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(Serial No. 240000001 and Above)

PART NO. 03126SL (Rev.D)

Service Manual

Workman

R

3000/4000 Series

Preface

The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Workman 3000/4000 Series vehicles.

REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING,

MAINTENANCE

AND

ADJUSTMENT

INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manuals and Parts Cata-
logs for your vehicle. Replacement Operator’s Manuals
are available on the internet at www.toro.com.

The Toro Company reserves the right to change product
specifications or this publication without notice.

This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.

NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.

E

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

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Summary of Contents for Workman 3000 Series

Page 1: ...lacement Operator s Manuals are available on the internet at www toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOT...

Page 2: ...This page is intentionally blank Workman 3000 4000 Series ...

Page 3: ... and Repairs 5 3 KOHLER ENGINE SERVICE MANUAL Workman 3000 4000 Series Chapter 6 Drive Train General Information 6 2 Specifications 6 3 Special Tools 6 4 Adjustments 6 5 Troubleshooting 6 6 Service and Repairs 6 10 Chapter 7 Chassis Specifications 7 2 Special Tools 7 3 Troubleshooting 7 4 Service and Repairs 7 8 Chapter 8 Electrical System Electrical Schematics 8 2 Special Tools 8 2 Troubleshootin...

Page 4: ...This page is intentionally blank Workman 3000 4000 Series ...

Page 5: ...nts Chapter 10 Front Wheel Drive 4WD Specifications 10 2 General Information 10 3 Service and Repairs 10 4 Chapter 11 Electrical Schematics Vehicle Electrical Schematics 11 3 Wire Harness Drawings 11 10 Front Wheel Drive 4WD Electrical Schematics ...

Page 6: ...This page is intentionally blank Workman 3000 4000 Series ...

Page 7: ...er 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 3 Maintenance and Service 4 Jacking Vehicle 5 Using Bed Safety Support 6 Safety Workman 3000 4000 Series Page 1 1 Safety ...

Page 8: ...the controls and know how to stop the vehicle and engine quickly A re placement Operator s Manual is available on the Inter net at www Toro com 2 Keep all shields safety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the ve hicle Also tighten any loose nuts bolts or screws to en sure vehicle is in safe operatin...

Page 9: ... pedal E Turn ignition key to START 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly 4 Do not touch engine radiator muffler or exhaust pipe while engine is running or soon after it is stopped These areas could be hot enough to cause burns 5 Before getting off the seat A Stop movement of the vehicle B Lower bed C Shut engi...

Page 10: ...or an adjustment keep clothing hands feet and other parts of the body away from moving parts Keep by standers away 10 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 11 Shut engine off before checking or adding oil to the engine crankcase 12 Disconnect battery before servicing the vehicle Dis connect negative battery cable first and...

Page 11: ...injury 1 Do not start engine while vehicle is on jack because engine vibration or wheel movement could cause ve hicle to slip off jack 2 Do not work under vehicle without jack stands sup porting it The vehicle could slip off jack injuring any one beneath it 3 The jacking point at the front of the vehicle is under the front center frame support and at the rear it is under the axle tube 4 When jacki...

Page 12: ...port on a fully installed cylinder port insert into storage brackets on back of ROPS panel and lower bed 1 Bed safety support Figure 3 3 Bed 1 Raise bed until lift cylinders are fully extended 2 Cylinder barrel 2 Remove bed safety support from storage brackets on back of ROPS panel 3 Push bed safety support onto cylinder rod making sure support end tabs rest on end of cylinder barrel and on cylind...

Page 13: ... Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 MAINTENANCE 7 Product Records Insert Operator s Manual and Parts Catalog for your Workman at the end of this chapter Refer to Operator s Manual for recommended maintenance intervals Addi tionally insert Installation Instructions Operator s Manuals Parts Catalogs and Service Manuals for any accessories that have been i...

Page 14: ...Rev D 0 09375 Workman 3000 4000 Series Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 15: ...stener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength...

Page 16: ...3 47 4 50 4 68 5 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 5 75 7 77 7 104 9 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 10 142 14 1 2 20 UNF 32 3 53 7 72 9 85 8 115 11 120 10 163 14 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 UNC 93 12 140 20 190 27 265 25 359 34 375 35 508 47 3 4 16 UN...

Page 17: ... N m 229 22 ft lb 310 30 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 N m Product Records and Maintenance NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into th...

Page 18: ...s Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in lb No 8 32 UNC 30 5 in lb No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb 3 8 16 UNC 200 100 in lb Thread Size Size Threads per Inch Baseline Torque Baseline Torque Type A Type B No 6 18 20 20 5 in lb No 8 15 18 30 5 in lb No 10 12 16 38 7 in ...

Page 19: ...hat publication when per forming regular equipment maintenance Several main tenance procedures have break in intervals identified in the Operator s Manual Refer to the Engine Operator s Manual for additional engine specific maintenance pro cedures Product Records and Maintenance Workman 3000 4000 Series Page 2 7 Product Records and Maintenance ...

Page 20: ...This page is intentionally blank Product Records and Maintenance Page 2 8 Workman 3000 4000 Series ...

Page 21: ...ures are described in your Operator s Manual Information on engine trou bleshooting testing disassembly and reassembly is identified in the Briggs Stratton Daihatsu Repair Manual that is included at the end of this section Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Briggs Stratton Daihatsu Repair Manual The use o...

Page 22: ...d Fuel Pump 12 VDC Fuel Unleaded regular grade 87 octane minimum Fuel Tank Capacity liter U S gal 26 7 Governor Mechanical Idle Speed no load 1100 50 RPM High Idle no load 3600 50 RPM Engine Oil API Service Classification SH or better see Operator s Manual for viscosity Oil Pump Gear driven trochoid type Crankcase Oil Capacity liter U S qt 3 3 3 5 with filter Water Pump Belt driven centrifugal typ...

Page 23: ... fill device and the oil fill opening in the valve cover Fig 1 This clearance is necessary to allow vent ing when adding engine oil which will prevent oil from running into the breather tube and intake system Figure 1 Briggs Daihatsu Gasoline Engine Workman 3200 4200 Page 3 3 Briggs Daihatsu Gasoline Engine ...

Page 24: ...e governor lever C Position the rear edge of the bellcrank so it is 0 125 in 3 2 mm from the head of the low idle stop screw Fig 4 At this position the governor spring must be tight against the upper edge of the engine governor lever slot with no extension of the spring coils If necessary adjust low idle stop screw and or governor spring adjusting rod if equipped to allow correct governor spring p...

Page 25: ...igh idle speed High idle speed should be 3600 50 RPM Reposition the high idle stop screw to adjust high idle speed Make sure to tighten lock nut af ter adjusting high idle stop screw 10 After engine speed adjustments are complete lower the bed or install attachment s Figure 5 1 Throttle bracket 2 High idle stop screw 3 Idle stop screw 4 Governor spring 5 Bellcrank 6 Jam nut 7 Return spring 8 Adj r...

Page 26: ...nut 4 used 9 Cap screw 4 used 10 Flange nut 4 used 11 Magnetic catch 2 used 12 Radiator cap 13 Hose to coolant reservoir 14 Cap screw 4 used 15 Hose clamp 16 Upper radiator hose 17 Screw 2 used 18 Flat washer 19 Lock nut 4 used 20 Handle 21 Radiator cover screen 22 Cap screw 4 used 23 Lock washer 4 used 24 Fan 25 Idler pulley 26 Mount plate FRONT RIGHT 8 7 6 9 1 5 4 3 2 18 17 16 19 10 15 14 13 12 ...

Page 27: ...om the radiator filler neck 7 Detach fan shroud from the radiator by removing four 4 cap screws flat washers and lock nuts Position shroud away from radiator 8 Remove four 4 cap screws and flange nuts that se cure the radiator to the frame Pull radiator from the ve hicle 9 Plug all radiator and hose openings to prevent con tamination Installation Fig 5 1 Remove plugs from radiator and hoses placed...

Page 28: ...spacer 4 used 14 Rubber coupling 15 Flat washer 4 used 16 Cap screw 2 used 17 Cap screw 2 used 18 Driveshaft Figure 6 1 Lock nut 7 Bearing spacer 2 Flat washer 8 Shaft 3 Woodruff key 9 Lock nut 6 used 4 Pump drive belt 10 Frame support bracket 5 Pulley 11 Cap screw 4 used 6 Bearing 12 Coupling spacer 4 used Briggs Daihatsu Gasoline Engine Page 3 8 Workman 3200 4200 ...

Page 29: ...rt bracket by pressing on bearing outer race until bearing contacts shoulder in support bracket B Place the bearing spacer Item 7 into bracket ca vity C Install second bearing into bracket by pressing on the bearing outer race until bearing inner race con tacts spacer 2 Slide shaft Item 8 into installed bearings in frame support bracket Apply antisieze lubricant to pulley end of shaft before insta...

Page 30: ...HT 8 7 6 9 1 5 4 3 2 17 16 15 18 10 14 13 12 11 20 21 19 22 23 Thread Sealant 24 Sender Ground Wire 13 25 26 27 DANGER Because gasoline is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when vehicle is in an enclosed area Always fill fuel tank outside and wipe up any spilled fuel before startin...

Page 31: ...k to vehicle make sure that hydraulic lift cylinder does not con tact tank 2 Position fuel tank to tank straps and fuel tank sup ports Hook tank straps to fuel tank supports Tighten socket head screws and lock nuts to secure fuel tank 3 If fuel fitting was removed from tank apply thread sealant to threads of fitting before installing fitting into tank 4 Connect electrical wiring to the fuel sender...

Page 32: ...ngine 2 Hose clamp 3 Air intake hose 4 Radiator hose 5 Air inlet hood 6 Air cleaner hose 7 Air cleaner assembly 8 Flange nut 2 used 9 Clamp 10 Mounting band 11 Mount bracket 12 Cap screw 2 used 13 Flange nut 2 used 14 R clamp FRONT RIGHT 1 2 8 7 6 9 5 4 3 2 10 11 12 13 8 14 VACUATOR DIRECTION ...

Page 33: ...Installation Fig 8 IMPORTANT Any leaks in the air filter system will cause serious engine damage Make sure daily that all air cleaner components are in good condition and are properly secured during reassembly 1 Reassemble air cleaner system using Figures 8 and 9 as guides Air cleaner hose item 6 and air inlet hood item 5 should be positioned straight upward The va cuator valve on the air cleaner ...

Page 34: ... Hex nut 4 used 5 Exhaust manifold 6 Socket head screw 4 used 7 Cap screw 2 used 8 Flange nut 4 used 9 Cap screw 10 Hardened washer 11 Flange nut 4 used 12 Carriage bolt 2 used 13 Mount plate 14 Cap screw 15 Muffler 16 Transaxle 17 Shift cable mount bracket FRONT RIGHT Loctite 242 8 7 6 9 10 11 16 15 14 5 13 12 4 3 2 1 11 3 17 ...

Page 35: ...r equivalent to threads during installation 3 Using Figure 10 as a guide fit all exhaust compo nents to vehicle before tightening any fasteners When securing exhaust tighten fasteners in the following or der A Hex nuts item 4 that secure exhaust manifold to engine B Cap screw item 9 with washer item 10 that se cures muffler to transaxle C Socket head screws item 6 and flange nuts item 8 that secur...

Page 36: ...lerator cable 14 Bellcrank 15 Upper radiator hose 16 Hose clamp 17 Engine mount 18 Lock washer 8 used 19 Cap screw 8 used 20 Fusible link harness 21 Positive battery cable 22 Lock washer 23 Hex nut 24 Wire harness solenoid lead 25 Lower radiator hose 26 Hose clamp 27 Hex nut 28 Engine cover 29 Washer 30 Cap screw 31 Cap screw 32 Return spring 33 Governor spring FRONT RIGHT 2 3 5 4 1 7 8 9 6 10 30 ...

Page 37: ...switch temperature sender on water pump housing and high tempera ture switch D Harness connector and wire with ring terminal from alternator E Wires from fuel solenoid and choke assembly on carburetor F Six wires from ignition coils G Two harness connectors from ignition controller H Harness connector from crankshaft sensor 8 Disconnect accelerator cable from bellcrank on en gine Position accelera...

Page 38: ...le and the other person should help guide en gine out of chassis Move engine forward before lifting to disengage transaxle input shaft from clutch 18 Note location and retrieve two 2 dowel pins from bell housing Fig 14 19 If necessary remove engine mount from engine 20 If pressure plate and clutch disc removal is neces sary see Clutch Disassembly and Inspection in Chapter 6 Drive Train Engine Inst...

Page 39: ...Briggs Daihatsu Gasoline Engine This page is intentionally blank Workman 3200 4200 Page 3 19 Briggs Daihatsu Gasoline Engine ...

Page 40: ...pring 4 Lock nut 5 Ball joint 6 Accelerator cable 7 Lock washer 3 used 8 Flange head screw 3 used 9 Grease fitting 10 Shoulder bolt 11 Bellcrank 12 Governor spring 13 Idle stop screw 14 High idle stop screw 15 Throttle bracket 16 Lock nut 17 Spring adjusting rod if equipped FRONT RIGHT 2 3 5 4 1 7 6 8 11 12 14 13 10 9 16 15 2 17 ...

Page 41: ...sary see Engine Speed Adjustment in Ad justments section of this chapter 5 After engine speed has been checked and adjusted check operation and adjustment of accelerator cable see Operator s Manual If needed adjust accelerator cable Figure 18 1 Governor spring 2 Bellcrank 3 Engine governor lever 4 High idle stop screw 5 Low idle stop screw 6 Return spring 2 4 1 3 5 6 NOT EQUIPPED WITH GOVERNOR SPR...

Page 42: ...This page is intentionally blank Briggs Daihatsu Gasoline Engine Page 3 22 Workman 3200 4200 ...

Page 43: ...s are described in your Operator s Manual Information on engine trou bleshooting testing disassembly and reassembly is identified in the Briggs Stratton Daihatsu Repair Man ual that is included at the end of this section Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Briggs Stratton Daihatsu Repair Manual The use of ...

