Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
D)
Service Manual
(Serial No. 240000001 and Above)
General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 6
2
2
2
2
-----
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 4
ENGINES
Chapter 4 - Briggs/Daihatsu Diesel Engine
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 4
GINES
Chapter 5 - Kohler Gasoline Engine
-
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
7
-----
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 3
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 7
General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 4
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 9 -- 6
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 15
SERVICE MANUAL
Hydraulic
System
Electrical
System
Chassis
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
Chapter 7 - Chassis
-
Briggs/Daihatsu
Diesel Engine
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2
Kohler
Gasoline Engine
Drive Train
Chapter 1 - Safety
-
Safety
Table Of Contents
Rev. C
Electrical
Schematics
Front Wheel
Drive (4WD)
Table Of Contents
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service . . . . . . . . . . . . . . . . . . . .
Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Bed Safety Support . . . . . . . . . . . . . . . . . . . .
2
2
3
4
5
6
Page 1 1
Safety
Safety
Chapter 1
Safety Instructions
The Workman 3000/4000 series vehicles are designed
and tested to offer safe service when operated and
maintained properly. Although hazard control and accident prevention are partially dependent upon the design
and configuration of the vehicle, these factors are also
dependent upon the awareness, concern, and proper
training of the personnel involved in the operation, transport, maintenance, and storage of the vehicle. Improper
use or maintenance of the vehicle can result in injury or
WARNING
To reduce the potential for injury or death, comply with the following safety instructions.
Before Operating
1. Read and understand the contents of the Operators
Manual and Operators Video before starting and operating the vehicle. Become familiar with the controls and
know how to stop the vehicle and engine quickly. A replacement Operators Manual is available on the Internet at www.Toro.com.
Safety
Page 1 - 2
-
Rev. D
Page 1 3
Safety
Safety
While Operating
Safety
Page 1 4
Safety
Jacking Vehicle
WARNING
When changing attachments, tires or performing other service, use the correct blocks, hoists
and jacks. Always chock or block the wheels
and use jack stands or solid wood blocks to
support the vehicle. If the vehicle is not properly
supported by blocks or jack stands, the vehicle
may move or fall resulting in personal injury.
1
Figure 1
2. Do not work under vehicle without jack stands supporting it. The vehicle could slip off jack, injuring any one
beneath it.
3. The jacking point at the front of the vehicle is under
the front center frame support and at the rear it is under
the axle tube.
4. When jacking up front of vehicle, always place a
wood block (or similar material) between jack and vehicle frame support.
Page 1 - 5
-
1
Figure 2
1. Rear jacking point
Safety
Many of the procedures shown in this manual require raising and lowering the bed. The following
precautions must be taken or serious injury or
death could result.
1
WARNING
Before servicing or making adjustments to the
vehicle, stop engine, set parking brake and remove key from ignition switch. Any load material must be removed from bed or other attachment before working under raised bed. Never
work under a raised bed without positioning
bed safety support on a fully installed cylinder
rod.
2
After work is completed, remove bed safety support, insert into storage brackets on back of ROPS
panel and lower bed.
Figure 3
1. Bed safety support
2. Cylinder barrel
3. Bed
Safety
Page 1 6
Chapter 2
Product Records
and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and Steel
Fasteners (Inch Series Fasteners) . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and Steel
Fasteners (Metric Fasteners) . . . . . . . . . . . . . . .
Other Torque Specifications . . . . . . . . . . . . . . . . . .
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
2
2
3
3
4
5
6
6
7
Product Records
Insert Operators Manual and Parts Catalog for your
Workman at the end of this chapter. Refer to Operators
Manual for recommended maintenance intervals. Additionally, insert Installation Instructions, Operators
Manuals, Parts Catalogs and Service Manuals for any
accessories that have been installed on your Workman
at the end of this section.
Page 2 1
0.09375
Page 2 - 2 Rev. D
-
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Class 10.9
Page 2 3
Product Records
and Maintenance
Torque Specifications
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series Fasteners)
Thread Size
Grade 1, 5, &
8 with Thin
Height Nuts
inlb
inlb
Ncm
10 + 2
13 + 2
inlb
147 + 23
25 + 2
280 + 20
330 + 30
41 + 4
460 + 45
350 + 30
43 + 4
485 + 45
475 + 45
60 + 6
675 + 70
48 + 4
# 10 24 UNC
30 + 5
190 + 20
540 + 45
68 + 6
765 + 70
282 + 30
# 8 36 UNF
18 + 2
260 + 20
42 + 4
25 + 5
23 + 2
31 + 3
13 + 2
170 + 20
29 + 3
# 8 32 UNC
Ncm
17 + 2
# 6 40 UNF
inlb
15 + 2
# 6 32 UNC
Ncm
339 + 56
# 10 32 UNF
1/4 20 UNC
48 + 7
53 + 7
599 + 79
100 + 10
1125 + 100
140 + 15
1580 + 170
1/4 28 UNF
53 + 7
65 + 10
734 + 113
115 + 10
1300 + 100
160 + 15
1800 + 170
5/16 18 UNC
115 + 15
105 + 17
1186 + 169
200 + 25
2250 + 280
300 + 30
3390 + 340
5/16 24 UNF
138 + 17
128 + 17
1446 + 192
225 + 25
2540 + 280
325 + 30
3670 + 340
ftlb
ftlb
Nm
ftlb
Nm
ftlb
Nm
3/8 16 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 4
58 + 5
3/8 24 UNF
17 + 2
18 + 2
24 + 3
35 + 3
47 + 4
50 + 4
68 + 5
7/16 14 UNC
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
7/16 20 UNF
29 + 3
29 + 3
39 + 4
55 + 5
75 + 7
77 + 7
104 + 9
1/2 13 UNC
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
105 + 10
142 + 14
1/2 20 UNF
32 + 3
53 + 7
72 + 9
85 + 8
115 + 11
120 + 10
163 + 14
5/8 11 UNC
65 + 10
88 + 12
119 + 16
150 + 15
203 + 20
210 + 20
285 + 27
5/8 18 UNF
75 + 10
95 + 15
129 + 20
170 + 15
230 + 20
240 + 20
325 + 27
3/4 10 UNC
93 + 12
140 + 20
190 + 27
265 + 25
359 + 34
375 + 35
508 + 47
3/4 16 UNF
115 + 15
165 + 25
224 + 34
300 + 25
407 + 34
420 + 35
569 + 47
7/8 9 UNC
140 + 20
225 + 25
305 + 34
430 + 45
583 + 61
600 + 60
813 + 81
7/8 14 UNF
155 + 25
260 + 30
353 + 41
475 + 45
644 + 61
660 + 60
895 + 81
Page 2 4
Thread Size
M5 X 0.8
57 + 5 inlb
640 + 60 Ncm
78 + 7 inlb
885 + 80 Ncm
M6 X 1.0
96 + 9 inlb
133 + 13 inlb
M8 X 1.25
19 + 2 ftlb
26 + 3 Nm
27 + 2 ftlb
36 + 3 Nm
M10 X 1.5
38 + 4 ftlb
52 + 5 Nm
53 + 5 ftlb
72 + 7 Nm
M12 X 1.75
66 + 7 ftlb
90 + 10 Nm
92 + 9 ftlb
125 + 12 Nm
M16 X 2.0
166 + 15 ftlb
225 + 20 Nm
229 + 22 ftlb
310 + 30 Nm
M20 X 2.5
325 + 33 ftlb
440 + 45 Nm
450 + 37 ftlb
610 + 50 Nm
Page 2 5
Product Records
and Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Recommended Torque
Thread Size
Recommended Torque**
Thread Size
Square Head
Hex Socket
1/4 20 UNC
140 + 20 inlb
73 + 12 inlb
5/16 18 UNC
215 + 35 inlb
145 + 20 inlb
3/8 16 UNC
35 + 10 ftlb
18 + 3 ftlb
1/2 13 UNC
75 + 15 ftlb
7/16 20 UNF
Grade 5
65 + 10 ftlb
88 + 14 Nm
1/2 20 UNF
Grade 5
80 + 10 ftlb
108 + 14 Nm
M12 X 1.25
Class 8.8
80 + 10 ftlb
108 + 14 Nm
50 + 10 ftlb
M12 X 1.5
Class 8.8
80 + 10 ftlb
108 + 14 Nm
Baseline Torque*
No. 6 32 UNC
Thread
Size
20 + 5 inlb
No. 8 32 UNC
Type B
No. 6
18
20
20 + 5 inlb
30 + 5 inlb
No. 8
15
18
30 + 5 inlb
No. 10 24 UNC
38 + 7 inlb
No. 10
12
16
38 + 7 inlb
1/4 20 UNC
85 + 15 inlb
No. 12
11
14
85 + 15 inlb
5/16 18 UNC
110 + 20 inlb
3/8 16 UNC
Conversion Factors
inlb X 11.2985 = Ncm
ftlb X 1.3558 = Nm
Page 2 6
Maintenance
Page 2 7
Product Records
and Maintenance
Maintenance procedures and recommended service intervals for the Workman 3000/4000 are covered in the
Operators Manual. Refer to that publication when performing regular equipment maintenance. Several maintenance procedures have breakin intervals identified in
the Operators Manual. Refer to the Engine Operators
Manual for additional engine specific maintenance procedures.
Page 2 8
Chapter 3
Table of Contents
Briggs/Daihatsu
Gasoline Engine
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Adding Oil to Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . 4
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump Driveshaft Service . . . . . . . . . . . . . . . . . . . . . 8
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Throttle Bracket . . . . . . . . . . . . . . . . . . . . . 20
BRIGGS & STRATTON/DAIHATSU REPAIR MANUAL
FOR 3CYLINDER, LIQUIDCOOLED, GASOLINE
ENGINES
Introduction
Workman 3200/4200
Page 3 1
Specifications
Item
Description
Make / Designation
Number of Cylinders
72 x 78 (2.834 x 3.07)
952 (58.1)
Compression Ratio
8.6:1
Firing Order
1 (front) 2 3
62 (137)
Carburetor
Fuel Pump
12 VDC
Fuel
26 (7)
Governor
Mechanical
1100 + 50 RPM
3600 + 50 RPM
Engine Oil
Oil Pump
Water Pump
3.8 (4.0)
Starter
12 VDC
Alternator/Regulator
12 VDC 40 AMP
Page 3 2
Workman 3200/4200
General Information
Briggs/Daihatsu
Gasoline Engine
When adding oil to the engine, maintain clearance between the oil fill device and the oil fill opening in the valve
cover (Fig. 1). This clearance is necessary to allow venting when adding engine oil which will prevent oil from
running into the breather tube and intake system.
Figure 1
Workman 3200/4200
Page 3 3
Adjustments
Engine Speed Adjustment
1. Park vehicle on a level surface, engage parking
brake and place gear shift lever in neutral.
2. Raise the bed or remove attachment(s) to allow access to engine. If bed is raised, place safety support on
lift cylinder (see Operators Manual).
3
Figure 2
1. Engine governor lever
2. Governor spring
3
1
Figure 3
1. Governor spring
2. Bellcrank
3. Engine governor lever
4
3
2
5
Figure 4
1. Governor spring
2. Bellcrank
3. Engine governor lever
Page 3 4
Rev. B
Workman 3200/4200
7
6
5
4
Figure 5
1.
2.
3.
4.
Throttle bracket
High idle stop screw
Idle stop screw
Governor spring
5.
6.
7.
8.
Bellcrank
Jam nut
Return spring
Adj rod (if equipped)
Figure 6
1. Governor link
2. Idle speed screw
Workman 3200/4200
Page 3 5 Rev. B
3. Carburetor
Briggs/Daihatsu
Gasoline Engine
20
21
26
1
25
22
19
18
16
RIGHT
FRONT
23 24
17
15
14
13
12
2
3
11
10
4
5
6
7
8
9
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
9.
Hydraulic pump
Carriage screw (4 used)
Fan hub/pulley
Fan shroud
Lower radiator hose
Hose clamp
Radiator
Lock nut (4 used)
Cap screw (4 used)
10.
11.
12.
13.
14.
15.
16.
17.
18.
Page 3 6
19.
20.
21.
22.
23.
24.
25.
26.
Workman 3200/4200
Removal (Fig. 5)
Installation (Fig. 5)
1. Remove plugs from radiator and hoses placed during the removal procedure.
CAUTION
4. Remove the radiator cap. Drain radiator into a suitable container using the radiator drain located on the
lower right corner of the radiator.
5. Disconnect upper and lower radiator hoses from the
radiator.
6. Disconnect reservoir hose (item 13) from the radiator
filler neck.
7. Detach fan shroud from the radiator by removing four
(4) cap screws, flat washers and lock nuts. Position
shroud away from radiator.
8. Remove four (4) cap screws and flange nuts that secure the radiator to the frame. Pull radiator from the vehicle.
9. Plug all radiator and hose openings to prevent contamination.
Workman 3200/4200
Page 3 7
Briggs/Daihatsu
Gasoline Engine
11
18
RIGHT
14
9
12
FRONT
14
11
12
13
10
100 to 130 inlb
(11.3 to 14.7 Nm)
15
17
16
13
8
7
3
6
ANTISIEZE
LUBRICANT
5
1
15
4
2
Figure 6
1.
2.
3.
4.
5.
6.
Lock nut
Flat washer
Woodruff key
Pump drive belt
Pulley
Bearing
7.
8.
9.
10.
11.
12.
Bearing spacer
Shaft
Lock nut (6 used)
Frame support bracket
Cap screw (4 used)
Coupling spacer (4 used)
Page 3 8
13.
14.
15.
16.
17.
18.
Workman 3200/4200
Removal (Fig. 6)
Installation (Fig. 6)
Inspection
1. Inspect frame support bracket for wear or damage.
2. Inspect bearing spacer (Item 7) for wear or damage.
Also, check that spacer length is from 1.884 to 1.894
(47.85 to 48.10 mm). Replace spacer if necessary.
Workman 3200/4200
Page 3 9
Briggs/Daihatsu
Gasoline Engine
Fuel Tank
7
8
5
4
2
10
11
13
12
Sender
Ground
Wire
Thread Sealant
27
14
24
18
17
19
15
20
RIGHT
26
21
16
23
22
FRONT
25
13
Figure 7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Fuel tank
Fuel tank cap
Gasket
Fuel sender
Lock washer (5 used)
Screw (5 used)
Hex nut
Lock washer
Wire harness
Spacer
Fuel fitting
Hose clamp
Fuel hose (to fuel filter)
Clamp
Flange nut (2 used)
Flange nut (2 used)
Rear fuel tank support
Cap screw (2 used)
19.
20.
21.
22.
23.
24.
25.
26.
27.
DANGER
Because gasoline is highly flammable, use caution 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 in a clean, safetyapproved
container and keep cap in place. Use fuel for the
engine only; not for any other purpose.
Check fuel lines and connections periodically as recommended in the Operators Manual. Check lines for deterioration, damage, leaks, or loose connections. Replace
hoses, clamps, and connections as necessary.
Page 3 10
Workman 3200/4200
3. Disconnect negative battery cable first and then positive battery cable. Remove battery from vehicle (see
Operators Manual).
IMPORTANT: Review safety information regarding
fuel handling in the Operators Manual and Chapter
2 Safety.
C. Apply skinover grease to the wire terminal connections and cover center terminal with harness
boot.
5. Connect fuel hose from tank outlet to fuel filter and
secure with clamp.
CAUTION
Connecting battery cables to the wrong battery
post could result in personal injury and/or damage to the electrical system.
6. Position battery in vehicle (see Operators Manual).
Connect positive battery cable first and then negative
battery cable.
7. Lower or install the bed or other attachment(s).
8. Fill fuel tank (see Operators Manual). Check for fuel
leakage and correct if found.
Workman 3200/4200
Page 3 11
Briggs/Daihatsu
Gasoline Engine
3
4
2
RIGHT
13
14
FRONT
6
8
2 12
11
10
VACUATOR
DIRECTION
8
Figure 8
1.
2.
3.
4.
5.
Engine
Hose clamp
Air intake hose
Radiator hose
Air inlet hood
6.
7.
8.
9.
10.
Page 3 12
11.
12.
13.
14.
Mount bracket
Cap screw (2 used)
Flange nut (2 used)
Rclamp
Workman 3200/4200
Removal (Fig. 8)
1
Figure 9
1. Plug
2. Upper housing
3. Element
4. Gasket
5. Lower housing
6. Vacuator valve
Workman 3200/4200
Page 3 13
Briggs/Daihatsu
Gasoline Engine
Installation (Fig. 8)
Exhaust System
11
14
15
13
1
12
16
11
2
10
4
7
8
Loctite #242
17
3
5
3
RIGHT
FRONT
Figure 10
1.
2.
3.
4.
5.
6.
Engine
Stud (4 used)
Exhaust gasket
Hex nut (4 used)
Exhaust manifold
Socket head screw (4 used)
7.
8.
9.
10.
11.
12.
Page 3 14
13.
14.
15.
16.
17.
Mount plate
Cap screw
Muffler
Transaxle
Shift cable mount bracket
Workman 3200/4200
3. Using Figure 10 as a guide, fit all exhaust components to vehicle before tightening any fasteners. When
securing exhaust, tighten fasteners in the following order:
A. Hex nuts (item 4) that secure exhaust manifold to
engine.
4. Discard gaskets and thoroughly clean flange surfaces of manifold and muffler.
B. Cap screw (item 9) with washer (item 10) that secures muffler to transaxle.
C. Socket head screws (item 6) and flange nuts
(item 8) that secure muffler to manifold.
D. Cap screws (item 7) and flange nuts (item 11) that
secure muffler to shift cable mount bracket.
E. Carriage bolts (item 12) and flange nuts (item 11)
that secure muffler to mount plate.
4. Lower or install bed or attachment(s).
Workman 3200/4200
Page 3 15
Briggs/Daihatsu
Gasoline Engine
Engine
12
13
11
32
6
10
7
14
9
8
4
33
16
15
17
18
19
20
21
27
RIGHT
22
FRONT
23
26
31
29
24
25
28
30
Figure 11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Engine
Hex nut
Lock washer
Flat washer
Wire harness alternator lead
Fuel hose
Hose clamp
Hose clamp
Air intake hose
Throttle bracket
Lock nut
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Ball joint
Accelerator cable
Bellcrank
Upper radiator hose
Hose clamp
Engine mount
Lock washer (8 used)
Cap screw (8 used)
Fusible link harness
Positive battery cable
Lock washer
Page 3 16
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Hex nut
Wire harness solenoid lead
Lower radiator hose
Hose clamp
Hex nut
Engine cover
Washer
Cap screw
Cap screw
Return spring
Governor spring
Workman 3200/4200
3
5
6
7
4. Remove exhaust manifold from vehicle (see Exhaust System Removal in this section).
8
7
6
5
10
Briggs/Daihatsu
Gasoline Engine
Figure 12
1.
2.
3.
4.
5.
Engine pulley
Cap screw (4 used)
Coupling spacer (4 used)
Rubber coupling
Lock nut (6 used)
6.
7.
8.
9.
10.
5
7
7
6
9
8
6
10
8. Disconnect accelerator cable from bellcrank on engine. Position accelerator cable away from engine.
Figure 13
9. Drain coolant from radiator (see Operators Manual).
Loosen hose clamps and remove upper and lower radiator hoses from engine. Position hoses away from engine.
1.
2.
3.
4.
5.
Cap screw
Flat washer
Rclamp
Spacer
Engine mount
6.
7.
8.
9.
10.
