Page 1 IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine. E The Toro Company - - 2003, 2004, 2006, 2007, 2011...
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Page 3: Table Of Contents
Table Of Contents Chapter 1 - - Safety Chapter 6 - - Drive Train Safety Instructions ......1 -- 2 General Information .
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Page 5 Table Of Contents Chapter 10 - - Front Wheel Drive (4WD) Specifications ......10 -- 2 General Information .
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Page 7 Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS ..... . 2 Before Operating ......2 While Operating .
Page 8: Safety Instructions
A re- this purpose. placement Operator’s Manual is available on the Inter- net at www.Toro.com. B. Do not remove vehicle fuel tank cap while engine is hot or running. 2. Keep all shields, safety devices, and decals in place.
Page 9: While Operating
While Operating 1. Sit on the seat when starting and operating the ve- 4. Do not touch engine, radiator, muffler or exhaust pipe hicle. while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. 2.
Page 10: Maintenance And Service
Hydraulic 15.To assure optimum performance and continued fluid escaping under pressure can penetrate skin and safety of the vehicle, use genuine Toro replacement cause injury. Fluid accidentally injected into the skin parts and accessories. Replacement parts and acces-...
Page 11: Jacking Vehicle
Jacking Vehicle WARNING When changing attachments, tires or perform- ing 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.
Page 12: Using Bed Safety Support
Using Bed Safety Support Many of the procedures shown in this manual re- quire raising and lowering the bed. The following precautions must be taken or serious injury or death could result. WARNING Before servicing or making adjustments to the vehicle, stop engine, set parking brake and re- move key from ignition switch.
Page 13: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......1 EQUIVALENTS AND CONVERSIONS ... 2 Decimal and Millimeter Equivalents .
Page 14: Equivalents And Conversions
Equivalents and Conversions 0.09375 Rev. D Product Records and Maintenance Page 2 - - 2 Workman 3000/4000 Series...
Page 15: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 16: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Inch Series Fasteners)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series Fasteners) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 17: Standard Torque For Dry, Zinc Plated, And Steel Fasteners (Metric Fasteners)
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
Page 18: Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 – 20 UNF 65 + 10 ft–lb 88 + 14 N–m Grade 5 1/4 –...
Page 19: Maintenance
Maintenance Maintenance procedures and recommended service in- tervals for the Workman 3000/4000 are covered in the Operator’s Manual. Refer to that publication when per- forming regular equipment maintenance. Several main- tenance procedures have break–in intervals identified in the Operator’s Manual. Refer to the Engine Operator’s Manual for additional engine specific maintenance pro- cedures.
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Page 21: Briggs & Stratton/Daihatsu Repair Manual
Briggs & Stratton/Daihatsu Repair Manual that is included at the end of this section. Service and repair parts for Briggs & Stratton/Daihatsu 3LC gasoline engines are supplied through your local Toro distributor. Workman 3200/4200 Briggs/Daihatsu Gasoline Engine Page 3 – 1...
Page 22: Specifications
Specifications Item Description Make / Designation Briggs & Stratton/Daihatsu, 4–stroke, Liquid Cooled, OHV Gasoline Number of Cylinders Bore x Stroke mm (in.) 72 x 78 (2.834 x 3.07) Total Displacement cc (cu. in.) 952 (58.1) Compression Ratio 8.6:1 Firing Order 1 (front) –...
Page 23: General Information
General Information Adding Oil to Engine When adding oil to the engine, maintain clearance be- tween the oil fill device and the oil fill opening in the valve cover (Fig. 1). This clearance is necessary to allow vent- ing when adding engine oil which will prevent oil from running into the breather tube and intake system.
Page 24: Adjustments
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 ac- cess to engine. If bed is raised, place safety support on lift cylinder (see Operator’s Manual).
Page 25 8. Using a tachometer, check low idle speed. Low idle speed should be 1100 + 50 RPM. If low idle is incorrect, repeat idle stop screw adjustment (step 5). If low idle is still incorrect, adjust the idle speed screw on the carbu- retor to obtain 1100 + 50 RPM (Fig.
Page 26: Service And Repairs
Service and Repairs Radiator RIGHT FRONT Figure 5 19. Lock nut (4 used) 1. Hydraulic pump 10. Flange nut (4 used) 2. Carriage screw (4 used) 11. Magnetic catch (2 used) 20. Handle 3. Fan hub/pulley 12. Radiator cap 21. Radiator cover/screen 4.
Page 27 Removal (Fig. 5) Installation (Fig. 5) 1. Park vehicle on a level surface, stop engine, engage 1. Remove plugs from radiator and hoses placed dur- parking brake, and remove key from the ignition switch. ing the removal procedure. Allow engine to cool. 2.
Page 28: Pump Driveshaft Service
Pump Driveshaft Service RIGHT FRONT 100 to 130 in–lb (11.3 to 14.7 N–m) ANTISIEZE LUBRICANT Figure 6 1. Lock nut 7. Bearing spacer 13. Coupling spacer (4 used) 2. Flat washer 8. Shaft 14. Rubber coupling 3. Woodruff key 9. Lock nut (6 used) 15.
Page 29 Removal (Fig. 6) Installation (Fig. 6) 1. Park vehicle on a level surface, raise and support 1. To install bearings (Item 6) into frame support brack- bed (if installed), shut engine off and engage the parking brake. A. Install pulley side bearing into support bracket by 2.
Page 30: Fuel Tank
Fuel Tank Sender Ground Wire Thread Sealant RIGHT FRONT Figure 7 1. Fuel tank 10. Spacer 19. Lock nut (2 used) 2. Fuel tank cap 11. Fuel fitting 20. Front fuel tank support 3. Gasket 12. Hose clamp 21. Socket head screw (2 used) 13.
Page 31 Fuel Tank Removal (Fig. 7) Fuel Tank Installation (Fig. 7) 1. Put vehicle on a level surface and engage parking 1. Check felt straps (item 23) and replace if worn or brake. Stop the engine and remove key from ignition damaged.
Page 32: Air Cleaner System
Air Cleaner System RIGHT FRONT VACUATOR DIRECTION Figure 8 1. Engine 6. Air cleaner hose 11. Mount bracket 2. Hose clamp 7. Air cleaner assembly 12. Cap screw (2 used) 3. Air intake hose 8. Flange nut (2 used) 13. Flange nut (2 used) 4.
Page 33 Removal (Fig. 8) 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder (see Operator’s Manual).
Page 34: Exhaust System
Exhaust System Loctite #242 RIGHT FRONT Figure 10 1. Engine 7. Cap screw (2 used) 13. Mount plate 2. Stud (4 used) 8. Flange nut (4 used) 14. Cap screw 3. Exhaust gasket 9. Cap screw 15. Muffler 4. Hex nut (4 used) 10.
Page 35 Removal (Fig. 10) Installation (Fig. 10) 1. Put vehicle on a level surface and engage parking 1. Replace any removed gaskets. brake. Stop the engine and remove key from ignition 2. If cap screw (item 9) was removed, apply Loctite switch.
Page 36: Engine
Engine RIGHT FRONT Figure 11 1. Engine 12. Ball joint 23. Hex nut 2. Hex nut 13. Accelerator cable 24. Wire harness solenoid lead 3. Lock washer 14. Bellcrank 25. Lower radiator hose 4. Flat washer 15. Upper radiator hose 26.
Page 37 Engine Removal (Fig. 11) 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s) to gain access to engine. If bed is raised, place safety sup- port on lift cylinder (see Operator’s Manual).
Page 38 11. Remove any clamps and cable ties used to attach wiring harness, hoses or cables to the engine. 12.On 4WD vehicles, remove differential drive shaft (see Differential Driveshaft in the Service and Repairs section of Chapter 10 – Front Wheel Drive (4WD)). 13.Put blocking under transaxle for support.
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Page 40: Engine Throttle Bracket
Engine Throttle Bracket RIGHT FRONT Figure 17 1. Engine 7. Lock washer (3 used) 13. Idle stop screw 2. Jam nut 8. Flange head screw (3 used) 14. High idle stop screw 3. Return spring 9. Grease fitting 15. Throttle bracket 4.
Page 41 Disassembly (Fig. 17) NOT EQUIPPED WITH GOVERNOR SPRING ADJUSTING ROD 1. Remove throttle bracket components from engine as needed using Figures 17, 18 and 19 as guides. Assembly (Fig. 17) 1. Install removed throttle bracket components to en- gine using Figures 17, 18 and 19 as guides. 2.
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Page 43: Briggs & Stratton/Daihatsu Repair Manual
Briggs & Stratton/Daihatsu Repair Man- ual that is included at the end of this section. Service and repair parts for Briggs and Stratton/Daihat- su 3LC diesel engines are supplied through your local Toro distributor. Workman 3300–D/4300–D Briggs/Daihatsu Diesel Engine Page 4 – 1...
Page 44: Specifications
Specifications Item Description Make / Designation Briggs & Stratton/Daihatsu, 4–stroke, Liquid Cooled, OHV Diesel Number of Cylinders Bore x Stroke mm (in.) 72 x 78 (2.834 x 3.07) Total Displacement cc (cu. in.) 952 (58.1) Compression Ratio 24.0:1 Firing Order 1 (front) –...
Page 45: General Information
General Information Adding Oil to Engine When adding oil to the engine, maintain clearance be- tween the oil fill device and the oil fill opening in the valve cover (Fig. 1). This clearance is necessary to allow vent- ing when adding engine oil which will prevent oil from running into the breather tube and intake system.
Page 46: Adjustments