Page 44: ...Pump Bosch VE Distributor type Fuel Injector Nozzle Bosch throttle type Fuel Tank Capacity liter U S gal 26 7 Governor Mechanical Idle Speed no load 1500 50 RPM High Idle no load 3600 50 RPM Engine Oil API Classification CF or better see Operator s Manual for viscosity Oil Pump Gear driven trochoid type Crankcase Oil Capacity liter U S qt 3 3 3 5 with filter Water Pump Belt driven centrifugal type...

Page 45: ... fill device and the oil fill opening in the valve cover Fig 1 This clearance is necessary to allow vent ing when adding engine oil which will prevent oil from running into the breather tube and intake system Figure 1 Briggs Daihatsu Diesel Engine Workman 3300 D 4300 D Page 4 3 Briggs Daihatsu Diesel Engine ...

Page 46: ...incorrect adjust idle speed screw Fig 2 A Loosen lock nut on idle speed screw B Adjust idle speed screw to obtain 1500 50 RPM C Tighten lock nut Recheck idle speed 6 Increase engine speed to high idle Use a tachome ter to check that engine is operating at 3600 50 RPM 7 If high idle speed is incorrect adjust high speed screw on fuel injection pump Fig 3 A Loosen lock nut on high speed screw B Adjus...

Page 47: ...Briggs Daihatsu Diesel Engine This page is intentionally blank Workman 3300 D 4300 D Page 4 5 Briggs Daihatsu Diesel Engine ...

Page 48: ... nut 4 used 9 Cap screw 4 used 10 Flange nut 4 used 11 Magnetic catch 2 used 12 Radiator cap 13 Hose to coolant reservoir 14 Cap screw 4 used 15 Hose clamp 16 Upper radiator hose 17 Screw 2 used 18 Flat washer 19 Lock nut 4 used 20 Handle 21 Radiator cover screen 22 Cap screw 4 used 23 Lock washer 4 used 24 Fan 25 Idler pulley 26 Mount plate FRONT RIGHT 8 7 6 9 1 5 4 3 2 18 17 16 19 10 15 14 13 12...

Page 49: ...om the radiator filler neck 7 Detach fan shroud from the radiator by removing four 4 cap screws flat washers and lock nuts Position shroud away from radiator 8 Remove four 4 cap screws and flange nuts that se cure the radiator to the frame Pull radiator from the ve hicle 9 Plug all radiator and hose openings to prevent con tamination Installation Fig 4 1 Remove plugs from radiator and hoses placed...

Page 50: ...pacer 4 used 14 Rubber coupling 15 Flat washer 4 used 16 Cap screw 2 used 17 Cap screw 2 used 18 Driveshaft Figure 5 1 Lock nut 7 Bearing spacer 2 Flat washer 8 Shaft 3 Woodruff key 9 Lock nut 6 used 4 Pump drive belt 10 Frame support bracket 5 Pulley 11 Cap screw 4 used 6 Bearing 12 Coupling spacer 4 used Briggs Daihatsu Diesel Engine Page 4 8 Workman 3300 D 4300 D ...

Page 51: ...rt bracket by pressing on bearing outer race until bearing contacts shoulder in support bracket B Place the bearing spacer Item 7 into bracket ca vity C Install second bearing into bracket by pressing on the bearing outer race until bearing inner race con tacts spacer 2 Slide shaft Item 8 into installed bearings in frame support bracket Apply antisieze lubricant to pulley end of shaft before insta...

Page 52: ...r 32 Fitting 33 Fuel hose to engine FRONT RIGHT 8 7 6 9 1 5 4 3 2 17 16 15 18 10 14 13 12 11 20 21 19 22 23 Thread Sealant 24 Sender Ground Wire 25 26 27 28 29 32 30 33 31 13 29 DANGER Because diesel fuel is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when vehicle is in an enclosed area Alwa...

Page 53: ...sitioning fuel tank to vehicle make sure that hydraulic lift cylinder does not con tact tank 2 Position fuel tank to tank straps and fuel tank sup ports Hook tank straps to fuel tank supports Tighten socket head screws and lock nuts to secure fuel tank 3 If fuel fitting was removed from tank apply thread sealant to threads of fitting before installing fitting into tank 4 Connect electrical wiring ...

Page 54: ...Engine 2 Hose clamp 3 Air intake hose 4 Radiator hose 5 Air inlet hood 6 Air cleaner hose 7 Air cleaner assembly 8 Flange nut 2 used 9 Clamp 10 Mounting band 11 Mount bracket 12 Cap screw 2 used 13 Flange nut 2 used 14 R clamp FRONT RIGHT 1 2 8 7 6 9 5 4 3 2 10 11 12 13 8 14 VACUATOR DIRECTION ...

Page 55: ...s Installation Fig 7 IMPORTANT Any leaks in the air filter system will cause serious engine damage Make sure daily that all air cleaner components are in good condition and are properly secured during reassembly 1 Reassemble air cleaner system using Figure 7 and 8 as guides Air cleaner hose item 6 and air inlet hood item 5 should be positioned straight upward The va cuator valve on the air cleaner...

Page 56: ... Hex nut 4 used 5 Exhaust manifold 6 Socket head screw 4 used 7 Cap screw 2 used 8 Flange nut 4 used 9 Cap screw 10 Hardened washer 11 Flange nut 4 used 12 Carriage bolt 2 used 13 Mount plate 14 Cap screw 15 Muffler 16 Transaxle 17 Shift cable mount bracket FRONT RIGHT Loctite 242 8 7 6 9 10 11 16 15 14 5 13 12 4 3 2 1 11 3 17 ...

Page 57: ...r equivalent to threads during installation 3 Using Figure 10 as a guide fit all exhaust compo nents to vehicle before tightening any fasteners When securing exhaust tighten fasteners in the following or der A Hex nuts item 4 that secure exhaust manifold to engine B Cap screw item 9 with washer item 10 that se cures muffler to transaxle C Socket head screws item 6 and flange nuts item 8 that secur...

Page 58: ...screw 12 Washer 13 Cap screw 14 Lock washer 8 used 15 Cap screw 8 used 16 Engine mount 17 Hose clamp 18 Upper radiator hose 19 Throttle bellcrank 20 Accelerator cable 21 Ball joint 22 Throttle bracket 23 Air intake hose 24 Hose clamp 25 Fuel supply hose 26 Hose clamp 27 Fuel hose return 28 Wire harness alternator lead 29 Lock washer 30 Hex nut 31 Flat washer FRONT RIGHT 6 5 4 3 2 1 12 11 10 9 8 7 ...

Page 59: ... pressure switch temperature sender on water pump housing and high tempera ture switch D Harness connector and wire with ring terminal from alternator E Harness connector with ring terminal from glow plug connector F Harness connector from fuel solenoid on injec tion pump G Harness connector from crankshaft sensor 8 Disconnect accelerator cable from throttle lever on engine Position accelerator ca...

Page 60: ...ackle and the other person should help guide en gine out of chassis Move engine forward before lifting to disengage transaxle input shaft from clutch 18 Note location and retrieve two 2 dowel pins from bell housing Fig 13 19 If necessary remove engine mount from engine 20 If pressure plate and clutch disc removal is neces sary see Clutch Disassembly and Inspection in Chapter 6 Drive Train Engine I...

Page 61: ...Briggs Daihatsu Diesel Engine This page is intentionally blank Workman 3300 D 4300 D Page 4 19 Briggs Daihatsu Diesel Engine ...

Page 62: ... 4 7 13 14 2 3 5 7 6 9 8 11 10 5 5 12 15 16 Disassembly Fig 14 1 Remove throttle bracket components from engine as needed using Figure 14 as a guide Assembly Fig 14 1 Install removed throttle bracket components to en gine using Figure 14 as a guide 2 Lubricate bellcrank grease fitting after assembly 3 Check operation and adjustment of accelerator cable see Operator s Manual If needed adjust accel ...

Page 63: ...ly and reassembly is identified in the Kohler Engine Service Manual that is in cluded 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 Engine Service Manu al The use of some specialized test equipment is ex plained However the cost of the test equipment and the specialized nature of so...

Page 64: ...on Ratio 8 5 1 Dry Weight approximate 41 kg 90 lb Fuel Unleaded Regular Gasoline Minimum 87 Octane Fuel Tank Capacity 26 liters 7 U S gal Governor Mechanical Idle Speed no load 1200 100 RPM High Idle no load 3600 50 RPM Engine Oil See Operator s Manual Oil Pump Gear driven trochoid type Crankcase Oil Capacity 1 9 liters 2 U S qt with filter Starter 12 VDC Kohler Gasoline Engine Page 5 2 Workman 31...

Page 65: ...ehicle on a level surface stop engine engage parking brake and remove key from the ignition switch 2 Raise or remove the bed or other attachment s If bed is raised place safety support on lift cylinder see Operator s Manual IMPORTANT Never clean engine with pressurized water Water could enter and contaminate the fuel system 3 Clean cooling fins on both cylinder heads 4 Clean grass screen and blowe...

Page 66: ... 17 16 15 18 10 14 13 12 11 20 21 19 22 23 Thread Sealant 24 Sender Ground Wire 13 25 26 DANGER Because gasoline is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when vehicle is in an enclosed area Always fill fuel tank outside and wipe up any spilled fuel before starting the engine Store fuel...

Page 67: ...NT Make sure that hydraulic lift cylinder does not contact fuel tank 2 Position fuel tank to tank straps and fuel tank sup ports Hook tank straps to fuel tank supports Tighten socket head screws and lock nuts to secure fuel tank 3 If fuel fitting was removed from tank apply thread sealant to threads of fitting before installing fitting into tank 4 Connect electrical wiring to the fuel sender A Con...

Page 68: ...used 4 Exhaust gasket 2 used 5 Flange nut 6 Screw 7 Cap screw 8 Bracket 9 Muffler gasket 10 Flange nut 4 used 11 Cap screw 12 Hardened washer 13 Carriage bolt 2 used 14 Mount plate 15 Cap screw 16 Muffler 17 Cap screw 2 used 18 Shift cable mount bracket FRONT RIGHT Loctite 242 8 7 6 9 10 11 17 16 5 15 14 1 5 13 12 4 3 2 5 12 18 ...

Page 69: ...ng installation 3 Using Figure 3 as a guide fit all exhaust components to vehicle before tightening any fasteners When secur ing exhaust tighten fasteners in the following order A Hex nuts item 3 that secure manifold to engine B Cap screw item 11 with washers item 12 that secures muffler to transaxle C Socket head screws item 1 and flange nuts item 10 that secure muffler to manifold D Cap screws i...

Page 70: ... battery cable 37 Lock nut 4 used 38 Flat washer 4 used 39 Engine mount 40 Cap screw 4 used 41 Lock washer 42 Pump drive belt 43 Engine assembly FRONT RIGHT 30 29 28 27 26 25 24 31 23 19 32 22 21 20 35 33 34 14 16 15 17 13 12 11 10 41 9 7 7 8 6 18 5 36 4 3 2 1 43 42 40 39 38 37 35 to 41 ft lb 47 to 56 N m Anti seize Lubricant Anti seize Lubricant Engine Removal Fig 4 1 Put vehicle on a level surfa...

Page 71: ...ig 6 15 Use a hoist or block and tackle to remove engine from chassis One person should operate hoist or block and tackle and the other person should help guide en gine out of chassis Move engine forward before lifting to disengage transaxle input shaft from clutch 16 Note location and retrieve two 2 bushings Fig 6 item 2 from bell housing 17 If necessary remove hydraulic pump drive pulley from st...

Page 72: ... removed from en gine apply antiseize lubricant on shaft surface before installing pulley 4 To install the engine perform Engine Removal steps in reverse order Scrape RTV sealant off engine bell housing surface Apply new sealant in same area during engine installation seize lubricant to bolt shoulder before installing 6 Install a new engine oil filter Fill engine with the cor rect oil see Operator...

Page 73: ...REPAIRS 10 Shift Cable Replacement 10 Stub Axle and Drive Shaft Service 12 Drive Shaft Universal Joint Service 14 P T O Removal and Installation If Equipped 15 Transaxle 16 Removal 17 Installation 18 Clutch Service 20 Transaxle Service 22 Disassembly 22 Inspection 33 Assembly 37 Power Take Off PTO Service 54 Disassembly 54 Inspection 58 Assembly 59 Workman 3000 4000 Series Page 6 1 Drive Train Dri...

Page 74: ...d PTO operates at 540 RPM The transaxle with automotive type clutch is bolted to the engine with the engine transaxle assembly isolation mounted to the vehicle frame Two heavy duty universal drive shafts transfer power from the transaxle to the rear wheels A fully indepen dent rear suspension and Dedion type rear axle isolate the mid mounted engine transaxle assembly from the terrain The transaxle...

Page 75: ...Specifications Item Specification Transaxle Oil Dexron III ATF Transaxle Oil Capacity 8 quart U S 7 6 liter system capacity Workman 3000 4000 Series Page 6 3 Drive Train Drive Train ...

Page 76: ...4 Drive Train Special Tools Order special tools from your Toro Distributor Clutch Alignment Tool Use clutch alignment tool Part No TOR6002 to align clutch friction disk to engine flywheel before tightening pressure plate cap screws Figure 2 ...

Page 77: ...rm 2 Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in PTO lever arm 3 Reinstall clevis pin and tighten jam nut after adjust ment 3 1 4 2 Figure 3 1 PTO lever arm 3 Clevis pin 2 PTO cable 4 Clevis jam nut Workman 3000 4000 Series Page 6 5 Drive Train Drive Train ...

Page 78: ...ly Damaged clutch disc Excessive wear of clutch disc facing Weak or broken clutch torsion spring Damaged or broken clutch pressure plate Bent or broken clutch diaphragm spring tip Dirty or improperly lubricated clutch disk spline Damaged or distorted flywheel Damaged release bearing Clutch noisy Improper installation of clutch cover assembly Excessive wear of clutch disc facing Worn clutch disc sp...

Page 79: ...rusted clutch disc spline Damaged pressure plate or flywheel Damaged release bearing Clutch chatters Worn or damaged clutch disc facing Oil adhered to clutch disc facing Uneven height of diaphragm spring Weak or damaged clutch torsion spring Damaged pressure plate or flywheel Damaged clutch release bearing Loose or worn front wheel bearings Workman 3000 4000 Series Page 6 7 Drive Train Drive Train...

