Toro Workman GTX Service Manual Download Page 118

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Workman GTX Gasoline

Chassis

Troubleshooting

Suspension and Steering

Problem

Possible Cause

Front end is noisy.

Front wheel lug nuts are loose.

Front wheel bearings are loose or worn.

Front suspension struts are loose or worn.

Front end components (e.g. tie--rod, spindle, A--arm) are loose or

worn.

Steering rack assembly is damaged or worn.

Rear end is noisy.

Rear wheel lug nuts are loose.

Rear suspension shocks are loose or worn.

Rear wheel bearings are loose or worn.

Rear end components (e.g. rubber bushing, stabilizer, anti--sway

bar, A--arm) are loose or worn.

Clutch or transaxle problem (see Chapter 4 -- Drive Train).

Excessive steering play.

Front wheel lug nuts are loose.

Front wheel bearings are loose or worn.

Steering shaft joints are loose or worn.

Tie rod ends are worn.

Bushings in spindle or A--arm are loose or worn.

Steering rack assembly is damaged or worn.

Vehicle is unstable or wanders.

Tire pressure is low or uneven between tires.

Wheel lug nuts are loose.

Front wheel bearings are loose or worn.

Steering shaft bearings are worn.

Front wheel alignment (toe--in) is incorrect.

Bushings in spindle or A--arm are loose or worn.

Rubber shock insert in front suspension strut is loose or worn.

Steering rack assembly is damaged or worn.

Summary of Contents for Workman GTX

Page 1: ...Form No 16224SL Rev C Workman GTX Gasoline Original Instructions EN ...

Page 2: ...ment or the disclosure of its content This document shall not be reproduced by a third party without the express written consent of The Toro Company and or the appropriate affiliated company Revision History Revision Date Description 2016 Initial Issue A 03 2018 Incorporated EFI information and procedures Added revision history B 02 2020 Updated torque values C 05 2020 Updated Chassis and Electric...

Page 3: ...blications To do this effectively we encourage user feedback Please comment on the completeness accuracy organization usability and readability of this manual by an e mail to servicemanuals toro com or Mail to Technical Publication Manager Commercial The Toro Company 8111 Lyndale Avenue South Bloomington MN 55420 1196 Phone 1 952 887 8495 ...

Page 4: ...NOTES _ ...

Page 5: ...erator s Manual and Parts Catalog are avail able on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOT...

Page 6: ...Workman GTX Gasoline This page is intentionally blank ...

Page 7: ...fications 4 2 Drive Train Operation 4 3 Special Tools 4 6 Adjustments 4 7 Service and Repairs 4 10 Chapter 5 Electrical System General Information 5 2 Electrical Drawings 5 2 Special Tools 5 4 Troubleshooting 5 6 Electrical System Quick Checks 5 8 Component Testing 5 9 Service and Repairs 5 26 ADVANCED MOTORS DRIVES STARTER GENERATOR TROUBLESHOOTING GUIDE Chapter 6 Chassis General Information 6 1 ...

Page 8: ...Workman GTX Gasoline This page is intentionally blank ...

Page 9: ...AFETY INSTRUCTIONS 2 Supervisor s Responsibilities 2 Before Operating 2 While Operating 3 Maintenance and Service 3 JACKING AND OTHER INSTRUCTIONS 4 Jacking Vehicle 4 Transporting Vehicle 4 Towing Vehicle 4 Transaxle Neutral Position 5 SAFETY AND INSTRUCTION DECALS 6 Safety ...

Page 10: ...e operators are thoroughly trained and fa miliar with the Operator s Manual and all labels on the vehicle 2 Be sure to establish your own special procedures and work rules for unusual operating conditions e g slopes too steep for vehicle operation Before Operating 1 Read and understand the contents of the Operator s Manual and Operator s DVD before starting and operat ing the vehicle Become famili...

Page 11: ...not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed The maximum engine speed for the Workman GTX is 3750 RPM 7 Shut engine off before checking or adding oil to the engine crankcase 8 Disconnect battery before servicing the vehicle Dis connect negative battery cable first and positive cable last If battery voltage is required for troublesho...

Page 12: ...d support the vehicle Jacking Locations 1 Jack front of the vehicle on the front of the frame be hind the towing tongue Fig 1 2 Jack rear of the vehicle under each rear axle tube Do not jack vehicle below the transaxle case Fig 2 1 Front of frame 2 Towing tongue Figure 1 2 1 1 Rear axle tube 2 Transaxle case Figure 2 2 1 1 Transporting Vehicle When moving the vehicle long distances use a trailer o...

Page 13: ...ey switch 2 Move shift lever to the neutral position Fig 3 3 Make sure transaxle is in the neutral position by ro tating the secondary clutch Fig 4 The rear tires should not rotate as the secondary clutch is rotated If tire rota tion does occur see Adjust Shift Cable in the Adjustment section of Chapter 5 Drive Train 1 Shift lever in neutral 2 Forward position 3 Reverse position Figure 3 1 2 3 1 S...

Page 14: ...uction Decals Numerous safety and instruction decals are affixed to your Workman GTX If any decal becomes illegible or damaged install a new decal Part numbers are listed in the Parts Catalog Order replacement decals from your Authorized Toro Distributor ...

Page 15: ...lated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 Product Records Insert Operator s Manual and Parts Catalog for your Workman at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installation Instructions Op erator s Manuals and Parts Catalogs for those options at the end of thi...

Page 16: ...0 09375 Workman GTX Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 17: ...or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Fastener Identification Figure 1 Grade 1 Grade 5 Grade 8 Inch Series Bolts and Screws Figure 2 Class 8 8 Class 10 9 Metric Bolts and Screws Using a Torque Wrench with an Offset Wrench Use of an offset wrench e g crowfoot wrench will affect torque wrench calibrati...

Page 18: ...3 8 24 UNF 17 2 18 2 24 3 35 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 3...

Page 19: ...N m M16 X 2 0 166 15 ft lb 225 20 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 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 t...

Page 20: ... lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Class 8 8 80 10 ft lb 108 14 N m For steel wheels and non lubricated fasteners Thread Cutting Screws Zinc Plated Steel Thread Size Threads per Inch Baseline Torque Type A Type B No 6 18 20 20 5 in lb No...

Page 21: ... only 3 Rear Frame Panel Cover 3 SPECIFICATIONS 4 ADJUSTMENTS 5 Adjust Accelerator Cable 5 SERVICE AND REPAIRS 6 Cooling System 6 Accelerator Control 7 Air Cleaner System 8 Exhaust System 10 Fuel Lines and Connections 12 Fuel Tank and Fuel Pumps 14 Fuel Evaporative Control System 16 Engine 18 Engine Removal 19 Engine Installation 20 KOHLER Command PRO CH260 CH440 Service Manual KOHLER Command PRO ...

Page 22: ... EFI engines Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the KOHLER Service Manuals and the use of some specialized test equipment is ex plained The cost of the test equipment and the special ized nature of some repairs may dictate that engine work be done at an engine repair facility Kohler Gasoline Engine The engine...

Page 23: ...offers an EFI Service Tool Kit Kohler P N 24 761 01 S which includes a pressure gauge a test light fittings wiring and adapters required to maintain the fu el system Kohler diagnostic software and service tool kits can be obtained through Kohler Distributors and Dealers or purchased online IMPORTANT Do not plug or unplug the engine ECU for a period of forty 40 seconds after the machine key switch ...

Page 24: ...igh Idle no load 3700 50 RPM Carburetor Float Feed Single Barrel Fuel Pump Pulsating Crankcase Vacuum Fuel Unleaded regular grade gasoline Fuel Tank Capacity 5 0 U S gal 18 9 l Lubrication System Splash Lubrication Crankcase Oil Capacity 1 1 U S qt 1 0 l Engine Oil See Operator s Manual Spark Plugs Champion RC 12LC4 or equivalent Spark Plug Gap 0 030 in 0 76 mm Starter Generator 220 Amps starting ...

Page 25: ... and prop with rod to gain access to the engine 3 Make sure that shift lever on steering column is in the neutral position to prevent the vehicle from moving NOTE If phototac is to be used to measure engine speed DO NOT use secondary clutch on transaxle for speed measurement 4 Start engine and fully depress accelerator pedal Have a second person measure engine speed with a ta chometer With pedal f...