Snubbing washer
Engine mount
Engine support
Lock nut
Guard (2 used)
Page 3 17
2
3
Figure 14
1. Bell housing
2. Cap screw (6 used)
3. Harness bracket
Page 3 18
Workman 3200/4200
Briggs/Daihatsu
Gasoline Engine
Workman 3200/4200
Page 3 19
2
7
3
9
11
10
12
17
16
15
13
14
RIGHT
FRONT
Figure 17
1.
2.
3.
4.
5.
6.
Engine
Jam nut
Return spring
Lock nut
Ball joint
Accelerator cable
7.
8.
9.
10.
11.
12.
Page 3 20 Rev. B
13.
14.
15.
16.
17.
Workman 3200/4200
Figure 18
1. Governor spring
2. Bellcrank
3. Engine governor lever
4
3
1
2
5
Figure 19
1. Governor spring
2. Bellcrank
3. Engine governor lever
Figure 20
1. Engine governor lever
2. Governor spring
Workman 3200/4200
Page 3 21 Rev. B
Briggs/Daihatsu
Gasoline Engine
Page 3 22
Workman 3200/4200
Chapter 4
Table of Contents
Briggs/Daihatsu
Diesel Engine
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Adding Oil to Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjust Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump Driveshaft Service . . . . . . . . . . . . . . . . . . . . . 8
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Throttle Bracket . . . . . . . . . . . . . . . . . . . . . 20
BRIGGS & STRATTON/DAIHATSU REPAIR MANUAL
FOR 3CYLINDER, LIQUIDCOOLED, DIESEL ENGINES
Introduction
Workman 3300D/4300D
Page 4 1
Specifications
Item
Description
Make / Designation
Number of Cylinders
72 x 78 (2.834 x 3.07)
952 (58.1)
Compression Ratio
24.0:1
Firing Order
1 (front) 2 3
78 (172)
Fuel
26 (7)
Governor
Mechanical
1500 + 50 RPM
3600 + 50 RPM
Engine Oil
Oil Pump
Water Pump
3.8 (4.0)
Starter
12 VDC 1.2 KW
Alternator/Regulator
12 VDC 40 AMP
Page 4 2
Workman 3300D/4300D
General Information
Briggs/Daihatsu
Diesel Engine
When adding oil to the engine, maintain clearance between the oil fill device and the oil fill opening in the valve
cover (Fig. 1). This clearance is necessary to allow venting when adding engine oil which will prevent oil from
running into the breather tube and intake system.
Figure 1
Workman 3300D/4300D
Page 4 3
Adjustments
3
2
2. Raise the bed or remove attachment(s) to allow access to engine. If bed is raised, place safety support on
lift cylinder (see Operators Manual).
3. Allow engine to reach operating temperature before
checking or adjusting engine speed.
4. With engine running at idle speed, use a tachometer
to check that engine is operating at 1500 + 50 RPM.
5. If idle speed is incorrect, adjust idle speed screw
(Fig. 2).
Figure 2
1. Speed control lever
2. Idle speed screw
3. Lock nut
1
3
Figure 3
Page 4 4
3. Lock nut
Workman 3300D/4300D
Briggs/Daihatsu
Diesel Engine
Workman 3300D/4300D
Page 4 5
20
21
26
1
25
22
19
18
16
RIGHT
FRONT
23 24
17
15
14
13
12
2
3
11
10
4
5
6
7
8
9
Figure 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
Hydraulic pump
Carriage screw (4 used)
Fan hub/pulley
Fan shroud
Lower radiator hose
Hose clamp
Radiator
Lock nut (4 used)
Cap screw (4 used)
10.
11.
12.
13.
14.
15.
16.
17.
18.
Page 4 6
19.
20.
21.
22.
23.
24.
25.
26.
Workman 3300D/4300D
Removal (Fig. 4)
Installation (Fig. 4)
1. Remove plugs from radiator and hoses placed during the removal procedure.
CAUTION
4. Remove the radiator cap. Drain radiator into a suitable container using the radiator drain located on the
lower right corner of the radiator.
5. Disconnect upper and lower radiator hoses from the
radiator.
6. Disconnect reservoir hose (item 13) from the radiator
filler neck.
7. Detach fan shroud from the radiator by removing four
(4) cap screws, flat washers and lock nuts. Position
shroud away from radiator.
8. Remove four (4) cap screws and flange nuts that secure the radiator to the frame. Pull radiator from the vehicle.
9. Plug all radiator and hose openings to prevent contamination.
Workman 3300D/4300D
Page 4 7
Briggs/Daihatsu
Diesel Engine
11
18
RIGHT
14
9
12
FRONT
14
11
12
13
10
100 to 130 inlb
(11.3 to 14.7 Nm)
15
17
16
13
8
7
3
6
ANTISIEZE
LUBRICANT
5
1
15
4
2
Figure 5
1.
2.
3.
4.
5.
6.
Lock nut
Flat washer
Woodruff key
Pump drive belt
Pulley
Bearing
7.
8.
9.
10.
11.
12.
Bearing spacer
Shaft
Lock nut (6 used)
Frame support bracket
Cap screw (4 used)
Coupling spacer (4 used)
Page 4 8
13.
14.
15.
16.
17.
18.
Workman 3300D/4300D
Removal (Fig. 5)
Installation (Fig. 5)
Inspection
1. Inspect frame support bracket for wear or damage.
Workman 3300D/4300D
Page 4 9
Briggs/Daihatsu
Diesel Engine
Fuel Tank
7
8
RIGHT
10
Sender
Ground
Wire
FRONT
4
13
11
12
19
2
20
13
18
29
Thread Sealant
14
17
22
30
29
21
23
24
28
25
16
32
15
27
31
33
26
Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Fuel tank
Fuel tank cap
Gasket
Fuel sender
Lock washer (5 used)
Screw (5 used)
Hex nut
Lock washer
Spacer
Wire harness lead
Fuel fitting
Hose clamp
Fuel hose (to fuel filter)
Clamp
Flange nut (2 used)
Flange nut (2 used)
Fuel hose (return from engine)
Hose clamp
Fitting
Bushing
Rear fuel tank support
Cap screw (2 used)
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
DANGER
Because diesel fuel is highly flammable, use caution 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 in a clean, safetyapproved
container and keep cap in place. Use fuel for the
engine only; not for any other purpose.
Check fuel lines and connections periodically as recommended in the Operators Manual. Check lines for deterioration, damage, leaks, or loose connections. Replace
hoses, clamps, and connections as necessary.
Page 4 10
Workman 3300D/4300D
C. Apply skinover grease to the wire terminal connections and cover center terminal with harness
boot.
5. Connect return hose to fitting on top of tank and secure with clamp.
6. Connect fuel hose from tank outlet to fuel filter and
secure with clamp.
CAUTION
Connecting battery cables to the wrong battery
post could result in personal injury and/or damage to the electrical system.
7. Position battery in vehicle (see Operators Manual).
Connect positive battery cable first and then negative
battery cable.
8. Lower or install the bed or other attachment(s).
9. Fill fuel tank (see Operators Manual). Check for fuel
leakage and correct if found.
Workman 3300D/4300D
Page 4 11
Briggs/Daihatsu
Diesel Engine
3
4
2
RIGHT
13
14
FRONT
6
8
2 12
11
7
10
VACUATOR
DIRECTION
8
Figure 7
1.
2.
3.
4.
5.
Engine
Hose clamp
Air intake hose
Radiator hose
Air inlet hood
6.
7.
8.
9.
10.
Page 4 12
11.
12.
13.
14.
Mount bracket
Cap screw (2 used)
Flange nut (2 used)
Rclamp
Workman 3300D/4300D
Removal (Fig. 7)
1
Installation (Fig. 7)
Figure 8
1. Plug
2. Upper housing
3. Element
4. Gasket
5. Lower housing
6. Vacuator valve
Workman 3300D/4300D
Page 4 13
Briggs/Daihatsu
Diesel Engine
Exhaust System
11
14
15
13
1
12
16
11
2
10
4
7
8
Loctite #242
17
3
5
3
RIGHT
FRONT
Figure 9
1.
2.
3.
4.
5.
6.
Engine
Stud (4 used)
Exhaust gasket
Hex nut (4 used)
Exhaust manifold
Socket head screw (4 used)
7.
8.
9.
10.
11.
12.
Page 4 14
13.
14.
15.
16.
17.
Mount plate
Cap screw
Muffler
Transaxle
Shift cable mount bracket
Workman 3300D/4300D
4. Discard gaskets and thoroughly clean flange surfaces of manifold and muffler.
B. Cap screw (item 9) with washer (item 10) that secures muffler to transaxle.
Workman 3300D/4300D
Page 4 15
Briggs/Daihatsu
Diesel Engine
Engine
25
21
27
22
23
24
26
28 29
30
20
19
31
18
1
17
16
2
15
14
9
RIGHT
FRONT
13
3
5
7
12
10
11
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Engine
Fusible link harness
Positive battery cable
Wire harness solenoid lead
Lock washer
Hex nut
Hose clamp
Lower radiator hose
Hex nut
Engine cover
Cap screw
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Washer
Cap screw
Lock washer (8 used)
Cap screw (8 used)
Engine mount
Hose clamp
Upper radiator hose
Throttle bellcrank
Accelerator cable
Ball joint
Page 4 16
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Throttle bracket
Air intake hose
Hose clamp
Fuel supply hose
Hose clamp
Fuel hose (return)
Wire harness alternator lead
Lock washer
Hex nut
Flat washer
Workman 3300D/4300D
3
5
6
7
4. Remove exhaust manifold from vehicle (see Exhaust System Removal in this section).
9
8
7
6
5
Figure 11
1.
2.
3.
4.
5.
Engine pulley
Cap screw (4 used)
Coupling spacer (4 used)
Rubber coupling
Lock nut (6 used)
6.
7.
8.
9.
10.
5
7
7
6
9
8
7
6
10
Figure 12
1.
2.
3.
4.
5.
Cap screw
Flat washer
Rclamp
Spacer
Engine mount
6.
7.
8.
9.
10.
Snubbing washer
Engine mount
Engine support
Lock nut
Guard (2 used)
Page 4 17
Briggs/Daihatsu
Diesel Engine
6. Disconnect fuel hose from fuel injection pump on engine. Plug end of fuel hose to prevent contamination and
fuel spillage. Position disconnected fuel hose away from
engine.
10
2
3
Figure 13
1. Bell housing
2. Cap screw (6 used)
3. Harness bracket
Page 4 18
Workman 3300D/4300D
Briggs/Daihatsu
Diesel Engine
Workman 3300D/4300D
Page 4 19
9
7
6
10
5
4 3
12
11
13
14
15
5
16
RIGHT
FRONT
Figure 14
1.
2.
3.
4.
5.
6.
Engine
Lock nut
Cap screw
Cap screw
Lock nut
Lock nut
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Ball joint
Jam nut
Threaded rod
Accelerator cable
Return spring
Shoulder bolt
Grease fitting
Throttle bellcrank
Throttle bracket
Engine mount
Page 4 20
Workman 3300D/4300D
Chapter 5
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KOHLER ENGINE SERVICE MANUAL
1
2
3
3
4
6
8
Workman 3100
Page 5 1
Kohler
Gasoline Engine
Introduction
Specifications
Item
Description
Make / Designation
Number of Cylinders
Bore x Stroke
80 mm x 67 mm (3.15 x 2.64)
Total Displacement
Compression Ratio
8.5:1
41 kg (90 lb.)
Fuel
Governor
Mechanical
3600 + 50 RPM
Engine Oil
Oil Pump
Starter
12 VDC
Page 5 2
Workman 3100
NOTE: Perform this maintenance procedure at the interval specified in the Operators Manual.
3. Blower housing
Kohler
Gasoline Engine
Workman 3100
Page 5 3
Fuel Tank
7
8
5
4
2
10
11
13
12
Sender
Ground
Wire
Thread Sealant
1
14
24
26
17
18
19
15
20
RIGHT
21
16
23
FRONT
22
25
13
Figure 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Fuel tank
Fuel tank cap
Gasket
Fuel sender
Lock washer (5 used)
Screw (5 used)
Hex nut
Lock washer
Wire harness
Spacer
Fuel fitting
Hose clamp
Fuel line
Clamp
Flange nut (2 used)
Flange nut (2 used)
Rear fuel tank support
Cap screw (2 used)
19.
20.
21.
22.
23.
24.
25.
26.
DANGER
Because gasoline is highly flammable, use caution 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 in a clean, safetyapproved
container and keep cap in place. Use fuel for the
engine only; not for any other purpose.
Check fuel lines and connections periodically as recommended in the Operators Manual. Check lines for deterioration, damage, leaks, or loose connections. Replace
hoses, clamps, and connections as necessary.
Page 5 4
Workman 3100
C. Apply skinover grease to the wire terminal connections and cover center terminal with harness
boot.
5. Connect fuel line from tank outlet to fuel filter and secure with clamp.
CAUTION
Connecting battery cables to the wrong battery
post could result in personal injury and/or damage to the electrical system.
6. Position battery in vehicle (see Operators Manual).
Connect positive battery cable first and then negative
battery cable.
7. Lower or install the bed or other attachment(s).
8. Fill fuel tank (see Operators Manual). Check for fuel
leakage and correct if found.
Workman 3100
Page 5 5
Kohler
Gasoline Engine
Exhaust System
15
5
16
14
13
12
5
17
12
11
10
6
Loctite #242
5
18
8
4
7
RIGHT
FRONT
2
9
1
Figure 3
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Cap screw
Bracket
Muffler gasket
Flange nut (4 used)
Cap screw
Hardened washer
Page 5 6
13.
14.
15.
16.
17.
18.
Workman 3100
Removal (Fig. 3)
1. Put vehicle on a level surface and engage parking
brake. Stop the engine and remove key from ignition
switch. Allow engine to cool.
4. Discard gaskets and thoroughly clean flange surfaces of manifold and muffler.
Installation (Fig. 3)
1. Replace any removed gaskets.
F. Screw (item 6) and flange nut (item 5) that secures exhaust manifold to bracket (item 8).
4. Lower or install bed or attachment(s).
Kohler
Gasoline Engine
Workman 3100
Page 5 7
Engine
26
Antiseize
Lubricant
15
14
16
13
17
18
12
23
25
24
22
11
27
21
10
9
7
19
28
8
29
7
30
31
5
32
20
33
43
35 to 41 ftlb
(47 to 56 Nm)
Antiseize
Lubricant
35
4
34
3
36
2
37
38
RIGHT
FRONT
42
41
39
40
Figure 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Lock nut
Flat washer
Pulley
Woodruff key
Flange nut
Cap screw
Jam nut
Cap screw
Throttle bracket
Lock nut
Throttle lever
Spring
Accelerator cable ball joint
Socket head screw
Shoulder bolt
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Choke lever
Choke cable
Accelerator cable
Cap screw (2 used)
Lock nut
Flat washer (4 used)
Lock washer (4 used)
Cap screw (4 used)
Woodruff key
Pin (3 used)
Cap screw (6 used)
Lock washer (6 used)
Pressure plate
Clutch disc
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
Pilot bearing
Socket head screw
Washer
Flywheel
Clutch adapter
Nut
Positive battery cable
Lock nut (4 used)
Flat washer (4 used)
Engine mount
Cap screw (4 used)
Lock washer
Pump drive belt
Engine assembly
Page 5 8
Workman 3100
2
3
4
5
7. Loosen fasteners that secure hydraulic pump to engine mount (Fig. 5). Rotate pump to allow drive belt (Item
42) to be removed from pump and engine pulley.
Figure 5
4. Pump drive belt
5. Carriage screw
6. Cap screw
13.Loosen and remove four (4) lock nuts (Item 37), flat
washers (Item 38) and cap screws (Item 40) that secure
engine to engine mount. Locate and retrieve lock washer (Item 41) from cap screw on right front corner of engine.
5
4
3
Kohler
Gasoline Engine
1. Hydraulic pump
2. Lock nut (2 used)
3. Engine mount
Figure 6
1.
2.
3.
4.
Engine
Bushing (2 used)
Clutch bell housing
Lock washer (4 used)
Page 5 9
6. Install a new engine oil filter. Fill engine with the correct oil (see Operators Manual).
7. Install and adjust hydraulic pump drive belt (see Operators Manual).
8. Adjust accelerator and choke cables (see Operators
Manual).
9. Lower or install bed or attachment(s).
Page 5 10
Workman 3100
Chapter 6
Drive Train
Table of Contents
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37
Power TakeOff (PTO) Service . . . . . . . . . . . . . . . 54
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59
Drive Train
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
PTO Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 10
Page 6 1
Drive Train
General Information
Workman 3000/4000 Series vehicles are equipped with
a Toro designed transaxle with 3 forward speeds, 1 reverse speed and a differential lock. HiLo range gives an
effective 6 forward and 2 reverse speeds.
Optional PTO
The transaxle is a constant mesh, collar shift transmission with synchronizers for gears 1, 2 and 3. Reverse
and HighLow range must be shifted with the vehicle
stationary.
An optional top mounted PTO operates at 540 RPM.
The transaxle with automotive type clutch is bolted to the
engine with the engine/transaxle assembly isolation
mounted to the vehicle frame.
Two heavy duty universal drive shafts transfer power
from the transaxle to the rear wheels. A fully independent rear suspension and Dedion type rear axle isolate
the midmounted engine/transaxle assembly from the
terrain.
The transaxle housing also functions as the hydraulic
system reservoir.
Transaxle
Figure 1
Drive Train
Page 6 2
Specifications
Item
Specification
Transaxle Oil
Drive Train
Page 6 3
Drive Train
Special Tools
Order special tools from your Toro Distributor.
Figure 2
Drive Train
Page 6 - 4 Rev. C
-
Adjustments
2
1
Figure 3
3. Clevis pin
4. Clevis jam nut
Drive Train
Page 6 5
Drive Train
Troubleshooting
Clutch
Problem
Possible Causes
Clutch slips.
Clutch noisy.
Drive Train
Page 6 6
Clutch (Continued)
Problem
Possible Causes
Clutch chatters.
Drive Train
Page 6 7
Drive Train
Transaxle
Problem
Possible Causes
Noisy operation.
Difficult shifting.
Drive Train
Page 6 8
Transaxle (Continued)
Problem
Possible Causes
Overheating of transaxle.
Drive Train
Page 6 9
Drive Train
19
18
6
9
7
10
8
6
11
11
10
17
16
15
12
4
RIGHT
FRONT
13
14
Figure 4
1.
2.
3.
4.
5.
6.
7.
Shift knob
Jam nut
Boot seal
Shift cable
Shift pin
Jam nut
Cotter pin
Drive Train
8.
9.
10.
11.
12.
13.
Clevis pin
Shift lever
Shift link
Cable clevis
Cap screw
Lower shift boot
Page 6 10
14.
15.
16.
17.
18.
19.
Lock nut
Lever support
Hex nut (2 used)
Shift stop bolt (2 used)
Screw (3 used)
Cable clamp
Removal (Fig. 4)
1. Remove knobs from control levers, then remove center console shift boot and control plate (Fig. 5).
2. Remove three screws (Item 18) and cable clamp
(Item 19) that secure shift cables to lever support.
3. Remove cotter pin and clevis pin that secure shift
cable clevis to shift link (Item 10) on shifter in operator
platform.
4. Loosen jam nut that retains clevis to shift cable and
remove clevis from cable.
