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WorkmanR 3000/4000 Series

1. BED LIFT 1 3 113 PROTECTION BED LIFT REMOTE VERT VERT DIODE 2 STAR USIBLE LINK ALTERNATOR FUEL PUMP CHOK amp REMOT LIFT reel PROTECTION on TEM HARNESS Bt ire HEATER HYD KIT SHUNT SHUNT KIT SWITCH IODE SWITCH SENDER a sof pr A B C af 102 sis 1 pofa B pil 8 8 A 8 pof po A 8 ss 1 shi ul E x E I xz o gt 90 RED X 5 5 gt gt gt 44 a a 2 5 gt 8 5 PINK tt T B YELLOW RED GRAY WHITE sP6 a BLACK x m 2 E gt RED gt BLUEWHITE A 8 PINK P4 BLACK 4 1 2 T BLACK T BLACK Pes EN BLACK A RED WHITE 8 RED BLACK M PIE BLACK A WHITE BLACK BROWN A RED WHITE RED BLACK RED BLACK L SP3 P8 SP4 RED WHITE RED WHITE E BLACK RED WHITE RED WHITE 3 WHITE 4 5 RED WHITE SP5 RED WHITE P3 WHITE VIOLET RED 1 BLACK A
2. REAR HARNESS p tee 0 POSITIVE BATTERY CABLE R R 30 x B DE der fe SEEN OV then ROA R mu E i D CR etant NT HARN ENGINE ie la M VIA MATING CONN VIA MATING CONN STARTER B wr m FACTORY SHUNT VIA MATING CONN TORT SHUNT FACTORY SHUNT FACTORY SHUNT START ENABLE i START Co DHL Ce iaa ESAE LOS Poe a a 8 HIGH FLOW HYDRAULICS KIT OFF PROTECTION DIODE 02 A coa eK D 2 Ber 1 E lt a e sy o BY 5 o 3 PTO KIT OFF CLUTCH SWITCH BED LIFT 8 4 3 VERT LIFT 9 ENGAGED REMOTE HYD F2 10 s 4 i RUN X E oR Y oR OR OR 5 ge il B d o Y v 8 NOT CONNECTED BK y 8 7 LIGHTS HORN BRAKE Ge BEET OT TG SS re juu i BN BN BN HORN SWITCH HORN LIGHT SW 1 15 A HEADLIGHTS P101 J R pod GN BK oF Ge Ww 8K W BK x Ww 8K
3. 5 2 Ss S c T ES EZ PR TION FUSIBLE LINK ALTERNATOR 25 me OIL PRESSURE PROTECTION OVER TEMP SENDER MED START HARNESS bi i s eg oe SWITCH TEMP SWITCH Bo E cu no 8 P2 1 n i p 4 8 pif A P20 La 5 l x gt gt neo 3 i 5 3 reo 2 i Hi P ui 5 BE 2 2 GRAY m GRAY 2 BLACK GRAY 5 5 J4 JI3 BLUE WHITE 4 A P4 PINK ee B s BLACK BLACK l P23 RED RED BLACK B PIS BLACK A WHITE BLACK 9 BROWN A RED RED BLACK L SP3 SP4 J RED P100 BLACK RED ORANGE g 5 5 x 5 5 gt a gt 5 5 x X ys g alm s 96 gt amp 3 5 a Cs 1234 5 x B c x AW ee MAJ PIOI ap rll GLOW TACH SENSOR FRONT FRONT HIGH FLOW 30 85 87 87 86 START PLUGS i KIT MT HARNESS HARNESS HYD SOLENOID GLOW RELAY FRAME GROUND FUEL
4. P8 TRANMISS ION HI LO SWITCH P1 FUSIBLE LINK HARNESS La P7 TRANSMISSION 3RD GEAR SWITCH P23 Ph PTO SHUNT PTO KIT P2 START RELAY P24 GLOW RELAY COIL 2 4 x J17 GLOW RELAY IN Damn Bum SP1 SP2 a INN H 1 LE HT LH eae SP3 mum SP5 SP4 P20 ON OIL PRESSURE PROTECTION SWITCH DIODE 1 J n CLUTCH SW ITCH CLUTCH SWITCH J2 FRAME GROUND p102 INTERCONNECT FRONT HARNESS 9 T 1 P101 HIGH FLOW INTERCONNECT HYD SOLENOID FRONT HARNESS t 21 FUEL SOL GLOW PLUGS P22 START 2 T 1 TACH SENSOR PS T ALTERNATOR 1 1 P18 a BED LIFT amp 4 REMOTE HYD SHUNT ALTERNATOR B 15 OVER TEMP SWITCH P15 O 4 3 VERTICAL TAIL LIGHT LIFT KIT P19 BED LIFT amp D REMOTE HYD KIT FUEL SENDER TEMP SENDER J14 FUEL SENDER GND p17 1 3 VERTICAL LIFT SHUNT Page 11 22 Rev C J16 GLOW RELAY QUT Workman 3300 and 4300 Briggs Daihatsu Diesel Engine Rea
5. HIGHFLOW HYDRAULIC SHUNT B A Bc ODE gt lt REAR HARNESS INTERCONNECT REAR HARNESS INTERCONNECT REAR HARNESS INTERCONNECT Workman 3000 4000 Front Wire Harness Diagram Serial Number Below 270999999 HORN SUPERVISO UNFUSED ELECTRIC HIGHFLOW LIGHT _ SUPERVISOR FUSE BLOCK AUXILIARY ACCESSORY GLOW PLUG BRAKE HYDRAULIC HARNESS HEADLIGHT BRAKE SWITCH SWITCH SWITCH POWE LEAD SWITCH KIT KIT SWITCH KIT SWITCH SWITCH JIS J5 J6 2 4 3 mpg 12 5s pela cot i234 5 6 7 8 2 lt a a E 5 x Zu Eu ED 2 T ws 54 Sr EZ x E 25 25829 rp E 9 a 9 T 5 89623 56 Eo g tt sP P9 SN 280000001 2 AND UP 3 BLACK PT 3 VIOLET RED 2 BLACK K ORANGE BROWN WHITE ORANGE 4 GRAY 1 YELLOW BLUE RED BLACK 4 SPs GT BROWN WHITE BLACK 26 GREEN BLACK PES ORANGE 3 RED 5 GRAY Te I RED BLACK SP6 VIOLET YELLOW RED WHITE 4 PT I BLUE WHITE 2 BLACK i ORANGE ORANGE 9 P23 2 BLACK 3 ORANGE ORANGE 4 1 10 BLACK BLACK 5 4 JI BLACK SP3 52 2 5 E X 5 g 5 ax 9 2 9 5
6. SPLICE E BLACK 16A 17A 18A 19A yl yl P101 P100 INTERCONNECT BONSE ea L Au GROUND P102 INTERCONNEC FRONT HARNES SWITCH 5 m uj HG e P 5 5 ee SPLICE SPLICE _ FUSIBLE LINK BLACK RED WHITE SPLICE D I SPLICE A 7B 16B 248 1B 10B 30B RED BLACK cr 6B 158 298 mam m 25B 278 8B 20B 9B 11B 318 E En Les fom amp Ce d 7 i Wine CONNECTOR CONNECTOR Sed COLOR SESTNATION DESTINATION 1 RED WHT ENGINE HARNESS SPICE C 2 BLACK ENGINE HARNESS KILL RELAY supervisor 08 3 BRN WHT ENGINE HARNESS FRONT HARNESS P101 PIN A 4 PNK BLU STARTER DIODE 5 PNKIBLU STARTER START RELAY 6 GRAY STARTER SPLICE A 7 BLACK DIODE SPLICE B 8 RED WHT SUPR SWITCH TRANS SPLICE C 9 RED BLK SUPR SWITCH TRANS SPLICE D 10 REDIWHT SUPR SWITCH TRANS SPLICE C RED BLK SUPR SWITCH TRANS SPLICE D 12 GRAY START RELAY FRONT HARNESS P101 PIN C 18 PINK CLUTCH SWITCH PTO SWITCH 14 PINK PTO SWITCH START RELAY 15 PINK CLUTCH SWITCH SPLICE A 16 BLACK SPLICE E SPLICE B 17 BLACK SPLICE E START RELAY 18 BLACK SPLICE E START RELAY 19 SPLICEE FUEL SENDER 20 RED WHT KILL RELAY SPLICE C 21 BLU WHT FUELSENDER FRONT HARNESS P102 PIN C 22 BROWN TAILLIGHT FRONT HARNESS P101 PINH 28 WHT BLK TAILLIGHT FRONT HARNESS P101 PIN J 24 BLACK TAILLIGHT SPLICE B 25 BLACK GROUND
7. 5 Air inlet hood 10 Mounting band Briggs Daihatsu Diesel Engine Page 4 12 Workman 3300 D 4300 D 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 3 Remove air cleaner components as needed using Figure 7 and 8 as guides Installation Fig 7 IMPORTANT Any leaks in the air filter system will cause serious engine damage Make sure daily that all air cleaner components are in good condition and are properly secured during reassembly 1 Reassemble air cleaner system using Figure 7 and 8 as guides Air cleaner hose item 6 and air inlet hood item 5 should be positioned straight upward The va cuator valve on the air cleaner assembly should be posi tioned downward 2 Lower or install bed or attachment s 1 Plug 2 Upper housing 3 Element Workman 3300 D 4300 D Page 4 13 Figure 8 4 Gasket 5 Lower housing 6 Vacuator valve Briggs Daihatsu Diesel Engine EJ a 2 a gt m Exhaust System 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 Hexnut 4 used 10 Hardened washer 16
8. 7 0 EA ro Workman 3000 4000 Series Page 9 11 Hydraulic System Troubleshooting The cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equip ment and a thorough understanding of the complete hy draulic system Ahydraulic system with an excessive increase in heat or noise is a potential failure Should either of these condi tions 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 Hydraulic System Page 9 12 ued use of an improperly functioning hydraulic system could lead to extensive internal component damage The charts that follow contain information to assist in troubleshooting There may possibly be more than one cause for a vehicle malfunction Refer to the Testing section of this Chapter for precau tions and specific test procedures Workman 3000 4000 Series Lift cylinders extend with valve in neutral position Bed drops from raised position with lift valve in centered position Steering inoperative or sluggish Workman 3000 4000 Series Load checks in hydraulic lift valve are leaking Lift valve lever is sticking Lift valve control handle is not in correct location Hydraulic relief valve stuck or damaged See TEST NO 1 Improperly positioned valve Lift valve worn or damaged Internal leakage of lift cyli
9. Vehicle Electrical Schematics 11 3 Wire Harness Drawings 11 10 Workman 3000 4000 Series Rev C This page is intentionally blank Workman 3000 4000 Series Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS 2 Before 2 While Operating 3 Maintenance and Service 4 Jacking Vehicle 5 Using Bed Safety 6 Workman 3000 4000 Series Page 1 1 Safety 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 acci dent 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 inthe operation trans port maintenance and storage of the vehicle Improper use or maintenance of the vehicle can result in injury or Before Operating 1 Read and understand the contents of the Operator s Manual and Operator s Video before starting and oper ating the vehicle Become familiar with the controls and know how to stop the vehicle and engine quickly A re placement Operator s Manual is available on the Inter net at www Toro com 2 Keep all shields saf
10. BK BU BN W R T VIO R G d BU W a Y LOW HIGH OTHER 3RD i P101 B FRONT HARNESS P101 K P102 C P102 B P101 F P102 A P101 A VA PNE uL Ss aS I MEI Bee EE CM RI e IN REAR HARNESS A POSITIVE BATTERY CABLE TIE POINT RW VIO R GN BK BU W NOTGONNECTED BU VIO BN W ON STARTER Ei ar PLA ERA Bp NEGATIVE BATTERY CABLE EN BK BK R BK FUEL lt RW SENDER ENGINE OVER TEMP OIL PRESSURE 9 n SWITCH SWITCH ee TEMPERATURE LOW PRESSURE ENGINE FRAME SENDER BATTERY GROUND GROUNDS ENGINE ENGINE ENGINE FRAME GROUND TO FRONT HARNESS EX BK E IS VIA THE REAR HARNESS SEE P100 A BK Br R BK L VIO ALTERNATOR CHOKE HEATER VIO R R W 3 POWER ENGINE _ STL BK BK 2 2 w Rw 4 KEY TO WIRE COLORS GROUND SGN OIL S T FUEL SOLENOID R RED BK BLACK GN GREEN OR ORANGE Be o 87a zh Workman 3200 and 4200 Ne me MA LI i E THIS WIRE DASHED LINE IGNCOIL2 W FUEL PUMP BK TAN Minden Neon Briggs Daihatsu Gasoline Engine EE MEE on YY Y nw 8 ea Vehicle Electrical Schematic e rae J 250000001 TO 250999999 PRAN 5 MA 122717570 IGNCOIL3 UEL PUMP i POSITION 5 Serial Number Below 260000000 4 TACH P31 P32 FUEL PUMP NITION CONTROL All relays and solenoids MODULE are shown
11. PIO1 H PROTECTION DIODE D1 1 BN BN HORN SWITCH HORN ONE A HeHT Sw HEADLIGHTS 1 1 gor s GN BK iS j W EK wek W BK I3 POWER POINT d D ma 2 4 TAIL BRAKE 1 R AUX FUSE BLOCK ELEC BRAKE KIT i LIGHTS R Lw BN FUSE BLOCK AUX LIGHT i OFF BK e i E 4 PN e OR GROUND TIE POINT OVER BATT P100 B AT FUSE BLOCK P100 A P101 G P101 D OR OR OR OR OR EMP PRES CNN IL db qs I 2 i GLOW PLUG 3 3 3 i FUSIBLE LINK HARNESS L L L QV SWITCH i 99 3441 ge ERE 3 S S S i Ba AO 4 A A i LR TRANSMISSION TACH HR TEMP FUEL SWITCHES KIT ae vio BN W i gt 21 MAR G BU W Y G G GLOW PLUG LAMP EBK FRONT e e e BK TOW s HIGHS SOTER SROI as P101 B HARNESS P101 K P102 C P102 B P101 102 101 MICRO eee AN RERHARNESS RR Rm DUET Dp ma dr apt E PONTo R rd SIBE BU Y BU vio BN W ET 4 ZO TACH SENSOR FUEL SOLENOID 4 TACH KIT FUEL SENDER ENGINE OVER TEMP LOW PRESSURE a m p TEMPERATURE SWITCH 5 4 OIL PRESSURE SWITCH ENGINE FRAME um SENDER BATTERY GROUND GROUNDS ENGINE BK ENGINE ENGINE ENGINE L L L c FRAME GROUND TO FRONT HARNESS IS VIA THE REAR HARNESS SEE 100 e BK BH R R L vo ALTERNATOR pon
12. 26 Workman 3000 4000 Series 20 Remove oil cap Item 1 and O ring from transaxle case if necessary 21 Remove air breather Item 2 if necessary 22 Loosen cap screws Item 1 and remove upper cover Item 2 from transaxle case 1 Figure 42 i S 2 Workman 3000 4000 Series Page 6 27 Drive Train 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 Remove 2 needle bearings Item 5 and gear Item 4 Inspect needle bearings and replace if nec essary D Remove synchro ring Item 6 E Remove snap ring Item 7 F Remove shifter Item 8 together with spring hub and 3 keys G Remove key Item 9 H Remove snap ring Item 10 1 Remove synchro ring Item 6 gear Item 11 2 needle bearings Item 12 and washer Item 13 In spect needle bearings and replace if necessary J Use a bearing puller to remove bearing Item 14 K Remove gear Item 15 snap ring Item 16 gear Item 17 and gear Item 18 Figure 44 Drive Train Page 6 28 Workman 3000 4000 Series 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
13. 3 18 102to 122N m 47 58 to 65 ft Ib 267 7910 88 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 Workman 4000 Series 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 Drive 4 0 2 Secure carrier assembly 15 so that pinion gear shaft 8 is facing up Remove eight cap screws 16 se curing the front housing to the carrier assembly 3 Separate front housing 2 from the carrier assembly 15 using a cold chisel to initially separate the two parts Use a putty knife to further separate the housing and carrier assembly Fig 13 Figure 12 IMPORTANT The bearing caps are marked for reas sembly Place caps in a safe place to avoid damag ing their machined surface Place caps back in the same position during reassembly 4 Remove four cap screws 11 and both bearing caps from the bearing cradles Fig 14 IMPORTANT Keep mating bearing bearing cups 30 with 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 t
14. FUEL SOLENOID p12 UE IGN CONTROLLER ET J3 T CLUTCH SWITCH Hi SP6 a CLUTCH SWITCH 5 5 5 BN H SP1 lt a RS T E Lr BE I x I TS gt sp3 5 2 0 p101 INTERCONNECT FRONT HARNESS 25 PROTECTION DIODE 1 L_ P20 OIL PRESSURE Sw ITCH EX 3 n FUEL PUMP FRAME GNO 5 48 RELAY PT Jn TRANSMISSION N COIL 4 P 3RD GEAR SWITCH TON eee 102 m INTERCONNECT HIGH FLOW HYD IGN COIL 1 NEG FRONT HARNESS SOLENOID wo IGN COIL 3 NEG 9 START P19 P5 18 BED LIFT 8 REMOTE ALT 1 0 IGN COIL 3 POS HY KIT 2 1 t P TACH SENDER aerem An p18 ALT B BED LIFT amp REMOTE HY SHUNT 16 1 3 VERTICAL LIFT KIT 15 TAIL LIGHT p17 1 3 VERTICAL LIFT SHUNT Page 11 18 Rev C J13 FUEL SENDER J14 FUEL SENDER GND Workman 3200 and 4200 Briggs Daihatsu Gasoline Engine Rear Wire Harness Drawing Serial Number Below 260000000 CLUTCH SWITCH PTO KIT PTO SHUNT TRANSMISSION 3RD GEAR SWITCH HI LO TRANSMISSION SWITCH FUEL SOLENOID FUEL PUMP RELAY
15. Front Wheel Drive 4WD Page 10 6 Rev B 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 74 If necessary to install cotter pin tighten nut fur ther and secure assembly with cotter pin IMPORTANT Hex flange nut 22 should be replaced whenever it is removed 11 Apply Loctite 271 or equivalent to the threads of the CV joint Install hardened washer 21 and hex flange nut 22 to the CV joint threads Torque flange nut from 170 to 200 ft lb 230 to 271 12 Secure brake hose bracket 13 to the axle housing with cap screw and flat washer NOTE Make sure access hole on both the brake drum and stub axle align when installed 13 Install brake drum to stub axle 14 Adjust brake shoes A Align access hole in brake drum with adjuster bolt on adjuster assembly B Rotate adjusting bolt to increase adjuster length until brake shoes contact brake drum C Back off adjuster until drum rotates freely 15 Secure wheel to the brake drum with five wheel nuts Lower front wheel to the ground Torque wheel nuts from 45 to 65 ft lb 61 to 88 PRESS BEARING CONE TO HERE EN E STUB AXLE Figure 4 Workman 4000 Series Workman 4000 Series This page is intentionally blank Page 10 7 Front Wheel Drive AWD E o LL Drive AWD Front Brake 45 to 65 ft lb 61 to 88 LOC
16. WiRE COLOR DESTINATION DESTINATION RED WHT ENGINE HARNESS SPICE C 2 WHITE ENGINE HARNESS KILL RELAY 3 BRN WHT ENGINE HARNESS FRONT HARNESS 4 STARTER DIODE 5 PNK BLU STARTER START RELAY 6 GRAY STARTER SPLICE liri BLACK DIODE SPLICE B SWITCH 8 RED WHT SUPR SWITCH TRANS SPLICE C 9 RED BLK SUPR SWITCH TRANS SPLICE 10 RED WHI SUPR SWITCH TRAN PLICE 1 RED BLK SUPR SWITCH TRANS SPLICE D SUPERVISOR 12 GRAY START RELAY PTO SWITCH SWITCH 13 GRAY CLUTCH SWITCH PTO SWITCH TRANSANLE 14 PINK SPLICE START RELAY 15 GRAY CLUTCH SWITCH FRONT HARNESS 16 BLACK SPLICE E SPLICE 1 BLACK SPLICE E START RELAY 18 BLACK SPLICE t START RELAY 19 BLACK SPLICE E FUEL SENDER 20 RED WHT KILL RELAY SPLICE 2 BLU WHT FUEL SENDER FRONT HARNESS 22 BROWN TAIL LIGHT FRONT HARNESS 23 TAIL LIGHT FRONT HARNESS 24 BLACK TAIL LIGHT SPLICE B 25 BLACK GROUND SPLICE B 26 BLACK GROUND FRONT HARNESS 2 BLACK SPEED PICKUP SPLICE B 28 BLUE SPEED PICKUP FRONT HARNESS 29 RED FRONT HARNESS SPLICE 30 RED WHT FRONT HARNESS SPLICE C 3 RED BLK FRONT HARNESS SPLICE D 32 GRAY PTO SWITCH PLUG PTO SWITCH PLUG 33 PINK SPEED PICKUP PLUG SPEED PICKUP PLUG 34 BLACK SPLICE E START RELAY Workman 3100 Kohler Gasoline Engine Rear Wire Harness Serial Number From 260000001 To 260000400
17. gt E I X c tr SP 9 HOUR ORANGE 2 METER j BLACK P100 REAR s HARNESS J INTERCONNECT Pet s VIOLET RED TACH 6 BLACK 1 3 ORANGE BROWNMWHITE LK gt ORANGE 2 GRAY t REAR ttn gt HARNESS YELLOW INTERCONNECT BLUE F RED BLACK EF BROWN WHITE BLACK Me SPS m x ORANGE X id 2 IGNITION SWITCH 8 RED S5 GRAY x ae 9 34 I RED BLACK SPG VIOLET REAR SP8 YELLOW 8 HARNESS c INTERCONNECT RED WHITE gt s s BLUE WHITE FUEL 6 BLACK GAUGE ORANGE EH ORANGE gt J8 ufo P23 3 6 A Black E ORANGE ORANGE J9 1 10 BLACK GROUND TIE POINT Ji BLACK S BLACK SP3 SP a 6 x 55 8 8 8 5 S ou 59 29 2 2 5 5 lt 5 m a m E Workman 3000 4000 Front Wire Harness Diagram ne Cr Serial Number Above 280000000 TEMPERATURE BATTERY GLOW PLUG OIL POWER HORN LEFT RIGHT LAMP LAMP LAMP LAMP POINT HEADLIGHT HEADLIGHT Page 11 13 Rev C FUEL SENDER
18. GY BK B LL As Ss Sy SS iS SS LLLI CLUTCH SWITCH PTO KIT OFF R R Start FRONT HARNESS ENGAGED _ 86 L855 F1 10A m ae poU E BK U STARTER i Pyare a FACTORY SHUNT VIA MATING CONN iia ENABLE eae Iv ay eM te Oo el MATING CONN VIA MATING CONN BK HIGH FLOW HYDRAULICS KIT OFF FACTORY SHUNT FACTORY SHUNT i A 101 i p qp 5 tee 1 lt 1 2 GY 1 2 Gy i dE oS GY 2 2 1 8 VERTICAL LIFT KIT BED LIFT amp REMOTE HYD 3 4 CE VEHICLES ONLY 4 PK F2 10A L 4 RUN x E a OR 12 OR z PIOISE HIGH FLOW HYDRAULICS KIT Se Y Y BK SF 8 d 7 IGNITION SWITCH BK gt tym ed ee EE M i BRAKESWTOH 000000000 PK 15 101 HORN BRAKE Seid PROTECTION DIODE D1 w w BN BN i HORN SWITCH HORN FA 15A POWER POINT LIGHT SWITCH Pi01 J PK gt O GN v W BK W BK i Bk i 1 W BK 4 1 d LIGHTS AUX FUSE BLOCK PIS Ww ELEC BRAKE KIT HEADLIGHTS i P BK n n BN i AUX FUSE BLOCK AT SUPERVISOR AUX LIGHT KIT SWITCH Bk a OFF Q BK OR AT F
19. Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Briggs amp Stratton Daihatsu Repair Manual The use of some specialized test equip ment is explained However the cost of the test equip ment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Briggs and Stratton Daihat su diesel engines are supplied through your local Toro distributor Briggs Daihatsu Diesel Engine 5 2 a gt Specifications Item Description Make Designation Briggs amp Stratton Daihatsu 4 stroke Liquid Cooled OHV Diesel Number of Cylinders Bore x Stroke mm in 72 78 2 834 x 3 07 Total Displacement cc cu in 952 58 1 Compression Ratio 24 0 1 Firing Order 1 front 2 3 Dry Weight approximate kg Ib 78 172 Fuel Grade No 2 0 or 1 D automotive type diesel fuel Fuel Injection Pump Bosch VE Distributor type Fuel Injector Nozzle Bosch throttle type Fuel Tank Capacity liter U S gal 26 7 Governor Mechanical Idle Speed no load 1500 50 RPM High Idle no load 3600 50 RPM Engine Oil API Classification CF or better see Operator s Manual for viscosity Oil Pump Gea
20. POWER POINT LIGHTS FUSE BLOC e ELEC BRAKE KIT 4 4 4 TAIL BRAKE 1 R BK w BN AUX FUSF BLOC 5 5 1 i 5 SUPERS OD AUX LIGHT KIT T FUSE BLOC i AT FUSE BL GROUND TIE POINT 4 OIL 100 100 _ 101 6 e P102 D OR OR OR OR OR PRES T GLOW PLUG SWITCH OVER TEMP LAMP aii 29 NOT USED P21 NOT USED FUSIBLE LINK INSIDE HARNESS i 5 xii 5 cx 5 cx BATTERY LAMP TRANSMISSION i TACH HR 6 MP LOW PLUG LAM P20 USED SWITCHES i P lt NOT USED d m R W 10 8 G G BU W G Y Le ONT ME LOW HIGH OTHER 380 101 HARNESS 101 P402 C P102 B P101 F P102 A 101 E e x eU REAR HARNESS NG je vocet 4 4 N 1 1 Bi BN W POSITIVE BATTERY ETIE POINT RA NOT CONNECTED NOT CONNECTED a ei A C TUI zc IE NEGATIVE BATTERY CABLE 35 ENGINE 55 a w w go TACH SENSOR d Ex TACH KIT FUEL 5 eu 36 SENDER LOW PRESSURE 6 91 1 ain zE OIL PRESSURE M SWITCH ENGINE RAME BATTERY GROUND GROUNDS i i BK ENGINE I Bk m GROUND CONNECTION TO FRONT HARNESS IS VIA THE REAR HARNESS SEE P100 A re Ten Fa BK BK BK R 3 MAGNETO PETERE ENGINE HARNESS BK R W R R 9666 ENGINE Workman 3100 FUEL SOLENOID L 2080
21. 5 This page is intentionally blank Briggs Daihatsu Gasoline Engine Page 3 22 Workman 3200 4200 TORO Table of Contents 1 SPECIFICATIONS 2 GENERAL INFORMATION 3 Adding Oil to 3 ADJUSTMENTS 4 Adjust Engine Speed 4 SERVICE AND REPAIRS 6 Radiator eben bed 6 Pump Driveshaft Service 8 Fuel Tank occ imer eoa bese hades 10 Air Cleaner 12 Exhaust System 14 ENGINE 16 Engine Throttle 20 BRIGGS amp STRATTON DAIHATSU REPAIR MANUAL FOR 3 CYLINDER LIQUID COOLED DIESEL EN GINES Introduction This Chapter gives information about specifications and repair of the Briggs and Stratton Daihatsu 3LC diesel engine used in the Workman 3300 D 4300 D General engine maintenance procedures are described in your Operator s Manual Information on engine trou bleshooting testing disassembly and reassembly is identified in the Briggs amp Stratton Daihatsu Repair Man ual that is included at the end of this section Workman 3300 D 4300 D Page 4 1 Chapter 4 Briggs Daihatsu Diesel Engine
22. Check fuel lines and connections periodically as recom mended in the Operator s Manual Check lines for dete rioration damage leaks or loose connections Replace hoses clamps and connections as necessary Briggs Daihatsu Gasoline Engine Page 3 10 Workman 3200 4200 Fuel Tank 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 3 Disconnect negative battery cable first and then pos itive battery cable Remove battery from vehicle see Operator s Manual IMPORTANT Review safety information regarding fuel handling in the Operator s Manual and Chapter 2 Safety 4 Disconnect fuel hose item 13 from fuel filter located on right frame rail Drain fuel from the fuel tank into a suitable container NOTE To prevent fuel leakage do not loosen lower nut on fuel sender stud 5 Disconnect electrical wiring from the fuel sender on the fuel tank 6 Loosen socket head screws item 21 and lock nuts item19 to allow tank straps to be unhooked from fuel tank supports 7 Remove fuel tank from vehicle Workman 3200 4200 Page 3 11 Fuel Tank Installation Fig 7 1 Check felt straps item 23 and replace if worn or damaged IMPORTANT When positioning fuel tank to vehicl
23. GY Wate 3 i i Fe UN iE 4 1 gt 4 8 ge B o Y Y lt NOT CONNECTED 1 1 1 1 IGNITION SWITCH BK Jera alaa Aveta eee rete VA nus ea 202 tates F3 15A BRAKE SWITCH LIGHTS HORN BRAKE e o 101 w w gt BN BN lt BN HORN i E POWER POINT HORN SWITCH m LIGHT SWITCH ES AA gt o o o W BK wBK lt lt wek n 1 BK us BN i HEADLIGHTS LIGHTS R AUX FUSE BLOCK BK ELEC BRAKE KIT TAIL BRAKE R BK BN AUX FUSE BLOCK AUX LIGHT KIT ats BK OFF BK AT FUSE BLOCK BK OR i GROUND TIE POINT olL 100 100 P101 G P102 D OR OR OR OR OR OR OR PRES lt 0 422 4 GLOW PLUG SWITCH OVER TEMP LAMP R BK 6 l P29 NOT USED P21 NOT USED R FUSIBLE LINK INSIDE HARNESS s xc fx s so TRANSMISSION dacH GLOW PLUG LAMP BATTERY LAMP SWITCHES TACH HR TEMP FUEL gt _ lt P19 NOT USED P20 USED KIT BU BN W BU G BK GN BK W Y BK BK VIO LOW HIGH OTHER 3RD i P101 B P101 K P102 C P102 B P101 F P102 A P101 A ERE SEES FRONT HARNESS sr on cal sea Irae ie cd e ie me reca patrc Ny p y d ANTEA SUIS n eoa REAR HARNES
24. L BROWNMWHITE BLACK VIOLET 2 BLACK GRAY BLACK VIOLET RED 100 BLACK RED ORANGE YELLOW Cu JI8 a pr Cus Pea 2 3 A B C p Plo2 A B C DE Ff J ag Pll GLOW OUT IN COIL TACH SENSOR START INTERCONNECT INTERCONNECT HIGH FLOW PLUGS GLOW RELAY KIT ELAY FRONT HARNESS FRONT HARNESS HYD SOLENOID FRAME GROUND FUEL SENDER FUEL SENDER GND TAIL LIGHTS INTERCONNECT FRONT HARNESS Workman 3300 and 4300 Briggs Daihatsu Diesel Engine Rear Wire Harness Diagram Serial Number Below 260000000 Page 11 23 Rev C 100 FRONT HARNESS P101 FRONT HARNESS Page 11 24 Rev C P19 BED LIFT amp REMOTE HYD KIT P24 GLOW RELAY P7 P8 TRANSMISSION HI LO 3RD GEAR TRANSMISSION SW ITCH SWITCH 1 FUSIBLE LINK HARNESS P10 PROTECTION DIODE 2 2 START ET RELAY P17 1 3 VERTICAL P9 LIFT SHUNT PROTECTION DIODE 1 J2 FRAME GROUND P16 4 3 VERTICAL LIFT KIT P20 OIL PRESSURE SWITCH HIGH FLOW HYD SOLENOID ALTERNATOR 15 OVER TEMP P15 TAIL SWITCH LIGHTS P18 BED LIFT amp REMOTE HYD SHUNT J6 TEMP SENDER FUEL SENDER GND SENDER Workman 3300 and 4300 Briggs Daihatsu Diesel Engine Rear Wire Harness Drawing Serial Number From 260000001 To 270999999 CLUTCH SW
25. if installed shut engine off and engage the parking brake 2 Loosen pump drive belt and remove belt from pump pulley see Operator s Manual 3 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter Before performing any service or repair on hy draulic system components relieve system pressure to avoid injury from pressurized hy draulic 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 4 Disconnect hydraulic hoses from gear pump Install caps or plugs in hoses to prevent contamination and leakage of hydraulic oil Install plugs in pump fittings 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 A Apply antiseize lubricant to gear pump shaft be fore installing pulley B After installing key and pulley on pump shaft tighten lock nut Item 8 to a torque from 130 to 160 in Ib 14 7 to 18 1 C Install pump suction hose to fitting on pump then fill pump through pressure port of pump with clean Dexron III ATF D Install pump pressure hose to fitting on pump 2 After installing the pump and connecting hydraulic hoses install belt and adjust belt tensi
26. 3 Woodruff key 9 Lock nut 6 used 15 Flat washer 4 used 4 Pump drive belt 10 Frame support bracket 16 Cap screw 2 used 5 Pulley 11 Cap screw 4 used 17 Cap screw 2 used 6 Bearing 12 Coupling spacer 4 used 18 Driveshaft Briggs Daihatsu Gasoline Engine Page3 8 Workman 3200 4200 Removal Fig 6 1 Park vehicle on a level surface raise and support bed if installed shut engine off and engage the parking brake 2 Disassemble driveshaft using Figure 6 as a guide 3 Do not reuse bearings Item 6 if they have been re moved from frame support bracket Replace with new bearings 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 Installation Fig 6 1 To install bearings Item 6 into frame support brack et A Install pulley side bearing into support bracket by pressing on bearing outer race until bearing contacts shoulder in support bracket B Place the bearing spacer Item 7 into bracket ca vity C Install second bearing into bracket by pressing on the bearing outer race until bearing inner race con tacts spacer 2 Slide shaft Item 8 into installed bearings in frame support bracket Apply antisieze lubricant to pulley end of shaft before installing woodruff key Item 3 and pul
27. ATF to wear plate Item 10 and install on stator 3 Install one crescent ring Item 4 to idler shaft then install ball key Item 23 gear Item 11 and other cres cent ring Make sure to maintain the original gear loca tion Apply Dexron ATF to gear and idler shaft assembly then install into stator 4 Install shear pin Item 7 then apply Dexron ATF to remaining gear and install to drive shaft Item 6 main taining the original timing and locations 5 Apply Dexron ATF to pressure plate seal Item 15 back up 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 ft lb 13 to 17 8 Install shaft seal see Shaft Seal Replacement Hydraulic System 2 E gt 2 D gt 72 Gear Pump Service Casappa Gear Pump 220 in Ib 25 N m Figure 23 1 1 Retaining ring 7 Pressure seal 2 Shaft seal 8 Front thrust plate 3 Front cover 9 Drive shaft 4 Dowel pin 10 Idler shaft 5 O ring 2 used 11 Body 6 Back up seal 12 Rear thrust plate Disassembly Fig 23 1 1 Plug pump ports and clean the outside of the pump thoroughly After cleaning remove plugs and dr
28. Adjust M center to center length to dimension shown in Figure 33 before tightening jam nut Torque jam nut 50 ft lb 68 14 520 36 88 cm for 2WD N m 15 040 38 20 cm for 4WD 2 Install steering cylinder to vehicle using Figures 31 and 32 as guides Figure 33 3 Replace o rings on hydraulic hoses and fittings Re move caps and plugs from hoses and fittings Connect hydraulic hoses to steering cylinder 4 Check oil level in transaxle see Operator s Manual Add Dexron ATF if necessary 5 Start the engine operate at idle speed and rotate the steering wheel in both directions until air is out of hydrau lic system 6 Stop the engine and check oil level in transaxle see Operator s Manual Add Dexron III ATF if necessary 7 Check front wheel alignment and adjust as needed see Front Wheel Alignment in the Service and Repair section of Chapter 7 Chassis 2 5 S gt I Workman 3000 4000 Series Page 9 39 Rev Hydraulic System Steering Cylinder Service 30 to 36 ft lb 41 to 49 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 Piston 10 Seal Disassembly Fig 34 1 Pump oil out of cylinder into a drain pan by slowly moving piston back and forth 2 Before disassembling cylinder plug ports wash exte rior with cleaning solvent and dry thoroughly IMPORTANT Use caution when
29. SP10 J2 TACH L TACH S 1 P30 SUPERVISOR SWITCH J12 HORN J13 HORN d _ JA J15 HORN SWITCH TIMER HORN SWITCH Ph HIGHFLOW HYDRAULIC KIT P8 HIGHFLOW HYDRAULIC SHUNT P15 LEFT HEADLIGHT a Workman 3000 4000 Front Wire Harness Drawing Serial Number Above 280000000 GLOW TIMER F LIGHT ORN UNFUSED ELECTRIC HIGHFLOW E SUPERVISOR FUSE BLOCK AUXILIARY ACCESSORY BRAKE HYDRAULIC HARNESS HEADLIGHT BRAKE SWITCH POWER AD SSO KI KIT SWITCH SWITCH SWITCH JIS P30 aee fe DA PIX 4 6 s i 123 6456 C 2 La c c c rJ BI oi od sli 23 45678 21 1 1 a J E 8 92 9 amp 9 EERE e uz gt ae 23 Crees cs lt amp o M ma 19644 I 6
30. 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 5 Reinstall differential drive shaft to the front differen tial 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 Operator s Manual 8 Bleed front brakes see Bleeding the Brakes in Ser vice and Repairs section of Chapter 7 Chassis Front Wheel Drive AWD o e Drive 4WD Front Differential Service 30 to 45 ft lb 15 to 20 ft lb 20 to 27 20 to 25 ft lb 27 to 33 41 to 61 BEARING CAP Vent Front housing Alignment pin 2 used Thrust washer Side bevel gear Pinion gear Thrust washer Pinion gear Bearing cone 10 Bearing cup 11 Cap screw 4 used 12 Plug 2 used Front Wheel Drive AWD Figure 11 O ring seal 2 used Shim Carrier assembly Cap screw 8 used Washer Lock nut Coupler flange Oil seal Shim Bearing cone Bearing cup Page 10 16 75 to 90 ft lb
