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Toro Workman HD Series Service Manual Download Page 34

Workman HDX

Page 3 -- 16

Briggs/Daihatsu Gasoline Engine

Radiator

Figure 13

1. Radiator assembly

2. Coolant reservoir

3. Upper radiator hose

4. Lower radiator hose

5. Hose clamp (4 used)

6. Hose (radiator to coolant reservoir)

7. Hose

8. Hose clamp (3 used)

9. Radiator screen

10. Radiator mount

11. Flange nut (4 used)

12. Flange head screw

13. Flange head screw (4 used)

14. Clip (2 used)

15. Flange nut (2 used)

16. Swell latch (4 used)

17. R--clamp (2 used)

18. Washer head screw

19. Flat washer (2 used)

20. RH frame rail

FRONT

RIGHT

8

7

6

9

1

5

4

3

2

18

17

16

19

10

15

14

13

12

11

6

8

13

11

11

13

5

19

13

14

20

Summary of Contents for Workman HD Series

Page 1: ... Operator s Manual and Parts Catalog are avail able on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury ...

Page 2: ...Workman HD Series This page is intentionally blank ...

Page 3: ... Gasoline Engine Specifications 5 2 General Information 5 3 Service and Repairs 5 5 KOHLER COMMAND ENGINE SERVICE MANUAL Chapter 6 Drive Train Specifications 6 2 General Information 6 3 Special Tools 6 4 Adjustments 6 5 Troubleshooting 6 6 Service and Repairs 6 10 Chapter 7 Chassis Specifications 7 2 General Information 7 3 Special Tools 7 4 Troubleshooting 7 5 Service and Repairs 7 8 Chapter 8 El...

Page 4: ...Workman HD Series This page is intentionally blank ...

Page 5: ...Service and Repairs 10 4 HILLIARD FRONT DRIVE DIFFERENTIAL PARTS and SERVICE MANUAL Chapter 11 Electrical Drawings Electrical Schematics 11 3 Workman HD Circuit Drawings 11 6 Workman HDX Circuit Drawings 11 8 Workman HDX D Circuit Drawings 11 10 Wire Harness Drawings 11 14 Front Wheel Drive 4WD Electrical Drawings ...

Page 6: ...Workman HD Series This page is intentionally blank ...

Page 7: ...Page 1 1 Safety Chapter 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 AND INSTRUCTION DECALS 6 Safety ...

Page 8: ... with the controls and know how to stop the vehicle and engine quickly Additional copies ofthe Operator s Manual are available on the internet 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 i...

Page 9: ... foot off accelerator 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 exhaust system components transaxle or radiator if equipped while engine is run ning or soon after it is stopped These areas could be hot enough to cause burns 5 Before getting off the seat A Sto...

Page 10: ... free of excessive grease grass leaves and dirt 10 If engine must be running to perform maintenance or an adjustment keep clothing hands feet and other parts of the body away from moving parts Keep by standers away 11 Do not overspeed the engine by changing governor setting To ensure safety and accuracy check maximum engine speed 12 Shut engine off before checking or adding oil to the engine crank...

Page 11: ...ehicle 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 Fig 1 When jacking up front of vehicle always place a wood block or similar material betwe...

Page 12: ...ck of ROPS panel and lower bed 1 Raise bed until lift cylinders are fully extended 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 cylinder rod end Fig 3 4 To store bed safety support remove support from lift cylinder and insert into storage brackets on back of ROP...

Page 13: ...ator s Manual and Parts Catalog for your Workman HD series vehicle at the end of this chapter Refer to Operator s Manual for recommended mainte nance intervals Additionally insert Installation Instruc tions Operator s Manuals Parts Catalogs and Service Manuals for any accessories that have been installed on your Workman at the end of this section Maintenance Maintenance procedures and recommended ...

Page 14: ...0 09375 Workman HD Series Page 2 2 Product Records and Maintenance Equivalents and Conversions ...

Page 15: ...ad 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 calibr...

Page 16: ...6 2 16 2 22 3 30 3 41 4 43 5 58 7 3 8 24 UNF 17 2 18 2 24 3 35 4 47 5 50 6 68 8 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 6 75 8 77 8 104 11 1 2 13 UNC 30 3 48 7 65 9 75 8 102 11 105 11 142 15 1 2 20 UNF 32 4 53 7 72 9 85 9 115 12 120 12 163 16 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 21 285 28 5 8 18 UNF 75 10 95 15 129 20 170 18 230 24 240 24 325 33 3 4 ...

Page 17: ...b 90 10 N m 93 10 ft lb 126 14 N m M16 X 2 0 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 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 engine oil or thread sealant such as Loctite NOTE Torque values may have to be reduced whe...

Page 18: ... 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 Size Type A Type B Baseline Torque No ...

Page 19: ...NE DIAGNOSTICS 6 Check Engine Light 6 SERVICE AND REPAIRS 8 Air Cleaner System 8 Fuel Tank 10 Fuel Pump 12 Exhaust System 14 Radiator 16 Engine 18 Engine Removal 19 Engine Installation 21 Engine Throttle Bracket 22 EFI SYSTEM 24 Overview 24 EFI System Components 24 EFI Troubleshooting 27 BRIGGS STRATTON DAIHATSU REPAIR MANUAL FOR 3 CYLINDER LIQUID COOLED GASOLINE ENGINES EFI TROUBLESHOOTING GUIDE ...

Page 20: ...2 VDC fuel tank mounted Fuel Unleaded regular grade 87 octane minimum Fuel Tank Capacity 6 5 U S gallons 24 6 liters Governor Mechanical Idle Speed no load 1000 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 3 5 U S quarts 3 3 liters with filter Water Pump Belt dri...

Page 21: ... explained However the cost of the test equip ment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Briggs Stratton Daihatsu 3LC gasoline engines are supplied through your local Toro distributor Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenanc...

Page 22: ...on switch is moved from the OFF position to either the ON or START position If the engine control ler or any engine components are to be disconnected for any reason make sure that the ignition switch is in the OFF position with the key removed before disconnect ing the engine controller IMPORTANT Before performing any welding on the vehicle disconnect the battery cables from the bat teries disconn...

Page 23: ...peration and adjustment of accelerator cable see Operator s Manual If needed adjust accel erator cable 7 Start and run engine until engine is at normal operat ing temperature When accelerator pedal is fully de pressed engine speed should be 8 Using a tachometer check low idle speed Low idle speed should be 1000 50 RPM If low idle is incorrect adjust the idle speed screw on the throttle body to obt...

Page 24: ...nects the two 2 ser vice shunt wires located near engine controller Fig 5 3 Remove termination cap from service shunt wires and connect the two 2 shunt leads together 4 Monitor the check engine light on the dash panel to determine the two 2 digit component failure code that will be displayed by the flashing check engine light A The first digit will be shown with from 0 to 9 light flashes followed ...

Page 25: ...ater temperature sensor 1 3 Intake air temperature sensor 1 7 Oxygen sensor 2 4 Battery voltage 3 3 Cylinder 1 fuel injector 3 4 Cylinder 2 fuel injector 3 5 Cylinder 3 fuel injector 3 7 Cylinder 1 ignition coil 3 8 Cylinder 2 ignition coil 3 9 Cylinder 3 ignition coil 4 1 Fuel pump relay 4 5 Oxygen heater 5 8 75 ohm resister or circuit wiring Briggs Daihatsu Gasoline Engine ...

Page 26: ...and Repairs Air Cleaner System Figure 6 1 Engine 2 Hose clamp 4 used 3 Air intake hose 4 Mounting bracket 5 Air inlet hood 6 Air cleaner hose 7 Air cleaner assembly 8 Flange nut 2 used 9 Flange head screw 2 used VACUATOR DIRECTION FRONT RIGHT 8 7 6 9 5 4 3 2 1 2 ...

Page 27: ...Fig 6 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 Assemble air cleaner system using Figures 6 and 7 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 assembly should...

Page 28: ... 16 17 18 19 20 2 21 7 7 3 4 5 6 3 DANGER Because gasoline is highly flammable use cau tion when storing or handling it Do not smoke while filling or servicing the fuel tank Do not fill or service 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 be fore starting the engine Store fuel in a clean safety approved c...

Page 29: ...vent leakage or contaminant entry 5 Remove washer head screws item 18 and retainer plate item 14 that secure fuel tank 6 Remove fuel tank from vehicle Fuel Tank Installation Fig 8 1 Position fuel tank to support tube on vehicle 2 Remove plugs placed in fuel hoses during fuel tank removal Connect fuel supply hose to fuel pump sender and tank vent hose to rollover valve Fig 9 Secure fuel hoses with ...

Page 30: ...ply hose 2 Hose clamp 3 Rollover valve 4 Fuel filter 5 Gasket 6 Cap 7 Washer head screw 2 used 8 Grommet 9 Fuel tank 10 Fuel cap 11 Fuel pump sender assembly 12 Retainer plate 13 Fuel hose FRONT RIGHT 175 to 200 in lb 20 to 22 N m TO PURGE PORT TO ENGINE 1 2 9 10 11 12 8 2 13 7 4 5 6 3 ...

Page 31: ... purposes 6 Remove cap item 6 that secures fuel pump sender assembly in fuel tank 7 Carefully remove fuel pump sender and gasket item 6 from tank Fuel Pump Installation Fig 10 1 Make sure that fuel tank and fuel pump sender gas ket surfaces are thoroughly clean 2 Position gasket item 6 to sealing surface of fuel pump sender 3 Carefully insert fuel pump sender and gasket into tank Orientate fuel fi...

Page 32: ...1 5 13 12 4 3 2 6 10 3 8 8 1 Engine 2 Muffler 3 Exhaust gasket 2 used 4 Hex nut 4 used 5 Exhaust tube 6 Flange head screw 2 used 7 Transaxle 8 Flange nut 8 used 9 Flange head screw 2 used 10 Mount plate 11 Flange head screw 12 Shift cable mount bracket 13 Carriage bolt 2 used 14 Flange head screw 4 used ...

Page 33: ...ation Fig 12 1 Replace any removed gaskets 2 Using Figure 12 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 tube to en gine B Flange head screw item 11 that secures muffler to transaxle C Flange head screws item 14 and flange nuts item 8 that secure muffler to ex...

Page 34: ...adiator to coolant reservoir 7 Hose 8 Hose clamp 3 used 9 Radiator screen 10 Radiator mount 11 Flange nut 4 used 12 Flange head screw 13 Flange head screw 4 used 14 Clip 2 used 15 Flange nut 2 used 16 Swell latch 4 used 17 R clamp 2 used 18 Washer head screw 19 Flat washer 2 used 20 RH frame rail FRONT RIGHT 8 7 6 9 1 5 4 3 2 18 17 16 19 10 15 14 13 12 11 6 8 13 11 11 13 5 19 13 14 20 ...

Page 35: ... the mount B Remove two 2 flange head screws and flange nuts that secure the bottom of the radiator assembly to the mount 11 Carefully separate radiator assembly from mount and remove from vehicle 12 Plug all radiator and hose openings to prevent con tamination 13 If necessary remove components from radiator as sembly using Figure 14 as a guide Installation Fig 13 1 If radiator assembly was disass...

Page 36: ...e to lift valve 8 O ring 9 90o hydraulic fitting 10 Flange nut 4 used 11 Square key 12 Pump engine mount 13 Flange head screw 4 used 14 Flange head screw 4 used 15 Pump hub 16 Coupling spacer 6 used 17 Flange nut 6 used 18 Flat washer 2 used 19 Coupling spacer 2 used 20 Flange head screw 4 used 21 Gasoline engine 22 Rubber coupling 2 used 23 Square head screw 2 used 24 Coupling 25 Upper radiator h...

Page 37: ...from engine 7 Note location of cable ties used to secure wire har ness leads Label and disconnect wire harness connec tors that attach to engine A Battery cable and fusible link harness fromstarter solenoid stud Fig 16 B Harness wire from spade terminal on starter sole noid C Harness wire from oil pressure switch D Harness wires from temperature sender and thermal fan switch on water pump housing ...

Page 38: ...hydraulic accessories NOTE If vehicle is equipped with High Flow Hydraulics Kit label hydraulic hoses for assembly purposes 13 Thoroughly clean junction of gear pump fittings and hydraulic hoses Disconnect hydraulic hoses from gear pump Install caps or plugs in hoses and pump fittings to prevent contamination and leakage of hydraulic oil 14 Put blocking under transaxle to prevent the transaxle fro...

Page 39: ...gine mount to engine support with two 2 cap screws snubbing washers and flange nuts Fig 17 10 Remove plugs from hydraulic hoses and gear pump fittings Connect hydraulic hoses to gear pump see Hy draulic Hose and Tube Installation in the General Infor mation section of Chapter 9 Hydraulic System 11 On 4WD vehicles install differential drive shaft see Differential Driveshaft Installation in the Serv...

Page 40: ... used 3 Governor spring 4 Lock nut 5 Ball joint 6 Accelerator cable 7 Flange nut 8 Flange head screw 9 Grease fitting 10 Shoulder bolt 11 Bellcrank 12 Flange nut 13 Flange head screw 3 used 14 Throttle bracket 15 Governor link rod 16 Throttle return spring 8 7 6 9 10 15 14 5 13 12 4 16 2 1 11 3 2 FRONT RIGHT ...

