Form No.
Revision History Revision Date -- 2015 A 02/2018 Updated Electrical, Chassis and Electrical Drawings chapters. Added revision history. B 03/2019 Updated Electrical chapter. C 05/2020 Updated Electrical Drawings. © THE TORO COMPANY 2020 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. 15217SL (Rev. C) Service Manual WorkmanR HDX Auto 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 HDX Auto vehicles. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts Catalog for your machine into Chapter 2 of this service manual.
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Chapter 2 -- Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 2 ----- 1 1 2 3 3 3 3 3 ----- 2 3 4 5 Chapter 3 -- Kohler Gasoline Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . .
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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 HDX Auto 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. 3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and could possibly be deadly. 2. When starting the engine: A. Sit on operator’s seat and engage the parking brake. B. Make sure that high flow hydraulics (if so equipped) are disengaged and hand throttle lever (if so equipped) is in OFF position. 4.
Maintenance and Service 1. Before servicing or making adjustments: A. Ensure that the machine is stopped and all accessories are OFF. B. Move the transmission lever to the P (Park) position and then set the parking brake. 11. Do not overspeed the engine by changing governor setting. To ensure safety and accuracy, check maximum engine speed. 12.Shut engine off before checking or adding oil to the engine crankcase. 2.
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 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.
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 Thread Size Recommended Torque 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 Kohler Gasoline Engine Table of Contents Workman HDX Auto Page 3 − 1 Kohler Gasoline Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Kohler Aegis Service Manual . . . . . . . . . . . . . . . . . 3 Engine Electronic Control Unit (ECU) . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Kohler, LH775, 4−stroke, V−Twin Liquid Cooled, OHV Number of Cylinders 2 Bore x Stroke 3.27 in x 2.72 in (83 mm x 69 mm) Total Displacement 45.6 in3 (747 cc) Compression Ratio 8.7:1 Fuel System Electronic fuel injection Fuel Pump 12 VDC, fuel tank mounted Fuel Unleaded, Regular Gasoline (Minimum 87 Octane) Fuel Tank Capacity 6.5 U.S. gallons (24.
General Information General engine maintenance procedures are described in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly and assembly is identified in the Kohler Aegis 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. Special tools are described in the Kohler Aegis Service Manual. The use of some specialized test equipment is explained.
Adjustments Adjust Accelerator Control Proper accelerator operation is dependent upon correct adjustment of the accelerator control. Make sure accelerator control is operating properly. 7. Fully depress accelerator pedal to the FAST position. Accelerator pedal should have from 0.200” to 0.350” (5.1 to 8.9 mm) clearance between bottom of pedal and floor plate when pedal is fully depressed.
Service and Repairs Accelerator Control Two styles of accelerator control have been used on Workman HDX Auto machines. On vehicles with serial numbers below 315000000 (Fig. 4), the accelerator control includes a bellcrank that is rotated by the accelerator cable to change engine speed. Vehicles with serial numbers above 315000000 (Fig. 5) use an accelerator control with additional components. SERIAL NUMBER BELOW 315000000 7 8 Kohler Gasoline Engine 4 Disassembly (Fig. 4 or 5) 9 3 1.
Air Cleaner System RIGHT 2 FRONT 3 2 5 1 4 8 6 VACUATOR DIRECTION 7 Figure 6 1. Engine 2. Hose clamp (2) 3. Intake hose Kohler Gasoline Engine 4. Air cleaner assembly 5. Air inlet hood 6. Mounting bracket Page 3 − 6 7. Flange head screw (2) 8.
Removal (Fig. 6) 1 1. Park vehicle on a level surface and engage parking brake. 6 2. Raise or remove the cargo bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 3 3. Make sure that the engine is stopped and the key is removed from ignition switch. Allow engine to cool. 4 2 4. Remove air cleaner components as needed using Figures 6 and 7 as guides. Installation (Fig. 6) IMPORTANT: Any leaks in the air filter system will cause serious engine damage.
Fuel Tank 16 18 6 20 10 175 to 200 in−lb (20 to 22 N−m) 12 5 17 TO ENGINE FUEL INLET 9 12 21 2 8 7 4 19 15 TO ENGINE PURGE PORT 1 3 11 RIGHT FRONT 19 13 14 Figure 8 1. 2. 3. 4. 5. 6. 7. Support tube Washer head screw (2) Flange nut (2) Fuel tank Grommet Rollover valve Retainer plate Kohler Gasoline Engine 8. 9. 10. 11. 12. 13. 14. Washer head screw (2) Fuel tank cap Fuel pump assembly Carbon canister Hose clamp (2) Fuel hose Fresh air filter Page 3 − 8 15. 16. 17. 18. 19. 20. 21.
Fuel Tank Installation (Fig. 8) DANGER 1. Position fuel tank to support tube. Check Fuel Lines and Connections Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check lines for deterioration, damage, leaks or loose connections. Replace hoses, clamps and connections as necessary. 2. Remove plugs placed in fuel hoses during fuel tank removal. Connect fuel hoses to fuel pump assembly and rollover valve (Fig. 9). Secure fuel hoses with hose clamps. 3.
Fuel Evaporative Control System FUEL VENT HOSE ROLLOVER VALVE FUEL SUPPLY HOSE CARBON CANISTER FUEL TANK TO ENGINE PURGE PORT FRESH AIR FILTER VACUUM CHECK VALVE Figure 10 Your Workman vehicle is equipped with a fuel evaporative control system (EVAP) designed to collect and store evaporative emissions from the fuel tank. The EVAP uses a carbon canister to collect these evaporative emissions. Fuel vapors from the fuel tank are vented to the canister where they are stored.
Disassembly 3 4 5 6 DANGER TO ENGINE FUEL INLET 2 1 Gasoline is flammable. Use caution when storing or handling it. Wipe up any spilled fuel before starting the engine. 1. Park vehicle on a level surface and engage parking brake. 10 10 Kohler Gasoline Engine 11 2. Raise or remove the cargo bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 7 3. Make sure that the engine is stopped and the key is removed from ignition switch. Allow engine to cool.
Fuel Pump 16 18 6 20 10 175 to 200 in−lb (20 to 22 N−m) 12 5 17 TO ENGINE FUEL INLET 9 12 21 2 8 7 4 19 15 TO ENGINE PURGE PORT 1 3 11 RIGHT 19 13 FRONT 14 Figure 14 1. 2. 3. 4. 5. 6. 7. Support tube Washer head screw (2) Flange nut (2) Fuel tank Grommet Rollover valve Retainer plate 8. 9. 10. 11. 12. 13. 14. Washer head screw (2) Fuel tank cap Fuel pump assembly Carbon canister Hose clamp (2) Fuel hose Fresh air filter 15. 16. 17. 18. 19. 20. 21.
1. Park vehicle on a level surface and engage parking brake. 2. Raise or remove the cargo bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 3. Make sure that the engine is stopped and the key is removed from ignition switch. Allow engine to cool. 4. Disconnect vehicle wire harness connectors from fuel pump assembly on fuel tank. IMPORTANT: When securing the fuel pump assembly to the fuel tank, do not allow the fuel pump to rotate as the retainer is being tightened.
Exhaust System RIGHT 1 FRONT Antiseize Lubricant 28 to 36 ft−lb (38 to 48 N−m) 2 4 3 6 5 8 7 10 11 3 9 6 4 Figure 16 1. 2. 3. 4. Engine Muffler Carriage screw (4) Flange nut (4) Kohler Gasoline Engine 5. 6. 7. 8. Muffler bracket Clamp assembly (2) Intermediate exhaust pipe Exhaust manifold Page 3 − 14 9. Flange nut (4) 10. Exhaust gasket (2) 11.
Removal (Fig. 16) Installation (Fig. 16) 1. Park vehicle on a level surface and engage parking brake. 1. Replace any removed gaskets. 3. Make sure that the engine is stopped and the key is removed from ignition switch. Allow engine to cool. 4. Remove exhaust system components as needed using Figure 16 as a guide. 2. Using Figure 16 as a guide, fit all exhaust components to vehicle before tightening any fasteners. A.
Radiator 20 7 21 6 22 17 29 2 1 3 8 17 19 19 19 23 5 29 12 9 19 7 13 4 5 18 23 17 15 28 19 10 13 14 19 27 17 16 RIGHT 19 FRONT 25 11 24 26 Figure 17 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Radiator mount Clip (2) Radiator and fan assembly Flange head screw Flange nut (4) Flat washer (2) Flange head screw (4) Flange nut (2) Upper coolant hose Hot coolant pipe 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
4. Connect coolant hose (item 29) to the radiator filler neck. Secure hose with hose clamp. CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot coolant can escape and cause burns. 5. Connect upper coolant hose (item 9) and straight radiator hose (item 12) to the radiator. Secure hoses with hose clamps. 6. Connect wire harness connector to radiator fan. Ethylene−glycol antifreeze is poisonous.
Oil Filter Assembly 9 8 3 Thread Sealant 7 12 11 10 17 6 1 21 20 15 16 19 5 4 18 Thread Sealant 13 14 2 RIGHT FRONT Figure 19 1. 2. 3. 4. 5. 6. 7. Engine Sub−frame assembly Pump mount Oil filter assembly Washer head screw (2) Flange head screw Tube clamp (2) Kohler Gasoline Engine 8. 9. 10. 11. 12. 13. 14. Washer (2) Flange nut Hydraulic fitting O−ring Hydraulic tube O−ring 90o hydraulic fitting Page 3 − 18 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 19) 2 1. Park vehicle on a level surface and engage parking brake. 2. Raise or remove the cargo bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 3. Make sure that the engine is stopped and the key is removed from ignition switch. Allow engine to cool. 3 4. To prevent contamination of engine lubrication system during adapter removal, thoroughly clean exterior of filter adapter, hoses and fittings. Figure 20 1. Oil filter assembly 2. Hydraulic tube 3.
Engine 43 Thread Sealant 46 3 Thread Locker Thread Sealant 44 27 28 45 22 9 29 31 34 20 8 33 23 30 19 15 1 4 21 40 41 6 36 24 16 17 42 18 37 38 35 39 26 25 32 5 10 7 Thread Sealant 14 Thread Locker 12 13 2 RIGHT FRONT 11 Figure 21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Engine Removal (Fig. 21) 12.Label and disconnect wire harness connectors that attach to engine and engine accessories. Position wire harness leads away from the engine. A. The positive battery cable and fusible link harness from starter solenoid stud on starter motor. B. The machine wire harness spade connector from the starter solenoid start terminal. 1. Park vehicle on a level surface and engage parking brake. C.