31. Transaxle 5 Exhaust manifold 11 Flange nut 4 used 17 Shift cable mount bracket 6 Socket head screw 4 used 12 Carriage bolt 2 used Briggs Daihatsu Diesel Engine 4 14 Workman 3300 D 4300 D 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 If bed is raised place safety support on lift cylinder see Operator s Manual 3 Remove exhaust system components as needed us ing Figure 10 as a guide 4 Discard gaskets and thoroughly clean flange sur faces of manifold and muffler Workman 3300 D 4300 D Page 4 15 Installation Fig 10 1 Replace any removed gaskets 2 If cap screw item 9 was removed apply Loctite 242 or equivalent to threads during installation 3 Using Figure 10 as a guide fit all exhaust compo nents to vehicle before tightening any fasteners When securing exhaust tighten fasteners in the following or der A Hex nuts item 4 that secure exhaust manifold to engine B Cap screw item 9 with washer item 10 that se cures muffler to transaxle C Socket head screws item 6 and flange nuts item 8 that 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 pla
32. a ax uz Sx B we o o 5 o rm z gt B A 8B M Pe B pia B A 1 5 8 A TEMPERATURE BATTERY GLOW PLUG OIL POWER ORN LEFT RIGHT LAMP LAM LAMP LAMP POINT HEADLIGHT HEADLIGHT Page 11 11 Rev C P1 FUSE BLOCK JA GROUND TIE POINT HH P102 HARNESS INTRCONNECT P14 RIGHT HEADLIGHT P100 REAR HARNESS INTRCONNECT 101 REAR HARNESS INTERCONNECT Page 11 12 Rev C FUEL GAUGE P18 OIL LAMP P3 BRAKE KIT P19 GLOW PLUG LAMP PS HEADLIGHT SWITCH 2 Ibi p17 7 POWER POINT 1 i i E n BRAKE SWITCH 1 8459 797 i P26 IGNITION SWITCH 26 x 1 55 82 P21 15 3i TEMP LAMP Jb IBN SW 1 P20 BATTERY LAMP J8 L p9 FUEL GAUGE HOUR METER 3l P25 AUXILIARY POWER UNFUSED 5 3 00 26 P23 AUXILIARY POWER 7 TEMP GAUGE SP5 _ T pu u T aus SP9 SP6 SP3 SP4 S SP7 P10 ROPS KIT OPTIONAL
33. 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 ser vice See Steering Control Valve and Steering Control Valve Service Hydraulic System 2 5 gt 2 D gt 72 TEST NO 3 Lift Cylinder Internal Leakage STEERING CONTROL STEERING CYLINDER LIFT CYLINDERS LIFT VALVE IN LOWER POSITION STRAINER TRANSAXLE RESERVOIR Figure 16 Hydraulic System Page 9 20 Workman 3000 4000 Series Procedure for Lift Cylinder Internal Leakage Test Disconnect and plug this hose ANY oil flow or droplets from this fitting indicates internal leak 1 Shut off engine and engage parking brake 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 Pressure is applied to this port 2 Remove all pressure from cylinder by fully retracting it i e put hydraulic lift lever in LOWER position Figure 17 3 Disconnect hydraulic hose from base end of cylinder and install a steel plug with o ring seal in the hose Fig 17 Clean any remaining oil from cylinder po
34. 13 Lower shift boot 19 Cable clamp 7 Cotter pin Drive Train Page 6 10 Workman 3000 4000 Series 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 4 Loosen jam nut that retains clevis to shift cable and remove clevis from cable 5 Remove shift cable from transaxle shift lever Fig 7 A Remove cotter pin and clevis pin that secure shift cable to shift lever on transaxle B Loosen jam nuts on bulkhead fitting of cable C Disconnect cable from shift lever 6 Note routing of shift cable and location of cable ties used to secure cable Slide shift cable from lower shift boot and remove cable from vehicle Installation Fig 4 1 Route cable in same location as before 2 Install cable clevis on shift cable Adjust cable clevis as shown in Figure 6 Tighten jam nut to secure clevis to cable 3 Connect shift cable to shift link Item 10 on shifter in operator platform by inserting clevis pin Item 8 from the passenger side then install cotter pin 4 Secure shift cables to lever support with cable clamp Item 19 and three screws Item 18 5 Spread jam nuts on bulkhead fitting of cable Fig 7 With cable pr
35. 3000 4000 Series TORO Table of Contents 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 SPEGIALE TOOLS en b Re be rye hae 10 Hydraulic Pressure Test Kit 10 Hydraulic Tester Pressure and Flow 10 Hydraulic Test Fitting 11 Male Coupler For Optional High Flow Hydraulic Kit 11 TROUBLESHOOTING 12 TESTING 15 Test 1 Gear Pump Flow and System Relief PIOSSUIE eins th 16 Test No 2 Steering Control Valve and Steering Gylinder oss ects eh a 18 Test No 3 Lift Cylinder Internal Leakage 20 Test No 4 High Flow Hydraulic Kit Optional Gear Pump Flow and Relief Pressure 22 Workman 3000 4000 Series 9 1 Rev D Chapter 9 Hydraulic System SERVICE and REPAIRS 25 General Precautions for Removing and Installing Hydraulic System Components 25 Check Hydraulic Lines and Hoses 25 G
36. 4 used 35 Nut Ca 22 Lock washer 4 used 36 Positive battery cable 9 Throttle bracket 23 Cap screw 4 used 37 Lock nut 4 used 10 Lock nut 24 Woodruff key 38 Flat washer 4 used 11 Throttle lever 25 Pin 3 used 39 Engine mount 12 Spring 26 Cap screw 6 used 40 Cap screw 4 used 13 Accelerator cable ball joint 27 Lock washer 6 used 41 Lock washer 14 Socket head screw 28 Pressure plate 42 Pump drive belt 15 Shoulder bolt 29 Clutch disc 43 Engine assembly Engine Removal Fig 4 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 Kohler Gasoline Engine Page 5 8 3 Disconnect negative and then positive battery cables at the battery Disconnect battery cable Item 36 from starter on engine 4 Remove the muffler and exhaust manifold see Re move Exhaust System in this section Workman 3100 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 Loosen fasteners that secure hydraulic pump to en gine mount Fig 5 Rotate pump to allow drive belt Item 42 to be remove
37. 4000 Series 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 11 On machines with serial numbers above 260000000 the glow relay is attached to the wire harness with a four wire connector Fig 12 1 Verify coil resistance between terminals 86 and 85 with a multimeter ohms setting A On machines with serial numbers below 260000000 resistance should be from 41 to 51 ohms B On machines with serial numbers above 260000000 resistance should be approximately 72 ohms 2 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break Figure 12 continuity between terminals 30 and 87 as 12 VDC is applied and removed from terminal 85 3 Disconnect voltage and leads from the terminals Start Relay Kohler Engine The start relay used on Workman vehicles with a Kohler 5 Disconnect voltage and multimeter leads from the engine is attached to the frame near the hydraulic oil fil relay terminals Reconnect relay to vehicle wire har ter ness Testing 1 Disconnectthe harness connector from the relay that is to be tested 2 Connect m
38. 5 C Use a bearing puller to remove bearing Item 6 D Remove washer Item 7 needle bearing Item 9 and gear Item 8 E Remove spacer Item 10 F Remove snap ring Item 11 G Remove shifter Item 12 together with spring hub and 3 keys Figure 45 H Remove key Item 13 l Remove synchro ring Item 14 from gear Item 15 J Remove gear Item 15 needle bearing Item 16 and thrust washer Item 17 Inspect needle bearing and replace if necessary Measure thickness of thrust washer Replace thrust washer if thickness is less than 0709 in 1 8 mm Figure 46 x o gt Workman 3000 4000 Series Page 6 29 Drive Train 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 Use a bearing puller to remove bearing Item 1 from countershaft B Remove thrust washer Item 2 and snap ring Item 3 C Remove thrust washer Item 4 and gear Item 5 D Remove inner 6 and thrust washer Item 7 Inspect inner for wear and damage Replace in ner if O D is less than 1 258 in 81 95 mm Measure thickness of thrust washer Replace thrust washer if thickness is less than 0709 in 1 8 mm E Remove 2 snap rings Item 8 F
39. 60 to 75 ft lb 81 to 102 N m 3 Coat all cylinder parts with clean Dexron III ATF Slide shaft assembly and head into barrel being careful not to damage seals 4 Install retaining ring Item 9 to secure shaft assembly in barrel To install retaining ring align key slot in head with access groove in barrel Rotate head clockwise as far as the retaining ring will allow Offset end of retaining ring will be against left side of barrel groove as shown Spanner wrench Retaining ring 3 Offset end against left side of barrel groove after installing Workman 3000 4000 Series Page 9 45 ad Figure 40 Installing retaining ring Hydraulic System 2 E gt 2 D gt 2 Hydraulic Manifold Optional High Flow Hydraulic Kit Removal Fig 41 1 Park vehicle on a level surface raise bed shut en gine off and 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 Before performing any service or repair on hy draulic system components relieve system pressure to avoid injury from pressurized hy draulic 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 mani
40. 80 min Reserve Capacity at 80 F 27 C Electrolyte Specific Gravity Fully charged 1 250 1 280 Discharged less than 1 240 Removal Fig 24 IMPORTANT Be careful not to damage terminal posts or cable connectors when removing the bat tery cables 1 Remove battery cover from the frame Loosen bat tery retainer securing the back of the battery to the bat tery support 2 Loosen nut on ground cable post first and remove cable from battery This should prevent short circuiting the battery other components or the operators hands 3 Loosen nut on positive cable post and remove cable from battery 4 Remove battery from the battery compartment to a service area to allow better access for service Workman 3000 4000 Series Page 8 17 Figure 24 1 Battery Inspection Maintenance and Testing 1 Perform following inspections and maintenance A Check for cracks Replace battery if cracked or leaking B Check battery terminal posts for corrosion Use wire brush to clean corrosion from posts IMPORTANT Before cleaning the battery tape or block vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top of the battery which might indicate a loose filler cap overcharging loose terminal post overfilling Also check battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with c
41. Bearing 7 Shear 15 Pressure plate seal 23 Ball key 8 Stator 16 Dowel pin Before disassembling gear pump plug ports wash exte rior of pump with cleaning solvent and dry pump thor oughly Shaft Seal Replacement Fig 23 1 Remove retaining ring Item 1 2 Punch two 2 holes in face of seal 180 apart and install metal screws Remove shaft seal from gear pump by grasping and pulling on screws IMPORTANT Do not try to pry seal out of housing This can damage the shaft seal bore so oil will leak past the seal 3 Discard shaft seal Item 2 Remove spacer Item 3 Hydraulic System 9 28 Rev D 4 Clean any foreign material from seal bore and drive shaft of pump 5 Install spacer Item 3 on driveshaft 6 Puta seal protector tool on driveshaft or apply thin plastic or tape on shaft to protect new seal from damage 7 Apply grease or petroleum jelly to inside diameter of new seal 8 Use a seal installation tool to install new shaft seal Item 2 Make sure seal is installed square with seal bore 9 Install retaining ring Item 1 Workman 3000 4000 Series Disassembly Fig 23 1 Remove shaft seal see Shaft Seal Replacement IMPORTANT Use caution when using a vise to avoid distorting any pump components 2 Secure flange end of pump in a vise with drive shaft Item 6 facing down 3 Remove four 4 socket head cap screws Item 18 4 Put your hand on gear end housing I
42. CONTROLLER 12 P 2 P5 ALTERNATOR A P19 BED LIFT amp REMOTE HYD KIT P16 ENDVIEW P16 1 3 VERT LIFT KIT P18 BED LIFT TENENT 8 REMOTE LIFT SHUNT TAIL HYD SHUNT LIGHTS Ag Jn Workman 3200 and 4200 Briggs Daihatsu Gasoline Engine Rear Wire Harness Drawing Serial Number Above 260000000 Page 11 20 Rev C BED LIFT BED LIFT 1 3 113 OIL PROTECTON START FUSEABLE LINK ALTERNATOR FUEL PUMP CHOKE 8 REMOTE UR PRESSURE PROTECTION D TEM DIODE ARNESS Pat HEATER ANM SHUNT een SENDER sa d B c a i 12 12 mslh eo 8 es 9 rol A 8 Js Lu x Ex gt gt gt FO E amp amp x x Na I I amp 2
43. Decreasing backlash moves the ring gear closer to the pinion A Drive pattern convex side of gear moves lower and toward the toe B Coast pattern concave side of gear moves slightly higher and toward the heel 2 Increasing backlash moves the ring gear away from the pinion A Drive pattern convex side of gear moves higher and toward the heel B Coast pattern concave side of gear moves slightly lower and toward the toe 3 Thicker pinion position shim with the backlash constant moves the pinion closer to the ring gear A Drive pattern convex side of gear moves deeper on the tooth flank contact and slightly toward the toe B Coast pattern concave side of gear moves deeper on the tooth and toward the heel 4 Thinner pinion position shim with backlash constant moves the pinion further from the ring gear A Drive pattern convex side of gear moves toward the top of the tooth face contact and toward the heel B Coast pattern concave side of gear moves to ward the top of the tooth face contact and toward the heel RING GEAR DRIVE SIDE RING GEAR DRIVE SIDE Heel RING GEAR COAST SIDE Figure 54 RING GEAR COAST SIDE Heel Toe Toe RING GEAR DRIVE SIDE Heel Toe Workman 4000 Series Page 10 29 Figure 55 RING GEAR COAST SIDE Heel Toe Figure 56 Front Wheel Drive AWD Drive 4WD Differential Drive Shaft
44. Disassembly and Inspection Fig 20 1 Insert clutch alignment tool see Special Tools in fly wheel pilot bearing hole to keep clutch disk from falling off Fig 21 2 Loosen pressure plate screws Item 10 in a diagonal sequence 3 Remove cap screws washers Item 11 and pres sure 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 5 Check pressure plate surface for wear cracks and color change 6 Check strap plate rivets for looseness and replace pressure plate if loose 7 Check clutch disk facing for loose rivets uneven con tact deterioration due to seizure adhesion of oil or grease Replace clutch disk if damaged 8 Measure rivet sink and replace clutch disk if out of specification Fig 24 Clutch disk thickness 0 307 to 0 339 in 7 8 to 8 6 standard value mm Clutch disk rivet sink 0 012 in 0 3 mm minimum 9 Check for torsion spring play or damage Replace clutch disk if necessary 10 Install clutch disk on transaxle main shaft Make sure clutch slides freely on splines of shaft Check for exces sive play in rotating direction 11 Inspect flywheel surface for stepped wear streaking or seizure Replace if necessary Clean any oil or rus
45. Dust cover 12 Cap assembly 1 Apply a film of clean brake fluid to cylinder bore and piston assemblies 2 Install secondary piston assembly and primary pis ton assembly into cylinder 3 Install retainer washer 4 Install push rod and secure in place with circlip Install lower end of dust cover to housing 5 Push in on push rod so stop pin can be installed to retain secondary piston assembly then install flange seal and reservoir Workman 3000 4000 Series Page 7 21 Chassis Parking Brake Cable Replacement Removal Fig 11 1 Remove brake handle from parking brake lever Loosen set screw on parking brake control lever knob Turn knob on parking brake lever counterclockwise all the way to loosen brake cable adjustment 2 Remove knobs from control levers and then remove center console control plate to gain access to parking brake cables 3 Jack up and support rear of vehicle see Jacking In structions in Operator s Manual 4 Remove rear wheel and brake drum see Brake Ser vice in this section 5 Disconnect cable from rear brake Fig 12 A Remove clip that holds brake cable into brake backing plate B Remove parking brake cable end from parking brake lever on brake shoe 6 Remove retaining ring that secures brake cable to le ver support bracket Fig 11 7 Disconnect brake cable from brake equalizer plate Fig 13 8 Note routing of parking brake cable and location of cable ties
46. E o LL Drive AWD Service and Repairs Front Wheel and Axle Housing Assembly 45 to 65 ft lb 61 to 88 LOCTITE 680 170 to 200 ft lb 230 to 271 N m ACCESS HOLE N Pd 40 to 60 ft lb 54 to 81 N m SMALL SPACER APPLY GREASE TO SPLINES Figure 1 1 Wheel nut 5 used per wheel 11 Flat washer 20 Wheel bearing spacer 2 Wheel and tire assembly 12 Brake hose retainer clip 21 Hardened washer 3 Brake drum 13 Brake hose bracket 22 Hex flange nut 4 Stub axle 14 Constant velocity CV joint assembly 23 Tie rod end RH thread 5 Lock washer 15 Differential 24 Cotter pin 6 Hex bolt 5 used per wheel 16 Bearing assembly 25 Jam nut RH thread 7 Brake cable clip 17 Axle housing RH shown 26 Tie rod 8 Cap screw 4 used per brake 18 Brake plate plug 27 Jam nut LH thread 9 Lock washer 4 used per brake 19 Front brake assembly RH shown 28 Tie rod end LH thread 10 Cap screw Disassembly Fig 1 1 Park vehicle on a level surface Make sure engine is off Engage parking brake and block rear wheels 2 Partially loosen front wheel nuts Jack up and secure front wheel off the ground see Jacking Instructions in Operator s Manual Remove wheel nuts and wheel from the vehicle NOTE If the brake drum sticks to the brake shoes dur ing removal loosen brake shoes from the drum by turn ing bolt adjuster through access hole in brake drum Front Wheel Drive 4WD
47. Figure 6 1 Fuel tank 12 Hose clamp 2 Fuel tank cap 13 Fuel hose to fuel filter 3 Gasket 14 Clamp 4 Fuel sender 15 Flange nut 2 used 5 Lock washer 5 used 16 Flange nut 2 used 6 Screw 5 used 17 Fuel hose return from engine 7 Hex nut 18 Hose clamp 8 Lock washer 19 Fitting 9 Spacer 20 Bushing 10 Wire harness lead 21 Rear fuel tank support 11 Fuel fitting 22 Cap screw 2 used Lock nut 2 used Front fuel tank support Socket head screw 2 used Fuel tank strap 2 used Felt strap 2 used Cap screw 2 used Hose clamp Fitting Fuel filter water separator Fitting Fuel hose to engine Check Fuel Lines and Connections Check fuel lines and connections periodically as recom mended in the Operator s Manual Check lines for dete Because diesel fuel is highly flammable use cau rioration damage leaks or loose connections Replace tion when storing or handling it Do not smoke hoses clamps and connections as necessary 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 safety approved container and keep cap in place Use fuel for the engine only not for any other purpose Briggs Daihatsu Diesel Engine Page 4 10 Workman 3300 D 4300 D Fuel Tank Removal Fig 6 1 Put vehicle
48. Install new O ring Item 1 Apply multi purpose grease on O ring before installing 3 Assemble R H axle shaft A Install new oil seal Item 5 into seal cover Apply multi purpose grease on O ring before installing B Insert washer Item 6 C Use a press to install bearing Item 4 onto R H axle shaft x o gt D Install washer 3 snap ring Item 2 E Install R H axle shaft assembly into seal cover Figure 66 Item 7 4 Assemble differential fork shaft LOCK PIN A Drive 2 lock pins Item 6 into fork shaft Item 7 Make sure lock pins are installed with slit facing the correct direction Install fork Item 5 spring Item4 washer Item 3 and snap ring Item 2 onto fork shaft using a press Apply moly disulfide grease onto fork portion of fork shaft before installing C Install new O ring Item 1 Apply multi purpose grease on C ring before installing Figure 67 Workman 3000 4000 Series Page 6 37 Drive Train 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 C Rotate side gears until holes of pinion gears and liners line up with holes of differential case Item 1 D In
49. RED 8 BLUE r BLUE WHITE w w at Xx GREEN WHITEA ul no cs cz 5 em GREEN VIOLET ORANGE 117 112 115 ap qua 12 3 4 1 3 4 5 9 PIS 1 2 Pl4 1 2 3 4 5 2 a 8 c nl B A IGNITION IGNITION TAC START NTERCONNEC NTERCONNECT HIGH FLOW IGNITION IGNITION FONTROUEE CONTROLLE SENDER RELAY FRONT HARNESS FRONT HARNESS HYD COIL 3 COIL 2 COIL SOLENOI THIS WIRE DASHED LINE INCLUDED ONLY IN SERIAL NUMBERS FROM 250000001 TO 250999999 FRAME GROUND FUEL SENDER FUEL SENDER GND TAIL LIGHTS INTERCONNECT FRONT HARNESS Workman 3200 and 4200 Briggs Daihatsu Gasoline Engine Rear Wire Harness Diagram Serial Number Below 260000000 Page 11 19 Rev C 16 TEMP SENDER J5 OVER TEMP SWITCH J15 CHOKE HEATER B A w PB A con 3 toit 2 toi 4 P100 Ey FRONT TRANSMISSION F1 n HARNESS FUS IBLE d 5 SWITCH LINK mo HARNESS P6 FUEL PUMP P10 PROTECTION DIODE 2 Chua P21 FUEL SOLENOID P9 PROTECTION P101 DIODE 1 FRONT HARNESS ENDVIEW A B PUMP RELAY 11 HIGH FLOW P102 Y J2 Fog J K Pras SOLENOID FRAME H GROUND P20 Ph PTO OIL 5 SHUNT PRESSURE P13 SWITCH IGNITION PT TRANSMISSION P23 3RD GEAR SWITCH
50. Removal Fig 25 1 Jack up and support rear of vehicle See Jacking In structions in Operators Manual Remove rear wheel s 2 Support frame side rails so rear axle can be remo ved Chassis Page 7 30 3 Support rear axle then remove four 4 lock nuts Item 6 washers Item 7 and carriage screws item 14 securing rear axle to leaf spring 4 Remove two 2 lock nuts Item 1 from spring shackles Item 2 Remove spring shackles 5 Remove two 2 flange nuts Item 12 and flange head screws Item 10 securing spring mount Item 11 to frame rail then remove leaf spring assembly Workman 3000 4000 Series Installation Fig 25 1 Before installing new leaf spring insert four 4 rub ber bushings Item 3 into leaf spring Insert two 2 rub ber bushings into frame side rail 2 Insert one 1 spring shackle Item 2 from inside out into rear of leaf spring Insert spring mount Item 11 from outside in to front of leaf spring and secure finger tight with lock nut 3 Install leaf spring assembly to frame Secure front spring mount with flange head screws Item 10 and flange nuts Item 12 and tighten finger tight Install lock nuts Item 1 to spring shackles Item 2 and tighten fin ger tight Tighten lock nuts Item 6 Leave flange nuts Item 12 that secure spring mount to frame rail finger tight 4 Install spring plate Item 8 to top of spring then se cure axle to spring with carriage
51. Remove Hi Lo shifter Item 9 and collar spline Item 10 G Remove gear Item 11 Inspect bushing for wear and damage Replace gear if I D exceeds 1 184 in 30 08 mm H Remove washer Item 12 snap ring Item 13 and collar Item 14 Measure thickness of washer and replace washer if thickness is less than 110 in 2 8 mm 1 Use a bearing puller to remove 2 bearings Item 15 Figure 49 Drive Train Page 6 30 Workman 3000 4000 Series 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 28 Disassemble Hi Lo fork shaft assembly A Remove shift fork Item 1 steel ball Irem 2 and spring Item 3 from Hi Lo shift fork assembly B Remove E ring Item 4 29 Disassemble differential gear assembly A Use a bearing puller to remove bearing Item 1 from differential case B Remove snap ring Item 2 C Use a bearing puller to remove bearing Item 3 and slider Item 4 D Loosen screws Item 5 from ring gear E Remove ring gear Item 6 from differential case and remove 2 dowel pins Item 7 Drive Train F Drive lock pin Item 8 out of pinion shaft Item 9 10 14 13 3 G Remove pinion shaft Item 9 from differential case H Remove 2 differential pinions
52. SPLICE B 26 BLACK GROUND FRONT HARNESS P100 PIN A 27 BLACK SPEED PICKUP SPLICE B 28 BLUE SPEED PICKUP FRONT HARNESS P101 PIN B 26 RED FRONT HARNESS P100 PIN B SPLICE A 30 RED WHT FRONT HARNESS P102 PIN D SPLICE C 31 RED BLK FRONT HARNESS P101 PING SPLICE D 32 PINK PTO SWITCH PLUG PTO SWITCH PLUG 38 SPEED PICKUP PLUG SPEED PICKUP PLUG Wo rkm an 3 1 00 34 BLACK SPLICE E START RELAY Page 11 14 Rev C Kohler Gasoline Engine Rear Wire Harness Serial Number Below 260000000 FUEL SENDER SPLICE E BLACK 6 17A 18A 9 rl ly P101 INTERCONNECT FRONT HARNESS P100 INTERCONNECT FRONT HARNESS P102 INTERCONNECT FRONT HARNESS GROUND C Eg PLICE 78 LICE FUSIBLE Link BLACK D WHITE LICE EX 8 168 248 8 08 308 TM 68 298 258 278 2 MB _ _ eas ENGINE HARNESS BA
53. and pinion gear shafts Secure shaft with roll pin 28 Figure 42 Workman 4000 Series Page 10 25 Front Wheel Drive AWD 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 Press bearing cone 29 onto the differential case 27 Fig 43 9 Position ring gear 32 to the differential case 27 Secure ring gear to the case with five cap screws 26 in a criss cross pattern so the gear is pulled evenly into place Torque cap screws from 58 to 65 ft lb 79 to 88 Fig 44 NOTE The bearing cradle are designed to apply a slight preload to the bearings Therefore it is important to push both bearing assemblies simultaneously into their cradles IMPORTANT If new bearing cones 29 were installed onto the differential case 27 new bearing cups 30 must be installed to the bearing cradles 10 Place bearing cups 30 onto bearing cones 29 Install bearing assemblies into the bearing cradles of the carrier assembly 15 Make sure bearing cups 30 are matched to the proper bearing cradle and bearing cone 29 Fig 45 IMPORTANT The bearing caps are marked for iden tification Place caps back in the same position dur ing reassembly Fig 46 11 Secure bearing caps to their original positions on the bearing c
54. 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 in jected into the skin it must be surgically re moved within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Workman 3000 4000 Series 9 25 Rev D After Repair or Replacement of Components 1 Check oil level in the transaxle and add correct oil if necessary Drain and refill transaxle and change oil filter if component failure was severe or system is contami nated 2 Lubricate O rings and seals with clean hydraulic oil before installing hydraulic components 3 Make sure caps or plugs are removed from the hy draulic tubes hydraulic fittings and components before reconnecting 4 Use proper tightening methods when installing hy draulic hoses and fittings see Hydraulic Fitting Installa tion in the General Information section of this chapter 5 After disconnecting or replacing any hydraulic com ponents operate vehicle functions slowly until air is out of system 6 Check for hydraulic oil leaks Shut off engine and cor rect leaks if necessary Check oil level in transaxle and add correct oil if necessary Check hydraulic lines and hoses daily for leaks kinked lines loose mou
55. are shown as de energized W WHITE BU BLUE VIO VIOLET T TAN Page 11 7 Rev C Rev C BEAR ARNESS B TO POSITIVE BATTERY CABLE PK 39 0 7 creek EIA NE NE EE ae R Start 77417 47 FRONT HARNESS F1 oy or 5 8 5 STARTER B B bul FACTORY SHUNT MATING CONN i START ENABLE START FACTORY SHUNT FACTORY SHUNT FACTORY SHUNT HIGH FLOW HYDRAULICS VIA MATING CONN VIA MATING CONN VIA MATING CONN PROTECTION DIODE D2 2757207 1 1 xe D 2 po 1 er 1 2 1 oe 2 uds cy o i 48 x ev or 1 3 VERTICAL LIFT BED LIFT 4 REMOTE HYD CLUTCH SWITCH PTO KIT OFF 4 ENGAGED F2 10A SUN x iit E 4 i EN oc E 5 gern 40 B 1 1 HIGH FLOW HYDRAULICS KIT i Y Y E a 8 7 F3 145A BRAKE SW ae cx GUTS HORN BRAKE
56. as de energized Page 11 5 Rev C REAR HARNESS PK FRONT HARNESS B TO POSITIVE BATTERY CABLE GY BK B Start i OFF 86 85 STARTER OO ec a eke be lt del ENGINE FACTORY SHUNT VIA MATING CONN i START ENABLE p i i A Pi mp c Si dr ae St ee i FACTORY SHUNT FACTORY SHUNT FACTORY SHUNT 4 eS i HIGH FLOW HYDRAULICS OFF i VIA MATING CONN VIA MATING CONN VIA MATING CONN PROTECTION DIODE D2 e P101 C cor a 0 2 1 e 1 2 1 bers 2 9 7 6 o 4 2 18 a cy oT 3 HYD LIFT INTERLOCK CE PARKING BRAKE SWITCH LIFT KIT CLUTCH SWITCH PTO KIT OFF i H 1 ENGAGED F2 10 x 4 id RUN Ro dupl Un gls B 101 HIGH FLOW HYDRAULICS Y Y Y Y lt 9998 t OTT n T cad E 8 127 7 E E 4 15 BRAKE SW P101 H PROTECTION DIODE D1 ee LIGHTS HORN BRAKE 5 n of o i i i
57. bolts Item 14 washers Item 7 and lock nuts Item 6 NOTE Make sure axle and plate are centered on leaf spring knob Fig 26 5 Tighten lock nuts Item 6 in a crossing pattern until spring plate leaf spring and axle contact Tighten flange nuts Item 12 securing spring mount to frame rail Tight en lock nuts Item 6 securing axle and clamp plate to leaf spring using a crossing pattern and the following torque values A Tighten lock nuts from 20 to 30 ft lb 27 to 41 a crossing pattern Tighten lock nuts from 50 to 60 ft lb 68 to 81 a crossing pattern Retighten lock nuts from 50 to 60 ft lb 68 to 81 N m 6 Install rear wheels see Wheel Installation in this sec tion 7 Lower vehicle to ground Workman 3000 4000 Series Page 7 31 Make sure axle and plate are centered on leaf spring knob Figure 26 Chassis Seat Base 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 Flat washer Chassis Page 7 32 Workman 3000 4000 Series 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 R
58. care when handling the valve car tridge Slight bending or distortion of the stem tube can cause binding and malfunction B Thread cartridge valve carefully into manifold port The valve should go in easily without binding C Using a deep socket torque cartridge valve from 30 to 35 ft lb 41 to 47 D For solenoid valve carefully install solenoid coil to the cartridge valve making sure that seal is installed on both top and bottom of coil Torque nut from 50 to 55 in lb 5 6 to 6 2 Over tightening may damage the solenoid or cause the valve to mal function 8 If problems still exist remove valve and clean again or replace valve Hydraulic System 2 5 gt This page is intentionally blank Hydraulic System Page 9 48 Workman 3000 4000 Series Chapter 10 Front Wheel Drive 4WD TORO E o LL Drive AWD Table of Contents SPECIFICATIONS 2 Constant Velocity CV Joint 12 GENERAL INFORMATION 3 Front Differential 14 SERVICE and REPAIRS 4 Front Differential Service 16 Front Wheel and Axle Housing Assembly 4 Ring to Pinion Gear Engagement 28 Front Brako due oe ay yee 8 Differential Drive Shaft 30 Front Brake Service 10 Drive Shaft Cross and Beari