Adjustments Adjust Engine Speed 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 ac- cess to engine. If bed is raised, place safety support on lift cylinder (see Operator’s Manual).
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Page 48: Service And Repairs
Service and Repairs Radiator RIGHT FRONT Figure 4 1. Hydraulic pump 10. Flange nut (4 used) 19. Lock nut (4 used) 2. Carriage screw (4 used) 11. Magnetic catch (2 used) 20. Handle 3. Fan hub/pulley 12. Radiator cap 21. Radiator cover/screen 4.
Page 49 Removal (Fig. 4) Installation (Fig. 4) 1. Park vehicle on a level surface, stop engine, engage 1. Remove plugs from radiator and hoses placed dur- parking brake, and remove key from the ignition switch. ing the removal procedure. Allow engine to cool. 2.
Page 50: Pump Driveshaft Service
Pump Driveshaft Service RIGHT FRONT 100 to 130 in–lb (11.3 to 14.7 N–m) ANTISIEZE LUBRICANT Figure 5 1. Lock nut 7. Bearing spacer 13. Coupling spacer (4 used) 2. Flat washer 8. Shaft 14. Rubber coupling 3. Woodruff key 9. Lock nut (6 used) 15.
Page 51 Removal (Fig. 5) Installation (Fig. 5) 1. Park vehicle on a level surface, raise and support 1. To install bearings (Item 6) into frame support brack- bed (if installed), shut engine off and engage the parking brake. A. Install pulley side bearing into support bracket by 2.
Page 52: Fuel Tank
Fuel Tank Sender Ground Wire RIGHT FRONT Thread Sealant Figure 6 1. Fuel tank 12. Hose clamp 23. Lock nut (2 used) 2. Fuel tank cap 13. Fuel hose (to fuel filter) 24. Front fuel tank support 3. Gasket 14. Clamp 25.
Page 53 Fuel Tank Removal (Fig. 6) Fuel Tank Installation (Fig. 6) 1. Put vehicle on a level surface and engage parking 1. Check felt straps (item 27) and replace if worn or brake. Stop the engine and remove key from ignition damaged.
Page 54: Air Cleaner System
Air Cleaner System RIGHT FRONT VACUATOR DIRECTION Figure 7 1. Engine 6. Air cleaner hose 11. Mount bracket 2. Hose clamp 7. Air cleaner assembly 12. Cap screw (2 used) 3. Air intake hose 8. Flange nut (2 used) 13. Flange nut (2 used) 4.
Page 55 Removal (Fig. 7) 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder (see Operator’s Manual).
Page 56: Exhaust System
Exhaust System Loctite #242 RIGHT FRONT Figure 9 1. Engine 7. Cap screw (2 used) 13. Mount plate 2. Stud (4 used) 8. Flange nut (4 used) 14. Cap screw 3. Exhaust gasket 9. Cap screw 15. Muffler 4. Hex nut (4 used) 10.
Page 57 Removal (Fig. 10) Installation (Fig. 10) 1. Put vehicle on a level surface and engage parking 1. Replace any removed gaskets. brake. Stop the engine and remove key from ignition 2. If cap screw (item 9) was removed, apply Loctite switch.
Page 58: Engine
Engine RIGHT FRONT Figure 10 1. Engine 12. Washer 22. Throttle bracket 2. Fusible link harness 13. Cap screw 23. Air intake hose 3. Positive battery cable 14. Lock washer (8 used) 24. Hose clamp 4. Wire harness solenoid lead 15.
Page 59 Engine Removal (Fig. 10) 1. Put vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s) to gain access to engine. If bed is raised, place safety sup- port on lift cylinder (see Operator’s Manual).
Page 60 11. Remove any clamps and cable ties used to attach wiring harness, hoses or cables to the engine. 12.On 4WD vehicles, remove differential drive shaft (see Differential Driveshaft in the Service and Repairs section of Chapter 10 – Front Wheel Drive (4WD)). 13.Put blocking under transaxle for support.
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Page 62: Engine Throttle Bracket
Engine Throttle Bracket RIGHT FRONT Figure 14 1. Engine 7. Ball joint 12. Shoulder bolt 2. Lock nut 8. Jam nut 13. Grease fitting 3. Cap screw 9. Threaded rod 14. Throttle bellcrank 4. Cap screw 10. Accelerator cable 15. Throttle bracket 5.
Page 63: Kohler Engine Service Manual
Chapter 5 Kohler Gasoline Engine Table of Contents INTRODUCTION ......1 SPECIFICATIONS .
Page 64: Specifications
Specifications Item Description Make / Designation Kohler, CH23S, 4–stroke, V–Twin Air Cooled, OHV Number of Cylinders Bore x Stroke 80 mm x 67 mm (3.15” x 2.64”) Total Displacement 674 cc (41.1 cu. in.) Compression Ratio 8.5:1 Dry Weight (approximate) 41 kg (90 lb.) Fuel Unleaded, Regular Gasoline (Minimum 87 Octane)
Page 65: Service And Repairs
Service and Repairs Cooling System To ensure proper engine cooling, make sure the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. NOTE: Perform this maintenance procedure at the in- terval specified in the Operator’s Manual. IMPORTANT: The engine that powers the Workman 3100 is air–cooled.
Page 66: Fuel Tank
Fuel Tank Sender Ground Wire Thread Sealant RIGHT FRONT Figure 2 1. Fuel tank 10. Spacer 19. Lock nut (2 used) 2. Fuel tank cap 11. Fuel fitting 20. Front fuel tank support 3. Gasket 12. Hose clamp 21. Socket head screw (2 used) 13.
Page 67 Fuel Tank Removal (Fig. 2) Fuel Tank Installation (Fig. 2) 1. Put vehicle on a level surface and engage parking 1. Check felt straps (item 23) and replace if worn or brake. Stop the engine and remove key from ignition damaged.
Page 68: Exhaust System
Exhaust System Loctite #242 RIGHT FRONT Figure 3 1. Socket head screw (4 used) 7. Cap screw 13. Carriage bolt (2 used) 2. Exhaust manifold 8. Bracket 14. Mount plate 3. Hex nut (3 used) 9. Muffler gasket 15. Cap screw 4.
Page 69 Removal (Fig. 3) 3. Using Figure 3 as a guide, fit all exhaust components to vehicle before tightening any fasteners. When secur- 1. Put vehicle on a level surface and engage parking ing exhaust, tighten fasteners in the following order: brake.
Page 70: Engine
Engine Anti–seize Lubricant 35 to 41 ft–lb (47 to 56 N–m) Anti–seize Lubricant RIGHT FRONT Figure 4 1. Lock nut 16. Choke lever 30. Pilot bearing 2. Flat washer 17. Choke cable 31. Socket head screw 3. Pulley 18. Accelerator cable 32.
Page 71 5. Disconnect fuel line from fuel pump on engine. Plug end of fuel line to prevent contamination and fuel spill- age. Position disconnected fuel line away from engine. 6. Disconnect and label electrical leads that attach to engine and engine accessories. 7.
Page 72 Engine Installation (Fig. 4) 5. If shoulder bolt (Item 15) was removed, apply anti– seize lubricant to bolt shoulder before installing. 1. Install flywheel (Item 33) and/or pilot bearing (Item 30) if removed. Torque socket head cap screw (Item 31) 6.
Page 73 Chapter 6 Drive Train Table of Contents GENERAL INFORMATION ..... . 2 Transaxle ........SPECIFICATIONS .
Page 74: General Information
General Information Workman 3000/4000 Series vehicles are equipped with a Toro designed transaxle with 3 forward speeds, 1 re- Optional PTO verse speed and a differential lock. Hi–Lo range gives an effective 6 forward and 2 reverse speeds. The transaxle is a constant mesh, collar shift transmis- sion with synchronizers for gears 1, 2 and 3.
Page 75: Specifications
Specifications Item Specification Transaxle Oil Dexron III ATF Transaxle Oil Capacity 8 quart U.S. (7.6 liter) system capacity Workman 3000/4000 Series Page 6 – 3 Drive Train...
Page 76: Special Tools
Special Tools Order special tools from your Toro Distributor. Clutch Alignment Tool Use clutch alignment tool (Part No. TOR6002) to align clutch friction disk to engine flywheel before tightening pressure plate cap screws. Figure 2 Rev. C Drive Train Page 6 - - 4...
Page 77: Adjustments
Adjustments PTO Cable Adjustment 1. Remove clevis pin securing PTO cable to PTO lever arm. 2. Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in PTO lever arm. 3. Reinstall clevis pin and tighten jam nut after adjust- ment.
Page 78: Troubleshooting
Troubleshooting Clutch Problem Possible Causes Clutch slips. Excessive wear of clutch disc facing. Clutch pedal out of adjustment. Hardening of clutch disc facing, or adhesion of oil. Weak or broken clutch diaphragm spring. Damaged pressure plate or flywheel. Clutch operation erratic or rough. Improper installation of clutch cover assembly.
Page 79 Clutch (Continued) Problem Possible Causes Clutch drags or does not release. Control cable loose or out of adjustment. Bent or broken clutch diaphragm spring tip. Damaged or distorted clutch disc. Worn or rusted clutch disc spline. Damaged pressure plate or flywheel. Damaged release bearing.
Page 80: Transaxle
Transaxle Problem Possible Causes Noisy operation. Low oil level in transaxle. Damaged or worn bearings. Gears worn, scuffed or broken. Excessive end play in countershaft. Gears loose on shaft. Excessive wear of differential side gear liners and pinion liners. Excessive wear of splined slider on axle drive joints. Difficult shifting.
Page 81 Transaxle (Continued) Problem Possible Causes Transaxle slips out of gear. Shift linkage out of adjustment. Gear loose on shaft. Gear teeth worn. Excessive end play in gears. Lack of spring pressure on shift fork detent ball. Badly worn bearings. Overheating of transaxle. Oil level too high.
Page 82: Service And Repairs
Service and Repairs Shift Cable Replacement RIGHT FRONT 180 to 210 in–lb (20.3 to 23.7 N–m) Figure 4 1. Shift knob 8. Clevis pin 14. Lock nut 2. Jam nut 9. Shift lever 15. Lever support 3. Boot seal 10. Shift link 16.
Page 83 Removal (Fig. 4) 1. Remove knobs from control levers, then remove cen- ter 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.
Page 84: Stub Axle And Drive Shaft Service
Stub Axle and Drive Shaft Service 40 to 60 ft–lb (54 to 81 N–m) 220 to 250 ft–lb Loctite #680 (298 to 339 N–m) 35 to 42 ft–lb 45 to 65 ft–lb (47 to 57 N–m) (61 to 88 N–m) RIGHT 200 to 250 in–lb (22.6 to 28.3 N–m)
Page 85: Chapter 7 - Chassis)