Page 80: ...Cable clamp securing cables near shifter is loose Sliding gear tight on shaft or splines Synchronizing unit damaged Sliding gear teeth damaged Synchronizer keys damaged Gears make clashing noise when shifting Shifting too fast Excessive wear of synchro rings Excessive wear of differential side gear liners and pinion liners Damaged synchro springs and or keys Main gear needle bearings worn or damag...

Page 81: ...stment Gear loose on shaft Gear teeth worn Excessive end play in gears Lack of spring pressure on shift fork detent ball Badly worn bearings Overheating of transaxle Oil level too high Excessive hydraulic load See Chapter 9 Hydraulic System Workman 3000 4000 Series Page 6 9 Drive Train Drive Train ...

Page 82: ...Shift pin 6 Jam nut 7 Cotter pin 8 Clevis pin 9 Shift lever 10 Shift link 11 Cable clevis 12 Cap screw 13 Lower shift boot 14 Lock nut 15 Lever support 16 Hex nut 2 used 17 Shift stop bolt 2 used 18 Screw 3 used 19 Cable clamp Figure 4 FRONT RIGHT 180 to 210 in lb 5 1 4 3 2 9 11 10 7 6 18 8 12 13 15 17 16 14 10 7 8 6 11 4 19 20 3 to 23 7 N m ...

Page 83: ...igure 6 Tighten jam nut to secure clevis to cable 3 Connect shift cable to shift link Item 10 on shifter in operator platform by inserting clevis pin Item 8 from the passenger side then install cotter pin 4 Secure shift cables to lever support with cable clamp Item 19 and three screws Item 18 5 Spread jam nuts on bulkhead fitting of cable Fig 7 With cable properly routed to transaxle install cable...

Page 84: ... 680 40 to 60 ft lb 54 to 81 N m 35 to 42 ft lb 47 to 57 N m Disassembly Fig 8 1 Loosen wheel nuts 2 Jack up rear of vehicle and support vehicle with jack stands see Jacking Instructions in Operator s Manual Remove wheel nuts and then remove wheel assembly NOTE It may be necessary to back off brake adjuster to remove brake drum To back off adjuster rotate brake drum until access hole lines up with...

Page 85: ...ward the bearing 12 Install new seal over shaft and into housing with the seal lip inward Be careful not to damage the seal during installation Assembly Fig 8 1 If driveshaft was removed from transaxle apply anti seize lubricant to transaxle shaft Slide driveshaft clamp end onto splined transaxle shaft 2 If removed install axle housing to frame A Position axle housing to frame and install three ca...

Page 86: ... Item 3 C Insert cross into yoke and bearing D Hold cross in alignment and press bearing in until it hits the yoke E Install snap ring into groove by first bearing cap installed F Place second bearing into yoke bore and onto cross shaft Press second bearing into yoke G Tap axle yoke outward with hammer and align ment punch to allow 2nd snap ring to fit Install snap ring H Repeat procedure for othe...

Page 87: ...move two alignment pins PTO Installation 1 Apply multi purpose grease to O ring and insert O ring into groove of transaxle case Insert 2 alignment pins in transaxle case IMPORTANT When installing PTO assembly make sure O ring is properly positioned in groove 2 Install PTO to transaxle Tighten cap screws and nut with lockwasher to a torque from 11 to 13 ft lb 15 to 17 N m 3 Install hydraulic hose t...

Page 88: ...ed 4 Transaxle mount 2 used 5 Lock nut 4 used 6 Cap screw 2 used 7 Cap screw 4 used 8 Shift arm 9 Nut 3 used 10 Hardened washer 3 used 11 Shift lever 2 used 12 Differential lock lever 13 Strainer 14 Shift cable mount bracket 15 Negative battery cable Figure 13 FRONT RIGHT 5 1 4 3 2 9 6 12 11 10 7 8 2 3 13 Loctite 242 Loctite 242 15 14 ...

Page 89: ...ver at left rear of transaxle Fig 16 10 Disconnect shifter control cables from levers on transaxle and PTO Do not loosen cable jam nuts at shift cable mount bracket 11 Remove shift cable mount bracket from transaxle keeping shifter control cables attached to bracket Posi tion bracket away from transaxle 12 On Workman 4000 series vehicles 4 Wheel Drive remove differential drive shaft bidirectional ...

Page 90: ...lease bearing A When installing driveshafts to transaxle align mounting holes in driveshaft with relief in transaxle shaft Install cap screws hardened washers and flange nuts to secure driveshaft to transaxle shaft Torque fasteners from 35 to 42 ft lb 47 to 57 N m B Apply Loctite 242 or equivalent to the threads of cap screws used to secure the control cable sup port bracket to the transaxle C Bef...

Page 91: ...This page is intentionally blank Workman 3000 4000 Series Page 6 19 Drive Train Drive Train ...

Page 92: ...ft of transaxle for wear or damaged splines 3 Remove roll pin Item 1 then remove throw out bearing Item 2 Inspect bearing and replace if it is loose on the sleeve if it appears burned or is worn Make sure bearing slides freely on release guide Item 3 4 Inspect clutch fork Item 4 release shaft Item 5 and bushings Item 6 for wear or damage Inspect ex tension spring Item 14 Replace worn or damaged pa...

Page 93: ... 0 307 to 0 339 in 7 8 to 8 6 mm Clutch disk rivet sink 0 012 in 0 3 mm minimum 9 Check for torsion spring play or damage Replace clutch disk if necessary 10 Install clutch disk on transaxle main shaft Make sure clutch slides freely on splines of shaft Check for exces sive play in rotating direction 11 Inspect flywheel surface for stepped wear streaking or seizure Replace if necessary Clean any oi...

Page 94: ...an outside surface of transaxle Figure 25 4 Loosen cap screws Item 1 and remove fork shaft case Item 2 from center plate Note location of longer cap screw Be careful when removing cover as steel balls inside are spring loaded 1 2 2 1 Figure 26 5 Hold your hand over the area and shift R 1 and 2 3 levers to move rails outward so balls Item 3 springs Item 2 and spindle Item 1 can be removed 6 Inspect...

Page 95: ...nt drive shaft and 41T gear from the gear case Remove bearings from gear case see Item 2 of Fig 30 and center plate SHAFT BEARING GEAR CASE BEARING 41T GEAR FRONT DRIVE CENTER PLATE Figure 29 9 Remove reverse shaft Item 1 from transaxle case 1 2 Figure 30 10 Remove main shaft assembly Item 1 together with fork shaft assembly Item 2 from transaxle case 2 1 Figure 31 Workman 3000 4000 Series Page 6 ...

Page 96: ...em 3 from L H side cover Item 4 still attached to transaxle Figure 33 13 Remove roll pin from differential lock lever Remove lever Item 1 from shaft Loosen cap screws Item 2 and remove L H side cover Item 3 from transaxle case 14 Inspect side cover for cracks or damage and replace if necessary 3 1 2 Figure 34 15 Loosen cap screws Item 1 and remove R H axle shaft assembly Item 2 from transaxle case...

Page 97: ... 1 together with fork shaft assembly Item 2 2 1 Figure 36 17 Remove washer Item 1 from inside of transaxle case NOTE Washer may stick to fork shaft when re moved in step 16 1 Figure 37 Workman 3000 4000 Series Page 6 25 Drive Train Drive Train ...

Page 98: ... Rev shift arm Item 11 and High Low shift arm not shown Remove shift arms C Loosen cap screws Fig 39 Item 12 and remove keeper plates Item 13 D Remove oil seals Item 14 E Inspect shift arms and keeper plates for bending or damage and replace if necessary 19 If P T O cover is on transaxle remove cap screws Item 1 and nut Item 2 with washer Separate P T O cover Item 3 from transaxle case Inspect P T...

Page 99: ...rom transaxle case if necessary 21 Remove air breather Item 2 if necessary 2 1 Figure 41 22 Loosen cap screws Item 1 and remove upper cover Item 2 from transaxle case 1 2 Figure 42 Workman 3000 4000 Series Page 6 27 Drive Train Drive Train ...

Page 100: ...emove synchro ring Item 6 E Remove snap ring Item 7 F Remove shifter Item 8 together with spring hub and 3 keys G Remove key Item 9 H Remove snap ring Item 10 I Remove synchro ring Item 6 gear Item 11 2 needle bearings Item 12 and washer Item 13 In spect needle bearings and replace if necessary J Use a bearing puller to remove bearing Item 14 K Remove gear Item 15 snap ring Item 16 gear Item 17 an...

Page 101: ...p ring Item 11 G Remove shifter Item 12 together with spring hub and 3 keys Figure 45 1 3 5 15 14 13 10 7 18 2 4 17 16 12 11 9 8 6 H Remove key Item 13 I Remove synchro ring Item 14 from gear Item 15 J Remove gear Item 15 needle bearing Item 16 and thrust washer Item 17 Inspect needle bearing and replace if necessary Measure thickness of thrust washer Replace thrust washer if thickness is less tha...

Page 102: ...or wear and damage Replace in ner if O D is less than 1 258 in 31 95 mm Measure thickness of thrust washer Replace thrust washer if thickness is less than 0709 in 1 8 mm E Remove 2 snap rings Item 8 F Remove Hi Lo shifter Item 9 and collar spline Figure 48 Item 10 G Remove gear Item 11 Inspect bushing for wear and damage Replace gear if I D exceeds 1 184 in 30 08 mm H Remove washer Item 12 snap ri...

Page 103: ... assembly A Use a bearing puller to remove bearing Item 1 from differential case B Remove snap ring Item 2 C Use a bearing puller to remove bearing Item 3 and slider Item 4 D Loosen screws Item 5 from ring gear E Remove ring gear Item 6 from differential case and remove 2 dowel pins Item 7 F Drive lock pin Item 8 out of pinion shaft Item 9 G Remove pinion shaft Item 9 from differential Figure 52 c...

Page 104: ...ve snap ring Item 2 C Remove L H axle shaft assembly Item 3 D Remove snap ring Item 4 and washer Item 5 E Use a bearing puller to remove bearing Item 6 L H SHAFT from axle shaft F Remove oil seal Item 7 from differential carrier Item 8 G Remove R H axle shaft assembly Item 1 from seal cover H Remove snap ring Item 2 and washer Item 3 from axle shaft I Use a bearing puller to remove bearing Item 4 ...

Page 105: ... color material or damage B Inspect the spline chamfer for excessive chipping or damage C Inspect I D of synchro gear for excessive wear or scoring If synchro gears have the following I D re place the synchro gear 22T 25T 40T I D exceeds 1 027 in 26 08 mm 49T I D exceeds 1 145 in 29 08 mm 5 On 4WD units inspect 41T gear and front drive shaft Fig 57 A Inspect gear teeth for roughness material trans...

Page 106: ...he clearance exceeds 039 in 1 0 mm Figure 58 7 Inspect main shaft A Inspect main shaft for worn or damaged surface If O D of needle bearing surface is less than 864 in 21 95 mm replace the main shaft B Inspect lip portion of oil seal for wear or damage C Insert spline in clutch disk and check for exces sive looseness and free sliding of clutch disk hub Figure 59 8 Inspect both snap ring item 3 and...

Page 107: ...place center plate if the snap ring groove has more than 15 of its edges damaged due to nicks rounding cracks or dents Fig 61 and 62 UNDAMAGED GROOVE Figure 61 DAMAGED GROOVE EDGES Figure 62 Workman 3000 4000 Series Page 6 35 Drive Train Drive Train ...

Page 108: ...ve wear or dam age If O D is less than 707 in 17 95 mm replace the pinion shaft B Measure thickness of pinion liners If thickness is less than 035 in 0 9 mm replace the pinion liners C Measure thickness of side gear liners If thick ness is less than 043 in 1 1 mm replace the side gear liners D Inspect the gear contact condition between spiral bevel pinion and ring gear Figure 65 E Inspect differen...

Page 109: ... grease on O ring before installing 3 Assemble R H axle shaft A Install new oil seal Item 5 into seal cover Apply multi purpose grease on O ring before installing B Insert washer Item 6 R H SHAFT C Use a press to install bearing Item 4 onto R H axle shaft D Install washer Item 3 and snap ring Item 2 E Install R H axle shaft assembly into seal cover Figure 66 Item 7 4 Assemble differential fork sha...

Page 110: ... gear Item 6 NOTE Ring gear and countershaft are supplied in matched sets only H Insert 2 dowel pins Item 7 onto ring gear Item 6 I Completely clean oil from threads of cap screws Item 5 Figure 69 2 3 4 6 7 11 10 14 13 9 8 12 14 10 11 1 5 1 18 5 to 22 ft lb 24 5 to 29 5 N m NOTE It is recommended that whenever the ring gear screws are removed that they be replaced with new screws J Apply Loctite t...

Page 111: ...e installing 2 7 Assemble R 1 and 2 3 fork shaft Figure 72 A Insert R 1 fork shaft Item 2 into R 1 fork Item 3 B Drive lock pin Item 1 into fork and fork shaft Pay attention to direction of slit in lock pin C Insert 2 3 fork shaft Item 2 into 2 3 fork Item 3 D Drive lock pin Item 1 into fork and fork shaft Pay attention to direction of slit in lock pin Figure 73 Workman 3000 4000 Series Page 6 39 ...

Page 112: ...face the gear D Install collar spline Item 10 and snap ring Item 8 E Install shifter Item 9 onto collar spline F Install snap ring Item 8 washer Item 7 and in ner Item 6 Oil groove on washer must face the gear Figure 74 G Install gear Item 5 H Install washer Item 4 and snap ring Item 3 Oil groove on washer must face the gear I Install washer Item 2 and a new bearing Item 1 using a press 16 15 14 1...

Page 113: ... into grooves of hub Item 2 1 2 Figure 76 B Install shifter Item 1 onto hub Item 2 1 2 Figure 77 C Insert 2 springs Item 3 into hub Pay attention to direction of spring Figure 78 Figure 79 Workman 3000 4000 Series Page 6 41 Drive Train Drive Train ...

Page 114: ...exron III transmission oil on cone face of gear before installing synchro ring C Insert key Item 13 onto reduction shaft 18 2 4 17 16 12 11 8 6 D Install synchro hub sub assembly Item 12 9 E Install snap ring Item 11 F Install spacer Item 10 onto gear Item 8 Figure 80 G Insert needle bearings Item 9 into gear Item 8 H Install washer Item 7 Oil groove on washer must face the gear I Use a press to i...