59. clearance exceeds 039 in 1 0 mm 7 Inspect main shaft A Inspect main shaft for worn or damaged surface If O D of needle bearing surface is less than 864 in 21 95 mm replace the main shaft In t li rtion of oil for wear or damage B Inspect lip portion of oil seal for wear or damage NEEDLE BEKANGS C Insert spline in clutch disk and check for exces OIL SEAL sive looseness and free sliding of clutch disk hub SPLINE FOR CLUTCH DISK Figure 59 8 Inspect both snap ring item 3 and shim s items 2 and 4 for damage Replace all parts if any part is cracked or broken Fig 60 Figure 60 Drive Train Page 6 34 Workman 3000 4000 Series 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 DAMAGED GROOVE EDGES Figure 62 gt e Workman 3000 4000 Series Page 6 35 Drive Train 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 11 Inspect countershaft for wear or damage If O D of inner portion is less than 1 100 in 27 95 mm or 71T gear portion is less than 1 179 in 29 95 mm replace the countershaft 12 Inspect differential A Inspect pinion shaft for excessive wear or d
60. engine 6 Disconnect fuel hose from fuel injection pump on en gine Plug end of fuel hose to prevent contamination and Figure 11 fuel spillage Position disconnected fuel hose away from 1 Engine pulley 6 Coupling spacer d used engine 2 Cap screw 4 used 7 Flat washer 4 used 3 Coupling spacer 4 used 8 Cap screw 2 used 2 7 Note location of cable ties used to secure wire leads one oe pump Baa ou Label and disconnect electrical leads that attach to en s Locknut G used 2 used D o gine A Battery cable and fusible link harness from starter solenoid stud B Double wire from spade terminal on starter sole noid C Wires from oil pressure switch temperature sender on water pump housing and high tempera ture switch D Harness connector and wire with ring terminal from alternator E Harness connector with ring terminal from glow plug connector F Harness connector from fuel solenoid on injec tion pump G Harness connector from crankshaft sensor 8 Disconnect accelerator cable from throttle lever on engine Position accelerator cable away from engine 9 Drain coolant from radiator see Operator s Manual Figure 12 Loosen hose clamps and remove upper and lower ra 1 Cap screw 6 Snubbing washer diator hoses from engine Position hoses away from en Flat washer 7 Engine mount 3 R clamp 8 Engine support gine 4 Spacer 9 Lock
61. housing mounted on the top of the transaxle The Rear PTO Switch is normally closed and opens when the PTO is en gaged Test the switch by disconnecting the wiring connector and connecting a continuity tester across the two termi nals With the engine off move PTO lever to OFF posi tion there should be an indication of continuity Move PTO lever to ON there should be no continuity 1 Diode 2 Male terminal Multimeter Red Lead on Electrical System Page 8 16 1 Figure 22 3 Female terminal Multimeter Black Lead Continuity Rear PTO switch Workman 3000 4000 Series 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 When working with batteries use extreme cau tion 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 Battery Specifications Liquid Cooled Engines BCI Group 34 Battery 690 Amp Cold Cranking Performance at 0 F 18 C 100 minute Reserve Capacity at 80 F 27 C Battery Specifications Air Cooled Engines BCI Group 26 Battery 525 Amp Cranking Performance at 0 F 189 C
62. hub Item 2 Install shifter 1 onto hub Item 2 C Insert 2 springs Item 3 into hub Pay attention to direction of spring 2 Figure 79 Workman 3000 4000 Series Page 6 41 Drive Train 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 Install synchro ring 14 onto gear Item 15 Apply Dexron Ill transmission oil on cone face of gear before installing synchro ring C Insert key Item 13 onto reduction shaft D Install synchro hub sub assembly Item 12 E Install snap ring Item 11 F Install spacer Item 10 onto gear Item 8 Figure 80 G Insert needle bearings Item 9 into gear Item 8 H Install washer Item 7 Oil groove on washer must face the gear l Usea press to install bearing Item 6 Figure 81 Drive Train Page 6 42 Workman 3000 4000 Series 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 artery oo B Install gear Item 15 C Use a press to install bearing Item 14 D Install washer Item 13 and 2
63. lock nut Item 8 to a torque from 130 to 160 14 7 to 18 1 C Apply Loctite 242 or equivalent to threads of set screw and install set screw into pulley hub Torque set screw from 27 to 33 in lb 3 to 3 7 D Install pump suction hose to bottom fitting on pump then fill pump through pressure port on top of pump with clean Dexron III ATF E Install pump pressure hose to top fitting on pump 2 After installing the pump and connecting hydraulic hoses install belt and adjust belt tension see Opera tor s Manual Hydraulic System Page 9 26 3 Check oil level in transaxle see Operator s Manual Add Dexron ATF if necessary 4 Start the engine and operate at idle speed until air is out of hydraulic system 5 Stop the engine and check oil level in transaxle see Operator s Manual Add Dexron III ATF if necessary ANTISIEZE LUBRICANT 27 to 33 in Ib 12 3 to 3 7 N m LOCTITE 242 130 to 160 in Ib 14 7 to 18 1 N m Figure 20 1 Gear pump 8 Lock nut 2 Pressure hose 9 Cap screw 4 used 3 Suction hose 10 Lock washer 4 used 4 Lock nut 4 used 11 Fan 5 Cap screw 4 used 12 Mount plate 6 Pump pulley 13 Set screw 7 Flat washer Figure 21 1 Gear pump 3 Suction hose 2 Pressure hose Workman 3000 4000 Series Gear Pump Vehicles with Air Cooled Engine Removal Fig 22 1 Park vehicle on a level surface raise and support bed
64. polishing B The rib face on the cone is worn back or roller ends are worn or scored The roller cage is cracked or broken C Peeling gouges or nicks inside the cup or on roll ers Scalloping high spots brinelling or burrs in the cups D The seal attached to the bearing cone is cracked torn or damaged 2 If ball joint seals are torn or cracked replace seals and lubricate ball joints 3 Replace worn or cross threaded wheel studs or wheel nuts 4 Replace wheel bearing spacer 20 if worn or dam aged Workman 4000 Series Page 10 5 Rev B Figure 2 1 Axle housing 6 Cap screw 2 Cotter pin 7 Lower ball joint 3 Slotted hex nut 8 CV joint 4 Upper ball joint 9 Ball joint seal 5 Lock nut 10 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 ft lb 54 to 81 Front Wheel Drive 4WD gt LL Drive 4WD IMPORTANT Bearing cones and bearing cups are part of a matched bearing set these parts are not in terchangeable Use one matched bearing set per axle housing 2 If a bearing cup was removed from the axle housing press new bearing cup s into each end of the axle housing 3
65. 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 itis 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 Assembly Fig 8 1 If driveshaft was removed from transaxle apply anti seize lubricant to transaxle shaft Slide driveshaft clamp end onto splined transaxle shaft 2 If removed install axle housing to frame A Position axle housing to frame and install three cap screws to secure axle housing to vehicle frame NOTE Upper cap screw for LH axle housing is short er than other cap screws used to secure axle housing to frame B Install brake assembly to axle housing see Brake Service in Service and Repairs Section of Chapter 7 Chassis 3 If wheel studs were removed from stub axle apply Loctite 680 or equivalent to threads near head of stud Install stud with lock washer into stub axle and torque from 40 to 60 ft lb 54 to 81 N m 4 Insert stub axle with greased bearing into axle hous ing Be careful not to damage the bearing seal during installation 5 Slide end yoke onto stub axle shaft IMPORTANT Flange nut 1 should be replaced whenever it is removed 6 In
66. press bearing in until it hits the yoke E Install snap ring into groove by first bearing cap installed gt Place second bearing into yoke bore and onto cross shaft Press second bearing into yoke G Tap axle yoke outward with hammer and align ment punch to allow 2nd snap ring to fit Install snap ring H Repeat procedure for other yoke Grease cross until grease comes out of all four 4 cups Drive Train Page 6 14 Snap ring Cross and bearings End yoke Yoke and hub Figure 10 5 Seal 6 Shaft 7 Tube yoke Workman 3000 4000 Series 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 3 Disconnect hydraulic hose from fitting on PTO Put la bels on hydraulic hoses for proper reassembly Put caps or plugs on all open hoses or fittings to prevent contami nation Label hoses and fittings for proper reinstallation 4 Loosen cap screws and remove nut with washer Sep Figure 11 arate and O ring from transaxle case Locate and 4 prod 3 Hydraulic hose remove two alignment pins 2 Cable clevis PTO Installation 1 Apply multi purpose grease to O ring and insert O i s 1 ring into groove of transaxle case Insert 2 alignment pins in
67. pulley 8 Lock nut 4 used 17 Screw 2 used 26 Mount plate 9 Cap screw 4 used 18 Flat washer Briggs Daihatsu Diesel Engine Page 4 6 Workman 3300 D 4300 D Removal Fig 4 1 Park vehicle on a level surface stop engine engage parking brake and remove key from the 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 3 Lift and remove the radiator screen from front of ra diator Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene glycol antifreeze is poisonous Dis pose of coolant properly or store it in a properly labeled container away from children and pets 4 Remove the radiator cap Drain radiator into a suit able 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 se cure the radiator to the frame Pull radiator from the ve hicle 9 Plug all radiator and hose openings to prevent con tamination Workman 3300 D 4300 D Page4 7 Install
68. pump speed continues to be 3000 RPM Record flow meter reading GAUGE READING TO BE Flow should be approxi mately 7 9 GPM 29 9 LPM at 1500 PSI 103 4 Bar 9 Open tester flow control valve turn Kit switch OFF and stop engine 10 If pump flow specification is not met inspect for A Slipping pump drive belt B Worn or stuck relief valve C Pump suction line restriction D Gear pump needs to be repaired or replaced To test High Flow Hydraulic system relief pressure A Make sure flow control valve on tester is fully open B Start engine and depress accelerator pedal so engine is running at high idle 3600 50 RPM Turn Kit switch ON IMPORTANT Close flow control valve on tester only enough to get a system relief pressure read ing C Watch pressure gauge carefully while slowly clos ing 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 E Open tester flow control valve release accelera tor 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 B Worn stuck or out of adjustment relief valve 13 Remove tester from quick disconnect couplings Hydraulic System 2 5 gt 2 D gt 72 This page is intentionally blan
69. shown in order of disassembly for example remove Item 1 first then Item 2 etc Reassemble in reverse order for example install Item 1 last 1 Put vehicle on a level surface Stop the engine and remove key from ignition switch Remove the bed or oth er attachment s Allow engine and radiator to cool 2 Remove PTO from top of transaxle see PTO Re moval and Installation in this chapter 3 Thoroughly clean outside surface of PTO case Figure 116 4 Loosen cap screws and nut Note location and length of cap screws Separate PTO cover from PTO housing Drive Train Page 6 54 Workman 3000 4000 Series 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 S 2 Figure 119 Workman 3000 4000 Series Page 6 55 Drive Train 7 Remove PTO input shaft from PTO housing A Shift PTO to ON position 5 GREASE 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 Slide input shaft toward other side F Remove bearing Item 5 G Remove thrust washer Item 6 and gear Item 7 sliding input shaft toward PTO shaft side H Release shift arm Item 8 from shifter
70. 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 be tween 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 The engine must be running to perform hydrau lic tests To guard against possible personal in jury engage parking brake and keep clothing hands feet face and other parts of the body away from fan and other moving parts 6 After installing tester start engine and run at idle speed Check for hydraulic leakage and correct before proceeding with test IMPORTANT In this test the flow tester is posi tioned before the relief valve Pump damage can oc cur if the oil flow is fully restricted 7 Start engine and adjust engine speed with accelera tor pedal so pump speed is 2700 RPM engine speed approximately 3600 RPM Verify pump speed with a phototac Workman 3000 4000 Series Page 9 17 8 While watching tester pressure gauges slowly close flow control valve on the tester until 1500 PSI 103 4 Bar is obtained on gauge Verify that pump speed con tinues to be correct 2700 RPM Record flow meter reading GAUGE
71. that can not be cleaned up with light polishing B The rib face on the cone is worn back or rollers are worn or scored The roller cage is cracked or bro ken Figure 29 C Peeling gouges or nicks inside the cup or on roll ers Scalloping high spots brinelling or burrs in the cups BEARING CONE Figure 30 Figure 31 Workman 4000 Series Page 10 21 Front Wheel Drive AWD Assembly Fig 11 PINION SHAFT 25 RING GEAR 32 CAP SCREW 26 s DIFFERENTIAL CASE 27 SHIM 31 PINION GEAR 6 THRUST WASHER 7 THRUST WASHER 4 SIDE BEVEL GEAR 5 CAP SCREW 11 BEARING CAP BEARING CRADLE BEARING CONE 29 BEARING CUP 30 BEARING CONE 9 BEARING SPACER 24 BEARING CONE 22 COUPLER __ FLANGE 19 3 750 INCH WASHER 17 LOCK NUT 18 Figure 32 NOTE In Figure 32 numbers in parentheses corre spond to the reference numbers in Figure 11 Front Wheel Drive AWD Page 10 22 ROLL PIN 28 CARRIER ASSEMBLY 15 BEARING CUP 10 SHIMS 14 SHIMS 21 BEARING CUP 23
72. the correct specification before re checking the pattern Every gear has a characteristic pattern The illustrations show typical patterns only and explain how patterns shift as gear location is changed When making pinion posi tion changes shims should be changed in the range of 002 to 004 until a correct pattern has been obtained Front Wheel Drive AWD Page 10 28 FILL PLUG DRAIN PLUG Figure 51 PROFILE TOP LAND ES LENGTHWISE BEARING ARC Jj Figure 52 RING GEAR RING GEAR DRIVE SIDE COAST SIDE Heel Heel Figure 53 Workman 4000 Series When a change in backlash is required backlash shims should be changed in the range of 1 1 2 times the amount of backlash required to bring the gears into specification For example if the backlash needed to be changed by 004 the shim pack should be changed by 006 as a starting point High backlash is corrected by moving the ring gear clos er 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 Example 2 Backlash correct Thinner pinion position shims required Fig 55 Example 3 Backlash incorrect Thinner pinion position shim required Adjust backlash to match Fig 56 GEAR PATTERN MOVEMENT SUMMARY 1
73. 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 Figure 15 and slowly heat the oil Fig 16 1 Temp shutdown switch 2 Thermostat housing CAUTION Handle the hot oil with extreme care to prevent personal injury or fire 3 Check continuity of the switch with a multimeter ohms setting The temperature switch is normally open and should close at approximately 238 F 114 C 4 Allow oil to cool while observing temperature The temperature switch should open at about 232 F 111 C 5 Replace switch if necessary 6 Install switch to the water pump A Clean threads of water pump housing and switch thoroughly Apply thread sealant to the threads of the switch B Screw switch into the water pump housing and tighten C Connect blue wire to switch 7 Fill engine cooling system see Operator s Manual 6 TO Workman 3000 4000 Series Page 8 13 Electrical System Fuel Gauge Sender Disconnect wire and remove the fuel gauge sender from the fuel tank 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 240 260 ohms With arm completely up
74. 02 Ee ara AA PIOI a 1 3 ee ae TACH SENSOR FRONT FRONT HIGH FLOW SEON KIT HA HARNESS HYD SOLENOID Workman 3300 and 4300 Briggs Daihatsu Diesel Engine Rear Wire Harness Diagram Serial Number From 260000001 To 270999999 FRAME GROUND FUEL SENDER FUEL SENDER GND TAIL LIGHTS FRONT HARNESS Page 11 25 Rev C ut P24 GLOW RELAY P7 P8 TRANSMISSION HI LO TRANSMISSION SWITCH 3RD GEAR SW ITCH P100 p1 FRONT FUSIBLE HARNESS LINK HARNESS P10 PROTECTION DIODE 2 30 85 2 P2 START RELAY 3 86 87 5 a P17 1 3 VERTICAL LIFT SHUNT P9 PROTECTION DIODE 1 J2 FRAME GROUND P102 FRONT HARNESS P16 1 3 VERTICAL P101 P20 FRONT KIT E HARNESS PRESSURE SWITCH P HIGH FLOW HYD SOLENOID PS ALTERNATOR 5 P19 a BED LIFT amp REMOTE HYD KIT 215 SW ITCH TAIL LIGHTS P18 BED LIFT amp REMOTE HYD SHUNT J TEMP SENDER 1 FUEL SENDER GND SENDER Workman 3300 and 4300 Briggs Daihatsu Diesel Engine Rear Wire Harness Drawing Serial Number Above 280000000 Page 11 26 Rev C CLUTCH SWITCH PTO KIT PTO SHUNT TRANSMISSION 3RD GEAR SWITCH HI LO TRANSMISSION SWITCH FUEL SOL
75. 1 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 716 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Fo
76. 5 to 22 ft lb 24 5 to 29 5 Figure 107 Drive Train Page 6 50 Workman 3000 4000 Series 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 C Install axle shaft assembly and tighten cap screws Item 1 to a torque from 18 5 to 22 ft lb 24 5 to 29 5 N m 31 Measure backlash of ring gear through window on transaxle case Using a dial indicator check ring gear backlash in three equally spaced points Backlash should be 0031 to 0071 in 0 08 to 0 18 mm and must not vary more than 0019 in 0 05 mm at the points checked If backlash is not in this range replace shim set in end of differential carrier A If less than target range decrease total thickness of shim set until correct backlash is achieved B If exceeds the target range increase total thick ness of shim set until correct backlash is achieved NOTE The thickest shim should be installed against the bearing Workman 3000 4000 Series Page 6 51 Drive Train S 2 e 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 d
77. 5 used 15 Flange nut 2 used 24 7 Hex nut 16 Flange nut 2 used 25 8 Lock washer 17 Rear fuel tank support 26 9 Wire harness 18 Cap screw 2 used Because gasoline is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when vehicle is in an enclosed area Always fill fuel tank outside and wipe up any spilled fuel before starting the engine Store fuel in a clean safety approved container and keep cap in place Use fuel for the engine only not for any other purpose Lock nut 2 used Front fuel tank support Socket head screw 2 used Fuel tank strap 2 used Felt strap 2 used Cap screw 2 used Fuel filter Fuel line to engine Check Fuel Lines and Connections Check fuel lines and connections periodically as recom mended in the Operator s Manual Check lines for dete rioration damage leaks or loose connections Replace hoses clamps and connections as necessary Kohler Gasoline Engine 5 4 Workman 3100 Fuel Tank Removal Fig 2 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 IMPORTANT Review safety information regarding fuel handling in the Operator s Manua
78. 8 Flange nut 4 used 14 Cap screw 3 Exhaust gasket 9 Cap screw 15 Muffler 4 Hexnut 4 used 10 Hardened washer 16 Transaxle 5 Exhaust manifold 11 Flange nut 4 used 17 Shift cable mount bracket 6 Socket head screw 4 used 12 Carriage bolt 2 used Briggs Daihatsu Gasoline Engine Page 3 14 Workman 3200 4200 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 If bed is raised place safety support on lift cylinder see Operator s Manual 3 Remove exhaust system components as needed us ing Figure 10 as a guide 4 Discard gaskets and thoroughly clean flange sur faces of manifold and muffler Workman 3200 4200 Page 3 15 Installation Fig 10 1 Replace any removed gaskets 2 If cap screw item 9 was removed apply Loctite 242 or equivalent to threads during installation 3 Using Figure 10 as a guide fit all exhaust compo nents to vehicle before tightening any fasteners When securing exhaust tighten fasteners in the following or der A Hex nuts item 4 that secure exhaust manifold to engine B Cap screw item 9 with washer item 10 that se cures muffler to transaxle C Socket head screws item 6 and flange nuts item 8 that secure muffler to manifold D Cap screws item 7 and flange nuts item 11 that secure muffler to shif
79. 80 40 to 60 ft lb 54 to 81 Figure 3 1 Dust cap 8 Brake drum 15 Inner bearing cone 2 Cotter pin 9 Outer bearing cone 16 Bearing seal 3 Nut retainer 10 Outer bearing cup 17 Cap screw 4 used per brake 4 Jam nut 11 Front hub 18 Lock washer 4 used per brake 5 Tab washer 12 Lock washer 5 used per wheel 19 Brake assembly RH shown 6 Wheel nut 5 used per wheel 13 Hex bolt 5 used per wheel 20 Spindle RH shown 7 Wheel assembly 14 Inner bearing cup NOTE For Workman 4000 Series front wheel service procedures see Front Wheel and Axle Housing Assem bly in the Service and Repairs section of Chapter 10 Front Wheel Drive 4WD Disassembly Fig 3 1 Partially loosen wheel nuts then jack up and support front of vehicle see Jacking Instructions in Operator s Manual Remove wheel nuts and then remove wheel assembly NOTE It may be necessary to back off brake adjuster to remove brake drum To back off adjuster rotate brake drum until access hole lines up with star wheel on adjust er assembly Use a hooked piece of wire to pull pawl away from star wheel then turn star wheel 2 Remove brake drum from front hub 3 Remove dust cap Straighten and remove cotter pin from spindle shaft Remove nut retainer jam nut tab washer and outer bearing cone Pull wheel hub from spindle Chassis Page 7 10 4 Pull seal out of wheel hub and discard seal Remove inner bearing cone from wheel hub
80. CUITS MADE CONTINUITY AMONG TERMINALS POSITION 2 RUN 3 START Page 8 7 Figure 5 Electrical System 2 1 D 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 termi nals With the engine off depress the clutch pedal com pletely there should be an indication of continuity Release the clutch pedal there should be no continuity For clutch switch adjustment procedure see Clutch Pedal Adjustment in Chapter 6 Drive Train 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 termi nals With the engine off depress the brake pedal there should be an indication of continuity Release the brake pedal there should be no continuity Electrical System Page 8 8 Figure 6 1 Clutch switch Figure 7 1 Brake switch Workman 3000 4000 Series 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 a
81. Check bearing cups for wear pitting or other damage Replace worn or dam aged parts Assembly Fig 3 1 If hex bolts and lock washers were removed from the from hub A Thoroughly clean threads of hex bolt and hub 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 ft lb 54 to 81 N m 2 If bearing cups were removed from hub press new cups into hub until they seat against inside shoulder of hub 3 Pack inner bearing cone with grease Install inner bearing cone into bearing cup in hub Apply grease to new seal and press into wheel hub Workman 3000 4000 Series 4 Carefully slide wheel hub with inner bearing cone and seal onto spindle Fill cavity of wheel hub 50 full with grease 5 Pack outer bearing cone with grease and insert it into wheel hub over spindle Install tab washer over bearing and secure hub to spindle with jam nut DO NOT tighten jam nut 6 While rotating wheel hub tighten jam nut to a torque from 75 to 180 in lb 8 5 to 20 3 Back off jam nut until there is clearance between jam nut and tab washer While rotating wheel hub retighten jam nut to a torque from 10 to 15 in Ib 12 to 17 kg cm Position nut retain er to allow installation of cotter pin Install cotter pin and bend cotter pin completely around nut retainer Install dust cap 7 Install brake drum making sure that acce
82. ECT 2 FRONT HARNESS RED BLACK 6 H J K Jol SP03 BLACK sp05 102 FUSIBLE LINK SP02 4 8 pis r BLUE WHITE C RED WHITE D A RED WHITE SP01 ENGINE pol WHITE HARNESS C BROWN WHITE JOS FUEL SENDER BLACK 1 J06 _ s BLACK S BLACK KILL pos 23 RELAY l 4 5 5 REDMHITE X v 9 9 5 E x 5 5 z 5 2 a a 2 a L A A 101 PI PII PIO GROUND TAIL LIGHTS Workman 3100 SPEED PICKUP Kohler Gasoline Engine Rear Wire Harness Diagram Serial Number Above 260000400 Page 11 17 Rev C J6 TEMP SENDER 5 OVER TEMP SWITCH 10 IGN COIL 2 POS Ph P23 OPT PTO KIT r 9 HOKE HEATER P TO SHUNT IGN COIL 2 NEG Pid P1 FUSIBLE LINK HARNESS 2 urs P100 PB INTERCONNECT FRONT HARNESS ae 2 p2 1 START RELAY P6 P13 1 Nerd IGN CONTROLLER P21
83. EO Rp E 3 VIA MATING CONN VIA MATING CONN BK i STARI HIGH FLOW HYDRAULICS KIT OFF FACTORY SHUNT FACTORY SHUNT PROTECTION DIODE D2 i A i P101 C i oF ls Lg 1 ey lt Gy GY 1 2 1 2 OR oS GY I GY 0 ev HYD LIFT INTERLOCK PARKING BRAKE SWITCH CE VEHICLES ONLY LIFT KIT PK j e A RUN x L NEC P101 E HIGH FLOW HYDRAULICS KIT OR oy OR OR gt gt 5 Sie Y 9598 1 UE as i gt zd E PIRE KI lt BRAKE SWITCH 15 P101 H PROTECTION DIODE D1 LIGHTS HORN BRAKE fe 5 w w des BN BN C BN HORN i FA 15A POWER POINT HORN SWITCH LIGHT SWITCH P101 J i 5 o s W BK W BK amp WBK KA BK TC LIGHTS HEADLIGHTS AUX FUSE BLOCK ELEC BRAKE 1 TAIL BRAKE R w i R BK ud 5 BN i i p AUX FUSE BLOCK 5 SUPERVISOR AUX LIGHT KIT SWITCH BK BK i i OFF G BK OR en i AT FUSE BLOCK OVER BATT OIL P100 B GROUND TIE POINT P100 A P101 G 101 OR on OR OR H OR OR TEMP PRES PN Ne SG att Ee MAPAS UNT 5 22 s 7 li GLOW PLUG SWITCH P29 NOT USED R BK i j f fi f 5 a GLOW PLUG LAMP TRANSMISSION TACH HR TEMP FUEL lt P19 NOT USED gt i a SWITCHES
84. F Transaxle Oil Capacity 8 quart U S 7 6 liter system capacity x o gt Workman 3000 4000 Series 6 3 Drive Train Special Tools Order special tools from your Toro Distributor Clutch Alignment Tool Use clutch alignment tool Part No TOR6002 to align clutch friction disk to engine flywheel before tightening pressure plate cap screws Figure 2 Drive Train Page 6 4 Rev C Workman 3000 4000 Series 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 Figure 3 1 lever arm 3 Clevis pin 2 PTO cable 4 Clevis jam nut x o gt Workman 3000 4000 Series Page 6 5 Drive Train Troubleshooting Clutch 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 Damaged clutch disc Excessive wear of clutch disc facing Weak or broken clutch torsion spring Damaged or broken clutch pressure plate Bent or broken clutch diaphragm spring tip Dirty or improperly lubricated clutch disk spline Damaged or dis
85. Fig 14 Assembly Fig 14 1 Remove throttle bracket components from engine as 1 Install removed throttle bracket components to en needed using Figure 14 as a guide gine using Figure 14 as a guide 2 Lubricate bellcrank grease fitting after assembly 3 Check operation and adjustment of accelerator cable see Operator s Manual If needed adjust accel erator cable 4 Check engine speed both idle and high idle and ad just if necessary see Adjust Engine Speed in Adjust ments section of this chapter Briggs Daihatsu Diesel Engine Page 4 20 Workman 3300 D 4300 D TORO Table of Contents 1 SPECIFICATIONS 2 SERVICE AND REPAIRS 3 Cooling 3 Fuel Tank 4 Exhaust System 6 8 KOHLER ENGINE SERVICE MANUAL Introduction This Chapter gives information about specifications and repair of the Kohler engine used in the Workman 3100 General engine maintenance procedures are described in your Operator s Manual Information on engine trou bleshooting testing disassembly and reassembly is identified in the Kohler Engine Service Manual that is in cluded at the end of this section Workman 3100 5 1 Chapter 5 Kohler Gasoline Engine Most repairs and adjustments require tools which a
86. GINE FRAME SENDER BATTERY GROUND GROUNDS ENGINE ENGINE ENGINE DM MIN BK FRAME GROUND TO FRONT HARNESS IS VIA THE REAR HARNESS SEE 100 BK B R R R BK LL vo ALTERNATOR CHOKE HEATER VIO R RAN 3 POWER ENGINE BK 2 2 RW IE ONE COLORS 1 GROUND IGNCOIL 1 v R RED BK BLACK GN GREEN OR ORANGE Ire ye 87a FUEL SOLENOID al Y YELLOW BN BROWN GRAY PK PINK 62 ITN Workman 3200 and 4200 W WHITE BU BLUE VIOLET ZAN COES 2 87 FUEL PUMP a 4 T TAN 5 i Briggs Daihatsu Gasoline Engine PULSAR COIL 85 YYY 86 4 OR R W RW BU mn aw 6 COL3 eee oe J Vehicle Electrical Schematic CRANK POSITION PULSAR COIL FUEL PUMP 4 f Bi Serial Number Above 260000000 TACH P31 P32 FUEL PUMP ENTON CONTROL All relays and solenoids MODULE are shown as de energized BK Page 11 6 Rev C VIA MATING CONN FACTORY SHUNT B TO POSITIVE BATTERY CABLE SETS Fe aie E REAR HARNESS o 87a j PK w 30
87. H side cover Item 3 from transaxle case 14 Inspect side cover for cracks or damage and replace if necessary 15 Loosen cap screws Item 1 and remove R H axle shaft assembly Item 2 from transaxle case Figure 35 Drive Train Page 6 24 Workman 3000 4000 Series 16 Remove differential gear assembly Item 1 together with fork shaft assembly Item 2 17 Remove washer Item 1 from inside of transaxle case NOTE Washer may stick to fork shaft when re moved in step 16 Figure 37 2 e Workman 3000 4000 Series Page 6 25 Drive Train 18 To remove shift arms A Loosen and remove nut Item 1 Remove wash er Item 2 and 2nd 3rd shift arm 3 together with shift arm plate Item 4 spring Item 5 locknut Item 6 washer Item 7 and cap screw Item 8 B Loosen and remove locknut Item 9 and washer Item 10 from both 1st Rev shift arm Item 11 and High Low shift arm not shown Remove shift arms C Loosen cap screws Fig 39 Item 12 and remove keeper plates Item 13 D Remove oil seals Item 14 E Inspect shift arms and keeper plates for bending or damage and replace if necessary Figure 39 19 If P T O cover is on transaxle remove cap screws Item 1 and nut Item 2 with washer Separate P T O cover Item 3 from transaxle case Inspect P T O cover for cracks or damage and replace if necessary Figure 40 Drive Train Page 6