Figure 5
1. Shift boot
2. Control plate
Figure 6
1. Clevis
2. Shift cable
3. Clamp
4. Shift stop bolt
Drive Train
Figure 7
1. FirstReverse
2. 2nd3rd
7. Adjust shift cables (see Operators Manual) and secure cable clevis to transaxle shift lever with clevis pin
and cotter pin.
8. Check adjustment of shift stop bolts. Move shift lever
forward until lever stops. Hold lever in stopped position
and adjust stop bolt so that head just contacts lever.
Tighten hex nut on stop bolt.
9. Install shift boot, control plate and control lever
knobs.
Workman 3000/4000 Series
Page 6 11
Drive Train
40 to 60 ftlb
(54 to 81 Nm)
29
28
16
24
23
27
12
22
26
11
Loctite #680
10
21
35 to 42 ftlb
(47 to 57 Nm)
9 7
6
20
15
19
18
45 to 65 ftlb
(61 to 88 Nm)
17
13
RIGHT
14
8
2
1
ACCESS HOLE
FRONT
3
Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Flange nut
Wheel nut (5 used per wheel)
Wheel assembly
Brake drum
Stub axle
Lock washer (5 used per wheel)
Hex bolt (5 used per wheel)
Bearing
Bearing spacer
Cap screw (4 used per brake)
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Disassembly (Fig. 8)
Page 6 12 Rev. B
Figure 9
Workman 3000/4000 Series
Assembly (Fig. 8)
6. Position inner and outer bearing cups to axle housing. Press bearing cups into housing until they seat
against the housing shoulder.
7. Pack bearings with lithium based grease.
8. Position outer bearing cone, wide end first, onto stub
axle. Press bearing onto stub axle putting pressure on
inner race of bearing.
9. Insert stub axle with bearing into axle housing. Fill
housing with grease.
10.Insert bearing spacer onto stub axle inside housing.
NOTE: The stepped end of bearing spacer should be
positioned away from stub axle flange.
11. Insert inner, greased bearing, small end first, onto
stub axle inside housing.
IMPORTANT: The bearing seal must be pressed in
so it is flush with the end of the axle housing. The lip
of the seal must be toward the bearing.
12.Install new seal over shaft and into housing with the
seal lip inward. Be careful not to damage the seal during
installation.
Workman 3000/4000 Series
Page 6 13 Rev. B
Drive Train
Drive Train
7
6
2
3
1.
2.
3.
4.
Snap ring
Cross and bearings
End yoke
Yoke and hub
5. Seal
6. Shaft
7. Tube yoke
G. Tap axle yoke outward with hammer and alignment punch to allow 2nd snap ring to fit. Install snap
ring.
H. Repeat procedure for other yoke.
I. Grease cross until grease comes out of all four (4)
cups.
Drive Train
Page 6 14
2
1
3. Disconnect hydraulic hose from fitting on PTO. Put labels on hydraulic hoses for proper reassembly. Put caps
or plugs on all open hoses or fittings to prevent contamination. Label hoses and fittings for proper reinstallation.
4. Loosen cap screws and remove nut with washer. Separate P.T.O. and Oring from transaxle case. Locate and
remove two alignment pins.
Figure 11
1. PTO lever arm
2. Cable clevis
3. Hydraulic hose
PTO Installation
1. Apply multipurpose grease to Oring and insert O
ring into groove of transaxle case. Insert 2 alignment
pins in transaxle case.
11 to 13 ftlb
(15 to 17 Nm)
Page 6 15
2. Alignment pins
Drive Train
Transaxle
2
3
5
7
8
4
3
9
10
11
12
Loctite #242
13
RIGHT
14
Loctite #242
FRONT
15
Figure 13
1.
2.
3.
4.
5.
Transaxle assembly
Snubbing washer (4 used)
Isolation mount assembly (2 used)
Transaxle mount (2 used)
Lock nut (4 used)
Drive Train
6.
7.
8.
9.
10.
Page 6 16
11.
12.
13.
14.
15.
Removal
1. Put vehicle on a level surface. Stop the engine and
remove key from ignition switch. Remove the bed or other attachment(s). Allow engine and radiator to cool.
1
3
Figure 14
3. 90o fitting
1. Drain plug
2. Strainer
2
3
3. Support bracket
Drive Train
Figure 16
1. Differential lock cable
Page 6 17
Drive Train
16.Put blocking under engine for support. Support transaxle with a floor jack or suspend transaxle from vehicle
frame rails.
17.Remove transaxle isolation mounts and mount
brackets (Fig. 17).
18.Remove drive shaft clamp bolts, then slide transaxle
sidetoside to disconnect each drive shaft from axle
shafts on transaxle.
Figure 17
1. Mounting brackets
2. Drive shaft
Installation
1. To install the transaxle, perform Transaxle Removal
procedure in reverse order noting the following:
3
Figure 18
1. FirstReverse
2. HighLow
3. 2nd3rd
4. PTO clutch
Figure 19
Page 6 18
Drive Train
Page 6 19
Drive Train
Clutch Service
Silicone sealant
(Workman 3100 only)
5
RIGHT
14
FRONT
9
5 to 7 ftlb
(7 to 9 Nm)
12
11
10
13
7
2
Figure 20
1.
2.
3.
4.
5.
Spring pin
Throw out bearing
Release guide
Clutch release fork
Clutch release shaft
6.
7.
8.
9.
10.
11.
12.
13.
14.
Bushing
Spring pin (2 used)
Bell housing
Oil seal
Cap screw (6 used)
A. Fill annular groove of release bearing and coat remainder of bearing bore.
B. Apply thin coat to outside diameter of release
guide.
C. Apply thin coat to fingers of clutch release fork.
D. Remove any excess lubricant before final assembly.
Drive Train
Page 6 20
3. Remove cap screws, washers (Item 11) and pressure plate (Item 12), then slide out the transaxle main
shaft and remove clutch disk (Item 13). Note orientation
of clutch disk as it is removed (Fig. 22).
4. Inspect diaphragm spring end of pressure plate for
wear and uneven height. Replace if wear is evident or if
height difference exceeds 0.020 in. (0.5 mm).
Figure 21
Clutch Disc
7. Check clutch disk facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil or
grease. Replace clutch disk if damaged.
Engine
Flywheel
Side
Pressure
Plate Side
Figure 22
Pressure plate
Drive Train
Diaphragm spring
Torsion spring
Figure 23
Rivet sink
Page 6 - 21 Rev. C
-
Figure 24
Drive Train
Transaxle Service
Disassembly
NOTE: Item numbers in figures are shown in order of
disassembly; for example, remove Item 1 first, then Item
2, etc. Reassemble in reverse order; for example, install
Item 1 last.
Figure 26
6. Inspect fork shaft case for cracks or damage and replace if necessary.
3
Figure 27
Drive Train
Page 6 22
3
4
1
2
Figure 28
FRONT DRIVE
SHAFT
BEARING
(CENTER PLATE)
BEARING
(GEAR CASE)
41T GEAR
Figure 29
Drive Train
1
2
Figure 30
Figure 31
Workman 3000/4000 Series
Page 6 23
Drive Train
11. Remove, all at the same time, reduction shaft assembly (Item 1), 2nd3rd shift assembly (Item 2), countershaft assembly (Item 3) and HighLow shift assembly
(Item 4).
Figure 32
Figure 33
13.Remove roll pin from differential lock lever. Remove
lever (Item 1) from shaft. Loosen cap screws (Item 2)
and remove L.H. side cover (Item 3) from transaxle
case.
Figure 34
Drive Train
Page 6 24
Figure 35
Workman 3000/4000 Series
Figure 36
Drive Train
Figure 37
Page 6 25
Drive Train
1
2
A. Loosen and remove nut (Item 1). Remove washer (Item 2) and 2nd3rd shift arm (Item 3) together
with shift arm plate (Item 4), spring (Item 5), locknut
(Item 6), washer (Item 7) and cap screw (Item 8).
4
6
3
8
7
5
9
10
11
14
12
13
Figure 39
Figure 40
Drive Train
Page 6 26
Figure 41
Drive Train
Figure 42
Page 6 27
Drive Train
essary.
Figure 43
and 3 keys.
3 5
15
16
1817
14
19
10
11
12
13
Figure 44
Drive Train
Page 6 28
15
14
13
10
18
17
16
12
11
Figure 45
15).
14
12
15
13
17
16
8
18
97
11
5
3
Drive Train
Figure 46
Page 6 29
Drive Train
Figure 47
from countershaft.
(Item 3).
Figure 48
(30.08 mm).
16
(2.8 mm)
I. Use a bearing puller to remove 2 bearings (Item
15).
10
12
11
13
14
15
Figure 49
Drive Train
Page 6 30
assembly.
assembly.
Figure 50
5
1
Figure 51
29.Disassemble differential gear assembly:
A. Use a bearing puller to remove bearing (Item 1)
Drive Train
Figure 52
11
10
9
7
12
14
14
13
10
11
1
5
1
Figure 53
Workman 3000/4000 Series
Page 6 31
Drive Train
L.H. SHAFT
(Item 8).
seal cover.
Figure 55
Drive Train
Page 6 32
Inspection
1. Thoroughly clean and dry all parts.
2. Use emery cloth to remove nicks and burrs from all
parts.
3. Inspect synchronizer ring:
A. Inspect the chamfer for excessive wear or dam
age.
damage.
or damage.
FRONT DRIVE
SHAFT
BEARING
(CENTER PLATE)
BEARING
(GEAR CASE)
Figure 57
Page 6 33
Drive Train
Drive Train
Figure 58
7. Inspect main shaft:
A. Inspect main shaft for worn or damaged surface.
If O.D. of needle bearing surface is less than .864 in.
(21.95 mm), replace the main shaft.
B. Inspect lip portion of oil seal for wear or damage.
C. Insert spline in clutch disk and check for excessive looseness and free sliding of clutch disk hub.
Figure 59
4
1
2
Figure 60
Drive Train
Page 6 34
Figure 61
DAMAGED
GROOVE EDGES
Drive Train
Figure 62
Page 6 35
Drive Train
Figure 63
Figure 64
12.Inspect differential:
A. Inspect pinion shaft for excessive wear or damage. If O.D. is less than .707 in. (17.95 mm), replace
the pinion shaft.
B. Measure thickness of pinion liners. If thickness is
less than .035 in. (0.9 mm), replace the pinion liners.
C. Measure thickness of side gear liners. If thickness is less than .043 in. (1.1 mm), replace the side
gear liners.
D. Inspect the gear contact condition between spiral
bevel pinion and ring gear.
E. Inspect differential case for wear in side gears
and pinion shaft mating area. Replace the case if machined surfaces are scored or if the pinion shaft fits
loosely in the bore.
Drive Train
Page 6 36
Figure 65
Assembly
NOTE: Item numbers in figures are shown in reverse
order of assembly; for example, when reassembling,
install Item 1 last.
1. Clean gasket material from all mating surfaces before reassembling. Make sure all parts are clean and
free of dirt and dust.
IMPORTANT: Be careful not to damage mating surfaces when removing gasket material.
2. Assemble L.H. axle shaft:
A. Install new oil seal (Item 7) into differential carrier.
B. Use a press to install bearing (Item 6) onto L.H.
axle shaft.
carrier.
L.H. SHAFT
R.H. SHAFT
axle shaft.
Figure 66
Make sure lock pins are installed with slit facing the
correct direction.
ARM
Figure 67
Workman 3000/4000 Series
Page 6 37
Drive Train
Drive Train
13, 12), pinion liners (Item 11) and pinion gears (Item
10).
aid assembly.
Figure 68
side gears.
11
2
3
10
(Item 6).
6).
12
14
14
13
10
18.5 to 22 ftlb
(24.5 to 29.5 Nm)
new screws.
11
1
5
1
Figure 69
Figure 70
ential case.
Figure 71
Drive Train
Page 6 38
4
3
Figure 72
3).
B. Drive lock pin (Item 1) into fork and fork shaft. Pay
Drive Train
Figure 73
Page 6 39
Drive Train
8. Assemble countershaft:
Figure 74
16
10
12
11
13
14
15
Figure 75
Drive Train
Page 6 40
Figure 76
Figure 77
Drive Train
Figure 78
Figure 79
Workman 3000/4000 Series
Page 6 41
Drive Train
15
14
13
10
18
17
16
12
11
14
12
15
13
17
16
8
18
97
11
5
1
Figure 81
Drive Train
Page 6 42
Figure 82
Figure 83
8
17
18
15
16
14
Drive Train
19
11
12
13
before installing.
Figure 84
shaft.
Page 6 43
Drive Train
1
2
4
6
3
9
10
11
9
10
11
14
12
13
Figure 86
14.Install oil cap (Item 1) with Oring. Apply multipurpose grease to Oring.
1
Figure 87
Drive Train
Page 6 44
Figure 88
Drive Train
Figure 89
Figure 90
Figure 91
Workman 3000/4000 Series
Page 6 45
Drive Train
1
2
Figure 92
FRONT DRIVE
SHAFT
BEARING
(CENTER PLATE)
BEARING
(GEAR CASE)
41T GEAR
Figure 93
center plate.
Drive Train
Page 6 46
Figure 94
3
4
1
2
Figure 95
5
22.Install snap ring into the groove of the bearing housing (Fig. 96 and 97).
6
4
Figure 96
4. Snap ring
5. Center plate
6. Sealing cap
Drive Train
1. Countershaft
2. Bearing
3. Shims
Figure 97
Page 6 47
Drive Train
Figure 98
24.Insert sealing cap (Item 1) flush with face of housing.
Make sure not to insert sealing cap too far. Pay attention
to direction of sealing cap.
Figure 99
Drive Train
Page 6 48
Figure 100
Figure 101
Drive Train
Figure 102
Figure 103
Workman 3000/4000 Series
Page 6 49
Drive Train
Figure 104
Figure 105
28.Install side cover:
A. Insert 2 dowel pins onto transaxle case.
B. Apply silicone sealant onto mating surface of side
cover.
Figure 106
29.Install R.H. axle shaft assembly:
A. Apply silicone sealant onto mating surface of seal
cover.
Drive Train
Page 6 50
Figure 107
Workman 3000/4000 Series
Figure 108
C. Install axle shaft assembly and tighten cap
screws (Item 1) to a torque from 18.5 to 22 ftlb (24.5
to 29.5 Nm).
1
Figure 109
Drive Train
Page 6 51
Figure 110
Drive Train
32.Install differential lock arm (Item 1) onto fork shaft. Insert lock pin into fork shaft and arm. Pay attention to
direction of slit in lock pin.
Figure 111
Figure 112
Drive Train
Page 6 52
Figure 113
Drive Train
Figure 114
Page 6 53
Drive Train
33
34
35
3
32
28
26
29
30
31
17
25
2
3
24
27
11
18 to 22 ftlb
(24.5 to 29.5 Nm)
17
5
3
22
21
7
9
20
23
19
17
12
11
10
13
14
18
16
15
Figure 115
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
PTO cover
Cap screw (4 used)
Lock washer (7 used)
Cap screw (3 used)
Oring
Shift arm
Shifter block
Spring
Ball
Retaining ring
Bearing
Input shaft
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Shift collar
Gear (29T)
Bushing
Thrust washer
Bearing
Retaining ring
Shift lever
Spring pin
Spring pin
Alignment pin (2 used)
PTO housing
Gear (27T)
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Intermediate shaft
Gear (37T)
Retaining ring
Retaining ring
Thrust washer
Bearing
Oil seal
Output shaft
Stud
Lock washer
Hex nut
Figure 116
Page 6 54
Figure 117
Drive Train
Figure 118
Figure 119
Page 6 55
Drive Train
PTO housing.
shaft side.
Figure 120
9).
3
7
Figure 121
Figure 122
Drive Train
Page 6 56
Figure 123
Drive Train
Figure 125
Figure 126
Page 6 57
Drive Train
Inspection
1. Thoroughly clean and dry all parts.
2. Use emery cloth to remove nicks and burrs from all
parts.
3. Measure clearance between groove on shift collar
and shifter block. Replace shifter block if clearance exceeds .039 in. (1.0 mm).
Figure 127
Figure 128
5. Measure O.D. of bushing area on input shaft. Replace shaft if O.D. is less than .667 in. (16.95 mm). Inspect surface of bushing area for scoring or damage.
Figure 129
Figure 130
Drive Train
Page 6 58
IMPORTANT: Be careful not to damage mating surfaces when removing gasket material.
2. Make sure all parts are free of dirt and dust.
3. Assemble shift arm:
Figure 131
ling.
Drive Train
Figure 132
Figure 133
Page 6 59
Drive Train
Figure 134
Figure 135
5. Use a press to install bearing (Item 1) onto intermediate shaft.
Figure 136
Figure 137
Drive Train
Page 6 60
before installing.
ling.
Figure 138
shaft.
Drive Train
Figure 139
6
7
Figure 140
Moly disulfide
grease
Figure 141
Page 6 61
Drive Train
Figure 142
Figure 143
Figure 144
Drive Train
Page 6 62
cover.
to 29.5 Nm).
Figure 145
Drive Train
Page 6 63
Drive Train
Drive Train
Page 6 64
Chapter 7
Chassis
Table of Contents
Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . .
Brake Master Cylinder Service . . . . . . . . . . . . . . .
Parking Brake Cable Replacement . . . . . . . . . . .
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Arm Ball Joint Replacement . . . . . . . . . .
Tie Rod End Replacement . . . . . . . . . . . . . . . . . .
Front Wheel Alignment . . . . . . . . . . . . . . . . . . . . .
Front Compression Spring Service . . . . . . . . . . .
Front Shock Absorber Replacement . . . . . . . . . .
Rear Shock Absorber Replacement . . . . . . . . . .
Rear Leaf Spring Replacement . . . . . . . . . . . . . .
Seat Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
21
22
23
24
25
26
27
28
29
30
32
Chassis
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
Suspension and Steering . . . . . . . . . . . . . . . . . . . . 4
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front Wheel Assembly (2 Wheel Drive) . . . . . . . 10
Rear Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . 12
Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wheel Brake Cylinder Service . . . . . . . . . . . . . . . 17
Bleeding the Brakes . . . . . . . . . . . . . . . . . . . . . . . . 18
Page 7 1
Chassis
Specifications
Item
Specification
Front tire
20 x 10 10, 4 ply
20 PSI
Rear tire
24 x 12 12, 6 ply
18 PSI
Brake fluid
DOT 3
Tire Pressure
1. Tire pressure needed is determined by the payload
carried.
2. The lower the air pressure, the less the compaction,
and tire marks are minimized. Lower pressure should
not be used for heavy payloads at high speeds. Tire
damage may result.
3. High pressure should be used for heavier payloads
at higher speeds. Do not exceed maximum tire pressure.
4. See Operators Manual for additional tire pressure
information.
Chassis
Page 7 2
Special Tools
Item
1/2 nuts
5
20
Chassis
Figure 1
Page 7 3
Chassis
Troubleshooting
Possible Causes
Instability (wander).
Chassis
Page 7 4
Problem
Possible Causes
Hard steering.
Chassis
Page 7 5
Chassis
Brakes
Problem
Possible Causes
Brakes pulling.
Squealing brakes.
Chassis
Page 7 6
Brakes (Continued)
Problem
Possible Causes
Dragging brakes.
Wheel locks.
Brakes fade.
Shoe lock.
Page 7 7
Chassis
Chassis
Wheel Installation
1. Mount wheel and evenly tighten wheel nuts to a
torque from 45 to 65 ftlb (61 to 88 Nm).