Page 115: ...Apply Dexron III transmission oil on cone face of gear before installing synchro ring G Insert key Item 9 H Install synchro hub sub assembly Item 8 I Install snap ring Item 7 J Install synchro ring Item 6 onto gear Item 4 Apply Dexron III transmission oil to cone face of gear before installing synchro ring K Insert 2 needle bearings Item 5 into gear Item 4 Apply moly disulfide grease onto needle b...

Page 116: ...arms D Install 2 shift arms Item 11 Install shift arm as sembly Items 8 7 6 5 4 3 E Install washers Items 10 and 2 and locknuts Items 9 and 1 Tighten shift arm retaining locknuts to a torque from 200 to 280 in lb 22 6 to 31 6 N m 14 Install oil cap Item 1 with O ring Apply multi pur pose grease to O ring 15 If removed install air breather Item 2 Use sealing tape on threads of air breather 8 5 7 6 ...

Page 117: ... shaft Insert heads of shift arms into grooves of forks when installing them Figure 88 Figure 89 17 Install main shaft together with 2 3 fork shaft Insert head of shift arm into groove of fork while installing Figure 90 Drive Train Figure 91 Workman 3000 4000 Series Page 6 45 Drive Train ...

Page 118: ... DRIVE CENTER PLATE Figure 93 20 Install center plate A Insert 2 dowel pins into transaxle case B Apply silicone sealant onto mating surface of center plate C Position center plate to transaxle D Install and tighten cap screws to a torque from 18 5 to 22 ft lb 24 5 to 29 5 N m E Apply multi purpose grease onto lips of oil seal then insert oil seal flush with face of housing Figure 94 F Apply moly ...

Page 119: ...inst the tabbed shim Use thickest shims in set possible that will permit installation of the snap ring Fig 95 and 96 1 3 2 4 Figure 95 5 22 Install snap ring into the groove of the bearing hous ing Fig 96 and 97 1 3 4 2 6 Figure 96 1 Countershaft 4 Snap ring 2 Bearing 5 Center plate 3 Shims 6 Sealing cap Figure 97 Drive Train Workman 3000 4000 Series Page 6 47 Drive Train ...

Page 120: ...set with a feeler gauge Make sure shim set is held against the bearing during the measurement End play should be 0 000 to 0 0039 in 0 00 to 0 10 mm Fig 98 IMPORTANT If end play is too large replace shim shim set item 2 in steps 21 and 22 with thicker shims to reduce endplay Figure 98 24 Insert sealing cap Item 1 flush with face of housing Make sure not to insert sealing cap too far Pay attention t...

Page 121: ...ant to mating surface of fork shaft case D Install fork shaft case Item 2 Tighten cap screws Item 1 to a torque from 18 5 to 22 ft lb 24 5 to 29 5 N m Check operation of shifters and detent 1 2 Figure 102 26 Insert a washer Item 1 into housing of transaxle case Apply moly disulfide grease to washer before installing 1 Drive Train Figure 103 Workman 3000 4000 Series Page 6 49 Drive Train ...

Page 122: ...t onto mating surface of side cover C Install side cover Tighten cap screws to a torque from 18 5 to 22 ft lb 24 5 to 29 5 N m Figure 106 29 Install R H axle shaft assembly A Apply silicone sealant onto mating surface of seal cover B Install axle shaft assembly Item 2 and tighten cap screws Item 1 to a torque from 18 5 to 22 ft lb 24 5 to 29 5 N m 2 1 Figure 107 Drive Train Page 6 50 Workman 3000 ...

Page 123: ...transaxle case Using a dial indicator check ring gear backlash in three equally spaced points Backlash should be 0031 to 0071 in 0 08 to 0 18 mm and must not vary more than 0019 in 0 05 mm at the points checked If backlash is not in this range replace shim set in end of differential carrier A If less than target range decrease total thickness of shim set until correct backlash is achieved B If exc...

Page 124: ...ention to direction of slit in lock pin 1 Figure 111 33 Apply silicone sealant to mating surface of upper cover Item 2 Pay attention to direction of cover and install Tighten cap screws Item 1 to a torque from 18 5 to 22 ft lb 24 5 to 29 5 N m Figure 112 1 2 Drive Train Page 6 52 Workman 3000 4000 Series ...

Page 125: ...r cover Tighten nut with lockwasher Item 2 and cap screws Item 1 to a torque from 11 to 13 ft lb 15 to 17 N m 1 3 2 Figure 113 35 Install bell housing and secure with cap screws Item 2 Tighten cap screws to a torque from 18 5 to 22 ft lb 24 5 to 29 5 N m 36 Install extension spring Item 1 2 1 Figure 114 Workman 3000 4000 Series Page 6 53 Drive Train Drive Train ...

Page 126: ...Stud 10 Retaining ring 22 Alignment pin 2 used 34 Lock washer 11 Bearing 23 PTO housing 35 Hex nut 12 Input shaft 24 Gear 27T Disassembly Fig 115 NOTE Item numbers in figures are shown in order of disassembly for example remove Item 1 first then Item 2 etc Reassemble in reverse order for example install Item 1 last 1 Put vehicle on a level surface Stop the engine and remove key from ignition switc...

Page 127: ... oil seal from PTO cover 1 Figure 117 6 Remove intermediate shaft assembly Item 1 from PTO housing Remove intermediate gear Item 2 Re move bearing Item 3 from housing if necessary 1 2 Figure 118 3 Figure 119 Drive Train Workman 3000 4000 Series Page 6 55 Drive Train ...

Page 128: ...t shaft toward other side F Remove bearing Item 5 G Remove thrust washer Item 6 and gear Item 7 sliding input shaft toward PTO shaft side Figure 120 H Release shift arm Item 8 from shifter block Item 9 I Remove input shaft assembly 3 6 7 8 Figure 121 8 Disassemble PTO input shaft A Remove shift collar Item 1 B Remove 2 steel balls Item 2 and spring Item 3 2 1 3 2 Figure 122 Drive Train Page 6 56 W...

Page 129: ...aring Item 1 B Remove gear Item 2 and retaining ring Item 3 C Remove retaining ring Item 4 and thrust washer Item 5 D Use a bearing puller to remove bearing Item 6 if necessary Figure 124 3 6 4 7 5 1 2 Figure 125 11 Disassemble shift arm A Remove two 2 lock pins from shift arm B Remove two 2 O rings Item 1 1 Figure 126 Workman 3000 4000 Series Page 6 57 Drive Train Drive Train ...

Page 130: ...s 039 in 1 0 mm Figure 127 4 Measure I D of input shaft bushing Item 1 Replace bushing if I D exceeds 673 in 17 10 mm 1 Figure 128 5 Measure O D of bushing area on input shaft Re place shaft if O D is less than 667 in 16 95 mm In spect surface of bushing area for scoring or damage Figure 129 6 Inspect surface of oil seal area on output shaft for wear or damage Figure 130 Drive Train Page 6 58 Work...

Page 131: ... sure all parts are free of dirt and dust 3 Assemble shift arm 2 1 3 Figure 131 A Install two 2 new O rings Item 1 onto shift arm Apply moly disulfide grease to O rings before instal ling B Apply moly disulfide grease to arm pin and shaft C Install shift arm into PTO housing D Install shift lever onto shift arm E Drive lock pins into shift lever and shift arm Pay attention to direction of slit in ...

Page 132: ...ar Item 2 D Use a press to install bearing Item 1 3 6 4 7 5 1 2 Figure 134 Figure 135 1 5 Use a press to install bearing Item 1 onto intermedi ate shaft Figure 136 6 Assemble PTO input shaft A Insert spring Item 3 and two 2 steel balls Item 2 into hole B Insert shift collar Item 1 onto input shaft C Move shift collar to ON position 2 1 3 2 Figure 137 Drive Train Page 6 60 Workman 3000 4000 Series ...

Page 133: ...stall gear Item 7 with bushing and thrust wash er Item 6 onto input shaft after sliding the assembly toward PTO shaft side Apply moly disulfide grease to bushing of gear and thrust washer before instal 7 4 5 6 3 ling Figure 138 D Slide two 2 bearings Items 5 and 4 onto input shaft E Install two 2 retaining rings Items 2 and 1 3 Figure 139 6 7 Figure 140 Moly disulfide grease Drive Train Figure 141...

Page 134: ... B Put gear Item 2 on mating gear C Move gear until bores of gear and bearing line up D Insert intermediate shaft sub assembly Item 1 Apply grease to intermediate shaft to aid assembly 1 2 Figure 143 9 Insert PTO shaft assembly Item 1 into bearing housing of PTO housing 1 Figure 144 Drive Train Page 6 62 Workman 3000 4000 Series ...

Page 135: ... into PTO housing C Apply silicone sealant onto mating surface of PTO cover D Install PTO cover Tighten cap screws and nut with lockwasher to a torque from 18 to 22 ft lb 24 5 to 29 5 N m 11 Install PTO to transaxle see PTO Removal and Installation in this chapter Figure 145 Workman 3000 4000 Series Page 6 63 Drive Train Drive Train ...

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Page 137: ... Joint Replacement 24 SERVICE AND REPAIRS 8 Tie Rod End Replacement 25 Wheel Installation 8 Front Wheel Alignment 26 Front Wheel Assembly 2 Wheel Drive 10 Front Compression Spring Service 27 Rear Wheel Assembly 12 Front Shock Absorber Replacement 28 Brake Service 14 Rear Shock Absorber Replacement 29 Wheel Brake Cylinder Service 17 Rear Leaf Spring Replacement 30 Bleeding the Brakes 18 Seat Base 3...

Page 138: ... 3 Tire Pressure 1 Tire pressure needed is determined by the payload carried 2 The lower the air pressure the less the compaction and tire marks are minimized Lower pressure should not be used for heavy payloads at high speeds Tire damage may result 3 High pressure should be used for heavier payloads at higher speeds Do not exceed maximum tire pres sure 4 See Operator s Manual for additional tire ...

Page 139: ...ion Spring Tool Use to remove and install the two 2 front suspension compression springs Qty Item 2 1 2 x 20 threaded steel rods 4 1 2 nuts 4 1 2 flat washers 20 5 5 Figure 1 Workman 3000 4000 Series Page 7 3 Chassis Chassis ...

Page 140: ...ings Clutch drive shaft or transaxle problem see Chapter 6 Drive Train Excessive steering play Loose or worn front wheel bearings Loose or worn steering linkage Worn tie rod ends Front wheel shimmy Loose or worn front wheel bearings Tires out of round or uneven tire wear Worn tie rod ends Incorrect front wheel alignment toe in Worn shock absorbers Instability wander Low or uneven tire pressure Wor...

Page 141: ... see Chapter 9 Hydraulic System Damaged or binding steering cylinder Worn or damaged steering control valve Incorrect front wheel alignment Vehicle pulls to one side when not braking Low or uneven tire pressure Broken or weak rear leaf spring Incorrect front wheel alignment Damaged or bent suspension or steering component Worn or damaged brake components Workman 3000 4000 Series Page 7 5 Chassis C...

Page 142: ...en or worn brake pedal pivot bushing Brakes pulling Incorrect tire pressure Contaminated brake linings Front end out of alignment Incorrect brake adjustment Distorted brake shoes Restricted brake lines or hoses Broken rear spring Unmatched tires on same axle Squealing brakes Glazed brake lining Saturated brake lining Weak or broken shoe return spring Weak or broken shoe retaining spring Distorted ...

Page 143: ...lines or hoses Brake pedal linkage binding Wheel locks Contaminated brake linings Loose or damaged brake linings Wheel cylinder sticking Incorrect wheel bearing adjustment Brakes fade Overheated brake drums Saturated brake linings Surge at slow speeds Bent or out of round brake drums Chatter at fast speeds Shoe lock Machining grooves in contact face of brake drums Weak hold down springs Brakes do ...

Page 144: ...ld result in failure or loss of wheel and may wheel nuts from 45 to 65 ft lb 61 to 88 N m at 1 Mount wheel and evenly tighten wheel nuts to a WARNING result in personal injury Torque front and rear intervals recommended in Operator s Manual Figure 2 1 Wheel assembly 2 Wheel nut 5 used Chassis Page 7 8 Workman 3000 4000 Series ...

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Page 146: ...d then remove wheel assembly NOTE It may be necessary to back off brake adjuster to remove brake drum To back off adjuster rotate brake drum until access hole lines up with star wheel on adjust er assembly Use a hooked piece of wire to pull pawl away from star wheel then turn star wheel 2 Remove brake drum from front hub 3 Remove dust cap Straighten and remove cotter pin from spindle shaft Remove ...

Page 147: ...in er to allow installation of cotter pin Install cotter pin and bend cotter pin completely around nut retainer Install dust cap 7 Install brake drum making sure that access hole in brake drum aligns with hole in front hub 8 Adjust brake shoes A Align access hole in brake drum with adjuster bolt on adjuster assembly B Rotate adjusting bolt to increase adjuster length until brake shoes contact brak...

Page 148: ...g 16 Seal 17 End yoke 18 Yoke strap 2 used per yoke 19 Bolt 2 used per strap 20 Hardened washer 21 Flange head screw 22 Thrust washer 23 Cap screw 24 Cap screw 25 Rear axle 26 Drive shaft Figure 4 FRONT RIGHT 5 4 6 7 1 2 3 8 9 11 13 12 10 18 19 15 17 16 14 22 23 21 20 26 25 24 ACCESS HOLE 8 45 to 65 ft lb 61 to 88 N m Loctite 680 40 to 60 ft lb 54 to 81 N m 220 to 250 ft lb 298 to 339 N m 200 to 2...

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Page 150: ... Piston 12 Dust cover 13 Brake shoe 14 Upper shoe spring 15 Lower shoe spring 16 Female push rod 17 Bolt adjuster 18 Adjuster sleeve 19 Pawl 20 Adjuster spring 21 Pawl pin 22 Hold down washer 2 used 23 Hold down spring 2 used 24 Pipe guide 25 Inspection plug 26 Hold down pin 2 used 27 Adjuster assembly Figure 5 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 11 12 13 14 15 13 27 12 10 11 49 ...