Page 41: ...ricate bellcrank grease fitting after assembly 4 Check engine speed both idle and high idle and ad just if necessary 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 20 1 Governor spring 2 Bellcrank 3 Return spring...

Page 42: ...P sensor uses a 5V DC input reference and as intake manifold pressure changes it increases or de creases the amount of voltage returned to the ECU The ECU determines the engine load based on this return voltage The ECU can then regulate the proper amount of fuel to be injected as well as selecting the most ap propriate ignition timing advance based on the engine load Air Temperature Sensor The fun...

Page 43: ...atures the NTC type sensor s resist ance is very high but reduces as coolant temperature increases Heated Oxygen Sensor The oxygen sensor is the last in line device to provide input for the ECU It is used to inform the ECU about the effectiveness of its output commands The oxygen sen sor is placed in the exhaust system to detect whether or not the engine is operating in a rich lean or stoichiomet ...

Page 44: ...stroke each cyl inder is on for proper timing of fuel injection and ignition events This sensor is required for the system to inject fuel as the intake valve opens for most efficient perfor mance and idle quality The signals are used to control when to apply the ignition voltage to the spark plug for the proper ignition timing advance The crankshaft position sensor works by having a mag netic core...

Page 45: ... coils to apply voltage to the spark plug when appropriate Ignition timing advance is controlled by the ECU which varies the point when the spark is initiated at the plug in relation to where the pis ton is located in degrees before top dead center Dy namic ignition timing advance offers optimal torque and economy for any given RPM and engine load Figure 29 EFI Troubleshooting Information on EFI t...

Page 46: ...Rev A Workman HDX Page 3 28 Briggs Daihatsu Gasoline Engine This page is intentionally blank ...

Page 47: ...perator s Manual 3 Adding Oil to Engine 3 ADJUSTMENTS 4 Adjust Engine Speed 4 SERVICE AND REPAIRS 6 Air Cleaner System 6 Fuel Tank 8 Exhaust System 10 Radiator 12 Engine 14 Engine Removal 15 Engine Installation 16 Engine Throttle Bracket 18 BRIGGS STRATTON DAIHATSU REPAIR MANUAL FOR 3 CYLINDER LIQUID COOLED DIESEL ENGINES Briggs Daihatsu Diesel Engine ...

Page 48: ...ntent Fuel Injection Pump Bosch VE Distributor type Fuel Injector Nozzle Bosch throttle type Fuel Tank Capacity 6 5 U S gallons 25 liters 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 3 5 U S quarts 3 3 liters with filter Water ...

Page 49: ...s explained However the cost of the test equip ment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Briggs and Stratton Daihat su 3LC diesel engines are supplied through your local Toro distributor Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and mainte...

Page 50: ...s operating at 1500 50 RPM 5 If idle speed is 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...

Page 51: ...Workman HDX D Page 4 5 Briggs Daihatsu Diesel Engine This page is intentionally blank Briggs Daihatsu Diesel Engine ...

Page 52: ...pairs Air Cleaner System Figure 4 1 Mounting bracket 2 Air cleaner hose 3 Air inlet hood 4 Air cleaner assembly 5 Hose clamp 4 used 6 Engine 7 Air intake hose 8 Frame 9 Flange head screw 2 used 10 Flange nut 2 used FRONT RIGHT VACUATOR DIRECTION 8 7 6 9 5 4 3 10 1 2 5 ...

Page 53: ...4 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 Assemble air cleaner system using Figure 4 and 5 as guides Air cleaner hose item 2 and air inlet hood item 3 should be positioned straight upward The vacuator valve on the air cleaner assembly should be po...

Page 54: ...1 20 19 4 4 7 10 13 Thread Sealant 175 to 200 in lb 20 to 22 N m FROM TO ENGINE ENGINE DANGER Because dieselfuelis 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 55: ... retainer plate item 18 that secure fuel tank 6 Remove fuel tank from vehicle Fuel Tank Installation Fig 6 1 Position fuel tank to support tube 2 Remove plugs placed in fuel hoses during fuel tank removal Connect fuel hoses to fuel sender and rollover valve Fig 7 Secure fuel hoses with hose clamps 3 Connect wire harness connector to fuel sender 4 Position retainer plate item 18 to tank and frame M...

Page 56: ...aust gasket 2 used 4 Hex nut 4 used 5 Exhaust tube 6 Flange head screw 2 used 7 Transaxle 8 Flange nut 8 used 9 Flange head screw 2 used 10 Mount plate 11 Flange head screw 12 Shift cable mount bracket 13 Carriage bolt 2 used 14 Flange head screw 4 used FRONT RIGHT 8 7 9 11 14 1 5 13 12 4 3 2 6 10 3 8 8 ...

Page 57: ...lation Fig 8 1 Replace any removed gaskets 2 Using Figure 8 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 4 that secure exhaust tube to en gine B Flange head screw item 11 that secures muffler to transaxle C Flange head screws item 14 and flange nuts item 8 that secure muffler to exha...

Page 58: ... 6 Hose radiator to coolant reservoir 7 Hose 8 Hose clamp 3 used 9 Radiator screen 10 Radiator mount 11 Flange nut 4 used 12 Flange head screw 13 Flange head screw 4 used 14 Clip 2 used 15 Flange nut 2 used 16 Swell latch 4 used 17 R clamp 2 used 18 Washer head screw 19 Flat washer 2 used FRONT RIGHT 8 7 6 9 1 5 4 3 2 18 17 16 19 10 15 14 13 12 11 6 8 13 11 11 13 5 13 14 19 ...

Page 59: ...bly to the mount B Remove two 2 flange head screws and flange nuts that secure the bottom of the radiator assembly to the mount 11 Carefully separate radiator assembly from mount and remove from vehicle 12 Plug all radiator and hose openings to prevent con tamination 13 If necessary remove components from radiator us ing Figure 10 as a guide Installation Fig 9 1 If radiator assembly was disassembl...

Page 60: ... fitting 10 Flange nut 4 used 11 Square key 12 Pump engine mount 13 Flange head screw 4 used 14 Flange head screw 4 used 15 Pump hub 16 Coupling spacer 6 used 17 Flange nut 6 used 18 Flat washer 2 used 19 Coupling spacer 2 used 20 Flange head screw 4 used 21 Diesel engine 22 Rubber coupling 2 used 23 Square head screw 2 used 24 Coupling 25 Upper radiator hose 26 Hose clamp 27 Lower radiator hose 2...

Page 61: ... cable and fusible link harness fromstarter solenoid stud Fig 12 B Wire from spade terminal on starter solenoid C Wire from oil pressure switch D Wires from temperature sender and thermal fan switch on water pump housing E Harness connector and wire with ring terminal from alternator F Negative battery cable and harness ground con nector secured to engine mount Fig 12 Note loca tion ofground conne...

Page 62: ...ntamination and leakage of hydraulic oil 14 Put blocking under transaxle to prevent the transaxle from moving during engine removal 15 Loosen and remove two 2 flange nuts snubbing washers and cap screws that secure engine mount to engine support Fig 13 16 Remove six 6 cap screws that secure clutch bell housing to engine Note location of two 2 harness brackets as caps screws are being removed Fig 1...

Page 63: ...llation in the General Infor mation section of Chapter 9 Hydraulic System 11 On 4WD vehicles install differential drive shaft see Differential Driveshaft Installation in the Service and Re pairs section of Chapter 10 Front Wheel Drive 4WD 12 Install upper and lower radiator hoses to engine and secure with hose clamps Install R clamp item 35 to secure lower radiator hose to engine mount 13 Fill rad...

Page 64: ...GHT 2 7 8 7 Disassembly Fig 15 1 Remove throttle bracket components from engine as needed using Figure 15 as a guide Assembly Fig 15 1 Install removed throttle bracket components to en gine using Figure 15 as a guide 2 Lubricate bellcrank grease fitting item 13 after as sembly 3 Check operation and adjustment of accelerator cable see Operator s Manual If needed adjust accel erator cable 4 Check en...

Page 65: ...Contents SPECIFICATIONS 2 GENERAL INFORMATION 3 Operator s Manual 3 SERVICE AND REPAIRS 5 Cooling System 5 Fuel Tank 6 Exhaust System 8 Engine 10 Engine Removal 11 Flywheel and Pilot Bearing Inspection 11 Engine Installation 12 KOHLER COMMAND ENGINE SERVICE MANUAL Kohler Gasoline Engine ...

Page 66: ...on Ratio 8 5 1 Governor Mechanical Idle Speed no load 1200 100 RPM High Idle no load 3600 50 RPM Oil Pump Gear driven trochoid type Engine Oil See Operator s Manual Crankcase Oil Capacity 2 U S quarts 1 9 liters with filter Fuel Unleaded Regular Gasoline Minimum 87 Octane Fuel Pump Diaphragm engine mounted Fuel Tank Capacity 6 5 U S gallons 24 6 liters Starter 12 VDC Alternator Regulator 12 VDC 25...

Page 67: ...ly available in many service shops Special tools are described in the Kohler Command Engine Ser vice Manual The use of some specialized test equip ment is explained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair fa cility Service and repair parts for Kohler engines are supplied through your local Kohler dealer...

Page 68: ...Workman HD Page 5 4 Kohler Gasoline Engine This page is intentionally blank ...

Page 69: ...nd 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 CAUTION The engine may be hot Allow engine to cool be fore cleaning the engine cooling fins 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...

Page 70: ... 16 15 18 10 14 13 12 11 20 21 19 22 23 24 3 3 23 25 26 27 28 29 1 175 to 200 in lb 20 to 22 N m TO PURGE PORT TO ENGINE 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 befor...

Page 71: ...retainer plate item 14 that secure fuel tank 6 Remove fuel tank from vehicle Fuel Tank Installation Fig 2 1 Position fuel tank to support tube 2 Remove plugs placed in fuel hoses during fuel tank removal Connect fuel hoses to fuel sender and rollover valve Fig 3 Secure fuel hoses with hose clamps 3 Connect wire harness connector to fuel sender 4 Position retainer plate item 14 to tank and frame Ma...

Page 72: ...nut 4 used 4 Exhaust gasket 2 used 5 Flange nut 9 used 6 Flange head screw 3 used 7 Flange head screw 8 Bracket 9 Muffler gasket 10 Muffler 11 Flange head screw 12 Shift cable mount bracket 13 Carriage bolt 2 used 14 Muffler mount plate 15 Flange head screw 2 used FRONT RIGHT 8 7 6 9 10 11 5 15 14 1 5 13 12 4 3 2 5 5 6 ...

Page 73: ...ing Figure 4 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 Flange head screw item 11 that secures muffler to transaxle C Flange head screws item 1 and flange nuts item 5 that secure muffler to manifold D Flange head screws item 6 and flange nuts item...

Page 74: ...26 Cap screw 6 used 27 Pin 3 used 28 Woodruff key 29 Cap screw 4 used 30 Lock washer 4 used 31 Flat washer 4 used 32 Engine assembly 33 Choke cable 34 Flange nut 4 used 35 Lock nut 36 Flange head screw 4 used 37 Positive battery cable 38 Washer head screw 4 used 39 Lock washer 6 used 40 Ground wire harness 41 Fusible link harness 42 Negative battery cable 43 Wire harness connector 44 Engine mount ...

Page 75: ... from bracket Fig 7 11 Remove all clamps and cable ties that attach wire harness hoses and cables to the engine 12 Put blocking under transaxle to prevent it from mov ing during engine removal 13 Loosen and remove four 4 flange nuts item 34 and flange head screws item 36 that secure engine to engine mount 14 Remove six 6 cap screws item 19 and two 2 har ness brackets item 46 that secure clutch bel...

Page 76: ...guide engine to machine Align splines on transaxle input shaft and clutch while moving engine to bell hous ing on transaxle 6 Secure bell housing to clutch adapter on engine with six 6 cap screws item 19 and two 2 harness brack ets item 46 7 Secure engine to engine mount with four 4 flange nuts item 34 and flange head screws item 36 8 Connect choke cable item 33 to choke lever on en gine Fig 7 9 C...

Page 77: ...LESHOOTING 6 Clutch 6 Transaxle 8 SERVICE AND REPAIRS 10 Shift Cable Replacement 10 Driveshaft 12 Driveshaft Cross and Bearing Service 14 PTO Removal and Installation If Equipped 15 Transaxle 16 Transaxle Removal 17 Transaxle Installation 18 Clutch Service 20 Transaxle Service 22 Transaxle Disassembly 22 Transaxle Inspection 33 Transaxle Assembly 37 Power Take Off PTO Service If Equipped 54 Disass...

Page 78: ...Workman HD Series Page 6 2 Drive Train Specifications Item Specification Transaxle Oil Dexron III ATF Transaxle Oil Capacity 8 U S quart 7 6 liter system capacity ...

Page 79: ...2 heavy duty universal driveshafts 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 housing also functions as the hydraulic system reservoir On units equipped with four wheel drive 4WD a front output shaft in the transaxle transfers power from the tran...

Page 80: ...in Special Tools Order special tools from your Toro Distributor Clutch Alignment Tool Use clutch alignment tool to align clutch friction disk to engine flywheel before tightening pressure plate cap screws Toro Part Number TOR6002 Figure 2 ...