Page 26: ...eneral Information section of this chapter 4 Carefully remove spark plug wire from the spark plug to prevent the engine from starting unexpectedly IMPORTANT Never clean engine with pressurized water Water could enter and contaminate the fuel system 5 Clean cooling fins on cylinder head 6 Clean static debris screen and blower housing of dirt and debris Remove screen and housing if necessary Fig 4 7...

Page 27: ...nts to engine using Figures 6 and 7 as guides A If throttle lever was removed make sure that bushing flange is inserted into lever hole before in stalling flat washer and flange head screw Make sure that throttle lever rotates freely after assembly 2 After assembly is completed make sure that throttle lever moves freely as accelerator pedal is depressed fully and released 3 Check adjustment of acc...

Page 28: ...ner System Figure 8 1 Engine 2 Hose clamp 3 Intake hose 4 Hose clamp 5 Air cleaner assembly 6 Hose clamp 7 Air inlet hood 8 Mounting bracket 9 Flange head screw 2 used 10 Flange nut 2 used 11 Swing arm FRONT RIGHT VACUATOR DIRECTION 6 1 5 7 8 9 10 2 3 4 11 ...

Page 29: ...air cleaner components as needed using Figures 8 and 9 as guides Installation Fig 8 IMPORTANT Any leaks in the air filter system will cause serious engine damage Make sure that all air cleaner components are in good condition and are properly secured during assembly of air cleaner system 1 Assemble air cleaner system using Figures 8 and 9 as guides The air inlet hood item 5 in Fig 8 should be posi...

Page 30: ...7 Intermediate pipe 8 Flange head screw 9 Flange head screw 10 Muffler bracket 11 Flange nut 2 used 12 Cap screw 2 used 13 Swing arm 14 Flange nut 2 used 15 Exhaust gasket 16 Oxygen Sensor EFI G247348 11 11 12 13 14 14 15 15 16 1 2 3 3 4 5 6 7 8 9 10 37 to 44 N m 27 to 33 ft lb 22 to 27 N m 16 to 20 ft lb 17 to 21 N m 12 6 to 15 4 ft lb 22 to 27 N m 16 to 20 ft lb 37 to 44 N m 27 to 33 ft lb ...

Page 31: ...0 NOTE New oxygen sensor threads come pre coated with an anti seize compound If a previously installed oxygen sensor is used apply a small amount of anti seize to the threads 1 If installing an oxygen sensor do not allow the tip of the sensor to touch anything as it may become contami nated Tighten from 12 6 to 15 4 ft lb 17 to 21 N m 2 If the exhaust manifold was removed from engine install manif...

Page 32: ...ver the supply hose end with a rag while dis connecting the hose to absorb any fuel leakage 2 Disconnect the fuel supply hose from either the elec tric fuel pump or the fuel injector A Lift supply hose fitting lock up to unlock the fitting Fig 13 B Press supply hose fitting tab and pull fitting from barb 3 Connect the fuel supply hose to either the electric fu el pump or the fuel injector A Push s...

Page 33: ...Workman GTX Gasoline Gasoline Engine Page 3 13 Figure 13 1 Supply hose fitting lock locked down 2 Supply hose fitting lock unlocked up 3 Supply hose fitting tab 1 2 3 3 LOCKED UNLOCKED Gasoline Engine ...

Page 34: ...1 Carbon canister EVAP system 12 Pulse hose 13 Pulse line filter 14 Pulse hose to engine cover 15 Electric fuel pump fuel injected engines 16 Fuel filter fuel injected engines Figure 14 FRONT RIGHT 2 3 6 8 9 10 1 5 7 12 13 4 7 11 14 90 to 110 in lb 10 2 to 12 4 N m 16 15 11 7 to 14 3 ft lb 16 to 19 N m 18 to 22 in lb 2 to 2 5 N m CAUTION Read safety precautions for handling gasoline before working...

Page 35: ...to prevent harmful con tamination from entering the electric fuel pump assembly Fuel Tank Removal Fig 14 NOTE If fuel evaporative control system components require service see Fuel Evaporative Control System Service in this section of this chapter 1 Park machine on a level surface stop the engine en gage parking brake and remove the key from the key switch 2 Remove seat base assembly with attached...

Page 36: ...rbon canister 6 Carbon canister bracket 7 EVAP hose 8 Fresh air filter 9 CV cartridge 10 EVAP hose 11 Orifice adapter 12 EVAP hose to engine 13 Engine EFI 14 EVAP hose 15 Electric fuel pump 16 EVAP hose 17 Wye fitting Figure 16 G247513 11 12 11 12 13 14 16 15 17 1 2 3 4 5 6 7 8 9 9 10 10 6 3 4 5 2 7 8 CARBURETED ENGINE FUEL INJECTED ENGINE EFI ...

Page 37: ...ve seat base assembly from vehicle 3 Inspect carbon cannister and attached hoses for damage or obvious leaks A damaged or leaking cannis ter should be replaced 4 Remove EVAP components as needed using Fig ures 16 and 17 as guides A If hoses are removed from the carbon canister note hose location for assembly purposes Figure 17 identifies hose location B The orifice adapter item 11 in Fig 16 has a ...

Page 38: ...ew 37 CVT drive belt 38 Starter generator belt 39 Throttle bracket 40 Flange bushing 41 Throttle lever 42 Flat washer 43 Spring keeper 44 Ball stud 45 Spring 46 Negative cable 47 Flange head screw 2 used 48 Flange head screw 49 R clamp 50 Accelerator cable 51 Choke cable carbureted engine 52 Woodruff key 53 Oxygen sensor EFI engine FRONT RIGHT 17 to 22 ft lb 24 to 29 N m 17 to 22 ft lb 24 to 29 N ...

Page 39: ...ps that secure the air intake hose to the engine and the air cleaner assembly Remove the intake hose 7 Remove exhaust manifold and intermediate pipe from engine and muffler see Exhaust System in this section CAUTION Read safety precautions for handling gasoline before working on the fuel system see Safety In structions in Chapter 1 Safety 8 Disconnect hoses from carbureted engines Fig 19 A Disconn...

Page 40: ...arts and attachments to the engine before installing engine to vehicle CAUTION To prevent personal injury make sure that engine is properly supported as it is installed to the vehi cle Engine weighs approximately 76 pounds 34 5 kg IMPORTANT Make sure to not damage the engine fuel hoses control cables electrical harness or oth er parts while installing the engine 2 Carefully install engine to the v...

Page 41: ...t the high pressure fuel supply hose at the carburetor see Fuel Lines and Connections in this Chapter 12 Position and connect the cables to the engine Fig 19 A On machines with carbureted engines attach the choke cable to the carburetor choke lever and se cure with cable clamp Make sure that choke fully closes when choke is applied with dash mounted choke control B For all engines secure accelerat...

Page 42: ...Workman GTX Gasoline Page 3 22 Gasoline Engine This page is intentionally blank ...

Page 43: ...n 4 Primary Clutch Operation 5 Secondary Clutch Operation 5 SPECIAL TOOLS 6 TROUBLESHOOTING 7 SERVICE AND REPAIRS 8 CVT Drive Belt 8 Primary and Secondary Clutches 10 Primary Clutch Service 12 Secondary Clutch Service 14 Transaxle Shift Cable 16 Transaxle 18 Removal 18 Installation 19 Transaxle Service 22 Transaxle Disassembly 23 Transaxle Inspection 26 Transaxle Assembly 27 Drive Train ...

Page 44: ...nformation Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Workman vehicle Refer to the Opera tor s Manual for additional information when servicing the vehicle ...

Page 45: ...Capacity 1 7 U S quarts 1 6 liters Clutch System Continuously variable speed transmission type Primary Clutch Speed sensing with mechanical roller weights Secondary Clutch Torque sensing with spring loaded cam Cap Screw Torque for Primary Clutch 17 to 22 ft lb 24 to 29 N m Cap Screw Torque for Secondary Clutch 39 to 47 ft lb 53 to 63 N m Drive Train ...