Page 151: ...er 9 See Brake Cylinder Service in this section for infor mation on brake cylinder disassembly inspection and assembly procedures 10 If needed remove brake backing plate from vehicle by removing four cap screws and lock washers Inspection 1 Clean and inspect brake drum any time they are re moved for brake service A Check drum diameter at a minimum of three loca tions Diameter should not exceed the...

Page 152: ...nstall upper shoe spring 14 to both brake shoes 13 11 If servicing front brakes install wheel hub to vehicle see Front Wheel Assembly 2 Wheel Drive in this sec tion for series 3000 Workman vehicle or see Front Wheel and Axle Housing Assembly in the Service and Repairs section of Chapter 10 Front Wheel Drive 4WD for series 4000 Workman vehicle 12 If servicing rear brakes install stub axle to vehicl...

Page 153: ...metal parts with isopropyl alcohol then clean out and dry grooves and passageways with com pressed air Make sure brake cylinder bore and compo nent pieces are thoroughly clean 2 Check cylinder bore and pistons and spring for dam age or excessive wear Replace brake cylinder assem bly if signs of pitting scoring or cracks are evident Assembly 1 Apply a film of clean brake fluid to new L type seals a...

Page 154: ...e until pedal fades to floor then close bleeder valve 4 Repeat procedure until a continuous flow of brake fluid with no air bubbles is released from bleeder valve Make sure fluid level is maintained in brake fluid res ervoir at all times 5 Complete steps 1 4 for left rear right front and left front brakes CAUTION After servicing the brakes always check the brakes in a wide open level area that is ...

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Page 156: ...hem away from master cylinder 3 Remove two 2 cap screws and flange nuts that se cure master cylinder to vehicle frame 4 Pull master cylinder from vehicle Installation Fig 9 1 Position master cylinder to vehicle frame and secure with two 2 cap screws and flange nuts 2 Remove plugs from brake lines Install brake lines to master cylinder 3 Make sure that master cylinder push rod is fully ex tended Co...

Page 157: ...nd springs for dam age or excessive wear Replace brake cylinder assem bly if signs of pitting scoring or cracks are evident in cylinder bore Assembly Fig 10 1 Apply a film of clean brake fluid to cylinder bore and piston assemblies 2 Install secondary piston assembly and primary pis ton assembly into cylinder 3 Install retainer washer 4 Install push rod and secure in place with circlip Install low...

Page 158: ...ake cable to rear brake by inserting cable through brake backing plate and into parking brake le ver Install brake cable clip to secure cable to backing plate Fig 12 2 After installing cable to rear brake check to make sure bottoms of brake shoes are seated in grooves at bottom of backing plate 3 Route brake cable in same location as before and se cure with cable ties Start from rear of vehicle an...

Page 159: ...eering wheel from control valve Installation Fig 14 1 Apply anti seize lubricant to shaft of control valve 2 Slide steering wheel onto control valve shaft 3 Secure steering wheel with lock washer and hex nut Torque hex nut from 20 to 26 ft lb 28 to 35 N m 4 Install steering wheel cover Figure 14 1 Steering wheel 2 Lock washer 3 Hex nut 4 Steering control valve 5 Frame 2 4 1 3 5 Anti seize Lubrican...

Page 160: ...t or lower control arm 2 Remove cotter pin and slotted nut that secure af fected ball joint to spindle Separate ball joint from spindle Inspect ball joint seal and replace if damaged 3 Remove control arm 4 Remove snap ring Press ball joint out of control arm Installation Fig 15 1 Press new ball joint into control arm Install snap ring to secure ball joint 2 Install grease fitting into ball joint I...

Page 161: ...an be installed withoutchanging the toe inadjustment Installation Fig 16 1 Install new tie rod end to tie rod Thread in the same number of revolutions as the old one took to remove 2 Make sure that tie rod end shaft and spindle or pit man arm are thoroughly cleaned 3 Insert tie rod end shaft to spindle or pitman arm and secure with slotted nut Tighten slotted nut to a torque from 45 to 55 ft lb 61...

Page 162: ...0 125 to 0 375 inch 3 18 to 9 53 mm greater than the rear measurement toe out 4 If adjustment is needed loosen jam nuts on front tie rod ends and rotate tie rod s to change alignment Torque jam nuts to 50 ft lb 68 N m after adjustment is complete Make sure that the tie rod ends are aligned with each other as the jam nuts are being tightened 5 After alignment has been checked and or adjusted check ...

Page 163: ...th jack stands see Jacking Instructions in Operator s Manual Re move front wheels 3 Remove front shock absorbers WARNING FRONT SUSPENSION IS SPRING LOADED To prevent possible personal injury use special tool to remove compression springs before dis assembling the front suspension 4 Install a compression spring tool rod through holes in each spring cradle Item 1 then install nuts and washers on bot...

Page 164: ...onto stud above control arm 4 Install new shock absorber with ram end down and secure upper end with outer washer and lock nut 5 Insert capscrew down through angled hole in control arm tower Install washer onto cap screw and slide shock absorber onto cap screw Install second washer onto capscrew and secure with lock nut 1 1 2 3 4 5 6 7 8 10 8 9 Figure 21 1 Rubber bushing 6 Lock nut 2 Spacer 7 Cap ...

Page 165: ...d of new shock absorber 3 Install one large washer onto each shock absorber mounting stud 4 Install new shock absorber with ram end down Se cure each end with with large washer and lock nut 1 1 2 2 3 4 5 4 5 Figure 23 1 Rubber bushing 4 Large washer 2 Large washer 5 Lock nut 3 Shock absorber Shock absorber Figure 24 Workman 3000 4000 Series Page 7 29 Chassis Chassis ...

Page 166: ...text 13 IMPORTANT For proper vehicle performance al ways replace the springs on both sides of the ve hicle Removal Fig 25 1 Jack up and support rear of vehicle See Jacking In structions in Operator s Manual Remove rear wheel s 2 Support frame side rails so rear axle can be remo ved 3 Support rear axle then remove four 4 lock nuts Item 6 washers Item 7 and carriage screws item 14 securing rear axle...

Page 167: ...plate Item 8 to top of spring then se cure axle to spring with carriage bolts Item 14 washers Item 7 and lock nuts Item 6 NOTE Make sure axle and plate are centered on leaf spring knob Fig 26 5 Tighten lock nuts Item 6 in a crossing pattern until spring plate leaf spring and axle contact Tighten flange nuts Item 12 securing spring mount to frame rail Tight en lock nuts Item 6 securing axle and cla...

Page 168: ...Seat Base 1 Passenger seat 2 Screw 6 used 3 Control plate 4 Hose to radiator 5 Coolant reservoir 6 Operator seat 7 Lock nut 8 Flat washer 9 Cap screw 10 Seat base 11 Socket head screw 4 used per seat Figure 27 2 4 1 3 5 7 6 8 10 9 11 FRONT RIGHT ...

Page 169: ... flat washer and lock nut that se cure each front corner of seat base to frame 6 Disconnect radiator overflow tank hose at radiator and plug the hose 7 Carefully lift seat base from vehicle Installation Fig 27 1 Position and secure seats and seat base to vehicle with removed fasteners 2 Reconnect radiator overflow tank hose to radiator 3 Secure center console control plate to vehicle Install knobs...

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Page 171: ...ine and Fuel Pump Briggs Daihatsu Gas Engine Relay 10 Glow Relay Briggs Daihatsu Diesel Engine 11 Start Relay Kohler Engine 11 Battery 12 Indicator Lights and Gauges 12 High Temperature Shutdown Switch Briggs Daihatsu Gas and Diesel Engine 13 Fuel Gauge Sender 14 Headlight Switch 14 Glow Plug Switch Briggs Daihatsu Diesel Engine 15 Diodes Briggs Daihatsu Gas and Diesel Engine 15 Diode Assembly Koh...

Page 172: ...urrent is off Figure 1 Multimeter The meter can testelectricalcomponents and circuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause dam...

Page 173: ...ks but should not with PTO engaged PTO switch faulty Starter solenoid clicks but starter will not crank If solenoid clicks problem is not in interlock system Low battery charge Loose or corroded battery cables or ground Loose corroded or damaged wiring at starter Loose starter mounting bolts Faulty starter Faulty starter solenoid Starter cranks but engine will not start 3rd High lockout key switch...

Page 174: ...ty Start relay wiring loose corroded or damaged Starter solenoid wiring loose corroded or damaged Starter solenoid faulty Engine runs but should not with 3rd High lockout 3rd High lockout key switch faulty switch in Slow position and transaxle in 3rd gear and High range 2 3 lockout switch on transaxle faulty High Low lockout switch on transaxle faulty Engine kills when shifted to 3rd gear 3rd High...

Page 175: ...Test This is a simple test used to determine if a charging sys Start the engine and run at high idle Allow the battery to tem is functioning It will tell you if a charging system has charge for at least 3 minutes Record the battery voltage an output but not its capacity Test results should be example Use a multimeter set to the DC volts setting Connect the positive meter lead to the positive batte...

Page 176: ...on 3 If engine cranks or starts there is a malfunction in the interlock system that must be repaired before operating vehicle To verify operation of hydraulic lift interlock switch TC models 1 Sit on operator s seat and engage parking brake Move shift lever to NEUTRAL position Disengage rear PTO if so equipped 2 Move hydraulic lift lever out of neutral position 3 Depress clutch pedal and rotate ig...

Page 177: ...TION connected When testing electrical components for continu ity with a volt ohm meter or continuity tester make sure that power to the circuit has been dis Ignition Key Switch The ignition key switch has three positions OFF START and RUN The terminals are marked as shown in Figure 4 The circuitry of the ignition switch is shown in the chart Fig 5 With the use of a continuity tester the switch fu...

Page 178: ...here should be no continuity For clutch switch adjustment procedure see Clutch Pedal Adjustment in Chapter 6 Drive Train Figure 6 1 1 Clutch switch Brake Switch The brake switch is normally open and closes when the brake pedal is depressed The closed switch allows a current path to the stop light Test the switch by disconnecting the wiring connector and connecting a continuity tester across the tw...

Page 179: ...ng the wiring connector and connecting a continuity tester across the two termi nals With the engine off move shifter to Low range there should be an indication of continuity Move shift le ver to High range there should be no continuity 1 2 Figure 8 1 2 3 lockout switch 2 Hi Low lockout switch 3rd High Lockout Key Switch The 3rd High Lockout switch is closed in Fast position and open in Slow posit...

Page 180: ...ness connector from the relay that is to be tested 2 Using a multimeter ohms setting measure coil re sistance between terminals 85 and 86 Fig 10 Resist ance should be between 70 and 90 ohms 3 Connect multimeter ohms setting leads to relay ter minals 30 and 87 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 appli...

Page 181: ...uity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage and leads from the terminals Figure 11 86 87 85 30 30 87 85 86 Figure 12 86 87 85 30 85 86 87 30 Start Relay Kohler Engine The start relay used on Workman vehicles with a Kohler engine is attached to the frame near the hydraulic oil fil ter Testing 1 Disconnect the harness connector from the rel...

Page 182: ... Test the lamp by disconnecting the wires and applying 12 VDC between the lamp wiring ter minals Glow Light Diesel Engine The glow light should be on when the ignition key switch is in the RUN position and the glow switch is ON Test the lamp by disconnecting the wires and applying 12 VDC between the lamp wiring terminals Hourmeter Test the hourmeter by connecting a 12 volt battery so the positive ...

Page 183: ...le the hot oil with extreme care to prevent personal injury or fire VOA 3 Check continuity of the switch with a multimeter ohms setting The temperature switch is normally open and should close at approximately 238oF 114oC Figure 16 4 Allow oil to cool while observing temperature The temperature switch should open at about 232oF 111oC 5 Replace switch if necessary 6 Install switch to the water pump...

Page 184: ...et proper gauge reading for a 1 2 full tank approximately 110 ohms Headlight Switch The headlight switch is located on the control panel This rocker switch allows the headlights to be turned on and off The switch terminals are marked as shown in Figure 19 The circuitry of the headlight switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested t...

Page 185: ...ITS OFF 2 3 5 6 MOMENTARY 1 2 4 5 ON Diodes Briggs Daihatsu Gas and Diesel Engine Diodes D1 and D2 are used for circuit protection from voltage spikes that occur when a solenoid is de ener gized Diode D1 is in the optional hydraulic circuit and D2 is in the starting circuit 2 These diodes plug into the vehicle wiring harness at vari ous locations see appropriate vehicle electrical sche matic in Ch...

Page 186: ...ultimeter Multimeter Red Lead Black Lead Continuity on on Terminal Blade Terminal Blade Male Female YES Female Male NO Rear PTO Switch Optional On vehicles equipped with the optional rear PTO kit the rear PTO switch is located in the rear PTO housing mounted on the top of the transaxle The Rear PTO switch is normally closed and opens when the PTO is en gaged Test the switch by disconnecting the wi...

Page 187: ...t circuiting the battery other components or the operators hands 3 Loosen nut on positive cable post and remove cable from battery 4 Remove battery from the battery compartment to a service area to allow better access for service 1 Figure 24 1 Battery Inspection Maintenance and Testing 1 Perform following inspections and maintenance A Check for cracks Replace battery if cracked or leaking B Check ...

Page 188: ...attery terminals prior to testing the battery If the voltage is less than 12 4 VDC recharge the battery B If the battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a battery load tester following the manufactur er s instructions C Make sure battery terminals are free of corrosion D If battery filler caps are removable measure the temperature of the center...

Page 189: ...3 hrs 4 amps 10 5 hrs 4 amps 15 8 hrs 4 amps 21 hrs 4 amps 126 to 170 5 5 hrs 5 amps 11 hrs 5 amps 16 5 hrs 5 amps 22 hrs 5 amps 171 to 250 5 8 hrs 6 amps 11 5 hrs 6 amps 17 3 hrs 6 amps 23 hrs 6 amps above 250 6 hrs 10 amps 12 hrs 10 amps 18 hrs 10 amps 24 hrs 10 amps CAUTION Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60_F 15 5_ C before connec...

Page 190: ...Slide seal onto the headlight until the seal is firmly in place NOTE Applying soapy water to the outside of the seal will aid in sliding the seal into the hood Make sure to thoroughly dry headlights before turning lights on 6 Align notch on the outside of the seal with the notch in the hood Push headlight and seal into the hood until it is firmly in place 7 Connect the wiring harness connector to ...