14.Remove all clamps and cable ties that attach wire harness, hoses and cables to the engine. Note locations of clamps and cable ties for assembly purposes. FRONT 1 15.Remove five (5) washer head screws that secure spanner plate to air inlet housing attached to engine (Fig. 23). For assembly purposes, note the locations of the five (5) removed screws. Two (2) holes in the spanner plate that align with holes in the air inlet housing are used to secure the CVT enclosure cover.
A. Remove cap screws and flat washers that secure rubber coupler to pump coupler adapter attached to flywheel. Remove coupler and pump hub assembly. B. Remove cap screws and flange nuts that secure pump hub to rubber coupler. C. If necessary, remove socket head screws that secure pump coupler adapter to flywheel and remove adapter. Engine Installation (Fig. 21) 1. Make sure that all parts removed from the engine during maintenance or rebuilding are installed to the engine. 2.
12.Install hydraulic pump to machine (see Gear Pump (Vehicles with Standard Hydraulics) or Gear Pump (Vehicles with High Flow Hydraulics) in the Service and Repairs section of Chapter 7 − Hydraulic System). 13.Install primary clutch to engine crankshaft. Make sure that CVT drive belt and enclosure cover are properly installed (see Primary and Secondary Clutches in the Service and Repairs section of Chapter 4 − Drive Train). 17.Install the exhaust system (see Exhaust System in this section). 18.
Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DRIVE TRAIN OPERATION . . . . . . . . . . . . . . . . . . . . . 4 Drive Train Operation . . . . . . . . . . . . . . . . . . . . . . . . . 4 Clutch System Operation . . . . . . . . . . . . . . . . . . . . . . 5 Primary Clutch Operation . . . . . . . . . . . . . . . . . . . . .
Specifications Item Specification Clutch System Continuously Variable Speed Transmission with Enclosed CVT Belt Drive and Speed Control Override Speed Sensing with Mechanical Flyweights Torque Sensing with Spring Loaded Cam Primary Clutch Secondary Clutch Speed Control System Fluid DOT 3 Brake Fluid Speed Control System Fluid Capacity 16 fluid ounces (470 milliliter) System Capacity (approximate) Transmission Two−Speed Forward (Drive and Low), Reverse, Neutral and Park Transmission Oil Transmissio
Safety General Information Operator’s Manual Drive Train Product Records 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.
Drive Train Operation Drive Train Operation Workman HDX Auto vehicles have a variable speed drive system with positions for neutral, forward high and low range, reverse and park. Drive system components include an engine driven primary clutch, a secondary clutch, a CVT drive belt, a transmission, a drive shaft driven rear differential and two (2) CV (constant velocity) axles to drive the rear wheels.
4 Product Records Safety Clutch System Operation 5 3 6 7 LOW ENGINE SPEED LIGHT LOAD Drive Train 8 1 FULL ENGINE SPEED DECREASING LOAD 1 FULL ENGINE SPEED INCREASING LOAD 2 2 Figure 3 1. Primary clutch 2. Secondary clutch 3. Moveable sheave (primary clutch) 4. Stationary sheave (primary clutch) 5. Moveable sheave (secondary clutch) 6.
Primary Clutch Operation The operation of the primary clutch is affected by engine shaft speed. With the engine not turning, the CVT drive belt rests low within the primary clutch sheaves as the pressure of the clutch spring holds the sheaves apart. As the engine increases in speed, the clutch weights attached to the moveable sheave move outward as they spin about the engine crankshaft.
Safety Secondary Clutch Operation The operation of the secondary clutch (Fig. 6) is affected by traction load. When the vehicle is stopped, the drive belt is held at the outer diameter of the secondary clutch sheaves from the pressure of the clutch spring pushing the moveable sheave against the stationary sheave and away from the fixed cam. Product Records 1 Once the drive belt starts rotating, the secondary clutch also starts to rotate.
Special Tools Order the following special tools from your Authorized Toro Distributor. Clutch Removal Tools The clutch removal tool is required to remove the primary clutch from the tapered drive shaft of the engine. It is threaded into the primary clutch after the clutch retaining screw is removed. 1 2 The clutch removal tool can also be used to remove the secondary clutch from the transmission input shaft.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ
Transmission ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Safety Adjustments For correct vehicle operation, shift cable adjustment should allow the transmission lever on the seat base console (Fig. 10) to move fully between all transmission positions. Product Records Shift Cable Adjustment 1 1. Park vehicle on a level surface, raise and support vehicle cargo bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2 3. Make sure that jam nuts are properly tightened after adjustment. Figure 10 1.
Service and Repairs Shift Cable 3 2 5 4 RIGHT FRONT 7 6 11 10 9 2 8 12 1 Figure 12 1. 2. 3. 4. Transmission lever Knob (2) Speed range lever Hydraulic lever 5. 6. 7. 8. Knob Cable clamp Screw (2) Clevis pin Shift Cable Removal (Fig. 12) 9. 10. 11. 12. Hairpin Shift cable clevis Shift cable Lever support assembly 5. Remove shift cable from transmission shift lever (Fig. 14): 1.
Safety 6. Note routing of shift cable and location of cable ties used to secure cable to vehicle. Remove shift cable from vehicle. Shift Cable Installation (Fig. 12) Product Records 1 7. If necessary, remove jam nut and clevis from ends of shift cable. 2 1. If clevis was removed from ends of shift cable, install clevis and secure with jam nut. Center jam nuts on threaded area of shift cable during assembly. 3 5 2. Route shift cable in same location as noted during cable removal. 3.
Bleed Speed Control System The speed limiter cover assembly is used on the Workman Auto vehicle to adjust the maximum opening of the primary clutch moveable sheave. The speed limiter control uses a manually operated hydraulic cylinder to change the location of the piston in the speed limiter cover assembly. The piston location determines the maximum primary clutch opening.
Safety Product Records Drive Train This page is intentionally blank.
Speed Control System 1 RIGHT FRONT 2 9 7 5 6 3 8 4 Figure 17 1. Primary clutch 2. Speed limiter assembly 3. CVT enclosure cover 4. Speed limiter cover 5. CVT intake hose 6. Speed control hose 7. Cylinder 8. Hose 9. Reservoir The Workman Auto speed control system includes the speed limiter assembly, cylinder, reservoir, speed range lever and connecting hoses. 3 1 Disassembly (Fig. 17) 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake.
Safety 2 1 4. Remove speed control components as needed using Figures 17, 19 and 20 as guides. If hydraulic hoses are removed, discard banjo washers and replace during assembly. NOTE: If speed limiter assembly (item 2 in Fig. 17) needs to be removed or disassembled, see Speed Limiter Assembly and Speed Limiter Cover Service in this section. 4 5 Assembly (Fig. 17) 1. Install all removed speed control components using Figures 17, 19 and 20 as guides.
Speed Limiter Assembly 1 RIGHT 3 105 to 120 in−lb (11.9 to 13.5 N−m) FRONT 12 11 10 8 9 17 21 19 2 20 16 18 19 4 13 5 14 15 7 6 Figure 21 1. 2. 3. 4. 5. 6. 7. Engine Transmission Primary clutch Secondary clutch CVT drive belt Washer head screw (3) Speed limiter cover 8. 9. 10. 11. 12. 13. 14.
Removal (Fig. 21) 1. Park vehicle on a level surface, raise and support vehicle cargo bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Move speed range lever to the transport (T) position to remove pressure in the speed control system (Fig. 22). 3. Install speed limiter cover (item 7) to CVT enclosure cover. Make sure that speed control hose (item 13) is routed through slot in limiter cover. Secure cover with three (3) washer head screws (item 6). 4.
Speed Limiter Cover Service 1 4 5 6 7 2 3 8 9 10 11 Figure 24 1. 2. 3. 4. Speed control hose Button head screw (3) Retainer Banjo washer Drive Train 5. 6. 7. 8. Rotary union O−ring (2) Speed limiter control cover U−cup Page 4 − 20 9. Quad ring 10. Hydraulic piston 11.
1. Remove speed limiter assembly with attached hydraulic hose from primary clutch (see Speed Limiter Assembly in this section). 4. Separate speed control hose (item 1) from rotary union (item 5) by holding fitting on speed control hose and loosening hex on rotary union. Discard banjo washer (item 4). 5. Remove three (3) button head screws that secure retainer (item 3) to speed limiter control cover. Remove retainer. 6.
CVT Enclosure Cover 1 3 105 to 120 in−lb (11.9 to 13.5 N−m) RIGHT FRONT 12 11 10 8 9 17 21 19 2 20 16 18 19 4 13 5 14 15 7 6 Figure 26 1. 2. 3. 4. 5. 6. 7. Engine Transmission Primary clutch Secondary clutch CVT drive belt Washer head screw (3) Speed limiter cover Drive Train 8. 9. 10. 11. 12. 13. 14. Banjo washer Flange head screw (6) Speed limiter assembly Compression spring Compression spring Speed control hose CVT enclosure cover Page 4 − 22 15. 16. 17. 18. 19. 20. 21.
Removal (Fig. 26) 1. Park vehicle on a level surface, raise and support vehicle cargo bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Place speed range lever in the transport (T) position to remove pressure in the speed control system. 3. Remove speed limiter assembly (item 9) with attached speed control hose from primary clutch to allow removal of CVT enclosure cover (see Speed Limiter Assembly in this section).
CVT Drive Belt 1 105 to 120 in−lb (11.9 to 13.5 N−m) RIGHT 3 12 FRONT 11 10 8 9 17 21 19 2 20 16 18 19 4 13 5 14 15 7 6 Figure 28 1. 2. 3. 4. 5. 6. 7. Engine Transmission Primary clutch Secondary clutch CVT drive belt Washer head screw (3) Speed limiter cover Drive Train 8. 9. 10. 11. 12. 13. 14. Banjo washer Flange head screw (6) Speed limiter assembly Compression spring Compression spring Speed control hose CVT enclosure cover Page 4 − 24 15. 16. 17. 18. 19. 20. 21.
Safety CAUTION The engine, exhaust system and drive system components may be hot. To avoid possible burns, allow all components to cool before working on drive system components. 2 Removal (Fig. 28) 1. Park vehicle on a level surface, raise and support vehicle cargo bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. Product Records 1 3. Use 1” open end wrench or equivalent in opening of secondary clutch (Fig.
Primary and Secondary Clutches 21 20 27 to 33 ft−lb (37 to 44 N−m) RIGHT FRONT 1 19 3 11 10 105 to 120 in−lb (11.9 to 13.5 N−m) 18 17 9 16 8 28 26 27 15 25 2 26 4 24 12 23 22 5 13 14 23 to 28 ft−lb (32 to 37 N−m) 7 6 Figure 30 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Engine Transmission Primary clutch Secondary clutch CVT drive belt Washer head screw (3) Speed limiter cover Flange head screw (6) Speed limiter assembly Compression spring Drive Train 11. 12. 13. 14. 15. 16. 17. 18. 19.