88. HORN SWITCH HORN WE LIGHT SW HEADLIGHTS P101 J o o GN BK W BK W BK W BK POWER POINT wek Pa 4 TAIL BRAKE FUSE BLOCK ELEC BRAKE KIT LIGHTS 1 R BK 1 Lw BN AUX FUSE BLOCK b i SUPERVISOR AUX LIGHT KIT i SWITCH i OFF BK BK Q OR GROUND TIE POINT OVER BATT OIL 100 FUSE BLOCK 100 101 6 101 0 OR OR OR OR OR 5 ee a RBIS oly d 2 gt GLOW PLUG SWITCH 3 3 3 P29 NOT USED R BK 1 L L L 1 5 A VA fea ix TRANSMISSION HR TEMP FUEL lt EIS NOT USED ENIM R BK SWITCHES R W BK VOR G G G Y i 1 6 1 FRONT LOW HIGH OTHER SRD Ih sug P101 B HARNESS P101 K P102 C P102 B P101 102 101 Jr eher a cca ape Jy ust ads stus eh ide cni de SER cab cma XA ecd e MITES Wet Ge MENO Qu AN Aen aE CX E cae Wc ub do utr uu NEL Aim caca DUE REAR HARNESS 7 BU vio BN W POSITIVE BATTERY CABLE TIE POINT ViO R GN BK BU W NOT CONNECTED roses Rer aioe ON STARTER 1 P21 ge See Rte eue Jt aK du FUEL 6 SENDER ENGINE OVER TEMP LOW PRESSURE e TEMPERATURE SWITCH 4 OIL PRESSURE SWITCH EN
89. ITCH PTO KIT PTO SHUNT TRANSMISSION 3RD GEAR SWITCH HI LO TRANSMISSION SWITCH FUEL SOL GLOW RELAY 5 zi 4 eocs 5 LE 5 Ll zu zd co PROTECTION FUSIBLE LINK ALTERNATOR 75 m Z p OVER NDER 10DE 2 HARNESS i So ez ee lt TEMP SWITCH oc A 8 5 ps 2 8 L DE sl x x 2 x o gt d RED 5 amp amp 9 lt lt 5 RED a I a 2 2 z GRAY m 5 GRAY BLACK B GRAY SP5 J4 J13 BLUE WHITE A P4 n PINK si 8 BLACK BLACK P23 BLACK 5 x RED 5 e RED BLACK m PT 8 a PIS BLACK A 2 WHITE BLACK 34 2 BROWN RED 5 RED BLACK SP3 SP4 L RED Pel 5 P100 3 m BLACK RED ORANGE al 5 x gt 5 5 5 9 amp Ex 5 2 5 9 d a ul amp a 2 m o 5 gt gt gt C aur i P2 ES P1
90. Installation Instructions 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 IMPORTANT Make sure that the oil flow indicator arrow on the flow meter is showing that the oil will flow from the pressure coupler through the tester and into the return tank coupler Fig 19 4 With the engine off install tester with pressure gauges and flow meter in series between the quick dis connect couplings Make sure the tester flow control valve is open 5 Make sure the Hydraulic Kit reservoir is full after con necting the tester The engine must be running to perform hydrau lic tests To guard against possible personal in jury engage parking brake and keep clothing hands feet face and other parts of the body away from fan and other moving parts 6 After installing tester start engine and run at idle speed Turn hydraulic kit switch ON and check for hy draulic leakage from connections Correct before pro ceeding with test 7 Adjust engine speed with accelerator pedal so High Flow Kit gear pump speed is 3000 RPM engine speed approximately 3600 RPM Verify pump speed with a phototac Workman 3000 4000 Series Page 9 23 8 With Kit switch still in the ON position watch tester pressure gauges while slowly closing flow control valve on the tester until 1500 PSI 103 4 Bar is obtained on gauge Verify that
91. Item 10 and 2 lin ers Item 11 l Remove L H side gear Item 12 R H side gear Item 13 and 2 liners Item 14 Figure 53 Workman 3000 4000 Series Page 6 31 Drive Train 30 Disassemble differential fork shaft assembly LOCK PIN 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 3 Disassemble axle shaft assemblies Remove O ring Item 1 from differential carrier Remove snap ring Item 2 A B C Remove L H axle shaft assembly Item 3 D Remove snap ring Item 4 and washer Item 5 E Use a bearing puller to remove bearing Item 6 from axle shaft F Remove oil seal Item 7 from differential carrier Item 8 Remove axle shaft assembly Item 1 from seal cover H Remove snap ring Item 2 and washer Item 3 from axle shaft Use a bearing puller to remove bearing Item 4 J Remove oil seal Item 5 from seal cover Figure 55 Drive Train Page 6 32 Workman 3000 4000 Series Inspection 1 2 Thoroughly clean and dry all parts Use emery cloth to remove nicks and burrs from all parts 3 5 Inspect synchronizer ring A Inspect the chamfer for excessive wear or dam age B Inspect inner tapered area for excessive wear or damage C Measure the clearance between synchroni
92. NC Position 10 5 8 i 1 00 0 25 12 aa 0 75 0 25 Finger Tight After Proper Tightening 16 1 in 0 75 0 25 Figure 2 Hydraulic System Page 9 4 Workman 3000 4000 Series 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 Lubricate the O ring with a light coating of oil 4 Install the fitting into the port and tighten it down full length until finger tight Figure 3 5 Tighten the fitting to the correct Flats From Finger Tight F F F T Fitting Size Installation Torque Size FRET 9 10 ft lb 12 13 4 1 4 in nominal hose or tubing 1 00 0 25 20 21 ft lb 27 28 N m 6 3 8 in 1 50 0 25 480 35 37 ft lb 47 50 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 60 66 ft lb 81 89 12 3 4 in 1 50 0 25 16 1 in 1 50 0 25 81 87 ft lb 110 117 NOTE Installation torque values for non adjustable fit Tet etn tings listed in Figure 4 These torque values should Figure 4 only be used when a fitting can be accessed with a sock et Use of an offset wrench e g crowfoot wrench will af fect torque wrench accuracy and should not be used SAE Straight Thread O Ring Port Adjustable 1 Make sure both threads and sealing surfaces are free of bur
93. NLaY OF 1 HIOAH3S3H JIXVSNVH L H3NIVHIS HS3N 001 Q33dS 3NION3 697 969 NI 886 S3Nuva 15 0081 0S soe 4 0 danvs LINN 15 Workman 3000 4000 Series Page 9 6 Hydraulic System High Flow Hydraulic Kit Optional Schematic SONIIdNOD LOANNOOSIG HIOAH3S3H SSVdAd ISd Sc NOHOIIN OL 431009110 aal N ISd 0002 3A TVA 391199 AAWA SSVdA8 Q31VALLOV GION3 105 Qq3ads ANIONS 8 A3u 99 01 A3H NI OLO dNNd Or InvHaAH y HSAN 001 YANIVELS NOILONS Hydraulic System Page 9 7 Workman 3000 4000 Series Hydraulic Circuit Operation Steering Circuit The hydraulic gear pump supplies flow for the steering circuit and for raising and lowering the bed Pump output flows to the steering control valve before reaching the lift valve so the steering circuit has priority Circuit pressure is limited by a relief valve located in the steering control valve When the steering wheel is not being turned with the en gine running hydraulic pump being rotated flow enters the steering control valve at the P port and by passes th
94. OIL SEAL 20 PERMATEX Workman 4000 Series 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 dif ferential Fig 33 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 num ber 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 con trolled 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 pin ion 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 re quire 0 004 inch more shims than a pinion etched O By adding shims the running position is decreased to 3 746 inches The 4 represents a 0 004 inch decrease in the running position SHIMMING DIMENSION MATCHING NUMBERS Figure 33 When reusing a
95. Over heated springs lose their tension and could cause brake linings to wear out prematurely B Replace sagging bent or externally damaged springs 5 Inspect backing plate 2 A Replace if shoe contact surfaces have grooves that may restrict shoe movement and can not be re moved by sanding lightly with emery cloth B Replace if cracked warped or excessively rusted 6 Inspect female push rod 16 bolt adjuster 17 and adjuster sleeve 18 for rust corrosion bending and fa tigue Replace parts as necessary Assembly Fig 5 and 6 1 If backing plate was removed from vehicle secure backing plate to vehicle with four cap screws and lock washers 2 If brake cylinder was removed from backing plate install cylinder assembly see Brake Cylinder Service in this section 3 Clean backing plate 2 Lubricate shoe contact areas with a thin coat of grease 4 Apply a light coat of grease to the threaded areas of the adjuster assembly 27 5 Position brake shoe set 13 onto the backing plate 2 Secure shoes with hold down pins 26 hold down springs 23 and hold down washers 22 6 On rear brakes only attach parking brake cable to parking brake lever After installing cable to each rear brake check to make sure bottoms of brake shoes are seated in grooves at bottom of backing plate 7 Install lower shoe spring 15 to both brake shoes 13 8 Install adjuster assembly 27 in the slots on the br
96. Pack both bearing cones with Mobile high tempera ture grease or equivalent If the outer bearing cone was removed from the stub axle slide wide end of new bear ing 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 hous ing 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 bear ing spacer onto the shaft 6 Slide inner bearing cone with its narrow end first onto the shaft of the stub axle 7 Apply No 2 general purpose grease to the splines of the CV joint 8 Position stub axle axle housing assembly to the CV joint Insert splined end of the CV joint into the stub axle 9 Install axle housing as follows Fig 2 IMPORTANT Make sure cotter pin has a 0 002 inch 0 05 mm clearance from the CV joint boot A Connect lower ball joint to the axle housing Install slotted hex nut and torque from 80 to 90 ft lb 108 to 122 If necessary to install cotter pin tighten nut further and secure assembly with cotter pin B Install cap screw into axle housing and secure with lock nut C Connect upper ball joint to the axle housing Install slotted hex nut and torque from 80 to 90 ft lb 108 to 122 If necessary to install cotter pin tighten nut further and secure assembly with cotter pin
97. Page 10 4 Rev B 3 Remove brake drum from the stub axle 4 Remove hex flange nut 22 and hardened washer 21 from the threaded shaft of the CV joint 14 Discard nut 5 Pull stub axle 4 and outer bearing cone from the axle housing 6 Remove cap screw and flat washer securing the brake hose bracket 13 to the axle housing Workman 4000 Series 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 rod end assembly Separate tie rod end from the axle housing 9 Remove axle housing as follows Fig 2 A Remove cotter pin and slotted hex nut from the upper ball joint Separate upper ball joint from the axle housing B Remove cap screw 6 and lock nut 5 from axle housing C Remove cotter pin and slotted hex nut from the lower ball joint Separate lower ball joint from the axle housing Remove axle housing from the CV joint D Remove remaining inner bearing cone 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 A Spalling or pitting on roller or cone contact sur faces Corrosion that can not be cleaned up with light
98. Page 11 15 Rev C 9 KILL RELAY START RELAY 06 SWITCH 2 STARTER Jot J02 Pot ENGINE HARNESS POL SUPERVISOR OR TRANSMISSION SWITCH Page 11 16 Rev C p12 SPEED INTERCONNECT FRONT HARNESS Workman 3100 Kohler Gasoline Engine Rear Wire Harness Drawing Serial Number Above 260000400 PTO SWITCH CLUTCH SWITCH BED LIFT amp BED LIFT 8 SUPERVISOR OR TRANSMISSION SWITCH gt REMOTE HYD REMOTE HYD SHUNT 1 3 VERTICAL 1 3 VERTICAL LIFT SHUNT LIFT KIT 07 06 J04 103 19 P18 PIT PIG P03 Pod B 8 8 B B X TB ER x gt gt uo 5 lt e 5 o gt gt gt a E 5 RED amp g gu S en BLACK E A p15 START poa 9 3 RED RELAY ae ES 99 5 GRAY SP04 gu B GRAY PROTECTION A BLACK DIODE eye PINK Ef INTERCONN
99. Product Records and Maintenance Product Records 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 2 7 Chapter 3 Briggs Daihatsu Gasoline Engine Introduction 3 1 Specifications 3 2 General Information 3 3 Adjustments 3 4 Service and Repairs 3 6 BRIGGS amp STRATTON DAIHATSU REPAIR MANUAL FOR 3 CYLINDER LIQUID COOLED GASOLINE ENGINES Chapter 4 Briggs Daihatsu Diesel Engine Introduction 4 1 Specifications 4 2 General Information 4 3 Adjustments s oue ees EA 4 4 Service and Repairs 4 6 BRIGGS amp STRATTON DAIHATSU REPAIR MANUAL FOR 3 CYLINDER LIQUID COOLED DIESEL EN GINES Chapter 5 Kohler Gasoline Engine Introductio esnia e n a aa a EY 5 1 Specifications 5 2 Service and Repairs 5 KOHLER ENGINE SERVICE MANUAL Workman 3000 4000 Series Chapter 6 Drive Train General Information 6 2 Specifications 6 3 Special Tools 6 4 Adjustments 6 5 Troubleshoo
100. R 4 gt 3 8 16 UNC 1642 3 8 24 UNF 7 16 14 UNC 27 3 7 16 20 UNF 104 9 1 2 13 UNC 30 3 102 11 105 10 142 14 1 2 20 UNF 32 3 115 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 la I I NIN A 3 4 10 UNC 93 12 140 20 190 27 265 25 359 34 375 35 508 47 407 34 420 35 569 47 e umne ast omen caue mer me E atv ma me bcm m m Face mes omn 475245 3 4 16 UNF 115 15 165 25 224 34 300 25 7is 14UNF 155425 26030 353441 475 45 NOTE Reduce torque values listed in the table above on the fastener size the aluminum or base material by 25 for lubricated fasteners Lubricated fasteners strength length of thread engagement etc are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini NOTE Torque values may have to be reduced when mum proof load specified in SAE J429 The tolerance is installing fasteners into threaded aluminum
101. READING TO BE Flow should be approxi mately 4 3 GPM 16 3 LPM at 1500 PSI 103 4 Bar 9 Open tester flow control valve and stop engine 10 If pump flow specification is not met inspect for A Slipping pump drive belt B Worn or stuck relief valve C Pump suction line restriction D Gear pump needs to be repaired or replaced To test system relief pressure A Make sure flow control valve on tester is fully open B Start engine and depress accelerator pedal so engine is running at high idle 3600 50 RPM IMPORTANT Hold steering wheel at full lock only long enough to get a system pressure read ing Holding the steering wheel against the stop for an extended period can damage the steering control valve C Watch pressure gauge carefully while turning the steering wheel completely in one direction full steer ing lock and holding momentarily D System pressure should be approximately 1800 PSI 124 1 Bar as the relief valve lifts Return steer ing wheel to the center position E Release accelerator pedal to allow engine to re turn to low idle and turn off vehicle Record test re sults 12 If relief pressure is incorrect inspect for A Slipping pump drive belt B Worn or stuck relief valve 13 Remove tester and reinstall disconnected hose Hydraulic System 2 5 gt 2 D gt 72 TEST NO 2 Steering Control Valve and Steering Cylinder STEE
102. RFACE Workman 4000 Series Page 10 27 Figure 50 Front Wheel Drive 4WD lt Drive 4 0 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 Ring to Pinion Gear Engagement When replacing the ring and pinion gear set final posi tion of pinion is verified by using the gear contact pattern method as described in the following procedure NOTE engagement contact of original production ring and pin ion gear may differ slightly from gear pattern shown GEAR TOOTH DEFINITIONS Fig 52 Toe the portion of the tooth surface at the end to wards the center Heel the portion of the gear tooth at the outer end Top Land top surface of tooth 1 Paint the teeth of the ring gear both drive and coast side with a gear marking compound such as DyKem 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 Study the patterns in the following illustrations and cor rect engagement as necessary NOTE When making changes note that two variables are involved Example If you have the backlash set cor rectly to specifications and you change the pinion posi tion shim you may have to readjust backlash to
103. RING CONTROL RIGHT TURN STEERING CYLINDER LIFT CYLINDERS FILTER STRAINER LIFT VALVE TRANSAXLE RESERVOIR Figure 15 Hydraulic System Page 9 18 Workman 3000 4000 Series Procedure for Steering Control Valve and Steering Cylinder Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the vehicle for approximately 10 minutes NOTE This steering test procedure will be affected by incorrect tire pressure binding of the hydraulic steering cylinder excessive weight on the vehicle and or binding of the steering assembly e g wheel spindles tie rods Make sure that these items are checked before proceed ing with any hydraulic testing procedure 2 Perform the Gear Pump Flow and System Relief Pressure Tests see Test No 1 to make sure that gear pump and relief valve are functioning correctly 3 Drive vehicle slowly in a figure eight on a flat level sur face A There should be no shaking or vibration in the steering wheel or front wheels B Steering wheel movements should be followed immediately by a corresponding front wheel move ment without the steering wheel continuing to turn 4 Stop vehicle with the engine running Turn steering wheel with small quick movements in both directions Let go of the steering wheel after each movement The steering wheel or front wheels should not continue to
104. S MOMENTARY 1 2 4 5 ON Diodes Briggs Daihatsu Gas and Diesel Engine Diodes D1 and D2 are used for circuit protection from voltage spikes that occur when a solenoid is de ener gized Diode D1 is in the optional hydraulic circuit and D2 2 is in the starting circuit These diodes plug into the vehicle wiring harness at vari ous locations see appropriate vehicle electrical sche matic in Chapter 11 Electrical Schematics Gy Testing The diodes can be individually tested using a digital multimeter diode test or ohms setting and the table to Figure 21 the right 1 Diode 3 Female terminal 2 Male terminal Multimeter Multimeter Red Lead Black Lead Continuity on Terminal on Terminal 6 5 gt Y Workman 3000 4000 Series Page 8 15 Electrical System 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 Electrical Schematics Testing The diode assembly can be tested using a digital multi meter diode test or ohms setting and the table to the right Rear PTO Switch Optional On vehicles equipped with the optional rear PTO kit the rear PTO switch is located in the rear PTO
105. S T T T VIO R j EOSIUVE BATTERY CABLE 7 BUN NOT CONNECTED NOT CONNECTED ON STARTER ia P21 BK EP de T ATNTE METTER MART E PSS Low ROME ea cS iE uo Ji NEGATIVE BATTERY CABLE zE ENGINE HARNESS ida BK BK 3 BK i O5 TACH SENSOR g gt TACH KIT FUEL 2 SENDER OIL PRESSURE T ere RW E SWITCH at 29 TEMPERATURE LOW PRESSURE FRAME gt SENDER GROUND GROUNDS ENGINE Bic ENGINE i i GROUND CONNECTION TO FRONT HARNESS a i IS VIA THE REAR HARNESS SEE P100 A Z 45 Sor bot Sor MADE cet BK BK BK pim de nies MAGNETO ENGINE HARNESS i FUEL SOLENOID re BW Workman 3100 VOLTAGE REGULATOR Kohler Gasoline Engine SPARK MODULE ENGINE KILL bs Vehicle Electrical Schematic KEY TO WIRE COLORS a m Ww w BK 8 1 R RED BK BLACK GN GREEN OR ORANGE 87 i veto qot Serial Number Below 260000000 Y YELLOW BN BROWN GY GRAY PK PINK W WHITE BU BLUE VIO VIOLET SPARISMEDULE i All relays and solenoids LR BK BN Sige Bee 1 shown as de energized SPEED ADVANCE MODULE Page 11 3 Rev C
106. SENDER FUEL SENDER GND TAIL LIGHTS FRONT HARNESS Workman 3300 and 4300 Briggs Daihatsu Diesel Engine Rear Wire Harness Diagram Serial Number Above 280000000 Page 11 27 Rev C
107. 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 Engage parking brake and block rear wheels 2 Jack up and secure front wheels off the ground see Jacking Instructions in Operator s Manual Prevent flange yoke from dropping and causing personal injury when removing 3 Remove six socket head screws securing the differ ential drive shaft flange yoke to the coupler flange on the front differential Fig 58 4 Slide slip yoke towards the bidirectional clutch Pull slip yoke off the clutch shaft Fig 59 Installation 1 Slide slip yoke onto clutch shaft Fig 59 2 Position flange yoke to the coupler flange on the front differential Secure yoke to the flange with six socket head screws Fig 58 3 Grease differential drive shaft assembly See Opera tors Manual Figure 58 1 Flange yoke 3 Front differential 2 Socket head screw Figure 59 1 Slip yoke 3 Bidirectional clutch 2 Clutch shaft Front Wheel Drive AWD Page 10 30 Workman 4000 Series 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 a
108. Sie Kohler Gasoline Engine i SPARK MODULE eee o ig Vehicle Electrical Schematic KEY TO WIRE COLORS oblas y R BK BLACK GN GREEN ORANGE 1 ram KILL Imm Serial Number Above 260000000 Y YELLOW BROWN GY GRAY PK PINK SPARK MODULE WHITE BU BLUE VIO VIOLET All rel d sol id T 86 CY Y 88 2 P relays and solenoids EET 1 ENGINE are shown as de energized SPEED ADVANCE z MODULE N e N EEEE EEE 4 Page 11 4 Rev C BK VIA MATING CONN FACTORY SHUNT B TO POSITIVE BATTERY CABLE REAR HARNESS PK o w Q o GY BK B hey ety gue tong cay ie alee eels Seay ae fa ole Sip tig tet ig ote MEDIE E CLUTCH SWITCH PTO KIT OFF R R iStat FRONT HARNESS ENGAGED B 1 F1 10A STARTER D ENGINE 4 B F BK FACTORY SHUNT VIA MATING CONN ENABLE 11 1 LP E N
109. Stub Axle and Drive Shaft Service in the Service and Repairs section of Chapter 6 Drive Train Chassis Page 7 12 Workman 3000 4000 Series This page is intentionally blank Workman 3000 4000 Series Page 7 13 Chassis Brake Service 49 to 97 in Ib 5 5 to 11 Figure 5 1 screw and lock washer 2 used 10 L type seal 19 Pawl 2 Backing plate 11 Piston 20 Adjuster spring 3 Plug 12 Dust cover 21 Pawl pin 4 Bleed screw 13 Brake shoe 22 Hold down washer 2 used 5 Bleed screw cap 14 Upper shoe spring 23 Hold down spring 2 used 6 Brake cylinder body 15 Lower shoe spring 24 Pipe guide 7 Parking brake lever 16 Female push rod 25 Inspection plug 8 Pin 17 Bolt adjuster 26 Hold down pin 2 used 9 Spring 18 Adjuster sleeve 27 Adjuster assembly Chassis Page 7 14 Workman 3000 4000 Series Disassembly Fig 5 and 6 1 Partially loosen wheel nuts then jack up and support vehicle see Jacking Instructions in Operator s Manual Remove wheel nuts and then remove wheel 2 If servicing rear brakes loosen set screw on parking brake control lever knob Turn knob on parking brake le ver counterclockwise all the way to loosen parking brake cable adjustment NOTE It may be necessary to back off adjuster to re move brake drum To back off adjuster rotate brake drum until access hole lines up with bolt adjuster on ad juster assembly Use a hooked piece of wire to pull pawl away from
110. TITE 680 170 to 200 ft lb 230 to 271 N m ACCESS HOLE 40 to 60 ft lb 54 to 81 N m SMALL SPACER APPLY GREASE TO SPLINES Figure 5 Wheel nut 5 used per wheel Wheel and tire assembly Brake drum Stub axle Lock washer 5 used per wheel Hex bolt 5 used per wheel Brake cable clip Cap screw 4 used per brake 10 Brake tube 11 Cap screw 12 Flat washer 14 Brake hose 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 se cure front wheel off the ground see Jacking Instructions in Operator s Manual Remove wheel nuts and wheel from the brake drum NOTE If the brake drum sticks to the brake shoes dur ing removal loosen brake shoes from the drum by turn ing bolt adjuster through access hole in brake drum 3 Remove brake drum 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 15 Brake hose bracket 16 Constant velocity CV joint assembly Page 10 8 Rev B 9 Lock washer 4 used per brake 17 Bearing assembly 18 Axle housing RH shown 19 Brake plate plug 20 Front brake assembly RH shown 13 Brake hose retainer clip 21 Wheel bearing spacer 22 Hardened washer 23 Hex flange nut 5 Pull stub axle and outer bearing cone from the
111. TORO Preface The purpose of this publication is to provide the service technician with information for troubleshooting testing and repair of major systems and components on the Workman 3000 4000 Series vehicles REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT INSTRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Cata logs for your vehicle Replacement Operator s Manuals are available on the internet at www toro com The Toro Company reserves the right to change product specifications or this publication without notice PART NO 03126SL Rev D Service Manual Serial No 240000001 and Above Workman 3000 4000 Series This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2003 2004 2006 2007 2011 This page is intentionally blank Workman 3000 4000 Series Table Of Contents Chapter 1 Safety Safety Instructions 1 2 Chapter 2
112. UG LAMP Dy n KIT P5 HEADLIGHT SWITCH SP6 5 7 P100 REAR HARNESS INTERCONNECT P10 ROPS KIT OPTIONAL SP9 LI 2i SUPERVISOR SW ITCH SN 280000001 AND emp J6 SUPERVISOR SWITCH J5 SUPERVISOR SW ITCH Page 11 10 Rev C J13 HORN J12 HORN 5 2 HORN SWITCH 115 HORN SWITCH P15 LEFT HEADLIGHT P29 GLOW PLUG SWITCH Ph HIGHFLOW HYDRAULIC KIT P8 HIGHFLOW HYDRAULIC SHUNT Workman 3000 4000 Front Wire Harness Drawing Serial Number Below 270999999 HOUR METER _ TACH 6 IGNITION SWITCH no lt FUEL GAUGE TEMP GAUGE GROUND TIE POINT 2 s Eure p URINE S
113. USE BLOCK OVER OIL TEMP BAT PRES 100 GROUND TIE POINT P100 A P101 G 101 0 OR oH Seer OR On 152 2 2 4 d BPE EOE w GLOW PLUG FUSIBLE LINK HARNESS R BK L 4 SWITCH BK 1 1 1 5 5 5 TRANSMISSION Taon TACH ET TREA SWITCHES KIT 09 BU Bui 1 R BK R VIO R BK GN BK BU W i G o Y GLOW PLUG LAMP PRTA o o BK LOW HIGH OTHER i L 101 FRONT HARNESS P101 K P102 C Apioi F PIRA Npa REAR HARNESS POSITIVE BATTERY CABLE TIE POINT R VIO R GN BK BU Y BU VIO BN W PE ON STARTER ME NEGATIVE BATTERY CABLE MEI z 5 e j BK BK 3 a BK 96 TACH SENSOR FUEL p 2 TACH KIT SENDER OIL PRESSURE J WX Lh ES ENGINE OVER TEMP SWITCH 9 E 3 9 TEMPERATURE SWITCH gt LOW PRESSURE lt ENGINE FRAME St SENDER BATTERY GROUND GROUNDS ENGINE ENGINE ENGINE ENGINE BK a FRAME GROUND TO FRONT HARNESS IS VIA THE REAR HARNESS SEE 100 BK BR R BK L vio ALTERNATOR GLOW RELAY Workman 3300 and 4300 BK Y UJA Briggs Daihatsu Diesel Engine PK GLOW PLUGS 3 Vehicle Electrical Schematic 30 Serial Number Below 260000000 KEY TO WIRE COLORS All relays and solenoids R RED BK BLACK GN GREEN OR ORANGE Y YELLOW BN BROWN GY GRAY PK PINK
114. ain any oil out of the pump 2 Use a marker to make a diagonal line across the front thrust plate body and rear flange for assembly pur poses Fig 23 2 IMPORTANT Prevent damage when clamping the gear pump in a vise clamp on the front thrust plate only Also use a vise with soft jaws 3 Clamp front thrust plate of pump in a vise with soft jaws with the shaft end down 4 Loosen but do not remove screws that secure rear flange to pump 5 Remove pump from the vise and position pump so that the shaft end is facing down Remove screws 6 Carefully lift rear flange from body 7 Carefully remove body Lift body straight up to re move Make sure the rear thrust plate remains on the drive and idler gear shafts Locate and retrieve dowel pins Hydraulic System Page 9 29 1 Rev D 13 Pressure seal 14 Back up seal 15 Rear flange 16 Lock washer 4 used 17 Screw 4 used 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 Workman 3000 4000 Series IMPORTANT Make sure to not damage the seal bores when removing the seal from the front cover and rear flange 10 Carefully remove reta
115. ake shoes 13 Install pawl 19 into brake shoe and onto top of bolt adjuster 17 9 Install adjuster spring 20 to pawl 19 and brake shoe 13 10 Install upper shoe spring 14 to both brake shoes 13 Chassis Page 7 16 11 11 servicing front brakes install wheel hub to vehicle see Front Wheel Assembly 2 Wheel Drive in this sec tion for series 3000 Workman vehicle or see Front Wheel and Axle Housing Assembly in the Service and Repairs section of Chapter 10 Front Wheel Drive 4WD for series 4000 Workman vehicle 12 If servicing rear brakes install stub axle to vehicle see Stub Axle and Drive Shaft Service in the Service and Repairs section of Chapter 6 Drive Train 13 Install brake drum NOTE On rear wheels make sure access hole in brake drum aligns with hole in stub axle flange On front wheels access hole in brake drum should align with hole in front hub 14 Adjust brake shoes A Align access hole in brake drum with bolt adjust er B Rotate bolt adjuster to increase adjuster length until brake shoes contact brake drum C Back off adjuster until drum rotates freely 15 Install wheel and secure with wheel nuts Tighten wheel nuts in a crossing pattern to a torque from 45 to 65 ft lb 61 to 88 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 depr
116. aks in hy draulic lines that eject high pressure hydraulic fluid Use cardboard or paper to find hydraulic leaks Hydraulic fluid escaping under pressure can penetrate skin and cause injury Fluid accidentally injected into the skin must be surgically removed within a few hours by a doc tor familiar with this form of injury or gangrene may re sult 6 Before disconnecting or performing any work on the hydraulic system all pressure in hydraulic system must be relieved To relieve system pressure push dump le ver forward and backward and rotate steering wheel in both directions after the key switch has been turned off 7 If major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 8 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt Clean protective screen on vehicle frequently 9 If engine must be running to perform maintenance or an adjustment keep clothing hands feet and other parts of the body away from moving parts Keep by standers away 10 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed Safety Page 1 4 11 Shut engine off before checking or adding oil to the engine crankcase 12 Disconnect battery before servicing the vehicle Dis connect negative battery cable first and positive cable last If battery voltage is required for troubleshoot in