Page 46: ...SING LOAD 8 A B C Power is transferred from the engine to the transaxle by a variable clutch system that consists of two 2 clutches connected by a drive belt The primary clutch responds to engine speed and is mounted to the engine crank shaft The secondary clutch responds to changes in load to the rear axle and is mounted to the transaxle in put shaft The two clutches work together to automaticall...

Page 47: ...ry sheave 2 Moveable sheave 3 Spider assembly 4 Cover 5 Roller 6 used Figure 2 5 4 3 2 1 Secondary Clutch Operation The operation of the secondary clutch is affected by transaxle load When the vehicle is stopped the drive belt is held at the outer diameter of the secondary clutch sheaves from the pressure of the spring pushing the moveable sheave against the stationary sheave and away from the fix...

Page 48: ...w is removed Toro Part Number TOR6039 Figure 4 Primary Clutch Spider Removal Tool Kit This kit is required to remove the primary clutch spider from the post of the stationary sheave Kit includes clutch holding bar and spanner Toro Part Number TOR6016 1 Holding bar 2 Spanner 1 2 Figure 5 Secondary Clutch Press Tool The secondary clutch press tool is used to compress the compression spring in the se...

Page 50: ...e and Repairs CVT Drive Belt 1 Engine 2 Starter generator 3 Starter generator drive belt 4 Starter generator pulley 5 CVT drive belt 6 Primary clutch 7 Secondary clutch 8 Vehicle swing arm 9 Transaxle assembly Figure 7 v 7 4 5 3 2 6 1 8 9 FRONT RIGHT ...

Page 51: ...tion 2 Allow engine exhaust system and drive system to cool before working on drive system 3 Raise and support vehicle cargo bed to allow access to drive system 4 While rotating the secondary clutch route CVT drive belt from the secondary clutch sheaves 5 Remove drive belt from from the primary clutch and vehicle Drive Belt Installation Fig 7 1 Place CVT drive belt around primary clutch 2 Position...

Page 52: ...eize Lubricant 12 13 39 to 47 ft lb 53 to 63 N m CAUTION The engine exhaust system and drive system components may be hot To avoid possible burns allow all components to cool before work ing on drive system components Removal Fig 8 1 Park machine on a level surface stop engine set parking brake and remove key from the key switch 2 Allow engine exhaust system and drive system to cool before working...

Page 53: ...ure starter generator pulley to pri mary clutch with removed washer head screws Fig 10 Torque screws from 132 to 168 in lb 15 0 to 18 9 N m B Thoroughly clean the tapered surfaces of the en gine crankshaft and primary clutch C Slide primary clutch assembly onto the engine shaft D Secure primary clutch to engine shaft with cap screw and flat washer Torque screw from 17 to 22 ft lb 24 to 29 N m E In...

Page 54: ...f X marks cast on the cover and spider for assembly pur poses Remove cover from clutch assembly 2 Remove compression spring and shims item 6 from clutch Label shims and their location for assembly purposes 3 Make sure that starter generator pulley item 2 has been removed from the primary clutch see Primary and Secondary Clutches in this section 4 Use starter generator pulley washer head screws to ...

Page 55: ...ur Workman model and serial number Do not mix clutch components from different vehicles IMPORTANT For proper primary clutch operation DO NOT lubricate primary clutch components 1 If removed install moveable sheave onto post of sta tionary sheave 2 If removed install primary buttons button plugs and rollers to pockets in moveable sheave Rollers should not be lubricated 3 Place shim item 8 onto stat...

Page 56: ...l dust and debris from clutch compo nents If necessary use contact or brake cleaner to remove any oil or other lubricants from clutch com ponents B Inspect the spring and replace if damaged or fa tigued C Check the rollers in the stationary sheave for binding or wear If binding or uneven wear is found replace secondary clutch assembly D Check the contact surface of the sheaves for wear and or fray...

Page 57: ...Workman GTX Gasoline Drive Train Page 4 15 This page is intentionally blank Drive Train ...

Page 58: ... 2 Raise and support cargo bed to access the end of shift cable at the transaxle 3 Remove dash and position it toward the front of the vehicle to access the end of the shift cable at the shift lever see Dash in the Service and Repairs section of Chapter 6 Chassis It is not necessary to remove choke cable from dash 4 Disconnect shift cable from transaxle Fig 14 A Loosen jam nuts that secure shift c...

Page 59: ... column is in the NEUTRAL position and that shift lever on transaxle is in the NEUTRAL position 4 Connect rear of shift cable to transaxle Fig 14 A Fully install ball joint item 8 to end of shift cable and secure to cable with jam nut B Position shift cable to spanner bar item 3 mak ing sure that spanner bar is between washers and jam nuts on cable C Adjust cable position with jam nuts on spanner ...

Page 60: ...b 34 to 42 N m 200 to 230 in lb 23 to 25 N m Grade 8 Grade 5 CAUTION The engine exhaust system and drive system components may be hot To avoid possible burns allow all components to cool before work ing on drive system components IMPORTANT Torque tighten the fasteners based on the fastener grade Make sure to use the correct torque refer to Figure 17 Transaxle Removal Fig 17 1 Park vehicle on a lev...

Page 61: ...he Service and Repairs section of Chapter 7 Chas sis 10 Support transaxle from below to prevent it from mov ing CAUTION To prevent personal injury make sure that transaxle is properly supported as it is removed from the vehicle Transaxle weighs approximate ly 55 pounds 25 kg 11 Remove four 4 flange head screws item 11 and lock nuts item 12 that secure the transaxle to the swing arm IMPORTANT Take ...

Page 62: ... section of Chapter 7 Chassis 9 Check that forward neutral and reverse positions engage as shift lever is moved to each position If neces sary adjust shift cable at spanner bar so that all posi tions engage 10 Lower vehicle to ground 11 Install cargo bed to the frame see Cargo Bed in the Service and Repairs section of Chapter 7 Chassis 12 Make sure that transaxle is filled with 1 7 quarts 1 6 lite...

Page 63: ...Workman GTX Gasoline Drive Train Page 4 21 This page is intentionally blank Drive Train ...

Page 64: ... to 42 N m 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 16 28 31 19 44 15 2 41 42 44 45 47 46 48 41 43 48 16 to 19 ft lb 21 to 25 N m 40 to 45 ft lb 54 to 61 N m 26 to 31 ft lb 35 to 42 N m 16 to 19 ft lb 21 to 25 N m 12 to 15 ft lb 16 to 20 N m 38 13 ...

Page 65: ... assembly Fig 20 A For assembly purposes mark axle case and transaxle case before removing the axle case The right and left axle cases and axle shafts have differ ent lengths so correct assembly is critical B Remove five 5 flange bolts that secure axle case assembly to transaxle case C Slide axle case assembly with installed axle shaft from transaxle case D Repeat process to remove second axle cas...

Page 66: ...gs from the counter shaft assem bly Discard removed bearings B Remove gear from the counter shaft 9 Disassemble center shaft assembly Fig 24 A Remove bearings from the center shaft assem bly Discard removed bearings B Remove spacers gear 51 gear 17 and pin clutch from the center shaft C Remove gear 52 and collar from shaft with puller Collar is a press fit on shaft D Replace pin clutch if worn cra...

Page 67: ...o bore in RH case during shaft removal Slide shaft from RH case 13 Remove oil seals from transaxle cases taking care to not damage bores in cases during seal removal Discard removed seals 14 If necessary pull breather from LH case with pliers Fig 27 Discard and replace breather after removal 15 Remove axle shafts from axle cases RH and LH A Remove axle shaft from case by pulling it out of bearing ...

Page 68: ... surfaces of shafts for wear or damage and replace shafts if necessary 8 Inspect shift shaft and pin clutch Fig 28 A The shift shaft should move freely in the groove of the pin clutch B The engagement arm of the shift shaft should not have excessive scoring at surfaces that contact the pin clutch groove C The shift pins on the pin clutch should not be worn or damaged 9 Inspect differential assembl...

Page 69: ...ng sure that gear teeth mesh properly with side gear C Slide pinion shaft through case and installed pin ion gears D Align holes in pinion shaft and differential case to allow installation of pin Install new pin into the differ ential case to secure pinion shaft E Place second side gear into case making sure that gear teeth mesh properly with pinion gears F Install gear 60 to case with outer side ...