The engine, exhaust system and drive system components may be hot. To avoid possible burns, allow all components to cool before working on drive system components. A. If removed, secure CVT fan (item 19) and fan stiffener (item 20) to primary clutch with removed fasteners. Removal (Fig. 26) B. Thoroughly clean the tapered surfaces of the engine crankshaft and primary clutch. 1.
Primary Clutch Service 9 8 5 1 7 6 3 4 40 to 50 in−lb (4.6 to 5.6 N−m) 2 Figure 31 1. Spider assembly 2. Shoulder screw (3) 3. Lock nut (3) Drive Train 4. Clutch weight (3) 5. Moveable sheave 6. Cap Page 4 − 28 7. Thrust washer (2) 8. Bearing 9.
Disassembly (Fig. 31) Safety 2 1. Remove lock nut (item 3) from each of the shoulder screws (item 2). Discard lock nuts after removal. 1 3. Clean all dust and debris from clutch components with a soft bristle brush. If necessary, use water to remove dirt and dry immediately with compressed air to remove all dirt and water. Remove any remaining debris with a fast drying contact or brake parts cleaner. Focus debris removal on and around moving components. Product Records 2.
Secondary Clutch Service 2 5 6 7 9 13 11 14 1 16 3 4 8 18 10 8 to 12 ft−lb (11 to 16 N−m) 12 14 15 13 17 Figure 35 1. 2. 3. 4. 5. 6. Torx screw (4) Cam assembly Retaining ring Outer dampened spider External retaining ring (2) Thrust washer (2) 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.
4. Carefully, release clutch press tool to allow the compression spring to extend fully. 2 1 5. Remove outer dampened spider assembly (items 4, 5, 6 and 7), spider dampener (item 8), spider insert (item 9), compression spring (item 10) and moveable sheave assembly (items 12, 13 and 14) from stationary sheave. 6. If bearing (item 17) replacement is necessary, remove clutch shaft (item 11) with bearing from stationary sheave (item 16). Remove retaining ring and bearing from clutch shaft.
Rear CV (Constant Velocity) Axles 9 35 to 40 ft−lb (48 to 55 N−m) 5 4 11 8 3 12 13 Antiseize Lubricant 10 7 14 6 Antiseize Lubricant 170 to 180 ft−lb (231 to 244 N−m) 2 1 RIGHT FRONT 80 to 90 ft−lb (109 to 122 N−m) Figure 38 1. 2. 3. 4. 5. Lug nut (5 per wheel) Rear wheel assembly (2) Brake rotor (2) Brake caliper (2) Flange head screw (2 per caliper) Drive Train 6. 7. 8. 9. 10.
Safety Test Rear CV Axle 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 CV axle bearing components and initiate worn conditions. 1. Test drive vehicle on a smooth surface to verify CV axle joint problem. 1 2. Accelerate or back−up vehicle slowly with the front wheels turned. Listen for snapping or clicking noise at the wheel, then drive straight ahead. B.
CV Axle Boots 12 2 4 10 9 9 1 3 10 11 8 5 6 7 Figure 40 1. 2. 3. 4. Center shaft Outboard joint housing Outboard CV joint Spring clip 5. 6. 7. 8. Inboard joint housing Inboard CV joint Inner retaining ring Outer retaining ring A torn CV axle boot is the most common cause of CV axle failures. Look for grease on front suspension components, inner tire sidewall or fender to indicate a possible torn boot. Inspect boots for cracks, holes, tears or loose clamps.
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Rear Driveshaft RIGHT FRONT 2 5 11 12 14 8 13 10 7 4 23 to 27 ft−lb (32 to 36 N−m) 3 9 6 15 Grease 1 Figure 41 1. 2. 3. 4. 5. Transmission Rear differential Rear driveshaft Socket head screw (4) Parking brake rotor Drive Train 6. 7. 8. 9. 10. Parking brake caliper Flange head screw (2) Lock nut (2) Brake mount plate Spacer Page 4 − 36 11. 12. 13. 14. 15.
Removal (Fig. 41) Product Records 2 2. Support driveshaft to prevent it from shifting or falling. 3 3. Loosen and remove four (4) socket head screws that secure driveshaft and parking brake rotor to rear differential input shaft (Fig. 42). The center of the parking brake rotor is fitted to shoulder on differential input shaft and, with parking brake applied, the rotor can remain in place during driveshaft removal. 4.
Rear Driveshaft Cross and Bearing Service 1. Remove driveshaft from vehicle (see Rear Driveshaft in this section). 2 IMPORTANT: When placing yoke in vise, clamp lightly on the solid part of the yoke to prevent yoke damage. Also, the use of a vise with soft jaws is recommended. 2. Lightly clamp yoke in vise. Remove snap rings that secure bearings at the inside of each yoke. Remove yoke from vise. 4 3 IMPORTANT: Yokes must be supported when removing and installing bearings to prevent damage. 5 1 3.
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Rear Differential RIGHT 16 FRONT 21 20 16 17 16 2 22 18 Antiseize Lubricant 5 11 12 8 14 8 13 19 16 4 23 to 27 ft−lb (32 to 36 N−m) 10 16 3 7 9 6 1 15 Figure 45 1. 2. 3. 4. 5. 6. 7. 8. Transmission Rear differential Rear driveshaft Socket head screw (4) Parking brake rotor Parking brake caliper Flange head screw (2) Lock nut (6) 9. 10. 11. 12. 13. 14. 15. Brake mount plate Spacer Parking brake cable Clevis pin Hair pin Retaining ring Engine/transmission mount 16. 17. 18. 19. 20. 21.
2. If rear differential is to be disassembled, drain lubricant from rear differential. 3. Jack up and support rear of vehicle (see Jacking Vehicle in the Safety Instructions section of Chapter 1 − Safety). Once the machine is raised, support rear of engine/transmission mount to prevent it from moving or shifting during rear differential removal. 10.On the sides of the rear differential, remove flange head screws that secure the differential to the engine/ transmission mount.
Installation (Fig. 45) 1. Carefully raise rear differential into machine from the rear of the machine. Support differential in position to prevent it from shifting or falling. NOTE: When securing the rear differential to the machine, loosely install all fasteners before fully tightening any of the fasteners. 2. On the sides of the rear differential, install flange head screws that secure the differential to the engine/ transmission mount. 3.
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Rear Differential Service 7 to 10 ft−lb (9.5 to 13.
9. Remove dowel pin (item 25) that retains differential gear pin in the differential housing. Discard the removed pin. 10.Remove differential gear pin (item 26), pinion gears (item 27) and output gear (item 23) from the differential housing. Also, remove output gear (item 22) from spiral gear. PRY POINT 11. Remove oil seals from output cover and gear case taking care to not damage bores in cases during seal removal. Discard removed seals. PRY POINT 12.If necessary, remove shift fork from cover (Fig.
Differential Inspection 1. Thoroughly clean and dry all internal rear differential parts. 2. Use emery cloth to remove nicks and burrs from all differential components. 3. Inspect all gear teeth for roughness, material transfer or other damage. Cracked, broken, missing or chipped gear teeth are not acceptable. Replace gears if worn or damaged. 4. Inspect splines on pinion gear (item 10) and output gears (items 22 and 23). If cracked, broken, chipped or missing splines are found, replace shaft. 5. Inspect I.
B. Slide output gear (item 23) into differential housing and then position both pinion (item 27) gears into housing making sure that pinion gears mesh properly with output gear. C. Slide differential gear pin (item 26) into differential housing and pinion gears. Make sure that dowel pin holes in gear pin and differential housing align. D. Secure differential gear pin into the differential housing with new dowel pin (item 25). E. Slide output gear (item 22) into spiral gear bore.
Transmission RIGHT FRONT 16 27 to 33 ft−lb (37 to 44 N−m) 17 1 18 Grease 105 to 120 in−lb (11.9 to 13.5 N−m) 3 25 9 10 15 24 14 6 8 22 7 2 11 12 23 4 26 21 20 28 19 5 23 to 28 ft−lb (32 to 37 N−m) 13 27 11 Figure 52 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Engine Transmission Primary clutch Secondary clutch CVT drive belt Speed limiter assembly Flange head screw (6) Banjo washer Compression spring Compression spring 11. 12. 13. 14. 15. 16. 17. 18. 19.
Safety CAUTION 7 1 8 Product Records The engine, exhaust system and drive system components may be hot. To avoid possible burns, allow all components to cool before working on drive system components. 9 Transmission Removal (Fig. 52) 1. Park vehicle on a level surface, raise and support vehicle cargo bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 3 4 2. If transmission is to be disassembled, drain lubricant from transmission. 4.
Transmission Installation (Fig. 52) 1. Carefully lower and rotate transmission to allow it to clear engine and tabs on engine/transmission mount. Support transmission in position. 2. Loosely secure transmission to tabs on engine/transmission mount with two (2) flange head screws and flange nuts. Tighten fasteners only enough so that transmission can be moved for alignment purposes. 6.
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Transmission Service 50 21 20 29 23 8 12 54 17 45 8 to 10 ft−lb (11 to 13 N−m) 45 23 24 44 9 14 48 13 15 49 19 15 13 59 40 24 37 8 14 12 9 18 57 17 10 20 6 9 to 12 ft−lb (12 to 16 N−m) 34 42 5 28 60 27 41 53 10 52 32 30 31 35 18 26 14 56 16 18 11 38 51 33 43 22 9 39 7 2 18 Silicone Sealant 25 46 47 3 12 to 18 ft−lb (17 to 24 N−m) 55 4 57 58 10 to 14 ft−lb (14 to 18 N−m) Silicone Sealant 36 15 to 20 ft−lb (21 to 27 N−m) 1 10 to 14 ft−lb (14
Safety Transmission Disassembly (Fig. 55) 1. Clean exterior of transmission assembly. 3. Remove rotary switch (Fig. 55 item 56) from transmission: 4 Product Records 1 2. Use suitable blocks to support the transmission with the rear gear case side orientated upwards. 2 A. Remove snap ring, thrust washer and spring washer that secure rotary switch to shift drum shaft. B. Slide rotary switch from shift drum shaft.
8. Remove flange head screws that secure transmission gear cases. Carefully separate and remove rear gear case taking care to not damage sealing surfaces of the gear cases (Fig. 59). 3 9. Note location of two (2) dowel pins (Fig. 55 item 10) and remove pins from gear case. 1 2 3 Figure 59 1. Rear gear case 2. Front gear case 10.Carefully rotate shift drum (Fig. 55 item 29) to separate the drum from the shift fork pins. Lift shift drum from transmission. Lift shift shaft rail (Fig.