117. allow ac cess to engine If bed is raised place safety support on lift cylinder see Operator s Manual 3 Stop engine and remove key from the ignition switch 4 Make sure governor spring is assembled to bellcrank on throttle bracket and outer most slot in engine gover nor lever Fig 2 5 Check low idle stop screw adjustment Figs 3 4 and 5 Proper low idle stop screw adjustment will prevent engine run on when the accelerator pedal is released A Remove return spring from throttle bracket and bellcrank Disconnect throttle cable from balljoint on bellcrank B Move the governor lever to its rearmost position and check that the governor spring is loose in the slot on the engine governor lever Also check that the rear edge of the bellcrank is against the low idle stop screw Release governor lever C Position the rear edge of the bellcrank so it is 0 125 in 3 2 mm from the head of the low idle stop screw Fig 4 At this position the governor spring must be tight against the upper edge of the engine governor lever slot with no extension of the spring coils If necessary adjust low idle stop screw and or governor spring adjusting rod if equipped to allow correct governor spring positioning D Install return spring to throttle bracket and bell crank Connect throttle cable to balljoint on bell crank 6 Check operation and adjustment of accelerator cable see Operator s Manual If needed adjust accel
118. am age If O D is less than 707 in 17 95 mm replace the pinion shaft B Measure thickness of pinion liners If thickness is less than 035 in 0 9 mm replace the pinion liners C Measure thickness of side gear liners If thick ness is less than 043 in 1 1 mm replace the side gear liners D Inspect the gear contact condition between spiral bevel pinion and ring gear E Inspect differential case for wear in side gears and pinion shaft mating area Replace the case if ma chined surfaces are scored or if the pinion shaft fits loosely in the bore Drive Train Page 6 36 Figure 63 Figure 64 PINION LINERS 2 PINION SHAFT SIDE GEAR 2m LINERS 2 Figure 65 Workman 3000 4000 Series 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 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 C Install washer Item 5 and snap ring Item 4 D Install L H axle shaft assembly into differential LH Install snap ring Item 2 F
119. amps 81 to 125 5 3hrs 10 5 hrs 15 8hrs 21 hrs 4amps 4amps 4amps 4 amps 126 to 5 5 hrs 11 hrs 16 5 hrs 22 hrs 170 5 amps 5 amps 5 amps 5 amps 171 to 5 8hrs 11 5 hrs 17 3hrs 23 hrs 250 Q Q Q 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 Q 10 amps 10 amps 10 amps 10 amps Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge the battery in a well ventilated place to dissipate gases produced from charging These gases are explosive keep open flame and elec trical spark away from the battery Do not smoke Nausea may result if the gases are inhaled Un plug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts 4 Following the manufacturer s instructions con nect the charger cables to the battery Make sure a good connection is made 5 Charge the battery following the manufacturer s instructions 6 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 6 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 7 Three hours prior to the end of the charging measure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing fr
120. and adjust the oil level in the transaxle after connecting hydraulic test equipment 10 All hydraulic tests should be made with the hydraulic oil at normal operating temperature 11 After testing is completed check and adjust the level in the transaxle before returning the vehicle to ser vice Hydraulic System 2 5 gt 2 D gt 72 TEST NO 1 Gear Pump Flow and System Relief Pressure STEERING CONTROL 2 H LX Q x 1 STEERING oe Pee CYLINDER LIFT CYLINDERS STRAINER LIFT VALVE TRANSAXLE RESERVOIR Figure 13 Figure 14 1 Gear pump 3 Suction hose 2 Pressure hose Hydraulic System Page 9 16 Workman 3000 4000 Series Procedure for Gear Pump Flow and System Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the vehicle for approximately 10 minutes 2 Park vehicle on a level surface raise and support bed if installed shut engine off and engage the parking brake After turning engine off operate all hydraulic con trols to relieve hydraulic system pressure 3 Make sure that gear pump drive belt is adjusted prop erly see Operator s Manual 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 IMPORTANT Make
121. ap screw 2 used 3 Air intake hose 8 Flange nut 2 used 13 Flange nut 2 used 4 Radiator hose 9 Clamp 14 5 Air inlet hood 10 Mounting band Briggs Daihatsu Gasoline Engine Page 3 12 Workman 3200 4200 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 3 Remove air cleaner components as needed using Figures 8 and 9 as guides Installation Fig 8 IMPORTANT Any leaks in the air filter system will cause serious engine damage Make sure daily that all air cleaner components are in good condition and are properly secured during reassembly 1 Reassemble air cleaner system using Figures 8 and 9 as guides Air cleaner hose item 6 and air inlet hood item 5 should be positioned straight upward The va cuator valve on the air cleaner assembly should be posi tioned downward 2 Lower or install bed or attachment s 1 Plug 2 Upper housing 3 Element Workman 3200 4200 Page 3 13 Figure 9 4 Gasket 5 Lower housing 6 Vacuator valve Briggs Daihatsu Gasoline Engine 5 a 2 a a Exhaust System Figure 10 1 Engine 7 Cap screw 2 used 13 Mount plate 2 Stud 4 used
122. asoline Engine Service and Repairs Radiator Figure 5 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 Fan shroud 13 Hose to coolant reservoir 22 Cap screw 4 used 5 Lower radiator hose 14 Cap screw 4 used 23 Lock washer 4 used 6 Hose clamp 15 Hose clamp 24 Fan 7 Radiator 16 Upper radiator hose 25 Idler pulley 8 Lock nut 4 used 17 Screw 2 used 26 Mount plate 9 Cap screw 4 used 18 Flat washer Briggs Daihatsu Gasoline Engine Page 3 6 Workman 3200 4200 Removal Fig 5 1 Park vehicle on a level surface stop engine engage parking brake and remove key from the 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 3 Lift and remove the radiator screen from front of ra diator Do not open radiator cap or drain coolant if the radiator or engine is hot Pressurized hot cool ant can escape and cause burns Ethylene glycol antifreeze is poisonous Dis pose of coolant properly or store it in a properly labeled container away from children and pets 4 Remove the radiator cap Drain radiator into a suit able container using the radiator drain located on the lower right corner of the radiator 5 Disconnect upper and lower radia
123. ation Fig 4 1 Remove plugs from radiator and hoses placed dur ing the removal procedure 2 Position radiator to the frame Secure radiator to the vehicle with four 4 cap screws and flange nuts 3 Attach fan shroud to the radiator with four 4 cap screws flat washers and lock nuts Make sure that clear ance exists between shroud and fan at all points 4 Connect reservoir hose item 11 to the radiator filler neck 5 Connect upper and lower hoses to the radiator 6 Make sure radiator drain is closed Fill radiator with coolant see Operator s Manual 7 Install the radiator screen 8 Lower or install bed or other attachment s Briggs Daihatsu Diesel Engine 5 2 a 5 Pump Driveshaft Service RIGHT A FRONT 100 to 130 in Ib 11 3 to 14 7 N m ANTISIEZE LUBRICANT Figure 5 1 Locknut 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 Flat washer 4 used 4 Pump drive belt 10 Frame support bracket 16 Cap screw 2 used 5 Pulley 11 Cap screw 4 used 17 Cap screw 2 used 6 Bearing 12 Coupling spacer 4 used 18 Driveshaft Briggs Daihatsu Diesel Engine Page4 8 Workman 3300 D 4300 D Removal Fig 5 1 Park vehicle on a level surface raise and support bed if installed shut engine off and engage the parking brake 2 Disasse
124. ation see Battery Service in Service and Repairs section of this Chapter Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if a charging system has an output but not its capacity Use a multimeter set to the DC volts setting Connect the positive meter lead to the positive battery post and the negative meter lead to the negative battery post Leave the test leads connected and record the battery voltage NOTE Upon starting the engine the battery voltage will drop and then should increase once the engine is run ning NOTE Depending upon the condition of the battery charge and battery temperature the charging system voltage will increase at different rates as the battery charges Workman 3000 4000 Series Page 8 5 Voltage Measured Battery Charge Level 12 68 v or higher Fully charged 100 12 45 v 75 charged 12 24 v 5096 charged 12 06 v 2596 charged 11 89 v 096 charged 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 At least 0 50 volt over initial battery voltage Initial Battery Voltage 12 30 Battery Voltage after 3 Minute Charge 12 80 v Electrical System 6 s Verify Interlock System Operation The purpose of the interlock system is to prevent the en gine from crankin
125. awing 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 This page is intentionally blank Electrical Schematics Page 11 2 Workman 3000 4000 VIA MATING CONN FACTORYSHUNT I fee B TO POSITIVE BATTERY CABLE REAR HARNESS D i 30 5 7 a GY BK 3 B efe EOS SSS Se Se Se Se Se Rue Sede ee Sees ee ees eS el SS See See SS E CLUTCH SWITCH PTO KIT OFF MES PK BU PK BU 3 Start FRONT HARNESS ENGAGED d F1 10 E RU PKBU STARTER ENGINE FACTORY SHUNT VIA MATING CONN R R BK START ENABLE fene n es Me sisi etie pns ua 4 lt BK HIGH FLOW HYDRAULICS OFF i PROTECTION DIODE D2 101 F D GY GY
126. 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 as sembly from the axle housing for servicing some com ponents such as the brake cylinder assembly 6 If necessary remove brake assembly as follows A Disconnect brake tube 10 from the brake as sembly 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 wash ers 9 from the housing Workman 4000 Series Installation Fig 5 1 If the brake assembly was removed from the axle housing install brake assembly as follows A Secure brake assembly to the axle housing with four cap screws and lock washers IMPORTANT Make sure brake hose connections are clean and free of dirt B Remove plug from front brake hose Connect brake tube to brake assembly 2 f 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 ft lb 54 to 81 3 Insert small spacer and then wheel bearing spacer onto the stub axle Make sure bearing cones are suffi ciently greased 4 Apply No 2 general purpose grease to the splines of the CV
127. block Item 9 l Remove input shaft assembly Figure 121 8 Disassemble PTO input shaft A Remove shift collar Item 1 B Remove 2 steel balls Item 2 and spring Item 3 Figure 122 Drive Train Page 6 56 Workman 3000 4000 Series 9 Disassemble PTO intermediate shaft A Use a bearing puller to remove bearing Item 1 if necessary 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 Remove retaining ring 4 and thrust washer Item 5 D Use a bearing puller to remove bearing Item 6 if necessary Figure 124 x o gt is a Figure 125 11 Disassemble shift arm A Remove two 2 lock pins from shift arm B Remove two 2 O rings Item 1 Figure 126 Workman 3000 4000 Series Page 6 57 Drive Train Inspection 1 Thoroughly clean and dry all parts CLEARANCE 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 Measure 1 0 of input shaft bushing Item 1 Replace bushing if 1 0 exceeds 673 in 17 10 mm Figure 128 5 Measure O D of bushing area on input shaft Re place shaft if O D is less than 667 in 16 95 mm In spect surface of bu
128. 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 Figure 1 1 Donot start engine while vehicle is on jack because 1 Front jacking point engine vibration or wheel movement could cause ve hicle to slip off jack 2 Do not work under vehicle without jack stands sup porting it The vehicle could slip off jack injuring any one beneath it 3 The jacking point at the front of the vehicle is under the front center frame support and at the rear it is under the axle tube 4 When jacking up front of vehicle always place a wood block or similar material between jack and ve hicle frame support Figure 2 1 Rear jacking point Workman 3000 4000 Series 1 5 Safety 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 Before servicing or making adjustments to the vehicle stop engine set parking brake and re move key from ignition switch Any load mate rial must be removed from bed or other attach ment before working under raised bed Never work under a raised bed without positioning bed safety support on a fully installed cylinder rod After work is completed remove bed safety sup port insert into storage brackets on back of ROPS panel and lower bed Figu
129. bolt adjuster then turn bolt adjuster 3 Remove brake drum 4 If servicing front brakes remove wheel hub from ve hicle 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 ve hicle see Stub Axle and Drive Shaft Service in the Ser vice 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 fe male 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 8 If servicing rear brakes disengage parking brake cable from parking brake lever 9 See Brake Cylinder Service in this section for infor mation on brake cylinder disassembly inspection and assembly procedures 10 If needed remove brake backing plate from vehicle by removing four cap screws and lock washers Inspection 1 Clean and inspect brake drum any time they are re moved for brake service A Check drum diameter at a minimum of three loca tions Diameter should not exceed the over size limit cast into the outside of the drum Re
130. c 8528 5 956 3 m aad am c Q T s gt SP6 ra GRAY m 5 GRAY 2 m BLACK 1 FRAME 5 GROUND x o 5 ce J4 a gt a JI3 BLUEWHITE FUEL PTO a GRAY SENDER KIT o GRAY P4 JI4 FUEL PTO A BLACK SENDER GND SHUNT PINK BLACK LE SP2 P23 TRANSMISSION X RED WHITE 3RD GEAR SWITCH P RED BLACK PT PIS BLACK A WHITE BLACK 8 TAIL BROWN c LIGHTS HI LO A RED WHITE TRANSMISSION SWITCH Le RED BLACK 3 PB SP4 FUEL REDMHITE SOLENOID Pal 2 RED WHITE FUEL 2 REDMHITE PUMP RELAY gt 2 4 WHITE gt 5 RED WHITE Be Me P100 BLACK A B FRONT HARNESS w gu x E E E a 5 xxi x m 5 x 8 2 5 2i 9 i im a ITE 458 5 5 lS d o lt 2Img mm cn gt fr c m 1 all 4 98 1159 pu pau 1 02 3 4 jPle BS 405 6 ih ieee ae eo he A B C 102 A B C D E F G6 H J a g PU 30 85 87A 87 86 me ES CONTROLLER SENDER HARNESS HARNESS OM COIL 3 COIL 2 COIL I CONTROLLER H1D Workman 3200 and 4200 Briggs Daihatsu Gasoline Engine Rear Wire Harness Diagram Serial Number Above 260000000 Page 11 21 Rev C 100 INTERCONNECT FRONT HARNESS 1 P10 PROTECTION DIODE 2
131. ccelerate or back up vehicle slowly with the front wheels turned Listen for snapping or clicking noise at the wheel then drive straight ahead A If the noise remains constant the wheel bearing is the likely problem see Front Wheel and Axle Housing Assembly in this section B If the noise gets louder when turning the out board CV joint is likely worn A badly worn joint will snap or click when driving straight ahead however the noise will increase when accelerating or backing up into a turn 3 Accelerate vehicle quickly and straight ahead Vibra tion 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 worn or damaged the CV joint assembly must be replaced Workman 4000 Series Page 10 11 Front Wheel Drive AWD Constant Velocity CV Joint 45 to 65 ft Ib 61 to 88 170 to 200 ft Ib 230 to 271 N Pd Figure 8 1 Wheel nut 5 used per wheel 11 Flat washer 2 Wheel and tire assembly 12 Brake hose retainer clip 3 Brake drum 13 Brake hose bracket 4 Stub axle 14 Constant velocity CV joint assembly 5 Lock washer 5 used per wheel 15 Differential 6 Hex bolt 5 used per wheel 16 Bearing assembly 7 Brake cable clip 17 Axle housing RH shown 8 Cap screw 4 used per brake 18 Brake plate plug 9 Lock washer 4 used per brake 19 Front b
132. crew cap 14 Upper shoe spring 23 Hold down spring 2 used 6 Brake cylinder body 15 Lower shoe spring 24 Pipe guide 7 Parking brake lever 16 Female push rod 25 Inspection plug 8 Pin 17 Bolt adjuster 26 Hold down pin 2 used 9 Spring 18 Adjuster sleeve 27 Adjuster assembly For brake service procedures refer to Brake Service in the Service and Repairs section of Chapter 7 Chassis Front Wheel Drive AWD Page 10 10 Workman 4000 Series Inspect Constant Velocity CV Joint Boot and Test CV Joint Inspect CV Joint Boot o Drive 4 0 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 Pot holes curb contact or collision damage can chip bear ing components and initiate worn conditions 1 Look for grease on the suspension inner tire side wall or fender to indicate a possible torn boot Inspect boot for cracks holes tears or loose clamps Dirty grease within the boot may indicate damage to the CV joint Figure 7 2 If the boot is cracked or torn or has any holes or 1 Inboard boot 3 Differential loose clamps remove CV joint see Constant Velocity 2 Outboard boot Joint in this section and replace boot Test CV Joint 1 Test drive vehicle on a smooth surface to verify CV joint problem 2 A
133. d 63 Be careful not to drop parts or damage oil seal 2 Pull ball bearings 4 and or oil seal 13 if they re quire replacement see Inspection Workman 4000 Series 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 4 Replace thrust bearing 9 if bent distorted or the needles do not spin freely 5 Replace rollers 7 or cam 8 if any of the following conditions occur A Contact surfaces have excessive spalling or pit ting Peeling gouges or nicks are present B Corrosion that can not be cleaned up with light polishing is present C Roller ends are worn or scored The rolling sur face of the roller has any flat spots 6 Replace garter spring 6 if it is distorted in any way that the rollers 7 are not held snuggly by the cam 8 and cage 12 when assembled Fig 62 7 Replace ball bearings 4 if any of the following conditions occur A Play between bearing races and balls is exces sive The bearing cage is cracked or distorted B The inner or outer bearing races are cracked dis torted discolored from over heating or corroded C The balls are nicked distorted discolored from over heating or corroded 8 Replace oil seal 13 if its metal ring is
134. d Flow TOR214678 Use to test hydraulic circuits and components for flow and pressure capacities as recommended in the Testing section of this chapter This tester includes the following 1 INLET HOSE Hose connected from the system cir cuit to the inlet side of the hydraulic tester 2 LOAD VALVE A simulated working load is created in the circuit by turning the valve to restrict flow 3 PRESSURE GAUGE Glycerine filled 0 to 5000 PSI gauge to provide operating circuit pressure 4 FLOW METER This meter measures actual oil flow in the operating circuit with a gauge rated from 1 to 15 GPM 5 to 55 LPM Figure 10 5 OUTLET HOSE A hose from the outlet side of the hydraulic tester connects to the hydraulic system circuit 6 FITTINGS An assortment of hydraulic fittings are in cluded with this kit Hydraulic System Page9 10 Rev D Workman 3000 4000 Series Hydraulic Test Fitting Kit TOR4079 This kit includes a variety of O ring Face seal fittings to enable connection of test gauges to the hydraulic sys tem TORO TEST FITTING KIT NO TOR4079 The kit includes tee s unions reducers plugs caps and male test fittings Figure 11 Male Coupler For Optional High Flow Hydraulic Kit 105 4170 Male coupler that fits into female hydraulic coupler that is included in High Flow Hydraulic Kit Male coupler can be used when testing hydraulic components of High Flow Kit Figure 12 1 Male coupler
135. d Workman 3300 and 4300 BK Y 85 86 WU Briggs Daihatsu Diesel Engine 5 GLOW PLUGS 3 Vehicle Electrical Schematic KEY TO WIRE COLORS Serial Number Above 260000000 R RED BK BLACK GN GREEN ORANGE Y YELLOW BROWN GRAY PK PINK W WHITE BU BLUE VIOLET All relays and solen 5 shown as de energized Page 11 8 This Page Is Intentionally Blank Page 11 9 Rev C 8459 70 P1 FUSE BLOCK P102 REAR HARNESS INTERCONNECT P14 RIGHT HEADLIGHT P17 POWER POINT P25 AUXILIARY POWER P2 AUXILIARY POWER UNFUSED P26 IGNITION SWITCH Ji IGNITION SWITCH P9 HOUR METER 3 1 P21 TEMPERATURE LAMP P23 TEMP GAUGE P6 BRAKE SWITCH P20 BATTERY J8 FUEL GAUGE J LAMP P7 FUEL GAUGE E d OIL LAMP P19 2 GLOW PL
136. d from pump and engine pulley 8 Disconnect accelerator cable from throttle lever on engine Position accelerator cable away from bracket 9 Disconnect choke cable from choke lever on engine Remove choke cable from bracket 10 Remove all clamps and wire ties that attach wiring harness hoses or cables to the engine 11 Put blocking under transaxle for support Figure 5 12 Attach hoist or block and tackle to engine for support y PE aged 3 Engine mount 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 wash er Item 41 from cap screw on right front corner of en gine 14 Remove four 4 cap screws with lock washers that secure clutch bell housing to engine Fig 6 15 Use a hoist or block and tackle to remove engine from chassis One person should operate hoist or block and tackle and the other person should help guide en gine out of chassis Move engine forward before lifting to disengage transaxle input shaft from clutch Gasoline Engine 16 Note location and retrieve two 2 bushings Fig 6 item 2 from bell housing 17 If necessary remove hydraulic pump drive pulley from stub shaft on flywheel side of engine Locate and retrieve woodruff key Figure 6 18 If pressure plate and clutch disc removal is neces 3 HN 1 Engine 5 Cap screw 4 used
137. d play is too large replace shim shim set item 2 in steps 21 and 22 with thicker shims to reduce endplay 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 Drive Train Page 6 48 Figure 99 Workman 3000 4000 Series 25 nstall fork shaft case A Insert spindle Item 1 between fork shafts B Insert 2 steel balls Item 2 and 2 springs Item 1 into the grooves C Apply silicone sealant to mating surface of fork shaft case D Install fork shaft case Item 2 Tighten cap screws Item 1 to a torque from 18 5 to 22 ft lb 24 5 to 29 5 Check operation of shifters and detent S 2 26 Insert a washer 1 into housing of transaxle case Apply moly disulfide grease to washer before installing Figure 103 Workman 3000 4000 Series Page 6 49 Drive Train 27 Install differential gear assembly Item 1 together with fork shaft Item 2 onto transaxle case 28 Install side cover A Insert 2 dowel pins onto transaxle case B Apply silicone sealant onto mating surface of side cover C Install side cover Tighten cap screws to a torque from 18 5 to 22 ft lb 24 5 to 29 5 N m 29 Install R H axle shaft assembly A Apply silicone sealant onto mating surface of seal cover B Install axle shaft assembly Item 2 and tighten cap screws Item 1 to a torque from 18
138. distorted or bent Distortion cracks or tears of the rubber seal is not acceptable 9 Replace adapter plate 14 if the contact surface with the oil seal is nicked cracked or distorted Fig 65 Workman 4000 Series Page 10 33 Figure 62 a Figure 64 1 Thrust bearing 2 Cam Figure 65 Front Wheel Drive AWD lt z Drive 4 0 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 67 4 Insert cam with thrust bearing thrust washer and spring into the cage Fig 68 NOTE Rollers must be replaced as a complete set 5 Insert rollers into the slots of the cage Make sure garter spring fits snuggly into the groove of all rollers Fig 68 NOTE Both bearings must be replaced as a set 6 If the ball bearings 4 were removed press new bearings into the housing and race 5 7 f 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 Installation Fig 61 1 Clean adapter plate 14 thoroughly of all dirt and de bris to prevent damage to the bidirectional clutch and transaxle 2 If the adapter plate 14 was removed from the tran
139. e make sure that hydraulic lift cylinder does not con tact tank 2 Position fuel tank to tank straps and fuel tank sup ports Hook tank straps to fuel tank supports Tighten Socket head screws and lock nuts to secure fuel tank 3 If fuel fitting was removed from tank apply thread sealant to threads of fitting before installing fitting into tank 4 Connect electrical wiring to the fuel sender A Connect blue white wire with ring terminal to the center fuel sender terminal and secure with lock washer and hex nut B Connect black ground wire with the screw item 6 that is closest to the frame rail C Apply skin over grease to the wire terminal con nections and cover center terminal with harness boot 5 Connect fuel hose from tank outlet to fuel filter and secure with clamp Connecting battery cables to the wrong battery post could result in personal injury and or dam age to the electrical system 6 Position battery in vehicle see Operator s 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 Operator s Manual Check for fuel leakage and correct if found Briggs Daihatsu Gasoline Engine 5 Do no Air Cleaner System VACUATOR DIRECTION Figure 8 1 Engine 6 Air cleaner hose 11 Mount bracket 2 Hose clamp 7 Air cleaner assembly 12 C
140. e corroded or damaged Start relay faulty Start relay wiring loose corroded or damaged Starter solenoid wiring loose corroded or damaged Starter solenoid faulty Engine runs but should not with 3rd High lockout 3rd High lockout key switch faulty switch in Slow position and transaxle in 3rd gear and High range 2 3 lockout switch on transaxle faulty High Low lockout switch on transaxle faulty Engine kills when shifted to 3rd gear 3rd High lockout key switch on Slow position with transaxle in High range instruct operator Damaged or disconnected wiring for 3rd High lockout key switch Damaged or disconnected wiring for 2 3 lockout switch or High Low switch on transaxle Battery does not charge Loose or broken wire s Faulty alternator Dead battery Electrical System Page 8 4 Workman 3000 4000 Series Electrical System Quick Checks Battery Test Open Circuit Test Use a multimeter to measure the voltage between the battery terminals Set the multimeter to the DC volts setting The battery should be at a temperature of 60 to 100 F 16 to 38 C The ignition key should be in the OFF position and all accessories turned off Connect the positive meter lead to the positive battery post and the negative me ter lead to the negative battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate inform
141. e free of burrs nicks scratches or any foreign material 2 Make sure the O ring is installed and properly seated in the groove It is recommended that the O ring be replaced any time the connection is opened 3 Lubricate the O ring with a light coating of oil 4 Putthe tube and nut squarely into position on the face seal end of the fitting and tighten the nut until finger tight 5 Mark the nut and fitting body Hold the body with a wrench Use another wrench to tighten the nut to the cor rect Flats From Finger Tight F F F T The markings on 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 surgi cally removed within a few hours by a doctor familiar with this type of injury Gangrene may result from such an injury Nut Sleeve Figure 1 the nut and fitting body will verify that the connection has been tightened Final Position Size F F F T Mark Nut and Body 4 1 4 in nominal hose or tubing 0 75 0 25 Initial 6 3 8 in 0 75 0 25 Extend Li 8 1 2 in 0 75 0 25 BU
142. e see Battery Specifications rating of the bat tery for 15 seconds G Take a voltage reading at 15 seconds then re move the load H Using the table below determine the minimum voltage for the cell temperature reading Minimum Battery Electrolyte Temperature Voltage 7 96 oram 2 9 4 50 F 10 0 C 4 49C l If the test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service 9 3 409F Installation Fig 24 IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure ignition and all accessories are off 2 Make sure battery compartment is clean and re painted if necessary 3 Make sure all battery cables and connections are in good condition and battery retainer has been repaired or replaced 4 Place battery in its compartment Make sure battery is level and flat Connect positive cable connector onto positive battery post Tighten cap screw and nut with two wrenches 5 Secure battery retainer Do not overtighten retainer to prevent cracking or distorting the battery case Workman 3000 4000 Series 6 Apply a light coat of grease on all battery posts and cable connectors to reduce corrosion after connections are made 7 Connect a digital multimeter set to amps between the negative battery post and the negative ground cable connector The reading should be less
143. e 143 9 Insert PTO shaft assembly Item 1 into bearing housing of PTO housing Figure 144 Drive Train Page 6 62 Workman 3000 4000 Series 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 11 Install PTO to transaxle see PTO Removal and Installation in this chapter Figure 145 2 Workman 3000 4000 Series Page 6 63 Drive Train This page is intentionally blank Drive Train Page 6 64 Workman 3000 4000 Series Chapter 7 TORO Chassis Table of Contents SPECIFICATIONS 2 Brake Master Cylinder 20 SPECIAL TOOLS 3 Brake Master Cylinder Service 21 TROUBLESHOOTING 4 Parking Brake Cable Replacement 22 Suspension and Steering 4 Steering Wheel 23 Brakes oc xu SUM ES 6 Control Arm Ball Joint Replacement 24 SERVICE AND REPAIRS 8 Tie Rod End Replacement 25 Wheel Installation 8 Front Wheel Alignment 26 Front Whe
144. e 19 Workman 3000 4000 Series This page is intentionally blank x o gt Workman 3000 4000 Series Page 6 19 Drive Train Clutch Service Silicone sealant Workman 3100 only 5 to 7 ft lb 7 to 9 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 Release guide 8 Bell housing 13 Clutch disc 4 Clutch release fork 9 Oil seal 14 Spring 5 Clutch release shaft 10 Cap screw 6 used Clutch Release Mechanism Fig 20 5 During assembly apply anti seize lubricant to the following 1 Remove transaxle See Transaxle Removal in this section A Fill annular groove of release bearing and coat re mainder of bearing bore 2 Inspect main shaft of transaxle for wear or damaged splines B Apply thin coat to outside diameter of release guide 3 Remove roll pin Item 1 then remove throw out bearing Item 2 Inspect bearing and replace if it is loose C Apply thin coat to fingers of clutch release fork on the sleeve if it appears burned or is worn Make sure bearing slides freely on release guide Item 3 D Remove any excess lubricant before final assem bly 4 Inspect clutch fork Item 4 release shaft Item 5 and bushings Item 6 for wear or damage Inspect ex tension spring Item 14 Replace worn or damaged parts Replace seals Item 9 Drive Train Page 6 20 Workman 3000 4000 Series Clutch