Page 81: ...o PTO le ver arm 2 Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in PTO lever arm 3 Tighten jam nut making sure that holes in clevis and lever arm still align 4 Secure PTO cable clevis to PTO lever arm with clevis pin 1 PTO lever arm 2 PTO cable 3 Clevis pin 4 Clevis jam nut Figure 3 1 2 3 4 Drive Train ...

Page 82: ...proper installation of clutch cover assembly Damaged clutch disc Excessive wear of clutch disc facing Weak or broken clutch torsion spring Damaged or broken clutch pressure plate 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...

Page 83: ...p Damaged or distorted clutch disc Worn or rusted clutch disc spline Damaged pressure plate or flywheel Damaged release bearing Clutch chatters Worn or damaged clutch disc facing Oil adhered to clutch disc facing Uneven height of diaphragm spring Weak or damaged clutch torsion spring Damaged pressure plate or flywheel Damaged clutch release bearing Loose or worn front wheel bearings Drive Train ...

Page 84: ...tor station Loose shift lever on transaxle 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 k...

Page 85: ...slips out of gear Shift linkage out of adjustment Gear loose on shaft Gear teeth worn Excessive end play in gears Lack of spring pressure on shift fork detent ball Badly worn bearings Overheating of transaxle Oil level too high Excessive hydraulic load See Chapter 9 Hydraulic System Drive Train ...

Page 86: ...7 6 18 8 12 13 15 17 16 14 10 7 8 6 11 4 19 Shift Cable Removal Fig 4 1 Parkvehicleonalevelsurface raiseand supportbed if installed shut engine off and engage the parking brake Remove key from the ignition switch 2 Remove knobs fromcontrollevers then removecen ter console shift boot and control plate Fig 5 3 Remove three 3 screws item 18 and cable clamp item 19 that secure shift cables to lever su...

Page 87: ...platform by inserting clevis pin item 8 from the passenger side then install hair pin 4 Secure shift cables to lever support with cable clamp item 19 and three 3 screws item 18 5 Spread jam nuts on bulkhead fitting of cable Fig 6 With cable properly routed to transaxle install cable bulkhead fitting to shift cable mount bracket on transaxle and tighten jam nuts 6 Install cable ties in the original...

Page 88: ...per wheel 12 Driveshaft assembly 2 used 13 Flange nut 2 used per shaft 14 Cap screw 2 used per shaft 15 Hardened washer 2 used per shaft 16 Parking brake return spring 2 used 17 Hitch 18 Clevis pin 2 used 19 Flange head screw 20 used Figure 7 FRONT RIGHT 5 4 6 7 1 3 8 9 11 13 12 10 18 19 15 17 16 14 2 13 19 19 80 to 90 ft lb 109 to 122 N m 40 to 45 ft lb 55 to 61 N m 170 to 180 ft lb 231 to 244 N ...

Page 89: ...veshaft A Apply antiseize lubricant to splined shaft and install into driveshaft B Apply Loctite 271 or equivalent to threads of splined shaft C Install flange nut item 5 onto splined shaft and tighten 2 Secure driveshaft to transaxle shaft Fig 8 A Apply antiseize lubricant to transaxle shaft B Slide driveshaft yoke onto transaxle shaft C Align mounting holes in driveshaft with relief in transaxle...

Page 90: ... To install new cross and bearings A Apply a coating of grease to bearing bores of end yoke and shaft yoke Also apply grease to bearings and seal of bearing assembly Make sure that all bearing rollers are properly seated in bearing cage B Press one bearing partially into yoke IMPORTANT Take care when installing cross into bearing to avoid damaging bearing seal C Carefully insert cross into bearing...

Page 91: ...ransaxle Separate PTOand O ring from transaxle case Locate and remove two alignment pins PTO Installation 1 Apply multi purpose grease to O ring and insert O ring into groove of transaxle case Insert two 2 align ment pins in transaxle case IMPORTANT When installing PTO assembly make sure O ring is properly positioned in transaxle case groove 2 Install PTO to transaxle Secure PTO to transaxle with ...

Page 92: ... used 5 Flange nut 4 used 6 Cap screw 2 used 7 Flange head screw 4 used 8 Shift arm 9 Lock nut 3 used 10 Shift cable mount bracket 11 Shift lever 2 used 12 Differential lock lever 13 Strainer 14 Shift arm plate 15 O ring 16 Suction hose 17 90o fitting 18 Drain plug 19 O ring Figure 12 FRONT RIGHT 5 1 4 3 2 9 6 12 11 10 7 8 2 3 13 9 14 15 17 16 19 18 ...

Page 93: ...o remove differential lock cable from support bracket then disconnect differential lock cable from lock lever at left rear of transaxle Fig 14 10 Disconnect shifter control cables from levers on transaxle and PTO if equipped Fig 15 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 tio...

Page 94: ...clutch or release bearing A When installing driveshafts to transaxle apply antiseize lubricant to transaxle shafts Align mount ing 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 40 to 45 ft lb 55 to 61 N m B Before installing two 2 shift levers and shift arm onto transaxle shafts t...

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Page 96: ...ase Mechanism Fig 19 1 Inspect main shaft of transaxle for wear or damaged splines 2 Remove spring 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 3 Inspect clutch release fork item 4 release shaft item 5 and bushings item 6 for wear or damage In spect ex...

Page 97: ...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 oil or rust fromflywheelsurf...

Page 98: ...using assembly from trans axle 3 Thoroughly clean outside surface of transaxle 4 Loosen flange head screws items 1 and 2 and re move fork shaft case item 3 from center plate Note location of longer flange head screw item 1 Be careful when removing cover as steel balls inside are spring loaded 5 Hold your hand over the area and shift R 1 and 2 3 levers to move rails outward so balls item 3 springs ...

Page 99: ... from center plate 8 On 4WD units remove front drive shaft and 41T gear from the gear case Remove bearings from gear case Fig 29 item 2 and center plate 9 Remove reverse shaft item 1 from transaxle case 10 Remove main shaft assembly item 1 together with fork shaft assembly item 2 from transaxle case 1 3 2 4 Figure 27 41T GEAR FRONT DRIVE SHAFT BEARING GEAR CASE BEARING CENTER PLATE Figure 28 1 2 F...

Page 100: ...d shims item 3 from L H side cover item 4 still attached to trans axle 13 Remove roll pin from differential lock lever Remove lever item 1 from shaft Loosen and remove five 5 flange head screws item 2 Remove L H side cover item 3 from transaxle case 14 Inspect side cover for cracks or damage and replace if necessary 15 Loosen and remove four 4 flange head screws item 1 Remove R H axle shaft assemb...

Page 101: ...n 16 Remove differential gear assembly item 1 together with fork shaft assembly item 2 17 Remove washer item 1 from inside of transaxle case NOTE Washer may stick to fork shaft when re moved in step 16 1 2 Figure 35 1 Figure 36 Drive Train ...

Page 102: ... 9 and High Low shift arm not shown Remove shift arms C Loosen cap screws Fig 38 item 10 and remove keeper plates item 11 D Remove oil seals item 12 E Inspect shift arms and keeper plates for bending or damage and replace if necessary 19 If PTO cover is on transaxle remove five 5 cap screws item 1 and nut item 2 with washer Separate PTO cover item 3 from transaxle case Inspect PTO cover for cracks...

Page 103: ... Remove oil cap item 1 and O ring from transaxle case if necessary 21 Remove air breather item 2 if necessary 22 Loosen four 4 flange head screws item 1 and re move upper cover item 2 from transaxle case 1 2 Figure 40 1 2 Figure 41 Drive Train ...

Page 104: ...edle bearings and replace if necessary D Remove synchro ring item 6 E Remove snap ring item 7 F Remove shifter item 8 together with spring hub and three 3 keys G Remove key item 9 H Remove snap ring item 10 I Remove synchro ring item 6 gear item 11 two 2 needle bearings item 12 and washer item 13 Inspect needle bearings and replace if necessary J Use a bearing puller to remove bearing item 14 K Re...

Page 105: ... 8 E Remove spacer item 10 F Remove snap ring item 11 G Remove shifter item 12 together with spring hub and three 3 keys 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 than 0 0709 i...

Page 106: ...asher item7 Inspect inner for wear and damage Replace inner 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 0 0709 in 1 8 mm E Remove two 2 snap rings item 8 F Remove Hi Lo shifter item 9 and collar spline 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 ...

Page 107: ...l gear 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 two 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 c...

Page 108: ...1 from differential carrier B Remove snap ring item 2 C Remove L H axle shaft assembly item 3 D Remove snap ring item 4 and washer item 5 E Use a bearing puller to remove bearing item 6 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 t...

Page 109: ...ce for roughness material transfer brass 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 56 A Inspect...

Page 110: ...er groove and fork Replace shift fork if the clearance exceeds 0 039 in 1 0 mm 7 Inspect main shaft A Inspect main shaft for worn or damaged surface If O D of needle bearing surface is less than 0 864 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 8 Inspect...

Page 111: ...nspectcenter platefor cracksand damage Replace center plate if the snap ring groove has more than 15 of its edges damaged due to nicks rounding cracks or dents Figs 60 and 61 UNDAMAGED GROOVE Figure 60 DAMAGED GROOVE EDGES Figure 61 Drive Train ...

Page 112: ...inion shaft for excessive wear or dam age If O D is less than 0 707 in 17 95 mm replace the pinion shaft B Measure thickness of pinion liners If thickness is less than 0 035 in 0 9 mm replace the pinion lin ers C Measure thickness of side gear liners If thick ness is less than 0 043 in 1 1 mm replace the side gear liners D Inspect the gear contact condition between spiral bevel pinion and ring gea...

Page 113: ...w O ring item 1 Apply multi purpose 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 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 item 7 4 Assemble differ...

Page 114: ...an oil from threads in ring gear item 6 NOTE Ring gear and countershaft are supplied in matched sets only H Insert two 2 dowel pins item 7 onto ring gear item 6 I Completely clean oil from threads of cap screws item 5 NOTE It is recommended that whenever the ring gear screws are removed that they be replaced with new screws J Apply Loctite to threads of cap screws K Clean oil from contact surface ...

Page 115: ...sulfide grease onto the shaft before installing 7 Assemble R 1 and 2 3 fork shaft 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 1 5 4 2 3 Figure 71 Fi...

Page 116: ...efore installing Oil groove on washer must face the gear D Install collar spline item 10 and snap ring item 8 E Install shifter item 9 onto collar spline F Install snap ring item 8 washer item 7 and in ner item 6 Oil groove on washer must face the gear 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 bearin...

Page 117: ...emble synchro hub A Install 3 keys item 1 into grooves of hub item 2 B Install shifter item 1 onto hub item 2 C Insert two 2 springs item 3 into hub Pay atten tion to direction of spring 1 2 Figure 75 1 2 Figure 76 Figure 77 Figure 78 Drive Train ...

Page 118: ... gear item 15 Apply clean Dexron III transmission oil on cone face of gear before installing synchro ring C Insert key item 13 onto reduction shaft D Install synchro hub sub assembly item 12 E Install snap ring item 11 F Install spacer item 10 onto gear item 8 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 install b...

Page 119: ...ng item 6 onto gear item 11 Apply clean 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 clean Dexron III transmission oil to cone face of gear before installing synchro ring K Insert 2 needle bearings item 5 into gear item 4 A...

Page 120: ...reads and tapers of shift fork arms D Install two 2 shift arms item 9 Install shift arm assembly items 7 6 5 4 3 and 2 E Install lock nuts items 8 and 1 Tighten shift arm retaining lock nuts to a torque from 230 to 240 in lb 26 to 27 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 ...

Page 121: ...shaft and countershaft assembly into transaxle case Insert heads of shift arms into grooves of forks when installing them 18 Assemble main shaft together with 2 3 fork shaft 19 Insert main shaft and 2 3 fork shaft assembly into transaxle case Insert head of shift arm into groove of fork while installing Figure 87 Figure 88 Figure 89 Figure 90 Drive Train ...

Page 122: ... plate A Insert two 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 fifteen 15 flange head 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 F Apply moly disulfide grease to spline of main...

Page 123: ...gainst the bearing In sertshimset item2 againstthe tabbedshim Usethick est shims in set possible that will permit installation of the snap ring Fig 94 and 95 24 Install snap ring into the groove of the bearing hous ing Fig 95 and 96 1 3 2 4 Figure 94 1 Countershaft 2 Bearing 3 Shims 4 Snap ring 5 Center plate 6 Sealing cap Figure 95 1 5 3 6 4 2 Figure 96 Drive Train ...

Page 124: ...ure space between the snap ring and shim set with a feeler gauge Make sure shim set is held against the bearing during the measurement End play should be from 0 000 to 0 0039 in 0 00 to 0 10 mm Fig 97 IMPORTANT If end play is too large replace shim shim set item 2 in steps 21 and 22 with thicker shims to reduce endplay 26 Insert sealing cap item 1 flush with face of housing Make sure to not insert...

Page 125: ...nt to mating surface of fork shaft case item 3 D Install fork shaft case item 3 Install and tighten flange head screws items 2 and 1 to a torque from 18 5 to 22 ft lb 24 5 to 29 5 N m E Check operation of shifters and detent 28 Insert a washer item 1 into housing of transaxle case Apply moly disulfide grease to washer before installing 1 Figure 99 1 2 Figure 100 1 3 1 1 2 Figure 101 1 Figure 102 D...