7. Carefully slide stub axle from axle housing. Assembly (Fig. 8) 8. If required, slide driveshaft from transaxle. 1. If driveshaft was removed from transaxle, apply anti– seize lubricant to transaxle shaft. Slide driveshaft clamp 9. If bearings are being serviced, remove axle housing end onto splined transaxle shaft.
Page 86: Drive Shaft Universal Joint Service
Drive Shaft Universal Joint Service 1. Remove drive shaft from vehicle (see Stub Axle and Drive Shaft Service). 2. Remove snap rings (Item 1). IMPORTANT: Yokes must be supported when re- moving and installing bearings to prevent bending. 3. While supporting yoke, use a press to remove cross and bearings (Item 2).
Page 87: Removal And Installation (If Equipped)
P.T.O. Removal and Installation (If Equipped) PTO Removal 1. Remove clevis pin to disconnect PTO control cable clevis from shift arm on PTO. Do not loosen jam nuts to remove cable from support bracket. 2. Disconnect and label electrical lead that attaches to PTO switch.
Page 88: Transaxle
Transaxle Loctite #242 Loctite #242 RIGHT FRONT Figure 13 1. Transaxle assembly 6. Cap screw (2 used) 11. Shift lever (2 used) 12. Differential lock lever 2. Snubbing washer (4 used) 7. Cap screw (4 used) 3. Isolation mount assembly (2 used) 8.
Page 89: Removal
Removal 1. Put vehicle on a level surface. Stop the engine and remove key from ignition switch. Remove the bed or oth- er attachment(s). Allow engine and radiator to cool. 2. Disconnect negative (–) battery cable from battery first. Then disconnect positive (+) battery cable from bat- tery.
Page 90: Installation
16.Put blocking under engine for support. Support trans- axle 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 side–to–side to disconnect each drive shaft from axle shafts on transaxle.
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Page 92: Clutch Service
Clutch Service Silicone sealant (Workman 3100 only) RIGHT FRONT 5 to 7 ft–lb (7 to 9 N–m) Figure 20 1. Spring pin 6. Bushing 11. Lock washer (6 used) 2. Throw out bearing 7. Spring pin (2 used) 12. Pressure plate 3.
Page 93 Clutch Disassembly and Inspection (Fig. 20) 3. Install pressure plate. Install and tighten six cap screws and lock washers a little at a time, working in a 1. Insert clutch alignment tool (see Special Tools) in fly- diagonal sequence. Torque screws from 5 to 7 ft--lb (7 to wheel pilot bearing hole to keep clutch disk from falling 9 N--m).
Page 94: Transaxle Service
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. 1. Remove extension spring (Item 1). 2.
Page 95 7. Loosen cap screws and separate center plate from transaxle case. Note dowel pins in transaxle case. Re- move seal cap (Item 1), shims (Item 2 and 4) and snap ring (Item 3) from center plate. Figure 28 FRONT DRIVE 8.
Page 96 11. Remove, all at the same time, reduction shaft as- sembly (Item 1), 2nd–3rd shift assembly (Item 2), coun- tershaft assembly (Item 3) and High–Low shift assembly (Item 4). Figure 32 12.Loosen cap screws (Item 1) and remove L.H. axle shaft assembly (Item 2) and shims (Item 3) from L.H.
Page 97 16.Remove differential gear assembly (Item 1) together with fork shaft assembly (Item 2). Figure 36 17.Remove washer (Item 1) from inside of transaxle case. NOTE: Washer may stick to fork shaft when re- moved in step 16. Figure 37 Workman 3000/4000 Series Page 6 –...
Page 98 18.To remove shift arms: A. Loosen and remove nut (Item 1). Remove wash- er (Item 2) and 2nd–3rd 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). B.
Page 99 20.Remove oil cap (Item 1) and O–ring from transaxle case if necessary. 21.Remove air breather (Item 2) if necessary. Figure 41 22.Loosen cap screws (Item 1) and remove upper cover (Item 2) from transaxle case. Figure 42 Workman 3000/4000 Series Page 6 –...
Page 100 23.Disassemble main shaft assembly: A. Use a bearing puller to remove bearing (Item 1) from main shaft. B. Remove snap ring (Item 2) and washer (Item 3). Measure thickness of washer. Replace washer if it is less than .0709 in. (1.8 mm) thick. C.
Page 101 24.Disassemble reduction shaft assembly: A. Use a bearing puller to remove bearing (Item 1) from reduction shaft. B. Remove gear (Item 2), helical gear (Item 3), collar (Item 4) and gear (Item 5). C. Use a bearing puller to remove bearing (Item 6). D.
Page 102 25.Disassemble reverse shaft assembly: A. Use a bearing puller to remove bearing (Item 1) from reverse shaft. B. Remove gear (Item 2). C. Use a bearing puller to remove bearing (Item 3) from reverse shaft. Figure 47 26.Disassemble countershaft assembly: A.
Page 103 27.Disassemble fork shaft assemblies: A. Remove lock pin (Item 1) from 2nd–3rd fork shaft assembly. B. Remove shift fork (Item 2) from fork shaft. C. Remove lock pin (Item 1) from 1st–R fork shaft assembly. D. Remove fork (Item 2) from fork shaft. Figure 50 28.Disassemble Hi–Lo fork shaft assembly: A.
Page 104 30.Disassemble differential fork shaft assembly: A. Remove O–ring (Item 1) from fork shaft. B. Remove snap ring (Item 2), washer (Item 3) and spring (Item 4). C. Remove fork (Item 5). D. Remove lock pin (Item 6) if necessary. Figure 54 31.Disassemble axle shaft assemblies: A.
Page 105: Inspection
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. B. Inspect inner tapered area for excessive wear or damage.
Page 106 6. Inspect hub, shifter, synchro key and synchro spring: A. Inspect hub for worn or damaged spline. B. Inspect shifter for chipping or damaged chamfer. C. Inspect synchro keys for wear or damage. D. Inspect synchro springs for wear or damage. E.
Page 107 9. Inspect center plate for cracks and damage. Replace center plate if the snap ring groove has more than 15% of its edges damaged due to nicks, rounding, cracks, or dents (Fig. 61 and 62). UNDAMAGED GROOVE Figure 61 DAMAGED GROOVE EDGES Figure 62 Workman 3000/4000 Series...
Page 108 10.Inspect reduction shaft for wear or damage. If O.D. of needle bearing area is less than .864 in. (21.95 mm) or .982 in. (24.95 mm), replace the reduction shaft. Figure 63 11. Inspect countershaft for wear or damage. If O.D. of inner portion is less than 1.100 in.
Page 109: Assembly
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 be- fore reassembling. Make sure all parts are clean and free of dirt and dust. IMPORTANT: Be careful not to damage mating sur- faces when removing gasket material.
Page 110 5. Assemble differential gears: A. Apply moly disulfide grease on pinion liners (Item 11), holes of pinion gears (Item 10), side gear liners (Item 14) and hubs of side gears (Item 13, 12). B. Install side gear liners (Item 14), side gears (Item 13, 12), pinion liners (Item 11) and pinion gears (Item 10).
Page 111 6. Assemble Hi–Lo fork shaft: A. Install E–ring (Item 4) onto fork shaft (Item 5). B. Insert spring (Item 3) and steel ball (Item 2) into fork (Item 1). C. Insert fork shaft into fork. Put moly disulfide grease onto the shaft before installing. 7.
Page 112 8. Assemble countershaft: A. Use a press to install 2 new bearings (Item 15) onto countershaft. B. Install collar (Item 14) and snap ring (Item 13). C. Install washer (Item 12) and gear (Item 11). Apply moly disulfide grease into bushing of countershaft gear before installing.
Page 113 9. Assemble synchro hub: A. Install 3 keys (Item 1) into grooves of hub (Item 2). Figure 76 B. Install shifter (Item 1) onto hub (Item 2). Figure 77 C. Insert 2 springs (Item 3) into hub. Pay attention to direction of spring.
Page 114 10.Assemble reduction shaft: A. Install washer(s) (Item 17), 2 needle bearings (Item 16) and gear (Item 15) onto reduction shaft (Item 18). Apply moly disulfide grease to washer and needle bearings before installing. Oil groove on washer must face the gear. B.
Page 115 11. Assemble reverse shaft: A. Install gear (Item 2) onto reverse shaft. B. Use a press to install bearings (Item 3 and 1). Figure 82 12.Assemble main shaft: A. Install gear (Item 18), gear (Item 17) and snap ring (Item 16). B.
Page 116 13.Assemble shift arms: 200 to 280 in–lb 200 to 280 in–lb (22.6 to 31.6 N–m) (22.6 to 31.6 N–m) A. Install 3 new oil seals (Item 14) onto transaxle case. Apply multi–purpose grease on lips of oil seals before installing. B.
Page 117 16.Install reduction shaft and countershaft together with R–1 fork shaft and Hi–Lo fork shaft. Insert heads of shift arms into grooves of forks when installing them. Figure 88 Figure 89 17.Install main shaft together with 2–3 fork shaft. Insert head of shift arm into groove of fork while installing. Figure 90 Figure 91 Workman 3000/4000 Series...
Page 118 18.Install reverse shaft (Item 1). Rotate main shaft and reverse shaft gears to mesh gears when installing. Figure 92 19.On 4WD vehicles, install bearing to gear case (see FRONT DRIVE Item 2 of Fig. 92) and center plate. Install front drive shaft SHAFT and 41T gear to the gear case.
Page 119 NOTE: The thickest shim of the shim set (Item 2) should be positioned against the snap ring (Fig. 95). 21.Insert tabbed shim (Item 4) against the bearing. In- sert shim set (Item 2) against the tabbed shim. Use thickest shims in set possible, that will permit installation of the snap ring.
Page 120 23.Measure countershaft end play. Rotate one of the axle shafts back and forth to take up all back lash. Rotat- ing the shaft in one direction will pull the shaft and bear- ing away from the snap ring. Rotate axle shaft in this direction, then measure space between the snap ring and shim (set) with a feeler gauge.