Page 191: ...re 16 Test No 2 Steering Control Valve and Steering Cylinder 18 Test No 3 Lift Cylinder Internal Leakage 20 Test No 4 High Flow Hydraulic Kit Optional Gear Pump Flow and Relief Pressure 22 SERVICE and REPAIRS 25 General Precautions for Removing and Installing Hydraulic System Components 25 Check Hydraulic Lines and Hoses 25 Gear Pump Vehicles With Liquid Cooled Engine 26 Gear Pump Vehicles With Ai...

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Page 193: ... GPM 30 LPM at 1 500 PSI 103 4 Bar Optional High Flow Hydraulic Kit System Relief Pressure 2 000 PSI 137 9 Bar Optional High Flow Hydraulic Kit Hydraulic Oil Multigrade Hydraulic Fluid ISO VG 46 Optional High Flow Hydraulic Kit Reservoir 4 5 U S gallon 17 Liter capacity Optional High Flow Hydraulic Kit Hydraulic Filter Automotive 10 micron spin on cartridge type 25 PSI by pass valve 100 mesh strai...

Page 194: ... and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the cor rect Flats From Finger Tight F F F T The markings on the nut and fitting body will verify that the connection has been tightened Size F F F T 4 1 4 in nominal hose or tubing 0 75 0 25 ...

Page 195: ... 13 N m 6 20 21 ft lb 27 28 N m 8 35 37 ft lb 47 50 N m 10 60 66 ft lb 81 89 N m 12 81 87 ft lb 110 117 N m 16 121 131 ft lb 164 177 N m 1 Make sure both threads and sealing surfaces are free of burrs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil 4 Turn back the jam nut a...

Page 196: ...S ROD 750 IN 19 1 MM BORE 1 50 IN 38 1 MM STROKE 16 25 IN 41 3 CM 100 MESH STRAINER W 25 PSI BYPASS T E R 10 MICRON PUMP BARNES 388 IN 3 REV 6 36 CC REV STEERING CYLINDER TEXAS HYDRAULICS ROD 625 IN 15 9 MM BORE 1 750 IN 44 5 MM STROKE 5 56 IN 14 1 CM 2WD 769 ENGINE SPEED RETURN FILTER TRANSAXLE PARKER RESERVOIR VY13 VALVE Hydraulic System Page 9 6 Workman 3000 4000 Series ...

Page 197: ...SUCTION STRAINER 100 MESH HYDRAULIC GEAR PUMP 610 IN 833 ENGINE SPEED 2000 PSI SOLENOID REV 3 10 CC REV RETURN FILTER OIL COOLER RELIEF VALVE ACTIVATED BYPASS VALVE 10 MICRON WITH 4 GALLON 25 PSI BYPASS RESERVOIR Workman 3000 4000 Series Page 9 7 Hydraulic System Hydraulic System ...

Page 198: ...ing on the steering wheel Fluid leaving the steering cylinder flows back through the spool valve then out the T port and returns to the hy draulic reservoir transaxle The steering wheel and steering control valve return to the neutral position when turning is completed Right Turn When a right turn is made with the engine running the turning of the steering wheel positions the spool valve so that f...

Page 199: ... cylin der shafts At the same time the pistons push the hy draulic fluid in the rod end of the lift cylinders out and through the lift valve to the reservoir transaxle When the control valve lever is released spring action returns the lift valve spool to the center position and lift cylinder movement is stopped The cylinder position is locked in place since there is no complete circuit of flow to ...

Page 200: ...se to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter This tester includes the following 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 PRESSURE GAUGE Glycerine filled 0 ...

Page 201: ...sys tem The kit includes tee s unions reducers plugs caps and male test fittings Figure 11 TORO TEST FITTING KIT NO TOR4079 Male Coupler For Optional High Flow Hydraulic Kit 105 4170 Male coupler that fits into female hydraulic coupler that is included in High Flow Hydraulic Kit Male coupler can be used when testing hydraulic components of High Flow Kit 1 Male coupler Figure 12 1 Hydraulic System ...

Page 202: ... s hose s or tube s are loose or damaged O ring s or seal s are missing or damaged Squealing noise Hydraulic lift valve held in raise or lower position hydraulic oil flow ing over relief valve Hydraulic oil is overheating Oil level in transaxle is incorrect Hydraulic oil is contaminated or incorrect oil use Dexron III ATF Kinked or severely bent hose or tubing Hydraulic oil going over relief valve...

Page 203: ...ve or sluggish Engine speed is low Oil level in transaxle is low Steering components Pitman arm tie rods steering cylinder rod ends worn or binding Gear pump drive belt is loose Note Loose belt will also cause the bed not to lift or other attachment to not operate Steering cylinder is binding Hydraulic relief valve stuck or damaged see TEST NO 1 Steering control valve is worn or damaged Pulley key...

Page 204: ...ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Quick couplers not fully engaged Quick couplers are interchanged Sheared key on gear pump shaft Excessive l...

Page 205: ...h an injury 1 Thoroughly clean the vehicle before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination will cause excessive wear of hydraulic components 2 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components 3 The engine must be in good operating condi...

Page 206: ...sure P T E L R STRAINER TRANSAXLE RESERVOIR PUMP STEERING CONTROL STEERING GEAR CYLINDER TESTER FILTER LIFT CYLINDERS LIFT VALVE Figure 13 2 3 1 Figure 14 1 Gear pump 3 Suction hose 2 Pressure hose Hydraulic System Page 9 16 Workman 3000 4000 Series ...

Page 207: ...he relief valve Pump damage can oc cur if the oil flow is fully restricted 7 Start engine and adjust engine speed with accelera tor pedal so pump speed is 2700 RPM engine speed approximately 3600 RPM Verify pump speed with a phototac 8 While watching tester pressure gauges slowly close flow control valve on the tester until 1500 PSI 103 4 Bar is obtained on gauge Verify that pump speed con tinues ...

Page 208: ...ol Valve and Steering Cylinder STEERING CONTROL RIGHT TURN PLUG LIFT CYLINDERS GEAR PUMP STRAINER LIFT VALVE P T E L R STEERING CYLINDER FILTER TRANSAXLE RESERVOIR Figure 15 Hydraulic System Page 9 18 Workman 3000 4000 Series ...

Page 209: ... right clockwise until the steering cylinder rod is fully extended C Turn engine off and engage the parking brake D Read Precautions for Hydraulic Testing E Clean and remove hydraulic hose from the fitting on the rod end of the steering cylinder Plug the end of the disconnected hose Fig 15 Keep body and hands away from disconnected under high pressure Use paper or cardboard WARNING hoses and fitti...

Page 210: ...der Internal Leakage P T E L R STRAINER TRANSAXLE RESERVOIR PUMP STEERING CONTROL STEERING GEAR CYLINDER PLUG IN LOWER POSITION FILTER LIFT CYLINDERS LIFT VALVE Figure 16 Hydraulic System Page 9 20 Workman 3000 4000 Series ...

Page 211: ... cylinder and install a steel plug with o ring seal in the hose Fig 17 Clean any remaining oil from cylinder port 4 Start engine and apply pressure to rod end of cylinder i e put hydraulic lift lever in LOWER position 5 If any oil comes out of open cylinder port cylinder has an internal leak Repair or replace cylinder 6 Reconnect hose disconnected in step 3 after test or repairs are complete Disco...

Page 212: ...Pressure HYDRAULIC GEAR PUMP 610 IN 833 ENGINE SPEED IN TANK SUCTION STRAINER 100 MESH 4 GALLON RESERVOIR RETURN FILTER 10 MICRON WITH 25 PSI BYPASS OIL COOLER RELIEF VALVE 2000 PSI SOLENOID ACTIVATED BYPASS VALVE QUICK DISCONNECT COUPLINGS TESTER REV 3 ENERGIZED Figure 18 1 Pressure coupler 2 Return coupler Figure 19 1 2 ...

Page 213: ...ect before pro ceeding with test 7 Adjust engine speed with accelerator pedal so High Flow Kit gear pump speed is 3000 RPM engine speed approximately 3600 RPM Verify pump speed with a phototac 8 With Kit switch still in the ON position watch tester pressure gauges while slowly closing flow control valve on the tester until 1500 PSI 103 4 Bar is obtained on gauge Verify that pump speed continues to...

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Page 215: ...s and tubes After Repair or Replacement of Components 1 Check oil level in the transaxle and add correct oil if necessary Drain and refill transaxle and change oil filter if component failure was severe or system is contami nated 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fi...

Page 216: ...instructions A Apply antiseize lubricant to gear pump shaft be fore installing pulley B After installing key and pulley on pump shaft tighten lock nut Item 8 to a torque from 130 to 160 in lb 14 7 to 18 1 N m C Apply Loctite 242 or equivalent to threads of set screw and install set screw into pulley hub Torque set screw from 27 to 33 in lb 3 to 3 7 N m D Install pump suction hose to bottom fitting...

Page 217: ...all gear pump to mount using Figure 22 as a guide and using the following instructions A Apply antiseize lubricant to gear pump shaft be fore installing pulley B After installing key and pulley on pump shaft tighten lock nut Item 8 to a torque from 130 to 160 in lb 14 7 to 18 1 N m C Install pump suction hose to fitting on pump then fill pump through pressure port of pump with clean Dexron III ATF...

Page 218: ...nt and dry pump thor oughly Shaft Seal Replacement Fig 23 1 Remove retaining ring Item 1 2 Punch two 2 holes in face of seal 180o apart and install metal screws Remove shaft seal from gear pump by grasping and pulling on screws IMPORTANT Do not try to pry seal out of housing This can damage the shaft seal bore so oil will leak past the seal 3 Discard shaft seal Item 2 Remove spacer Item 3 4 Clean ...

Page 219: ... for smooth operation Re place bearing if loose on shaft or noisy when rotated 5 Inspect square key Item 5 shear pin Item 7 ball key Item 23 and keyways in shafts for wear or damage Replace parts as necessary Assembly Fig 23 1 Install one crescent ring Item 4 on inside portion of driveshaft Item 6 then install bearing Item 22 and other crescent ring Install driveshaft and bearing as sembly into st...

Page 220: ...amage when clamping the gear pump in a vise clamp on the front thrust plate only Also use a vise with soft jaws 3 Clamp front thrust plate of pump in a vise with soft jaws with the shaft end down 4 Loosen but do not remove screws that secure rear flange to pump 5 Remove pump from the vise and position pump so that the shaft end is facing down Remove screws 6 Carefully lift rear flange from body 7 ...

Page 221: ...ls back up seals and thrust plate grooves with a thin coat of petroleum jel ly Lubricate allother internalparts freely with clean Dex ron III ATF 1 Gear shaft spline 2 Gear shaft 3 Gear teeth 4 Gear face edge Figure 23 3 3 4 1 2 2 Press new shaft seal into front cover until it reaches the bottom of the bore and secure with retaining ring 3 Install the lubricated pressure and backup seals into the ...

Page 222: ...pump into a vise clamp on the front cover only Also use a vise with soft jaws 14 Place front cover of the pump into a vise with soft jaws and alternately torque the cap screws 220 in lb 25 N m 15 Remove pump from vise 16 Place a small amount of clean Dexron III ATF in the inlet of the pump and rotate the drive shaft away from the inlet one revolution If any binding is noted disassemble the pump an...

Page 223: ...Rev D 29 4 Page 9 Workman 3000 4000 Series Hydraulic System This page is intentionally blank Hydraulic System ...

Page 224: ...c filter 7 Flange nut 8 Lift lever 9 Clevis pin 10 Hairpin 11 Jam nut 12 Link rod 13 Clevis 14 Hyd hose to male quick fitting 15 Hyd hose to female quick fitting 16 90o hydraulic fitting 17 O ring 18 Hydraulic adapter 19 Cap screw 20 Hyd hose pressure supply 21 90o hydraulic fitting Figure 24 1 2 3 4 5 6 7 8 9 10 FRONT RIGHT 11 12 13 14 15 16 17 18 19 20 2 5 5 5 10 17 21 ...

Page 225: ...rts 5 Remove lift valve from vehicle using Figure 24 as a guide Installation Fig 24 1 Install lift valve to vehicle using Figure 24 as a guide Make sure that lift lever can be moved in control plate slot to allow correct operation of lift lock Readjust loca tion of clevis on link rod if needed Fig 25 2 Replace o rings on hydraulic hoses and fittings Re move caps and plugs from hoses and fittings C...

Page 226: ...ibe or thin screwdriver to remove o rings Item 9 from inside bore of valve body be careful not to scratch valve bore finish These o rings are the seals for the spool 6 Inspect all components for wear paying special attention to the spool Signs of wear on one side of the spool may indicate a bent spool Inspect the spool for flatness and replace if necessary Assembly Fig 26 1 Clean all components th...

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Page 228: ...ve P port 18 Bulkhead fitting to valve E port 19 Hyd hose to steer cyl shaft end 20 Hyd hose to steer cyl barrel end Figure 27 FRONT RIGHT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 FRONT OF VEHICLE CONTROL VALVE PORTS Anti seize Lubricant 20 to 26 ft lb 28 to 35 N m Removal Fig 27 1 Park vehicle on a level surface shut engine off and engage the parking brake 2 Remove steering wheel see St...

Page 229: ... ports Installation Fig 27 1 Replace o rings on hydraulic hoses and fittings Re move caps and plugs from hoses and fittings Connect hydraulic hoses to correct steering control valve ports refer to Figures 27 and 29 Make sure that hoses are not twisted while tightening 2 Secure steering control valve to vehicle with four 4 cap screws 3 Install hydraulic hose cover over hoses and secure with cable t...

Page 230: ... O ring 14 Distribution plate 15 Inner gearwheel 16 Outer gearwheel 17 End cover 18 O ring 5 used 19 Screw fitting ports L R T 20 Screw fitting ports P and E 21 P port check ball 22 Spring set Figure 30 1 2 3 11 13 17 12 14 16 15 4 5 6 8 9 10 7 13 13 18 19 20 21 22 20 to 24 ft lb 27 to 33 N m NOTE For service of the steering control valve see the Sauer Danfoss Steering Unit Type OSPM Service Manua...