Page 126: ...nto mating surface of side cover C Install side cover and secure with ten 10 flange head screws Torque screws from 18 5 to 22 ft lb 24 5 to 29 5 N m 31 Install R H axle shaft assembly A Apply silicone sealant onto mating surface of seal cover B Install axle shaft assembly item 2 and secure with four 4 flange head screws item 1 Torque screws from 18 5 to 22 ft lb 24 5 to 29 5 N m Figure 103 1 2 Fig...

Page 127: ...gear through window on transaxle case Using a dial indicator check ring gear backlash in three equally spaced points Backlash should be 0 0031 to 0 0071 in 0 08 to 0 18 mm and must not vary more than 0 0019 in 0 05 mm at the points checked If backlash is not in this range replace shim set in end of differential carrier A If less than target range decrease total thickness of shim set until correct ...

Page 128: ...n into fork shaft and arm Pay attention to direction of slit in lock pin 35 Apply silicone sealant to mating surface of upper cover item 2 Pay attention to direction of cover and install Secure with four 4 flange head screws item 1 Torque screws from 18 5 to 22 ft lb 24 5 to 29 5 N m 1 Figure 110 1 2 Figure 111 ...

Page 129: ...que fasteners from 11 to 13 ft lb 15 to 17 N m NOTE If equipped with optional PTO install PTO as sembly after the transaxle has been installed in vehicle Plug transaxle opening to prevent debris entry into transaxle 37 Install bell housing and secure with nine 9 flange head screws item 2 Torque screws from 18 5 to 22 ft lb 24 5 to 29 5 N m 38 Install extension spring item 1 1 2 3 Figure 112 1 2 Fi...

Page 130: ... 4 23 22 9 6 7 8 18 17 3 16 19 20 21 13 14 15 2 12 11 10 2 3 3 32 33 31 30 29 27 28 26 25 24 17 17 11 35 34 18 to 22 ft lb 24 5 to 29 5 N m Disassembly Fig 114 NOTE Item numbers in figures are shown in order of disassembly for example remove item 1 first then item 2 etc Assemble in reverse order for example install item 1 last 1 Put vehicle on a level surface Stop the engine and remove key from ig...

Page 131: ...haft assembly item 1 from PTO housing Remove oil seal from PTO cover 7 Remove intermediate shaft assembly item 1 from PTO housing Remove intermediate gear item 2 Re move bearing item 3 from housing if necessary 1 Figure 115 1 2 Figure 116 3 Figure 117 Drive Train ...

Page 132: ...move bearing item 4 E Slide input shaft toward other side F Remove bearing item 5 G Remove thrust washer item 6 and gear item 7 sliding input shaft toward PTO shaft side H Release shift arm item 8 from shifter block item 9 I Remove input shaft assembly 9 Disassemble PTO input shaft A Remove shift collar item 1 B Remove two 2 steel balls item 2 and spring item 3 Moly disulfide grease Figure 118 6 8...

Page 133: ...e a bearing puller to remove bearing item 1 B Remove gear item 2 and retaining ring item 3 C Remove retaining ring item 4 and thrust washer item 5 D Use a bearing puller to remove bearing item 6 if necessary 12 Disassemble shift arm A Remove two 2 lock pins from shift arm B Remove two 2 O rings item 1 1 Figure 121 Figure 122 1 2 3 7 6 4 5 Figure 123 1 Figure 124 Drive Train ...

Page 134: ... block if clearance ex ceeds 0 039 in 1 0 mm 4 Measure I D of input shaft bushing item 1 Replace bushing if I D exceeds 0 673 in 17 10 mm 5 Measure O D of bushing area on input shaft Re place shaft if O D is less than 0 667 in 16 95 mm In spect surface of bushing area for scoring or damage 6 Inspect surface of oil seal area on output shaft for wear or damage CLEARANCE Figure 125 1 Figure 126 BUSHI...

Page 135: ...ing sur faces when removing gasket material 2 Make sure all parts are free of dirt and dust 3 Assemble shift arm A Apply moly disulfide grease to two 2 new O rings item 1 and install onto shift arm 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 two 2 spring pins into shift lever and shift arm Pay attention to dir...

Page 136: ...em 4 C Install retaining ring item 3 and gear item 2 D Use a press to install bearing item 1 5 Use a press to install bearing item 1 onto intermedi ate shaft 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 1 2 3 7 6 4 5 Figure 132 Figure 133 1 Figure 134 1 2 2 3 Figure 135 ...

Page 137: ...b assembly item 3 on the shifter block C Install 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 ling D Slide two 2 bearings items 5 and 4 onto input shaft E Install two 2 retaining rings items 2 and 1 5 4 6 7 3 Figure 136 3 Figure 137 6 7 Figure 138 M...

Page 138: ...bearing item 3 into PTO housing 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 9 Insert PTO shaft assembly item 1 into bearing housing of PTO housing 3 Figure 140 1 2 Figure 141 1 Figure 142 ...

Page 139: ...f oil seal B Insert two 2 alignment pins into PTO housing C Applysilicone sealantonto matingsurface ofPTO cover D Install PTO cover Secure cover with cap screws nut and lock washers Torque fasteners from 18 to 22 ft lb 24 5 to 29 5 N m 11 Install PTO to transaxle see PTO Removal and Installation in this section Figure 143 Drive Train ...

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Page 141: ...RVICE AND REPAIRS 8 Wheel Assembly 8 Brake System 10 Brake Caliper Service 12 Parking Brake Caliper Service 13 Bleed Brake System 14 Brake Master Cylinder 16 Brake Master Cylinder Service 18 Parking Brake Cable 20 Wheel Hub 22 Steering Assembly 24 Front Control Arms 28 Front Compression Spring Service 30 Front Shock Absorber 32 Rear Shock Absorber 33 Rear Leaf Spring 34 Front Wheel Alignment 36 St...

Page 142: ...Specification Front tire 20 x 9 12 6 ply Maximum front tire pressure 32 PSI 220 kPa Front wheel alignment 0 0 120 in 0 3 mm Rear tire 24 x 12 12 6 ply Maximum rear tire pressure 18 PSI 124 kPa Wheel nut torque 80 to 90 ft lb 109 to 122 N m Brake fluid DOT 3 ...

Page 143: ...servicing the vehicle Tire Pressure 1 Tire pressure should be determined by the payload carried 2 The lower the tire pressure the less the compaction and tire marks are minimized Lower pressure should not be used for heavy payloads at higher speeds Tire damage may result 3 Higher tire pressure should be used for heavier pay loads at higher speeds Do not exceed maximum tire pressure see Specificati...

Page 144: ... Page 7 4 Chassis Special Tools Compression Spring Tool Use to remove and install the two 2 front suspension compression springs Quantity Item 2 1 2 x 20 threaded steel rods 4 1 2 nuts 4 1 2 flat washers 20 5 5 Figure 1 ...

Page 145: ... absorbers Worn leaf spring bushings Clutch driveshaft 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 ...

Page 146: ...pressure Broken or weak rear leaf spring Incorrect front wheel alignment Damaged or bent suspension or steering component Worn or damaged brake components Brakes Problem Possible Causes Brake pedal goes to floor Low brake fluid level Air in brake system Leaking wheel caliper s Loose or broken brake lines Leaking or worn brake master cylinder Excessively worn brake pads or rotors Spongy brake pedal...

Page 147: ...arking brake adjustment Weak or broken parking brake return spring Binding brake pedal Sticking brake master cylinder Saturated brake pads Scored or bent brake rotors Hard brake pedal Incorrect brake pad material Damaged brake hoses Brake pedal linkage is binding Wheel locks Contaminated brake pads Loose or damaged brake pads Wheel caliper is sticking Sticking brake master cylinder Wheel bearing i...

Page 148: ...ake caliper 6 Flange head screw 7 Parking brake caliper LH shown 8 Parking brake bracket LH shown 9 Parking brake return spring 10 Clevis pin 2 used 11 Rear wheel assembly 12 Rear axle Figure 2 5 6 7 3 8 9 11 12 10 2 4 80 to 90 ft lb 109 to 122 N m 35 to 40 ft lb 48 to 55 N m 5 4 6 1 2 3 80 to 90 ft lb 109 to 122 N m 35 to 40 ft lb 48 to 55 N m 6 FRONT RIGHT ...

Page 149: ... then remove wheel assembly from vehicle Installation Fig 2 1 Install wheel Secure with five 5 lug nuts 2 Lower vehicle to ground WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury Torque wheel lug nuts from 80 to 90 ft lb 109 to 122 N m 3 Wheel lug nuts should be tightened in a star pattern Fig 3 and in two 2 steps Fi...

Page 150: ... ft lb 109 to 122 N m 35 to 40 ft lb 48 to 55 N m 6 FRONT RIGHT 13 Disassembly Fig 4 1 Park vehicle on a level surface shut engine off and remove key from ignition switch 2 For brake that is to be serviced remove wheel from vehicle see Wheel Assembly Removal in this section Make sure that vehicle is supported with jack stands NOTE Brake caliper can be removed from brake rotor without removing brak...

Page 151: ...hreads on cable are showing towards the rear of the vehicle 3 On rear axle install parking brake assembly to brake rotor A Slide parking brake bracket assembly bracket cable and parking brake caliper onto brake rotor Make sure that rotor is between brake pads B Secure parking brake bracket to rear axle with two 2 flange head screws 4 Slide brake caliper onto brake rotor Make sure that rotor is bet...

Page 152: ...to less than 1 32 0 8 mm NOTE The replacement brake pad kit includes inner brake pad outer brake pad pins and anti rattle clip Assembly Fig 5 1 If brake pads are being replaced it will be necessary to push caliper pistons back into the caliper bore before installing new pads 2 Slide brake pads into caliper Make sure that lining material on pads is toward brake rotor position 3 Secure pads into cal...

Page 153: ...r body Assembly Fig 6 1 If removed install cam lever into caliper body and then place pivot pins into lever holes Insert lever retain er spring with tangs bent away from housing until the spring tabs contact the pivot pin at the bottom of the housing pocket 2 Install cam side pad support notch facing cam lever and brake pad into caliper body 3 Slidecarriersidepadsupportand brakepad intocali per bo...

Page 154: ...pedal fades to floor then close bleed er valve 5 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 6 Torque bleeder valve from 60 to 80 in lb 6 8 to 9 0 N m 7 Complete steps 2 through 6 for right rear left front and then right front brake calipers 8 Install hood see H...

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Page 156: ...r Cylinder 1 Brake master cylinder 2 Flange head screw 2 used 3 Clevis pin 4 Grease fitting 5 Brake pedal 6 Flange bushing 7 Flange nut 8 Flange nut 2 used 9 Cotter pin 10 Shoulder screw 11 Brake shaft Figure 8 2 1 5 6 4 3 7 10 11 9 8 2 FRONT RIGHT ...

Page 157: ...ehicle frame 6 Remove master cylinder from vehicle Installation Fig 8 1 Position master cylinder to vehicle frame and secure with two 2 flange head screws and flange nuts 2 Remove plugs from brake lines Install brake lines to master cylinder Make sure that brake lines are properly connected to master cylinder Fig 9 3 Make sure that master cylinder push rod is fully ex tended Connect push rod clevi...

Page 158: ...d dry grooves and passageways 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 10 1 Apply a film of clean brake fluid to cylinder bore and piston assemblies 2 Install secondary pi...

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Page 160: ...ver counterclockwise all the way to loosen brake cable adjustment 3 Jack up and support rear of vehicle see Jacking Ve hicle in the Safety Instructions section of Chapter 1 Safety 4 For parking brake cable that is to be serviced re move rear wheel from vehicle see Wheel Assembly Re moval in this section Make sure that vehicle is supported with jack stands 5 Disconnect brake cable from parking brak...

Page 161: ...d to brake equalizer on parking brake lever Secure brake cable to lever support assem bly with retaining ring Fig 13 WARNING Failure to maintain proper wheel lug nut torque could result in failure or loss of wheel and may result in personal injury Torque wheel lug nuts from 80 to 90 ft lb 109 to 122 N m 4 Install rear wheel see Wheel Installation in this sec tion Lower vehicle to ground and make s...

Page 162: ... nut 18 Flat washer 19 Knuckle LH shown 20 Lock nut 21 Hardened washer 22 Cap screw Figure 14 FRONT RIGHT 5 6 7 3 8 9 11 12 10 2 4 80 to 90 ft lb 109 to 122 N m 35 to 40 ft lb 48 to 55 N m 5 4 6 1 2 3 80 to 90 ft lb 109 to 122 N m 35 to 40 ft lb 48 to 55 N m 6 6 6 14 15 16 17 170 to 180 ft lb 231 to 244 N m 35 to 40 ft lb 48 to 55 N m 18 19 22 21 20 170 to 180 ft lb 231 to 244 N m 35 to 40 ft lb 4...

Page 163: ... and 21 and lock nut item 20 from wheel hub assembly so that these components can be installed on replacement hub Installation Fig 14 1 If front wheel hub is being replaced install cap screw item 22 washers items 18 and 21 and lock nut item 20 to new hub Torque lock nut from 170 to 180 ft lb 231 to 244 N m 2 If any wheel studs were removed from hub press new stud s fully into hub making sure that ...