Page 121 25.Install fork shaft case: A. Insert spindle (Item 1) between fork shafts. Figure 100 B. Insert 2 steel balls (Item 2) and 2 springs (Item 1) into the grooves. Figure 101 C. Apply silicone sealant to mating surface of fork shaft case.
Page 122 27.Install differential gear assembly (Item 1) together with fork shaft (Item 2) onto transaxle case. 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. C.
Page 123 30.Install L.H. axle shaft assembly: A. Thoroughly clean mating surface of differential carrier and side cover (Item 1). B. Insert selected shims (Item 2) into housing of side cover. NOTE: The thickest shim should be inserted against the bearing. Figure 108 C.
Page 124 32.Install differential lock arm (Item 1) onto fork shaft. In- sert lock pin into fork shaft and arm. Pay attention to direction of slit in lock pin. Figure 111 33.Apply silicone sealant to mating surface of upper cover (Item 2). Pay attention to direction of cover and install.
Page 125 34.Apply multi–purpose grease to O–ring and insert O– ring into groove of transaxle case. If installing P.T.O., in- sert 2 dowel pins in transaxle case. Install P.T.O. or cover. Tighten nut with lockwasher (Item 2) and cap screws (Item 1) to a torque from 11 to 13 ft–lb (15 to 17 N–m).
Page 126: Power Take-Off (Pto) Service
Power Take–Off (P.T.O.) Service 18 to 22 ft–lb (24.5 to 29.5 N–m) Figure 115 1. PTO cover 13. Shift collar 25. Intermediate shaft 2. Cap screw (4 used) 14. Gear (29T) 26. Gear (37T) 3. Lock washer (7 used) 15. Bushing 27.
Page 127 5. Remove PTO output shaft assembly (Item 1) from PTO housing. Remove oil seal from PTO cover. Figure 117 6. Remove intermediate shaft assembly (Item 1) from PTO housing. Remove intermediate gear (Item 2). Re- move bearing (Item 3) from housing if necessary. Figure 118 Figure 119 Workman 3000/4000 Series...
Page 128 7. Remove PTO input shaft from PTO housing: A. Shift PTO to ”ON” position. B. Remove 2 retaining rings (Items 1 and 2) from PTO housing. C. Slide input shaft assembly (Item 3) toward PTO shaft side. D. Remove bearing (Item 4). E.
Page 129 9. Disassemble PTO intermediate shaft: A. Use a bearing puller to remove bearing (Item 1) if necessary. Figure 123 10.Disassemble PTO output shaft: A. Use a bearing puller to remove bearing (Item 1). B. Remove gear (Item 2) and retaining ring (Item 3). C.
Page 130: Inspection
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 ex- ceeds .039 in. (1.0 mm). Figure 127 4.
Page 131: Assembly
Assembly (Fig. 115) 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 mating surfaces of hous- ing and cover. IMPORTANT: Be careful not to damage mating sur- faces when removing gasket material.
Page 132 4. Assemble PTO output shaft: A. If bearing (Item 6) was removed, use a press to install bearing onto output shaft. B. Install washer (Item 5) and retaining ring (Item 4). C. Install retaining ring (Item 3) and gear (Item 2). D.
Page 133 7. Install PTO input shaft sub–assembly: A. Insert shifter block (Item 9) onto pin of shift arm. Apply moly disulfide grease onto both sides of block before installing. B. Put shift collar of PTO input shaft sub–assembly (Item 3) on the shifter block. C.
Page 134 8. Install PTO intermediate shaft sub–assembly: A. If removed during disassembly, insert bearing (Item 3) into PTO housing. Figure 142 B. Put gear (Item 2) on mating gear. C. Move gear until bores of gear and bearing line up. D. Insert intermediate shaft sub–assembly (Item 1). Apply grease to intermediate shaft to aid assembly.
Page 135 10.Install PTO cover: A. Insert new oil seal into PTO cover. Apply multi– purpose grease to lip of oil seal. B. Insert two (2) alignment pins into PTO housing. C. Apply silicone sealant onto mating surface of PTO cover. D. Install PTO cover. Tighten cap screws and nut with lockwasher to a torque from 18 to 22 ft–lb (24.5 to 29.5 N–m).
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Page 137 Chapter 7 Chassis Table of Contents SPECIFICATIONS ......Brake Master Cylinder ..... . 20 SPECIAL TOOLS .
Page 138: Specifications
Specifications Item Specification Front wheel toe–in 0 to 0.125 in. (0 to 3 mm) Front tire 20” x 10” – 10, 4 ply Maximum front tire pressure 20 PSI Rear tire 24” x 12” – 12, 6 ply Maximum rear tire pressure 18 PSI Wheel nut torque 45 to 65 ft–lb (61 to 88 N–m)
Page 139: Special Tools
Special Tools Compression Spring Tool Use to remove and install the two (2) front suspension compression springs. 5” Qty. Item 1/2” x 20” threaded steel rods 1/2” nuts 5” 1/2” flat washers 20” Figure 1 Workman 3000/4000 Series Page 7 – 3 Chassis...
Page 140: Troubleshooting
Troubleshooting Suspension and Steering Problem Possible Causes Front end noise. Loose or worn front wheel bearings. Worn front shock absorbers. Worn stabilizer link bushings. Loose steering components (e.g. tie rods, steering cylinder). Worn control arm bushings. Tire pressure low (4WD vehicles). Worn tires (4WD vehicles).
Page 141 Suspension and Steering (Continued) Problem Possible Causes Hard steering. Loose, worn or glazed hydraulic pump drive belt. Binding or damaged steering linkage. Low or uneven tire pressure. Low hydraulic pressure (see Chapter 9 – Hydraulic System). Damaged or binding steering cylinder. Worn or damaged steering control valve.
Page 142: Brakes
Brakes Problem Possible Causes Brake pedal goes to floor. Incorrectly adjusted brakes. Low brake fluid level. Air in brake system. Leaking wheel cylinder(s). Loose or broken brake lines. Leaking or worn brake master cylinder. Excessively worn brake shoes or drums. Spongy brake pedal.
Page 143 Brakes (Continued) Problem Possible Causes Dragging brakes. Improper brake or parking brake adjustment. Parking brake engaged. Weak or broken brake shoe return spring. Binding brake pedal. Sticking brake master cylinder. Saturated brake linings. Bent or out of round brake drums. Hard brake pedal.
Page 144: Service And Repairs
Service and Repairs Wheel Installation 1. Mount wheel and evenly tighten wheel nuts to a torque from 45 to 65 ft–lb (61 to 88 N–m). WARNING Failure to maintain proper wheel nut torque could result in failure or loss of wheel and may result in personal injury.
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Page 146: Front Wheel Assembly (2 Wheel Drive)
Front Wheel Assembly (2 Wheel Drive) 45 to 65 ft–lb (61 to 88 N–m) Loctite #680 40 to 60 ft–lb (54 to 81 N–m) See tightening procedure in text ACCESS HOLE RIGHT FRONT Figure 3 1. Dust cap 8. Brake drum 15.
Page 147 4. Carefully slide wheel hub with inner bearing cone 8. Adjust brake shoes: and seal onto spindle. Fill cavity of wheel hub 50% full A. Align access hole in brake drum with adjuster bolt with grease. on adjuster assembly. 5. Pack outer bearing cone with grease and insert it into B.
Page 148: Rear Wheel Assembly
Rear Wheel Assembly 40 to 60 ft–lb (54 to 81 N–m) 220 to 250 ft–lb Loctite #680 (298 to 339 N–m) 45 to 65 ft–lb (61 to 88 N–m) RIGHT 200 to 250 in–lb (22.6 to 28.3 N–m) ACCESS HOLE FRONT Figure 4 1.
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Page 150: Brake Service
Brake Service 49 to 97 in–lb (5.5 to 11 N–m) Figure 5 1. Cap screw and lock washer (2 used) 10. L–type seal 19. Pawl 20. Adjuster spring 2. Backing plate 11. Piston 3. Plug 12. Dust cover 21. Pawl pin 4.
Page 151 Disassembly (Fig. 5 and 6) B. Replace drums if they are cracked or heat spotted. 1. Partially loosen wheel nuts then jack up and support vehicle (see Jacking Instructions in Operator’s Manual). C. Scoring, grooves, taper, out of round and glazing Remove wheel nuts and then remove wheel.
Page 152 4. Inspect upper shoe spring (14), lower shoe spring 11. If servicing front brakes, install wheel hub to vehicle (15) and adjuster spring (20). (see Front Wheel Assembly (2 Wheel Drive) in this sec- tion for series 3000 Workman vehicle or see Front A.
Page 153: Wheel Brake Cylinder Service
Wheel Brake Cylinder Service Disassembly 1. Disassemble brakes as described in Brake Service. 2. If brake line is still attached to brake cylinder, discon- nect brake line from cylinder. Put a cap on brake line to prevent contamination of system and brake fluid leak- age.
Page 154: Bleeding The Brakes
Bleeding the Brakes 1. Connect a suitable transparent hose to bleeder valve on right rear wheel cylinder and submerge other end of hose in a glass container partially filled with clean brake fluid. 2. Have a helper pump brake pedal several times, then hold pedal down firmly.
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Page 156: Brake Master Cylinder
Brake Master Cylinder RIGHT FRONT Figure 9 1. Brake master cylinder 3. Clevis pin 5. Flange nut (2 used) 2. Cap screw (2 used) 4. Cotter pin 6. Brake pedal Removal (Fig. 9) Installation (Fig. 9) 1. Remove cotter pin from the clevis pin that connects 1.
Page 157: Brake Master Cylinder Service
Brake Master Cylinder Service Disassembly (Fig. 10) 1. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 2. Disconnect lower end of the dust cover from the housing. 3. Push in on the push rod and remove circlip, then re- move push rod with dust cover and clevis.
Page 158: Parking Brake Cable Replacement
Parking Brake Cable Replacement Removal (Fig. 11) 7. Install center console control plate and control lever knobs. 1. Remove brake handle from parking brake lever. Loosen set screw on parking brake control lever knob. 8. Adjust parking brake lever (see Operator’s Manual) Turn knob on parking brake lever counterclockwise all and check operation of brakes before using the vehicle.
Page 159: Steering Wheel