WARNING
Failure to maintain proper wheel nut torque
could result in failure or loss of wheel and may
result in personal injury. Torque front and rear
wheel nuts from 45 to 65 ftlb (61 to 88 Nm) at
intervals recommended in Operators Manual.
Figure 2
1. Wheel assembly
Chassis
Page 7 8
Chassis
Page 7 9
Chassis
45 to 65 ftlb
(61 to 88 Nm)
Loctite #680
40 to 60 ftlb
(54 to 81 Nm)
10
4
9
11
12
See tightening
procedure in text
13
17
18
19
20
RIGHT
14
ACCESS HOLE
15
16
FRONT
Figure 3
1.
2.
3.
4.
5.
6.
7.
Dust cap
Cotter pin
Nut retainer
Jam nut
Tab washer
Wheel nut (5 used per wheel)
Wheel assembly
8.
9.
10.
11.
12.
13.
14.
Brake drum
Outer bearing cone
Outer bearing cup
Front hub
Lock washer (5 used per wheel)
Hex bolt (5 used per wheel)
Inner bearing cup
15.
16.
17.
18.
19.
20.
Disassembly (Fig. 3)
Assembly (Fig. 3)
Chassis
Page 7 10
CAUTION
After reassembly, check the brakes in a wide
open, level area that is free of other persons and
obstructions.
Chassis
Page 7 11
Chassis
25
40 to 60 ftlb
(54 to 81 Nm)
16
24
23
12
11
22
Loctite #680
10
26
9 7
21
6
15
20
19
18
FRONT
45 to 65 ftlb
(61 to 88 Nm)
17
13
RIGHT
14
8
2
1
ACCESS HOLE
Figure 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
Flange nut
Wheel nut (5 used per wheel)
Wheel assembly
Brake drum
Stub axle
Lock washer (5 used per wheel)
Hex bolt (5 used per wheel)
Bearing
Bearing spacer
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Chassis
Page 7 12
Chassis
Page 7 13
Chassis
Brake Service
49 to 97 inlb
(5.5 to 11 Nm)
13
26
25
11
6
9
12
10
10
24
12
11
14
16
17
18
21
13
15
27
19
20
23
22
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
9.
Chassis
10.
11.
12.
13.
14.
15.
16.
17.
18.
Ltype seal
Piston
Dust cover
Brake shoe
Upper shoe spring
Lower shoe spring
Female push rod
Bolt adjuster
Adjuster sleeve
Page 7 14
19.
20.
21.
22.
23.
24.
25.
26.
27.
Pawl
Adjuster spring
Pawl pin
Hold down washer (2 used)
Hold down spring (2 used)
Pipe guide
Inspection plug
Hold down pin (2 used)
Adjuster assembly
NOTE: It may be necessary to back off adjuster to remove brake drum. To back off adjuster, rotate brake
drum until access hole lines up with bolt adjuster on adjuster assembly. Use a hooked piece of wire to pull pawl
away from bolt adjuster, then turn bolt adjuster.
3. Remove brake drum.
4. If servicing front brakes, remove wheel hub from vehicle (see Front Wheel Assembly (2 Wheel Drive) in this
section for series 3000 Workman vehicle or see Front
Wheel and Axle Housing Assembly in the Service and
Repairs section of Chapter 10 Front Wheel Drive
(4WD) for series 4000 Workman vehicle).
5. If servicing rear brakes, remove stub axle from vehicle (see Stub Axle and Drive Shaft Service in the Service and Repairs section of Chapter 6 Drive Train).
6. Remove upper shoe spring (14), adjuster spring (20)
and then lower shoe spring (15).
NOTE: The adjuster assembly (27) consists of the female push rod (16), bolt adjuster (17) and adjuster
sleeve (18).
7. Remove hold down washers (22) and hold down
springs (23) from the hold down pins (26). Remove
brake shoes (13), pawl (19) and adjuster assembly (27).
7
1
4
4
8
2
9. See Brake Cylinder Service in this section for information on brake cylinder disassembly, inspection and
assembly procedures.
6
3
Chassis
1. Clean and inspect brake drum any time they are removed for brake service.
A. Check drum diameter at a minimum of three locations. Diameter should not exceed the over size limit
cast into the outside of the drum. Replace drum if limit is exceeded.
Inspection
Figure 6
1.
2.
3.
4.
Page 7 15
5.
6.
7.
8.
Brake shoe
Adjuster assembly
Brake cylinder assy
Pawl
Chassis
CAUTION
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
16.After servicing brakes, start the engine and depress
brake pedal several times while vehicle is moving in reverse.
17.Adjust parking brake (see Operators Manual).
Burnish Brake Shoes
To ensure maximum brake performance after brake
shoes are replaced, burnish new brake shoes.
IMPORTANT:While burnishing brakes, do not allow
the brakes to lock up. Allow brakes to cool between
applications.
1. Drive vehicle while making 6 to 7 normal stops at
about 200 ft (60 m) intervals while traveling at 10 to 15
mph (16 to 24 KPH).
2. Make several normal stops with the vehicle going in
the reverse direction. This will self adjust the clearance
between the brake shoe and drum.
Page 7 16
2. If brake line is still attached to brake cylinder, disconnect brake line from cylinder. Put a cap on brake line to
prevent contamination of system and brake fluid leakage.
3
2
Figure 7
1.
2.
3.
4.
Inspection
5. Bleed screw
6. Bleed screw cap
7. Brake cylinder body
CAUTION
Use eye protection such as goggles when using
compressed air.
1. Clean all metal parts with isopropyl alcohol, then
clean out and dry grooves and passageways with compressed air. Make sure brake cylinder bore and component pieces are thoroughly clean.
2. Check cylinder bore and pistons and spring for damage or excessive wear. Replace brake cylinder assembly if signs of pitting, scoring or cracks are evident.
Assembly
1. Apply a film of clean brake fluid to new Ltype seals
and then install seals onto pistons.
Chassis
Page 7 17
Chassis
Bleeder valve
CAUTION
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
6. After bleeding of brakes is completed, road test vehicle to make sure brakes are operating correctly and
pedal is solid.
Chassis
Page 7 18
Chassis
Page 7 19
Chassis
RIGHT
FRONT
3
4
5
Figure 9
1. Brake master cylinder
2. Cap screw (2 used)
3. Clevis pin
4. Cotter pin
Removal (Fig. 9)
Installation (Fig. 9)
3. Remove two (2) cap screws and flange nuts that secure master cylinder to vehicle frame.
3. Make sure that master cylinder push rod is fully extended. Connect push rod clevis to brake pedal with clevis pin and cotter pin.
4. Bleed brakes (see Bleed Brake System).
CAUTION
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
5. Check brake operation.
Chassis
Page 7 20
3. Push in on the push rod and remove circlip, then remove push rod with dust cover and clevis. Remove retainer washer.
4. Remove primary piston assembly and secondary
piston assembly from cylinder housing.
7
11
8
9
12
10
Inspection
1. Clean all metal parts with isopropyl alcohol, then
clean out and dry grooves and passageways with compressed 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)
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Push rod
Circlip
Retainer washer
Primary piston assy.
Secondary piston assy.
Cap assembly
Page 7 21
Chassis
Chassis
7
4
9
10
3. Jack up and support rear of vehicle (see Jacking Instructions in Operators Manual).
4. Remove rear wheel and brake drum (see Brake Service in this section).
5. Disconnect cable from rear brake (Fig. 12):
11
Figure 11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
RH brake cable
Washer
Bellcrank
Brake handle
Lever support bracket
1
4
2
3
Figure 12
1. Rear brake backing plate
2. Parking brake lever
3. Route brake cable in same location as before and secure with cable ties. Start from rear of vehicle and work
towards front.
Figure 13
1. Brake cable
2. Retaining ring
3. Equalizer bracket
Page 7 22
Steering Wheel
Removal (Fig. 14)
2. Remove hex nut and lock washer that secure steering wheel to steering control valve.
5
20 to 26 ftlb
(28 to 35 Nm)
Antiseize
Lubricant
Figure 14
4. Steering control valve
5. Frame
Chassis
1. Steering wheel
2. Lock washer
3. Hex nut
Page 7 23 Rev. B
Chassis
8
3
12
2
80 to 90 ftlb
(108 to 122 Nm)
10
9
11
6
4
RIGHT
FRONT
11
5
8
9
10
Figure 15
1.
2.
3.
4.
Cotter pin
Slotted hex nut
Upper control arm (RH shown)
Lower control arm (RH shown)
5.
6.
7.
8.
Snap ring
Ball joint
Ball joint seal
Grease fitting
Flange bushing
Cap screw
Lock nut
Spindle (RH, 2WD shown)
1. Press new ball joint into control arm. Install snap ring
to secure ball joint.
WARNING
FRONT SUSPENSION IS SPRING LOADED! To
prevent possible personal injury, use special
tool to remove compression springs before disassembling the front suspension.
1. If servicing upper ball joint or control arm, remove
front compression springs (see Front Compression
Spring Service in this section). NOTE: Front compression springs do not need to be removed if servicing only
the lower ball joint or lower control arm.
2. Remove cotter pin and slotted nut that secure affected ball joint to spindle. Separate ball joint from
spindle. Inspect ball joint seal and replace if damaged.
3. Remove control arm.
4. Remove snap ring. Press ball joint out of control arm.
Chassis
9.
10.
11.
12.
Page 7 24
9
8
1
45 to 55 ft-lb
(61 to 75 N-m)
7
2
3
4
5
RIGHT
FRONT
50 ft-lb
(68 N-m)
2
6
45 to 55 ft-lb
(61 to 75 N-m)
Figure 16
1. Tie rod end
2. Cotter pin
3. Jam nut
4. Tie rod
5. Jam nut (LH thread)
6. Tie rod end (LH thread)
7. Pitman arm
8. Steering cylinder
9. Spindle (RH shown)
1. Install new tie rod end to tie rod. Thread in the same
number of revolutions as the old one took to remove.
2. Make sure that tie rod end shaft and spindle or pitman arm are thoroughly cleaned.
4. Remove tie rod end from tie rod. Count the number
of revolutions it takes to remove rod end so new rod end
can be installed without changing the toe--in adjustment.
Page 7 - 25 Rev. A
-
Chassis
Chassis
Figure 17
Cylinder Length to Center the Pitman Arm
Figure 18
FRONT OF VEHICLE
Center- -center
-toDistance
Center- -center
-toDistance
Figure 19
Chassis
Page 7 - 26
-
Rev. A
20I
5I
Compression
spring tool rod
Spring cradle
5I
(4) 1/2I nuts
Compression
spring
9
5
2
4
Figure 19
1. Spring cradle
2. Spring
3. Lock nut
4. Cap screw
5. Stabilizer link
6. Lock nut
1. Remove seat base to gain access to front suspension assembly (see Seat Base removal in this section).
2. Jack up front of vehicle and secure with jack stands
(see Jacking Instructions in Operators Manual). Remove front wheels.
7. Cap screw
8. Control arm tower
9. Spring pivot sleeve
6. Remove lock nut (Item 6) and cap screw (Item 7) securing each spring cradle to control arm towers (Item 8),
then remove springs and cradles along with the stabilizer links.
7. Reverse this procedure to install springs.
Chassis
WARNING
FRONT SUSPENSION IS SPRING LOADED! To
prevent possible personal injury, use special
tool to remove compression springs before disassembling the front suspension.
4. Install a compression spring tool rod through holes
in each spring cradle (Item 1), then install nuts and
washers on both ends of each rod. Tighten one nut on
each rod to secure springs (Item 2). NOTE: Extended
portion of each compression spring tool must be on opposite ends so cap screws (Item 7) can be removed.
Install compression
spring tool before
disassembling
Figure 20
Chassis
10
6
5
2
1
8
9
Figure 21
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Rubber bushing
Spacer
Inner washer
Shock absorber
Outer washer
Lock nut
Cap screw
Washer
Lock nut
Control arm tower
Shock absorber
Figure 22
Chassis
Page 7 28
1
4
5
4. Install new shock absorber with ram end down. Secure each end with with large washer and lock nut.
2
5
1
Figure 23
1. Rubber bushing
2. Large washer
3. Shock absorber
4. Large washer
5. Lock nut
Shock absorber
Chassis
Figure 24
Page 7 29
Chassis
1
2
3
3
2
12
4
5
7
8
9
13
RIGHT
10
11
FRONT
3
14
Figure 25
1.
2.
3.
4.
5.
Lock nut
Spring shackle
Rubber bushing
Axle bumper
Hex nut
6.
7.
8.
9.
10.
11.
12.
13.
14.
Spring mount
Flange nut (2 per mount)
Rear axle
Carriage screw (4 used per spring)
IMPORTANT: For proper vehicle performance, always replace the springs on both sides of the vehicle.
1. Jack up and support rear of vehicle (See Jacking Instructions in Operators Manual). Remove rear
wheel(s).
Chassis
Page 7 30
Figure 26
4. Install spring plate (Item 8) to top of spring, then secure axle to spring with carriage bolts (Item 14), washers
(Item 7) and lock nuts (Item 6). NOTE: Make sure axle
and plate are centered on leaf spring knob (Fig. 26).
5. Tighten lock nuts (Item 6) in a crossing pattern until
spring plate, leaf spring and axle contact. Tighten flange
nuts (Item 12) securing spring mount to frame rail. Tighten lock nuts (Item 6) securing axle and clamp plate to
leaf spring using a crossing pattern and the following
torque values:
A. Tighten lock nuts from 20 to 30 ftlb (27 to 41
Nm) in a crossing pattern.
B. Tighten lock nuts from 50 to 60 ftlb (68 to 81
Nm) in a crossing pattern.
C. Retighten lock nuts from 50 to 60 ftlb (68 to 81
Nm).
6. Install rear wheels (see Wheel Installation in this section).
Chassis
Page 7 31
Chassis
Seat Base
5
3
11
10
8
9
RIGHT
FRONT
Figure 27
1.
2.
3.
4.
Passenger seat
Screw (6 used)
Control plate
Hose to radiator
Chassis
5.
6.
7.
8.
Coolant reservoir
Operator seat
Lock nut
Flat washer
Page 7 32
9. Cap screw
10. Seat base
11. Socket head screw (4 used per seat)
2
4
Figure 28
Chassis
Page 7 33
Chassis
Chassis
Page 7 34
Chapter 8
Electrical System
Table of Contents
Start Relay (Kohler Engine) . . . . . . . . . . . . . . . . . . 11
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Indicator Lights and Gauges . . . . . . . . . . . . . . . . . . 12
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Headlamp Replacement . . . . . . . . . . . . . . . . . . . . . 20
Electrical
System
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . .
3
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . . 5
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . . 7
Clutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine) Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Page 8 1
Electrical System
Electrical Schematics
The electrical schematics for the Workman are located
in Chapter 11 -- Electrical Schematics.
Special Tools
Order special tools from your Toro Distributor. Some
tools may also be available from a local supplier.
Continuity Tester
Battery powered test lamp which is helpful in testing for
continuity of circuits and electrical components when the
current is off.
Figure 1
Multimeter
The meter can test electrical components and circuits for
current, resistance, or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 2
Skin-Over Grease
Special non--conductive grease (Toro Part No.
TOR50547) which forms a light protective skin which
helps waterproof electrical switches and contacts.
Figure 3
Electrical System
Page 8 - 2
-
Rev. D
Troubleshooting
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
Condition
Possible Cause
Electrical
System
Engine does not shut off immediately when ignition key Damaged or disconnected wiring for shutdown relay.
switch is turned off (Workman 3100 only).
Shutdown relay faulty.
Page 8 3
Electrical System
Condition
Possible Cause
Electrical System
Page 8 4
Voltage Measured
12.45 v
75% charged
12.24 v
50% charged
12.06 v
25% charged
11.89 v
0% charged
NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional
and more accurate information (see Battery Service in
Service and Repairs section of this Chapter).
Start the engine and run at high idle. Allow the battery to
charge for at least 3 minutes. Record the battery voltage.
Test results should be (example):
= 12.30 v
= 12.80 v
Difference
= +0.50 v
Electrical
System
Page 8 5
Electrical System
CAUTION
Check the operation of the interlock switches
daily for proper operation. Replace any malfunctioning switches before operating the machine.
To verify clutch interlock switch operation:
1. Sit on operators seat and engage parking brake.
Move shift lever to NEUTRAL position. On TC models,
make sure that hydraulic lift lever is in neutral position.
Disengage rear PTO (if so equipped).
2. Without depressing clutch pedal, rotate ignition key
clockwise to START position.
3. If engine cranks or starts, there is a malfunction in the
interlock system that must be repaired before operating
vehicle.
Electrical System
3. Depress clutch pedal and rotate ignition key clockwise to START position.
4. If engine cranks or starts, there is a malfunction in the
interlock system that must be repaired before operating
vehicle.
To verify rear PTO interlock switch (if equipped) operation:
1. Sit on operators seat and engage parking brake.
Move shift lever to NEUTRAL position. On TC models,
make sure that hydraulic lift lever is in neutral position.
2. Engage rear PTO.
3. Depress clutch pedal and rotate ignition key clockwise to START position.
4. If engine cranks or starts, there is a malfunction in the
interlock system that must be repaired before operating
vehicle.
Page 8 - 6 Rev. D
-
Component Testing
For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the
circuit (e.g. unplug the clutch switch connector before
doing a continuity check).
CAUTION
When testing electrical components for continuity with a voltohm meter or continuity tester,
make sure that power to the circuit has been disconnected.
B
S
I
X
Figure 4
1. OFF
CONTINUITY
AMONG
TERMINALS
NONE
2. RUN
B+A+I
3. START
B+S+I
OTHER
CIRCUITS
MADE
NONE
X+Y
NONE
Figure 5
Page 8 7
Electrical System
Electrical
System
POSITION
Clutch Switch
The clutch switch is normally open and closes when the
clutch pedal is depressed. The clutch switch is attached
to a bracket on the left side of the clutch bell housing (Fig.
6).
Test the switch by disconnecting the wiring connector
and connecting a continuity tester across the two terminals. With the engine off, depress the clutch pedal completely there should be an indication of continuity.
Release the clutch pedal there should be no continuity.
Brake Switch
The brake switch is normally open and closes when the
brake pedal is depressed. The closed switch allows a
current path to the stop light.
Test the switch by disconnecting the wiring connector
and connecting a continuity tester across the two terminals. With the engine off, depress the brake pedal
there should be an indication of continuity. Release the
brake pedal there should be no continuity.
Figure 7
1. Brake switch
Electrical System
Page 8 8
Figure 8
1. 23 lockout switch
Electrical
System
Figure 9
Page 8 9
Electrical System
Start (Briggs/Daihatsu Gas and Diesel Engine) and Fuel Pump (Briggs/Daihatsu Gas
Engine) Relay
The start relay used on Workman vehicles with a Briggs/
Daihatsu gasoline or diesel engine and the fuel pump
relay on Workman vehicles with a Briggs/Daihatsu gasoline engine are identical. These relays are attached to
the frame near the hydraulic oil filter.
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 value from the measured value of the component you are
testing.
86
87A
87
85
30
Figure 10
3. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
4. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
5. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between terminals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
6. Disconnect voltage and multimeter leads from the
relay terminals. Reconnect relay to vehicle wire harness.
Electrical System
Page 8 10
86
85
30
87
87
85
30
86
Figure 11
86
87
30
85
85
30
2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
86
87
Figure 12
Testing
2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87 (Fig. 13). Ground terminal 86 and apply
+12 VDC to terminal 85. The relay should make and
break continuity between terminals 30 and 87 as +12
VDC is applied and removed from terminal 85.