145. e are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Product Records and Maintenance Product Records 2 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque Thread Size Grade 5 _ 1 2 20 UNF 80 10 ft lb 108 14 Class 8 8 75 15 ftb M12 X 1 5 80 10 ft lb 108 14 us For steel wheels and non lubricated fasteners Thread Cutting Screws Thread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Threads per Inch Size Baseline Torque Thread Size Baseline Torque Type B 6 20 18 16 No 6 32 UNC 20 5 in lb 20 5 in Ib No 8 32 UNC 30 5 in lb 38 7 in lb 85 15 in lb No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 in lb Hole size material strength material thickness amp finish must be considered when determining specific torque 3 8 16 UNC 200 100 in Ib values All torque values are based on non lubricated fasteners Conversion Factors in lb X 11 2985 X 0 08851 in Ib ft lb 1 3558 N m N m X 0 7376 ft Ib Product Records and Maintenance Page 2 6 Workman 3000 4000 Series Maintenance Maintenance procedur
146. e rotary meter and steering cylinder Flow leaves the control valve through the E port and is directed to the lift valve 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 propor tional to the amount of the turning on the steering wheel STEERING CYLINDER PISTON MOVEMENT gt STEERING CYLINDER NO PISTON MOVEMENT Fluid leaving the steering cylinder flows back through the spool valve then out the T port and returns to the hy draulic reservoir transaxle The steering wheel and steering control valve return to the neutral position when turning is completed Right Turn When a right turn is made with the engine running the turning of the steering wheel positions the spool valve so that flow goes through the bottom of the spool Flow en tering the steering control valve at the P port passes through the rotary meter and is directed out port R Pres sure extends the steering cylinder for a right turn The rotary meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel Fluid leaving the cylinder flows back throu
147. ear 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 acorn IND 30 Lift Valve 32 Steering Control Valve 34 Steering Control Valve Service 36 Steering 38 Steering Cylinder Service 40 Lift Cylinder eae ins 42 Lift Cylinder Service 44 Hydraulic Manifold Optional High Flow Hydraulic Kit 46 SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Hydraulic System 9 5 5 Ga 9 gt 20 I This page is intentionally blank Hydraulic System Page 9 2 Workman 3000 4000 Series Specifications C 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 ATF Reservoir Transaxle 8 U S quart 7 5 Liter system capacity Hydraulic Filter Automotive 10 micron spin on cartridge type 25 PSI by pass valve 100 mesh strainer in reservoir Optional High Flow Hydraulic Kit Pum
148. ed apply anti seize lubricant to bolt shoulder before installing 6 Install a new engine oil filter Fill engine with the cor rect oil see Operator s Manual 7 Install and adjust hydraulic pump drive belt see Op erator s Manual 8 Adjust accelerator and choke cables see Operator s Manual 9 Lower or install bed or attachment s Workman 3100 Chapter 6 TORO Drive Train Table of Contents GENERAL INFORMATION 2 Transaxle 16 SPECIFICATIONS 3 Removal ee 17 SPECIAL TOOLS 4 Installation llle 18 Clutch Alignment Tool 4 Clutch Service 20 ADJUSTMENTS 5 Transaxle Service 22 PTO Cable Adjustment 5 Disassembly 22 TROUBLESHOOTING 6 Inspection enses s eke eid 33 Cl tCh ire emen dea ae ade d 6 2 eee eee bees 37 Transaxle ocn pep A Rad EE CAE 8 Power Take Off PTO Service 54 SERVICE AND REPAIRS 10 Disassembly 54 Shift Cable 10 INSPOCtION aanren ee Reb 58 Stub Axle and Drive Shaft Service 12 Ass
149. eely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive read ings 8 If battery filler caps are removable check the electro lyte level in each cell Adjust electrolyte level if needed Electrical System 6 TO 5 gt F 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 4 Remove rubber seal from around the headlight Dis card headlight 5 Align notch on the inside of the seal with the notch on the new headlight Slide seal onto the headlight until the seal is firmly in place NOTE Applying soapy water to the outside of the seal will aid in sliding the seal into the hood Make sure to thoroughly dry headlights before turning lights on 6 Align notch on the outside of the seal with the notch in the hood Push headlight and seal into the hood until it is firmly in place 7 Connect the wiring harness connector to the head light Tail Lamp Replacement Disassemble and assemble tail lamp using Fig 26 as a guide The tail lamp uses a standard 1157 12volt bulb Electrical System Page 8 20 Figure 25 Front hood 3 Headlight mount Headlight Figure 26 Screw 2 used 3 Bulb Lens 4 Gasket Workman
150. el Assembly 2 Wheel Drive 10 Front Compression Spring Service 27 Rear Wheel Assembly 12 Front Shock Absorber Replacement 28 Brake Service 14 Rear Shock Absorber Replacement 29 Wheel Brake Cylinder Service 17 Rear Leaf Spring Replacement 30 Bleeding the Brakes 18 Seat Base os ces ubi eh or p Er 32 Workman 3000 4000 Series Page 7 1 Chassis 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 Brake fluid DOT Tire Pressure 1 Tire pressure needed is determined by the payload carried 2 The lower the air pressure the less the compaction and tire marks are minimized Lower pressure should not be used for heavy payloads at high speeds Tire damage may result 3 High pressure should be used for heavier payloads at higher speeds Do not exceed maximum tire pres sure 4 See Operator s Manual for additional tire pressure information Chassis Page 7 2 Workman 3000 4000 Series Special Tools Compression Spring Tool Use to remove and install the two 2 front suspension co
151. embly le eet REA ERAI 59 Drive Shaft Universal Joint Service 14 P T O Removal and Installation If Equipped 15 o gt Workman 3000 4000 Series Page 6 1 Drive Train General Information Workman 3000 4000 Series vehicles are equipped with a Toro designed transaxle with 3 forward speeds 1 re verse speed and a differential lock Hi Lo range gives an effective 6 forward and 2 reverse speeds Optional PTO The transaxle is a constant mesh collar shift transmis sion with synchronizers for gears 1 2 and 3 Reverse and High Low 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 indepen dent rear suspension and Dedion type rear axle isolate the mid mounted engine transaxle assembly from the Transaxle terrain The transaxle housing also functions as the hydraulic Figure 1 System reservoir On units equipped with four wheel drive 4WD the front drive shaft in the transaxle transfers power from the transaxle to the front differential and then to the front wheels Drive Train Page 6 2 Workman 3000 4000 Series Specifications Item Specification Transaxle Oil Dexron AT
152. emove four 4 socket head screws that secure each seat to vehicle Lift both seats from vehicle 5 Remove cap screw flat washer and lock nut that se cure each front corner of seat base to frame 6 Disconnect radiator overflow tank hose at radiator and plug the hose 7 Carefully lift seat base from vehicle Installation Fig 27 1 Position and secure seats and seat base to vehicle with removed fasteners 2 Reconnect radiator overflow tank hose to radiator 3 Secure center console control plate to vehicle Install knobs on control levers 4 Install ROPS to vehicle with four 4 cap screws and flange nuts Fig 28 Figure 28 1 ROPS frame 4 Flange nut 4 used 2 Cap screw 4 used 5 RH ROPS receiver 3 LH ROPS receiver Workman 3000 4000 Series Page 7 33 Chassis This page is intentionally blank Chassis Page 7 34 Workman 3000 4000 Series Chapter 8 TORO Electrical System Table of Contents ELECTRICAL SCHEMATICS 2 Start Relay Kohler Engine 11 SPECIAL TOOLS 2 Baten eee i eee ae EN 12 TROUBLESHOOTING 3 Indicator Lights and Gauges 12 ELECTRICAL SYSTEM QUICK CHECKS 5 High Temperature Shutdown Switch Briggs Battery Test Open Circuit Test 5 Daihatsu Gas and Diesel Engine 13 Charging System Test 5 Fuel Gau
153. entical 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 val ue from the measured value of the component you are testing 1 Disconnect the harness connector from the relay that is to be tested 2 Using a multimeter ohms setting measure coil re sistance between terminals 85 and 86 Fig 10 Resist ance should be between 70 and 90 ohms 3 Connect multimeter ohms setting leads to relay ter minals 30 and 87 Ground terminal 86 and apply 12 VDC to terminal 85 The relay should make and break continuity between terminals 30 and 87 as 12 VDC is 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 ter minals 30 and 87A Apply 12 VDC to terminal 85 The relay should make and break continuity between termi nals 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 har ness Electrical System Page 8 10 30 B6 SS 85 87a 87 Figure 10 Workman 3000
154. er as steel balls inside are spring loaded 5 Hold your hand over the area and shift R 1 and 2 3 levers to move rails outward so balls Item 3 springs Item 2 and spindle Item 1 can be removed 6 Inspect fork shaft case for cracks or damage and re place if necessary Figure 27 Drive Train Page 6 22 Workman 3000 4000 Series 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 8 On 4WD units remove front drive shaft and 41T gear from the gear case Remove bearings from gear case see Item 2 of Fig 30 and center plate BEARING CENTER PLATE SHAFT BEARING GEAR CASE 9 Remove reverse shaft Item 1 from transaxle case x o gt 10 Remove main shaft assembly 1 together with fork shaft assembly Item 2 from transaxle case Figure 31 Workman 3000 4000 Series Page 6 23 Drive Train 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 12 Loosen cap screws Item 1 and remove L H axle shaft assembly Item 2 and shims Item 3 from L H side cover Item 4 still attached to transaxle 13 Remove roll pin from differential lock lever Remove lever Item 1 from shaft Loosen cap screws Item 2 and remove L
155. erator cable 7 Start and run engine until engine is at normal operat ing temperature Make sure that carburetor choke is ful ly open Briggs Daihatsu Gasoline Engine Page 3 4 Rev B Figure 2 1 Engine governor lever 3 Spring mounting slot 2 Governor spring Figure 3 4 High idle stop screw 5 Low idle stop screw 6 Return spring 1 Governor spring 2 Bellcrank 3 Engine governor lever Figure 4 1 Governor spring 4 High idle stop screw 2 Bellcrank 5 Low idle stop screw 3 Engine governor lever 6 Spring adjusting rod Workman 3200 4200 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 6 9 Check high idle speed High idle speed should be 3600 50 RPM Reposition the high idle stop screw to adjust high idle speed Make sure to tighten lock nut af ter adjusting high idle stop screw 10 After engine speed adjustments are complete lower the bed or install attachment s ae Figure 5 1 Throttle bracket 5 Bellcrank 2 High idle stop screw 6 nut oS 3 Idle stop screw 7 Return spring D 4 Governor spring 8 Adj rod if equipped mo Figure 6 1 Governor link 3 Carburetor 2 Idle speed screw Workman 3200 4200 Page 3 5 Rev B Briggs Daihatsu G
156. es Page 9 35 7 Start the engine operate at idle speed and rotate the steering wheel in both directions until air is out of hydrau lic system 8 Stop the engine and check oil level in transaxle see Operator s Manual Add Dexron III ATF if necessary Figure 28 1 Hood 5 Cap screw 2 used 2 Screw 7 used 6 Knob 3 Well nut 7 used 7 Cover 4 Flat washer 2 used 8 Dash Figure 29 1 Hyd hose to L port 2 Hyd hose to R port 3 Hyd hose to P port 4 Hyd hose to T port 5 Hyd hose to E port Hydraulic System 3 g 5 gt Steering Control Valve Service 1 Sleeve 9 2 Cross pin 10 3 Ring 11 4 Spool 12 5 Bearing assembly 13 6 Shaft seal 14 7 Ball stop 15 8 Ball Figure 30 Dust seal ring Housing Cardan shaft Spacer O ring Distribution plate Inner gearwheel NOTE For service of the steering control valve see the Sauer Danfoss Steering Unit Type OSPM Service Manual at the end of this chapter Hydraulic System Page 9 36 20 to 24 ft lb 27 to 33 N m Outer gearwheel End cover O ring 5 used Screw fitting ports L R T Screw fitting ports P and E P port check ball Spring set Workman 3000 4000 Series This page is intentionally blank 2 N SS o Workman 3000 4000 Series Page 9 37 Hydraulic System Steering Cylinder Figure 31 1 Steering cylinder 6 Hyd hose from steering valve L 11 D
157. es and fittings Connect hydraulic hoses to lift valve 3 Install seat base to vehicle see Seat Base Installa tion in the Service and Repairs section of Chapter 7 Chassis 4 Check oil level in transaxle see Operator s Manual Add Dexron III ATF if necessary 5 Start the engine operate at idle speed and operate the lift lever in both directions until air is out of hydraulic system 6 Stop the engine and check oil level in transaxle see Operator s Manual Add Dexron III ATF if necessary 7 On TC models verify correct operation of lift lever in terlock switch 2 5 5 0 9 gt gt 0 I Workman 3000 4000 Series Page 9 31 Hydraulic System 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 3 Remove two 2 hex cap plugs Item 1 from side of valve body Inside valve body behind each hex cap plug there is a spring Item 3 ball Item 4 and cam pin Item 6 remove these parts NOTE Remove check ball seats Item 5 only if they need replacement the seats are press fit into the valve body 4 Remove retaining ring Item 14 from spool Item 8 Remove spool retaining ring Item 13 spring retainer Item 10 spacer Item 12 spring Item 11 and second spo
158. es 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 Product Records 6 7 E 75 6 Workman 3000 4000 Series Page 2 7 Product Records and Maintenance This page is intentionally blank Product Records and Maintenance Page 2 8 Workman 3000 4000 Series TORO Table of Contents 1 SPECIFICATIONS 2 GENERAL INFORMATION 3 Adding Oil to 3 ADJUSTMENTS 4 Engine Speed 4 SERVICE AND REPAIRS 6 Radiator dieser deme bed 6 Pump Driveshaft Service 8 Fuel Tank i imer eoa bese hades 10 Air Cleaner 12 Exhaust System 14 ENGINE 16 Engine Throttle 20 BRIGGS amp STRATTON DAIHATSU REPAIR MANUAL FOR 3 CYLINDER LIQUID COOLED GASOLINE ENGINES Introduction This Chapter g
159. ess brake pedal several times while vehicle is moving in re verse 17 Adjust parking brake see Operator s 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 Workman 3000 4000 Series 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 3 Remove two 2 cap screws and lock washers that secure brake cylinder to brake backing plate Remove brake cylinder assembly 4 Remove dust covers pistons L type seals and spring from brake cylinder body Fig 7 Discard dust covers and seals Figure 7 1 Dust cover 2 used 5 Bleed screw Inspection 2 Piston 2 used 6 Bleed screw cap 3 L type seal 2 used Brake cylinder body 4 Spring A CAUTION Use eye protection such as goggles when using compressed air 1 Clean all metal parts wit
160. ety devices and decals in place If a shield safety device or decal is defective illegible or damaged repair or replace it before operating the ve hicle Also tighten any loose nuts bolts or screws to en sure vehicle is in safe operating condition 3 Assure interlock switches are adjusted correctly so engine cannot be started unless clutch pedal is de pressed On TC models engine should start only when hydraulic lever is in the neutral position On vehicles equipped with the optional PTO kit engine should start only when PTO is disengaged Safety Page1 2 Rev D death To reduce the potential for injury or death comply with the following safety instructions To reduce the potential for injury or death com ply with the following safety instructions 4 Since fuel used in Workman vehicles is highly flam mable handle it carefully A Store fuel in containers specifically designed for this purpose Do not remove vehicle fuel tank cap while engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill the fuel tank E Wipe up any spilled fuel Workman 3000 4000 Series 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
161. fold Install caps or plugs in hoses to prevent con tamination and leakage of hydraulic oil Install plugs in manifold ports 4 Remove manifold from vehicle using Figure 41 guide Installation Fig 41 1 Install manifold to vehicle using Figure 41 as a guide 2 Replace o rings on hydraulic hoses and fittings Re move caps and plugs from hoses and fittings Connect hydraulic hoses to manifold 3 Check oil level in reservoir see High Flow Hydraulic Kit Installation Instructions Add correct oil if necessary Valve Cartridge Service Fig 42 1 Make sure the entire outer surface of the manifold is clean before removing the valve 2 For solenoid cartridge valve remove nut securing solenoid to the cartridge valve Carefully slide solenoid Figure 41 Hydraulic manifold 5 Cap screw O ring 6 Lock nut 2 used Hydraulic fitting 7 Engine mount bracket O ring 50 to 55 in Ib 5 6 to 6 2 30 to 35 ft lb 41 to 47 30 to 35 ft lb 41 to 47 off the valve Locate and retrieve seals from top and bot Figure 42 tom of coil 1 Retaining nut 5 Seal kit 2 Solenoid seal 6 Manifold body IMPORTANT Use care when handling the valve car Solenoid 7 Seal kit tridge Slight bending or distortion of the stem tube 4 Solenoid cartridge valve 8 Relief valve cartridge can cause binding and malfunction 3 Remove cartridge valve with a deep socket wrench Note c
162. full position resistance should Figure 17 be 29 34 ohms 1 Fuel gauge sender NOTE If necessary bend float arm to get proper gauge reading for a 1 2 full tank approximately 110 ohms Headlight Switch The headlight switch is located on the control panel This rocker switch allows the headlights to be turned on and off The switch terminals are marked as shown in Figure 19 The circuitry of the headlight switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch terminals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS 1 Headlight switch Figure 19 Electrical System Page 8 14 Workman 3000 4000 Series 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 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 Figure 20 SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUIT
163. g cone 22 and shim 21 from the pinion gear shaft Decrease shim thick ness to increase bearing preload E Install shim bearing cone coupler flange wash er and lock nut to the pinion gear shaft Torque lock nut from 75 to 90 ft lb 102 to 122 F The torque required to rotate the pinion gear shaft Figure 40 should be from 7 to 12 in lb 8 to 14 kg cm If the torque to rotate the pinion gear shaft does not meet specification repeat steps C or D and E as neces SPLINES sary G If the torque required to rotate the shaft of the pin ion gear shaft is as specified in step B or F remove lock nut washer coupler flange bearing cone 22 from the shaft of the pinion gear Press new oil seal 20 into the carrier assembly 15 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 Install flange coupler washer and lock nut back Figure 41 onto the pinion gear Torque lock nut from 75 to 90 ft lb 102 to 122 N m 7 Install thrust washers 7 to pinion gear shafts 6 and thrust washers 4 to side bevel gears 5 Fig 42 A Place gears and washers into the differential case 27 B Rotate both sets of gears simultaneously until the pinion shaft 25 can be inserted through the differ ential case thrust washers and pinion gear shafts C Install pinion shaft into the differential case
164. g or starting unless the clutch pedal is depressed all models the hydraulic lift lever is in the neutral position TC models and rear PTO if so equipped is disengaged A CAUTION Check the operation of the interlock switches daily for proper operation Replace any malfunc tioning switches before operating the machine To verify clutch interlock switch operation 1 Sit on operator s 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 Page 8 6 Rev D To verify operation of hydraulic lift interlock switch TC models 1 Sit on operator s seat and engage parking brake Move shift lever to NEUTRAL position Disengage rear PTO if so equipped 2 Move hydraulic lift lever out of neutral position 3 Depress clutch pedal and rotate ignition key clock wise to START position 4 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 op eration 1 Sit on operator s seat and engage parking brake Move shift lever to NEUTRAL positio
165. g or test procedures temporarily connect the battery Reconnect positive cable first and negative cable last 13 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 14 Battery gases can explode Keep cigarettes sparks and flames away from the battery 15 To assure optimum performance and continued safety of the vehicle use genuine Toro replacement parts and accessories Replacement parts and acces sories made by other manufacturers may result in non conformance with safety standards and the warranty may be voided 16 When raising the vehicle to change tires or to per form other service use correct blocks hoists and jacks Make sure vehicle is parked on a solid level surface such as a concrete floor Prior to raising the vehicle remove any attachments that may interfere with the safe and proper raising of the vehicle Always chock or block wheels Use jack stands or solid wood blocks to support the raised vehicle If the vehicle is not properly sup ported by blocks or jack stands the vehicle may move or fall which may result in personal injury see Jacking Instructions in Operator s Manual Workman 3000 4000 Series Jacking Vehicle 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
166. ge Sender 14 Verify Interlock System Operation 6 Headlight Switch 14 COMPONENT TESTING 7 Glow Plug Switch Briggs Daihatsu Diesel Ignition Key Switch 7 Engine ELI Gece 15 Clutch Switch ccce ne fetes senda Vora 8 Diodes Briggs Daihatsu Gas and Diesel Brake Switch 8 Engine 15 Transaxle Lockout Switches 9 Diode Assembly Kohler Engine 16 3rd High Lockout Key Switch 9 Rear PTO Switch Optional 16 Start Briggs Daihatsu Gas and Diesel Engine SERVICE AND REPAIRS 17 and Fuel Pump Briggs Daihatsu Gas Battery Service 17 Engine 10 Headlamp Replacement 20 Glow Relay Briggs Daihatsu Diesel Engine 11 Tail Lamp Replacement 20 2 1 D Workman 3000 4000 Series 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 circuit
167. gh the spool valve then out the T port and to the hydraulic res ervoir transaxle The steering wheel and steering control valve return to the neutral position when turning is completed STEERING CYLINDER PISTON MOVEMENT lt EN LY pou STEERING Y CONTROL i A E Fy STEERING STEERING Y Y CONTROL Y Y CONTROL NEUTRAL POSITION LEFT TURN RIGHT TURN Figure 7 Hydraulic System Page 9 8 Workman 3000 4000 Series Raise and Lower Bed The hydraulic gear pump supplies flow for the steering circuit and for raising and lowering the bed Pump output flows through the steering control valve and then to the lift valve for raising and lowering the bed flow priority to the steering circuit Circuit pressure is limited by a relief valve located in the steering control valve When the lift valve is in the center position flow from the gear pump by passes 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 cylin der shafts At the same time the pistons push the hy draulic fluid in the rod end of the lift cylinders out and through the lift va
168. h isopropyl alcohol then clean out and dry grooves and passageways with com pressed air Make sure brake cylinder bore and compo nent pieces are thoroughly clean 2 Check cylinder bore and pistons and spring for dam age or excessive wear Replace brake cylinder assem bly if signs of pitting scoring or cracks are evident Assembly 1 Apply a film of clean brake fluid to new L type seals and then install seals onto pistons 2 Apply a film of clean brake fluid to cylinder bore and piston assemblies Carefully install one piston the spring and then the other piston 3 Install new dust covers 4 Install brake cylinder assembly to brake backing plate with two 2 cap screws and lock washers Torque cap screws from 49 to 97 in lb 5 5 to 11 5 Connect brake line to brake cylinder 6 Reassemble brakes see Brake Service in this sec tion 7 Bleed brakes see Bleeding Brakes in this section Workman 3000 4000 Series Page 7 17 Chassis 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 3 With pedal firmly depressed open bleeder valve of right rear brake until pedal fades to floor then close Bleeder valve bleeder valve gt du 4 Repeat procedure until a contin
169. he highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery 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 be tween the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test A CAUTION Follow the manufacturer s instructions when us ing 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 manufactur er s instructions C Make sure battery terminals are free of corrosion Electrical System Page 8 18 D If battery filler caps are removable measure the temperature of the center cell E Connect a battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply a test load of one half the Cranking Perfor manc
170. heels 2 Drain front differential oil into a suitable container by removing the drain plug from its bottom Install drain plug when draining is complete 3 Remove both CV inboard joint assemblies from the front differential see Constant Velocity CV Joint As sembly Removal 4 Remove differential drive shaft from the front differ ential flange see Differential Drive Shaft Removal 5 Remove front brake lines and clamps that might in terfere with the removal of the front differential Tie any cables out of the way that might interfere with removal Support front differential during removal to pre vent 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 8 Remove three cap screws 28 and lock washers 29 from the differential front bracket 27 and front dif ferential 9 Pull front differential from the vehicle Workman 4000 Series Page 10 15 Installation Fig 10 Support front differential during installation to prevent personal injury from falling and damage to the differential 1 Secure front differential to the differential front brack et with three cap screws 28 and lock washers 29 2
171. ifter is loose Sliding gear tight on shaft or splines Synchronizing unit damaged Sliding gear teeth damaged Synchronizer keys damaged Gears make clashing noise when shifting Shifting too fast Excessive wear of synchro rings Excessive wear of differential side gear liners and pinion liners Damaged synchro springs and or keys Main gear needle bearings worn or damaged Excessive wear of drive shaft s Transaxle sticks in gear Clutch not releasing Shift fork detent ball stuck Shift linkage damaged loose or out of adjustment Sliding gears tight on shaft splines Synchronizer shift keys damaged Drive Train Page 6 8 Workman 3000 4000 Series Transaxle Continued 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 Excessive hydraulic load See Chapter 9 Hydraulic System o gt Workman 3000 4000 Series Page 6 9 Drive Train Service and Repairs Shift Cable Replacement 180 to 210 in Ib 20 3 to 23 7 N m Figure 4 1 Shift knob 8 Clevis pin 14 Lock nut 2 Jamnut 9 Shiftlever 15 Lever support 3 Boot seal 10 Shift link 16 Hex nut 2 used 4 Shift cable 11 Cable clevis 17 Shift stop bolt 2 used 5 Shift pin 12 Cap screw 18 Screw 3 used 6 Jam nut
172. in access to steering control Fig 28 A Remove seven 7 screws item 2 that secure hood and dash to frame B Remove two 2 cap screws item 5 and flat washers item 4 that secure dash to steering control C Carefully lift dash to allow steering control remov al 6 Remove steering control valve from vehicle frame by removing four 4 cap screws 7 Remove cable ties that secure cover item 12 over hydraulic hoses Remove cover from hoses 8 Label and disconnect hydraulic hoses from steering control valve refer to Figures 27 and 29 Install caps or plugs in hoses to prevent contamination and leakage of hydraulic oil Install plugs in valve ports Installation Fig 27 1 Replace o rings on hydraulic hoses and fittings Re move caps and plugs from hoses and fittings Connect hydraulic hoses to correct steering control valve ports refer to Figures 27 and 29 Make sure that hoses are not twisted while tightening 2 Secure steering control valve to vehicle with four 4 cap screws 3 Install hydraulic hose cover over hoses and secure with cable ties 4 Position dash and hood to frame Fig 28 Secure with seven 7 screws and two 2 cap screws with flat washers 5 Install steering wheel see Steering Wheel Installa tion in the Service and Repairs section of Chapter 7 Chassis 6 Check oil level in transaxle see Operator s Manual Add Dexron III ATF if necessary Workman 3000 4000 Seri