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Page 232: ...3 Grease fitting 4 90o hydraulic fitting 5 Hyd hose from steering valve R 6 Hyd hose from steering valve L 7 45o hydraulic fitting 8 Jam nut 9 Pitman arm 10 Slotted hex nut 11 Dust seal 12 Cotter pin 13 Ball joint 14 Slotted hex nut 15 Ball joint Figure 31 FRONT RIGHT 8 1 2 4 3 5 10 6 7 9 14 11 15 12 13 12 3 ...

Page 233: ...d ball joint onto shaft Adjust center to center length to dimension shown in Figure 33 before tightening jam nut Torque jam nut 50 ft lb 68 N m 2 Install steering cylinder to vehicle using Figures 31 and 32 as guides 3 Replace o rings on hydraulic hoses and fittings Re move caps and plugs from hoses and fittings Connect hydraulic hoses to steering cylinder 4 Check oil level in transaxle see Operat...

Page 234: ...h exte rior with cleaning solvent and dry thoroughly IMPORTANT Use caution when using a vise to avoid scratching or distorting any parts 3 Put cylinder in a vise so shaft end is facing up 4 Use a spanner wrench to rotate head Item 6 and re move retaining ring Item 9 Grasp end of shaft and use a twisting and pulling motion to carefully extract the pis ton shaft and head assembly from the barrel 5 R...

Page 235: ... with new seals onto shaft Item Figure 36 13 Install piston Item 5 with new seals and back ups Installing retaining ring onto shaft Install piston onto shaft and secure with lock nut Item 1 Torque lock nut from 30 to 36 ft lb 41 to 49 N m 3 Coat all cylinder parts with clean Dexron III ATF Slide shaft assembly and head into barrel being careful not to damage seals 4 Install retaining ring Item 9 t...

Page 236: ...ft Cylinder 1 Box frame 2 O ring 3 Hydraulic fitting 4 O ring 5 Hydraulic hose 6 Lift cylinder LH shown 7 Hydraulic hose 8 Cotter pin 9 Engine support 10 Frame rail LH shown 11 Clevis pin 12 Lynch pin Figure 37 1 2 3 4 5 6 7 8 9 2 3 4 10 11 12 FRONT RIGHT ...

Page 237: ... lift cylinder Install caps or plugs in hoses to prevent contamination and leakage of hydraulic oil Install plugs in cylinder ports 4 Remove lynch pin and clevis pin that secure lift cylin der to bed 5 Remove cotter pin that secures lift cylinder to engine support 6 Remove lift cylinder from vehicle Installation Fig 37 1 Make sure that lift cylinder is fully retracted 2 Position lift cylinder to v...

Page 238: ...exte rior with cleaning solvent and dry thoroughly IMPORTANT Use caution when using a vise to avoid scratching or distorting any parts 3 Put cylinder in a vise so shaft end is facing up 4 Use a spanner wrench to rotate head Item 6 and re move retaining ring Item 9 Grasp end of shaft and use a twisting and pulling motion to carefully extract the pis ton shaft and head assembly from the barrel 5 Rem...

Page 239: ... with new seals onto shaft Item Figure 40 13 Install piston Item 5 with new seals and back ups Installing retaining ring onto shaft Install piston onto shaft and secure with lock nut Item 1 Torque lock nut from 60 to 75 ft lb 81 to 102 N m 3 Coat all cylinder parts with clean Dexron III ATF Slide shaft assembly and head into barrel being careful not to damage seals 4 Install retaining ring Item 9 ...

Page 240: ...gs on hydraulic hoses and fittings Re move caps and plugs from hoses and fittings Connect hydraulic hoses to manifold 3 Check oil level in reservoir see High Flow Hydraulic Kit Installation Instructions Add correct oil if necessary Valve Cartridge Service Fig 42 1 Make sure the entire outer surface of the manifold is clean before removing the valve 2 For solenoid cartridge valve remove nut securin...

Page 241: ... to flush out contamination Be extremely careful not to damage car tridge Use compressed air for cleaning 7 Reinstall the cartridge valve A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and seal ing IMPORTANT Use care when handling the valve car tridge...

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Page 243: ...ERVICE and REPAIRS 4 Front Differential Service 16 Front Wheel and Axle Housing Assembly 4 Ring to Pinion Gear Engagement 28 Front Brake 8 Differential Drive Shaft 30 Front Brake Service 10 Drive Shaft Cross and Bearing Service 31 Inspect Constant Velocity CV Joint Boot and Bidirectional Clutch 32 Test CV Joint 11 Workman 4000 Series Page 10 1 Front Wheel Drive 4WD ...

Page 244: ...escription Front Differential 5 0 to 1 ratio single reduction Front Brakes Hydraulically operated self adjusting 8 inch diameter drum Bidirectional Clutch Overrunning type Front Wheel Drive 4WD Page 10 2 Workman 4000 Series ...

Page 245: ...The four wheel drive system continues to deliver power to the front wheels until the rear wheels have enough traction to move the vehicle without slip ping Once this occurs the system stops delivering pow er to the front wheels and the handling characteristics become similar to that of a two wheel drive vehicle The four wheel drive system functions in both forward and reverse When front wheels are...

Page 246: ...4 25 26 20 11 12 13 14 15 17 16 27 SMALL SPACER ACCESS HOLE CUP CONE 16 24 FRONT RIGHT 28 LOCTITE 680 45 to 65 ft lb 61 to 88 N m 40 to 60 ft lb 54 to 81 N m APPLY GREASE TO SPLINES LOCTITE 271 170 to 200 ft lb 230 to 271 N m Disassembly Fig 1 1 Park vehicle on a level surface Make sure engine is off Engage parking brake and block rear wheels 2 Partially loosen front wheel nuts Jack up and secure ...

Page 247: ...g 3 A Spalling or pitting on roller or cone contact sur faces Corrosion that can not be cleaned up with light polishing B The rib face on the cone is worn back or roller ends are worn or scored The roller cage is cracked or broken C Peeling gouges or nicks inside the cup or on roll ers Scalloping high spots brinelling or burrs in the cups D The seal attached to the bearing cone is cracked torn or ...

Page 248: ...ut and torque from 80 to 90 ft lb 108 to 122 N m If necessary to install cotter pin tighten nut further and secure assembly with cotter pin B Install cap screw into axle housing and secure with lock nut C Connect upper ball joint to the axle housing Install slotted hex nut and torque from 80 to 90 ft lb 108 to 122 N m If necessary to install cotter pin tighten nut further and secure assembly with ...

Page 249: ...Front Wheel Drive 4WD This page is intentionally blank Workman 4000 Series Page 10 7 Front Wheel Drive 4WD ...

Page 250: ...gage parking brake and block rear wheels 2 Partially loosen front wheel lug nuts Jack up and se cure front wheel off the ground see Jacking Instructions in Operator s Manual Remove wheel nuts and wheel from the brake drum NOTE If the brake drum sticks to the brake shoes dur ing removal loosen brake shoes from the drum by turn ing bolt adjuster through access hole in brake drum 3 Remove brake drum ...

Page 251: ...ease to the splines of the CV joint 5 Insert stub axle with outer bearing cone and spacers into the axle housing and onto the splined end of the CV joint IMPORTANT Hex flange nut 23 should be replaced whenever it is removed 6 Apply Loctite 271 or equivalent to the threads of the CV joint Install hardened washer and new hex flange nut to the CV joint threads Torque flange nut from 170 to 200 ft lb ...

Page 252: ...e spring 15 Lower shoe spring 16 Female push rod 17 Bolt adjuster 18 Adjuster sleeve 19 Pawl 20 Adjuster spring 21 Pawl pin 22 Hold down washer 2 used 23 Hold down spring 2 used 24 Pipe guide 25 Inspection plug 26 Hold down pin 2 used 27 Adjuster assembly Figure 6 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 24 25 26 11 12 13 14 15 13 27 12 10 11 49 to 97 in lb 5 5 to 11 N m For brake service proc...

Page 253: ...tboard boot Joint in this section and replace boot Test CV Joint 1 Test drive vehicle on a smooth surface to verify CV joint problem 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 A If the noise remains constant the wheel bearing is the likely problem see Front Wheel and Axle Housing Assembly in this ...

Page 254: ... Brake hose bracket 14 Constant velocity CV joint assembly 15 Differential 16 Bearing assembly 17 Axle housing RH shown 18 Brake plate plug 19 Front brake assembly RH shown 20 Wheel bearing spacer 21 Hardened washer 22 Hex flange nut 23 Tie rod end RH thread 24 Cotter pin 25 Jam nut RH thread 26 Tie rod 27 Jam nut LH thread 28 Tie rod end LH thread Figure 8 1 2 3 4 5 6 7 8 9 10 19 18 21 22 23 24 2...

Page 255: ...aced 3 Inspect front wheel bearings see Inspection in Front Wheel And Axle Housing Assembly in this section Installation Fig 8 1 If necessary install a new circular clip onto the splined inboard end of the CV joint 2 Grease splines of CV joint with No 2 general pur pose lithium base grease 3 Insert end of CV joint into the front differential until a snap is heard Pull outward on CV joint as close ...

Page 256: ... used 19 Cap screw 4 used 20 Front differential 21 Differential rear mount 22 Lock washer 4 used 23 Cap screw 4 used 24 Differential drive shaft 25 Upper ball joint 26 Socket hex head screw 6 used 27 Differential front bracket 28 Cap screw 3 used 29 Lock washer 3 used 30 Cap screw 31 Lock nut 32 Lower control arm 33 Cap screw 34 Cotter pin 35 Support bracket RH shown 36 Cap screw 3 used per bracke...

Page 257: ...and snubbing washers 18 8 Remove three cap screws 28 and lock washers 29 from the differential front bracket 27 and front dif ferential 9 Pull front differential from the vehicle Installation Fig 10 CAUTION Support front differential during installation to to the differential prevent personal injury from falling and damage 1 Secure front differential to the differential front brack et with three c...

Page 258: ...pacer 2 Front housing 14 Shim 25 Pinion shaft 3 Alignment pin 2 used 15 Carrier assembly 26 Cap screw 5 used 4 Thrust washer 16 Cap screw 8 used 27 Differential case 5 Side bevel gear 17 Washer 28 Roll pin 6 Pinion gear 18 Lock nut 29 Bearing cone 2 used 7 Thrust washer 19 Coupler flange 30 Bearing cup 2 used 8 Pinion gear 20 Oil seal 31 Shim 9 Bearing cone 21 Shim 32 Ring gear 10 Bearing cup 22 B...

Page 259: ...two parts Use a putty knife to further separate the housing and carrier assembly Fig 13 IMPORTANT The bearing caps are marked for reas sembly Place caps in a safe place to avoid damag ing their machined surface Place caps back in the same position during reassembly 4 Remove four cap screws 11 and both bearing caps from the bearing cradles Fig 14 IMPORTANT Keep mating bearing bearing cups 30 with m...

Page 260: ... Fig 17 8 Remove both sets of pinion gear shafts 5 and 6 and thrust washers 4 and 7 by rotating the gears 90o through the opening in the differential case 27 Fig Figure 16 18 PUNCH IMPORTANT Avoid damaging gear teeth when re moving the gear ring 32 from the differential case 27 9 Remove five cap screws 26 from the differential case 27 and gear ring 32 Drive ring gear off the dif ferential case usi...

Page 261: ... carrier assembly 15 If necessary press pinion gear shaft out of the carrier housing Remove oil seal 20 and discard it Remove bearing cone 22 shims 21 and spacer 24 from the carrier housing 15 Fig 21 NOTE Remove bearing cone 9 from the pinion gear shaft 8 only if it needs replacing see Inspection 12 Press pinion gear shaft 8 out of the bearing cone 9 using bearing press Make sure shaft does not dr...

Page 262: ...nt housing 2 Fig 25 Figure 24 Inspection Fig 11 1 Inspect front housing 2 and carrier assembly 15 for cracks and damage Replace either part if its condi tion could affect the operation of the front differential as sembly Clean flange surfaces of any sealant oil and dirt Fig 26 2 Inspect needle bearings 34 for wear and damage Replace bearings if needles are bent do not rotate free ly or do not rema...

Page 263: ...not acceptable Fig 29 Figure 28 IMPORTANT If any part of a bearing needs replace ment both bearing cone and cup must be replaced 5 Replace bearing cones 9 22 or 29 and corre sponding bearing cups 10 23 or 30 if any of the follow ing conditions occur Fig 30 and 31 A Spalling or pitting on roller or cone contact sur faces Corrosion that can not be cleaned up with light polishing B The rib face on th...

Page 264: ...BEARING CAP BEARING CRADLE PINION GEAR 6 BEARING CONE 9 DIFFERENTIAL CASE 27 BEARING PERMATEX LOCK NUT 18 OIL SEAL 20 ASSEMBLY 15 WASHER 17 SPACER 24 CUP 10 CUP 30 CAP SCREW 26 SHAFT 25 WASHER 7 WASHER 4 CAP SCREW 11 ROLL PIN 28 CUP 23 Figure 32 NOTE In Figure 32 numbers in parentheses corre spond to the reference numbers in Figure 11 Front Wheel Drive 4WD Page 10 22 Workman 4000 Series ...

Page 265: ...nch decrease in the running position NUMBERS SHIMMING DIMENSION MATCHING Figure 33 When reusing an old ring gear and pinion gear shaft set measure the old shim pack thickness and build a new shim pack to the same thickness Measure each shim separately with a micrometer Add each shim thickness to get the total shim pack thickness If a new gear set is being used note the or etching on both the old a...

Page 266: ...ension from 3 750 inch For Example If the pinion gear shaft is etched 4 Add 0 004 to 3 750 to get 3 754 inch If the pinion gear shaft is etched 4 Subtract 0 004 from 3 750 to get 3 746 inch E Now determine the difference between the mea surement taken in a step C and the value calculated in step D This difference is the new shim thickness F Remove bearing cup from the carrier assembly G Install re...

Page 267: ...t should be from 7 to 12 in lb 8 to 14 kg cm If the torque to rotate the pinion gear shaft does not meet specification repeat steps C or D and E as neces sary G If the torque required to rotate the shaft of the pin ion gear shaft is as specified in step B or F remove lock nut washer coupler flange bearing cone 22 from the shaft of the pinion gear Press new oil seal 20 into the carrier assembly 15 ...