Page 70: ... that snap ring is fully installed into groove in shaft C Apply oil to lip of new oil seal and carefully install oil seal into RH case Take care to not damage seal during installation D Make sure that selector shaft rotates freely after assembly 8 Apply oil to lip of new oil seals and install seals into transaxle cases 9 Install transaxle shaft assemblies into RH case Fig 35 A Support the RH case ...

Page 71: ...ss new bearing into axle case fully to the shoulder in the axle case C Install new snap ring into the axle case to secure bearing Make sure that snap ring is fully installed in to axle case groove IMPORTANT Make sure that longer axle shaft is installed in longer axle case The RH axle case is the longer case D Insert axle shaft through axle case and bearing Make sure that threaded end of axle shaft...

Page 72: ...Workman GTX Gasoline Drive Train Page 4 30 This page is intentionally blank ...

Page 73: ...t Run Solenoid 13 Electric Fuel Pump fuel injected engines EFI 14 Key Start Latch and Magneto ECU Relays 16 Delay Timer fuel injected engines EFI 18 Accelerator Pedal Switch 19 Diode Assemblies 20 Starter Generator Voltage Regulator 21 Starter Generator 23 Parking Brake Alarm Switch If Equipped 24 Reverse Alarm Switch If Equipped 25 SERVICE AND REPAIRS 26 Battery Service 26 Battery Specifications ...

Page 74: ...n though the ignition switch is OFF If the engine ECU is to be disconnected for any reason make sure that the ignition switch is in the OFF position with the key removed before disconnecting the engine ECU Also to prevent possible ECU damage when welding on the machine disconnect and remove the en gine ECU from the machine before welding Kohler Engine Electrical Components When servicing or troubl...

Page 75: ... secured to the top of the rear frame be hind the seats to prevent debris entry to the front of the swing arm area The cover can easily be removed by re leasing the latches and lifting the cover from the rear frame 1 Rear frame 2 Panel cover 3 Latch 2 used Figure 1 1 2 3 Electrical System ...

Page 76: ...rcuits not designed to carry it Figure 2 Dielectric Gel Dielectric gel should be used to prevent corrosion of un sealed connection terminals To ensure complete coat ing of terminals liberally apply gel to both component and wire harness connector plug connector to compo nent unplug connector reapply gel to both surfaces and reconnect harness connector to component Connec tors should be thoroughly ...

Page 77: ...ce corrosion problems Apply terminal protector to the connection af ter the battery cable ring terminal or fork terminal has been secured Toro Part Number 107 0392 Figure 5 Spark Tester The spark tester can be used to test magneto ignitions on gasoline engines The spark tester determines if igni tion is present Toro Part Number TOR4036 Figure 6 Electrical System ...

Page 78: ...noid clicks but starter will not crank Battery is discharged Battery cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter generator is faulty Start run solenoid or circuit wiring is faulty Starter generator or circuit wiring is faulty Nothing happens when start attempt is made by depressing the accelerator pedal Key switch is not in the ON position Battery is...

Page 79: ...iagrams Magneto relay or circuit wiring is faulty Engine or fuel system is malfunctioning see Chapter 3 Gasoline Engine Accelerator pedal switch is faulty Engine and fuel may be too cold General Run Problems Problem Possible Causes Battery does not charge Wiring to the charging circuit components is loose corroded or damaged see electrical schematic and wire harness drawings in Chapter 7 Electrica...

Page 80: ...ess to battery Use a digi tal multimeter set to DC volts Connect the positive multimeter lead to the positive battery post and the neg ative multimeter lead to the negative battery post Keep the test leads connected to the battery posts and record the battery voltage NOTE When starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon ...

Page 81: ...d engage the parking brake Remove key from the key switch 2 Raise hood to allow access to wire harness connec tions for key switch Disconnect wire harness connector from the key switch 3 With the use of a multimeter ohms setting the key switch functions may be tested to determine whether continuity exists between the various terminals for each switch position The switch terminals are marked as sho...

Page 82: ...ther continuity exists between the various terminals for each headlight switch position The headlight switch termi nals are marked as shown in Figure 9 The circuitry of this switch is shown in the chart below Verify continuity between switch terminals SWITCH POSITION NORMAL CIRCUITS OTHER CIRCUITS ON 2 3 5 6 OFF 1 2 4 5 5 Replace headlight switch if testing determines that the switch is faulty 6 I...

Page 83: ...he right fuse block Machines with carbureted engine 15 amp pro tects the rear lift actuator circuit if equipped Machines with fuel injected engine 10 amp pro tects the delay timer and the engine ECU Second fuse from the bottom in the right fuse block Machines with fuel injected engine 15 amp pro tects the rear lift actuator circuit if equipped Figure 10 1 Left fuse block 2 Right fuse block 1 2 Eng...

Page 84: ...arness is to be disconnected from the charge port note the wire harness connections at the charge port for assembly purposes The white wire har ness lead should be connected to the positive termi nal on the charge port and the black wire harness lead should be connected to the negative terminal on the charge port Fig 13 Figure 12 1 USB charge port 1 1 Positive terminal 2 Negative terminal Figure 1...

Page 85: ... chap ter 4 Note wire connector locations on start run solenoid for assembly purposes Disconnect wire harness con nectors from solenoid 5 Apply 12 VDC directly across the solenoid coil posts The solenoid should click as the solenoid coil is ener gized Make sure resistance across the main contact posts is less than 1 ohm with voltage applied to solenoid coil posts 6 Remove voltage from solenoid coi...

Page 86: ... system to be pressurized Once the engine is running the fuel pump is always energized Testing 1 Park machine on a level surface stop engine and en gage parking brake 2 Raise cargo bed and support with prop rod Remove rear frame panel cover 3 Raise or remove the seat base CAUTION The fuel supply hose may contain pressurized fuel Cover the connection with a rag to prevent fuel spray when disconnect...

Page 87: ...ure should be approximately 40 PSI 276 kPa 7 If fuel pump pressure is low make sure that electrical power is available to fuel pump and fuel filter is not clogged Replace the fuel pump as necessary 8 After testing is completed remove pressure gauge from fuel supply hose and connect fuel hose to the fuel injector A Push supply hose fitting onto fuel injector until an audible Click is heard B Press ...

Page 88: ...lay timer works with the ECU relay to keep the ECU energized for 30 seconds after the engine stops magneto grounded Testing 1 Park vehicle on a level surface stop engine engage parking brake and remove key from the key switch Place vehicle shift lever in the NEUTRAL position 2 Raise hood to gain access to relays 3 Locate relay that is to be tested and disconnect the wire harness connector from the...

Page 89: ... 5 17 Electrical System 9 Replace relay if testing determines that it is faulty 10 After relay testing is complete secure relay to vehi cle and connect wire harness connector to relay 11 Lower and secure hood Electrical System ...

Page 90: ...er testing 4 At the delay connecter ground timer terminal 2 and apply 12 VDC to terminal 3 Fig 21 Connect multime ter leads DC voltage setting to terminals 1 and 2 The multimeter should read 0 VDC 5 Apply 12 VDC to terminal 4 12 VDC should appear on the multimeter Remove the power to terminal 4 only 12 VDC should continue to appear on the multimeter for 30 seconds before the multimeter returns to ...

Page 91: ... switch Note that wire harness connector is keyed to fit correctly onto the pedal switch 4 With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the switch terminals for both switch positions Verify continuity between switch termi nals using the following table PLUNGER POSITION CONTINUITY NO CONTINUITY IN NO Terminals NC Termina...

Page 92: ...rn signal kit that includes flashers four 4 addi tional diodes are used for hazard light and turn signal cir cuit logic These diodes plug into the brake and turn signal kit wire harness and can be accessed by raising the hood Testing 1 Park vehicle on a level surface stop engine engage parking brake and remove key from the key switch 2 Locate diode assembly that is to be tested 3 Remove cable tie ...