173. in and slotted nut that secure af fected ball joint to spindle Separate ball joint from spindle Inspect ball joint seal and replace if damaged 3 Remove control arm 4 Remove snap ring Press ball joint out of control arm Chassis Page 7 24 9 Flange bushing 10 Cap screw 11 Lock nut 12 Spindle RH 2WD shown Installation Fig 15 1 Press new ball joint into control arm Install snap ring to secure ball joint 2 Install grease fitting into ball joint Install boot over shaft on ball joint Edge of boot must be inserted into ball joint slot 3 Install and secure control arm to vehicle with cap screws and lock nuts Make sure frame tabs collapse against rubber bushings as control arm fasteners are tightened 4 Secure ball joint to spindle with slotted nut Tighten slotted nut to a torque from 80 to 90 ft lb 108 to 122 N m If necessary to install cotter pin tighten nut fur ther and secure assembly with cotter pin 5 If removed install front compression springs see Front Compression Spring Service in this section 6 Grease ball joint see Operator s Manual Workman 3000 4000 Series Tie Rod End Replacement 45 to 55 ft Ib 61 to 75 N m 45 to 55 ft Ib 61 to 75 N m Figure 16 1 Tie rod end 4 Tie rod 2 Cotter pin 5 Jam nut LH thread 3 Jam nut 6 Tie rod end LH thread Removal Fig 16 1 Loosen jam nut that secures affected tie rod end to tie rod 2 Remove c
174. inal with harness boot 5 Connect fuel line from tank outlet to fuel filter and se cure with clamp Connecting battery cables to the wrong battery post could result in personal injury and or dam age to the electrical system 6 Position battery in vehicle see Operator s 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 Operator s Manual Check for fuel leakage and correct if found Kohler Gasoline Engine 1c O Ss 7 6 Exhaust System Loctite 242 Figure 3 1 Socket head screw 4 used 7 Cap screw 13 2 Exhaust manifold 8 Bracket 14 3 Hex nut 3 used 9 Muffler gasket 15 4 Exhaust gasket 2 used 10 Flange nut 4 used 16 5 Flange nut 11 Cap screw 17 6 Screw 12 Hardened washer 18 Kohler Gasoline Engine Page 5 6 Carriage bolt 2 used Mount plate Cap screw Muffler Cap screw 2 used Shift cable mount bracket 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 2 Raise or remove the bed or other attachment s If bed is raised place safety support on lift cylinder see Operator s Manual 3 Remove exhaust system components as needed us ing Figure 3 as a guide 4 Discard gaskets and thoroughly clean flange sur faces
175. inder 3 Make sure that master cylinder push rod is fully ex tended Connect push rod clevis to brake pedal with cle vis pin and cotter pin 4 Bleed brakes see Bleed Brake System 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 Workman 3000 4000 Series 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 Remove re tainer washer 4 Remove primary piston assembly and secondary piston assembly from cylinder housing Inspection 1 Clean all metal parts with isopropyl alcohol then clean out and dry grooves and passageways with com pressed air Make sure cylinder bore and component pieces are thoroughly clean 2 Check cylinder bore pistons and springs for dam Figure 10 age or excessive wear Replace brake cylinder assem bly if sians of pitting scorin r cracks are evident in 1 Master cylinder reservoir Push rod Sig pitting Scoring or cracks are evide 2 Flange seal 8 Circlip cylinder bore 3 Stop pin 9 Retainer washer 4 Clevis 10 Primary piston assy 5 Nut 11 Assembly Fig 10 6
176. ine mount from engine 20 If pressure plate and clutch disc removal is neces sary see Clutch Disassembly and Inspection in Chapter 6 Drive Train Engine Installation Fig 10 1 If pressure plate and clutch disc were removed see Installing Clutch Disc and Cover in the Repairs section of Chapter 6 Drive Train 2 If removed secure engine mount to engine with eight 8 cap screws and lock washers 3 To install the engine perform Engine Removal steps in reverse order 4 Install a new engine oil filter Fill engine with the cor rect oil see Operator s Manual 5 Adjust accelerator cable see Operator s Manual 6 Check engine speed both idle and high idle and ad just if necessary see Adjust Engine Speed in Adjust ments section of this chapter Figure 13 1 Bell housing 4 Flat washer 3 used 2 Cap screw 6 used 5 Dowel pins 2 used 3 Harness bracket Briggs Daihatsu Diesel Engine Page 4 18 Workman 3300 D 4300 D o o 2 a 5 a E Q a This page is intentionally blank Workman 3300 D 4300 D Page 4 19 Briggs Daihatsu Diesel Engine Engine Throttle Bracket Figure 14 1 Engine 7 joint 12 Shoulder bolt 2 Lock nut 8 nut 13 Grease fitting 3 Cap screw 9 Threaded rod 14 Throttle bellcrank 4 screw 10 Accelerator cable 15 Throttle bracket 5 Locknut 11 Return spring 16 Engine mount 6 Locknut Disassembly
177. ining ring and shaft seal from front cover Discard seal Inspection 1 Remove any nicks and burrs from all parts with emery cloth A CAUTION Use eye protection such as goggles when using compressed air 2 Clean all parts with solvent Dry all parts with com pressed air 3 Inspect drive and idler shafts for the following Fig 23 3 A Gear shafts should be free of rough surfaces and excessive wear at bushing points and sealing areas Scoring rough surfaces or wear on gear shafts indi cates need for replacement B Gear teeth should be free of excessive scoring and wear Any broken or nicked gear teeth must be replaced C Inspect gear face edge for sharpness Sharp edges of gears will mill into wear plates and thus must be replaced 4 Inspect thrust plates for the following A Bearing areas should not have excessive wear or scoring B Face ofthrust plates that are in contact with gears should be free of wear roughness or scoring C Thickness of thrust plates should be equal 5 Inspect front cover and rear flange for damage or wear Assembly Fig 23 1 NOTE When assembling the pump check the marker line on each part to make sure the pump components are properly aligned during assembly Fig 23 2 1 Lubricate O rings pressure seals back up seals and thrust plate grooves with a thin coat of petroleum jel ly Lubricate all other internal parts freely with clean Dex ron ATF Wor
178. into fork Put moly disulfide grease onto the shaft before installing 7 Assemble R 1 2 3 fork shaft Figure 72 A Insert 1 fork shaft 2 into 1 fork Item 3 B Drive lock pin Item 1 into fork and fork shaft Pay attention to direction of slit in lock pin Insert 2 3 fork shaft Item 2 into 2 3 fork Item 3 D Drive lock pin Item 1 into fork and fork shaft Pay attention to direction of slit in lock pin Figure 73 x o gt Workman 3000 4000 Series Page 6 39 Drive Train 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 Oil groove on washer must face the gear D Install collar spline Item 10 and snap ring Item 8 E Install shifter Item 9 onto collar spline F Install snap ring Item 8 washer Item 7 and ner Item 6 Oil groove on washer must face the gear G Install gear Item 5 H Install washer Item 4 and snap ring Item 3 Oil groove on washer must face the gear 1 Install washer Item 2 and a new bearing Item 1 using a press Figure 75 Drive Train Page 6 40 Workman 3000 4000 Series 9 Assemble synchro hub A Install 3 keys Item 1 into grooves of
179. 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 1 Thoroughly clean the vehicle before disconnecting or disassembling any hydraulic components Always keep in mind the need for cleanliness when working on hy draulic equipment Contamination will cause excessive wear of hydraulic components 2 Put caps or plugs on any hydraulic lines left open or exposed during testing or removal of components Workman 3000 4000 Series Page 9 15 3 engine must in good operating condition Use a tachometer when making a hydraulic test Engine speed will affect the accuracy of the tester readings 4 Because the hydraulic pump is belt driven check for proper pump belt adjustment before performing any hy draulic test 5 To prevent damage to tester or components the inlet and the outlet hoses must be properly connected and not reversed when using tester with pressure and flow capabilities 6 To minimize the possibility of damaging components completely open load valve in hydraulic tester when us ing tester with pressure and flow capabilities 7 Install fittings finger tight far enough to insure that they are not cross threaded before tightening the fit tings with a wrench 8 Position the tester hoses so that rotating vehicle parts will not make contact with them and result in hose or tester damage 9 Check
180. irection of cover and install Tighten cap screws Item 1 to a torque from 18 5 to 22 ft lb 24 5 to 29 5 Figure 112 Drive Train Page 6 52 Workman 3000 4000 Series 34 Apply multi purpose grease to O ring and insert 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 1 to a torque from 11 to 13 ft lb 15 to 17 N m 35 Install bell housing and secure with cap screws Item 2 Tighten cap screws to a torque from 18 5 to 22 ft lb 24 5 to 29 5 36 Install extension spring Item 1 Figure 114 2 Workman 3000 4000 Series Page 6 53 Drive Train Power Take Off P T O Service 18 to 22 ft lb 24 5 to 29 5 Figure 115 1 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 Retaining ring 4 Cap screw 3 used 16 Thrust washer 28 Retaining ring 5 O ring 17 Bearing 29 Thrust washer 6 Shift arm 18 Retaining ring 30 Bearing 7 Shifter block 19 Shift lever 31 Oil seal 8 Spring 20 Spring pin 32 Output shaft 9 Ball 21 Spring pin 33 Stud 10 Retaining ring 22 Alignment pin 2 used 34 Lock washer 11 Bearing 23 PTO housing 35 Hex nut 12 Input shaft 24 Gear 27T Disassembly Fig 115 NOTE Item numbers in figures are
181. ith PTO engaged PTO switch faulty Starter solenoid clicks but starter will not crank Low battery charge If solenoid clicks problem is not in interlock system Loose or corroded battery cables or ground Loose corroded or damaged wiring at starter Loose starter mounting bolts Faulty starter Faulty starter solenoid Starter cranks but engine will not start 3rd High lockout key switch in Slow position with transaxle in 3rd gear and High range instruct operator terminal wire of ignition key switch loose corroded or damaged Engine or fuel system problem see appropriate Engine chapter Engine does not shut off immediately when ignition key Damaged or disconnected wiring for shut down relay switch is turned off Workman 3100 only Shut down relay faulty 6 0 5 6 Workman 3000 4000 Series Page 8 3 Electrical System 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 Clutch switch out of adjustment or faulty Clutch switch wiring loose corroded or damaged Rear PTO switch if equipped faulty Rear PTO switch if equipped wiring loose corroded or damaged Faulty ignition key switch Ignition switch wiring loos
182. ives information about specifications and repair of the Briggs amp Stratton Daihatsu 3LC gasoline engine used in the Workman 3200 and 4200 General engine maintenance procedures are described in your Operator s Manual Information on engine trou bleshooting testing disassembly and reassembly is identified in the Briggs amp Stratton Daihatsu Repair Manual that is included at the end of this section Workman 3200 4200 Page 3 1 Chapter 3 Briggs Daihatsu Gasoline Engine Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Briggs amp Stratton Daihatsu Repair Manual The use of some specialized test equip ment is explained However the cost of the test equip ment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Briggs amp Stratton Daihatsu gasoline engines are supplied through your local Toro distributor Briggs Daihatsu Gasoline Engine 2 sD 9 x Specifications Item Description Make Designation Briggs amp Stratton Daihatsu 4 stroke Liquid Cooled OHV Gasoline Number of Cylinders Bore x Stroke mm in 72 78 2 834 x 3 07 Total Displacement cc cu in 952 58 1 Compression Ratio 8 6 1 Firing Order 1 front 2 3 Dry Weight app
183. joint 5 Insert stub axle with outer bearing cone and spacers into the axle housing and onto the splined end of the CV joint Workman 4000 Series 10 9 Rev B IMPORTANT Hex flange nut 23 should be replaced whenever it is removed 6 Apply Loctite 271 or equivalent to the threads of the CV joint Install hardened washer and new hex flange nut to the CV joint threads Torque flange nut from 170 to 200 ft lb 230 to 271 N m NOTE Make sure access hole on both the brake drum and stub axle align when installed 7 Install brake drum to stub axle 8 Adjust brake shoes as follows A Align access hole in the brake drum with the bolt adjuster B Rotate bolt adjuster so adjuster assembly length makes both brake shoes contact the brake drum C Back off bolt adjuster until drum rotates freely 9 Bleed front brakes see Bleeding the Brakes in the Service and Repairs section of Chapter 7 Chassis 10 Secure front wheel to the brake drum with five lug nuts Lower front wheel to the ground Torque lug nuts from 45 to 65 ft lb 61 to 88 Front Wheel Drive 4WD gt LL Drive 4AWD 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 4 Bleed screw 13 Brake shoe 22 Hold down washer 2 used 5 Bleed s
184. k Hydraulic System Page 9 24 Workman 3000 4000 Series Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1 Before removing any parts from the hydraulic sys tem park vehicle on a level surface engage parking brake and stop engine Remove key from the ignition switch 2 Clean vehicle before disconnecting removing or disassembling any hydraulic components Make sure hydraulic components hoses connections and fittings are cleaned thoroughly Always keep in mind the need for cleanliness when working on hydraulic equipment Before performing any service or repair on hy draulic system components relieve system pressure to avoid injury from pressurized hy draulic 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 Putcaps or plugs on any hydraulic lines hydraulic fit tings and components left open or exposed to prevent contamination 4 Putlabels on disconnected hydraulic lines and hoses for proper installation after repairs are completed 5 Note the position of hydraulic fittings especially el bow fittings on hydraulic components before removal Mark parts if necessary to make sure they will be aligned properly when reinstalling hydraulic hoses and tubes Check Hydraulic Lines and Hoses Keep body
185. kman 3000 4000 Series Page 9 29 2 Rev D Figure 23 3 3 Gear teeth 1 Gear shaft spline 2 Gear shaft 4 Gear face edge 2 Press new shaft seal into front cover until it reaches the bottom of the bore and secure with retaining ring 3 Install the lubricated pressure and backup seals into the grooves in the front and rear thrust plates Install lu bricated O rings to the body 4 Place front cover seal side down on a flat surface Apply a light coating of petroleum jelly to the exposed side of the front cover 5 Lubricate the drive shaft with clean Dexron III ATF Carefully insert the drive end of the drive shaft through the front thrust plate with the pressure seal side down IMPORTANT When installing drive shaft into front cover make sure that shaft seal item 2 is not dam aged 6 Carefully install shaft with front thrust plate into front cover taking care to not damage shaft seal 7 Lubricate the idler shaft with clean Dexron III ATF Install idler shaft into the remaining position in the front thrust plate Apply a light coating of clean hydraulic oil to gear faces 8 Install rearthrustplate with pressure seal side up and open side of the seals pointing to the inlet side of the pump 9 Install two 2 dowel pins into front cover Align mark er line on the body and front cover IMPORTANT Do not dislodge seals during installa tion 10 Gently slide the body onto the assembly Firm hand press
186. l and Chapter 2 Safety 3 Disconnect negative battery cable first and then pos itive battery cable Remove battery from vehicle see Operator s Manual 4 Disconnect fuel line item 13 from fuel filter on right side frame rail Drain fuel from the fuel tank into a suit able container NOTE To prevent fuel leakage do not loosen lower nut on fuel sender stud 5 Disconnect electrical wiring from the fuel sender on the fuel tank 6 Loosen socket head screws item 21 and lock nuts item19 to allow tank straps to be unhooked from fuel tank supports 7 Remove fuel tank from vehicle Workman 3100 5 5 Fuel Tank Installation Fig 2 1 Check felt straps item 23 and replace if worn or damaged IMPORTANT Make sure that hydraulic lift cylinder does not contact fuel tank 2 Position fuel tank to tank straps and fuel tank sup ports Hook tank straps to fuel tank supports Tighten Socket head screws and lock nuts to secure fuel tank 3 If fuel fitting was removed from tank apply thread sealant to threads of fitting before installing fitting into tank 4 Connect electrical wiring to the fuel sender A Connect blue white wire with ring terminal to the center fuel sender terminal and secure with lock washer and hex nut B Connect black ground wire with the screw item 6 that is closest to the frame rail C Apply skin over grease to the wire terminal con nections and cover center term
187. l prevent dirt and debris from getting into bell housing and damaging clutch or release bearing A When installing driveshafts to transaxle align mounting holes in driveshaft with relief in transaxle shaft Install cap screws hardened washers and flange nuts to secure driveshaft to transaxle shaft Torque fasteners from 35 to 42 ft lb 47 to 57 B Apply Loctite 242 or equivalent to the threads of cap screws used to secure the control cable sup port bracket to the transaxle C Before installing two shift levers and shift arm onto transaxle shafts thoroughly clean shafts and apply Loctite 680 to threads and tapers of shafts Secure by torquing nut from 200 to 280 22 6 to 31 6 N m while holding lever to prevent torque transfer into transaxle Fig 19 2 Install a new hydraulic oil filter and fill transaxle with the correct oil see Operator s Manual Check for oil leaks and repair as necessary 3 Adjust clutch pedal shift cables high low cable and differential lock cable see Operator s Manual 4 f equipped with PTO adjust PTO cable see PTO Cable Adjustment in the Adjustments section of this chapter Drive Train Page 6 18 Figu re 17 1 Mounting brackets 2 Drive shaft Figure 18 1 First Reverse 3 2nd 3rd 2 High Low 4 PTOclutch 200 to 280 in lb 39 22 6 to 31 6 200 to 280 in Ib 22 6 to 31 6 N m Apply Loctite 680 to threads and tapers Figur
188. le 6 Lock washer 5 used per wheel 16 Seal 26 Drive shaft 7 Hex bolt 5 used per wheel 17 End yoke 27 Flange nut 8 Bearing 18 Yoke strap 2 used per yoke 28 Hardened washer 9 Bearing spacer 19 Bolt 2 used per strap 29 Cap screw 10 Cap screw 4 used per brake 20 Hardened washer Disassembly Fig 8 1 Loosen wheel nuts 2 Jack up rear of vehicle and support vehicle with jack stands see Jacking Instructions in Operator s Manual Remove wheel nuts and then remove wheel assembly NOTE It may be necessary to back off brake adjuster to remove brake drum To back off adjuster rotate brake drum until access hole lines up with star wheel on adjust er assembly Use a hooked piece of wire to pull pawl away from star wheel then turn star wheel 3 Remove brake drum NOTE Loosening driveshaft at transaxle will allow eas ier driveshaft removal from end yoke 4 Loosen and remove flange nuts cap screws and hardened washers securing driveshaft to splined axle shaft of transaxle Fig 9 Drive Train 6 12 Rev B 5 Remove the yoke straps 18 securing driveshaft bearing cross to the end yoke 17 then disconnect dri veshaft from the end yoke 6 Loosen flange nut 1 that secures end yoke to stub axle 5 Remove flange nut and flange head screw 21 Discard flange nut Pull end yoke from stub axle Figure 9 Workman 3000 4000 Series 7 Carefully slide stub axle from axle housing 8 If
189. lean water D Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking E 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 Charge at 15 to 25 amps for 15 minutes to allow suffi cient mixing of the electrolyte Electrical System 2 1 D 2 D gt 72 2 If battery filler caps are removable conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the temper ature of the cell B Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 7 C add 0 004 to the specific gravity reading For each 10 F 5 5 C below 80 F 26 7 C subtract 0 004 from the specific gravity reading Example Cell Temperature 100 F Cell Gravity 1 245 100 F minus 80 F equals 20 F 37 79C minus 26 7 C equals 11 0 C 20 F multiply by 0 004 10 F equals 0 008 11 C multiply by 0 004 5 5 C equals 0 008 ADD conversion above 0 008 Correction to 80 F 26 7 C 1 253 C If the difference between t
190. ley Item 5 3 Secure pulley to shaft with washer and lock nut Torque lock nut from 100 to 130 in Ib 11 3 to 14 7 Make sure that shaft rotates freely after pulley is installed 4 Assemble driveshaft using Figure 6 as a guide 5 Adjust pump drive belt tension after assembly see Operator s Manual Briggs Daihatsu Gasoline Engine 5 9 Fuel Tank Figure 7 1 Fuel tank 10 Spacer 19 2 Fuel tank cap 11 Fuel fitting 20 3 Gasket 12 Hose clamp 21 4 Fuel sender 13 Fuel hose to fuel filter 22 5 Lock washer 5 used 14 Clamp 23 6 Screw 5 used 15 Flange nut 2 used 24 7 Hex nut 16 Flange nut 2 used 25 8 Lock washer 17 Rear fuel tank support 26 9 Wire harness 18 Cap screw 2 used 27 Because gasoline is highly flammable use cau tion when storing or handling it Do not smoke while filling the fuel tank Do not fill fuel tank while engine is running hot or when vehicle is in an enclosed area Always fill fuel tank outside and wipe up any spilled fuel before starting the engine Store fuel in a clean safety approved container and keep cap in place Use fuel for the engine only not for any other purpose Lock nut 2 used Front fuel tank support Socket head screw 2 used Fuel tank strap 2 used Felt strap 2 used Cap screw 2 used Fuel filter Fuel pump Fuel line to engine Check Fuel Lines and Connections
191. lock front wheels Jack up rear of vehicle under rear axle and install jack stands so transaxle can be re moved by sliding out from under rear axle see Jacking Information in Operator s Manual Figure 14 1 Drain plug 3 90 fitting 2 Strainer Figure 15 1 Clutch cable 3 Support bracket 2 Clutch release lever x o gt Figure 16 1 Differential lock cable 2 Differential lock lever Workman 3000 4000 Series Page 6 17 Drive Train 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 19 Remove cap screws securing clutch bell housing to engine Note location of washers and harness brackets 20 Carefully pull transaxle back to disengage transaxle input shaft from clutch Use floor jack to lower transaxle and slide out rear of vehicle under the frame 21 Note location and retrieve dowel pins from bell hous ing Installation 1 To install the transaxle perform Transaxle Removal procedure in reverse order noting the following IMPORTANT Workman 3100 air cooled gasoline engine vehicles require application of silicone seal ant to mating surface of bell housing and clutch adapter plate on engine This wil
192. ls off the ground see Jacking Instructions in Operator s Manual 4 Remove differential drive shaft 18 from clutch shaft 1 and the front differential see Differential Drive Shaft Removal 5 Remove six hex socket head screws 17 and lock washers 16 securing the clutch shaft 1 to the housing and race 5 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 AWD Page 10 32 14 Adapter plate 15 Screw 4 used 16 Lock washer 6 used 17 Hex socket head screw 6 used 18 Differential drive shaft 19 Front drive shaft transaxle IMPORTANT When removing the bidirectional clutch from the front drive shaft 19 hold the bear ing end of the housing and race 5 down as it is re moved to prevent dropping of parts Be careful not to damage oil seal 13 on drive shaft splines 8 Pull bidirectional clutch 5 through 12 from the trans axle front drive shaft 19 and adaptor plate 14 Disassembly Fig 61 NOTE The cage and roller assembly consists of the garter spring 6 rollers 7 cam 8 thrust bearing 9 thrust washer 10 spring 11 and cage 12 1 Tilt bearing end of the clutch up and slowly pull cage and roller assembly out of the housing and race 5 as a complete assembly see Fig 62 an
193. luminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighten the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Product Records and Maintenance Product Records 2 6 E 75 6 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Fasteners Grade 1 5 amp SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts 147 23 339 56 599 79 100 10 1125 100 140 15 1580 170 734 113 115 10 1300 100 160 15 1800 170 1186 169 200 25 2250 280 300 30 3390 340 1446 192 225 25 2540 280 325 30 3670 340 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 48 7 1 4 28 UNF 65 10 5 16 18 UNC 115 15 105 17 5 16 24 UNF 138 17 128 17 gt TE A A
194. lve to the reservoir transaxle LIFT CYLINDERS 2 PISTON MOVEMENT LIFT VALVE IN RAISE POSITION RAISE BED When the control valve lever is released spring action returns the lift valve spool to the center position and lift cylinder movement is stopped The cylinder position is locked in place since there is no complete circuit of flow to and from the lift cylinders Lower Bed Circuit operation for lowering the bed lift lever pushed forward is similar to raising the bed However the lift valve spool directs flow from the B port of the lift valve to the rod end of the lift cylinders Hydraulic pressure against the cylinder pistons retracts the cylinder shafts to lower the bed LIFT CYLINDERS 2 PISTON MOVEMENT LIFT VALVE IN LOWER POSITION LOWER BED A Figure 8 Workman 3000 4000 Series Page 9 9 Hydraulic System 5 gt 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 Contains one each 1000 PSI 70 Bar 5000 PSI 350 Bar and 10000 PSI 700 Bar gauges Use gauges as recommended in Testing section of this chapter Figure 9 Hydraulic Tester Pressure an
195. maged see TEST NO 1 Hydraulic lift valve worn or damaged Hydraulic component s on attachment malfunctioning or damaged Hydraulic System Page 9 14 Workman 3000 4000 Series Testing The most effective method for isolating problems in the hydraulic system is by using hydraulic test equipment such as pressure gauges and flow meters in the circuits during various operational checks See Special Tools section in this Chapter Failure to use gauges with recommended pres sure 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 link age 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 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 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 skin and cause serious injury If fluid is injected
196. mble driveshaft using Figure 5 as a guide 3 Do not reuse bearings Item 6 if they have been re moved from frame support bracket Replace with new bearings 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 3300 D 4300 D Page 4 9 Installation Fig 5 1 To install bearings Item 6 into frame support brack et A Install pulley side bearing into support bracket by pressing on bearing outer race until bearing contacts shoulder in support bracket B Place the bearing spacer Item 7 into bracket ca vity C Install second bearing into bracket by pressing on the bearing outer race until bearing inner race con tacts spacer 2 Slide shaft Item 8 into installed bearings in frame support bracket Apply antisieze lubricant to pulley end of shaft before installing woodruff key Item 3 and pulley Item 5 3 Secure pulley to shaft with washer and lock nut Torque lock nut from 100 to 130 in lb 11 3 to 14 7 Make sure that shaft rotates freely after pulley is installed 4 Assemble driveshaft using Figure 5 as a guide 5 Adjust pump drive belt tension after assembly see Operator s Manual Briggs Daihatsu Diesel Engine 5 2 a o D 2 Fuel Tank
197. mpression springs Qty Item 2 1 2 x 20 threaded steel rods 4 1 2 nuts 4 1 2 flat washers Figure 1 Workman 3000 4000 Series Page 7 3 Chassis Troubleshooting Suspension and Steering Front end noise Rear end noise Excessive steering play Front wheel shimmy Instability wander Chassis Page Possible Causes 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 Worn or brinelled rear wheel bearings Worn rear shock absorbers Worn leaf spring bushings Clutch drive shaft or transaxle problem see Chapter 6 Drive Train Loose or worn front wheel bearings Loose or worn steering linkage Worn tie rod ends Loose or worn front wheel bearings Tires out of round or uneven tire wear Worn tie rod ends Incorrect front wheel alignment Worn shock absorbers Low or uneven tire pressure Worn or loose wheel bearings Worn pitman arm bushings Broken or loose rear leaf spring Worn shock absorber s Incorrect front wheel alignment toe in Worn or loose joints 7 4 Workman 3000 4000 Series Suspension and Steering Continued Hard steering Loose worn or glazed hydraulic pump drive belt Binding or damaged steering linkage Lo
198. n 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 clock wise to START position 4 cranks or starts there is a malfunction in the interlock system that must be repaired before operating vehicle Workman 3000 4000 Series Component Testing This section will define given components and the tests that can be performed on those components when those parts are disconnected from the electrical system For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g unplug the clutch switch connector before doing a continuity check Ignition Key Switch The ignition key switch has three positions OFF START and RUN The terminals are marked as shown in Figure 4 The circuitry of the ignition switch is shown in the chart Fig 5 With the use of a continuity tester the switch functions may be tested to determine whether all circuits are being completed while the key is moved to each position Workman 3000 4000 Series NOTE Electrical troubleshooting of any 12 Volt power connection can also be performed through voltage drop tests without disconnection of the component When testing electrical components for continu ity with a volt ohm meter or continuity tester make sure that power to the circuit has been dis connected Figure 4 OTHER CIR