Page 164: ... link 21 Flat washer 2 used 22 Cap screw 2 used 23 Flange head screw 12 used 24 Washer 2 used 25 Grease fitting 2 used 26 Ball bearing 2 used 27 Flange nut 2 used 28 Flange head bolt 2 used 29 Flange nut 2 used 30 Cap screw 2 used 31 Snap ring 2 used 32 Cap screw 2 used 33 Lock nut 2 used Figure 15 18 19 15 17 16 20 13 12 14 11 10 3 6 8 9 5 1 4 2 7 12 2 1 3 12 14 14 11 21 28 29 31 24 27 22 23 23 3...

Page 165: ... frame Remove assembly from frame E Disassemble steering linkage and center link as sembly as required using Figures 15 and 17 as guides Assembly Fig 15 1 If steering linkage and center link assembly was dis assembled use Figures 15 and 17 as guides for assem bly A If flange bushings items 2 and 3 in Fig 17 were removed from pivot mount make sure that new bushings are pressed fully into the pivot ...

Page 166: ...ie rod item 11 to vehicle A If tie rod was separated make sure that jam nut is on inner tie rod threads Thread outer tie rod end onto inner tie rod the same number of revolutions as the old one took to remove B Apply Loctite 271 or equivalent to threads of inner tie rod end Thread tie rod into center link and torque from 70 to 80 ft lb 94 to 109 N m C Clean tapers of knuckle and outer tie rod end ...

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Page 168: ...rew 4 used 6 Flange nut 4 used 7 Flange head screw 6 used 8 Lock nut 8 used 9 Cap screw 2 used 10 Flange bushing 2 used per arm 11 Ball joint 12 Grease fitting 13 Ball joint seal 14 Knuckle LH shown 15 Retaining ring Figure 18 FRONT RIGHT 15 13 12 14 11 10 3 6 8 9 5 1 4 2 7 7 7 11 10 12 12 12 13 15 40 to 50 ft lb 55 to 67 N m 70 to 80 ft lb 94 to 109 N m ...

Page 169: ...control arm from vehicle frame 5 Disassemble control arm as needed A Remove retaining ring and press ball joint out of control arm B Press flange bushings from control arm Installation Fig 18 1 Assemble control arm A Press ball joint into control arm and secure with retaining ring Make sure that grease fitting is in ball joint B Lightly oil flange bushings and press bushings fully into control arm...

Page 170: ...n Spring Service 1 Spring cradle 2 used 2 Compression spring 2 used 3 Flange nut 4 Cap screw 5 Stabilizer link 6 Lock nut 7 Cap screw 8 LH control arm tower 9 Spring pivot sleeve 10 RH control arm tower Figure 19 2 3 4 7 6 1 5 9 8 10 11 12 4 FRONT RIGHT ...

Page 171: ... item 1 then install nuts and washers on both ends of each rod Tight en one nut on each rod to secure compression springs item 2 NOTE Extended portion of each compression spring tool must be on opposite ends so cap screws item 7 that secure spring cradles to control arm towers can be removed Fig 21 6 Remove flange nut item 3 and cap screw item 4 from lower end of each stabilizer link item 5 7 Remo...

Page 172: ...new shock absorber Insert spacer into ram lower end of shock absorber 2 Install inner washer item 3 onto frame stud above control arm 3 Install shock absorber with ram end down and se cure upper end with outer washer item 5 and lock nut 4 Insert cap screw down through angled hole in control arm tower Install washer onto cap screw and then slide shock absorber onto cap screw Install second washer o...

Page 173: ...r is being replaced or bushings are worn insert two 2 new rubber bush ings into each end of shock absorber Insert spacer into ram lower end of shock absorber 2 Install washer item 4 onto shock absorber mount ing stud on frame 3 Slide upper end of shock absorber onto stud on frame Install flat washer and lock nut onto stud Tighten lock nut 4 Place flat washer item 7 onto cap screw Insert cap screw ...

Page 174: ...proper vehicle performance al ways replace the springs on both sides of the ve hicle Removal Fig 26 1 Park vehicle on a level surface shut engine off re move key from ignition switch and apply parking brake 2 Jack up and support rear of vehicle with jack stands See Jacking Vehicle in the Safety Instructions section of Chapter 1 Safety 3 Remove rear wheels see Wheel Assembly Remov al in this sectio...

Page 175: ...ight 4 Insert second spring shackle item 10 through rub ber bushings in frame rail and onto spring shackle al ready placed in leaf spring Install flange nuts item 5 to spring shackles and tighten finger tight NOTE During leaf spring installation make sure axle and spring plate are centered on leaf spring knob 5 Install spring plate item 11 to top of leaf spring then secure spring to axle with bolt...

Page 176: ... measurement 3 If measurements determine that an adjustment is needed loosen jam nuts on front tie rod ends and rotate tie rods equally to change wheel alignment Torque jam nuts to 45 to 55 ft lb 61 to 74 N m after adjustment is complete 4 After alignment has been checked and or adjusted check for component interference as steering wheel is turned from lock to lock If necessary adjust tie rods equ...

Page 177: ...ve 4 Pull steering wheel from control valve If necessary use suitable puller to remove steering wheel Installation Fig 28 1 Apply antiseize lubricant to shaft of control valve 2 Slide steering wheel onto control valve shaft 3 Secure steering wheel with flat washer and hex nut Torque hex nut from 20 to 25 ft lb 28 to 33 N m 4 Install steering wheel cover Figure 28 1 Steering wheel 2 Flat washer 3 H...

Page 178: ... Flange nut 9 used 10 U clip nut 8 used 11 Rubber bumper 2 used 12 Mudflap 2 used 13 Flat washer 8 used 14 Flange head screw 4 used 15 Flange nut 4 used 16 Control plate 17 Socket head screw 18 Spacer 19 Nylon washer 20 Spring washer 21 Flat washer 22 Detent lever 23 Socket head screw 8 used Figure 29 18 19 15 17 16 20 13 12 14 11 10 3 6 8 9 5 1 4 2 7 23 22 21 13 9 12 in lb maximum 1 3 N m FRONT R...

Page 179: ... vehicle 5 Lift engine coolant overflow tank from slots in rear of seat base Position overflow tank away from seat base 6 Carefully lift seat base from vehicle Installation Fig 29 1 Lower seat base to vehicle while guiding control lev ers through seat base opening 2 Secure seats to vehicle with removed fasteners 3 Secure engine coolant overflow tank into slots in rear of seat base 4 Secure center ...

Page 180: ...l surface shut engine off and apply the parking brake Remove key from ignition switch 2 Grasp hood at headlight openings and carefully pull hood away from operator frame 3 Unplug the wire harness connector from the two 2 headlights 4 Remove hood from vehicle Installation Fig 31 1 Position hood to operator frame 2 Plug the wire harness connector to the two 2 head lights 3 Secure hood to frame by pr...

Page 181: ...r Terminals 16 Relay Five Terminals 17 Diodes 18 Fusible Link 19 Fuel Gauge Sender 20 Fuel Pump Workman HDX 21 Temperature Sender Workman HDX and HDX D 22 Thermal Fan Switch Workman HDX and HDX D 23 Speed Sensor Workman HDX and HDX D 24 Glow Plug Timer Workman HDX D 25 Delay Timer Vehicles with 4WD 26 High Flow Hydraulics Kit Switch Vehicles with High Flow Hydraulics Kit 26 Hydraulic Solenoid Valv...

Page 182: ...ernal 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 damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease which forms a light pro tective skin to help waterproof electrical switches and contacts Toro Part Number 505 165 Figure 2 Dielectric Gel Dielec...

Page 183: ...minals to reduce corrosion problems Apply battery terminal protector after the battery cable has been secured to the battery terminal Toro Part Number 107 0392 Figure 4 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte Obtain this tool locally Figure 5 Electrical System ...

Page 184: ...ch pedal not depressed instruct operator Hydraulic lift lever not in neutral position instruct operator Rear PTO if equipped engaged instruct operator Low battery charge Loose or corroded battery cables Loose or corroded ground RUN fuse 10 amp faulty Fusible link faulty Clutch switch faulty Clutch switch wiring loose corroded or damaged Lift lever interlock switch out of adjustment or faulty Lift ...

Page 185: ...ge instruct operator 10 amp fuse is faulty Engine or fuel system problem see appropriate Engine chapter Engine does not shut off immediately when ignition key switch is turned off Workman HD only Damaged or disconnected wiring for kill relay Kill relay faulty Engine runs but should not with 3rd High lockout switch in Slow position and transaxle in 3rd gear and High range 3rd High lockout key switc...

Page 186: ...increase once the engine is run ning NOTE Depending upon the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges Start the engine and run at high idle Allow the battery to charge for at least three 3 minutes Record the battery voltage An example of a charging system that is functioning At least 0 50 volt over i...

Page 187: ...ignition key to START position 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 lever interlock switch 1 Sit on operator s seat and engage parking brake Move shift lever to NEUTRAL position Disengage rear PTO if equipped 2 Move hydraulic lift lever out of neutral position 3 Depress clutc...

Page 188: ...ke sure that pow er to the circuit has been disconnected Ignition Key Switch The ignition key switch has three positions OFF ON and START The ignition switch is located on the dash Fig 6 Testing The switch terminals are identified as shown in Figure 7 The circuit wiring of the ignition switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested t...

Page 189: ...own in either miles per hour or kilometers per hour de pending on the status of the MPH KPH shunt Engine Coolant Temperature Gauge Workman HDX and HDX D The temperature gauge on Workman HDX and HDX D vehicles displays the engine coolant temperature If the coolant temperature exceeds 230oF 110oC the tem perature gauge will display a blinking red LED Tachometer Workman HDX and HDX D The tachometer o...

Page 190: ...elsys tem Third Row RH Optional kit Fourth Row LH Protects power supply for powerpoint and horn if equipped Fourth Row RH Protects power supply for 4WD differ ential vehicles with 4WD On Workman HDX and HDX D vehicles an additional 30 amp fuse is located in a fuse holder near the cooling fan This fuse protects the power supply for the radiator fan Fuse Testing 1 Make sure that ignition switch is O...

Page 191: ...H Brake Switch The brake switch is a normally closed switch that is at tached to the frame under the dash Fig 12 When the brakes are not applied the brake pedal presses the brake switch plunger to open the switch When the brakes are applied the pedal moves away from the brake switch plunger to allow the switch to be in the nor mally closed state and to allow a current path to illumi nate the stop ...

Page 192: ...l surface shut engine off re move key from ignition switch and apply parking brake Locate the clutch switch Fig 13 2 Remove hood see Hood Removalin the Service and Repairs section of Chapter 7 Chassis 3 Disconnect the wire harness connector from the clutch switch 4 With the use of a multimeter ohms setting test for continuity across the two 2 switch terminals There should be continuity zero ohms w...

Page 193: ...nd apply parking brake 2 Remove knobs fromcontrollevers then removecon trol plate assembly from seat base Fig 15 3 Locate the lift lever interlock switch Fig 14 4 Disconnect the wire harness connector from the lift lever interlock switch 5 With the use of a multimeter ohms setting test for continuity across the two 2 switch terminals There should be continuity zero ohms when the lift lever is in t...

Page 194: ...etting the switch functions may be tested to determine whether continuity exists between the various switch terminals for each switch position Disconnect wire harness con nector from 3rd High lockout key switch and verify con tinuity between switch terminals NOTE The 3rd High lockout key switch terminals B and C are not used on Workman HD series vehicles POSITION CIRCUITS SLOW B C FAST B C A D Aft...

Page 195: ...ot be continuity infinite ohms After testing connect wire harness connector to switch High Low Lockout Switch The transaxle High Low Lockout switch is located on the front of the transaxle Fig 18 The switch is closed in Low range and open in High range To test the switch disconnect the wire harness connec tor from the switch Use a multimeter ohms setting to test for continuity across the two 2 swi...

Page 196: ...chine for easier testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 4 Verify coil resistance between...

Page 197: ... bed support on bed lift cylinder to prevent bed from lowering Stop engine and remove key from ignition switch 2 Locate relay that is to be tested and disconnect the wire harness connector from the relay Remove relay from machine for easier testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance ...

Page 198: ...ipped with the optional light kit that in cludes flashers two 2 additional diodes are used for flasher circuit logic These diodes plug into the vehicle wiring harness atvari ous locations see appropriate vehicle electrical sche matic and wire harness drawings in Chapter 11 Electrical Drawings Testing The diodes can be individually tested using a digital multimeter diode test or ohms setting and th...

Page 199: ...y cable from battery ter minal and then disconnect positive cable from battery see Battery Service in the Service and Repairs section of this chapter 4 Locate and unplug fusible link connector P1 from ve hicle wire harness 5 Use a multimeter to make sure that continuity zero ohms exists between each terminal pin in connector P1 and connector J1 at the starter Fig 25 If any of the fus ible links ar...

Page 200: ...n tinue testing fuel sender if circuit wiring and gauge are acceptable 4 Remove fuelhoses fromfuelsender fittings Remove fuel sender cap that secures the sender in the fuel tank 5 Remove sender and gasket from the fuel tank Clean all fuel from the sender CAUTION Make sure sending unit is completely dry no fuel on it before testing Perform test away from the tank to prevent an explosion or fire fro...