11. With the help of a second person, carefully remove front and rear output shafts (items 35 and 38) along with reverse and input shafts (Fig. 55 items 37 and 50) as a complete assembly. The silent chains (Fig. 55 items 53 and 54) will keep the paired shaft assemblies together (Fig. 61 and 62). Safety 2 Product Records 1 12.Carefully remove and discard all seals from front and rear gear cases. Make sure that bores in cases are not damaged during seal removal. 13.
Transmission Assembly (Fig. 55) 1. Make sure that all internal transmission components are thoroughly cleaned before transmission assembly. Lubricate all transmission components with clean Dexron VI automatic transmission fluid before installing them into the transmission. 2 NOTE: Use a press to install new bearings onto transmission shafts. All shaft bearings should be pressed only on the inner bearing race during installation onto the shaft.
8. Carefully lower shift drum (Fig. 55 item 29) into transmission while engaging the drum slots to the shift fork pins (Fig. 67). 9. Make sure that mating surfaces of front and rear gear case are clean. Apply silicone sealant to mating surface of front gear case. Safety 3 4 Product Records 1 10.Install two (2) dowel pins (Fig. 55 item 10) into gear case locations. 2 11. Carefully install rear gear case taking care to not damage seal in gear case. 3 Figure 67 1. Rear gear case 2. Front gear case 3.
17.Slide rotary switch (Fig. 55 item 56) onto shift drum shaft and align tab on switch with slot in sector gear cover. Secure switch with spring washer, thrust washer and snap ring. 18.Noting location of missing tooth, slide shift lever (item 39) onto shift shaft. Secure lever with lock nut. Torque lock nut from 12 to 18 ft−lb (17 to 24 N−m). 19.If speed sensor (Fig. 55 item 55) was removed, apply a light coating of multi−purpose lithium grease onto new O−ring (Fig. 55 item 58) and install onto sensor.
Chapter 5 Chassis Table of Contents Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . Brake Master Cylinder Service . . . . . . . . . . . . . . . Parking Brake Cable . . . . . . . . . . . . . . . . . . . . . . . Parking Brake Caliper . . . . . . . . . . . . . . . . . . . . . . Wheel Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering Assembly . . . . . . . . . . . . . . . . . . . . . . . . . Front Control Arms . . . . . . . . . . . . . . . . . . . . . . . . .
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.
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Operator’s Manual for additional information when servicing the vehicle. Tire Pressure 1. Tire pressure should be determined by the payload carried. A. The lower the tire pressure, the less the compaction and tire marks are minimized. Lower pressure should not be used for heavy payloads at higher speeds.
Special Tools Compression Spring Tool Use to remove and install the two (2) front suspension compression springs.
Troubleshooting Suspension and Steering Problem Possible Causes Excessive 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). Excessive rear end noise. Worn or brinelled rear wheel bearings. Worn rear shock absorbers. Worn leaf spring bushings. Excessive steering play.
Suspension and Steering (Continued) Problem Possible Causes Hard steering. Binding or damaged steering linkage. Low or uneven tire pressure. Incorrect front wheel alignment. Binding or damaged steering cylinder. Low hydraulic pressure (see Chapter 7 − Hydraulic System). Worn or damaged steering control valve (see Chapter 7 − Hydraulic System). Vehicle pulls to one side when not braking. Low or uneven tire pressure. Broken or weak rear leaf spring. Incorrect front wheel alignment.
Brakes (Continued) Problem Possible Causes Brakes pulling. Incorrect tire pressure. Contaminated brake pads. Incorrect front wheel 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 caliper(s). Sticking brake master cylinder.
Adjustments Parking Brake Adjustment 1. Park vehicle on a level surface, shut engine off and remove key from ignition switch. 2. Remove brake lever handle from parking brake lever. Loosen set screw on end of parking brake lever knob. 1 3. Adjust parking brake with knob on parking brake lever until a force of 45 to 50 lb (20 to 22 kg) is required to actuate the brake lever. 3 4. After adjustment, tighten set screw in knob to secure parking brake adjustment and then install brake lever handle.
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Service and Repairs Wheel Assembly 9 35 to 40 ft−lb (48 to 55 N−m) 6 5 3 2 35 to 40 ft−lb (48 to 55 N−m) 6 3 5 1 8 4 7 80 to 90 ft−lb (109 to 122 N−m) 2 RIGHT 4 FRONT 80 to 90 ft−lb (109 to 122 N−m) Figure 4 1. Front wheel assembly 2. Brake rotor 3. Wheel hub assembly Chassis 4. Lug nut (5 per wheel) 5. Brake caliper 6. Flange head screw (2 per caliper) Page 5 − 10 7. Front knuckle (LH shown) 8. Rear wheel assembly 9.
Removal (Fig. 4) 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 2. Partially loosen wheel lug nuts that secure wheel to be removed, then jack up and support vehicle (see Jacking Vehicle in the Safety Instructions section of Chapter 1 − Safety). 4 1 2 3. Remove lug nuts and then remove wheel assembly from vehicle. Installation (Fig. 4) 3 5 1. Install wheel. Secure with five (5) lug nuts. 2. Lower vehicle to ground.
Brake System 35 to 40 ft−lb (48 to 55 N−m) 10 54 to 66 in−lb (6.2 to 7.4 N−m) 6 8 5 35 to 40 ft−lb (48 to 55 N−m) 2 3 54 to 66 in−lb (6.2 to 7.4 N−m) 6 3 8 9 5 4 1 7 80 to 90 ft−lb (109 to 122 N−m) 2 RIGHT FRONT 4 80 to 90 ft−lb (109 to 122 N−m) Figure 6 1. 2. 3. 4. Front wheel assembly Brake rotor Wheel hub assembly Lug nut (5 per wheel) Chassis 5. Brake caliper 6. Flange head screw (2 per caliper) 7. Front knuckle (LH shown) Page 5 − 12 8. Bleed screw 9. Rear wheel assembly 10.
Disassembly (Fig. 6) WARNING 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury. Torque wheel lug nuts from 80 to 90 ft- lb (109 to 122 N- m). WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - Safety. 2. Chock wheels not being jacked up.
Brake Caliper Service 9 White Lithium Grease 4 27 to 33 ft−lb (37 to 44 N−m) 3 8 7 6 1 5 BAF−12 Assembly Lube 2 Figure 8 1. Bolt (2) 2. Caliper body 3. O−ring (4) Chassis 4. Caliper bracket 5. Square seal (2) 6. Dust seal (2) Page 5 − 14 7. Piston (2) 8. Brake pad (2) 9.
Disassembly (Fig. 8) Assembly (Fig. 8) 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 IMPORTANT: Use DOT 3 brake fluid in the brake system. 1. Remove hood to access brake master cylinder (see Hood in this section). Make sure that brake fluid level is correct. Bleeder valve 2. Connect a suitable transparent hose to bleeder valve on left rear wheel caliper and submerge other end of hose in a clean glass container partially filled with clean brake fluid. 3. Have a second person pump brake pedal several times, then hold pedal down firmly. 4.
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Brake Master Cylinder 1 2 10 11 6 3 8 4 6 9 5 7 RIGHT FRONT Figure 10 1. 2. 3. 4. Brake master cylinder Flange head screw (2) Clevis pin Grease fitting Chassis 5. 6. 7. 8. Brake pedal Flange bushing Flange nut Flange nut (2) Page 5 − 18 9. Cotter pin 10. Shoulder screw 11.
Removal (Fig. 10) 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 in this section). 3. Remove cotter pin from the clevis pin that connects master cylinder to brake pedal. 2 4. Clean hydraulic brake line area of master cylinder to prevent system 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. 12) 1 1. Thoroughly clean outside of master cylinder before disassembly. 2 2. Remove reservoir and flange seal. Push in on the push rod (item 8) so the stop pin (item 3) can be removed. 3 12 3. Disconnect lower end of the dust cover from the housing. 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. 11 4 5.
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Parking Brake Cable 15 RIGHT 16 14 FRONT 5 4 13 6 9 3 7 3 2 10 6 8 17 1 12 11 Figure 13 1. 2. 3. 4. 5. 6. Lever support assembly Parking brake lever Spacer (2) Curved washer Clevis pin Lock nut (2) 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Bellcrank (2) Cap screw (2) Hair pin Flat washer Hair pin Clevis pin Parking brake cable Retaining ring Speed control lever Hydraulic lever Shift lever Removal (Fig. 13) 1.
4. Disconnect parking brake cable from parking brake caliper at rear differential (Fig. 15): 4 2 A. Remove retaining ring that secures parking brake cable to engine mount. 6 B. Remove hair pin and clevis pin that secure parking brake cable clevis to parking brake caliper lever. 7 1 5 C. Disconnect brake cable from caliper lever and remove cable from engine mount. 5. Remove retaining ring (item 14) that secures brake cable to lever support assembly. 3 8 6.
Parking Brake Caliper RIGHT FRONT 2 7 5 4 3 9 4 6 12 13 10 23 to 27 ft−lb (32 to 36 N−m) 11 8 14 Grease 1 Figure 17 1. 2. 3. 4. 5. Transmission Rear differential Parking brake cable Retaining ring (2) Clevis pin 6. 7. 8. 9. 10. Hairpin Parking brake rotor Parking brake caliper Flange nut (2) Flange head screw (2) 11. 12. 13. 14. Brake mount plate Parking brake spacer Socket head screw (4) Rear driveshaft Disassembly (Fig. 17) 1.
4. Remove parking brake caliper from vehicle: 6 A. Remove flange nuts (item 9) and flange head screws (item 10) that secure brake mount plate (item 11) to frame. Locate and retrieve parking brake spacer (item 12). 2 4 B. Slide parking brake caliper with attached brake cable and brake mount plate from parking brake rotor. 3 7 C. Remove hairpin (item 6) and clevis pin (item 5) that secure parking brake cable to parking brake caliper. Separate cable from caliper. D. Remove brake caliper from vehicle.
Wheel Hub 35 to 40 ft−lb (48 to 55 N−m) 14 RIGHT FRONT 54 to 66 in−lb (6.2 to 7.4 N−m) 6 8 5 2 15 18 17 13 35 to 40 ft−lb (48 to 55 N−m) 3 54 to 66 in−lb (6.2 to 7.4 N−m) 6 16 35 to 40 ft−lb (48 to 55 N−m) 3 8 12 4 5 170 to 180 ft−lb (231 to 244 N−m) 1 11 7 80 to 90 ft−lb (109 to 122 N−m) 13 10 9 2 35 to 40 ft−lb (48 to 55 N−m) 4 170 to 180 ft−lb (231 to 244 N−m) 80 to 90 ft−lb (109 to 122 N−m) Figure 20 1. 2. 3. 4. 5. 6.