Steering Wheel Removal (Fig. 14) 1. Carefully remove steering wheel cover from steering wheel. 2. Remove hex nut and lock washer that secure steer- ing wheel to steering control valve. 20 to 26 ft–lb (28 to 35 N–m) 3. Pull steering wheel from control valve. Installation (Fig.
Page 160: Control Arm Ball Joint Replacement
Control Arm Ball Joint Replacement 80 to 90 ft–lb (108 to 122 N–m) RIGHT FRONT Figure 15 1. Cotter pin 5. Snap ring 9. Flange bushing 2. Slotted hex nut 6. Ball joint 10. Cap screw 3. Upper control arm (RH shown) 7.
Page 161: Tie Rod End Replacement
Tie Rod End Replacement 45 to 55 ft- -lb (61 to 75 N- -m) 50 ft- -lb (68 N- -m) RIGHT FRONT 45 to 55 ft- -lb (61 to 75 N- -m) Figure 16 1. Tie rod end 4. Tie rod 7.
Page 162: Front Wheel Alignment
Front Wheel Alignment 1. Before inspecting or adjusting front wheel alignment, check that when fully retracted, the steering cylinder has CYLINDER LENGTH WHEN FULLY RETRACTED a length as shown in Figure 17. If the retracted cylinder length is incorrect, see Steering Cylinder Installation in Service and Repair section of Chapter 9 -- Hydraulic System for steering cylinder ball joint installation proce- dure.
Page 163: Front Compression Spring Service
Front Compression Spring Service COMPRESSION SPRING TOOL TOP VIEW 20 I Control arm tower (4) 1/2 flat washers Compression spring tool rod (2) 1/2 steel rods Spring cradle Compression (4) 1/2 nuts spring Install compression spring tool rods with extended portion on opposite ends so cap screws (Item 7) securing spring cradles to control arm tower can be removed.
Page 164: Front Shock Absorber Replacement
Front Shock Absorber Replacement 1. Remove lower and upper lock nuts, then remove shock absorber and washers. Note that washers on up- per end of shock absorber are different. Washers on lower end of shock are identical. 2. Insert two (2) new rubber bushings into each end of new shock absorber.
Page 165: Rear Shock Absorber Replacement
Rear Shock Absorber Replacement 1. Remove lower and upper lock nuts, then remove shock absorber and washers from vehicle. 2. Insert two (2) new rubber bushings into each end of new shock absorber. 3. Install one large washer onto each shock absorber mounting stud.
Page 166: Rear Leaf Spring Replacement
Rear Leaf Spring Replacement RIGHT FRONT See tightening procedure in text Figure 25 1. Lock nut 6. Lock nut (4 used per spring) 11. Spring mount 2. Spring shackle 7. Washer (4 used per spring) 12. Flange nut (2 per mount) 3.
Page 167 Installation (Fig. 25) 1. Before installing new leaf spring, insert four (4) rub- Make sure axle and plate are centered ber bushings (Item 3) into leaf spring. Insert two (2) rub- on leaf spring knob ber bushings into frame side rail. 2.
Page 168: Seat Base
Seat Base RIGHT FRONT Figure 27 1. Passenger seat 5. Coolant reservoir 9. Cap screw 2. Screw (6 used) 6. Operator seat 10. Seat base 3. Control plate 7. Lock nut 11. Socket head screw (4 used per seat) 4. Hose to radiator 8.
Page 169 Removal (Fig. 27) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. 2. Remove ROPS from vehicle (Fig. 28) 3. Remove knobs from control levers, then remove center console control plate assembly. 4.
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Page 171 Chapter 8 Electrical System Table of Contents ELECTRICAL SCHEMATICS ....2 Start Relay (Kohler Engine) ....11 SPECIAL TOOLS .
Page 172: Electrical Schematics
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 me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 173: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and com- CAUTION ponents used on this vehicle (see Vehicle Electrical Schematics in Chapter 11). Remove all jewelry, especially rings and If the vehicle has any interlock switches by–passed, they watches, before doing any electrical trouble- must be reconnected for proper troubleshooting and shooting or testing.
Page 174 Condition Possible Cause Nothing happens when start attempt is made. Clutch pedal not depressed – instruct operator. PTO engaged – instruct operator. Low battery charge. Loose or corroded battery cables. Loose or corroded ground. ”RUN” fuse open. Fusible link open. Clutch cable out of adjustment.
Page 175: Electrical System Quick Checks
Electrical System Quick Checks Battery Test (Open Circuit Test) Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 v (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery 12.45 v 75% charged should be at a temperature of 60...
Page 176: Verify Interlock System Operation
Verify Interlock System Operation The purpose of the interlock system is to prevent the en- To verify operation of hydraulic lift interlock switch gine from cranking or starting unless the clutch pedal is (TC models): depressed (all models), the hydraulic lift lever is in the 1.
Page 177: Component Testing
Component Testing This section will define given components, and the tests NOTE: Electrical troubleshooting of any 12 Volt power that can be performed on those components, when connection can also be performed through voltage drop those parts are disconnected from the electrical system. tests without disconnection of the component.
Page 178: Clutch Switch
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. Test the switch by disconnecting the wiring connector and connecting a continuity tester across the two termi- nals.
Page 179: Transaxle Lockout Switches
Transaxle Lockout Switches 2–3 Lockout Switch The transaxle 2–3 Lockout switch is closed in 2nd gear and open in 3rd gear. Test the switch by disconnecting the wiring connector and connecting a continuity tester across the two termi- nals. With the engine off, move transmission shifter to 2nd gear –...
Page 180: Start (Briggs/Daihatsu Gas And Diesel Engine) And Fuel Pump (Briggs/Daihatsu Gas
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 gaso- line engine are identical.
Page 181: Glow Relay (Briggs/Daihatsu Diesel Engine)
Glow Relay (Briggs/Daihatsu Diesel Engine) On Workman vehicles with a diesel engine, the glow relay is attached to the the hydraulic oil filter bracket. Two styles of glow relays have been used on the Work- man. On machines with serial numbers below 260000000, two of the four relay connections are se- cured with screws (Fig.
Page 182: Battery
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. Figure 13 1.
Page 183: High Temperature Shutdown Switch (Briggs/Daihatsu Gas And Diesel Engine)
High Temperature Shutdown Switch (Briggs/Daihatsu Gas and Diesel Engine) The high temperature shutdown switch is threaded into the thermostat housing (Fig. 15). There s a blue wire at- tached to the switch. Testing CAUTION Make sure engine is cool before removing the temperature switch.
Page 184: Fuel Gauge Sender
Fuel Gauge Sender Disconnect wire and remove the fuel gauge sender from the fuel tank. 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.
Page 185 Glow Plug Switch (Briggs/Daihatsu Diesel Engine) The glow plug switch is located on the control panel on vehicles powered with a diesel engine. This rocker switch allows the glow plugs to be energized. The switch terminals are marked as shown in Figure 20. The circuitry of the glow plug switch is shown in the chart below.
Page 186: Diode Assembly (Kohler Engine)
Diode Assembly (Kohler Engine) The diode assembly on Kohler powered Workman ve- hicles is used for circuit protection from voltage spikes that occur when the starter solenoid is de–energized. The diode assembly plugs into the vehicle wiring har- ness (see Workman 3100 electrical schematic in Chap- ter 11 –...
Page 187: Service And Repairs
Service and Repairs Battery Service The battery is the heart of the electrical system. With reg- ular and proper service, battery life can be extended. Ad- ditionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid slashing or spilling electrolyte.
Page 188 2. If battery filler caps are removable, conduct a D. If battery filler caps are removable, measure the hydrometer test of the battery electrolyte. temperature of the center cell. IMPORTANT: Make sure the area around the cells is E. Connect a battery load tester to the battery termi- clean before opening the battery caps.
Page 189 6. Apply a light coat of grease on all battery posts and Battery Battery Charge Level cable connectors to reduce corrosion after connections Reserve (Percent of Fully Charged) are made. Capacity Capacity (Minutes) 7. Connect a digital multimeter (set to amps) between 80 or less 3.8 hrs 7.5 hrs...
Page 190: Tail Lamp Replacement
Headlight Replacement Disassemble and assemble headlight as follows: 1. Set parking brake, turn ignition off, and remove key. 2. Reach beneath dash and disconnect the wiring har- ness connector from the headlight. 3. From beneath the dash, push headlight out of the hood.
Page 191 Chapter 9 Hydraulic System Table of Contents SPECIFICATIONS ......SERVICE and REPAIRS .
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Page 193: Specifications
Specifications Item Description Hydraulic Pump Positive Displacement Gear Pump Pump Performance 4 GPM (15 LPM) at 1,500 PSI (103.4 Bar) System Relief Pressure 1,800 PSI (124.1 Bar) Lift Control Valve Three position control valve Spring return to neutral Ball checks to maintain load Hydraulic Oil Dexron III ATF Reservoir (Transaxle)
Page 194: General Information
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such as pressure differentials during operation and exposure WARNING to weather, sun, chemicals, very warm storage condi- tions, or mishandling during operation or maintenance. Before disconnecting or performing any work These conditions can cause damage or premature dete- on hydraulic system, relieve all pressure in rioration.