Page 201: ...rized fuel Be careful when disconnecting fuel supply hose Wipe up any spilled fuel before starting the engine 3 Disconnect fuel supply hose from engine fuel rail 4 Install a fuel pressure gauge capable of measuring 50 PSI 350 kPa to the disconnected hose NOTE If pressure gauge is connected to a tee fitting fuel rail and injectors can be checked for potential leak age while measuring fuel pump pres...

Page 202: ...personal injury or fire NOTE Prior to taking resistance readings with a digital multimeter short the meter test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internalresis tance of the meter and test leads Subtract this value from from the measured value of the component you are testing 5 Check resistance of the sender with a...

Page 203: ... with extreme care to prevent personal injury or fire NOTE Prior to taking resistance readings with a digital multimeter short the meter test leads together The me ter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internalresis tance of the meter and test leads Subtract this value from from the measured value of the component you are testing 5 Check c...

Page 204: ... sen sor to transaxle Remove speed sensor from transaxle IMPORTANT Incorrect jumper wire connections during testing can damage the sensor 5 Using a 12 VDC battery a multimeter a 1K ohm re sistor and appropriate jumper wires connect the battery and multimeter to the speed sensor using Figure 35 as a guide 6 Set multimeter to DC volts setting 7 The multimeter should display very low voltage when a m...

Page 205: ...ow relay is energized C Glow plugs are energized D Glow indicator lamp goes out and glow plugs de energize after approximately five 5 seconds 4 Place ignition switch in the STARTposition Verify the following while in the START position A Dash glow indicator lamp is illuminated B Glow relay is energized C Glow plugs are energized D Power exists at terminal 5 of the glow plug timer NOTE If there is ...

Page 206: ...hicles with High Flow Hydraulics Kit On vehicles equipped with the high flow hydraulics kit the switch to engage the high flow hydraulic circuit is mounted on the dash Fig 39 When the high flow hy draulics kit switch is ON the solenoid coil on the control manifold is energized to allow hydraulic flow to the at tachment An indicator lighton the switch identifies when the switch is ON Testing 1 Park...

Page 207: ...all resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from from the measured value of the component you are testing 4 Using a multimeter ohms setting measure resis tance between the two connector terminals on the sole noid coil The resistance for the coil should be approximately 7 1 ohms 5 After testing is c...

Page 208: ...switch 2 Install bed support on bed lift cylinder to prevent bed from lowering 3 Locate rear PTO switch and disconnect the wire har ness connector from the switch 4 Use a multimeter ohms setting to test for continuity across the two 2 switch terminals With the engine off and the PTO lever in the OFF position there should be continuity zero ohms Move PTO lever to ON and there should not be continui...

Page 209: ...e gases are inhaled Un plug battery charger from electrical outlet be fore connecting or disconnecting charger leads to or from battery posts CAUTION IMPORTANT Do not remove battery fill caps while cleaning battery 2 Check battery condition weekly or after every fifty 50 hours of operation Keep terminals and entire bat tery case clean because a dirty battery will discharge slowly A Clean battery b...

Page 210: ...ative cable NOTE Before connecting the negative cable to the battery connect a digital multimeter set to DC Amps between the negative battery post and the negative cable connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the machine s electrical system should be tested for short circuits or faulty components and repaired 6 Coat battery posts and cable connectors wi...

Page 211: ...form a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test CAUTION Follow the manufacturer s instructions when us ing a battery load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is...

Page 212: ...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 60oF 15 5oC before connecting to a charger Charge the battery in a well ventil...

Page 213: ...oosen the bulb from the headlight by rotating it 1 4 turn counter clockwise Then grasp bulb base and remove bulb from the head light 4 If necessary remove headlight from hood A Remove three 3 clips that secure headlight to hood B Remove headlight from hood Headlight Assembly Fig 45 1 If headlight was removed secure headlight to hood A Insert headlight into hood opening Make sure that SPEAKER logo ...

Page 214: ...Workman HD Series Page 8 34 Electrical System Tail Lamps Disassemble and assemble tail lamp using Fig 46 as a guide 1 Screw 2 used 2 Lens 3 Bulb 4 Gasket Figure 46 1 2 3 4 ...

Page 215: ...Pump Flow and System Relief Pressure Workman HDX and HDX D 20 Gear Pump Flow and System Relief Pressure Workman HD 22 Steering Control Valve and Steering Cylinder 24 Lift Cylinder Internal Leakage 26 High Flow Hydraulics Kit If Equipped Gear Pump Flow and Relief Pressure 28 SERVICE and REPAIRS 31 General Precautions for Removing and Installing Hydraulic System Components 31 Check Hydraulic Lines a...

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Page 217: ...iner in transaxle High Flow Hydraulics Kit Pump If Equipped Front section displacement per revolution Rear section displacement per revolution Casappa positive displacement gear type pump 2 section 0 325 in3 5 3 cc 0 519 in3 8 5 cc High Flow Hydraulics Kit System Relief Pressure 2000 PSI 137 Bar High Flow Hydraulics Kit Hydraulic Oil Multigrade Hydraulic Fluid ISO VG 46 High Flow Hydraulics Kit Re...

Page 218: ...se be sure that the hose is straight not twisted before tightening the fittings This can be done by observing the imprint layline on the hose Use two wrenches hold the hose straight with one wrench and tighten the hose swivel nut onto the fitting with the other wrench See Hydraulic Hose and Tube Installation in this section If the hose has an elbow at one end tighten the swivel nut on that end bef...

Page 219: ...h in the Torque Specifica tions section of Chapter 2 Product Records and Main tenance 5 If a torque wrench is not available or if space at the swivel nut prevents use of a torque wrench an alternate method of assembly is the Flats From Wrench Resist ance F F W R method Fig 2 A Using a wrench tighten the swivel nut onto the fit ting until light wrench resistance is reached approxi mately 30 in lb B...

Page 220: ...Records andMaintenancetodeterminenecessaryconversionin formation 5 If a torque wrench is not available or if space at the port prevents use of a torque wrench an alternate meth od of assembly is the Flats From Finger Tight F F F T method A Install the fitting into the port and tighten it down full length until finger tight B If port material is steel tighten the fitting to the listed F F F T If po...

Page 221: ... with a wrench and use a torque wrench to tighten the fitting to the rec ommended installation torque shown in Figure 5 This tightening process will require the use of an offset wrench e g crowfoot wrench Use of an offset wrench will affect torque wrench calibration due to the effective length change of the torque wrench Tightening torque when using a torque wrench with an offset wrench will be lo...

Page 222: ...Workman HD Series Page 9 8 Hydraulic System Hydraulic Schematics Vehicle Hydraulic Schematic STEERING CONTROL VALVE STEERING CYLINDER LIFT CYLINDERS ...

Page 223: ...Workman HD Series Page 9 9 Hydraulic System High Flow Hydraulics Kit If Equipped Schematic HYDRAULIC MANIFOLD Hydraulic System ...

Page 224: ...propor tional to the amount of the turning 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 wh...

Page 225: ...ressure against the cylinder pistons extends the 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 plac...

Page 226: ...tachment connection a reser voir a hydraulic filter and an oil cooler High Flow Circuit OFF When the rocker switch is in the OFF position the man ifold solenoid operated relief valve SVRV is not ener gized Flow from the gear pump is routed through the manifold the oil cooler the oil filter and then returns to the reservoir High Flow Circuit ON Fig 10 When the rocker switch is in the ON position th...

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Page 228: ...r TOR47009 Figure 11 Hydraulic Tester Pressure and Flow This tester requires O ring Face Seal ORFS adapter fittings for use on this machine see Hydraulic Test Fit ting Kit TOR4079 in this section 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 PRESS...

Page 229: ...r face seal and port seal hydraulic connections It is recommended that O rings be replaced whenever a hydraulic connec tion is loosened Toro Part Number 16 3799 Figure 14 Male Coupler For High Flow Hydraulics Kit Male coupler that fits into the High Flow Hydraulics Kit female coupler Male coupler can be used when testing hydraulic components of High Flow Kit Two 2 couplers are required for testing...

Page 230: ...ling noise Hydraulic lift valve is being held in raise or lower position hydraulic oil flowing over relief valve Hydraulic oil is overheating Oil level in transaxle is incorrect Hydraulic oil is contaminated Incorrect oil in system see oil recommendations in Operator s Manual Hydraulic hose or tubing is kinked or severely bent Hydraulic oil is going over relief valve excessively e g too heavy a lo...

Page 231: ... a heavily loaded stationary vehicle hydraulic circuit pressure to steering control valve may be near relief pressure Engine RPM is low Oil level in transaxle is low Steering components e g pitman arm tie rods steering cylinder rod ends are worn or binding Hydraulic pump drive belt is loose Workman HD vehicles NOTE Entire hydraulic system is affected Steering cylinder is binding Hydraulic relief v...

Page 232: ...lied to attachment Hydraulic pump drive belt is loose Workman HD vehicles NOTE Entire hydraulic system is affected Gear pump key is sheared or missing NOTE Entire hydraulic sys tem is affected Woodruff key on drive pulley is sheared or missing Workman HD vehicles NOTE Entire hydraulic system is affected Gear pump flow or pressure is low see Gear Pump Flow and Sys tem Relief Pressure Test in the Te...

Page 233: ...e the machine and the other should read and record test results 1 Thoroughlycleanthevehiclebeforedisconnectingor 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 Review all test steps before starting the test proce dure 3 Put metal caps or plugs on any hydraulic...

Page 234: ...edure is for the single gear pump used on Workman HDX and HDX D vehicles If vehicle is equipped with the High Flow Hydraulics Kit use this test for the front pump section and refer to the High Flow Hydraulics KitGear Pump Flow and Relief Pressure Test for testing of the rear pump section 1 Gear pump 2 Pressure hose 3 Suction hose Figure 17 1 2 3 WORKMAN HDX and HDX D GEAR PUMP FRONT ...

Page 235: ...the oil flow is fully restricted 6 Fully depress and hold accelerator pedal Check that engine speed is 3600 RPM Verify engine speed with a phototac 7 While watching tester pressure gauges slowly close flow control valve on the tester until 1500 PSI 103 bar is obtained on gauge Verify that engine speed contin ues to be correct 3600 RPM Record flow meter read ing GAUGE READING TO BE For a pump in go...

Page 236: ...nd System Relief Pressure Workman HD TESTER STEERING CONTROL VALVE LIFT CYLINDERS Figure 18 NOTE This test procedure is for the belt driven gear pump used on Workman HD vehicles 1 Gear pump 2 Pressure hose 3 Suction hose Figure 19 GEAR PUMP 1 2 3 WORKMAN HD FRONT ...

Page 237: ...test the flow tester is posi tioned before the relief valve Pump damage can oc cur if the oil flow is fully restricted 8 While watching tester pressure gauges slowly close flow control valve on the tester until 1500 PSI 103 bar is obtained on gauge Verify that pump speed continues to be correct 2270 RPM Record flow meter reading GAUGE READING TO BE Flow should be approxi mately 3 4 GPM 12 9 LPM at...

Page 238: ...Workman HD Series Page 9 24 Hydraulic System Steering Control Valve and Steering Cylinder PLUG STEERING CYLINDER ROTATED FOR RIGHT TURN STEERING CONTROL VALVE LIFT CYLINDERS Figure 20 ...

Page 239: ...se 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 ofthe steering cylinder Plug the end of the disconnected hose Fig 20 WARNING Keep body and hands away from disconnected hoses and fittings that might eject hydraulic fluid under high pressure U...

Page 240: ...Workman HD Series Page 9 26 Hydraulic System Lift Cylinder Internal Leakage STEERING CYLINDER PLUG IN LOWER POSITION LIFT CYLINDERS STEERING CONTROL VALVE Figure 21 ...

Page 241: ...osition 3 Disconnect hydraulic hose from base end of cylinder and install a steel plug with O ring seal in the hose Fig 22 Clean any remaining oil from cylinder port 4 Startengineandapply pressureto rodend ofcylinder i e put hydraulic lift lever in LOWER position 5 If any oil comes out ofopen cylinder port cylinder has an internal leak Repair or replace cylinder 6 Reconnect hose that was disconnec...

Page 242: ...IZED Figure 23 NOTE This test procedure is for the rear gear pump section on Workman HDX and HDX D vehicles that are equipped with the High Flow Hydraulics Kit For testing the front pump section on vehicles with this kit refer to theGearPumpFlowand SystemReliefPressure Work man HDX and HDX D Test 1 Pressure coupler 2 Return coupler Figure 24 2 1 FRONT LEFT ...

Page 243: ...3600 RPM Verify speed with a phototac 7 With High Flow 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 engine speed continues to be 3600 RPM Record flow meter reading GAUGE READING TO BE A pump in good condi tion should have a flow of approximately 7 3 GPM 27 6 LPM at 15...

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Page 245: ...s 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 fittings and...