Page 93: ...f running D Stop engine and turn key switch to OFF E Disconnect multimeter probes from battery posts 6 If battery voltage increased to 14 5 VDC during charging circuit test the charging system is working cor rectly and no further testing is required 7 If battery voltage did not increase to 14 5 VDC test starter generator A Disconnect wire harness connector from starter generator terminal DF Fig 26...

Page 94: ...charged This voltage may rise to 14 VDC when the accelerator pedal is re leased and the engine is coasting to a stop D If measured voltage is incorrect stop engine and replace voltage regulator Retest charging circuit af ter replacing voltage regulator Step 5 above 9 When testing is complete stop engine and remove multimeter leads 10 Install seat base assembly to vehicle 11 Install rear frame pane...

Page 95: ...ly purposes Disconnect all wire connections on starter generator to separate starter generator circuits 6 Measure resistance Ohms between starter gener ator terminals F1 and F2 The meter reading should be very low approximately 0 006 Ohms but not zero 7 Measure resistance Ohms between starter gener ator terminals DF and F1 The meter reading should be approximately 3 to 6 Ohms 8 Measure resistance ...

Page 96: ...eter ohms setting across the common and normally closed NC terminals of the alarm switch Fig 31 5 With the parking brake released not applied the washer on the parking brake lever should be depressing the lever on the alarm switch In this switch position there should not be continuity infinite ohms between the common and normally closed NC switch terminals 6 With the parking brake applied the wash...

Page 97: ... transaxle shift arm Fig 32 4 Disconnect the wire harness connector from the re verse alarm switch 5 With the use of a multimeter ohms setting test for continuity across the two 2 switch terminals There should not be continuity infinite ohms when the dash mounted shift lever is either in the neutral or the forward position There should be continuity zero ohms when the shift lever is in the reverse...

Page 98: ...cable Always CONNECT the positive red battery cable before connecting the negative black cable Do not allow metal tools to short between the battery terminals and metal parts of the ve hicle Always keep the battery retaining components secure to protect the battery Battery Removal Fig 34 IMPORTANT Be careful to not damage battery ter minal posts or cable connectors when removing the battery cables...

Page 99: ... broken or leaking 5 If battery design allows removal of battery caps check the electrolyte level in each cell If the level is be low the tops of the plates in any cell fill all cells with dis tilled water to the bottom of the cap tubes or fill line Charge at 15 to 25 amps for 15 minutes to allow suffi cient mixing of the electrolyte Battery Installation Fig 34 IMPORTANT To prevent possible electr...

Page 100: ...sting a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test CAUTION Follow the battery load tester manufacturer s instructions when using a load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 0 VDC recharge the battery before load testing B Make sure the battery termin...

Page 101: ...it can ex plode and cause injury Let the battery warm to 60F 16C before connecting to a charger Charge battery in a well ventilated place to dissi pate gases produced from charging These gases are explosive Keep open flame and electrical spark away from the battery Do not smoke Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts...

Page 102: ... 9 200 to 230 in lb 23 to 25 N m 7 200 to 230 in lb 23 to 25 N m 16 to 20 ft lb 22 to 27 N m 25 to 31 ft lb 34 to 42 N m 200 to 230 in lb 23 to 25 N m Grade 8 Grade 5 IMPORTANT Torque tighten the fasteners based on the fastener grade Make sure to use the correct torque refer to Figure 35 Removal Fig 35 1 Park vehicle on a level surface stop engine engage parking brake and remove key from the key s...

Page 103: ...d install pulley to the starter generator shaft A Position woodruff key to the shaft Slide pulley onto the shaft with the larger diameter pulley hub installed toward starter generator B Secure pulley to the shaft with spring washer and nut Torque nut from 17 to 22 ft lb 24 to 29 N m 2 Install starter generator to the vehicle A Raise starter generator from bottom of vehicle and then rotate it into ...

Page 104: ...tor Service 1 Drive head end 2 Bearing 3 Retaining ring 4 Armature assembly 5 Frame and field assembly 6 Brush kit 7 Brush spring 4 used 8 Brush box assembly 9 Bearing 10 Wave washer 11 Commutator end head 12 Rubber plug 4 used Figure 37 2 3 6 8 9 10 11 1 5 7 12 4 ...

Page 105: ...ator end head of starter generator Figure 38 2 Check the length of the brush that extends from the top of the brush box If the brush is less than 0 140 3 5 mm from the top of the brush box brush replacement is necessary Figure 39 3 Use a marker to make a diagonal line across the frame housing and end heads for assembly purposes Position the starter generator on the commutator end head and support ...

Page 106: ...I 103 kPa 7 Clean inside of the frame housing with compressed air IMPORTANT Remove bearings from armature only if they are to be replaced Use proper bearing re moval and installation tools 8 Clean bearings using a clean cloth Inspect bearings for damage Replace both bearings if either bearing meets any of the following conditions A Bearings do not spin smoothly are noisy when ro tated or have exce...

Page 107: ... on commutator end head Figure 43 10 Remove two 2 screws that secure the brush box to the commutator end head Carefully remove brush box from the commutator end head Figure 44 11 Remove brush assemblies from the brush box Minimum brush length is 0 375 in 9 5 mm Maximum brush length is 0 790 in 20 mm Figure 45 Electrical System ...

Page 108: ...so the brushes do not go into the brush box fully Figure 46 13 Verify the correct position of the brushes If the brushes are not in the correct orientation the starter generator will not function A Terminal A1 connects to brush boxes 2 and 4 B Terminal A2 connects to brush boxes 1 and 3 Figure 47 2 3 1 4 14 Assemble the brush box to the commutator end head Make sure that the brush leads are dresse...

Page 109: ...in lb 4 6 to 5 6 N m Figure 49 16 Secure commutator end head assembly to frame housing with two 2 screws Use marks placed on end head and housing to properly orientate head Torque screws from 49 to 66 in lb 5 6 to 7 4 N m Figure 50 17 Position the starter generator on the commutator end head and support the assembly to prevent damage to the terminals in the end head Figure 51 Electrical System ...

Page 110: ...ive end head as sembly into the frame housing making sure that arma ture bearing is inserted into bearing bore in commutator end head 21 Use marks placed on drive end head and housing to properly orientate head Secure drive end head to frame housing with two 2 screws Torque screws from 49 to 66 in lb 5 6 to 7 4 N m Figure 53 22 Release brushes and center the brush springs between the wire and the ...

Page 111: ...lectrical motors and generators It may be more economically feasible to replace the starter generator than have it re worked Detail Specification Armature Resistance at 75F 24C 0 0125 Ohms between bar 1 and 11 Field Resistance at 75F 24C 0 0069 Series Ohms Total 3 20 Shunt Ohms Total Maximum brush length 0 790 in 20 mm Minimum brush length 0 375 in 9 5 mm Commutator bars 41 Commutator original max...

Page 112: ...Workman GTX Gasoline Page 5 40 Electrical System This page is intentionally blank ...

Page 113: ...ure 11 Inspect Tires and Wheels 11 Front Wheels and Hubs 12 Rear Wheels and Hubs 14 Front Brake Calipers 16 Front Brake Caliper Service 18 Rear Brake Calipers 20 Rear Brake Caliper Service 22 Parking Brake Cables and Lever Assembly 24 Brake Master Cylinder 26 Brake Master Cylinder Service 28 Bleed Brake System 29 Steering Assembly 30 Steering Rack Assembly Service 32 Shift Lever Assembly 34 Front ...

Page 114: ... intervals for your Workman GTX vehicle Refer to the Operator s Manual for additional information when ser vicing the vehicle Thread Forming Fasteners Numerous thread forming fasteners are used to secure Workman GTX frame components If the threads in the frame are found to be stripped a nut can be used on the backside of the frame to allow the fastener to be properly tightened ...

Page 115: ...Range 24 to 30 PSI 165 to 207 kPa Wheel Lug Nut Torque all wheels 75 to 95 ft lb 102 to 128 N m Front Wheel Toe In 0 0 125 inch 0 3 mm Brake Fluid DOT 3 Standard Front Suspension Strut Pre load Adjustment Position Lowest Position Standard Rear Shock Absorber Pre load Adjustment Position Lowest Position Chassis ...