Page 195 SAE Straight Thread O–Ring Port – Non–adjustable 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O–ring seal when this type of fit- ting shows signs of leakage. 3.
Page 196: Hydraulic Schematics
Hydraulic Schematics Vehicle Hydraulic Schematic Hydraulic System Page 9 – 6 Workman 3000/4000 Series...
Page 197: High Flow Hydraulic Kit (Optional) Schematic
High Flow Hydraulic Kit (Optional) Schematic Workman 3000/4000 Series Page 9 – 7 Hydraulic System...
Page 198: Hydraulic Circuit Operation
Hydraulic Circuit Operation Steering Circuit The hydraulic gear pump supplies flow for the steering Fluid leaving the steering cylinder flows back through circuit and for raising and lowering the bed. Pump output the spool valve, then out the T port and returns to the hy- flows to the steering control valve before reaching the lift draulic reservoir (transaxle).
Page 199: Raise And Lower Bed
Raise and Lower Bed The hydraulic gear pump supplies flow for the steering When the control valve lever is released, spring action circuit and for raising and lowering the bed. Pump output returns the lift valve spool to the center position and lift flows through the steering control valve and then to the cylinder movement is stopped.
Page 200: Special Tools
Special Tools Order these tools from your Toro Distributor. Hydraulic Pressure Test Kit (TOR47009) Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on vehicle test ports without tools. A high pressure hose is provided for remote readings.
Page 201: Hydraulic Test Fitting Kit
Hydraulic Test Fitting Kit (TOR4079) This kit includes a variety of O–ring Face seal fittings to TORO TEST FITTING KIT (NO. TOR4079) enable connection of test gauges to the hydraulic sys- tem. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.
Page 202: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic system ued use of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equip- could lead to extensive internal component damage. ment and a thorough understanding of the complete hy- The charts that follow contain information to assist in draulic system.
Page 203 Problem Possible Cause Lift cylinders extend with valve in Load checks in hydraulic lift valve are leaking. neutral position. Lift valve lever is sticking. Lift valve control handle is not in correct location. Hydraulic relief valve stuck or damaged (see TEST NO. 1). Bed drops from raised position with Improperly positioned valve.
Page 204 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Difficulty in connecting or discon- Pressure not relieved (coupler under pressure –...
Page 205: Testing
Testing The most effective method for isolating problems in the 3. The engine must be in good operating condition. Use a tachometer when making a hydraulic test. Engine hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits speed will affect the accuracy of the tester readings.
Page 206: Test No. 1: Gear Pump Flow And System Relief Pressure
TEST NO. 1: Gear Pump Flow and System Relief Pressure STEERING CONTROL STEERING CYLINDER TESTER LIFT CYLINDERS GEAR PUMP FILTER STRAINER LIFT VALVE TRANSAXLE RESERVOIR Figure 13 Figure 14 1. Gear pump 3. Suction hose 2. Pressure hose Hydraulic System Page 9 –...
Page 207 Procedure for Gear Pump Flow and System Relief 8. While watching tester pressure gauges, slowly close Pressure Test flow control valve on the tester until 1500 PSI (103.4 Bar) is obtained on gauge. Verify that pump speed con- 1. Make sure hydraulic oil is at normal operating tem- tinues to be correct (2700 RPM).
Page 208: Test No. 2: Steering Control Valve And Steering Cylinder
TEST NO. 2: Steering Control Valve and Steering Cylinder STEERING CONTROL (RIGHT TURN) PLUG STEERING CYLINDER LIFT CYLINDERS GEAR PUMP FILTER STRAINER LIFT VALVE TRANSAXLE RESERVOIR Figure 15 Hydraulic System Page 9 – 18 Workman 3000/4000 Series...
Page 209 Procedure for Steering Control Valve and Steering WARNING Cylinder Test 1. Make sure hydraulic oil is at normal operating tem- Keep body and hands away from disconnected perature by operating the vehicle for approximately 10 hoses and fittings that might eject hydraulic fluid minutes.
Page 210: Test No. 3: Lift Cylinder Internal Leakage
TEST NO. 3: Lift Cylinder Internal Leakage STEERING CONTROL STEERING CYLINDER LIFT CYLINDERS LIFT VALVE (IN LOWER POSITION) GEAR PUMP PLUG FILTER STRAINER TRANSAXLE RESERVOIR Figure 16 Hydraulic System Page 9 – 20 Workman 3000/4000 Series...
Page 211 Procedure for Lift Cylinder Internal Leakage Test Disconnect and plug this hose 1. Shut off engine and engage parking brake. ANY oil flow or droplets from this fitting indicates internal leak CAUTION Prevent personal injury and/or damage to equip- ment. Read all WARNINGS, CAUTIONS, and Pre- cautions for Hydraulic Testing at the beginning of this section.
Page 212 TEST NO. 4: High Flow Hydraulic Kit (Optional) Gear Pump Flow and Relief Pressure QUICK DISCONNECT COUPLINGS HYDRAULIC TESTER GEAR PUMP .610 IN /REV .833 ENGINE SOLENOID SPEED ACTIVATED BYPASS VALVE (ENERGIZED) RELIEF VALVE 2000 PSI IN TANK SUCTION STRAINER 100 MESH OIL COOLER RETURN FILTER...
Page 213 Procedure for High Flow Hydraulic Kit (Optional) 8. With Kit switch still in the ON position, watch tester Gear Pump Flow and System Relief Pressure Test pressure gauges while slowly closing flow control valve on the tester until 1500 PSI (103.4 Bar) is obtained on 1.
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Page 215: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the transaxle and add correct oil if tem, park vehicle on a level surface, engage parking necessary.
Page 216: Gear Pump (Vehicles With Liquid Cooled Engine)
Gear Pump (Vehicles with Liquid Cooled Engine) Removal (Fig. 20) 3. Check oil level in transaxle (see Operator’s Manual). Add Dexron III ATF if necessary. 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage parking brake. 4.
Page 217: Gear Pump (Vehicles With Air Cooled Engine)
Gear Pump (Vehicles with Air Cooled Engine) Removal (Fig. 22) 3. Check oil level in transaxle (see Operator’s Manual). Add Dexron III ATF if necessary. 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking 4.
Page 218: Gear Pump Service Barnes Gear Pump)
Gear Pump Service (Barnes Gear Pump) 9.5 to 12.5 ft- -lb (13 to 17 N- -m) Figure 23 1. Retaining ring 9. Seal plate 17. Gear end housing 2. Shaft seal 10. Wear plate 18. Socket head cap screw 3. Spacer 11.
Page 219 Disassembly (Fig. 23) Assembly (Fig. 23) 1. Remove shaft seal (see Shaft Seal Replacement). 1. Install one crescent ring (Item 4) on inside portion of driveshaft (Item 6), then install bearing (Item 22) and IMPORTANT: Use caution when using a vise to other crescent ring.
Page 220: Gear Pump Service (Casappa Gear Pump)
Gear Pump Service (Casappa Gear Pump) 220 in- -lb (25 N- -m) Figure 23.1 1. Retaining ring 7. Pressure seal 13. Pressure seal 2. Shaft seal 8. Front thrust plate 14. Back- -up seal 3. Front cover 9. Drive shaft 15.
Page 221 IMPORTANT: Make sure to not damage the seal bores when removing the seal from the front cover and rear flange. 10.Carefully remove retaining ring and shaft seal from front cover. Discard seal. Inspection 1. Remove any nicks and burrs from all parts with emery cloth.
Page 222 12.Carefully install rear flange onto pump assembly. 15.Remove pump from vise. 13.Install the four (4) screws (item 17) with lock washers 16.Place a small amount of clean Dexron III ATF in the and hand tighten. inlet of the pump and rotate the drive shaft away from the inlet one revolution.
Page 223 This page is intentionally blank. 29.4 Rev. D Workman 3000/4000 Series Page 9 - - Hydraulic System...
Page 224: Lift Valve
Lift Valve RIGHT FRONT Figure 24 1. Lift valve 8. Lift lever 15. Hyd. hose (to female quick fitting) 2. O–ring 9. Clevis pin 16. 90 hydraulic fitting 3. Tee fitting 10. Hairpin 17. O–ring 4. Hyd. hose (steering circuit return) 11.
Page 225 Removal (Fig. 24) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. 2. Remove seat base from vehicle (see Seat Base Re- moval in the Service and Repairs section of Chapter 7 –...
Page 226: Lift Valve Service
Lift Valve Service Disassembly (Fig. 26) 1. After removing lift valve from vehicle, wash valve in solvent and dry thoroughly. 2. Carefully mount lift valve in a vise so that mounting pads are against jaws of vise. Lift valve spool retaining ring (Item 14) should be facing up.
Page 227 This page is intentionally blank. Workman 3000/4000 Series Page 9 – 33 Hydraulic System...
Page 228: Steering Control Valve
Steering Control Valve 20 to 26 ft- -lb (28 to 35 N- -m) RIGHT FRONT CONTROL VALVE PORTS Anti- -seize Lubricant FRONT OF VEHICLE Figure 27 1. Hex nut 8. Hyd hose (to control valve R port) 15. Bulkhead fitting (to valve R port) 2.
Page 229 7. Start the engine, operate at idle speed and rotate the steering wheel in both directions until air is out of hydrau- CAUTION lic system. 8. Stop the engine and check oil level in transaxle (see Before performing any service or repair on hy- Operator’s Manual).
Page 230: Sauer/Danfoss Steering Unit Type Ospm Service Manual
Steering Control Valve Service 20 to 24 ft–lb (27 to 33 N–m) Figure 30 1. Sleeve 9. Dust seal ring 16. Outer gearwheel 2. Cross pin 10. Housing 17. End cover 3. Ring 11. Cardan shaft 18. O–ring (5 used) 4.
Page 231 This page is intentionally blank. Workman 3000/4000 Series Page 9 – 37 Hydraulic System...