Page 246: ...coupling 2 used 23 Square head screw 2 used 24 Coupling 25 O ring 26 90o hydraulic fitting 27 High flow gear pump 28 Suction hose from reservoir 29 Hose to high flow manifold Figure 25 FRONT RIGHT 1 3 4 5 6 7 8 9 11 12 13 14 15 16 18 19 20 2 10 17 21 14 14 16 16 17 18 19 20 22 22 23 6 7 8 9 3 4 5 2 3 4 2 29 25 2 26 27 28 HIGH FLOW GEAR PUMP LOCTITE 242 LOCTITE 242 25 to 30 ft lb 33 to 40 N m 25 to...

Page 247: ... and discard O rings Installation Fig 25 1 If fittings were removed from gear pump lubricate and place new O rings onto fittings Install fittings into pump openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor mation section of this chapter 2 Install square key to the pump shaft Apply antiseize l...

Page 248: ...fittings Install fittings into pump openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hydraulic Fitting Installation in the General Infor mation section of this chapter 2 Installgear pump to mountusing Figure 26 as aguide and using the following instructions A Apply antiseize lubricant to gear pump shaft be fore installing pulley B Install pum...

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Page 250: ...ew 2 used Figure 28 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 21 22 23 11 13 14 15 12 5 4 130 in lb 15 N m 220 in lb 25 N m WORKMAN HDX AND HDX D GEAR PUMP 1 2 3 4 5 6 7 8 220 in lb 25 N m WORKMAN HD GEAR PUMP 4 5 9 10 12 17 16 13 14 15 11 NOTE If vehicle is equipped with High Flow Hydraulics Kit refer to High Flow Hydraulics Kit Gear Pump Service later in this section NOTE The Workman HDX and HDX D gea...

Page 251: ...r thrust plate idler shaft drive shaft and front thrust plate from the front cover 10 Remove and discard O rings back up seals and pressure seals from pump IMPORTANT Make sure to not damage the seal bores when removing the seal from the front cover and rear flange 11 Carefully remove retaining ring and shaft seal from both the front cover and rear flange HDX and HDX D Discard seals Inspection 1 Re...

Page 252: ...ont thrust plate Apply a light coating of clean hydraulic oil to gear faces 8 Install rear thrust plate with pressure seal side up and open side of the seals pointing to the inlet side of the pump 9 Install two 2 dowel pins into front cover Align mark er line on the body and front cover IMPORTANT Do not dislodge seals during installa tion 10 Gently slide the body onto the assembly Firm hand pressu...

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Page 254: ...sure seal 14 Back up seal 15 Rear flange 16 Lock washer 2 used 17 Socket head screw 2 used 18 Shaft seal 19 Retaining ring 20 O ring 21 Rear cover 22 Washer 4 used 23 Cap screw 4 used 24 Cap screw 2 used 25 Coupler 26 Thrust plate 27 Idler shaft 28 Drive shaft 29 Rear pump section body 30 Thrust plate 31 Front flange Figure 31 HIGH FLOW HYDRAULICS KIT GEAR PUMP 1 2 6 7 8 9 19 22 23 11 13 14 15 3 4...

Page 255: ...The High Flow Kit gear pump supplies oil flow for two circuits and uses two separate reservoirs and oil types Fig 32 The front pump section closest to pump input shaft uses oil from the transaxle Dexron III ATF The rear pump section uses oil from the High Flow Hydrau lics Kit reservoir hydraulic oil During gear pump as sembly lubricate front section components with clean Dexron III ATF and rear se...

Page 256: ... 7 Flange nut 2 used 8 Lift lever 9 Clevis pin 10 Hairpin 11 Retainer pin 12 Link 13 90o hydraulic fitting 14 Hyd tube to male quick fitting 15 Hyd tube to female quick fitting 16 90o hydraulic fitting 17 O ring 18 Hydraulic adapter 19 Flange head screw 2 used 20 Hyd tube pressure supply Figure 33 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 17 5 ...

Page 257: ...e move fittings from valve and discard O rings Installation Fig 33 1 If fittings were removed from lift valve lubricate and place new O rings onto fittings Install fittings into valve openings using marks made during the removal process to properly orientate fittings Tighten fittings see Hy draulic Fitting Installation in the General Information section of this chapter 2 Install lift valve to vehi...

Page 258: ...MPORTANT When removing O rings from valve body be very careful to not scratch valve bore fin ish 5 Use a hooked scribe or thin screwdriver to remove O rings item 9 from inside bore of valve body 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 flat...

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Page 260: ...g to valve 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 36 FRONT RIGHT 1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 Antiseize Lubricant 20 to 25 ft lb 28 to 33 N m 14 15 16 17 18 Removal Fig 36 1 Park vehicle on a level surface shut engine off and engage the parking brake Remove key from the ignition switch 2 Remove steering wheel ...

Page 261: ...steering control valve ports refer to Figures 37 and 38 see Hydraulic Hose and Tube Installation in the General Information section of this chapter Make sure that hoses are not twisted while tightening 2 Position steering control valve to vehicle frame with port R toward front of vehicle Fig 37 Secure steering control valve to vehicle with four 4 cap screws 3 Install hydraulic hose cover over hose...

Page 262: ...ing 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 39 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 Manual at...

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Page 264: ...enter link 21 Flat washer 2 used 22 Cap screw 2 used 23 Flange head screw 12 used 24 Washer 2 used 25 Grease fitting 2 used 26 Ball bearing 2 used 27 Flange nut 2 used 28 Flange head bolt 2 used 29 Flange nut 2 used 30 Cap screw 2 used 31 Snap ring 2 used 32 Cap screw 2 used 33 Lock nut 2 used Figure 40 FRONT RIGHT 18 19 15 17 16 20 13 12 14 11 10 3 6 8 9 5 1 4 2 7 12 2 1 3 12 14 14 11 21 28 29 31...

Page 265: ...ngs Fig 41 Installation Fig 40 1 If fittings were removed from steering cylinder lubri cate and place new O rings onto fittings Install fittings into cylinder openings using marks made during the re moval process to properly orientate fittings Tighten fit tings see Hydraulic Fitting Installation in the General Information section of this chapter 2 Install steering cylinder to vehicle using Figure ...

Page 266: ... both heads in barrel A Use a spanner wrench to rotate head clockwise until the edge of the retaining ring appears in the bar rel opening B Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening C Rotate the head counter clockwise to remove re taining ring from barrel and head 5 Use a twisting and pulling motion to carefully extract the fr...

Page 267: ...ups onto rear shaft IMPORTANT When installing roll pin into front and rear shafts make sure that shaft surfaces are not damaged 4 Slide frontshaftonto rear shaftand align rollpin holes in shafts Install new roll pin to secure shafts IMPORTANT Prevent damage when clamping the cylinder s barrel into a vise clamp on the clevis only Do not close vise on barrel 5 Mount steering cylinder in a vise equip...

Page 268: ...linder 1 Bed frame 2 O ring 3 90o 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 43 1 2 3 4 5 6 7 8 9 2 3 4 10 11 12 FRONT RIGHT ...

Page 269: ...ures lift cylinder to engine support 6 Remove lift cylinder from vehicle 7 If hydraulic fittings are to be removed from lift cylin der mark fitting orientation to allow correct assembly Remove fittings from cylinder and discard O rings Installation Fig 43 1 If fittings were removed from lift cylinder lubricate and place new O rings onto fittings Install fittings into cylinder openings using marks ...

Page 270: ... Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening C Rotate the head counter clockwise to remove re taining ring from barrel and head 5 Extract shaft with head and piston by carefully twist ing and pulling on the shaft IMPORTANT When securing shaft in vise clamp on shaft clevis only Do not clamp vise jaws against the shaft surface 6 M...

Page 271: ...d piston onto the shaft C Secure piston to shaft with lock nut Torque lock nut from 60 to 75 ft lb 81 to 102 N m 4 Lubricate head and piston with clean Dexron III ATF Slide shaft assembly carefully into cylinder barrel IMPORTANT Prevent damage when clamping the cylinder s barrel into a vise clamp on the clevis only Do not close vise on barrel 5 Mount lift cylinder in a vise equipped with soft jaws...

Page 272: ...as a guide 5 If hydraulic fittings are to be removed from manifold mark fitting orientation to allow correct assembly Re move fittings from manifold and discard O rings Valve Cartridge Service Fig 46 1 Make sure the entire outer surface of the manifold is clean before removing the valve 2 Remove nut securing solenoid coil to the cartridge valve Carefully slide solenoid off the valve IMPORTANT Use ...

Page 273: ...nged properly on the cartridge valve for proper operation and sealing IMPORTANT Use care when handling the car tridge valve Slight bending or distortion of the stem tube can cause binding and malfunction B Thread cartridge valve carefully into manifold port The valve should go in easily without binding C Using a deep socket torque cartridge valve 25 ft lb 34 N m D Slide solenoid coil onto the cart...

Page 274: ...Workman HD Series Page 9 60 Hydraulic System This page is intentionally blank ...

Page 275: ...or s Manual 3 SERVICE and REPAIRS 4 CV Axle Assembly 4 Inspect CV Boot and Test CV Joint 6 Differential Driveshaft 8 Driveshaft Cross and Bearing Service 10 Front Differential 12 Front Differential Service 14 Front Differential Disassembly 15 Front Differential Assembly 19 HILLIARD FRONT DRIVE DIFFERENTIAL PARTS and SERVICE MANUAL Front Wheel Drive 4WD ...

Page 276: ...Workman HDX HDX D Page 10 2 Front Wheel Drive 4WD Specifications Item Description Differential Oil Capacity 8 5 fl oz 250 ml Differential Oil Type Mobil 424 Hydraulic Oil ...

Page 277: ...tinues to deliver power to the front wheels until the rear wheels have enough traction to move the vehicle without slipping Once this occurs the system stops de livering power to the front wheels and the handling char acteristics become similar to that of a two wheel drive vehicle The four wheel drive system functions in both forward and reverse When the front wheels are turned the rear wheels wil...

Page 278: ...40 ft lb 48 to 55 N m 170 to 180 ft lb 231 to 244 N m ANTISEIZE LUBRICANT ANTISEIZE LUBRICANT 1 2 10 8 11 16 Disassembly Fig 1 1 Park vehicle on a level surface shut engine off re move key from ignition switch and apply parking brake 2 For CV axle to be removed remove wheel assembly brake caliper and brake rotor see Brake System Disas sembly in the Service and Repairs section of Chapter 7 Chassis ...

Page 279: ...xle is prop erly secured into the differential 3 Place wheel spacer item 10 onto CV axle 4 Apply antiseize lubricant to splines on outer end of CV axle 5 Slide wheel hub onto CV axle Loosely install four 4 flange head screws item 11 to locate wheel hub to knuckle Do not fully tighten screws 6 Install new spindle nut item 1 onto CV axle Torque spindle nut from 170 to 180 ft lb 231 to 244 N m Af ter...

Page 280: ...Axle 1 Test drive vehicle on a smooth surface to verify CV axle 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 and if so the wheel hub assem bly must be replaced B If the noise gets louder when turning the out board ...

Page 281: ...Workman HDX HDX D Page 10 7 Front Wheel Drive 4WD This page is intentionally blank Front Wheel Drive 4WD ...

Page 282: ...el Drive 4WD Differential Driveshaft 1 Transaxle 2 Cap screw 3 Flat washer 4 Driveshaft 5 Differential assembly 6 CV axle assembly 7 Flange head screw 4 used Figure 4 FRONT RIGHT 1 2 3 4 5 ANTISEIZE LUBRICANT ANTISEIZE LUBRICANT 2 3 6 6 7 ...

Page 283: ...lidedriveshaftyokesfromthedifferentialinputshaft and the transaxle output shaft 5 Lower rear of driveshaft and remove shaft from ve hicle Installation Fig 4 1 Apply antiseize lubricant to differential input shaft and transaxle output shaft 2 Position driveshaft to vehicle frame differential as sembly and transaxle 3 Slide driveshaft yokes onto differential input shaft and transaxle output shaft 4 ...

Page 284: ...ally re moved bearing and tap on yoke to completely re move the bearing D Repeat process for remaining bearings E Thoroughly clean and inspect all components Assembly Fig 7 1 To install new cross and bearings A Apply a coating of grease to bearing bores of end yoke and shaft yoke Also apply grease to bearings and seal of bearing assembly Make sure that all bearing rollers are properly seated in be...

Page 285: ...Workman HDX HDX D Page 10 11 Front Wheel Drive 4WD This page is intentionally blank Front Wheel Drive 4WD ...

Page 286: ...er 8 Wheel hub assembly 9 Tie rod assembly 10 Axle spacer 11 Flange head screw 12 Brake caliper LH shown 13 Brake rotor 14 Slotted hex nut 15 Cotter pin 16 Knuckle LH shown Figure 8 FRONT RIGHT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 35 to 40 ft lb 48 to 55 N m 35 to 40 ft lb 48 to 55 N m 170 to 180 ft lb 231 to 244 N m ANTISEIZE LUBRICANT ANTISEIZE LUBRICANT 1 2 10 8 11 16 ANTISEIZE LUBRICANT ...

Page 287: ...t unexpected front sus pension movement do not loosen outer flange head screws and flange nuts IMPORTANT Make sure to not damage brake lines electrical harness control cables or other parts while removing the differential 8 Tip differential toward left side driver side of ve hicle Remove differential assembly toward the right side passenger side of the vehicle Installation Fig 8 IMPORTANT Make sur...