Page 116: ... TOR6010 Figure 1 Shock Spring Compressor Use shock spring compressor to remove and install spring from the rear shock absorber Tool includes a bracket to secure the shock spring to the compressor spring plate to prevent unexpected movement of the shock spring during tool use Secure compressor to bench for stability during use NOTE The shock spring compressor can be modified for use with the Workm...

Page 117: ...mbly as follows 1 Remove flange head screw item 2 in Fig 6 that se cures the right front corner of the throttle bracket There is no need to remove flange head screw that secures R clamp item 3 in Fig 6 to engine 2 Install threaded rod from tool kit fully into the engine and secure rod to engine with flange nut from tool kit 3 Place bridge onto installed threaded rod making sure that the bridge ext...

Page 118: ...ilizer anti sway bar A arm are loose or worn Clutch or transaxle problem see Chapter 4 Drive Train Excessive steering play Front wheel lug nuts are loose Front wheel bearings are loose or worn Steering shaft joints are loose or worn Tie rod ends are worn Bushings in spindle or A arm are loose or worn Steering rack assembly is damaged or worn Vehicle is unstable or wanders Tire pressure is low or u...

Page 119: ...ing or damaged Front wheel alignment toe in is incorrect Steering rack assembly is damaged or worn Vehicle pulls to one side when not braking Tire pressure is low or uneven between tires Front wheel alignment toe in is incorrect Steering or suspension component may be damaged Brakes Problem Possible Cause Brake pedal goes to the floor Brake fluid level in master cylinder is low Brake fluid leak ex...

Page 120: ...ding Parking brake cable is binding Brake pads are saturated Floating calipers are binding due to dirt or corrosion Brake rotors are bent Brake pedal is hard to push Incorrect brake pad material Brake pedal is binding New brake pads and or rotors are not burnished Wheels lock up when braking Brake pads are worn or contaminated Wheel or transaxle bearings are damaged Calipers are binding due to dir...

Page 121: ...Starting on one of the rear wheels locate the parking brake rod on the inside of the rear brake caliper 4 Using two 2 wrenches loosen lock nut on parking brake rod while holding brake rod to prevent it from rotat ing 5 Making sure that lock nut stays loose on parking brake rod adjust brake rod until rear wheel rotates with little evidence of brake drag on brake rotor 6 Hold parking brake rod in pl...

Page 122: ...e facing straight ahead 5 Measure the distance between the front tires at axle height at both the front and rear of the tires Fig 9 Front wheel toe in should be 0 0 125 inch 0 3 mm 6 If the front wheel toe in is incorrect adjust as follows Fig 10 A Loosen jam nuts at both ends of steering rack tie rods B Rotate both tie rods equally to move front of tires inward or outward C Tighten tie rod jam nu...

Page 123: ...e marks Lower pres sure should not be used for heavy payloads at higher speeds Higher pressures should be used for heavier payloads at higher speeds Do not exceed the maximum tire pres sure Inspect Tires and Wheels Operating accidents such as hitting curbs can damage a tire or rim and also disrupt wheel alignment Inspect tire and rim condition after any accident Check wheels to ensure they are mou...

Page 124: ...102 to 128 N m See text for tightening procedure Lifted suspension models Medium Strength Thread Locker Removal Fig 11 1 Park vehicle on a level surface stop engine set parking brake and remove key from the key switch WARNING Before jacking up the vehicle review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being removed Use a jack to raise front wheel that is to be remove...

Page 125: ...d press it into the wheel hub with the seal lip toward the bearing 5 Fill wheel hub cavity between bearings approximate ly 50 full of grease Position remaining bearing into the outer bearing cup 6 Slide the wheel hub assembly onto the spindle shaft and secure it in place with the tab washer and jam nut DO NOT fully tighten the nut 7 While rotating the wheel hub by hand torque the jam nut to 130 in...

Page 126: ... 10 Cotter pin 11 Slotted hex nut 12 Thrust washer 13 Wheel hub 14 Hardened spacer 15 Brake rotor 16 Socket head screw 4 per rotor 17 Wheel stud 4 per hub Figure 13 FRONT RIGHT Antiseize Lubricant 2 3 6 8 9 10 1 2 5 7 4 35 to 40 ft lb 48 to 54 N m 11 12 13 14 15 16 220 to 240 ft lb 299 to 325 N m 220 to 240 ft lb 299 to 325 N m 9 to 11 ft lb 13 to 14 N m 17 10 11 12 13 17 75 to 95 ft lb 102 to 128...

Page 127: ...ulder is fully pressed against housing surface IMPORTANT Do not get antiseize lubricant onto brake rotor or brake pads 3 Apply a light coating of antiseize lubricant to both the transaxle shaft and splines in wheel hub bore 4 Install the wheel hub to the transaxle shaft A Install hardened spacer wheel hub and then thrust washer onto the transaxle shaft B Secure wheel hub assembly with slotted hex ...

Page 128: ...sembly 2 used 5 Brake rotor 2 used 6 Socket head screw 4 per rotor 7 Spindle RH shown 8 Front brake line 9 Banjo bolt 10 Bleed screw 11 Washer head screw Figure 14 FRONT RIGHT 9 to 11 ft lb 13 to 14 N m 2 3 6 8 9 10 11 1 5 7 4 108 to 132 in lb 12 3 to 14 9 N m 54 to 66 in lb 6 1 to 7 4 N m 35 to 40 ft lb 48 to 54 N m Medium Strength Thread Locker ...

Page 129: ...to brake rotor Make sure that rotor is between brake pads IMPORTANT The socket head screws that secure the brake calipers have a patch lock feature If screws are being re installed on vehicle apply medium strength thread locker to screw threads be fore installation 3 Align caliper mounting holes with spindle Secure caliper with two 2 socket head screws Torque screws from 35 to 40 ft lb 48 to 54 N ...

Page 130: ...r Service 1 Bolt 2 used 2 Caliper body 3 O ring 4 used 4 Caliper bracket 5 Square seal 2 used 6 Dust seal used 7 Piston 2 used 8 Brake pad 2 used 9 Caliper anvil Figure 16 2 3 6 8 1 5 7 4 37 to 44 N m 27 to 33 ft lb BAF 12 Assembly Lube White Lithium Grease 9 ...

Page 131: ...wear Replace brake pistons or complete brake caliper assembly if necessary 3 Check that pins on caliper bracket are not worn cor roded or damaged Wear on the pins will prevent smooth brake operation Assembly Fig 16 1 If caliper body was disassembled install compon ents in caliper body A Apply hydraulic brake cylinder assembly lube BAF 12 or equivalent to square seals dust seals and piston before i...

Page 132: ... stop engine and re move key from the key switch Do not apply parking brake WARNING Before jacking up the vehicle review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being removed Use a jack to raise rear wheel that is to be removed off the ground Support vehicle with appropriate jack stands beneath the frame 3 Remove rear wheel from machine see Rear Wheels and Hubs in th...

Page 133: ...orque screws to 35 to 40 ft lb 48 to 54 N m 3 Connect brake line to rear brake caliper A Place washer on each side of brake line fitting B Install banjo bolt through brake line fitting and banjo washers and then thread into caliper Torque banjo bolt from 108 to 132 in lb 12 3 to 14 9 N m 4 Connect parking brake cable to rear brake caliper Fig 18 A Make sure that parking brake is not applied B Inse...

Page 134: ...Anti rattle spring 2 used 4 Brake pad assembly 5 Bleed screw Figure 19 30 to 35 ft lb 41 to 47 N m 2 3 1 5 4 108 to 132 in lb 12 3 to 14 9 N m NOTE Replacement parts for the rear caliper assem bly are limited to the brake pad assembly and bleed screw If any other caliper components are damaged or worn replace the caliper assembly ...

Page 135: ...iston back into the caliper bore be fore installing new pads A Loosen lock nut on parking brake push rod and then unscrew the push rod that threads into the brake armature in the caliper Fig 20 B While loosening push rod make sure that lock nut remains loose on push rod Also periodically push caliper piston back into caliper until there is suf ficient room in the caliper for the brake pads and bra...