Removal (Fig. 20) Installation (Fig. 20) 1. Park vehicle on a level surface, shut engine off and remove key from ignition switch. 1. If front wheel hub is being replaced, install cap screw (item 12), washers (items 11 and 10) and lock nut (item 9) to new hub. Torque lock nut from 170 to 180 ft−lb (231 to 244 N−m). 3.
Steering Assembly 40 to 50 ft−lb (55 to 67 N−m) 80 to 90 ft−lb (109 to 122 N−m) RIGHT 19 FRONT 27 6 30 17 33 25 15 3 28 9 12 35 to 40 ft−lb (48 to 55 N−m) 12 18 32 16 23 8 14 3 11 21 20 22 26 24 35 to 40 ft−lb (48 to 55 N−m) 11 5 13 1 12 31 14 29 7 23 40 to 50 ft−lb (55 to 67 N−m) 35 to 40 ft−lb (48 to 55 N−m) 10 170 to 180 ft−lb (231 to 244 N−m) 2 4 80 to 90 ft−lb (109 to 122 N−m) Figure 21 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Disassembly (Fig. 21) 1 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 70 to 80 ft−lb (94 to 109 N−m) 45 to 55 ft−lb (61 to 74 N−m) 2 2. Remove front wheel assembly to access steering components that are to be serviced (see Wheel Assembly in this section). 3 4 3. To remove tie rod (item 11) from vehicle (Fig. 22): 5 A. Remove cotter pin and slotted hex nut that secure outer tie rod ball joint stud to knuckle.
Assembly (Fig. 21) 3. To install tie rod (item 11) to vehicle: 1. If steering linkage and center link assembly were disassembled, use Figures 21 and 23 as guides for assembly. A. If flange bushings (items 2 and 3 in Fig. 23) were removed from pivot mount, make sure that new bushings are pressed fully into the pivot mount. B. Install and torque new spindle nut (item 8 in Fig. 23) to 85 ft−lb (115 N−m). Deform spindle nut into slot in idler arm or pitman arm after torquing nut. C.
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Front Control Arms 12 10 15 1 11 13 5 6 40 to 50 ft−lb (55 to 67 N−m) 14 3 7 4 70 to 80 ft−lb (94 to 109 N−m) 7 8 9 8 13 11 RIGHT 7 2 FRONT 10 15 70 to 80 ft−lb (94 to 109 N−m) 12 Figure 24 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 used per arm) Page 5 − 32 11. 12. 13. 14. 15.
Removal (Fig. 24) Installation (Fig. 24) 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. NOTE: Front compression springs do not need to be removed if servicing only the lower control arm. 2.
Front Compression Spring Service 2 10 4 1 6 5 3 9 4 8 7 11 12 RIGHT FRONT Figure 25 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 5 − 34 8. LH control arm tower 9. Spring pivot sleeve 10.
Disassembly (Fig. 25) 4 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 4 3 2. Remove seat base to gain access to front suspension assembly (see Seat Base in this section). 2 3. Jack up front of vehicle and secure with jack stands (see Jacking Vehicle in the Safety Instructions section of Chapter 1 − Safety). Remove front wheels. 1 4. Remove front shock absorbers (see Front Shock Absorber in this section).
Front Shock Absorber Removal (Fig. 28) 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 (Fig. 28) 1 1. If necessary (e.g.
Rear Shock Absorber Removal (Fig. 30) 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 29 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 70 to 80 ft−lb (94 to 109 N−m) FRONT See tightening procedure in text Figure 31 1. 2. 3. 4. 5. Washer (4 used per plate) Spring mount (LH shown) Rear frame Flange head screw Flange nut 6. 7. 8. 9. 10. Rear axle Axle bumper (2) Lock nut Bolt (4 used per plate) Spring shackle (2 used per spring) IMPORTANT: For proper vehicle performance, always replace the springs on both sides of the vehicle. 11. 12. 13. 14.
8. Remove flange nut that secures spring mount to leaf spring and remove mount from spring. 9. Remove rubber bushings (item 12) from leaf spring and frame side rails. Installation (Fig. 31) 1. Make sure that four (4) rubber bushings (item 12) are positioned in leaf spring and two (2) rubber bushings are fitted in frame side rail. 2. Insert one (1) spring shackle (item 10), from inside/ out, into rear of leaf spring.
Steering Wheel Removal (Fig. 32) 1 1. Park vehicle on a level surface, shut engine off, remove key from ignition switch and apply parking brake. 3 RIGHT FRONT 2. Carefully remove steering wheel cover from steering wheel. 2 Antiseize Lubricant 5 3. Remove hex nut and flat washer that secure steering wheel to steering control valve. 20 to 25 ft−lb (28 to 33 N−m) 4. Pull steering wheel from control valve. If necessary, use suitable puller to remove steering wheel. 4 Installation (Fig. 32) 1.
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Seat Base 2 12 in−lb (maximum) (1.3 N−m) 16 3 1 15 18 4 23 17 5 21 20 19 22 8 13 12 11 12 14 6 9 RIGHT 7 10 FRONT Figure 33 1. 2. 3. 4. 5. 6. 7. 8. LH (operator) seat RH (passenger) seat Washer head screw (10) Shift decal Shift plate Carriage bolt (8) Seat bracket (4) Seat base 9. 10. 11. 12. 13. 14. 15. 16. Flange nut (8) U−clip nut (8) Mudflap (2) Flat washer (8) Flange head screw (4) Flange nut (4) Control plate Socket head screw Removal (Fig. 33) 1.
5. Remove knobs from control levers (Fig. 36). 1 6. Remove six (6) washer head screws that secure center console control plate assembly to seat base. Remove center console control plate assembly. 3 2 3 7. Remove four (4) washer head screws that secure shift plate (item 5) to seat base. Lift shift plate from seat base, carefully unplug plate connector from vehicle wire harness and remove shift plate. 8. Remove four (4) socket head screws that secure each seat to vehicle. Lift both seats from vehicle.
Hood 7 1 7 2 6 7 3 7 5 RIGHT 4 FRONT Figure 37 1. Hood 2. Clip (3 used per headlight) 3. Headlight (2) 4. Bumper 5. Bumper bracket 6. Operator frame 7. Hood mounting tab Removal (Fig. 37) Installation (Fig. 37) 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. Plug the wire harness connector to the two (2) headlights. Insert the top mounting tabs into the frame slots. 2.
Windshield Wiper Assembly (Machines with Operator Cab) 1 2 3 26 4 5 6 16 5 to 6 N m (45 to 53 in-- lb) 7 8 24 22 23 21 19 20 17 18 12 14 13 Chassis 20 to 22 N m (177 to 194 in-- lb) 25 9 7 to 8 N m (62 to 70 in-- lb) 15 10 11 Figure 38 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 HDX Auto 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 38) 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. 38) 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 6 Electrical System Table of Contents Front Differential Interrupter Switch (Vehicles with 4WD) . . . . . . . . . . . . . . . . . . . . . . . 18 Main Power Relay (Four Terminals) . . . . . . . . . . . 19 Relays with Five (5) Terminals . . . . . . . . . . . . . . . . 20 Diode Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Fusible Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Fuel Gauge Sender . . . . . . . . . . . . . . . . . . . . . . . . .
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. Electrical Drawings The electrical schematics and other electrical drawings for Workman HDX Auto vehicles are located in Chapter 9 − 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. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits.
Battery Terminal Protector Aerosol spray that should be used on battery terminals, ring terminals and fork terminals to reduce corrosion problems. Apply terminal protector to the connection after the battery cable, ring terminal or fork terminal has been secured. Toro Part Number: 107−0392 Figure 4 Spark Tester The spark tester can be used to test magneto ignitions on gasoline engines. The spark tester determines if ignition is present.
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 9 − 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 solenoid clicks, but starter will not crank. (If solenoid clicks, problem is not in interlock system.) Battery cables are loose or corroded. Ground connection(s) is loose or corroded. Battery is discharged or faulty. Cable connection at starter motor is faulty. Starter mounting fasteners are loose or not supplying a sufficient ground for starter operation. Starter solenoid is faulty. Starter motor is faulty. Starter cranks but engine will not start. Fuel tank is empty.
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 v (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery should be at a temperature of 60oF to 100oF (16oC to 38oC). The ignition key should be in the OFF position and all accessories turned off.
Verify Interlock System Operation The purpose of the interlock system is to prevent the engine from cranking or starting unless the brake pedal is depressed and the hydraulic lift lever is in the neutral position. To verify operation of hydraulic lift lever interlock switch: 1. Sit on operator’s seat and engage parking brake. Move transmission lever to NEUTRAL or PARK position. 2. Move hydraulic lift lever out of neutral position. CAUTION Do not disconnect safety switches.
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 (6) minutes that the ignition switch is in the RUN position. 4 1 6 5 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 block is located below the center of the dash panel (Fig. 9). Identification and Function (Fig. 10) Top Row Position A2 (15 amp): Protects power point circuit. FRONT Top Row Position A1 (10 amp): Protects engine start circuit. Second Row Position B2 (10 amp): Protects power supply circuit for hazard lights (if equipped). Second Row position B1 (10 amp): Protects power supply circuit for ignition switch ON. Third Row Position C2 (15 amp): Protects power supply circuit for differential lock.
Headlight Switch This headlight switch allows the headlights to be turned on and off. The headlight switch is located on the dash (Fig. 11). 1 Testing 1. Park machine on a level surface, stop engine, apply parking brake and remove key from ignition switch. 2 2. To ease access to headlight switch, remove hood of vehicle (see Hood in the Service and Repairs section of Chapter 5 − Chassis). 3. Locate headlight switch on dash and disconnect wire harness electrical connector from the switch. 4.
Rear Differential Lock Switch The rear differential lock switch allows the rear axle differential to be locked for increased traction or un−locked for normal differential operation. The rear differential lock switch is located on the dash (Fig. 13). An indicator light on the differential lock switch identifies when the rear differential is locked. The differential lock mechanism is in the locked position when the differential solenoid is de−energized.
Brake Switch The brake switch is a normally closed switch that is attached to the frame under the dash (Fig. 15). When the brakes are not applied, the brake pedal presses the brake switch plunger to open the switch. When the brakes are applied, the pedal moves away from the brake switch plunger to allow the switch to be in the normally closed state. This will allow a current path to energize the start enable relay and also to illuminate the stop lights. 2 Testing 1.