Page 288: ...8 Gear case 19 Grommet 20 Input cover 21 Drain plug 22 Bushing 23 Oil seal 24 Oil seal 2 used 25 Female output hub 26 Male output hub 27 Pinion shaft 28 Fill plug 29 Ring gear 30 Roller 18 used 31 Roller cage 32 Spring 33 Gear spacer 2 used 34 Thrust button 35 Internal retaining ring 36 Thrust bearing 37 O ring Figure 10 1 2 3 4 5 6 7 8 9 10 16 17 18 19 20 22 23 21 24 25 26 11 12 14 15 27 28 29 30...

Page 289: ...11 Remove the cover 3 Remove the pinion shaft from housing by pulling it out of the gear case by hand Fig 12 4 Inspect the inner pinion bushing in the gear case Fig 13 If the bushing is excessively worn the gear case must be replaced The bushing is not serviced sep arately 1 Input cover 2 Pinion shaft Figure 11 2 1 1 Pinion shaft 2 Gear case Figure 12 2 1 1 Pinion bushing 2 Gear case Figure 13 2 1...

Page 290: ...om the cover plate and inspect for wear Fig 15 Replace the thrust bearing if the red coating is worn completely off the bearing sur face The thrust bearing is used to set the backlash of theringgearandpinion seeFrontDifferentialAssembly in this section for backlash adjustment procedure 8 Lift the roller cage assembly from the center of the ring gear Fig 16 Note the rollers are loose in the cage an...

Page 291: ...e the seal in the gear case The seal cannot be serviced sepa rately 11 Turn the gear case over Using a hammer and a suit able drift carefully remove the female output hub and bearing by driving it in toward the center of the gear case Fig 19 The bearing has a slight interference fit to the bore of the gear case Take care to not damage the oil seal in the gear case during hub removal 1 Ring gear 2 ...

Page 292: ...e cover plate over and place it on blocking or in a vise Using a hammer and suitable punch carefully remove the male output hub and bearing from the cover plate by driving the output hub down The bearing has a slight interference fit to the bore of the cover plate Be careful to not damage the seal in the cover plate 17 Discard the removed output hub assemblies Clean and inspect all removed parts N...

Page 293: ...nded bushing 3 Press the new male output hub bearing assembly into the cover plate assembly The bearing has a slight interference fit to the bore so it should not take much force to press in Fig 23 Take care to not damage the seal in the cover plate during installation of the output hub assembly 4 Set the armature plate onto the coil located in the cover plate Fig 24 The internal tangs of the arma...

Page 294: ...e roller cage on a flat surface with the torsion spring end facing up Fig 27 Install nine 9 rollers into the slots on the bottom row of the cage If needed use grease or petroleum jelly to help hold the rollers in place 9 Align torsion spring on roller cage with the slot in the ring gear and then carefully lower the cage assembly into the ring gear bore Fig 28 The torsion spring must align and fit ...

Page 295: ... to gear case with five 5 flange head screws Torque screws from 14 to 17 ft lbs 19 to 27 N m 14 Install the pinion shaft and then the input cover Fig 30 Secure cover with four 4 flange head screws Torque screws from 14 to 17 ft lbs 19 to 27 N m 15 Remove the oil fill plug and fill the unit with 8 45 oz 250 ml of Mobil 424 hydraulic oil or equivalent 16 Adjust differential gear backlash as follows ...

Page 296: ...Rev A Workman HDX HDX D Page 10 22 Front Wheel Drive 4WD This page is intentionally blank ...

Page 297: ...Circuits 6 Run Circuits 7 WORKMAN HDX CIRCUIT DRAWINGS Start Circuits 8 Run Circuits 9 WORKMAN HDX D CIRCUIT DRAWINGS Glow Plug Circuits 10 Start Circuits 11 Run Circuits 12 WIRE HARNESS DRAWINGS Front Wire Harness Drawing Workman HD Series All Models 14 Rear Wire Harness Drawing Workman HD 16 Rear Wire Harness Drawing Workman HDX 18 Rear Wire Harness Drawing Workman HDX D 20 Electrical Drawings ...

Page 298: ...Workman HD Series Electrical Drawings Page 11 2 This page is intentionally blank ...

Page 299: ...FLASHER SIGNAL FLASHER TURN MPH KPH SHUNT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT IF EQUIPPED IF EQUIPPED 3rd HIGH LOCKOUT SWITCH SLOW LIFT LEVER INTERLOCK SWITCH OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT LEFT FRONT TURN RUNNING LIGHT RIGHT FRONT TURN RUNNING LIGHT OPTIONAL KIT OPTIONAL KIT ELECTRIC BRAKE KIT ...

Page 300: ...R TURN MPH KPH SHUNT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT IF EQUIPPED IF EQUIPPED 3rd HIGH LOCKOUT SWITCH SLOW LIFT LEVER INTERLOCK SWITCH OPTIONAL KIT OPTIONAL KIT LEFT FRONT TURN RUNNING LIGHT RIGHT FRONT TURN RUNNING LIGHT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT ELECTRIC BRAKE KIT 1 SECOND TIME DELAY 4 WD VEHICLES ONLY ...

Page 301: ...R TURN MPH KPH SHUNT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT IF EQUIPPED IF EQUIPPED 3rd HIGH LOCKOUT SWITCH SLOW LIFT LEVER INTERLOCK SWITCH OPTIONAL KIT OPTIONAL KIT LEFT FRONT TURN RUNNING LIGHT RIGHT FRONT TURN RUNNING LIGHT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT ELECTRIC BRAKE KIT 1 SECOND TIME DELAY 4 WD VEHICLES ONLY ...

Page 302: ...orkman HD Ignition Switch in START Position Transmission in Neutral Clutch Pedal Depressed IF EQUIPPED IF EQUIPPED 3rd HIGH LOCKOUT SWITCH SLOW LIFT LEVER INTERLOCK SWITCH LIFT LEVER IN NEUTRAL OPTIONAL KIT OPTIONAL KIT LEFT FRONT TURN RUNNING LIGHT RIGHT FRONT TURN RUNNING LIGHT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT ELECTRIC BRAKE KIT ...

Page 303: ...on Current Workman HD Ignition Switch in RUN Position Transmission in Neutral IF EQUIPPED IF EQUIPPED 3rd HIGH LOCKOUT SWITCH SLOW LIFT LEVER INTERLOCK SWITCH LIFT LEVER IN NEUTRAL OPTIONAL KIT OPTIONAL KIT LEFT FRONT TURN RUNNING LIGHT RIGHT FRONT TURN RUNNING LIGHT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT ELECTRIC BRAKE KIT ...

Page 304: ...nition Switch in START Position Transmission in Neutral Clutch Pedal Depressed IF EQUIPPED IF EQUIPPED 3rd HIGH LOCKOUT SWITCH SLOW LIFT LEVER INTERLOCK SWITCH LIFT LEVER IN NEUTRAL OPTIONAL KIT OPTIONAL KIT LEFT FRONT TURN RUNNING LIGHT RIGHT FRONT TURN RUNNING LIGHT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT ELECTRIC BRAKE KIT 1 SECOND TIME DELAY 4 WD VEHICLES ONLY ...

Page 305: ...PH KPH SHUNT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT IF EQUIPPED IF EQUIPPED 3rd HIGH LOCKOUT SWITCH SLOW LIFT LEVER INTERLOCK SWITCH LIFT LEVER IN NEUTRAL OPTIONAL KIT OPTIONAL KIT LEFT FRONT TURN RUNNING LIGHT RIGHT FRONT TURN RUNNING LIGHT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT ELECTRIC BRAKE KIT 1 SECOND TIME DELAY 4 WD VEHICLES ONLY ...

Page 306: ...Workman HDX D Ignition Switch in RUN Position Transmission in Neutral IF EQUIPPED IF EQUIPPED 3rd HIGH LOCKOUT SWITCH SLOW LIFT LEVER INTERLOCK SWITCH LIFT LEVER IN NEUTRAL OPTIONAL KIT OPTIONAL KIT LEFT FRONT TURN RUNNING LIGHT RIGHT FRONT TURN RUNNING LIGHT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT ELECTRIC BRAKE KIT 1 SECOND TIME DELAY 4 WD VEHICLES ONLY ...

Page 307: ... FLASHER TURN MPH KPH SHUNT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT IF EQUIPPED IF EQUIPPED 3rd HIGH LOCKOUT SWITCH SLOW LIFT LEVER INTERLOCK SWITCH LIFT LEVER IN NEUTRAL OPTIONAL KIT OPTIONAL KIT LEFT FRONT TURN RUNNING LIGHT RIGHT FRONT TURN RUNNING LIGHT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT ELECTRIC BRAKE KIT 1 SECOND TIME DELAY 4 WD VEHICLES ONLY ...

Page 308: ... MPH KPH SHUNT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT IF EQUIPPED IF EQUIPPED 3rd HIGH LOCKOUT SWITCH SLOW LIFT LEVER INTERLOCK SWITCH LIFT LEVER IN NEUTRAL OPTIONAL KIT OPTIONAL KIT LEFT FRONT TURN RUNNING LIGHT RIGHT FRONT TURN RUNNING LIGHT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT OPTIONAL KIT ELECTRIC BRAKE KIT 1 SECOND TIME DELAY 4 WD VEHICLES ONLY ...

Page 309: ...Page 11 13 This page is intentionally blank ...

Page 310: ...Page 11 14 Front Wire Harness Drawing Workman HD Series All Models 3RD HIGH LOCKOUT SWITCH ...

Page 311: ...WHITE YELLOW GRAY RED BLACK TAN GREEN ORANGE WHITE BLACK RED YELLOW BLACK BLACK BLACK BLACK BLACK ORANGE TAN ORANGE YELLOW PINK BLACK TAN ORANGE WHITE BLACK RED YELLOW BROWN BLACK WHITE BLACK RED GREEN BROWN BLACK WHITE BLACK BLACK WHITE BLACK GREEN BROWN GREEN GREEN GREEN GRAY BLACK GREEN RED BLUE PINK RED YELLOW RED BLACK RED BLACK BLACK TAN GREEN GREEN 3RD HIGH LOCKOUT SWITCH VIOLET VIOLET VIOL...

Page 312: ...Page 11 16 Rear Wire Harness Drawing Kohler Gasoline Engine Workman HD LIFT LEVER INTERLOCK SWITCH ...

Page 313: ...ACK GRAY GRAY GRAY PINK YELLOW WHITE GREEN ORANGE BLUE ORANGE WHITE BLACK ORANGE BLACK RED BLACK BLACK RED BLACK GRAY WHITE BLACK ORANGE GREEN RED BLACK BLACK BLACK BLACK ORANGE WHITE BLACK BLACK BLACK ORANGE BLACK BLACK BLACK RED BLACK RED BLACK ORANGE RED BLACK BLACK BLUE BLACK 3RD HIGH LOCKOUT LIFT LEVER INTERLOCK SWITCH ...

Page 314: ...ne Engine Workman HDX LIFT LEVER INTERLOCK SWITCH TO HARNESS P20 CONNECTOR ON EARLY PRODUCTION VEHICLES WITH 4WD A SMALL WIRE HARNESS IS CONNECTED TO THE P20 HARNESS CONNECTOR FOR THE DELAY TIMER AND DIFFERENTIAL DELAY RELAY THIS WIRE HARNESS IS DEPICTED BELOW ...

Page 315: ...LLOW BLACK RED BLACK RED BLACK BLUE YELLOW BLUE GREEN RED BLACK ORANGE BLACK WHITE BLACK ORANGE BLACK WHITE BLACK BLACK BLACK PINK ORANGE YELLOW ORANGE ORANGE GRAY GREEN GREEN PINK BROWN VIOLET ORANGE BLUE GREEN BLACK GRAY GREEN ORANGE ORANGE ORANGE ORANGE WHITE TAN GREEN WHITE BLUE WHITE ORANGE PINK BLUE BLACK BLACK GREEN BLACK ORANGE BLACK GREEN YELLOW ORANGE ORANGE WHITE ORANGE PINK ORANGE ORAN...

Page 316: ... Engine Workman HDX D LIFT LEVER INTERLOCK SWITCH TO HARNESS P20 CONNECTOR ON EARLY PRODUCTION VEHICLES WITH 4WD A SMALL WIRE HARNESS IS CONNECTED TO THE P20 HARNESS CONNECTOR FOR THE DELAY TIMER AND DIFFERENTIAL DELAY RELAY THIS WIRE HARNESS IS DEPICTED BELOW ...

Page 317: ...UE YELLOW YELLOW BROWN ORANGE BLUE PINK ORANGE PINK GRAY GRAY GRAY TAN GRAY YELLOW BLACK YELLOW BLACK RED GREEN ORANGE RED BLACK YELLOW BLUE YELLOW BLUE ORANGE GREEN BLACK BLACK ORANGE BLACK WHITE BLACK ORANGE BLACK BLACK RED BLACK BLACK PINK ORANGE PINK VIOLET BLACK GRAY ORANGE PINK BLACK RED BLACK RED BLACK ORANGE RED BLACK ORANGE BLUE BLACK BLUE RED RED YELLOW GRAY PINK YELLOW BLACK BLACK BLACK...

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