BLACK RED BLACK PINK GRAY GRAY GRAY GRAY PINK BLUE WHITE BLUE GREEN YELLOW BLUE PINK BLACK BLACK WHITE BLACK BLACK WHITE ORANGE PINK YELLOW GRAY RED/BLACK TAN GRAY RED RED YELLOW GREEN GRAY TAN VIOLET BLUE YELLOW TAN BLUE GREEN BROWN BROWN GREEN ORANGE WHITE/BLACK BLACK BLACK YELLOW BLACK RED VIOLET GRAY BROWN PINK YELLOW RED BLACK YELLOW BLUE ORANGE BLUE TAN GREEN YELLOW BLUE BROWN BROWN BLACK RED RED RED RED BROWN BROWN BLA
122--0279 Rev.
122--0279 Rev.
122--0693 Rev.
122--0693 Rev.
122--0889 Rev.
122--0889 Rev.
122--2210 Rev.
122--2210 Rev.
3RD--HIGH LOCKOUT SWITCH 3RD--HIGH LOCKOUT SWITCH Workman HDX--D Kubota Diesel Engine Front Wire Harness Drawing (Serial Number 313000000 to 314000000) Page 11 -- 50
3RD--HIGH LOCKOUT SWITCH TAN BLACK BLACK TAN GREEN ORANGE WHITE/BLACK RED/BLACK TAN PINK BLACK GRAY RED RED ORANGE PINK RED/BLACK YELLOW TAN ORANGE WHITE BLUE TAN VIOLET RED GREEN GREEN YELLOW BLUE ORANGE BLUE YELLOW PINK GRAY BLACK BLACK YELLOW GRAY RED/BLACK TAN BROWN GREEN ORANGE WHITE/BLACK BLACK PINK YELLOW BLACK RED GREEN WHITE/BLACK PINK BLACK GREEN ORANGE YELLOW ORANGE RED BLACK GREEN BLACK BLACK PINK BLUE GREEN ORANGE VIOLET BROWN GREEN TAN BLACK BLACK BLACK
122--0222 Rev.
122--0222 Rev.
122--0822 Rev.
122--0822 Rev.
122--0962 Rev.
122--0962 Rev.
122--0900 Rev.
122--0900 Rev.
122--1447 Rev.
122--1447 Rev.
122--2212 Rev.
122--2212 Rev.
Workman HDX--D Kubota Diesel Engine Rear Wire Harness Drawing (Serial Numbers 313000000 to 400000000) Page 11 -- 64
ORANGE BLACK WHITE BLACK ORANGE PINK BLACK RED/BLACK RED/BLACK ORANGE RED/BLACK ORANGE BLUE BLACK BLUE BLACK YELLOW BLUE RED BLUE RED BLACK BLACK YELLOW PINK GRAY GRAY GRAY GRAY PINK ORANGE WHITE BLUE TAN VIOLET GREEN YELLOW ORANGE BLUE PINK BLACK YELLOW GRAY RED /BLACK TAN BROWN GREEN ORANGE WHITE/BLACK BLACK BLACK YELLOW BLACK RED GRAY PINK BLACK VIOLET BLACK ORANGE BLACK YELLOW BLUE BLUE PINK ORANGE VIOLET YELLOW BLUE BLACK PINK BLACK BLACK ORANGE BLACK WHITE/BLACK ORANG
122--0963 Rev.
122--0963 Rev.
122--0901 Rev.
122--0901 Rev.
122--2213 Rev.
122--2213 Rev.
Workman HDX--D (Industrial) Kubota Diesel Engine Front Wire Harness Drawing Page 11 -- 72
BLACK TAN BLACK TAN GREEN BLUE GREEN GREEN RED RED/BLACK TAN PINK BLACK GRAY 3RD--HIGH LOCKOUT SWITCH RED ORANGE PINK RED/BLACK YELLOW TAN ORANGE WHITE RED BLUE TAN GREEN VIOLET GREEN YELLOW BLUE YELLOW ORANGE BLUE PINK GRAY BLACK BLACK YELLOW GRAY RED/BLACK TAN BROWN GREEN ORANGE BLUE BLACK PINK YELLOW BLACK RED BLACK YELLOW BLACK ORANGE RED BLUE TAN GREEN ORANGE GREEN BLACK BLACK GREEN VIOLET BROWN GREEN VIOLET BLACK BLUE BLACK BROWN BLUE GREEN BLACK RED GREEN RE
Workman HDX--D (Industrial) Kubota Diesel Engine Rear Wire Harness Drawing Page 11 -- 74
BLACK PINK BLACK BLACK ORANGE BLACK BLUE ORANGE BLACK BLUE BLACK ORANGE RED BLACK BLACK BLACK RED WHITE TAN VIOLET ORANGE BLUE PINK YELLOW ORANGE BLACK YELLOW BLUE YELLOW GRAY RED/BLACK TAN YELLOW BLUE GREEN BROWN GREEN ORANGE BLUE GRAY VIOLET BLACK PINK YELLOW BLACK RED BLACK YELLOW PINK ORANGE VIOLET Workman HDX--D (Industrial) Kubota Diesel Engine Rear Wire Harness Diagram Page 11 -- 75 ORANGE BLACK WHITE BLACK ORANGE PINK BLUE RED/BLACK GREEN BLACK RED/BLACK ORANGE RED/BLA
6 5 4 3 2 1 D D C C B B A Drawing No: 120--3996 Rev.