Page 232: Steering Cylinder
Steering Cylinder RIGHT FRONT Figure 31 1. Steering cylinder 6. Hyd. hose (from steering valve L) 11. Dust seal 2. Retaining ring 7. 45 hydraulic fitting 12. Cotter pin 3. Grease fitting 8. Jam nut 13. Ball joint 4. 90 hydraulic fitting 9.
Page 233 Removal (Fig. 31) 50 ft- -lb 1. Park vehicle on a level surface, shut engine off and (68 N- -m) engage the parking brake. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter. CAUTION Before performing any service or repair on hy- draulic system components, relieve system...
Page 234: Steering Cylinder Service
Steering Cylinder Service 30 to 36 ft–lb (41 to 49 N–m) Figure 34 1. Lock nut 6. Head 11. Wiper 2. Wear ring 7. O–ring 12. Barrel 3. Seal 8. Back–up ring 13. Shaft 4. O–ring 9. Retaining ring 14. O–ring 5.
Page 235 Inspection 1. Inspect head (Item 6), piston (Item 5) and shaft (Item 13) for excessive scoring, pitting or wear. Replace any Spanner wrench worn or damaged parts. 2. Inspect inside of barrel for scoring, pitting or out–of– round and replace if worn or damaged. Assembly (Fig.
Page 236: Lift Cylinder
Lift Cylinder RIGHT FRONT Figure 37 1. Box frame 5. Hydraulic hose 9. Engine support 2. O–ring 6. Lift cylinder (LH shown) 10. Frame rail (LH shown) 3. Hydraulic fitting 7. Hydraulic hose 11. Clevis pin 4. O–ring 8. Cotter pin 12.
Page 237 Removal (Fig. 37) Installation (Fig. 37) 1. Park vehicle on a level surface, lower bed until clevis 1. Make sure that lift cylinder is fully retracted. pins that secure lift cylinder to bed are loose in the bed 2. Position lift cylinder to vehicle. Secure lift cylinder to slots.
Page 238: Lift Cylinder Service
Lift Cylinder Service 60 to 75 ft–lb (81 to 102 N–m) Figure 38 1. Lock nut 6. Head 11. Wiper 2. Wear ring 7. O–ring 12. Barrel 3. Seal 8. Back–up seal 13. Shaft 4. O–ring 9. Retaining ring 14. O–ring 5.
Page 239 Inspection 1. Inspect head (Item 6), piston (Item 5) and shaft (Item 13) for excessive scoring, pitting or wear. Replace any Spanner wrench worn or damaged parts. 2. Inspect inside of barrel for scoring, pitting or out–of– round and replace if worn or damaged. Assembly (Fig.
Page 240: Hydraulic Manifold (Optional High Flow Hydraulic Kit)
Hydraulic Manifold (Optional High Flow Hydraulic Kit) Removal (Fig. 41) 1. Park vehicle on a level surface, raise bed, shut en- RIGHT gine off and engage the parking brake. FRONT 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter.
Page 241 4. Visually inspect the port in the manifold for damage 7. Reinstall the cartridge valve: to the sealing surfaces, damaged threads, and contami- A. Lubricate new seal kit components with clean hy- nation. draulic oil and install on valve. The o–rings, sealing 5.
Page 242 This page is intentionally blank. Hydraulic System Page 9 – 48 Workman 3000/4000 Series...
Page 243 Chapter 10 Front Wheel Drive (4WD) Table of Contents SPECIFICATIONS ......2 Constant Velocity (CV) Joint ....12 GENERAL INFORMATION .
Page 244: Specifications
Specifications Item Description Front Differential 5.0 to 1 ratio, single reduction Front Brakes Hydraulically operated, self adjusting, 8–inch diameter drum Bidirectional Clutch Overrunning type Front Wheel Drive (4WD) Page 10 – 2 Workman 4000 Series...
Page 245: General Information
General Information The “Automatic on Demand” four wheel drive feature, on have enough traction to move the vehicle without slip- this vehicle, does not require operator activation. The ping. Once this occurs, the system stops delivering pow- front wheel drive is not engaged (no power delivered to er to the front wheels and the handling characteristics front wheels) until the rear wheels begin to lose traction.
Page 246: Service And Repairs
Service and Repairs Front Wheel and Axle Housing Assembly 45 to 65 ft–lb (61 to 88 N–m) 40 to 60 ft–lb (54 to 81 N–m) LOCTITE #680 SMALL SPACER 170 to 200 ft–lb (230 to 271 N–m) ACCESS HOLE CONE RIGHT LOCTITE #271 FRONT...
Page 247 7. Remove four cap screws and lock washers securing the brake assembly (19) to the axle housing. Position brake assembly away from the housing. 8. Remove cotter pin and slotted hex nut from the tie 80 to 90 ft–lb rod end assembly. Separate tie rod end from the axle (108 to 122 N–m) housing.
Page 248 IMPORTANT: Bearing cones and bearing cups are 10.Connect tie rod end to the axle housing with slotted hex nut. Torque slotted hex nut from 45 to 55 ft–lb (61 to part of a matched bearing set; these parts are not in- terchangeable.
Page 249 This page is intentionally blank. Workman 4000 Series Page 10 – 7 Front Wheel Drive (4WD)
Page 250: Front Brake
Front Brake 45 to 65 ft–lb 40 to 60 ft–lb (61 to 88 N–m) (54 to 81 N–m) LOCTITE #680 SMALL SPACER 170 to 200 ft–lb (230 to 271 N–m) ACCESS HOLE RIGHT LOCTITE #271 FRONT APPLY GREASE TO SPLINES Figure 5 17.
Page 251 Installation (Fig. 5) IMPORTANT:Hex flange nut (23) should be replaced whenever it is removed. 1. If the brake assembly was removed from the axle housing, install brake assembly as follows: 6. Apply Loctite #271 (or equivalent) to the threads of the CV joint.
Page 252: Front Brake Service
Front Brake Service 49 to 97 in–lb (5.5 to 11 N–m) Figure 6 1. Cap screw and lock washer (2 used) 10. L–type seal 19. Pawl 2. Back plate 11. Piston 20. Adjuster spring 3. Plug 12. Dust cover 21. Pawl pin 13.
Page 253: Inspect Constant Velocity (Cv) Joint Boot And Test Cv Joint
Inspect Constant Velocity (CV) Joint Boot and Test CV Joint Inspect CV Joint Boot Inspect CV joint boot after every 200 hours of operation. A torn boot is the most common cause of CV joint fail- ures. NOTE: A worn and noisy CV joint with the boot in good condition and filled with grease is not uncommon.
Page 254: Constant Velocity (Cv) Joint
Constant Velocity (CV) Joint 45 to 65 ft–lb (61 to 88 N–m) 170 to 200 ft–lb (230 to 271 N–m) CONE RIGHT LOCTITE #271 FRONT APPLY GREASE TO SPLINES Figure 8 1. Wheel nut (5 used per wheel) 11. Flat washer 20.
Page 255 Removal (Fig. 8) LEVERAGE 1. Remove wheel, stub axle and axle housing from the POINT CV joint and front suspension (see Front Wheel And Axle Housing Assembly in this section). IMPORTANT: Make sure not to damage the oil seal on the front differential with the pry bars when re- moving the CV joints.
Page 256: Front Differential
Front Differential RIGHT FRONT Figure 10 1. Grease fitting 14. Front brake hose 27. Differential front bracket 2. Retaining ring 15. Cap screw (2 used per control arm) 28. Cap screw (3 used) 3. Upper control arm 16. Lock nut (2 used per control arm) 29.
Page 257 Removal (Fig. 10) Installation (Fig. 10) 1. Park vehicle on a level surface. Make sure engine is off. Set parking brake and block rear wheels. CAUTION 2. Drain front differential oil into a suitable container by removing the drain plug from its bottom. Install drain Support front differential during installation to plug when draining is complete.
Page 258: Front Differential Service
Front Differential Service 75 to 90 ft–lb 15 to 20 ft–lb (102 to 122 N–m) (20 to 27 N–m) 20 to 25 ft–lb (27 to 33 N–m) 30 to 45 ft–lb (41 to 61 N–m) BEARING CAP BEARING CRADLE 29 30 BEARING CAP 58 to 65 ft–lb (79 to 88 N–m)
Page 259 Disassembly (Fig. 11) 1. Remove flange (19) from the pinion shaft (8) by re- moving lock nut (18) and washer (17) from the threaded end of the shaft. Use a bearing puller if necessary to re- move the coupler flange (Fig. 12). 2.
Page 260 IMPORTANT: When using a hammer and punch to remove the roll pin (28) and pinion shaft (25), be careful not to damage any gear teeth. 6. Drive roll pin (28) from the pinion shaft (25) using a long thin drift punch (Fig. 16). 7.
Page 261 NOTE: Remove bearing cones (29) from the differen- tial 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.
Page 262 IMPORTANT: Make sure shims (14) are kept after they are removed from the carrier assembly (15). NOTE: Remove bearing cup (10) from the carrier hous- ing (15) only if it needs replacing (see Inspection). 14.Pull bearing cup (10) and shims (14) from the carrier assembly (15) (Fig.
Page 263 3. Inspect differential case (27) in the area where the bevel side gears (5) and pinion gear shafts (6) mesh. Replace case if machined areas are scored or if the pin- ion shaft (25) fits loosely in its bore (Fig. 28). IMPORTANT: The ring gear (32) and pinion gear (8) must be replaced as a matched set.
Page 264 Assembly (Fig. 11) PINION SHAFT (25) RING GEAR (32) PINION GEAR (6) CAP SCREW (26) THRUST WASHER (7) DIFFERENTIAL THRUST CASE (27) WASHER (4) SIDE BEVEL SHIM (31) GEAR (5) CAP SCREW (11) BEARING BEARING CRADLE BEARING CONE (29) BEARING CUP (30) 3.750 INCH ROLL PIN (28)
Page 265 The ring gear (32) and pinon gear (8) are supplied as a SHIMMING matched set. Both gears are etched for verification with DIMENSION 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 dif- ferential (Fig.
Page 266 2. If the bearing cup (23) was removed, press new bearing cup into the carrier assembly (15) (Fig. 35). 3. If the bearing cup (10) was removed, place shims (14) into the carrier assembly (15). Press new bearing cup into the assembly (Fig. 36). 4.
Page 267 6. Verify bearing preload and pinion gear shaft (8) rota- tion 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 ft–lb (102 to 122 N–m). B.
Page 268 IMPORTANT: When bearing cones (29) are removed removed from the differential case (27) they should replaced with new ones. When installing new bear- ing cones to the differential case, use original shims (31) or new shims of the same thickness. 8.