86
87A
87
87
86
87A
85
30
85
30
Electrical
System
Figure 13
4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between terminals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
Page 8 - 11 Rev. C
-
Electrical System
Battery
Use a digital multi meter to measure the voltage between
the battery terminals.
If the voltage is less than 12.3 Volts DC, the battery
should be charged.
NOTE: Regulated battery voltage will increase to
approximately 13.5 Volts when the engine is running.
1
Figure 13
1. Battery
To test a gauge, use a commercial gauge tester. If a commercial gauge tester is not available, substitute a new
gauge or test the sending unit.
2
1
3
6
Figure 14
1. Oil pressure light
2. Charging light
3. Glow light
4. Hourmeter
5. Temperature gauge
6. Fuel level gauge
Hourmeter
Test the hourmeter by connecting a 12 volt battery so the
positive (+) battery terminal is connected to the positive
terminal on the hourmeter. Connect the negative () battery terminal to the negative () terminal on the hourmeter. The hour meter should move 1/10 of an hour in six
minutes as 12 VDC. is applied between the terminals.
Electrical System
Page 8 12
Testing
CAUTION
Make sure engine is cool before removing the
temperature switch.
1. Lower coolant level in the engine and remove the
temperature shutdown switch.
2. Put switch in a container of oil with a thermometer
and slowly heat the oil (Fig. 16).
Figure 15
1. Temp. shutdown switch
2. Thermostat housing
CAUTION
VOA
Figure 16
switch.
tighten.
Electrical
System
Page 8 13
Electrical System
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 from sparks.
Install an ohm meter between the terminal and base.
With arm completely down (empty position), resistance
should be 240260 ohms.
With arm completely up (full position), resistance should
be 2934 ohms.
Figure 17
1. Fuel gauge sender
Headlight Switch
The headlight switch is located on the control panel. This
rocker switch allows the headlights to be turned on and
off.
The switch terminals are marked as shown in Figure 19.
The circuitry of the headlight switch is shown in the chart
below. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
position. Verify continuity between switch terminals.
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
ON
2+3
5+6
OFF
1+2
4+5
Figure 18
1. Headlight switch
Figure 19
Electrical System
Page 8 14
Figure 20
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
OFF
2+3
5+6
MOMENTARY
ON
1+2
4+5
These diodes plug into the vehicle wiring harness at various locations (see appropriate vehicle electrical schematic in Chapter 11 Electrical Schematics).
3
1
Testing
The diodes can be individually tested using a digital
multimeter (diode test or ohms setting) and the table to
the right.
Figure 21
1. Diode
2. Male terminal
3. Female terminal
Multimeter
Black Lead ()
on Terminal
Continuity
Female
Male
YES
Male
Female
NO
Electrical
System
Multimeter
Red Lead (+)
on Terminal
Page 8 15
Electrical System
The diode assembly plugs into the vehicle wiring harness (see Workman 3100 electrical schematic in Chapter 11 Electrical Schematics).
Testing
Figure 22
The diode assembly can be tested using a digital multimeter (diode test or ohms setting) and the table to the
right.
1. Diode
2. Male terminal
3. Female terminal
Multimeter
Multimeter
Black Lead ()
Red Lead (+)
on
on
Terminal Blade Terminal Blade
Continuity
Male
Female
YES
Female
Male
NO
Figure 23
1. Rear PTO switch
Electrical System
Page 8 16
Battery Service
The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can
be prevented.
CAUTION
When working with batteries, use extreme caution to avoid slashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or
eyes. Always wear safety goggles and a face
shield when working with batteries.
1
Figure 24
1. Battery
Page 8 17
Electrical System
Electrical
System
E. Connect a battery load tester to the battery terminals following the manufacturers instructions.
Connect a digital multimeter to the battery terminals.
F. Apply a test load of one half the Cranking Performance (see Battery Specifications) rating of the battery for 15 seconds.
G. Take a voltage reading at 15 seconds, then remove the load.
H. Using the table below, determine the minimum
voltage for the cell temperature reading.
Minimum
Voltage
Battery Electrolyte
Temperature
9.5
60oF
15.6oC
9.4
50oF
10.0oC
9.3
40oF
4.4oC
9.1
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given
in Charging or until all cells specific gravity is 1.225
or greater with the difference in specific gravity between the highest and lowest cell less than 0.050. If
these charging conditions can not be met, replace
the battery.
9.6
30oF
1.1oC
8.9
20oF
6.7oC
8.7
10oF
12.2oC
8.5
0oF
17.8oC
CAUTION
Follow the manufacturers instructions when using a battery tester.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.4 VDC, recharge the battery.
B. If the battery has been charged, apply a 150 amp
load for 15 seconds to remove the surface charge.
Use a battery load tester following the manufacturers instructions.
Page 8 18
Battery
Reserve
Capacity
(Minutes)
50%
25%
0%
80 or less
3.8 hrs
@
3 amps
7.5 hrs
@
3 amps
11.3 hrs
@
3 amps
15 hrs
@
3 amps
81 to 125
5.3 hrs
@
4 amps
10.5 hrs
@
4 amps
15.8 hrs
@
4 amps
21 hrs
@
4 amps
126 to
170
5.5 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
12 hrs
18 hrs
24 hrs
@
@
@
@
10 amps 10 amps 10 amps 10 amps
CAUTION
CAUTION
Follow the manufacturers instructions when using a battery charger.
Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to
60_F (15.5_ C) before connecting to a charger.
1. If battery filler caps are removable, check the electrolyte level in each cell. If the level is below the tops of the
plates in any cell, fill all cells with distilled water so that
plates are just covered with electrolyte.
2. Determine the battery charge level from either its
open circuit voltage or specific gravity (if filler caps are
removable).
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
1.265
12.68
75%
1.225
12.45
50%
1.190
12.24
25%
1.155
12.06
0%
1.120
11.89
4. Following the manufacturers instructions, connect the charger cables to the battery. Make sure a good
connection is made.
5. Charge the battery following the manufacturers
instructions.
Page 8 19
Electrical System
Electrical
System
Headlight Replacement
Disassemble and assemble headlight as follows:
1
Figure 25
1. Front hood
2. Headlight
3. Headlight mount
1
2
3
4
Figure 26
1. Screw (2 used)
2. Lens
Electrical System
Page 8 20
3. Bulb
4. Gasket
Chapter 9
Hydraulic System
Table of Contents
SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . 25
General Precautions for Removing and Installing
Hydraulic System Components . . . . . . . . . . . . . 25
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 25
Gear Pump (Vehicles With Liquid Cooled
Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Gear Pump (Vehicles With Air Cooled Engine) . 27
Gear Pump Service Barnes Gear Pump) . . . . . . 28
Gear Pump Service (Casappa Gear Pump) . . 29.1
Lift Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lift Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . 34
Steering Control Valve Service . . . . . . . . . . . . . . . 36
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Steering Cylinder Service . . . . . . . . . . . . . . . . . . . 40
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . 44
Hydraulic Manifold (Optional High Flow
Hydraulic Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SAUER/DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Hydraulic
System
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . 6
Vehicle Hydraulic Schematic . . . . . . . . . . . . . . . . . . 6
High Flow Hydraulic Kit (Optional) Schematic . . . 7
HYDRAULIC CIRCUIT OPERATION . . . . . . . . . . . . . 8
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Raise and Lower Bed . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic Pressure Test Kit . . . . . . . . . . . . . . . . . . 10
Hydraulic Tester (Pressure and Flow) . . . . . . . . . 10
Hydraulic Test Fitting Kit . . . . . . . . . . . . . . . . . . . . . 11
Male Coupler (For Optional High Flow
Hydraulic Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Test No. 1: Gear Pump Flow and System Relief
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Test No. 2: Steering Control Valve and Steering
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test No. 3: Lift Cylinder Internal Leakage . . . . . . 20
Test No. 4: High Flow Hydraulic Kit (Optional)
Gear Pump Flow and Relief Pressure . . . . . . . 22
Page 9 - 1 Rev. D
-
Hydraulic System
Hydraulic System
Page 9 2
Specifications
Item
Description
Hydraulic Pump
Pump Performance
Hydraulic Oil
Reservoir (Transaxle)
Hydraulic Filter
Hydraulic
System
Page 9 3
Hydraulic System
General Information
Hydraulic Hoses
Hydraulic hoses are subject to extreme conditions such
as pressure differentials during operation and exposure
to weather, sun, chemicals, very warm storage conditions, or mishandling during operation or maintenance.
These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these
conditions than others. Inspect the hoses frequently for
signs of deterioration or damage.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings. This
can be done by observing the imprint on the hose. Use
two wrenches; hold the hose straight with one and tighten the hose swivel nut onto the fitting with the other.
WARNING
Before disconnecting or performing any work
on hydraulic system, relieve all pressure in
system. Stop engine; lower or support box
and/or other attachment(s).
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands,
to search for leaks. Hydraulic fluid escaping
under pressure can have sufficient force to
penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgically removed within a few hours by a doctor
familiar with this type of injury. Gangrene may
result from such an injury.
Body
Sleeve
Seal
5. Mark the nut and fitting body. Hold the body with a
wrench. Use another wrench to tighten the nut to the correct Flats From Finger Tight (F.F.F.T.). The markings on
the nut and fitting body will verify that the connection has
been tightened.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Final
Position
F.F.F.T.
0.75 + 0.25
0.75 + 0.25
0.75 + 0.25
1.00 + 0.25
0.75 + 0.25
0.75 + 0.25
Mark Nut
and Body
Extend Line
Finger Tight
Initial
Position
Hydraulic System
Page 9 4
Figure 3
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
NOTE: Installation torque values for nonadjustable fittings are listed in Figure 4. These torque values should
only be used when a fitting can be accessed with a socket. Use of an offset wrench (e.g. crowfoot wrench) will affect torque wrench accuracy and should not be used.
Installation Torque
F.F.F.T.
Fitting Size
10
12
16
Backup Washer
ORing
Figure 5
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn (Step
3).
7. Hold the fitting in the desired position with a wrench
and turn the jam nut with another wrench to the correct
Flats From Finger Tight (F.F.F.T.) (Step 4).
Step 3
Step 2
Step 4
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
Page 9 5
Hydraulic
System
Size
Step 1
Figure 6
Hydraulic System
Hydraulic System
Page 9 6
100 MESH
STRAINER
TRANSAXLE
RESERVOIR
10 MICRON
RETURN FILTER
W/25 PSI BYPASS
(6.36 CC/REV)
.769 ENGINE SPEED
PUMP
BARNES
.388 IN 3 /REV
STEERING UNIT
SAUER OSPM PB
PARKER
VY13 VALVE
TEXAS HYDRAULICS
STEERING CYLINDER
TEXAS HYDRAULICS
ROD .625 IN (15.9 MM)
BORE 1.750 IN (44.5 MM)
STROKE 5.56 IN (14.1 CM) 2WD
4.47 IN (11.4 CM) 4WD
Hydraulic Schematics
Hydraulic
System
IN TANK
SUCTION
STRAINER
100 MESH
Page 9 7
4 GALLON
RESERVOIR
OIL COOLER
RELIEF VALVE
2000 PSI
SOLENOID
ACTIVATED
BYPASS VALVE
RETURN FILTER
10 MICRON WITH
25 PSI BYPASS
HYDRAULIC
GEAR PUMP
.610 IN 3 /REV
(10 CC/REV)
.833 ENGINE SPEED
QUICK DISCONNECT
COUPLINGS
Hydraulic System
Steering Circuit
Left Turn
When a left turn is made with the engine running, the
turning of the steering wheel positions the spool valve so
that flow goes through the top of the spool. Flow entering
the steering control valve at the P port passes through
the rotary meter and is directed out the L port. Pressure
contracts the steering cylinder for a left turn. The rotary
meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel.
1800
PSI
STEERING CYLINDER
PISTON MOVEMENT
Right Turn
STEERING CYLINDER
PISTON MOVEMENT
STEERING CYLINDER
NO PISTON MOVEMENT
1800
PSI
1800
PSI
When the steering wheel is not being turned with the engine running (hydraulic pump being rotated), flow enters
the steering control valve at the P port and bypasses
the rotary meter and steering cylinder. Flow leaves the
control valve through the E port and is directed to the lift
valve.
STEERING
STEERING
STEERING
CONTROL
CONTROL
CONTROL
NEUTRAL POSITION
LEFT TURN
RIGHT TURN
Figure 7
Hydraulic System
Page 9 8
When the lift valve is in the center position, flow from the
gear pump bypasses the lift valve and returns through
the hydraulic oil filter and to the reservoir (transaxle).
Raise Bed
When the bed is to be raised (lift lever pulled rearward),
the lift valve spool directs flow out the A port of the lift
valve to the barrel end of the lift cylinders. Hydraulic
pressure against the cylinder pistons extends the cylinder shafts. At the same time, the pistons push the hydraulic fluid in the rod end of the lift cylinders out and
through the lift valve to the reservoir (transaxle).
PISTON MOVEMENT
PISTON MOVEMENT
LIFT VALVE
(IN RAISE POSITION)
RAISE BED
LIFT VALVE
(IN LOWER POSITION)
LOWER BED
Hydraulic
System
Figure 8
Page 9 9
Hydraulic System
Special Tools
Order these tools from your Toro Distributor.
Figure 9
Figure 10
Hydraulic System
Page 9 - 10
-
Rev. D
Figure 11
Figure 12
Hydraulic
System
1. Male coupler
Page 9 11
Hydraulic System
Troubleshooting
The cause of an improperly functioning hydraulic system
is best diagnosed with the use of proper testing equipment and a thorough understanding of the complete hydraulic system.
A hydraulic system with an excessive increase in heat or
noise is a potential failure. Should either of these conditions be noticed, immediately stop the vehicle, turn off
the engine, locate the cause of the trouble and correct
it before allowing the vehicle to be used again. Contin-
Problem
Possible Cause
Squealing noise.
Hydraulic lift valve held in raise or lower position (hydraulic oil flowing over relief valve).
Hydraulic System
Page 9 - 12
-
Problem
Possible Cause
Hydraulic
System
Page 9 - 13
-
Hydraulic System
Hydraulic System
Page 9 14
Testing
CAUTION
Failure to use gauges with recommended pressure (psi) rating as listed in test procedures
could result in damage to gauge and possible
personal injury from leaking hot oil.
Before Performing Hydraulic Tests
All obvious areas such as oil supply, filter, binding linkage, loose fasteners, or improper adjustments must be
checked before assuming that a hydraulic component is
the source of the problem being experienced.
Precautions For Hydraulic Testing
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved by stopping the engine,
rotating the steering wheel in both directions,
lowering or supporting the bed and operating
other hydraulic accessories.
Page 9 15
Hydraulic
System
Hydraulic System
STEERING CONTROL
L
P
STEERING
CYLINDER
T
TESTER
LIFT CYLINDERS
GEAR
PUMP
FILTER
STRAINER
LIFT VALVE
TRANSAXLE
RESERVOIR
Figure 13
1
2
Figure 14
1. Gear pump
2. Pressure hose
Hydraulic System
3. Suction hose
Page 9 16
3. Make sure that gear pump drive belt is adjusted properly (see Operators Manual).
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
IMPORTANT: Make sure that the oil flow indicator
arrow on the flow meter is showing that the oil will
flow from the pump, through the tester, and into the
hydraulic hose.
4. With the engine off, clean hose fitting and disconnect
the pressure hose from the gear pump (Fig. 14). Install
tester with pressure gauges and flow meter in series between the gear pump and the disconnected hose. Make
sure the tester flow control valve is open.
5. Make sure the hydraulic reservoir (transaxle) is full
after connecting the tester.
CAUTION
The engine must be running to perform hydraulic tests. To guard against possible personal injury, engage parking brake and keep clothing,
hands, feet, face and other parts of the body
away from fan and other moving parts.
E. Release accelerator pedal to allow engine to return to low idle and turn off vehicle. Record test results.
12.If relief pressure is incorrect, inspect for:
A. Slipping pump drive belt.
IMPORTANT: In this test, the flow tester is positioned before the relief valve. Pump damage can occur if the oil flow is fully restricted.
Page 9 17
Hydraulic
System
7. Start engine and adjust engine speed with accelerator pedal so pump speed is 2700 RPM (engine speed
approximately 3600 RPM). Verify pump speed with a
phototac.
Hydraulic System
STEERING CONTROL
(RIGHT TURN)
PLUG
L
P
STEERING
CYLINDER
T
LIFT CYLINDERS
GEAR
PUMP
FILTER
STRAINER
LIFT VALVE
TRANSAXLE
RESERVOIR
Figure 15
Hydraulic System
Page 9 18
WARNING
Keep body and hands away from disconnected
hoses and fittings that might eject hydraulic fluid
under high pressure. Use paper or cardboard,
not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force
to penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgically
removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
IMPORTANT: Do not turn steering wheel to the
left (counterclockwise) as system damage may
occur.
F. With the engine off, continue turning the steering
wheel to the right (clockwise) with the steering cylinder fully extended. Observe the open fitting on the
steering cylinder as the wheel is turned. If oil comes
out of the fitting while turning the steering wheel to the
right, the steering cylinder has internal leakage and
must be repaired or replaced.
G. Remove plug from the disconnected hydraulic
hose. Reconnect hose to the steering cylinder.
6. If steering problem exists and the steering cylinder,
gear pump flow and system relief pressure (see Test No.
1) tested acceptably, steering control valve requires service (see Steering Control Valve and Steering Control
Valve Service).
Hydraulic
System
Page 9 19
Hydraulic System
STEERING CONTROL
L
P
STEERING
CYLINDER
T
LIFT CYLINDERS
LIFT VALVE
(IN LOWER POSITION)
GEAR
PUMP
PLUG
FILTER
STRAINER
TRANSAXLE
RESERVOIR
Figure 16
Hydraulic System
Page 9 20
CAUTION
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
2. Remove all pressure from cylinder by fully retracting
it (i.e. put hydraulic lift lever in LOWER position).
Pressure is applied
to this port
Figure 17
Hydraulic
System
Page 9 21
Hydraulic System
TEST NO. 4: High Flow Hydraulic Kit (Optional) Gear Pump Flow and Relief Pressure
QUICK DISCONNECT
COUPLINGS
HYDRAULIC
GEAR PUMP
.610 IN 3/REV
.833 ENGINE
SPEED
TESTER
SOLENOID
ACTIVATED
BYPASS VALVE
(ENERGIZED)
RELIEF VALVE
2000 PSI
IN TANK
SUCTION
STRAINER
100 MESH
RETURN FILTER
10 MICRON WITH
25 PSI BYPASS
4 GALLON
RESERVOIR
OIL COOLER
Figure 18
Figure 19
1. Pressure coupler
Hydraulic System
2. Return coupler
Page 9 22
CAUTION
5. Make sure the Hydraulic Kit reservoir is full after connecting the tester.
C. Watch pressure gauge carefully while slowly closing the tester flow control valve until the relief valve
opens.
D. System pressure should be approximately 2000
PSI (137.9 Bar) as the relief valve lifts.
CAUTION
The engine must be running to perform hydraulic tests. To guard against possible personal injury, engage parking brake and keep clothing,
hands, feet, face and other parts of the body
away from fan and other moving parts.
E. Open tester flow control valve, release accelerator pedal to allow engine to return to low idle and turn
Kit switch OFF. Turn off vehicle. Record test results.