Page 268: ...mportant to push both bearing assemblies simultaneously into their cradles IMPORTANT If new bearing cones 29 were installed onto the differential case 27 new bearing cups 30 must be installed to the bearing cradles 10 Place bearing cups 30 onto bearing cones 29 Install bearing assemblies into the bearing cradles of the carrier assembly 15 Make sure bearing cups 30 are matched to the proper bearing...

Page 269: ...d press two new bearings into the front housing 2 Press new oil seals into housing Fig 48 15 Make sure flange surface of carrier assembly 15 is clean and free of any sealant dirt and oil Apply thin bead of non acidic silicon sealer along the entire flange surface of the carrier assembly Fig 49 16 Make sure flange surface of front housing 2 is clean and free of any sealant dirt and oil Attached fro...

Page 270: ... ring gear has made one complete revolution Both the drive side pattern and the coast side pattern on the ring gear should be at the toe portion of the tooth Fig 53 Study the patterns in the following illustrations and cor rect engagement as necessary NOTE When making changes note that two variables are involved Example If you have the backlash set cor rectly to specifications and you change the p...

Page 271: ...e Toe 1 Decreasing backlash moves the ring gear closer to Figure 55 the pinion RING GEAR RING GEAR A Drive pattern convex side of gear moves lower DRIVE SIDE COAST SIDE and toward the toe Heel Heel B Coast pattern concave side of gear moves slightly higher and toward the heel 2 Increasing backlash moves the ring gear away from the pinion Toe Toe A Drive pattern convex side of gear moves higher and...

Page 272: ...s Manual WARNING 3 Remove six socket head screws securing the differ ential drive shaft flange yoke to the coupler flange on the 1 Flange yoke 3 Front differential front differential Fig 58 2 Socket head screw 4 Slide slip yoke towards the bidirectional clutch Pull slip yoke off the clutch shaft Fig 59 Installation 1 Slide slip yoke onto clutch shaft Fig 59 2 Position flange yoke to the coupler fl...

Page 273: ...g bores B Press one bearing partially into yoke 1 2 3 C Insert cross into yoke and bearing D Hold cross in alignment and press bearing in until Figure 60 it hits the yoke 1 Flange yoke 3 Snap ring 4 used 2 Cross and bearing kit 4 Tube yoke E Install snap ring into yoke groove to secure instal led bearing F Place second bearing into yoke bore and onto cross shaft Press bearing into yoke and secure ...

Page 274: ...retaining ring 3 from the transaxle front drive shaft 19 using a snap ring pliers Discard snap ring if it is cracked distorted or bent 14 Adapter plate 15 Screw 4 used 16 Lock washer 6 used 17 Hex socket head screw 6 used 18 Differential drive shaft 19 Front drive shaft transaxle IMPORTANT When removing the bidirectional clutch from the front drive shaft 19 hold the bear ing end of the housing and...

Page 275: ...er has any flat spots 6 Replace garter spring 6 if it is distorted in any way that the rollers 7 are not held snuggly by the cam 8 and cage 12 when assembled Fig 62 Figure 62 Figure 63 7 Replace ball bearings 4 if any of the following conditions occur A Play between bearing races and balls is exces sive The bearing cage is cracked or distorted B The inner or outer bearing races are cracked dis tor...

Page 276: ...e bidirectional clutch and transaxle 2 If the adapter plate 14 was removed from the trans axle install as follows A Make sure contact surfaces between the adapter plate and transaxle are free of dirt debris and oil B Apply Loctite 59375 black silicone sealant or equivalent to the back side of the adapter plate C Secure adapter plate to the transaxle with four screws 15 Make sure not to get sealant...

Page 277: ... when installing 6 Insert seal plug 2 into the housing and race 5 us ing a driver 7 Secure clutch shaft to housing and race 5 with lock washers 16 and hex socket head screws 17 8 Lower front wheels to ground 9 Make sure drain plug is installed properly to the transaxle Fill transaxle with Dexron III ATF see Opera tors Manual 10 Install differential drive shaft 18 to clutch shaft 1 and the front di...

Page 278: ...This page is intentionally blank Front Wheel Drive 4WD Page 10 36 Workman 4000 Series ...

Page 279: ...000000 8 WIRE HARNESS DRAWINGS Front Wire Harness Drawing Workman 3000 4000 Serial Number Below 270999999 10 Serial Number Above 280000000 12 Rear Wire Harness Drawing Workman 3100 Serial Number Below 260000000 14 Serial Number From 260000001 to 260000400 15 Serial Number Above 260000400 16 Rear Wire Harness Drawing Workman 3200 4200 Serial Number Below 260000000 18 Serial Number Above 260000000 2...

Page 280: ...Workman 3000 4000 Electrical Schematics Page 11 2 This page is intentionally blank ...

Page 281: ...SENDER L P102 C OR LIGHT SWITCH BRAKE SWITCH P102 B BN W BK CLUTCH SWITCH ENGINE BU P101 F BK P102 A OIL PRES W BK 86 TAIL BRAKE LIGHTS PK BU STARTER FACTORY SHUNT VIA MATING CONN TEMPERATURE SENDER TEMP I G S FUEL S G I GN GREEN OR ORANGE BK R BK GROUND CONNECTION TO FRONT HARNESS ENGINE NEGATIVE BATTERY CABLE LOW HIGH P100 B R F 3 OR R BK SPEED ADVANCE MODULE ENGINE KILL BK OTHER 3RD P102 D HIGH...

Page 282: ...Rev C Page 11 4 Vehicle Electrical Schematic Kohler Gasoline Engine All relays and solenoids are shown as de energized Workman 3100 Serial Number Above 260000000 ...

Page 283: ... SENDER BU W L P102 C BU W OR LIGHT SWITCH BRAKE SWITCH R W P102 B BN W BK CLUTCH SWITCH W BU SWITCH BU P101 F OVER TEMP BK P102 A OIL PRES BATT W BK 86 TAIL BRAKE LIGHTS BK R STARTER TEMPERATURE SENDER TEMP I G S FUEL S G I GN GREEN ALTERNATOR FRAME GROUND TO FRONT HARNESS ENGINE NEGATIVE BATTERY CABLE P100 B R F 3 OR R BK OTHER 3RD P101 D OR HIGH FLOW HYDRAULICS KIT OFF FACTORY SHUNT VIA MATING ...

Page 284: ...Rev C Page 11 6 Vehicle Electrical Schematic Briggs Daihatsu Gasoline Engine All relays and solenoids are shown as de energized Workman 3200 and 4200 Serial Number Above 260000000 ...

Page 285: ... W L P102 C BU W OR LIGHT SWITCH BRAKE SWITCH P102 B BN W BK CLUTCH SWITCH BU SWITCH BU P101 F OVER TEMP BK P102 A OIL PRES BATT W BK 86 TAIL BRAKE LIGHTS STARTER 30 85 86 87 FACTORY SHUNT VIA MATING CONN TEMP I G S TEMPERATURE SENDER FUEL S G I GLOW PLUG SWITCH GN GREEN ALTERNATOR FRAME GROUND TO FRONT HARNESS ENGINE NEGATIVE BATTERY CABLE P100 B R F 3 OR R BK OTHER 3RD P101 D HIGH FLOW HYDRAULIC...

Page 286: ...Rev C Page 11 8 Vehicle Electrical Schematic Briggs Daihatsu Diesel Engine All relays and solenoids are shown as de energized Workman 3300 and 4300 Serial Number Above 260000000 ...

Page 287: ...Rev C Page 11 9 This Page Is Intentionally Blank ...

Page 288: ...Rev C Page 11 10 Front Wire Harness Drawing Workman 3000 4000 AND UP SN 280000001 Serial Number Below 270999999 ...

Page 289: ...RAY ORANGE YELLOW BROWN WHITE WHITE BLACK WHITE WHITE BROWN WHITE RED BLACK BROWN WHITE GRAY YELLOW BLUE RED BLACK BROWN WHITE BLACK GREEN BLACK VIOLET YELLOW ORANGE BLUE WHITE BLACK ORANGE ORANGE ORANGE BLACK YELLOW BLACK BLACK BLACK BLACK ORANGE BLACK GREEN BLACK WHITE BLACK BLACK WHITE BLACK BLACK ORANGE ORANGE ORANGE GRAY GRAY AND UP SN 280000001 RED WHITE RED BLACK RED WHITE Serial Number Bel...

Page 290: ...Rev C Page 11 12 Front Wire Harness Drawing Workman 3000 4000 Serial Number Above 280000000 ...

Page 291: ...NGE ORANGE ORANGE BLACK YELLOW BLACK BLACK BLACK ORANGE ORANGE ORANGE ORANGE ORANGE BLACK GREEN BLACK WHITE BLACK BLACK WHITE BLACK BLACK RED WHITE BROWN WHITE GRAY YELLOW BLUE RED BLACK BROWN WHITE BLACK GREEN BLACK VIOLET YELLOW WHITE BROWN WHITE RED BLACK RED WHITE GRAY BLACK RED RED RED RED WHITE ORANGE YELLOW BROWN WHITE BLACK GRAY ORANGE YELLOW BROWN WHITE GRAY GRAY BLACK WHITE BLACK WHITE ...

Page 292: ...24 BLACK TAIL LIGHT SPLICE B 25 BLACK GROUND SPLICE B 26 BLACK GROUND FRONT HARNESS P100 PIN A 27 BLACK SPEED PICKUP SPLICE B 28 BLUE SPEED PICKUP FRONT HARNESS P101 PIN B 29 RED FRONT HARNESS P100 PIN B SPLICE A 30 RED WHT FRONT HARNESS P102 PIN D SPLICE C 31 RED BLK FRONT HARNESS P101 PIN G SPLICE D 32 PINK PTO SWITCH PLUG PTO SWITCH PLUG 33 SPEED PICKUP PLUG SPEED PICKUP PLUG 34 BLACK SPLICE E ...

Page 293: ...Rev C Page 11 15 Rear Wire Harness Kohler Gasoline Engine Workman 3100 Serial Number From 260000001 To 260000400 WIRE LIST ...

Page 294: ...Rev C Page 11 16 Rear Wire Harness Drawing Kohler Gasoline Engine Workman 3100 Serial Number Above 260000400 ...

Page 295: ...umber Above 260000400 BLACK WHITE BROWN WHITE GRAY RED BLACK PINK GRAY GRAY GRAY BLACK PINK GRAY GRAY FUSIBLE LINK GRAY RED WHITE RED BLACK RED WHITE RED BLACK RED GRAY RED BLACK BLUE WHITE RED WHITE BLACK BROWN WHITE BLACK BLACK PINK BLUE BLACK BLACK BLACK RED WHITE BLACK BLACK RED WHITE ...

Page 296: ...Rev C Page 11 18 Rear Wire Harness Drawing Briggs Daihatsu Gasoline Engine Workman 3200 and 4200 Serial Number Below 260000000 ...

Page 297: ...OWN WHITE BLACK YELLOW BLUE YELLOW GREEN BLACK BLACK BLUE WHITE BLACK BLACK WHITE BLACK BROWN BLACK RED BLACK RED WHITE BLACK VIOLET RED BLACK GREEN WHITE BLUE WHITE VIOLET RED WHITE GREEN BLUE RED WHITE RED WHITE WHITE RED BLACK RED WHITE RED WHITE RED WHITE RED WHITE ORANGE RED WHITE RED BLACK THIS WIRE DASHED LINE INCLUDED ONLY IN SERIAL NUMBERS FROM 250000001 TO 250999999 Serial Number Below 2...

Page 298: ...Rev C Page 11 20 Rear Wire Harness Drawing Briggs Daihatsu Gasoline Engine Workman 3200 and 4200 Serial Number Above 260000000 ...

Page 299: ...D WHITE RED WHITE WHITE RED WHITE RED WHITE RED WHITE RED WHITE RED WHITE RED BLACK GRAY GRAY GRAY RED RED RED WHITE RED BLACK RED WHITE BLUE ORANGE GREEN WHITE BLUE WHITE GREEN WHITE BLACK BLACK BLACK VIOLET RED WHITE VIOLET RED RED BLACK BLACK BLACK WHITE BLACK BLACK BROWN BLACK BLACK BLACK BLUE WHITE BLACK GRAY RED BLACK WHITE BLACK GRAY GRAY GRAY YELLOW BROWN WHITE GREEN BLACK ...

Page 300: ...Rev C Page 11 22 Rear Wire Harness Drawing Briggs Daihatsu Diesel Engine Workman 3300 and 4300 Serial Number Below 260000000 ...

Page 301: ...Y RED PINK BLACK BLACK RED RED BLACK PINK PINK PINK RED WHITE PINK RED RED BLACK RED BLACK WHITE BLACK BROWN BLACK BLACK RED RED BLACK RED BROWN WHITE GRAY VIOLET RED GRAY VIOLET BLACK BLACK YELLOW ORANGE Rear Wire Harness Diagram Briggs Daihatsu Diesel Engine Workman 3300 and 4300 Serial Number Below 260000000 ...

Page 302: ...Rev C Page 11 24 Rear Wire Harness Drawing Briggs Daihatsu Diesel Engine Workman 3300 and 4300 Serial Number From 260000001 To 270999999 ...

Page 303: ...260000001 To 270999999 GRAY BLACK RED GRAY GRAY PINK RED RED BLACK PINK RED RED BLACK PINK RED BLACK BLACK RED RED BLACK RED ORANGE YELLOW BLACK BLACK PINK VIOLET RED BLACK BLACK BLACK RED RED BLACK VIOLET RED GRAY BLACK BLACK BLACK BROWN WHITE BLACK BLUE WHITE BROWN WHITE GRAY GRAY BLUE GREEN BLACK GRAY GRAY GRAY ...

Page 304: ...Rev C Page 11 26 Rear Wire Harness Drawing Briggs Daihatsu Diesel Engine Workman 3300 and 4300 Serial Number Above 280000000 ...

Page 305: ...ve 280000000 GRAY RED BLACK BLACK ORANGE YELLOW WHITE BLACK BLUE WHITE BROWN WHITE BLUE GRAY RED GRAY PINK RED RED BLACK RED RED BLACK RED RED PINK RED BLACK PINK YELLOW RED BLACK GRAY GRAY PINK BLACK VIOLET RED GRAY RED BLACK VIOLET RED BLACK BLACK RED BLACK BROWN BLACK BLACK BLACK GREEN BLACK YELLOW BLACK GRAY ...

Page 306: ......

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