Page 136: ...Flange nut 2 used 9 Parking brake mount 10 Parking brake cable 2 used 11 Shift cable 12 Washer head screw 3 used 13 Flange nut 14 Front frame Figure 21 FRONT RIGHT 2 3 6 8 9 10 11 13 1 5 7 12 4 3 14 200 to 230 in lb 23 to 25 N m 12 40 to 45 in lb 4 5 to 5 N m NOTE The parking brake assembly includes the dash mounted parking brake lever two 2 identical brake ca bles and parking brake actuators in t...

Page 137: ...oward front of vehicle 10 If necessary remove parking brake lever compo nents using Figure 21 as a guide Assembly Fig 21 1 Install removed parking brake lever components us ing Figure 21 as a guide 2 Carefully route parking brake cables through the front frame and toward the rear wheels using cable rout ing noted during disassembly Position the brake cables in the vehicle so that the cable ends ar...

Page 138: ...ake Master Cylinder 1 Master cylinder 2 Hair pin 3 Clevis pin 4 Brake pedal 5 Pedal mount 6 Flange nut 2 used 7 Flange head screw 2 used 8 Front brake line 9 Rear brake line Figure 23 FRONT RIGHT 2 3 6 8 9 1 5 7 4 8 5 to 9 6 N m 75 to 85 in lb ...

Page 139: ...er cylinder 5 Remove two 2 flange nuts and flange head screws that secure master cylinder to pedal mount 6 Carefully remove master cylinder from vehicle Installation Fig 23 1 Position master cylinder to pedal mount and secure with flange head screws and flange nuts 2 Remove plugs from brake lines Install brake lines to master cylinder Torque brake lines from 75 to 85 in lb 8 5 to 9 6 N m 3 Connect...

Page 140: ...assageways with com pressed air Make sure cylinder bore and component pieces are thoroughly clean 2 Check cylinder bore pistons and springs for damage or excessive wear Replace brake cylinder assembly if signs of pitting scoring or cracks are evident in cylinder bore Assembly Fig 25 1 Apply a film of clean brake fluid to cylinder bore and piston assemblies 2 Install secondary piston assembly and p...

Page 141: ... fades to floor Close bleeder valve be fore releasing pedal 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 Torque bleeder valve from 54 to 66 in lb 6 1 to 7 4 N m 6 Repeat steps 1 to 5 for other brake calipers CAUTION After servicing the brakes always check the...

Page 142: ...e key switch 2 Raise front hood to gain access to the steering com ponents 3 Carefully remove steering wheel cover from the steering wheel Remove nut and flat washer securing the steering wheel to the steering shaft 4 Use suitable puller to remove steering wheel from steering shaft 5 Remove dash and position it toward the front of the vehicle to allow the steering column to be moved see Dash in th...

Page 143: ...and flange nuts 5 Secure lower steering shaft joint to the steering rack input shaft with cap screw and lock washer Torque screw from 16 to 20 ft lb 21 5 to 27 N m 6 Install extension spring to tension shift lever detent arm Fig 29 7 Place dust cover onto the steering shaft 8 Connect both steering rack tie rods to the spindles at the front wheel hubs see Front Suspension in this sec tion 9 Make su...

Page 144: ...al 8 Steering rack assembly Figure 30 2 3 1 5 4 34 to 42 ft lb 47 to 57 N m 45 to 50 ft lb 61 to 75 N m Medium Strength Thread Locker 6 7 8 NOTE Check parts catalog to identify individual com ponents that are available for the steering rack assem bly on your Workman GTX vehicle Depending on wear or damage that exists with the steering rack replace ment of the complete steering rack assembly might ...

Page 145: ...h and then repeat in opposite direction If any gear teeth are damaged steering rack assembly replacement is necessary Assembly Fig 30 1 If input shaft seal was removed from steering rack install new seal into rack Seal should be pressed fully into bore of rack until it contacts retaining ring in bore Fig 32 2 Lubricate steering rack shaft by rotating input shaft to extend rack shaft in one directi...

Page 146: ... Shift cable 6 Extension spring 7 Detent arm 8 Bearing 9 Lock nut 10 Shoulder screw 11 Flange nut 12 Ball joint 13 Lock nut 14 Shift arm 15 Slotted roll pin 16 Shift indicator 17 Set screw 18 Snap bushing 2 used 19 Shifter shaft 20 Knob 21 Flange nut 22 Shift decal Figure 33 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 21 FRONT RIGHT ...

Page 147: ... front of the vehicle to allow access to the shift lever assembly see Dash in this section It is not necessary to remove choke cable from dash 4 Disassemble shift lever as necessary using Figures 33 and 22 as guides Assembly Fig 33 1 Assemble shift lever using Figures 33 and 34 as guides 2 Carefully position and secure dash to vehicle see Dash in this section 3 Lower and secure front hood 1 Shift ...

Page 148: ...2 used 24 Front frame 25 Steering rack assembly 26 Cotter pin 27 Slotted hex nut 2 3 6 8 9 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 23 24 25 26 10 14 14 22 27 to 33 ft lb 37 to 44 N m 80 to 90 ft lb 109 to 122 N m 200 to 230 in lb 23 to 25 N m 200 to 230 in lb 23 to 25 N m 23 27 45 to 55 ft lb 61 to 75 N m Grade 8 Grade 5 27 to 33 ft lb 37 to 44 N m 45 to 55 ft lb 61 to 75 N m 27 to 33 ft lb 45 to...

Page 149: ... A arm D Install sleeves into spindle or A arm NOTE On Workman GTX vehicles suspension strut assembly should be set to lowest pre load setting Assembly Fig 35 IMPORTANT Torque tighten the fasteners based on the fastener grade Make sure to use the correct torque refer to Figure 35 1 Position A arm to the frame Secure A arm to the frame with cap screw and flange nut Torque screw re fer to Figure 35 ...

Page 150: ...d 18 Swing arm FRONT RIGHT 27 to 33 ft lb 37 to 44 N m 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 4 5 7 4 5 6 6 7 4 6 7 5 7 11 9 6 9 27 to 33 ft lb 37 to 44 N m 77 to 95 ft lb 104 to 128 N m 77 to 95 ft lb 104 to 128 N m 77 to 95 ft lb 104 to 128 N m Lifted suspension models 77 to 95 ft lb 77 to 95 ft lb 104 to 128 N m 104 to 128 N m 27 to 33 ft lb 37 to 44 N m 18 Disassembly Fig 35 1 Park vehicle on...

Page 151: ... be set to lowest pre load setting NOTE Use spanner wrench TOR6010 see Special Tools in this chapter if rear shock spring pre load re quires adjustment If the spring is to be removed from the shock absorber shock spring compressor tool TOR6015 see Special Tools in this chapter can be used Assembly Fig 35 IMPORTANT During assembly of rear suspension components install all components before fully ti...

Page 152: ...ame 2 Swing arm 3 Cap screw 4 Upper plate 5 Isolator upper portion 6 Isolator lower portion 7 Snubbing washer 8 Rear suspension mount 9 Cap screw 2 used 10 Flange nut 2 used Figure 40 FRONT RIGHT 2 3 6 8 9 1 5 7 4 140 to 160 ft lb 190 to 216 N m 27 to 33 ft lb 37 to 44 N m 10 ...

Page 153: ...e the rear suspension mount to the front frame Remove mount from front frame Installation Fig 40 1 If rear suspension mount was removed position mount to front frame and secure with two 2 cap screws washers and flange nuts Torque cap screws from 27 to 33 ft lb 37 to 44 N m IMPORTANT Make sure to not damage the brake lines electrical harness parking brake cables or other parts while assembling the ...

Page 154: ... support bracket 14 RH side support bracket 15 Washer head screw 5 used 16 Screw 12 used 17 Flange head screw 6 used 18 Washer head screw 6 used 19 Flange nut 6 used 20 RH hip restraint 21 LH hip restraint 22 Flange head screw 2 used 23 Flange nut 2 used Figure 41 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 16 6 16 15 16 12 17 17 12 22 23 FRONT RIGHT 40 to 45 in lb 4 6 to 5 0 N m 18 to 2...

Page 155: ...ase if they were removed Fig 43 Torque cap screws from 90 to 110 in lb 10 2 to 12 4 N m 2 Install all removed seat base supports to vehicle us ing Figure 41 as a guide When securing seat base sup ports to vehicle use torque values identified in Figures 41 and 42 3 If battery was removed from vehicle install battery see Battery Service in the Service and Repairs section of Chapter 5 Electrical Syst...