12.If relief pressure is incorrect, inspect for:
A. Slipping pump drive belt.
Hydraulic
System
Page 9 23
Hydraulic System
Hydraulic System
Page 9 24
1. Before removing any parts from the hydraulic system, park vehicle on a level surface, engage parking
brake, and stop engine. Remove key from the ignition
switch.
CAUTION
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
5. After disconnecting or replacing any hydraulic components, operate vehicle functions slowly until air is out
of system.
6. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in transaxle and
add correct oil if necessary.
3. Put caps or plugs on any hydraulic lines, hydraulic fittings, and components left open or exposed to prevent
contamination.
4. Put labels on disconnected hydraulic lines and hoses
for proper installation after repairs are completed.
5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal.
Mark parts if necessary to make sure they will be aligned
properly when reinstalling hydraulic hoses and tubes.
Page 9 - 25 Rev. D
-
Hydraulic
System
WARNING
Hydraulic System
ANTISIEZE
LUBRICANT
27 to 33 inlb
(3 to 3.7 Nm)
12
2
1
CAUTION
13
11
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
3
10
9
4
5
7
LOCTITE #242
130 to 160 inlb
(14.7 to 18.1 Nm)
Figure 20
1.
2.
3.
4.
5.
6.
7.
Gear pump
Pressure hose
Suction hose
Lock nut (4 used)
Cap screw (4 used)
Pump pulley
Flat washer
8.
9.
10.
11.
12.
13.
Lock nut
Cap screw (4 used)
Lock washer (4 used)
Fan
Mount plate
Set screw
1
2
Figure 21
1. Gear pump
2. Pressure hose
Page 9 26
3. Suction hose
9
10
11
CAUTION
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
12
ANTISIEZE
LUBRICANT
5
3
2
130 to 160 inlb
(14.7 to 18.1 Nm)
Figure 22
5. Remove gear pump from mount using Figure 22 as
a guide.
Installation (Fig. 22)
1. Install gear pump to mount using Figure 22 as a guide
and using the following instructions:
1.
2.
3.
4.
5.
6.
Drive belt
Lock nut
Flat washer
Pump pulley
Cap screw
Carriage screw
7.
8.
9.
10.
11.
12.
Mount
Suction hose
Square key
Gear pump
Lock nut (2 used)
Pressure hose
Hydraulic
System
Page 9 27
Hydraulic System
18
17
20
23
12
13
14
15
16
11
19
10
9
8
6
12
16
11
21
12
22
1.
2.
3.
4.
5.
6.
7.
8.
Retaining ring
Shaft seal
Spacer
Crescent ring
Square key
Drive shaft
Shear pin
Stator
9.
10.
11.
12.
13.
14.
15.
16.
Figure 23
Seal plate
Wear plate
Gear
Bearing
Pressure plate
Back-up seal
Pressure plate seal
Dowel pin
Before disassembling gear pump, plug ports, wash exterior of pump with cleaning solvent and dry pump thoroughly.
Shaft Seal Replacement (Fig. 23)
Hydraulic System
17.
18.
19.
20.
21.
22.
23.
Page 9 - 28 Rev. D
-
4. Install shear pin (Item 7), then apply Dexron III ATF
to remaining gear and install to drive shaft (Item 6) maintaining the original timing and locations.
5. Apply Dexron III ATF to pressure plate seal (Item 15),
backup seal (Item 14) and pressure plate (Item 13),
then install into gear end housing.
6. Install dowel pins (Item 16). Apply Dexron III ATF to
seal plate (Item 9) and wear plate seal (Item 21), then
install. Assemble gear end housing (Item 17) to stator
(Item 8).
7. Install four (4) cap screws (Item 18) and tighten in a
crossing pattern from 9.5 to 12.5 ftlb (13 to 17 Nm).
Hydraulic
System
5. Inspect square key (Item 5), shear pin (Item 7), ball
key (Item 23) and keyways in shafts for wear or damage.
Replace parts as necessary.
Page 9 29
Hydraulic System
4
13
3
1
14
16
5
10
12
17
15
11
220 in-lb
(25 N-m)
Figure 23.1
1.
2.
3.
4.
5.
6.
Retaining ring
Shaft seal
Front cover
Dowel pin
O-ring (2 used)
Back-up seal
7.
8.
9.
10.
11.
12.
Pressure seal
Front thrust plate
Drive shaft
Idler shaft
Body
Rear thrust plate
13.
14.
15.
16.
17.
Pressure seal
Back-up seal
Rear flange
Lock washer (4 used)
Screw (4 used)
MARKER LINE
Figure 23.2
IMPORTANT: Note position of the open and closed
side of the thrust plates before removing. Also,
identify thrust plates (front and rear) with a marker
for proper assembly.
8. Carefully remove rear thrust plate, idler shaft, drive
shaft and front thrust plate from the front cover.
9. Remove and discard O--rings, back--up seals and
pressure seals from pump.
Inspection
1. Remove any nicks and burrs from all parts with
emery cloth.
CAUTION
Figure 23.3
1.
2.
3.
4.
Gear teeth
Gear face edge
2. Clean all parts with solvent. Dry all parts with compressed air.
Hydraulic System
Hydraulic
System
13.Install the four (4) screws (item 17) with lock washers
and hand tighten.
Hydraulic System
Hydraulic
System
Hydraulic System
Lift Valve
20
17
18 17
16
RIGHT
21
19
FRONT
5
12 10
15
10 11
8
9
14
13
6
4
5
Figure 24
1.
2.
3.
4.
5.
6.
7.
Lift valve
Oring
Tee fitting
Hyd. hose (steering circuit return)
Oring
Hyd. hose (return to hydraulic filter)
Flange nut
Hydraulic System
8.
9.
10.
11.
12.
13.
14.
Lift lever
Clevis pin
Hairpin
Jam nut
Link rod
Clevis
Hyd. hose (to male quick fitting)
Page 9 30
15.
16.
17.
18.
19.
20.
21.
3
4
CAUTION
Figure 25
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
1. Lift lever
2. Clevis
3. Link rod
4. Lift valve spool
Hydraulic
System
Page 9 31
Hydraulic System
9
10
11
12
10
13
14
Figure 26
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
Spool
Oring
Spring retainer
Spring
Spacer
Spool retaining ring
Retaining ring
Hydraulic System
Page 9 32
Hydraulic
System
Page 9 33
Hydraulic System
RIGHT
20 to 26 ft-lb
(28 to 35 N-m)
10
FRONT
12
11
CONTROL VALVE PORTS
Anti-seize
Lubricant
13
4
9
FRONT OF VEHICLE
5
6
7
20
19
14
15
1.
2.
3.
4.
5.
6.
7.
16
17
18
Hex nut
Lock washer
Steering wheel
Steering control valve
Hyd hose (to control valve P port)
Hyd hose (to control valve E port)
Hyd hose (to control valve T port)
8.
9.
10.
11.
12.
13.
14.
Figure 27
Hydraulic System
15.
16.
17.
18.
19.
20.
Page 9 - 34
-
Rev. C
CAUTION
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
6
5
4
2
Figure 28
1.
2.
3.
4.
Hood
Screw (7 used)
Well nut (7 used)
Flat washer (2 used)
5.
6.
7.
8.
5
1
Figure 29
1. Hyd hose to L port
2. Hyd hose to R port
3. Hyd hose to P port
Page 9 35
Hydraulic
System
Hydraulic System
10
4
3
11
1
12
22
13
14
15
21
13
16
20
13
17
18
20 to 24 ftlb
(27 to 33 Nm)
19
Figure 30
1.
2.
3.
4.
5.
6.
7.
8.
Sleeve
Cross pin
Ring
Spool
Bearing assembly
Shaft seal
Ball stop
Ball
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Outer gearwheel
End cover
Oring (5 used)
Screw/fitting (ports L, R, T)
Screw/fitting (ports P and E)
P port check ball
Spring set
Hydraulic System
Page 9 36
Hydraulic
System
Page 9 37
Hydraulic System
Steering Cylinder
14
12
15
1
2
3
3
13
12
11
10
9
RIGHT
FRONT
Figure 31
1.
2.
3.
4.
5.
Steering cylinder
Retaining ring
Grease fitting
90o hydraulic fitting
Hyd. hose (from steering valve R)
Hydraulic System
6.
7.
8.
9.
10.
Page 9 38
11.
12.
13.
14.
15.
Dust seal
Cotter pin
Ball joint
Slotted hex nut
Ball joint
CAUTION
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
3. Label and disconnect hydraulic hoses from steering
cylinder. Install caps or plugs in hoses to prevent contamination and leakage of hydraulic oil. Install plugs in
cylinder ports.
4. Remove steering cylinder from vehicle using Figures
31 and 32 as guides.
2
6
Figure 32
1.
2.
3.
4.
O-ring
45o hydraulic fitting
O-ring
O-ring
5.
6.
7.
8.
Figure 33
3. Replace o--rings on hydraulic hoses and fittings. Remove caps and plugs from hoses and fittings. Connect
hydraulic hoses to steering cylinder.
4. Check oil level in transaxle (see Operators Manual).
Add Dexron III ATF if necessary.
5. Start the engine, operate at idle speed and rotate the
steering wheel in both directions until air is out of hydraulic system.
6. Stop the engine and check oil level in transaxle (see
Operators Manual). Add Dexron III ATF if necessary.
Hydraulic
System
Page 9 - 39 Rev. A
-
Hydraulic System
10
11
30 to 36 ftlb
(41 to 49 Nm)
6
2
12
13
14
Figure 34
1.
2.
3.
4.
5.
Lock nut
Wear ring
Seal
Oring
Piston
6.
7.
8.
9.
10.
11.
12.
13.
14.
Head
Oring
Backup ring
Retaining ring
Seal
Wiper
Barrel
Shaft
Oring
Spanner wrench
2. Before disassembling cylinder, plug ports, wash exterior with cleaning solvent and dry thoroughly.
IMPORTANT: Use caution when using a vise to avoid
scratching or distorting any parts.
Retaining ring
Figure 35
Removing retaining ring
Hydraulic System
Page 9 40
Inspection
1. Inspect head (Item 6), piston (Item 5) and shaft (Item
13) for excessive scoring, pitting or wear. Replace any
worn or damaged parts.
Spanner wrench
Retaining ring
(Offset end against left
side of barrel groove
after installing)
Figure 36
Installing retaining ring
3. Coat all cylinder parts with clean Dexron III ATF. Slide
shaft assembly and head into barrel, being careful not to
damage seals.
Hydraulic
System
Page 9 41
Hydraulic System
Lift Cylinder
12
1
11
RIGHT
FRONT
10
2
4
8
3
2
6
5
Figure 37
1.
2.
3.
4.
Box frame
Oring
Hydraulic fitting
Oring
Hydraulic System
5.
6.
7.
8.
Hydraulic hose
Lift cylinder (LH shown)
Hydraulic hose
Cotter pin
Page 9 42
9.
10.
11.
12.
Engine support
Frame rail (LH shown)
Clevis pin
Lynch pin
CAUTION
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
Hydraulic
System
Page 9 43
Hydraulic System
60 to 75 ftlb
(81 to 102 Nm)
11
10
6
3
12
13
14
Figure 38
1.
2.
3.
4.
5.
Lock nut
Wear ring
Seal
Oring
Piston
6.
7.
8.
9.
10.
11.
12.
13.
14.
Head
Oring
Backup seal
Retaining ring
Seal
Wiper
Barrel
Shaft
Oring
Spanner wrench
2. Before disassembling cylinder, plug ports, wash exterior with cleaning solvent and dry thoroughly.
IMPORTANT: Use caution when using a vise to avoid
scratching or distorting any parts.
Retaining ring
Figure 39
Removing retaining ring
Hydraulic System
Page 9 44
Inspection
1. Inspect head (Item 6), piston (Item 5) and shaft (Item
13) for excessive scoring, pitting or wear. Replace any
worn or damaged parts.
Spanner wrench
Retaining ring
(Offset end against left
side of barrel groove
after installing)
Figure 40
Installing retaining ring
3. Coat all cylinder parts with clean Dexron III ATF. Slide
shaft assembly and head into barrel, being careful not to
damage seals.
Hydraulic
System
Page 9 45
Hydraulic System
RIGHT
FRONT
6
1
3
4
CAUTION
5
4
3
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
3. Label and disconnect hydraulic hoses from hydraulic
manifold. Install caps or plugs in hoses to prevent contamination and leakage of hydraulic oil. Install plugs in
manifold ports.
Figure 41
1.
2.
3.
4.
Hydraulic manifold
Oring
Hydraulic fitting
Oring
1
50 to 55 inlb
(5.6 to 6.2 Nm)
5. Cap screw
6. Lock nut (2 used)
7. Engine mount bracket
3
2
2. Replace orings on hydraulic hoses and fittings. Remove caps and plugs from hoses and fittings. Connect
hydraulic hoses to manifold.
30 to 35 ftlb
(41 to 47 Nm)
30 to 35 ftlb
(41 to 47 Nm)
Figure 42
1.
2.
3.
4.
Retaining nut
Solenoid seal
Solenoid coil
Solenoid cartridge valve
5.
6.
7.
8.
Seal kit
Manifold body
Seal kit
Relief valve cartridge
Page 9 46
CAUTION
Use eye protection such as goggles when using
compressed air.
Hydraulic
System
Page 9 47
Hydraulic System
Hydraulic System
Page 9 48
Page 10 1
12
14
16
28
30
31
32
Front Wheel
Drive (4WD)
Chapter 10
Specifications
Item
Description
Front Differential
Front Brakes
Bidirectional Clutch
Overrunning type
Page 10 2
have enough traction to move the vehicle without slipping. Once this occurs, the system stops delivering power to the front wheels and the handling characteristics
become similar to that of a two wheel drive vehicle. The
four wheel drive system functions in both forward and
reverse. When front wheels are turned, the rear wheels
will slip slightly more before power is delivered to the
front wheels.
Page 10 3
Front Wheel
Drive (4WD)
General Information
45 to 65 ftlb
(61 to 88 Nm)
40 to 60 ftlb
(54 to 81 Nm)
LOCTITE #680
3
4
22
SMALL SPACER
21
8
9
10
11
12
13
16
CUP
20
ACCESS HOLE
19
CONE
18
15
23
RIGHT
17
24
16
LOCTITE #271
25
FRONT
14
26
27
24
28
APPLY GREASE
TO SPLINES
Figure 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Flat washer
Brake hose retainer clip
Brake hose bracket
Constant velocity (CV) joint assembly
Differential
Bearing assembly
Axle housing (RH shown)
Brake plate plug
Front brake assembly (RH shown)
20.
21.
22.
23.
24.
25.
26.
27.
28.
Disassembly (Fig. 1)
5. Pull stub axle (4) and outer bearing cone from the
axle housing.
8. Remove cotter pin and slotted hex nut from the tie
rod end assembly. Separate tie rod end from the axle
housing.
80 to 90 ftlb
(108 to 122 Nm)
5
2
B. Remove cap screw (6) and lock nut (5) from axle
housing.
6
9
10
Figure 2
Inspection (Fig. 1)
IMPORTANT: If any part of a bearing assembly (16)
needs replacement, replace bearings as a matched
set.
1. If any foreign material is in the bearing, clean bearing
and determine source of the material. Replace bearings
(16) if any of the following conditions occur (Fig. 3):
1.
2.
3.
4.
5.
Axle housing
Cotter pin
Slotted hex nut
Upper ball joint
Lock nut
6.
7.
8.
9.
10.
CUP
SEAL
A. Spalling or pitting on roller or cone contact surfaces. Corrosion that can not be cleaned up with light
polishing.
ROLLER
CONE
CAGE
Cap screw
Lower ball joint
CV joint
Ball joint seal
Inner bearing cone
Figure 3
Assembly (Fig. 1)
1. If hex bolts and lock washers were removed from the
stub axle:
A. Thoroughly clean threads of hex bolt and stub
axle. Apply Loctite #680 (or equivalent) to threads of
hex bolt closest to bolt head.
B. Install hex bolt with lock washer into stub axle.
Torque bolt from 40 to 60 ftlb (54 to 81 Nm).
Page 10 5 Rev. B
Front Wheel
Drive (4WD)
3. Pack both bearing cones with Mobile high temperature grease or equivalent. If the outer bearing cone was
removed from the stub axle, slide wide end of new bearing cone onto the shaft of the stub axle and press cone
onto the shaft (Fig. 4).
4. Position front brake assembly (19) to the axle housing. Secure brake assembly to the axle housing with four
cap screws (8) and lock washers (9).
5. Insert shaft of the stub axle into the axle housing.
Slide small spacer onto the shaft, then slide wheel bearing spacer onto the shaft.
PRESS BEARING
CONE TO HERE.
STUB AXLE
Page 10 6
Figure 4
Rev. B
Front Wheel
Drive (4WD)
Page 10 7
Front Brake
45 to 65 ftlb
(61 to 88 Nm)
40 to 60 ftlb
(54 to 81 Nm)
LOCTITE #680
3
4
23
SMALL SPACER
22
11
10
12
14
13
15
17
21
20
ACCESS HOLE
16
19
18
17
RIGHT
LOCTITE #271
FRONT
APPLY GREASE
TO SPLINES
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Removal (Fig. 5)
1. Park vehicle on a level surface. Make sure engine is
off. Engage parking brake and block rear wheels.
2. Partially loosen front wheel lug nuts. Jack up and secure front wheel off the ground (see Jacking Instructions
in Operators Manual). Remove wheel nuts and wheel
from the brake drum.
NOTE: If the brake drum sticks to the brake shoes during removal, loosen brake shoes from the drum by turning bolt adjuster through access hole in brake drum.
3. Remove brake drum from hub.
4. Remove hex flange nut (23) and hardened washer
(22) from the threaded shaft of the CV joint. Discard nut.
Front Wheel Drive (4WD)
17.
18.
19.
20.
21.
22.
23.
Bearing assembly
Axle housing (RH shown)
Brake plate plug
Front brake assembly (RH shown)
Wheel bearing spacer
Hardened washer
Hex flange nut
5. Pull stub axle and outer bearing cone from the axle
housing and the splined end of the CV joint. Make sure
wheel bearing spacer and small spacer come out with
the stub axle.
NOTE: It may be necessary to remove the brake assembly from the axle housing for servicing some components such as the brake cylinder assembly.
6. If necessary, remove brake assembly as follows:
A. Disconnect brake tube (10) from the brake assembly. Plug brake tube to prevent contaminants
from entering brake system.
B. Remove brake assembly from the axle housing
by removing the four cap screws (8) and lock washers (9) from the housing.
Page 10 8
Rev. B
Page 10 9 Rev. B
Front Wheel
Drive (4WD)
Installation (Fig. 5)
49 to 97 inlb
(5.5 to 11 Nm)
13
26
25
11
6
9
12
10
10
24
12
11
14
16
17
18
21
13
15
27
19
20
23
22
Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Ltype seal
Piston
Dust cover
Brake shoe
Upper shoe spring
Lower shoe spring
Female push rod
Bolt adjuster
Adjuster sleeve
19.
20.
21.
22.
23.
24.
25.
26.
27.
Pawl
Adjuster spring
Pawl pin
Hold down washer (2 used)
Hold down spring (2 used)
Pipe guide
Inspection plug
Hold down pin (2 used)
Adjuster assembly
Page 10 10
Front Wheel
Drive (4WD)
Figure 7
2. If the boot is cracked or torn, or has any holes or
loose clamps, remove CV joint (see Constant Velocity
Joint in this section) and replace boot.
1. Inboard boot
2. Outboard boot
3. Differential
Test CV Joint
1. Test drive vehicle on a smooth surface to verify CV
joint problem.