Parking Brake Switch The parking brake switch is a normally closed proximity switch that is attached to the control lever support (Fig. 16). The switch is in its normal closed position when the parking brake is applied. When the parking brake is not applied, the parking brake lever is positioned close to the brake switch causing the switch to open. The closed brake switch is used in the starting interlock system to make sure that the drive system is disengaged during engine starting.
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. 17). The interlock switch is in its normal open position whenever the hydraulic lift lever is moved away from the neutral position. When the lift lever is in the neutral position, the retainer pin that attaches the lift lever link to the lift valve is positioned close to the interlock switch causing the switch to close.
High Flow Hydraulics Switch (Vehicles with High Flow Hydraulics) On vehicles equipped with the high flow hydraulics kit, the switch to engage the high flow hydraulic circuit is mounted on the dash (Fig. 20). 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 high flow hydraulics switch identifies when the switch is ON. 1 2 Testing 1.
Front Differential Interrupter Switch (Vehicles with 4WD) The front differential interrupter switch is a normally closed switch that opens when the accelerator pedal is not depressed. When the accelerator pedal is depressed for vehicle acceleration, the flange on the accelerator pedal moves away from the switch plunger to allow the switch to be in its normally closed state. The differential interrupter switch is attached to the pedal support frame under the dash panel (Fig. 22). FRONT 1 3 Testing 1.
Main 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 RUN 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 engine (Fig. 23). FRONT Testing 3 1. Park machine on a level surface, raise bed, stop engine, apply parking brake and remove key from ignition switch. 1 2.
Relays with Five (5) Terminals Workman HDX Auto vehicles use a number of relays that have five (5) terminals: FRONT The start relay ensures that the hydraulic lift lever is in neutral before the engine starter solenoid can be energized. The start relay also prevents starting if the high flow hydraulics system (if equipped) is engaged. The fan relay allows powers to the engine cooling fan when the relay is energized.
5. Using a multimeter (ohms setting), measure coil resistance between terminals 85 and 86 (Fig. 27). Resistance should be between 70 and 90 ohms. 6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87 (Fig. 27). 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. 86 85 87A 87 30 7. Disconnect voltage from terminal 85 and multimeter lead from terminal 87. 8.
Diode Assemblies The protection diode assembly is used for starting circuit protection from voltage spikes that occur when the starter solenoid is de−energized. This diode plugs into the rear wire harness under the right side of the bed near the engine. Four (4) diode assemblies are used for circuit logic in the transmission gear selection system. The park, reverse low and high diode assemblies plug into the front wire harness behind the dash.
Fusible Link A Workman HDX Auto vehicle uses three (3) fusible links for circuit protection. These fusible links are located in a harness that connects the engine starter motor B+ terminal to the vehicle rear wire harness (Fig. 29). If any of these links should fail, current to the protected circuit will cease. Refer to electrical schematics and wire harness drawings in Chapter 9 − Electrical Drawings for additional fusible link information. 1 3 Testing 2 1.
Fuel Gauge Sender The fuel gauge sender on Workman HDX Auto vehicles is included with the fuel pump assembly that fits into the fuel tank (Fig. 31). Testing 1. Park machine on a level surface, raise bed, stop engine, apply parking brake and remove key from ignition switch. Install bed support on bed lift cylinder to prevent bed from lowering. 7.
Fuel Pump The fuel pump used on Workman HDX Auto vehicles is a positive displacement electric pump that provides pressurized fuel to the engine fuel rail in a return-less system. The fuel pump assembly includes the fuel pump, the fuel sender for the dash mounted fuel gauge and the fuel filter. The fuel pump assembly is mounted in the fuel tank. The fuel pump assembly includes a regulator to maintain fuel pressure of approximately 40 PSI (276 kPa).
Temperature Sender The temperature sender is threaded into a fitting in the top of the engine cylinder casting (Fig. 35). 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 violet wire attached to the sender. 6. Install temperature sender to the water pump housing. A. Clean threads of water pump housing and switch thoroughly.
Speed Sensor The speed sensor is attached to the upper transaxle cover (Fig. 37). It uses a magnetically based, Hall Effect integrated circuit. As the differential in the transaxle turns, the sensor accurately senses the movement of the differential ring gear teeth passing by the sensor. The red striped connector wire is the sensor positive lead, the black wire is the ground lead and the gray striped wire is the signal output. 2 1 Testing 1.
Hydraulic Solenoid Valve Coil (Vehicles with High Flow Hydraulics Kit) Vehicles equipped with the High Flow Hydraulics Kit use a hydraulic solenoid valve coil for system control (Fig. 39). When the solenoid coil is energized, hydraulic valve shift occurs to provide hydraulic flow for the attachment. Testing of the coil can be done with the coil installed on the hydraulic manifold valve. 3 4 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. 41). 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.
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Service and Repairs NOTE: Refer to the Kohler Aegis Service Manual for engine electrical component repair information. Battery Storage If the machine will be stored for more than thirty (30) days: 4. Store battery in a cool atmosphere to avoid quick deterioration of the battery charge. 1. Remove the battery from the machine and charge it fully (see Battery Service in this section). 5. To help prevent the battery from freezing, make sure it is fully charged (see Battery Service in this section). 2.
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. 3 2 RIGHT FRONT 1 CAUTION 4 When working with batteries, use extreme caution to avoid splashing or spilling electrolyte. Electrolyte can destroy clothing and burn skin and eyes. Always wear safety goggles and a face shield when working with batteries.
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. B.
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 in the Service and Repairs section of Chapter 7 − Chassis). Make sure to connect the wire harness connector to the headlight during hood installation. CAUTION The Workman headlights use a halogen bulb that becomes extremely hot when in operation. Handling a hot headlight bulb can cause severe burns and personal injury. Allow enough time for bulb to cool before handling.
Tail Lights Disassemble and assemble tail light using Fig. 45 as a guide. 1 2 3 4 Figure 45 1. Screw (2) 2. Lens Electrical System Page 6 − 36 3. Bulb 4.
Chapter 7 Hydraulic System Table of Contents SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 28 General Precautions for Removing and Installing Hydraulic System Components . . . . . . . . . . . . . . 28 Check Hydraulic Lines and Hoses . . . . . . . . . . . . . 29 Hydraulic Reservoir . . . . . . . . . . . . . . . . . . . . . . . . . 30 Gear Pump (Vehicles with Standard Hydraulics) . 32 Gear Pump Service (Vehicles with Standard Hydraulics) . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Hydraulic Pump Displacement (per revolution) Casappa positive displacement gear type pump 0.326 in3 (5.3 cc) System Relief Pressure 1800 PSI (124 Bar) Steering Control Valve Sauer Danfoss Steering Unit, Series OSPM Lift Control Valve Three (3) position control valve Spring return to neutral Ball checks to maintain load Hydraulic Oil Mobil M15 Reservoir System Capacity 8 U.S. quart (7.
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. Check Hydraulic Oil The hydraulic system on your Workman is designed to operate on Mobil M15 hydraulic oil. Check level of hydraulic fluid daily. See Operator’s Manual for fluid level checking procedure and hydraulic oil recommendations.
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. These conditions can cause hose damage and deterioration. Some hoses are more susceptible to these conditions than others.
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. 5) 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. 7) 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.
Hydraulic System Page 7 − 8 ENGINE 3600 / 1100 RPM 100 MESH 25 PSI GEAR PUMP 0.33 in3/rev 4.9 GPM STEERING CONTROL UNIT P L T 1800 PSI 2.44 CIR R 1.625” BORE 6.125” STROKE IN 2WD 4.89” STROKE IN 4WD 1.00” ROD E A B LIFT VALVE 1 OPTIONAL HIGH FLOW KIT SVRV 2000 PSI 1.500” BORE 16.25” STROKE 0.750” ROD EXTEND TO RAISE 1.500” BORE 16.25” STROKE 0.750” ROD 2 1. FLOWS SHOWN ARE CALCULATED AT HIGH IDLE AND 95% PUMP EFFICIENCY UNLESS OTHERWISE NOTED T OIL COOLER GEAR PUMP 0.
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Hydraulic System Page 7 − 10 STEERING CONTROL VALVE T NEUTRAL POSITION P E P LEFT TURN STEERING CONTROL VALVE 1800 PSI 1800 PSI R 2.44 CIR L L T STEERING CYLINDER PISTON MOVEMENT 2.44 CIR R STEERING CYLINDER NO PISTON MOVEMENT E P L RIGHT TURN STEERING CONTROL VALVE 1800 PSI 2.
Steering Circuit The hydraulic gear pump supplies flow for the steering circuit and for raising and lowering the bed. Pump output flows to the steering control valve before reaching the lift valve so the steering circuit has priority. Circuit pressure is limited by a relief valve located in the steering control valve. NOTE: On vehicles with High Flow Hydraulics, a two (2) section gear pump is used. The front gear pump section supplies oil for steering and raising/lowering the bed.
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 Auto vehicles that are equipped with high flow hydraulics, a second gear pump section is directly coupled to the standard gear pump. This second pump section provides hydraulic system flow for the high flow circuit that is designed to power hydraulic attachments. A hydraulic manifold equipped with a solenoid operated relief valve (SVRV) is used to control the accessory circuit and when energized, also provides circuit relief.
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 14 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.
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 components. Contamination will cause excessive wear of hydraulic components. 2.
Gear Pump Flow and System Relief Pressure R L QUICK DISCONNECT COUPLINGS 7.7 GPM GEAR PUMP 0.519 in3/rev 2.44 CIR STEERING CONTROL UNIT 2000 PSI OIL COOLER SVRV 1800 PSI P T E T OPTIONAL HIGH FLOW KIT 4.9 GPM LIFT VALVE TESTER B EXTEND TO RAISE A GEAR PUMP 0.33 in3/rev ENGINE 3600 / 1100 RPM 25 PSI 100 MESH Figure 17 NOTE: This test procedure is for the single section gear pump used on vehicles with standard hydraulics.
Procedure for Gear Pump Flow and System Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the vehicle for approximately ten (10) minutes. 2. Park vehicle on a level surface, raise and support cargo bed (if installed), shut engine off and engage the parking brake. After turning engine off, operate all hydraulic controls to relieve hydraulic system pressure. 7.
Steering Control Valve and Steering Cylinder PLUG R L QUICK DISCONNECT COUPLINGS 7.7 GPM ROTATED FOR RIGHT TURN GEAR PUMP 0.519 in3/rev 2.44 CIR STEERING CONTROL UNIT OIL COOLER 2000 PSI SVRV 1800 PSI P T E T OPTIONAL HIGH FLOW KIT 4.9 GPM LIFT VALVE B A GEAR PUMP 0.