Page 269 12.Check backlash of ring gear (32) with a dial indicator at three equally spaced positions (Fig. 47). A. Backlash should be from 0.002 to 0.006 inch (0.051 to 0.152 mm) and should not vary more than 0.002 inch (0.051 mm). B.
Page 270: Ring To Pinion Gear Engagement
17.Make sure both plugs (12) and O–rings (13) are installed. Verify that plugs are torqued between 20 to 25 ft–lb (27 to 33 N–m). FILL PLUG DRAIN PLUG Figure 51 Ring to Pinion Gear Engagement When replacing the ring and pinion gear set, final posi- PROFILE tion of pinion is verified by using the gear contact pattern TOP LAND...
Page 271 When a change in backlash is required, backlash shims RING GEAR RING GEAR should be changed in the range of 1-1/2 times the COAST SIDE DRIVE SIDE amount of backlash required to bring the gears into Heel Heel specification. For example, if the backlash needed to be changed by .004”, the shim pack should be changed by .006”...
Page 272: Differential Drive Shaft
Differential Drive Shaft SNAP RING SNAP RING Figure 57 1. Flange yoke 4. Slip yoke 6. Seal 2. Cross and bearing kit 5. Grease fitting 7. Socket head screw (6 used) 3. Tube yoke Removal 1. Park vehicle on a level surface. Make sure engine is off.
Page 273: Drive Shaft Cross And Bearing Service
Drive Shaft Cross and Bearing Service 1. Remove drive shaft from vehicle (see Differential Drive Shaft Removal). 2. Remove snap rings that secure bearings. IMPORTANT: Yokes must be supported when re- moving and installing bearings to prevent damage. 3. Use a press to remove cross and bearings from yokes.
Page 274: Bidirectional Clutch
Bidirectional Clutch CAGE AND ROLLER ASSEMBLY Figure 61 1. Clutch shaft 8. Cam 14. Adapter plate 2. Seal plug 9. Thrust bearing 15. Screw (4 used) 3. Retaining ring 10. Thrust washer 16. Lock washer (6 used) 4. Ball bearing 11.
Page 275 Inspection (Fig. 61) 1. Replace cage (12) if it is bent, cracked, or broken. Corrosion that can not be cleaned up with light polishing is not acceptable. 2. Replace spring (11) if flattened or distorted. 3. Replace thrust washer (10) if flat surfaces are pitted, gouged, or distorted.
Page 276 Assembly (Fig. 61) 1. Clean all parts thoroughly of all dirt and debris to pre- vent damage to the bidirectional clutch and transaxle. 2. Place garter spring around the cage and into the groove (Fig. 66). 3. Place thrust bearing, thrust washer, and spring onto the cam (Fig.
Page 277 IMPORTANT: Make sure retaining ring (3) is proper- 7. Secure clutch shaft to housing and race (5) with lock ly seated in the drive shaft (19) groove. Pull clutch washers (16) and hex socket head screws (17). out from the transaxle to make sure that it holds in 8.
Page 278 This page is intentionally blank. Front Wheel Drive (4WD) Page 10 – 36 Workman 4000 Series...
Page 279 Chapter 11 Electrical Schematics Table of Contents VEHICLE ELECTRICAL SCHEMATICS Workman 3100 Serial Number Below 260000000 ... . . Serial Number Above 260000000 ... . . Workman 3200 and 4200 Serial Number Below 260000000 .
Page 280 This page is intentionally blank. Electrical Schematics Page 11 - - 2 Workman 3000/4000...
Page 281: Workman 3100
VIA MATING CONN FACTORY SHUNT B+ TO POSITIVE BATTERY CABLE REAR HARNESS GY+BK CLUTCH SWITCH PTO KIT (OFF) PK/BU PK/BU Start (ENGAGED) FRONT HARNESS PK/BU STARTER 10 A ENGINE FACTORY SHUNT VIA MATING CONN R/BK START ENABLE START HIGH FLOW HYDRAULICS KIT (OFF) PROTECTION DIODE (D2) P101--C 10 A...
Page 282: Serial Number Above 260000000
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...
Page 283 VIA MATING CONN FACTORY SHUNT B+ TO POSITIVE BATTERY CABLE REAR HARNESS GY+BK CLUTCH SWITCH PTO KIT (OFF) Start (ENGAGED) FRONT HARNESS STARTER 10 A ENGINE FACTORY SHUNT VIA MATING CONN R/BK START ENABLE VIA MATING CONN VIA MATING CONN START HIGH FLOW HYDRAULICS KIT (OFF) FACTORY SHUNT...
Page 284: Workman 3200 And 4200
Workman 3200 and 4200 Briggs/Daihatsu Gasoline Engine Vehicle Electrical Schematic Serial Number Above 260000000 All relays and solenoids are shown as de- - energized. Page 11 - - 6 Rev. C...
Page 285: Serial Number Below 260000000
VIA MATING CONN B+ TO POSITIVE BATTERY CABLE FACTORY SHUNT REAR HARNESS GY+BK CLUTCH SWITCH PTO KIT (OFF) Start (ENGAGED) FRONT HARNESS STARTER 10 A ENGINE FACTORY SHUNT VIA MATING CONN R/BK START ENABLE VIA MATING CONN VIA MATING CONN START HIGH FLOW HYDRAULICS KIT (OFF) FACTORY SHUNT...
Page 286: Serial Number Above 260000000
Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Vehicle Electrical Schematic Serial Number Above 260000000 All relays and solenoids are shown as de- - energized. Page 11 - - 8 Rev. C...
Page 287 This Page Is Intentionally Blank. Page 11 - - 9 Rev. C...
Page 288: Serial Number Below 270999999
SN 280000001 AND UP Workman 3000/4000 Front Wire Harness Drawing Serial Number Below 270999999 Page 11 - - 10 Rev. C...
Page 289 ORANGE SN 280000001 AND UP BLACK VIOLET/RED BLACK ORANGE BROWN/WHITE ORANGE GRAY YELLOW BLUE RED/BLACK BROWN WHITE/BLACK GREEN/BLACK ORANGE ORANGE GRAY RED/BLACK VIOLET YELLOW RED/WHITE BLUE/WHITE BLACK ORANGE ORANGE BLACK ORANGE ORANGE BLACK BLACK BLACK Workman 3000/4000 Front Wire Harness Diagram Serial Number Below 270999999 Page 11 - - 11 Rev.
Page 290: Serial Number Above 280000000
Workman 3000/4000 Front Wire Harness Drawing Serial Number Above 280000000 Page 11 - - 12 Rev. C...
Page 291 ORANGE BLACK VIOLET/RED BLACK ORANGE BROWN/WHITE ORANGE GRAY YELLOW BLUE RED/BLACK BROWN WHITE/BLACK GREEN/BLACK ORANGE ORANGE GRAY RED/BLACK VIOLET YELLOW RED/WHITE BLUE/WHITE BLACK ORANGE ORANGE BLACK ORANGE ORANGE BLACK BLACK BLACK Workman 3000/4000 Front Wire Harness Diagram Serial Number Above 280000000 Page 11 - - 13 Rev.
Page 292: Serial Number Below 260000000
FUEL SENDER TAIL LIGHT KILL RELAY C B A SPLICE ”E” BLACK 16A 17A 18A SPEED PICKUP 19A 34A PLUG P101 P100 START INTERCONNECT INTERCONNECT RELAY FRONT HARNESS FRONT HARNESS GROUND P102 INTERCONNECT SPEED FRONT HARNESS PICKUP SWITCH STARTER SPLICE ”C” SPLICE ”B”...
Page 293: Serial Number From 260000001 To 260000400
WIRE LIST Workman 3100 Kohler Gasoline Engine Rear Wire Harness Serial Number From 260000001 To 260000400 Page 11 - - 15 Rev. C...
Page 294: Serial Number Above 260000400
Workman 3100 Kohler Gasoline Engine Rear Wire Harness Drawing Serial Number Above 260000400 Page 11 - - 16 Rev. C...
Page 295: Serial Number Above 260000000
BLACK PINK GRAY GRAY BLACK PINK RED/BLACK BLACK FUSIBLE LINK BLUE/WHITE RED/WHITE RED/WHITE WHITE BROWN/WHITE BLACK BLACK BLACK RED/WHITE Workman 3100 Kohler Gasoline Engine Rear Wire Harness Diagram Serial Number Above 260000400 Page 11 - - 17 Rev. C...
Page 296: Serial Number Below 260000000
Workman 3200 and 4200 Briggs/Daihatsu Gasoline Engine Rear Wire Harness Drawing Serial Number Below 260000000 Page 11 - - 18 Rev. C...
Page 297 PINK YELLOW GRAY WHITE BLACK 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 BLUE BLUE/WHITE GREEN/WHITE GREEN VIOLET ORANGE THIS WIRE (DASHED LINE) INCLUDED Workman 3200 and 4200 ONLY IN SERIAL NUMBERS FROM 250000001 TO 250999999...
Page 298 Workman 3200 and 4200 Briggs/Daihatsu Gasoline Engine Rear Wire Harness Drawing Serial Number Above 260000000 Page 11 - - 20 Rev. C...
Page 299 GRAY GRAY 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 Workman 3200 and 4200 Briggs/Daihatsu Gasoline Engine Rear Wire Harness Diagram Serial Number Above 260000000 Page 11 - - 21 Rev.
Page 300 Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Drawing Serial Number Below 260000000 Page 11 - - 22 Rev. C...
Page 301 PINK YELLOW BLACK PINK WHITE GRAY BLUE/WHITE PINK BLACK PINK BLACK BLACK BLACK RED/BLACK BLACK WHITE/BLACK BROWN RED/BLACK RED/BLACK BROWN/WHITE BLACK VIOLET BLACK GRAY BLACK VIOLET/RED BLACK ORANGE YELLOW Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Diagram Serial Number Below 260000000 Page 11 - - 23 Rev.
Page 302: Serial Number From 260000000 To 270999999
Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Drawing Serial Number From 260000001 To 270999999 Page 11 - - 24 Rev. C...
Page 303 GRAY GRAY BLACK GRAY BLUE/WHITE PINK BLACK BLACK BLACK RED/BLACK BLACK WHITE/BLACK BROWN RED/BLACK BLACK ORANGE Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Diagram Serial Number From 260000001 To 270999999 Page 11 - - 25 Rev. C...
Page 304: Serial Number Above 280000000
Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Drawing Serial Number Above 280000000 Page 11 - - 26 Rev. C...
Page 305 GRAY GRAY BLACK GRAY BLUE/WHITE PINK BLACK BLACK RED/BLACK BLACK WHITE/BLACK BROWN RED/BLACK BLACK ORANGE Workman 3300 and 4300 Briggs/Daihatsu Diesel Engine Rear Wire Harness Diagram Serial Number Above 280000000 Page 11 - - 27 Rev. C...

This manual is also suitable for:

Workman 4000 series

Toro Workman 3000 Series Service Manual

Table of Contents

Chapter 1 Safety

Product Records

Briggs & Stratton/Daihatsu Repair Manual/For 3-Cylinder, Liquid-Cooled, Gasoline

Chapter 1 -- Safety

Chapter 2 -- Product Records and Maintenance

Chapter 3 -- Briggs/Daihatsu Gasoline Engine

Briggs & Stratton/Daihatsu Repair Manual/For 3-Cylinder, Liquid-Cooled, Diesel en

Chapter 4 -- Briggs/Daihatsu Diesel Engine

Kohler Engine Service Manual

Chapter 6 Drive Train

Chapter 7 - Chassis)

Chassis

Chapter 8 Electrical System

Chapter 9 Hydraulic System

Chapter 5 -- Kohler Gasoline Engine

Chapter 8 -- Electrical System

Front Wheel Drive (4Wd)

Chapter 10 Constant Velocity (CV) Joint

Chapter 11 Electrical Schematics

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Toro Workman 3000 Series