2. Accelerate or backup 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
up into a turn.
3. Accelerate vehicle quickly and straight ahead. Vibration or shudder indicates a worn or sticking inboard CV
joint.
4. Accelerate vehicle at an angle over a ramp or up a
hill. A clunking noise indicates a worn inboard CV joint.
5. If any CV joint components are worn or damaged, the
CV joint assembly must be replaced.
Page 10 11
45 to 65 ftlb
(61 to 88 Nm)
2
3
4
22
21
8
9
10
11
12
13
16
CUP
20
CONE
19
14
18
15
23
RIGHT
17
24
LOCTITE #271
25
FRONT
16
26
27
APPLY GREASE
TO SPLINES
24
28
Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
Flat washer
Brake hose retainer clip
Brake hose bracket
Constant velocity (CV) joint assembly
Differential
Bearing assembly
Axle housing (RH shown)
Brake plate plug
Front brake assembly (RH shown)
Page 10 12
20.
21.
22.
23.
24.
25.
26.
27.
28.
LEVERAGE
POINT
LEVERAGE
POINT
Figure 9
IMPORTANT: With damaged CV joints, there is the
possibility that the wheel bearings may be damaged
as well. It is recommended that the wheel bearings
be inspected when CV joints are replaced.
1. CV joint
2. Front differential
Page 10 13
Front Wheel
Drive (4WD)
Removal (Fig. 8)
Front Differential
1
RIGHT
4
FRONT
3
15
25
24
7
22
19
4
38
35
16
16
6
14
17
18
6
28
4
4
18
18
29
13
19
17
34 15
11
10 12
32
26
17
37
5
33
18
36
21
23
27
30
20
31
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Grease fitting
Retaining ring
Upper control arm
Flange bushing
Slotted hex nut
Lock nut
Ball joint seal
Lower ball joint
Brake hose retainer
Cap screw
Brake hose bracket
Lock nut
Rclamp
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
Page 10 14
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
CAUTION
Support front differential during installation to
prevent personal injury from falling and damage
to the differential.
1. Secure front differential to the differential front bracket with three cap screws (28) and lock washers (29).
2. Secure differential rear mount (21) to frame with cap
screws (19), snubbing washers (18), mount assemblies
(17), and lock nuts (6).
3. Secure front differential to differential rear mount
with four cap screws (23) and lock washers (22).
4. Reconnect front brake lines and clamps. Reposition
cables.
CAUTION
Support front differential during removal to prevent personal injury from falling and damage to
the differential.
6. Remove four cap screws (23) and lock washers (22)
securing the front differential to the differential rear
mount (21).
7. Remove differential rear mount (21) from frame by
removing both lock nuts (6) and cap screws (19). Locate
and remove mount assemblies (17) and snubbing
washers (18).
5. Reinstall differential drive shaft to the front differential flange (see Differential Drive Shaft Installation).
6. Reinstall both CV joints to the front differential (see
Constant Velocity (CV) Joint Assembly Installation).
7. Make sure front differential drain plug is installed
properly. Fill front differential with oil (see Operators
Manual).
8. Bleed front brakes (see Bleeding the Brakes in Service and Repairs section of Chapter 7 Chassis).
Page 10 15
Front Wheel
Drive (4WD)
75 to 90 ftlb
(102 to 122 Nm)
15 to 20 ftlb
(20 to 27 Nm)
20 to 25 ftlb
(27 to 33 Nm)
16
14
30 to 45 ftlb
(41 to 61 Nm)
12
15
19
13
20
22
23
21
24
BEARING CAP
11
7
6
4 5
18
17
10
9
BEARING CRADLE
8
29 30
BEARING CAP
25
28
6
7
26
58 to 65 ftlb
(79 to 88 Nm)
32
34
27
33
31
Figure 11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Vent
Front housing
Alignment pin (2 used)
Thrust washer
Side bevel gear
Pinion gear
Thrust washer
Pinion gear
Bearing cone
Bearing cup
Cap screw (4 used)
Plug (2 used)
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Page 10 16
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Bearing spacer
Pinion shaft
Cap screw (5 used)
Differential case
Roll pin
Bearing cone (2 used)
Bearing cup (2 used)
Shim
Ring gear
Oil seal (2 used)
Needle bearing (2 used)
Front Wheel
Drive (4WD)
Figure 12
IMPORTANT: The bearing caps are marked for reassembly. Place caps in a safe place to avoid damaging their machined surface. Place caps back in the
same position during reassembly.
4. Remove four cap screws (11) and both bearing caps
from the bearing cradles (Fig. 14).
IMPORTANT: Keep mating bearing bearing cups
(30) with matching bearing cups (30) and bearing
caps.
5. Remove differential gears from the carrier assembly
by using two wooden handles under the differential case
(27) to pry up the case and gears (Fig. 15).
Figure 13
Figure 14
Figure 15
Page 10 17
Figure 16
IMPORTANT: Avoid damaging gear teeth when removing the gear ring (32) from the differential case
(27).
9. Remove five cap screws (26) from the differential
case (27) and gear ring (32). Drive ring gear off the differential case using a hard wood block and a hammer
(Fig. 19).
Figure 17
Figure 18
Figure 19
Front Wheel Drive (4WD)
Page 10 18
Front Wheel
Drive (4WD)
NOTE: Remove bearing cones (29) from the differential case only if they need replacing (see Inspection).
Retain shims (31) for reassembly of new bearing cones.
10.Remove bearing cone (29) from the differential case
(27) with a puller. Make sure puller is inserted into the
indentations on the differential case (Fig. 20).
IMPORTANT: Make sure shims (21) are kept after
they are removed from the carrier assembly (15).
11. Pull pinion gear shaft (8) and bearing cone (9) from
the carrier assembly (15). If necessary, press pinion
gear shaft out of the carrier housing. Remove oil seal
(20) and discard it. Remove bearing cone (22), shims
(21), and spacer (24) from the carrier housing(15) (Fig.
21).
Figure 20
Figure 21
Figure 22
Figure 23
Workman 4000 Series
Page 10 19
Figure 24
Figure 26
Figure 27
Front Wheel Drive (4WD)
Page 10 20
Front Wheel
Drive (4WD)
IMPORTANT: If any part of a bearing needs replacement, both bearing cone and cup must be replaced.
5. Replace bearing cones (9, 22, or 29) and corresponding bearing cups (10, 23, or 30) if any of the following conditions occur (Fig. 30 and 31):
A. Spalling or pitting on roller or cone contact sur
polishing.
ken.
Figure 29
C. Peeling, gouges, or nicks inside the cup or on roll
cups.
BEARING
CONE
Figure 30
BEARING
CUP
Figure 31
Workman 4000 Series
Page 10 21
PINION
SHAFT (25)
PINION
GEAR (6)
THRUST
WASHER (7)
DIFFERENTIAL
CASE (27)
THRUST
WASHER (4)
SIDE BEVEL
GEAR (5)
SHIM (31)
BEARING
CAP
BEARING
CRADLE
BEARING
CONE (29)
BEARING
CUP (30)
3.750 INCH
BEARING
CUP (10)
SHIMS (14)
BEARING
SPACER (24)
SHIMS (21)
BEARING
CONE (22)
BEARING
CUP (23)
COUPLER
FLANGE (19)
OIL SEAL (20)
WASHER (17)
PERMATEX
LOCK NUT (18)
Figure 32
NOTE: In Figure 32, numbers in parentheses ( ) correspond to the reference numbers in Figure 11.
Page 10 22
The ring gear (32) and pinon gear (8) are supplied as a
matched set. Both gears are etched for verification with
matching numbers. If a new gear set is being used,
verify that the matching numbers are the same on both
the ring and pinion gear before assembling the front differential (Fig. 33).
Front Wheel
Drive (4WD)
SHIMMING
DIMENSION
MATCHING
NUMBERS
The distance from the center line of the ring gear to the
bottom of the pinion gear teeth is 3.750 inches (5.525
cm). This distance represents the best running position
for the gear set (Fig. 32).
On the end of each pinion gear, there is an etched number indicated by plus (+), minus (), or zero (0). This
number indicates a shimming dimension for the best
running position of the gear set. This dimension is controlled by shimming between the the bearing cup (10)
and the carrier assembly (15) (Fig. 33).
For example: If a pinion gear shaft is etched +4, this pinion would require 0.004 inch less shims than a pinion
etched 0. By removing shims, the running position is
increased to 3.754 inches. The +4 represents a 0.004
inch increase in the running position. On the other hand:
If a pinion gear shaft is etched 4, this pinion would require 0.004 inch more shims than a pinion etched 0. By
adding shims, the running position is decreased to
3.746 inches. The 4 represents a 0.004 inch decrease
in the running position.
Figure 33
When reusing an old ring gear and pinion gear shaft set,
measure the old shim pack thickness and build a new
shim pack to the same thickness. Measure each shim
separately with a micrometer. Add each shim thickness
to get the total shim pack thickness.
If a new gear set is being used, note the (+) or () etching
on both the old and new pinion gear shaft. Change the
thickness of the new shim pack to compensate for the
difference between these two dimensions.
For example: If the old pinion gear shaft reads + 2 and
the new gear is 2, add 0.004 inch of shims to the old
shim pack (see Table 1).
NOTE: All shims (14, 21, and 31) are available in thicknesses of 0.003, 0.005, 0.010, and 0.030 inch.
Old Pinion
Marking
+1
+2
+3
+4
+4
+0.008
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
+3
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0.001
+2
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0.001
0.002
+1
+0.005
+0.004
+0.003
+0.002
+0.001
0.001
0.002
0.003
+0.004
+0.003
+0.002
+0.001
0.001
0.002
0.003
0.004
+0.003
+0.002
+0.001
0.001
0.002
0.003
0.004
0.005
+0.002
+0.001
0.001
0.002
0.003
0.004
0.005
0.006
+0.001
0.001
0.002
0.003
0.004
0.005
0.006
0.007
0.001
0.002
0.003
0.004
0.005
0.006
0.007
0.008
Table 1
1. If the bearing cone (9) was removed, press new
bearing cone onto the shaft of the pinion gear (8) (Fig.
34).
Figure 34
Workman 4000 Series
Page 10 23
Figure 35
Figure 36
E. Now determine the difference between the measurement taken in a step C and the value calculated
in step D. This difference is the new shim thickness.
F. Remove bearing cup from the carrier assembly.
G. Install required shim thickness and bearing cup
into the carrier assembly.
IMPORTANT: The pinion gear (8) and ring gear (32)
are supplied only as a matched set. Matching numbers on both gears are etched for verification. When
using a new gear set, make sure the matching numbers are verified before using (Fig. 33).
Figure 37
5. Install pinion gear (8) and bearing cone (9) into the
carrier assembly (15). Place bearing spacer (24), shims
(21), and bearing cone (22) on to the shaft of the pinion
gear (Fig. 38).
Figure 38
Front Wheel Drive (4WD)
Page 10 24
Front Wheel
Drive (4WD)
6. Verify bearing preload and pinion gear shaft (8) rotation as follows:
A. Install coupler flange (19), washer (17), and lock
nut (18) to the shaft of the pinion gear. Torque lock
nut from 75 to 90 ftlb (102 to 122 Nm).
B. The torque required to rotate the shaft of the pinion gear should be from 7 to 12 inlb (8 to 14 kgcm)
(Fig. 39).
C. If the torque required to rotate the shaft of the pinion gear is more than specified in step B, remove lock
nut, washer, coupler flange, bearing cone (22), and
shim (21) from the shaft of the pinion gear. Increase
shim thickness to decrease bearing preload.
Figure 39
Figure 40
SPLINES
G. If the torque required to rotate the shaft of the pinion gear shaft is as specified in step B or F, remove
lock nut, washer, coupler flange, bearing cone (22)
from the shaft of the pinion gear. Press new oil seal
(20) into the carrier assembly (15) (Fig. 40).
H. Apply No. 2 Permatex sealant or equivalent to the
splines of the pinion gear. Make sure not to get
sealant on the oil seal (20) (Fig. 41).
I. Install flange coupler, washer, and lock nut back
onto the pinion gear. Torque lock nut from 75 to 90
ftlb (102 to 122 Nm).
Figure 41
Page 10 25
Figure 43
Figure 44
IMPORTANT: The bearing caps are marked for identification. Place caps back in the same position during reassembly (Fig. 46).
11. Secure bearing caps to their original positions on the
bearing cradles with four cap screws (11). Torque cap
screws from 30 to 45 ftlb (41 to 61 Nm) (Fig. 46).
Figure 45
MARKING
MARKING
Figure 46
Front Wheel Drive (4WD)
Page 10 26
Front Wheel
Drive (4WD)
Figure 47
Figure 48
FLANGE
SURFACE
FLANGE
SURFACE
Figure 49
Figure 50
Page 10 27
FILL PLUG
DRAIN PLUG
Figure 51
PROFILE
TOP LAND
TOE
LENGTHWISE
BEARING
ARC
Toe - the portion of the tooth surface at the end towards the center.
HEEL
1. Paint the teeth of the ring gear, both drive and coast
side, with a gear marking compound, such as DyKemR
Steel Blue.
2. While applying a light load to the ring gear, rotate the
pinion gear until the ring gear has made one complete
revolution. Both the drive side pattern and the coast side
pattern on the ring gear should be at the toe portion of
the tooth (Fig. 53).
Figure 52
RING GEAR
DRIVE SIDE
RING GEAR
COAST SIDE
Heel
Heel
Toe
Toe
Study the patterns in the following illustrations and correct engagement as necessary.
NOTE: When making changes, note that two variables
are involved. Example: If you have the backlash set correctly to specifications and you change the pinion position shim, you may have to readjust backlash to the
correct specification before rechecking the pattern.
Figure 53
Page 10 28
Heel
Heel
Toe
High backlash is corrected by moving the ring gear closer to the pinion. Low backlash is corrected by moving the
ring gear away from the pinion. These corrections are
made by switching shims from one side of the differential
case to the other.
Example 1: Backlash correct. Thicker pinion position
shims required (Fig. 54).
RING GEAR
COAST SIDE
RING GEAR
DRIVE SIDE
Toe
Figure 54
Heel
Toe
RING GEAR
COAST SIDE
RING GEAR
DRIVE SIDE
Heel
Toe
RING GEAR
COAST SIDE
RING GEAR
DRIVE SIDE
Heel
Heel
Toe
Toe
Figure 56
toe.
heel.
the heel.
Page 10 29
Front Wheel
Drive (4WD)
1
6
SNAP RING
SNAP RING
3
Figure 57
1. Flange yoke
2. Cross and bearing kit
3. Tube yoke
4. Slip yoke
5. Grease fitting
6. Seal
7. Socket head screw (6 used)
Removal
1. Park vehicle on a level surface. Make sure engine is
off. Engage parking brake and block rear wheels.
2. Jack up and secure front wheels off the ground (see
Jacking Instructions in Operators Manual).
2
WARNING
Figure 58
1. Flange yoke
2. Socket head screw
3. Front differential
Figure 59
1. Slip yoke
2. Clutch shaft
Page 10 30
3. Bidirectional clutch
Front Wheel
Drive (4WD)
IMPORTANT: Yokes must be supported when removing and installing bearings to prevent damage.
Figure 60
1. Flange yoke
2. Cross and bearing kit
led bearing.
snap ring.
cups.
Page 10 31
Bidirectional Clutch
14
13
CAGE AND ROLLER ASSEMBLY
10
11
12
9
8
7
4
6
19
5
2
15
18
16
17
Figure 61
1.
2.
3.
4.
5.
6.
7.
Clutch shaft
Seal plug
Retaining ring
Ball bearing
Housing and race
Garter gear
Roller (6 used)
8.
9.
10.
11.
12.
13.
Cam
Thrust bearing
Thrust washer
Spring
Cage
Oil seal
14.
15.
16.
17.
18.
19.
Adapter plate
Screw (4 used)
Lock washer (6 used)
Hex socket head screw (6 used)
Differential drive shaft
Front drive shaft (transaxle)
6. Remove seal plug (2) from the housing and race (5).
Discard seal plug.
7. Remove retaining ring (3) from the transaxle front
drive shaft (19) using a snap ring pliers. Discard snap
ring if it is cracked, distorted, or bent.
Front Wheel Drive (4WD)
2. Pull ball bearings (4) and/or oil seal (13) if they require replacement (see Inspection).
Page 10 32
Front Wheel
Drive (4WD)
Figure 62
polishing is present.
Figure 64
1. Thrust bearing
2. Cam
Figure 65
Workman 4000 Series
Page 10 33
Figure 66
1. Garter spring
2. Cage
3
2
7. If the oil seal (13) was removed, press new seal into
the housing and race (5). Make sure the metal side of the
seal faces out from the housing.
Figure 67
Installation (Fig. 61)
1. Thrust bearing
2. Thrust washer
1. Clean adapter plate (14) thoroughly of all dirt and debris to prevent damage to the bidirectional clutch and
transaxle.
3. Spring
4. Cam
2. If the adapter plate (14) was removed from the transaxle, install as follows:
2
3
Figure 68
1. Cam
2. Cage
3. Roller
4. Garter spring
Page 10 34
Page 10 35
Front Wheel
Drive (4WD)
IMPORTANT: Make sure retaining ring (3) is properly seated in the drive shaft (19) groove. Pull clutch
out from the transaxle to make sure that it holds in
place. Replace ring if bent or damaged.