Procedure for Steering Control Valve and Steering Cylinder Test 1. Make sure hydraulic oil is at normal operating temperature by operating the vehicle for approximately ten (10) minutes. NOTE: This steering test procedure will be affected by incorrect tire pressure, binding of the hydraulic steering cylinder, excessive weight on the vehicle and/or binding of the steering assembly (e.g. wheel spindles, tie rods). Make sure that these items are checked before proceeding with any hydraulic testing procedure.
Lift Cylinder Internal Leakage R L QUICK DISCONNECT COUPLINGS 7.7 GPM GEAR PUMP 0.519 in3/rev 2.44 CIR STEERING CONTROL UNIT OIL COOLER 2000 PSI SVRV 1800 PSI P T E T OPTIONAL HIGH FLOW KIT 4.9 GPM LIFT VALVE (IN LOWER POSITION) B A GEAR PUMP 0.
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 lift cylinder by fully retracting it (i.e. put hydraulic lift lever in LOWER position).
High Flow Hydraulics Gear Pump Flow and System Relief Pressure L 7.7 GPM TESTER R QUICK DISCONNECT COUPLINGS GEAR PUMP 0.519 in3/rev 2.44 CIR STEERING CONTROL UNIT OIL COOLER 2000 PSI SVRV 1800 PSI P T E T OPTIONAL HIGH FLOW KIT 4.9 GPM LIFT VALVE B EXTEND TO RAISE A GEAR PUMP 0.33 in3/rev ENGINE 3600 / 1100 RPM 25 PSI 100 MESH Figure 22 NOTE: This test procedure is for the rear gear pump section on Workman vehicles that are equipped with High Flow Hydraulics.
Procedure for High Flow Hydraulics Gear Pump Flow and System Relief Pressure Test 1. Make sure hydraulic oil is at normal operating temperature by operating the vehicle for approximately ten (10) minutes. 2. Park vehicle on a level surface, raise and support cargo bed (if installed), shut engine off and apply the parking brake. After turning engine off, operate all hydraulic controls to relieve hydraulic system pressure. GAUGE READING TO BE: A pump in good condition should have a flow of approximately 7.
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 hydraulic reservoir and add correct oil if necessary.
Check Hydraulic Lines and Hoses Check hydraulic lines and hoses daily for leaks, kinked lines, loose mounting supports, wear, loose fittings or general deterioration. Make all necessary repairs before vehicle operation. WARNING Hydraulic System Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks.
Hydraulic Reservoir 3 HYDRAULIC RESERVOIR FOR STANDARD HYDRAULICS 6 5 2 4 90 to 110 ft−lb (123 to 149 N−m) 55 to 60 ft−lb (75 to 81 N−m) 1 7 8 TO OIL FILTER 9 10 11 12 17 16 13 15 19 18 11 20 14 21 22 21 RIGHT FRONT Figure 24 1. 2. 3. 4. 5. 6. 7. 8. Hydraulic reservoir Dipstick Reservoir cap Hydraulic hose Hose clamp Standpipe Bushing O−ring 9. 10. 11. 12. 13. 14. 15.
Hydraulic Reservoir Removal Hydraulic Reservoir Installation 1. Park vehicle on a level surface, raise and support cargo bed (if installed), shut engine off and engage parking brake. Remove key from the ignition switch. 1. Install removed strainer and hydraulic fittings with new, lubricated O−rings to hydraulic reservoir using Figure 24 or 25 as a guide (see Hydraulic Fitting Installation in the General Information section of this chapter). Torque fittings to values identified in illustration. 2.
Gear Pump (Vehicles with Standard Hydraulics) RIGHT FRONT 1 90 to 110 ft−lb (123 to 149 N−m) 18 TO OIL FILTER 17 55 to 60 ft−lb (75 to 81 N−m) 16 2 4 3 11 12 6 10 2 5 9 8 15 Antiseize Lubricant 7 14 13 Figure 26 1. 2. 3. 4. 5. 6. Hydraulic reservoir Hose clamp (2) Suction hose Spring 45o hydraulic fitting O−ring 7. 8. 9. 10. 11. 12. Hydraulic hose O−ring 45o hydraulic fitting O−ring Gear pump Flange nut (4) 13. 14. 15. 16. 17. 18.
Removal (Fig. 26) 4. Install four (4) flange head screws and flange nuts to secure pump to mount. Do not fully tighten fasteners. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of this section. CAUTION Before performing any service or repair on hydraulic system components, relieve system pressure to avoid injury from pressurized hydraulic oil.
Gear Pump Service (Vehicles with Standard Hydraulics) 130 in−lb (15 N−m) STANDARD HYDRAULICS GEAR PUMP 22 19 23 15 13 14 11 9 1 2 3 4 6 7 8 4 5 18 16 17 20 21 12 220 in−lb (25 N−m) 10 5 Figure 28 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. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23.
6. Remove pump from the vise and position pump so that the shaft end is facing down. Remove screws. 1 7. Carefully lift rear flange from body. 8. Carefully remove body. Lift body straight up to remove. Make sure the rear thrust plate remains on the drive and idler gear shafts. Locate and retrieve dowel pins. IMPORTANT: Note position of the open and closed side of the thrust plates before removing. Also, identify thrust plates (front and rear) with a marker for proper assembly. 9.
5. Lubricate the drive shaft with clean hydraulic oil. Carefully insert the drive end of the drive shaft through the front thrust plate with the pressure seal side down. IMPORTANT: When installing drive shaft into front cover, make sure that shaft seal (item 2) is not damaged. 6. Carefully install shaft with front thrust plate into front cover taking care to not damage shaft seal. 7. Lubricate the idler shaft with clean hydraulic oil.
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Gear Pump (Vehicles with High Flow Hydraulics) RIGHT FRONT 4 21 19 13 17 20 23 7 1 1 2 18 7 1 3 11 16 7 10 6 22 5 9 12 8 17 14 15 Antiseize Lubricant Figure 31 1. 2. 3. 4. 5. 6. 7. 8. Hose clamp (4) Hydraulic hose Hydraulic hose Hydraulic hose O−ring 45o hydraulic fitting O−ring Hydraulic hose 9. 10. 11. 12. 13. 14. 15. 16. O−ring 45o hydraulic fitting O−ring Gear pump Flange nut (4) Flange head screw (4) Pump mount Square key 17. 18. 19. 20. 21. 22. 23.
Removal (Fig. 31) 4. Install four (4) flange head screws and flange nuts to secure pump to mount. Do not fully tighten fasteners. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of this section. CAUTION Before performing any service or repair on hydraulic system components, relieve system pressure to avoid injury from pressurized hydraulic oil.
Gear Pump Service (Vehicles with High Flow Hydraulics) HIGH FLOW HYDRAULICS KIT GEAR PUMP 220 in−lb (25 N−m) 4 14 12 15 13 11 8 6 17 9 24 7 3 2 18 19 4 16 5 28 10 5 4 23 1 21 30 13 13 20 25 19 18 31 14 220 in−lb (25 N−m) 29 27 26 22 4 14 Figure 33 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 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
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Lift Valve 20 16 RIGHT 17 19 5 13 FRONT 5 2 15 11 1 14 12 9 5 2 18 10 17 3 8 6 4 5 5 7 Figure 34 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 90o hydraulic fitting Hyd. tube (to male quick fitting) Page 7 − 42 15. 16. 17. 18. 19. 20. Hyd.
Removal (Fig. 34) 2. Install lift valve to vehicle using Figure 34 as a guide. 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 3. Replace O−rings on hydraulic lines and fittings. Remove caps and plugs from tubes and fittings. Connect hydraulic tubes to lift valve (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 2.
Lift Valve Service Disassembly (Fig. 36) 1. After removing lift valve from vehicle, wash valve in solvent and dry thoroughly. 2. Carefully mount lift valve in a vise so that mounting pads are against jaws of vise. Lift valve spool retaining ring (item 14) should be facing up. 8 3. Remove two (2) hex cap plugs (item 1) from side of valve body. Inside valve body, behind each hex cap plug, there is a spring (item 3), ball (item 4) and cam pin (item 6); remove these parts.
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Steering Control Valve 1 20 to 25 ft−lb (28 to 33 N−m) 2 10 RIGHT FRONT 3 Antiseize Lubricant 4 8 9 12 5 6 18 19 7 11 13 14 15 16 17 Figure 37 1. 2. 3. 4. 5. 6. 7. Lock nut Flat washer Steering wheel Steering control valve Hyd hose (to control valve P port) Hyd hose (to control valve E port) Hyd hose (to control valve T port) 8. 9. 10. 11. 12. 13.
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 6. Remove four (4) flange head screws that secure steering control valve to vehicle frame. Move steering valve (with hydraulic hoses attached) away from vehicle frame. 7.
Steering Control Valve Service 8 9 7 6 10 5 4 3 2 1 11 12 13 22 14 15 13 21 16 20 13 17 20 to 24 ft−lb (27 to 33 N−m) 18 19 Figure 40 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 70 to 80 ft−lb (95 to 108 N−m) RIGHT FRONT 80 to 90 ft−lb (109 to 122 N−m) 19 6 27 30 33 17 25 15 3 28 12 9 35 to 40 ft−lb (48 to 55 N−m) 12 18 32 16 23 8 14 11 3 21 20 22 26 24 31 35 to 40 ft−lb (48 to 55 N−m) 11 5 13 1 12 14 29 7 23 35 to 40 ft−lb (48 to 55 N−m) 40 to 50 ft−lb (55 to 67 N−m) 170 to 180 ft−lb (231 to 244 N−m) 10 2 80 to 90 ft−lb (109 to 122 N−m) 4 Figure 41 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
Removal (Fig. 41) 1. Park vehicle on a level surface, shut engine off and engage the parking brake. Remove key from the ignition switch. 3. Remove caps and plugs from hoses and fittings. Install new O−rings on hydraulic fittings. Connect hydraulic hoses to fittings in steering cylinder ports (see Hydraulic Hose and Tube Installation in the General Information section of this chapter). 2. Remove seat base from vehicle (see Seat Base in the Service and Repairs section of Chapter 7 − Chassis). 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 43 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. 43) 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 4. Slide front shaft onto rear shaft and align roll pin holes in shafts. Install new roll pin to secure shafts. 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. 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 FRONT 11 10 2 3 4 8 3 2 4 9 7 6 5 Figure 44 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 7 − 54 9. 10. 11. 12.
Removal (Fig. 44) Installation (Fig. 44) 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) 1 2 3 4 14 5 6 13 7 8 9 10 11 12 Figure 45 1. 2. 3. 4. 5. Lock nut Wear ring Seal O−ring Piston 6. 7. 8. 9. 10. 11. 12. 13. 14. Head O−ring Back−up seal Retaining ring Seal Disassembly (Fig. 45) 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. 45) 4. Lubricate head and piston with clean hydraulic oil. 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 hydraulic oil. 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 lubricated piston seal, O−rings and wear ring to the piston. 5.