Page 156: ...0 LH dash bracket 11 Dash angle bracket 12 Dash bracket 13 Washer head screw 8 used 14 Washer head screw 4 used 15 Side dash bracket 2 used 16 Flange nut 2 used Figure 44 FRONT RIGHT 2 3 6 8 9 10 11 13 1 5 7 12 14 4 5 13 2 40 to 45 in lb 4 6 to 5 0 N m 40 to 45 in lb 4 6 to 5 0 N m 40 to 45 in lb 4 6 to 5 0 N m 90 to 100 in lb 10 2 to 11 3 N m 18 to 22 in lb 2 1 to 2 4 N m 13 15 16 5 18 to 22 in l...

Page 157: ...icle 6 If dash needs to be replaced or completely removed from vehicle disconnect choke cable from engine and remove it from dash Installation Fig 44 NOTE Do not fully tighten fasteners securing dash un til all fasteners are in place 1 If choke cable was removed install choke cable to dash and engine 2 Carefully position dash to vehicle by lowering it over parking brake lever 3 Secure dash with re...

Page 158: ... Flange head screw 4 used 15 Flat washer 4 used 16 Flange nut 4 used 17 Washer head screw 2 used 18 Screw 2 used 19 Hold down strap 2 used 20 Lock nut 2 used 21 Washer head screw 4 used 22 LED bulb 2 used 23 Angle bracket 2 used 24 Flange nut 4 used 25 Flat washer 2 used Figure 45 FRONT RIGHT 7 to 13 in lb 0 8 to 1 4 N m 2 3 6 8 9 10 11 13 1 5 7 12 14 15 16 17 18 19 20 4 21 22 23 24 25 18 to 22 in...

Page 159: ... switch 2 Remove front fenders hood or front bumper using Figure 45 as a guide Installation Fig 45 NOTE Do not fully tighten fasteners securing body components until all fasteners are in place 1 Install removed body components using Figure 45 as a guide During assembly use fastener torque speci fications that are identified in Figure 45 Chassis ...

Page 160: ...striker 2 used 5 Prop rod 6 RH cargo bed support 7 LH cargo bed support 8 Flange head screw 6 used 9 Flange nut 6 used 10 Lock nut 2 used 11 Prop rod bracket 12 Prop rod U bracket Figure 46 FRONT RIGHT 140 to 170 in lb 16 to 19 N m 27 to 33 ft lb 37 to 44 N m 2 3 6 8 9 10 11 1 5 7 12 4 4 8 3 133 to 147 in lb 15 to 16 N m ...

Page 161: ...vehicle B Secure cargo bed assembly to frame with two 2 cap screws item 1 and lock nuts Torque cap screws from 140 to 170 in lb 16 to 19 N m C Raise cargo bed and support bed so that prop rod assembly can be secured to bottom of bed D Make sure that end of prop rod item 5 is installed into slot in prop rod bracket item 11 attached to frame E Secure prop rod U bracket item 12 and prop rod to bed wi...

Page 162: ...Page 6 50 Workman GTX Gasoline Chassis This page is intentionally blank ...

Page 163: ...Switch in Start Position fuel injected models shown 8 Run Circuit Engine Started With Key Switch fuel injected models shown 9 Run Circuit Engine Started With Accelerator Pedal fuel injected models shown 10 WIRE HARNESSES Wire Harness Main carbureted engine Machine serial number below 401400000 11 Wire Harness Main carbureted engine Machine serial number 401400001 to 403448000 13 Wire Harness Main ...

Page 164: ... with an alternate color These wires are identified with the wire color and line color with either a or _ separating the color abbreviations listed above e g R BK is a red wire with a black line OR_BK is an orange wire with a black line NOTE The wire harness diagram in this chapter identi fies both the wire color and the wire gauge For example 16 BK on a harness diagram identifies a 16 gauge wire ...

Page 165: ... C B A 6 5 4 3 2 1 122 0226 REV A Electrical Schematic All relays and solenoids are shown as de energized All ground wires are black Workman GTX Gasoline Models 07042 and 07152 carbureted engine Machine serial number below 401400000 ...

Page 166: ... 3 2 1 D C B A 6 5 4 3 2 1 122 1144 REV A Electrical Schematic All relays and solenoids are shown as de energized All ground wires are black Workman GTX Gasoline carbureted engine 401400001 to 403448000 Machine serial number ...

Page 167: ...Page 7 5 122 1470 Rev A Workman GTX Gasoline carbureted engine Electrical Schematic Serial Numbers Above 403448001 All relays and solenoids are shown as de energized ...

Page 168: ... 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 1029 REV B Electrical Schematic All relays and solenoids are shown as de energized All ground wires are black Workman GTX Gasoline Machine Serial Numbers Below 403446000 EFI engine ...

Page 169: ...Page 7 7 122 1472 Rev A Workman GTX Gasoline EFI engine Electrical Schematic Serial Numbers Above 403446001 All relays and solenoids are shown as de energized ...

Page 170: ...Page 7 8 Start Circuit Power Current Control Current Indication Current Key Switch in START Position D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 1029 REV B fuel injected engine models shown ...

Page 171: ...Page 7 9 Run Circuit Power Current Control Current Indication Current Engine Started With Key Switch D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 1029 REV B fuel injected models shown ...

Page 172: ...Page 7 10 Run Circuit Power Current Control Current Indication Current Engine Started With Accelerator Pedal D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 1029 REV B fuel injected models shown ...

Page 173: ...Page 7 11 D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 0225 REV D Wire Harness Drawing Main Workman GTX Gasoline Models 07042 and 07152 carbureted engine Machine serial number below 401400000 ...

Page 174: ...Page 7 12 Workman GTX Gasoline Models 07042 and 07152 D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 0225 REV D Wire Harness Diagram Main carbureted engine Machine serial number below 401400000 ...

Page 175: ...Page 7 13 D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 1143 REV B Wire Harness Drawing Main Workman GTX Gasoline Carbureted engine Machine serial numbers 401400001 to 403448000 ...

Page 176: ...Page 7 14 Workman GTX Gasoline D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 1143 REV B Wire Harness Diagram Main carbureted engine Machine serial numbers 401400001 to 403448000 ...

Page 177: ...Page 7 15 CV 122 1471 Rev D Workman GTX Gasoline carbureted engine Wire Harness Diagram Main Serial Numbers Above 403448001 ...

Page 178: ...Page 7 16 122 1471 Rev D Workman GTX Gasoline carbureted engine Wire Harness Diagram Main Serial Numbers Above 403448001 ...

Page 179: ...Page 7 17 D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 1030 REV B Wire Harness Drawing Main Workman GTX Gasoline Machine serial numbers below 403446000 EFI Engine ...

Page 180: ...Page 7 18 Workman GTX Gasoline Machine serial numbers below 403446000 D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 1030 REV B Wire Harness Diagram Main EFI engine ...

Page 181: ...Page 7 19 CV 122 1473 Rev C Workman GTX Gasoline EFI engine Wire Harness Diagram Main Serial Numbers Above 403446001 ...

Page 182: ...Page 7 20 122 1473 Rev C Workman GTX Gasoline EFI engine Wire Harness Diagram Main Serial Numbers Above 403446001 ...

Page 183: ...Page 7 21 D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 0730 REV D Wire Harness Drawing and Diagram Cab Model 07142 Workman GTX ...

Page 184: ...Page 7 22 D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 0818 REV A Wire Harness Drawing and Diagram Light Kit Cab Workman GTX ...

Page 185: ...Page 7 23 D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 0785 REV A Wire Harness Drawing and Diagram Light Kit No Cab Workman GTX ...

Page 186: ...Page 7 24 D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 0739 REV D Wire Harness Drawing and Diagram Parking Brake Alarm Workman GTX Gasoline ...

Page 187: ...Page 7 25 D C B A 6 5 4 3 2 1 D C B A 6 5 4 3 2 1 122 3995 REV A Wire Harness Drawing and Diagram EU Tail Light Kit Workman GTX ...

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