Page 10 36
Chapter 11
Electrical
Schematics
Electrical Schematics
Table of Contents
VEHICLE ELECTRICAL SCHEMATICS
Workman 3100
Serial Number Below 260000000 . . . . . . . . . . . . . 3
Serial Number Above 260000000 . . . . . . . . . . . . . 4
Workman 3200 and 4200
Serial Number Below 260000000 . . . . . . . . . . . . . 5
Serial Number Above 260000000 . . . . . . . . . . . . . 6
Workman 3300 and 4300
Serial Number Below 260000000 . . . . . . . . . . . . . 7
Serial Number Above 260000000 . . . . . . . . . . . . . 8
WIRE HARNESS DRAWINGS
Front Wire Harness Drawing: Workman 3000/4000
Serial Number Below 270999999 . . . . . . . . . . . . 10
Serial Number Above 280000000 . . . . . . . . . . . . 12
Rear Wire Harness Drawing: Workman 3100
Serial Number Below 260000000 . . . . . . . . . . . . 14
Serial Number From 260000001 to 260000400 15
Serial Number Above 260000400 . . . . . . . . . . . . 16
Rear Wire Harness Drawing: Workman 3200/4200
Serial Number Below 260000000 . . . . . . . . . . . . 18
Serial Number Above 260000000 . . . . . . . . . . . . 20
Rear Wire Harness Diagram: Workman 3300/4300
Serial Number Below 260000000 . . . . . . . . . . . . 22
Serial Number From 260000000 to 270999999 24
Serial Number Above 280000000 . . . . . . . . . . . . 26
Workman 3000/4000
Page 11 - 1 Rev. C
-
Electrical Schematics
Electrical Schematics
Page 11 - 2
-
Workman 3000/4000
PK
10 A
F1
FRONT HARNESS
OFF
ENGINE
RUN
86
FACTORY SHUNT VIA MATING CONN
R/BK
PK
10 A
F2
RUN
OR
15 A
GY
GY
OR
PK/BU
STARTER
P101--C
GY
GY
GY
3
4
OR
BK
GY
OR
IGNITION SWITCH
F3
BK
B+
Start
START ENABLE
A
R
85
GY+BK
PK/BU
PK/BU
BK
START
87
CLUTCH SWITCH
(ENGAGED)
87a
30
PK
P101--E
NOT CONNECTED
BRAKE SWITCH
P101--H
BN
BN
BN
HORN
F4
HORN SWITCH
POWER POINT
15 A
LIGHT SWITCH
W/BK
W/BK
BK
BK
R/BK
BK
BK
P101--G
P102--D
OR
OR
R/BK
FUSIBLE LINK INSIDE HARNESS
OR
OR
R/W
VIO/R
BK
OR
TEMP
B+
TIE POINT
ON STARTER
HIGH
OTHER 3RD
P101--B
GN/BK
BK
BU
BK
BATTERY LAMP
P20 (NOT USED)
BN/W
VIO
P102--B
P102--C
P101--K
FRONT HARNESS
VIO/R
R/W
GN/BK
BU/W
P101--F
NOT CONNECTED
P21
P101--A
P102--A
(--)
BN/W
NOT CONNECTED
BK
BK
R/W
ENGINE
GROUND
BU/W
REAR HARNESS
FUEL
BK
LOW
HR
(--)
OIL
PRES
OR
I
S
TACH
KIT
TACH
PK
OR
I
(+)
TRANSMISSION
SWITCHES
BATTERY
LIGHTS
TAIL/BRAKE
HEADLIGHTS
OR
P100--A
(+)
BN
BK
P100--B
W/BK
BN
SUPERVISOR
SWITCH
(OFF)
AT FUSE BLOCK
GROUND TIE POINT
W/BK
P101--J
GN
PK
FRAME
GROUNDS
C
TACH SENSOR
(TACH KIT)
FUEL
SENDER
ENGINE
BK
OIL PRESSURE
SWITCH
(LOW PRESSURE)
TEMPERATURE
SENDER
ENGINE
BK
BK
ENGINE HARNESS
BK
BK
BK
R
MAGNETO
ENGINE HARNESS
R/W
BK
R
A
ENGINE
VOLTAGE REGULATOR
Y
POWER
ENGINE KILL
KEY TO WIRE COLORS
R = RED
Y = YELLOW
W = WHITE
T = TAN
BK = BLACK
BN = BROWN
BU = BLUE
GN = GREEN
GY = GRAY
OR = ORANGE
PK = PINK
VIO = VIOLET
BK
30
87a
SPARK MODULE
BN
W
KILL
87
Y
SPARK MODULE
R/W
86
85
BK
FUEL SOLENOID
BN
ENGINE
Workman 3100
Kohler Gasoline Engine
Vehicle Electrical Schematic
Serial Number Below 260000000
All relays and solenoids
are shown as de- energized.
-
SPEED ADVANCE
MODULE
Page 11 - 3
Rev. C
Workman 3100
Kohler Gasoline Engine
Vehicle Electrical Schematic
Serial Number Above 260000000
All relays and solenoids
are shown as de- energized.
-
Page 11 - 4
Rev. C
REAR HARNESS
PK
F1
FRONT HARNESS
OFF
10 A
ENGINE
RUN
CLUTCH SWITCH
(ENGAGED)
86
R/BK
START
PK
F2
10 A
RUN
OR
GY
OR
GY
OR
GY
4
6
1
2
HYD. LIFT INTERLOCK
(CE VEHICLES ONLY)
GY
GY+BK
R
B+
Start
STARTER
BK
BK
GY
GY
P101--E
Y
7
BK
85
BRAKE SWITCH
15 A
F3
OR
BK
GY
START ENABLE
A
R
87
87a
30
PK
P101--H
BN
BN
BN
HORN
F4
HORN SWITCH
POWER POINT
15 A
PK
LIGHT SWITCH
W/BK
BK
W/BK
W/BK
BK
P101--J
GN
R/BK
BN
LIGHTS
TAIL/BRAKE
HEADLIGHTS
W/BK
BN
BK
BK
OR
OR
AT FUSE BLOCK
GROUND TIE POINT
P100--B
P100--A
P101--G
P101--D
OR
FL3
LOW
HIGH
TACH
KIT
TACH
R/W
OTHER 3RD
OR
VIO/R
P101--B
TEMP
(--)
GN/BK
FUEL
BU/W
BATT.
OIL
PRES
BU
BK
P102--C
P101--K
FRONT HARNESS
HR
OVER
TEMP
OR
I
TRANSMISSION
SWITCHES
R/BK
OR
I
L
S
FL2
PK
(+)
R/BK
FL1
OR
OR
OR
I
BK
P102--B
VIO
P101--F
P102--A
BN/W
P101--A
REAR HARNESS
B+
TIE POINT
ON STARTER
R/W
VIO/R
GN/BK
BU/W
BU
NOT CONNECTED
P21
VIO
BN/W
BK
BK
FUEL
SENDER
R/W
(+)
(--)
ENGINE
GROUND
BATTERY
FRAME
GROUNDS
OIL PRESSURE
SWITCH
(LOW PRESSURE)
TEMPERATURE
SENDER
ENGINE
ENGINE
ENGINE
BK
BK
R/BK
VIO
ALTERNATOR
CHOKE HEATER
VIO/R
R = RED
Y = YELLOW
W = WHITE
T = TAN
BK = BLACK
BN = BROWN
BU = BLUE
GN = GREEN
GY = GRAY
OR = ORANGE
PK = PINK
VIO = VIOLET
BK
R/W
POWER
BK
GROUND
BK
BK
N.C.
BU/W
PULSAR COIL
CRANK
POSITION
TACH
R/W
-- IGN COIL 1 +
OR
-- IGN COIL 2 +
R/W
R/W
R/W
87a
30
R/W
GN
GN/W
PULSAR COIL
ENGINE
2
85
87
86
-- IGN COIL 3 +
FUEL PUMP
P31
P32
IGNITION CONTROL
MODULE
BU
FUEL PUMP
W
BU
ENGINE
FUEL SOLENOID
FUEL PUMP
BK
BK
Page 11 - 5
Rev. C
Page 11 - 6
Rev. C
REAR HARNESS
W
PK
10 A
F1
ENGINE
RUN
START
R
10 A
F2
PK
RUN
OR
GY
GY
OR
15 A
F4
GY
OR
IGNITION SWITCH
F3
BK
OR
GY
GY
4
6
GY
GY
BK
BN
LIGHT SWITCH
W/BK
BK
W/BK
BK
BK
OR
P101--G
P100--A
P101--D
OR
OR
OR
I
PK
OR
(+)
TACH
R/BK
BK
FL3
LOW
VIO/R
TACH
KIT
HR
GN/BK
GLOW PLUG
SWITCH
BK
S
TEMP
(--)
OIL
PRES
BATT.
FUEL
BU/W
BU
BK
Y
VIO
BN/W
BK
OTHER 3RD
P101--B
P101--K
FRONT HARNESS
P101--F
P102--B
P102--C
P102--A
P101--A
REAR HARNESS
B+
TIE POINT
ON STARTER
HIGH
OVER
TEMP
OR OR
OR
I
TRANSMISSION
SWITCHES
FL2
R/BK
FL1
LIGHTS
TAIL/BRAKE
HEADLIGHTS
BK
W/BK
BN
SUPERVISOR
SWITCH
(OFF)
AT FUSE BLOCK
GROUND TIE POINT
BN
BN
P101--J
W/BK
R/BK
P100--B
BK
P101--H
BN
BK
BK
HORN
HORN SWITCH
STARTER
BK
P101--E
GN
B+
Start
PK
POWER POINT
15 A
BRAKE SWITCH
LIGHTS, HORN, BRAKE
85
3
5
START ENABLE
GY+BK
87
86
FACTORY SHUNT VIA MATING CONN
R/BK
30
PK
PTO KIT (OFF)
CLUTCH SWITCH
(ENGAGED)
FRONT HARNESS
OFF
87a
VIO/R
GN/BK
BU/W
BU
VIO
BN/W
BK
R
(+)
BK
BK
(--)
ENGINE
GROUND
BATTERY
FRAME
GROUNDS
FUEL
SOLENOID
FUEL
SENDER
TACH SENSOR
(TACH KIT)
TEMPERATURE
SENDER
SWITCH
ENGINE
ENGINE
ENGINE
OIL PRESSURE
SWITCH
(LOW PRESSURE)
ENGINE
BK
BK
R/BK
VIO
ALTERNATOR
GLOW RELAY
BK
PK
87
BK = BLACK
BN = BROWN
BU = BLUE
GN = GREEN
GY = GRAY
85
OR = ORANGE
PK = PINK
VIO = VIOLET
86
30
Page 11 - 7
Rev. C
Page 11 - 8
Rev. C
Page 11 - 9
Rev. C
SN 280000001
AND UP
Workman 3000/4000
Front Wire Harness Drawing
Serial Number Below 270999999
Page 11 - 10
Rev. C
GRAY
RED/BLACK
RED/WHITE
RED/BLACK
RED/WHITE
WHITE
WHITE
BROWN
WHITE
WHITE/BLACK
BROWN
WHITE
YELLOW
GRAY
GRAY
ORANGE
BLACK
BROWN
WHITE/BLACK
ORANGE
YELLOW
RED
RED
RED
WHITE
RED
ORANGE
SN 280000001
AND UP
BLACK
VIOLET/RED
BLACK
ORANGE
ORANGE
BROWN/WHITE
GRAY
YELLOW
BLUE
RED/BLACK
BROWN
WHITE/BLACK
GREEN/BLACK
ORANGE
ORANGE
RED
GRAY
RED/BLACK
VIOLET
YELLOW
RED/WHITE
ORANGE
BLUE/WHITE
BLACK
ORANGE
ORANGE
BLACK
ORANGE
ORANGE
BLACK
BLACK
WHITE/BLACK
BLACK
WHITE/BLACK
BLACK
BLACK
GREEN
BLACK
ORANGE
YELLOW
BLACK
ORANGE
ORANGE
BLACK
Workman 3000/4000
Front Wire Harness Diagram
Serial Number Below 270999999
Page 11 - 11
Rev. C
Workman 3000/4000
Front Wire Harness Drawing
Serial Number Above 280000000
Page 11 - 12
Rev. C
GRAY
RED/BLACK
RED/WHITE
WHITE
WHITE
BROWN
WHITE
WHITE/BLACK
BROWN
WHITE
YELLOW
GRAY
GRAY
ORANGE
BLACK
BROWN
WHITE/BLACK
BLACK
ORANGE
GRAY
YELLOW
RED
RED
RED
WHITE
RED
ORANGE
BLACK
VIOLET/RED
BLACK
ORANGE
ORANGE
BROWN/WHITE
GRAY
YELLOW
BLUE
RED/BLACK
BROWN
WHITE/BLACK
GREEN/BLACK
ORANGE
ORANGE
RED
GRAY
RED/BLACK
VIOLET
YELLOW
RED/WHITE
ORANGE
BLUE/WHITE
BLACK
ORANGE
ORANGE
BLACK
ORANGE
ORANGE
BLACK
WHITE/BLACK
BLACK
WHITE/BLACK
BLACK
BLACK
GREEN
BLACK
ORANGE
YELLOW
ORANGE
ORANGE
ORANGE
BLACK
BLACK
Workman 3000/4000
Front Wire Harness Diagram
Serial Number Above 280000000
Page 11 - 13
Rev. C
21A
19B
FUEL
SENDER
23A
22A
24A
2B
TAIL
LIGHT
17B
CBA
SPLICE E
BLACK
16A 17A 18A
19A 34A
30
85
KILL
RELAY
SPEED
PICKUP
PLUG
20A
5B
B A
87A
86
18B
12A
P101
INTERCONNECT
FRONT HARNESS
START
RELAY
33A
86
26A
33B
25A
30
85 87
34B
14B
27A
28A
GROUND
5A
4A
BA
32A
4B
13B
P102
INTERCONNECT
FRONT HARNESS
14A
B A
6A
32B
STARTER
BA
7A
1A
SPLICE C
RED/WHITE
1B 10B 30B
8B 20B
SPLICE B
BLACK
7B 16B 24B
25B 27B
FUSIBLE LINK
SPLICE A
6B 15B 29B
SPLICE D
RED/BLACK
9B 11B 31B
CBA
2A
ENGINE
HARNESS
SPEED
PICKUP
PTO
SWITCH
3A
B
A
WIRE LIST
8A
CLUTCH
SWITCH
9A
SUPERVISOR
SWITCHTRANSAXLE
Page 11 - 14
Rev. C
ITEM
13A
15A
10A
11A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
WIRE
COLOR
RED/WHT
BLACK
BRN/WHT
PNK/BLU
PNK/BLU
GRAY
BLACK
RED/WHT
RED/BLK
RED/WHT
RED/BLK
GRAY
PINK
PINK
PINK
BLACK
BLACK
BLACK
BLACK
RED/WHT
BLU/WHT
BROWN
WHT/BLK
BLACK
BLACK
BLACK
BLACK
BLUE
RED
RED/WHT
RED/BLK
PINK
BLACK
TERMINAL A
CONNECTOR
DESTINATION
TERMINAL B
CONNECTOR
DESTINATION
ENGINE HARNESS
ENGINE HARNESS
ENGINE HARNESS
STARTER
STARTER
STARTER
DIODE
SUPR SWITCH TRANS
SUPR SWITCH TRANS
SUPR SWITCH TRANS
SUPR SWITCH TRANS
START RELAY
CLUTCH SWITCH
PTO SWITCH
CLUTCH SWITCH
SPLICE E
SPLICE E
SPLICE E
SPLICE E
KILL RELAY
FUEL SENDER
TAIL LIGHT
TAIL LIGHT
TAIL LIGHT
GROUND
GROUND
SPEED PICKUP
SPEED PICKUP
FRONT HARNESS (P100) PIN B
FRONT HARNESS (P102) PIN D
FRONT HARNESS (P101) PIN G
PTO SWITCH PLUG
SPEED PICKUP PLUG
SPLICE E
SPICE C
KILL RELAY
FRONT HARNESS (P101) PIN A
DIODE
START RELAY
SPLICE A
SPLICE B
SPLICE C
SPLICE D
SPLICE C
SPLICE D
FRONT HARNESS (P101) PIN C
PTO SWITCH
START RELAY
SPLICE A
SPLICE B
START RELAY
START RELAY
FUEL SENDER
SPLICE C
FRONT HARNESS (P102) PIN C
FRONT HARNESS (P101) PIN H
FRONT HARNESS (P101) PIN J
SPLICE B
SPLICE B
FRONT HARNESS (P100) PIN A
SPLICE B
FRONT HARNESS (P101) PIN B
SPLICE A
SPLICE C
SPLICE D
PTO SWITCH PLUG
SPEED PICKUP PLUG
START RELAY
Workman 3100
Kohler Gasoline Engine
Rear Wire Harness
Serial Number Below 260000000
P100
INTERCONNECT
FRONT HARNESS
WIRE LIST
Workman 3100
Kohler Gasoline Engine
Rear Wire Harness
Serial Number From 260000001 To 260000400
Page 11 - 15
Rev. C
Workman 3100
Kohler Gasoline Engine
Rear Wire Harness Drawing
Serial Number Above 260000400
Page 11 - 16
Rev. C
RED/BLACK
RED/WHITE
RED/BLACK
RED/WHITE
GRAY
GRAY
GRAY
GRAY
GRAY
GRAY
RED
BLACK
RED
PINK
GRAY
GRAY
BLACK
PINK
RED/BLACK
BLACK
FUSIBLE LINK
BLUE/WHITE
RED/WHITE
RED/WHITE
WHITE
BROWN/WHITE
BLACK
BLACK
BROWN
WHITE/BLACK
BLACK
BLACK
BLUE
PINK
BLACK
RED/WHITE
BLACK
BLACK
Workman 3100
Kohler Gasoline Engine
Rear Wire Harness Diagram
Serial Number Above 260000400
Page 11 - 17
Rev. C
BLUE
BLACK
YELLOW
GRAY
GRAY
GRAY
GRAY
WHITE
BROWN/WHITE
PINK
BLACK
RED/BLACK
RED
YELLOW
GRAY
RED
WHITE
GREEN/BLACK
WHITE
BLACK
RED
BLUE/WHITE
PINK
BLACK
PINK
BLACK
BLACK
BLACK
RED/WHITE
RED/BLACK
BLACK
WHITE/BLACK
BROWN
RED/WHITE
RED/BLACK
RED/BLACK
RED/WHITE
RED/WHITE
BLACK
RED/WHITE
RED/WHITE
WHITE
RED/WHITE
RED/WHITE
WHITE
VIOLET/RED
BLACK
RED
GREEN
BLUE/WHITE
BLACK
BLACK
RED/
WHITE
RED/
WHITE
RED/WHITE
BLUE
GREEN/WHITE
VIOLET
ORANGE
BLUE
BLACK
YELLOW
YELLOW
BROWN/WHITE
GRAY
GRAY
GRAY
WHITE
WHITE
BLACK
RED/BLACK
RED
RED
PINK
RED
BLACK
RED
GRAY
GRAY
GREEN/BLACK
BLACK
BLUE/WHITE
GRAY
GRAY
BLACK
BLACK
PINK
RED/WHITE
RED/BLACK
BLACK
WHITE/BLACK
BROWN
RED/WHITE
RED/BLACK
RED/WHITE
RED/WHITE
RED/WHITE
WHITE
RED/WHITE
BLACK
RED/BLACK
VIOLET/RED
RED/WHITE
VIOLET
BLACK
GREEN/WHITE
BLUE/WHITE
BLACK
BLACK
RED/WHITE
WHITE
GREEN
ORANGE
BLUE
RED/WHITE
RED/WHITE
RED/WHITE
BLACK
BLUE
PINK
GRAY
GRAY
RED
PINK
YELLOW
RED/BLACK
RED
WHITE
BLACK
GRAY
BLACK
YELLOW
PINK
RED
BLUE/WHITE
PINK
BLACK
PINK
BLACK
GREEN/BLACK
BLACK
BLACK
RED
RED/BLACK
BLACK
WHITE/BLACK
BROWN
RED
RED/BLACK
RED/BLACK
RED
BROWN/WHITE
VIOLET
BLACK
GRAY
RED
BLACK
GRAY
BLACK
VIOLET/RED
BLACK
RED
ORANGE
YELLOW
GRAY
BLUE
BLACK
GRAY
GRAY
BROWN/WHITE
GRAY
GRAY
RED
RED/BLACK
PINK
RED
BLACK
RED
GRAY
BLACK
GRAY
BLUE/WHITE
PINK
BLACK
GREEN/BLACK
BLACK
BLACK
RED
RED/BLACK
PINK
BLACK
WHITE/BLACK
BROWN
RED
RED/BLACK
BLACK
RED
BLACK
RED
BLACK
RED/BLACK
VIOLET/RED
GRAY
RED
VIOLET
GRAY
PINK
BLACK
YELLOW
ORANGE
GREEN/BLACK
BLUE
BLACK
YELLOW
YELLOW
BROWN/WHITE
GRAY
GRAY
GRAY
RED
RED/BLACK
PINK
RED
BLACK
RED
GRAY
BLACK
GRAY
BLUE/WHITE
PINK
BLACK
BLACK
RED
RED/BLACK
BLACK
WHITE/BLACK
BROWN
RED
RED/BLACK
RED
BLACK
RED
BLACK
RED/BLACK
VIOLET/RED
GRAY
RED
VIOLET
GRAY
PINK
BLACK
BLACK
YELLOW
RED/BLACK
PINK
ORANGE