Hydraulic Manifold (Vehicles with High Flow Hydraulics) 6 5 9 7 1 11 4 3 10 9 3 2 RIGHT 8 FRONT Figure 46 1. 2. 3. 4. Hydraulic manifold assembly Hydraulic hose O−ring Hydraulic tube 5. 6. 7. 8. Hydraulic tube Hydraulic hose Cap screw (2) Oil filter assembly 9. Tee fitting 10. O−ring 11. Engine mount assembly Workman HDX automatic vehicles equipped with High Flow Hydraulics use a hydraulic manifold mounted solenoid valve to engage the accessory hydraulic circuit.
Removal (Fig. 46) 1. Park vehicle on a level surface, raise and support cargo bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2 1 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter. CAUTION 3 Before performing any service or repair on hydraulic system components, relieve system pressure to avoid injury from pressurized hydraulic oil.
Installation (Fig. 46) CAUTION Use eye protection such as goggles when using compressed air. 6. Clean cartridge valve using clean mineral spirits. Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves. If cartridge design allows, use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination. Be extremely careful to not damage cartridge.
Chapter 8 Four Wheel Drive (Optional Kit) Table of Contents SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Front Wheel Drive Operation . . . . . . . . . . . . . . . . . 3 Installation Instructions . . . . . . . . . . . . . . . . . . . . . . 3 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 4 CV (Constant Velocity) Axle Assembly . . . . . . . . . 4 Test CV Axle . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Front Differential (Optional Kit) Ring and Pinion with Dual Bi−Directional Clutches Front Differential Oil Mobil 424 Front Differential Oil Capacity Four Wheel Drive (Optional Kit) 6 fluid ounces (180 milliliter) system capacity Page 8 − 2 Workman HDX Auto
General Information Front Wheel Drive Operation The Automatic on Demand front wheel drive feature on Workman HDX Auto vehicles equipped with the optional four wheel drive kit does not require operator activation. The front differential on Workman Auto vehicles equipped with the optional four wheel drive kit is an electro−mechanically activated bi−directional overrunning clutch system.
Service and Repairs CV (Constant Velocity) Axle Assembly Antiseize Lubricant 1 8 Antiseize Lubricant 10 6 170 to 180 ft−lb (231 to 244 N−m) 5 3 35 to 40 ft−lb (48 to 55 N−m) 20 9 7 16 2 11 19 8 17 1 19 18 2 20 17 10 4 15 14 RIGHT 11 35 to 40 ft−lb (48 to 55 N−m) FRONT 12 13 Figure 1 1. 2. 3. 4. 5. 6. 7. Spindle nut CV axle assembly (2) Differential assembly Flange head screw (4) Driveshaft Cap screw Lock nut Four Wheel Drive (Optional Kit) 8. 9. 10. 11. 12. 13. 14.
Test CV Axle 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. LEVERAGE POINT 1 1. Test drive vehicle on a smooth surface to verify CV axle joint problem. 2 LEVERAGE POINT A. If the noise remains constant, the wheel bearing is the likely problem and, if so, the wheel hub assembly must be replaced. B.
CV Axle Boots 12 2 4 10 9 9 1 3 10 11 8 5 6 7 Figure 3 1. 2. 3. 4. Center shaft Outboard joint housing Outboard CV joint Spring clip 5. 6. 7. 8. Inboard joint housing Inboard CV joint Inner retaining ring Outer retaining ring A torn CV axle boot is the most common cause of CV axle failures. Look for grease on front suspension components, inner tire sidewall or fender to indicate a possible torn boot. Inspect boots for cracks, holes, tears or loose clamps.
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Front Differential Driveshaft 1 Antiseize Lubricant 2 4 Antiseize Lubricant 3 6 5 9 RIGHT 8 9 FRONT 6 7 Figure 4 1. Transmission 2. Cap screw 3. Lock nut Four Wheel Drive (Optional Kit) 4. Front differential driveshaft 5. Front differential assembly 6. CV axle assembly (2) Page 8 − 8 7. Flange head screw (4) 8. Mount (4) 9.
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 (item 2) and lock nut (item 3) that secure the front driveshaft yoke to front differential input shaft. 3. Remove four (4) flange head screws (item 4) and lower differential plate (item 17) that secure the front differential to the frame. 4. Align splines in driveshaft yokes with shaft splines.
Driveshaft Cross and Bearing Service 6 4 1 2 3 6 FRONT 2 5 Figure 6 1. Drive shaft 2. Cross and bearing kit (2) 3. Connect yoke (to front differential) 4. Slip yoke (to transmission) 5. Grease fitting 6. Snap ring (4 used per cross) Disassembly (Fig. 6) Assembly (Fig. 6) 1. Remove front differential driveshaft from vehicle (see Front Differential Driveshaft in this section). 1.
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Front Differential Antiseize Lubricant 1 8 Antiseize Lubricant 10 170 to 180 ft−lb (231 to 244 N−m) 5 3 6 35 to 40 ft−lb (48 to 55 N−m) 9 7 16 2 11 8 17 1 2 10 15 14 11 12 13 RIGHT FRONT 35 to 40 ft−lb (48 to 55 N−m) 18 17 4 Figure 7 1. 2. 3. 4. 5. 6. Spindle nut (2) CV axle assembly (2) Differential assembly Flange head screw (4) Driveshaft Cap screw Four Wheel Drive (Optional Kit) 7. 8. 9. 10. 11. 12.
Removal (Fig. 7) Installation (Fig. 7) 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. IMPORTANT: Make sure to not damage brake lines, electrical harness, control cables or other parts while installing the differential to the vehicle. 2. Drain front differential oil into a suitable container by removing the drain plug. Install drain plug after draining. 3.
Front Differential Service 8 to 30 ft−lb (11 to 17 N−m) 4 14 to 20 ft−lb (19 to 27 N−m) 11 2 14 6 13 27 32 7 21 31 20 14 to 20 ft−lb (19 to 27 N−m) 24 22 23 26 18 4 29 3 10 9 25 17 30 8 5 19 16 8 to 30 ft−lb (11 to 17 N−m) 12 28 10 1 5 20 15 Figure 8 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. O−ring O−ring Set screw Flange head screw (9) Bearing (2) Bearing Bushing Bushing Bushing Oil seal (2) Oil seal Four Wheel Drive (Optional Kit) 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Disassembly of Front Differential 1. Make sure that the oil is drained from the front differential assembly. 2 2. Remove the four (4) flange head screws from the input cover (Fig. 9). Remove the cover. 1 Figure 9 1. Input cover 2. Pinion gear shaft 3. Remove the pinion gear with bearing from housing by pulling it out of the gear case by hand (Fig. 10). 2 1 Figure 10 1. Pinion gear shaft 2. Gear case 4. Inspect the inner pinion bushing in the gear case (Fig. 11).
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 assembly to gear case. Note location of plug clip for assembly purposes (Fig. 12). Carefully remove the cover plate from the gear case by lifting straight up. 3 2 Figure 12 1. Cover plate 2. Gear case 3. Plug clip 7. Remove the thrust bearing from the cover plate and inspect for wear (Fig. 13).
9. Carefully lift the ring gear out of the gear case (Fig. 15). Inspect ring gear teeth for any damage or abnormal wear. Also, inspect inner surface of ring gear for excessive wear caused by the rollers. 1 2 Figure 15 1. Ring gear 2. Gear case 10.Remove the gear shim from between the gear case and the ring gear location (Fig. 16). 1 2 Figure 16 1. Gear spacer 2. Gear case IMPORTANT: When removing output hub from gear case, be careful to not damage the seal in the gear case.
12.Place the cover plate on the workbench with the output hub facing up. 13.Using a screwdriver, carefully remove the internal retaining ring from the cover plate (Fig. 18). 1 2 Figure 18 1. Output hub 2. Retaining ring 14.Remove the gear spacer from the cover plate (Fig. 19). 1 2 Figure 19 1. Output hub 2. Gear spacer 15.Remove the armature plate from the cover plate (Fig. 20). 1 IMPORTANT: When removing output hub from cover plate, be careful to not damage the seal in the cover plate.
Assembly of Front Differential 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. Carefully install new square sectioned O−ring into the groove in the cover plate. 1 IMPORTANT: When installing output hub assembly into cover plate, be careful to not damage the seal in the cover plate. The seal cannot be serviced separately. NOTE: The output hub that is installed in the cover plate has an extended bushing.
IMPORTANT: When installing output hub assembly into gear case, be careful to not damage the seal in the gear case. The seal cannot be serviced separately. 2 3 6. Press the new 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 install. Take care to not damage the seal during installation of the output hub assembly. 7.
11. Install the thrust bearing onto the thrust button in the cover plate (Fig. 27). Make sure that the tang on the side of the thrust bearing is located toward the outer edge of the cover plate. Use grease or petroleum jelly on the back side of the thrust plate to keep the bearing in position while assembling the cover plate assembly to the gear case. 1 IMPORTANT: When installing the cover plate, make sure that the tangs on the armature plate are properly aligned into the slots on the roller cage.
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Chapter 9 Electrical Drawings Table of Contents Electrical Drawings System ELECTRICAL DRAWING DESIGNATIONS . . . . . . . 2 Wire Color . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Wire Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 VEHICLE ELECTRICAL SCHEMATIC Electrical Schematic (Serial Numbers 314000001 to 403430000) . . . . . . . . . . 3 Electrical Schematic (Serial Numbers Above 403430001) . . . . . . . . . . . . . . . .
Electrical Drawing Designations NOTE: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire harness diagram (e.g. SP01 is splice number 1). Wire Color The following abbreviations are used for wire harness colors on the electrical schematics and wire harness drawings in this chapter.
6 5 4 3 2 1 122--0090 REV. B D D C C B B A Workman HDX Auto Vehicle Electrical Schematic (Serial Numbers 314000001 to 403430000) A All relays and solenoids are shown as de-- energized.
122--1466 Rev. A Workman HDX Auto Vehicle Electrical Schematic (Serial Numbers Above 403430001) (All relays and solenoids are shown as de− energized.
6 5 4 3 2 1 122--0088 REV.
6 5 4 3 2 1 122--0088 REV.
6 5 4 3 2 1 122--0823 REV.
6 5 4 3 2 1 122--0823 REV.
122--1449 Rev.
122--1449 Rev.
6 5 4 3 2 1 122--0089 REV.
6 5 4 3 2 1 122--0089 REV.
6 5 4 3 2 1 122--0589 REV.
6 5 4 3 2 1 D D C C B B A Drawing No: 120--3996 Rev.