199. n 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 thick nesses of 0 003 0 005 0 010 and 0 030 inch Old Pinion New Pinion Marking Marking 0 008 0 007 0 006 0 005 0 004 0 003 0 002 0 001 40 007 40 006 40 005 40 004 40 003 40 002 40000 o 0001 0 006 0 005 0 004 0 003 0 002 0 001 0 005 0 004 0 003 0 002 0 001 0 003 0 002 0 001 0 002 0 001 PERENNE EN 0 001 0 001 2 42 0 002 o 0001 0 002 0 003 0 001 0 002 0 003 0 004 0 001 0 002 0 003 0 004 0 005 0 002 0 003 0 004 0 005 0 006 40000 0 001 0 002 0 003 0 004 0 005 0 006 0 007 000 0 002 0 003 0 004 0 005 0 006 0 007 0 008 1 1 If the bearing cone 9 was removed press new bearing cone onto the shaft of
200. nd bearings from yokes Thoroughly clean drive shaft yokes 4 To install new cross and bearings A Apply a coating of grease to all bearing bores B Press one bearing partially into yoke C Insert cross into yoke and bearing D Hold cross in alignment and press bearing in until it hits the yoke 1 Flange yoke 2 Cross and bearing kit E Install snap ring into yoke groove to secure instal led bearing F Place second bearing into yoke bore and onto cross shaft Press bearing into yoke and secure with snap ring G Repeat procedure for other yoke H Grease cross until grease comes out of all four 4 cups 5 Reinstall drive shaft to vehicle see Differential Drive Shaft Installation Workman 4000 Series Page 10 31 Figure 60 3 Snap ring 4 used 4 Tube yoke Front Wheel Drive AWD E o I LL Drive AWD Bidirectional Clutch CAGE AND ROLLER ASSEMBLY AN No FM 02 Figure 61 1 Clutch shaft 8 Cam 2 Seal plug 9 Thrust bearing 3 Retaining ring 10 Thrust washer 4 Ball bearing 11 Spring 5 Housing and race 12 Cage 6 Garter gear 13 Oil seal 7 Roller 6 used Removal Fig 61 1 Park vehicle on a level surface Make sure engine is off Engage parking brake and block rear wheels 2 Remove drain plug from the transaxle Drain all transaxle oil into a suitable container Install drain plug 3 Jack up and secure front whee
201. nd connecting a continuity tester across the two termi nals With the engine off move transmission shifter to 2nd gear there should be an indication of continuity Move shifter to 3rd gear there should be no continuity High Low Lockout Switch The transaxle High Low Lockout switch is closed in Low range and open High range Figure 8 De 1 2 3lockout switch 2 Hi Low lockout switch Test the switch by disconnecting the wiring connector and connecting a continuity tester across the two termi nals With the engine off move shifter to Low range there should be an indication of continuity Move shift le ver to High range there should be no continuity 3rd High Lockout Key Switch The 3rd High Lockout switch is closed in Fast position and open in Slow position Test the switch by disconnecting the wiring and connect ing a continuity tester across the two terminals With the engine off move key to Fast position there should be an indication of continuity Move key to Slow position there should be no continuity Figure 9 6 F W Workman 3000 4000 Series 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 gaso line engine are id
202. nd race 5 us ing a driver Workman 4000 Series Page 10 35 7 Secure clutch shaft to housing and race 5 with lock washers 16 and hex socket head screws 17 8 Lower front wheels to ground 9 Make sure drain plug is installed properly to the transaxle Fill transaxle with Dexron ATF see Opera tors Manual 10 Install differential drive shaft 18 to clutch shaft 1 and the front differential see Differential Drive Shaft Installation Front Wheel Drive AWD E o I LL Drive AWD This page is intentionally blank Front Wheel Drive AWD Page 10 36 Workman 4000 Series Chapter 11 TORO Electrical Schematics a Table of Contents 5 VEHICLE ELECTRICAL SCHEMATICS 5 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 Dr
203. nder s Lift cylinder hydraulic lines or fittings leaking Engine speed is low Oil level in transaxle is low Steering components Pitman arm tie rods steering cylinder rod ends worn or binding Gear pump drive belt is loose Note Loose belt will also cause the bed not to lift or other attachment to not operate Steering cylinder is binding Hydraulic relief valve stuck or damaged see TEST 1 Steering control valve is worn or damaged Pulley key either on drive or driven pulley is sheared lift circuit affected as well Steering cylinder leaks internally Low gear pump flow or pressure see TEST NO 1 Note Low pump flow or pressure will also cause the bed not to lift or other attachment to not operate Gear pump is worn or damaged Note entire hydraulic system af fected Page 9 13 Hydraulic System 9 5 c 29 5 gt 2 D gt 72 Difficulty in connecting or discon Pressure not relieved coupler under pressure engine running necting quick couplers Hydraulic lift valve not in neutral centered position Attachment does not function Quick couplers not fully engaged Quick couplers are interchanged Gear pump drive belt is loose steering circuit affected as well Sheared key on gear pump shaft Oil level in transaxle is low Engine RPM is low Excessive load on attachment Low gear pump flow or pressure see TEST NO 1 Hydraulic relief valve stuck or da
204. needle bearings Item 12 onto main shaft Apply moly disulfide grease onto washer and needle bearings before installing Oil groove on washer must face the gear E Install gear Item 11 and snap ring Item 10 F Install synchro ring Item 6 onto gear Item 11 Apply Dexron Ill transmission oil on cone face of gear before installing synchro ring G Insert key Item 9 H Install synchro hub sub assembly Item 8 x o 2 1 Install snap ring Item 7 J Install synchro ring Item 6 onto gear Item 4 Apply Dexron III transmission oil to cone face of gear before installing synchro ring K Insert 2 needle bearings Item 5 into gear Item 4 Apply moly disulfide grease onto needle bearings before installing Figure 84 L Install gear Item 4 with synchro ring onto main shaft M Install washer Item 3 and snap ring Item 2 Ap ply moly disulfide grease to washer before installing Oil groove on washer must face the gear Workman 3000 4000 Series Page 6 43 Drive Train 13 Assemble shift arms 200 to 280 in lb SZ 20010280 in tb 22 6 to 31 6 22 6 to 31 6 4 71 7 8 Q 7 A Install 3 new seals Item 14 onto transaxle case Apply multi purpose grease on lips of oil seals before installing B Install 3 keeper plates Item 13 and tighten 3 cap screws Item 12 to a torque from 11 to 13 ft lb 15 to 17 N m Apply Loc
205. ng Service 31 Inspect Constant Velocity CV Joint Boot and Bidirectional 32 Test CV Joint 11 Workman 4000 Series Page 10 1 Front Wheel Drive AWD Specifications Item Description Front Differential 5 0 to 1 ratio single reduction Front Brakes Hydraulically operated self adjusting 8 diameter drum Bidirectional Clutch Overrunning type Front Wheel Drive AWD Page 10 2 Workman 4000 Series General Information The Automatic on Demand four wheel drive feature on this vehicle does not require operator activation The front wheel drive is not engaged no power delivered to front wheels until the rear wheels begin to lose traction The bidirectional clutch senses the rear wheels slipping engages the front wheel drive and delivers power to the front wheels The four wheel drive system continues to deliver power to the front wheels until the rear wheels Workman 4000 Series Page 10 3 have enough traction to move the vehicle without slip ping Once this occurs the system stops delivering pow er to the front wheels and the handling characteristics become similar to that of a two wheel drive vehicle The four wheel drive system functions in both forward and reverse When front wheels are turned the rear wheels will slip slightly more before power is delivered to the front wheels Front Wheel Drive AWD
206. ng careful not to damage seals 4 Install retaining ring Item 9 to secure shaft assembly in barrel To install retaining ring align key slot in head with access groove in barrel Rotate head clockwise as far as the retaining ring will allow Offset end of retaining ring will be against left side of barrel groove as shown Spanner wrench Retaining ring 3 Offset end against left side of barrel groove after installing Workman 3000 4000 Series Page 9 41 ad Figure 36 Installing retaining ring Hydraulic System 2 E gt 2 D gt 2 Lift Cylinder 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 Lynch pin Hydraulic System Page 9 42 Workman 3000 4000 Series Removal Fig 37 1 Park vehicle on a level surface lower bed until clevis pins that secure lift cylinder to bed are loose in the bed slots Shut engine off and 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 Before performing any service or repair on hy draulic system components relieve system pressure to avoid injury from pressurized hy draulic oil Stop the engine remove key from the ignition switch r
207. nting supports wear loose fittings weather deterioration and chemical deterioration Make all necessary repairs before operating Hydraulic System 9 gt Gear Pump Vehicles with Liquid Cooled Engine Removal Fig 20 1 Park vehicle on a level surface raise and support bed if installed shut engine off and engage parking brake 2 Loosen pump drive belt and remove belt from pump pulley see Operator s Manual 3 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter Before performing any service or repair on hy draulic system components relieve system pressure to avoid injury from pressurized hy draulic 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 4 Disconnect hydraulic hoses from gear pump Fig 21 Install caps or plugs in hoses and pump fittings to prevent contamination and leakage of hydraulic oil 5 Remove mount plate with pump from vehicle 6 Remove gear pump from mount plate using Figure 20 as a guide Installation Fig 20 1 Install parts as shown in Figure 20 and using the fol lowing instructions A Apply antiseize lubricant to gear pump shaft be fore installing pulley B After installing key and pulley on pump shaft tighten
208. nto a drain pan Install drain plug 4 Note orientation of 90 fitting connected to strainer on side of transaxle Remove hydraulic hose and 909 fit ting from strainer Fig 14 5 Remove muffler see Muffler Removal in Engine Chapter 6 Remove hydraulic filter assembly and bracket 7 Disconnect and label electrical leads that attach to transaxle and PTO 8 Disconnect clutch cable from clutch release lever then loosen jam nut to remove clutch cable from support bracket Fig 15 9 Loosen jam nut to remove differential lock cable from support bracket then disconnect differential lock cable from lever at left rear of transaxle Fig 16 10 Disconnect shifter control cables from levers on transaxle and PTO Do not loosen cable jam nuts at shift cable mount bracket 11 Remove shift cable mount bracket from transaxle keeping shifter control cables attached to bracket Posi tion bracket away from transaxle 12 On Workman 4000 series vehicles 4 Wheel Drive remove differential drive shaft bidirectional clutch and adapter plate from the transaxle see Service and Re pairs section of Chapter 10 Front Wheel Drive 4WD 13 Disconnect return hydraulic hose from transaxle or PTO if equipped Put label on hydraulic hose for proper reassembly Put caps or plugs on all open hoses or fit tings to prevent contamination 14 Remove PTO if equipped from top of transaxle see PTO Removal and Installation 15 B
209. nut 5 Engine mount 10 Guard 2 used 10 Remove four 4 cap screws item 2 and lock nuts item 5 that fasten both ends of hydraulic pump drive shaft to rubber couplers Fig 11 Locate and retrieve coupling spacers item 3 Remove driveshaft Workman 3300 D 4300 D Page 4 17 Briggs Daihatsu Diesel Engine 11 Remove any clamps and cable ties used to attach wiring harness hoses or cables to the engine 12 0n 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 14 Attach hoist or block and tackle to engine for support 15 Loosen and remove two 2 locknuts Item 9 and cap screws Item 1 that secure engine mount to engine support Fig 13 Locate and retrieve flat washers item 2 spacers item 4 and snubbing washers item 6 16 Remove six 6 cap screws that secure clutch bell housing to engine Note location of three 3 flat washers and three 3 harness brackets as caps screws are be ing removed Fig 13 17 Use a hoist or block and tackle to remove engine from chassis One person should operate hoist or block and tackle and the other person should help guide en gine out of chassis Move engine forward before lifting to disengage transaxle input shaft from clutch 18 Note location and retrieve two 2 dowel pins from bell housing Fig 13 19 If necessary remove eng
210. o pry up the case and gears Fig 15 Figure 15 Workman 4000 Series Page 10 17 Front Wheel Drive AWD 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 Support differential case 27 in a vise Drive pinion shaft 25 from the differential case using a long drift punch Fig 17 8 Remove both sets of pinion gear shafts 5 and 6 and thrust washers 4 and 7 by rotating the gears 90 through the opening in the differential case 27 Fig Figure 16 18 IMPORTANT Avoid damaging gear teeth when re moving the gear ring 32 from the differential case 27 9 Remove five cap screws 26 from the differential case 27 and gear ring 32 Drive ring gear off the dif ferential case using a hard wood block and a hammer Fig 19 Figure Ta Figure 18 Figure 19 Front Wheel Drive AWD Page 10 18 Workman 4000 Series 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 lt z Drive 4 0 10 Remove bearing 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 a
211. o secure fuel tank 3 If fuel fitting was removed from tank apply thread sealant to threads of fitting before installing fitting into tank 4 Connect electrical wiring to the fuel sender A Connect blue white wire with ring terminal to the center fuel sender terminal and secure with lock washer and hex nut B Connect black ground wire with the screw item 6 that is closest to the frame rail C Apply skin over grease to the wire terminal con nections and cover center terminal with harness boot 5 Connect return hose to fitting on top of tank and se cure with clamp 6 Connect fuel hose from tank outlet to fuel filter and secure with clamp Connecting battery cables to the wrong battery post could result in personal injury and or dam age to the electrical system 7 Position battery in vehicle see Operator s 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 Operator s Manual Check for fuel leakage and correct if found Briggs Daihatsu Diesel Engine 5 a 2 a gt Air Cleaner System 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 Radiator hose 9 Clamp 14
212. ock nut 5 Ball joint 11 Bellcrank 17 Spring adjusting rod if equipped 6 Accelerator cable 12 Governor spring Briggs Daihatsu Gasoline Engine 3 20 Rev B Workman 3200 4200 Disassembly Fig 17 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 If removed attach governor spring to bellcrank on throttle bracket and outer most slot in engine governor lever Fig 20 3 Lubricate bellcrank grease fitting after assembly 4 Check engine speed both idle and high idle and ad just if necessary see Engine Speed Adjustment in Ad justments section of this chapter 5 After engine speed has been checked and adjusted check operation and adjustment of accelerator cable see Operator s Manual If needed adjust accelerator cable Workman 3200 4200 Page 3 21 Rev B Figure 18 4 High idle stop screw 5 Low idle stop screw 6 Return spring 1 Governor spring 2 Bellcrank 3 Engine governor lever Figure 19 4 High idle stop screw 5 Low idle stop screw 6 Spring adjusting rod 1 Governor spring 2 Bellcrank 3 Engine governor lever Figure 20 1 Engine governor lever 2 Governor spring 3 Spring mounting slot Briggs Daihatsu Gasoline Engine 5 a 2 6 e m a o o
213. of manifold and muffler Installation Fig 3 1 Replace any removed gaskets 2 If cap screw item 11 was removed apply Loctite 242 or equivalent to threads during installation Workman 3100 Page 5 7 3 Using Figure 3 as a guide fit all exhaust components to vehicle before tightening any fasteners When secur ing exhaust tighten fasteners in the following order A Hex nuts item 3 that secure manifold to engine B Cap screw item 11 with washers item 12 that secures muffler to transaxle C Socket head screws item 1 and flange nuts item 10 that secure muffler to manifold D Cap screws item 17 and flange nuts item 5 that secure muffler to shift cable mount bracket E Carriage screws item 13 and flange nuts item 5 that secure muffler to mount plate F Screw item 6 and flange nut item 5 that se cures exhaust manifold to bracket item 8 4 Lower or install bed or attachment s Kohler Gasoline Engine os 7 6 Engine Anti seize VA amp Lubricant 3 16 17 18 Anti seize Lubricant 35 to 41 ft lb 47 to 56 4 Figure 4 1 Locknut 16 Choke lever 30 Pilot bearing 2 Flat washer 17 Choke cable 31 Socket head screw 3 Pulley 18 Accelerator cable 32 Washer 4 Woodruff key 19 Cap screw 2 used 33 Flywheel 5 Flange nut 20 Lock nut 34 Clutch adapter 6 screw 21 Flat washer
214. ol retaining ring Item 13 Carefully push and twist spool to remove spool from valve body 5 Use a hooked scribe or thin screwdriver to remove rings Item 9 from inside bore of valve body be careful not to scratch valve bore finish These o rings are the seals for the spool 6 Inspect all components for wear paying special attention to the spool Signs of wear on one side of the spool may indicate a bent spool Inspect the spool for flatness and replace if necessary Assembly Fig 26 1 Clean all components thoroughly before assembly Use new o rings when reassembling 2 Coat all o rings and spool with clean Dexron III ATF before installation into valve body Assemble compo nents in reverse order of disassembly Install spool into valve body before inserting cam pins balls springs and hex cap plugs S Figure 26 Hex plug 2 used O ring 2 used Spring 2 used Check ball 2 used Check ball seat 2 used Cam pin 2 used Valve body Hydraulic System Page 9 32 8 Spool 9 O ring 10 Spring retainer 11 Spring 12 Spacer 13 Spool retaining ring 14 Retaining ring Workman 3000 4000 Series This page is intentionally blank 2 N SS o Workman 3000 4000 Series Page 9 33 Hydraulic System Steering Control Valve Hex nut Lock washer Steering wheel Steering control valve Hyd hose to control valve P po
215. ole in control arm tower Install washer onto cap screw and slide shock absorber onto cap screw Install second washer onto capscrew and secure with lock nut Pons Chassis Page 7 28 Rubber bushing Spacer Inner washer Shock absorber Outer washer Figure 21 6 7 Shock absor Figure 22 Lock nut Cap screw Washer Lock nut Control arm tower 2 Workman 3000 4000 Series 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 4 Install new shock absorber with ram end down Se cure each end with with large washer and lock nut Figure 23 1 Rubber bushing 4 Large washer 2 Large washer 5 Lock nut 3 Shock absorber Figure 24 Workman 3000 4000 Series Page 7 29 Chassis Rear Leaf Spring Replacement 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 Rubber bushing 8 Spring plate 13 Rear axle 4 Axle bumper 9 Leaf spring 14 Carriage screw 4 used per spring 5 Hexnut 10 Flange head screw 2 per mount IMPORTANT For proper vehicle performance al ways replace the springs on both sides of the ve hicle
216. on see Opera tor s Manual Workman 3000 4000 Series Page 9 27 3 Check oil level in transaxle see Operator s Manual Add Dexron ATF if necessary 4 Start the engine and operate at idle speed until air is out of hydraulic system 5 Stop the engine and check oil level in transaxle see Operator s Manual Add Dexron III ATF if necessary ANTISIEZE LUBRICANT 2 bot 130 to 160 in Ib 14 7 to 18 1 N m Figure 22 1 Drive belt 7 Mount 2 Locknut 8 Suction hose 3 Flat washer 9 Square key 4 Pump pulley 10 Gear pump 5 screw 11 Lock nut 2 used 6 Carriage screw 12 Pressure hose Hydraulic System 2 5 gt 2 D gt 72 Gear Pump Service Barnes Gear Pump THIS SIDE OF PRESSURE PLATE TOWARD HIGH THIS SIDE OF PRESSURE PRESSURE PLATE OUTLET PORT ADJACENT TO BOTTOM OF GEAR HOUSING POCKET THIS SIDE OF PRESSURE PLATE TOWARD LOW PRESSURE PORT THIS SIDE OF PRESSURE PLATE ADJACENT SEARS B gt B PRESSURE SECTION STE INSTALL SEAL BACK UP WITH EJECTOR PIN MARKS TOWARD GEARS PER VIEW A A 9 5 to 12 5 ft Ib 13 to 17 N m ELLO 1 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 Gear 19 Plug 4 Crescent ring 12 Bearing 20 Idler shaft 5 Square key 13 Pressure plate 21 Wear plate seal 6 Drive shaft 14 Back up seal 22
217. 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 3 Disconnect negative battery cable first and then pos itive battery cable Remove battery from vehicle see Operator s Manual IMPORTANT Review safety information regarding fuel handling in the Operator s Manual and Chapter 2 Safety 4 Loosen hose clamp and disconnect fuel hose item 13 from fuel filter located on right side frame rail Drain fuel from the fuel tank into a suitable container 5 Loosen hose clamp and remove return hose item 17 from fitting on top of tank NOTE To prevent fuel leakage do not loosen lower nut on fuel sender stud 6 Disconnect electrical wiring from the fuel sender on the fuel tank 7 Loosen socket head screws item 25 and lock nuts item 23 to allow tank straps to be unhooked from fuel tank supports 8 Remove fuel tank from vehicle Workman 3300 D 4300 D Page 4 11 Fuel Tank Installation Fig 6 1 Check felt straps item 27 and replace if worn or damaged IMPORTANT When positioning fuel tank to vehicle make sure that hydraulic lift cylinder does not con tact tank 2 Position fuel tank to tank straps and fuel tank sup ports Hook tank straps to fuel tank supports Tighten Socket head screws and lock nuts t
218. on center plate to transaxle D Install and tighten cap screws to a torque from 18 5 to 22 ft lb 24 5 to 29 5 E Apply multi purpose grease onto lips of oil seal then insert oil seal flush with face of housing n Figure 94 F Apply moly disulfide grease to spline of main shaft for clutch disk hub Drive Train Page 6 46 Workman 3000 4000 Series 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 sert shim set Item 2 against the tabbed shim Use thickest shims in set possible that will permit installation of the snap ring Fig 95 and 96 22 I nstall snap ring into the groove of the bearing hous ing Fig 96 and 97 Workman 3000 4000 Series Figure 96 1 Countershaft 4 Snapring 2 Bearing 5 Center plate 3 Shims 6 Sealing cap 2 e Figure 97 Page 6 47 Drive Train 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 Make sure shim set is held against the bearing during the measurement End play should be 0 000 to 0 0039 0 00 to 0 10 mm Fig 98 IMPORTANT If en
219. operly routed to transaxle install cable bulkhead fitting to shift cable mount bracket on transaxle and tighten jam nuts 6 Install cable ties in the original locations to secure shift cables to vehicle 7 Adjust shift cables See Operator s Manual and se cure 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 Figure 5 1 Shift boot 2 Control plate 390 to 510 in 9 9 to 13 mm Figure 6 1 Clevis 3 Clamp 2 Shift cable 4 Shift stop bolt 9 gt Figure 7 1 First Reverse 3 Bulkhead jam nut 2 2nd 3rd Workman 3000 4000 Series Page 6 11 Drive Train Stub Axle and Drive Shaft Service 35 to 42 ft lb 47 to 57 N m N 200 to 250 in Ib 22 6 28 3 40 to 60 ft lb 54 to 81 220 to 250 ft lb Loctite 680 298 to 339 45 to 65 ft Ib 61 to 88 N m ACCESS HOLE Figure 8 1 Flange nut 11 Lock washer 4 used per brake 21 Flange head screw 2 Wheel nut 5 used per wheel 12 Brake assembly 22 Thrust washer 3 Wheel assembly 13 Parking brake cable 23 Cap screw 4 Brake drum 14 Cable clip 24 Cap screw 5 Stub axle 15 Axle housing 25 Rear ax
220. or brass approximately 10 of the nominal torque value Thin The specific torque value should be determined based height nuts include jam nuts Product Records and Maintenance Page 2 4 Workman 3000 4000 Series Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Regular Height Nuts M5 X 0 8 57 5 in lb Class 8 8 Bolts Screws and Studs with Class 8 or Stronger Nuts 640 60 Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 78 7 in lb 885 80 N cm M6 X 1 0 96 9 in Ib 1018 100 N cm 133 13 in Ib 1500 150 M8 X 1 25 19 2 ft 26 3 N m 27 2 ft lb 36 3 N m Thread Size M12 X 1 75 66 7 ft 90 10 N m 92 9 ft lb 125 12 N m M16 X 2 0 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 M20 X 2 5 325 33 ft lb 440 45 450 37 ft lb 610 50 NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based Workman 3000 4000 Series 2 5 Ib Ib on the fastener size the aluminum or base material strength length of thread engagement etc NOTE The nominal torque values listed abov
221. ore disassembling cylinder plug ports wash exte rior with cleaning solvent and dry thoroughly IMPORTANT Use caution when using a vise to avoid scratching or distorting any parts 3 Put cylinder in a vise so shaft end is facing up 4 Use a spanner wrench to rotate head Item 6 and re move retaining ring Item 9 Grasp end of shaft and use a twisting and pulling motion to carefully extract the pis ton shaft and head assembly from the barrel 5 Remove cylinder from vise 6 Remove lock nut Item 1 from shaft then remove pis ton Item 5 and head Item 6 Remove and discard seals o rings wear ring and wiper from piston and head Hydraulic System 9 44 Spanner wrench Retaining ring Figure 39 Removing retaining ring Workman 3000 4000 Series 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 2 Inspect inside of barrel for scoring pitting or out of round and replace if worn or damaged Assembly Fig 38 1 Use a new seal kit to replace all seals o rings wear ring and wiper to piston and head Apply clean Dexron ATF to all seal kit components before installing 2 Install head Item 6 with new seals onto shaft Item 13 Install piston Item 5 with new seals and back ups onto shaft Install piston onto shaft and secure with lock nut Item 1 Torque lock nut from
222. orrect location for o rings sealing rings and backup rings Remove and discard seal kit Hydraulic System Page 9 46 Workman 3000 4000 Series 4 Visually inspect the port in the manifold for damage to the sealing surfaces damaged threads and contami nation 5 Visually inspect cartridge valve for damaged sealing surfaces and contamination A Contamination may cause valves to stick or hang up Contamination can become lodged in small valve orifices or seal areas causing malfunction B If valve sealing surfaces appear pitted or dam aged the hydraulic system may be overheating or there may be water in the system A CAUTION Use eye protection such as goggles when using compressed air 6 Clean cartridge valve using clean mineral spirits Submerge valve in clean mineral spirits to flush out con tamination Particles as fine as talcum powder can affect the operation of high pressure hydraulic valves If car tridge design allows use a wood or plastic probe to push the internal spool in and out 20 to 30 times to flush out contamination Be extremely careful not to damage car tridge Use compressed air for cleaning Workman 3000 4000 Series Page 9 47 7 Reinstall the cartridge valve A Lubricate new seal kit components with clean hy draulic oil and install on valve The o rings sealing rings and backup rings must be arranged properly on the cartridge valve for proper operation and seal ing IMPORTANT Use
223. ose clamp that secures air intake hose to carburetor Remove intake hose from carburetor Qe Do 6 Disconnect fuel hose from carburetor on engine 2295 Plug end of fuel hose to prevent contamination and fuel Figure 12 mno spillage Position disconnected fuel hose away from en 1 Engine pulley 6 Coupling spacer 4 used gine 2 Cap screw 4 used 7 Flat washer 4 used 3 Coupling spacer 4 used 8 Cap screw 2 used 7 Note location of cable ties used to secure wire leads 4 Rubber coupling 9 Hyd pump driveshaft 5 Lock nut 6 used 10 Cap screw 2 used Label and disconnect electrical leads that attach to en gine A Battery cable and fusible link harness from starter solenoid stud B Double wire from spade terminal on starter sole noid C Wires from oil pressure switch temperature sender on water pump housing and high tempera ture switch D Harness connector and wire with ring terminal from alternator E Wires from fuel solenoid and choke assembly on carburetor F Six wires from ignition coils G Two harness connectors from ignition controller H Harness connector from crankshaft sensor 8 Disconnect accelerator cable from bellcrank on en gine Position accelerator cable away from engine Figure 13 9 Drain coolant from radiator see Operator s Manual 1 screw 6 Snubbing washer Loosen hose clamps and remove upper and lower ra ee E oe mount i i R clamp Engine suppo
224. osen lock nut on idle speed screw B Adjust idle speed screw to obtain 1500 50 RPM C Tighten lock nut Recheck idle speed 6 Increase engine speed to high idle Use a tachome ter to check that engine is operating at 3600 50 RPM 7 If high idle speed is incorrect adjust high speed screw on fuel injection pump Fig 3 A Loosen lock nut on high speed screw B Adjust high speed screw to obtain 3600 50 RPM C Tighten lock nut Recheck high idle speed Briggs Daihatsu Diesel Engine Page 4 4 Figure 2 1 Speed control lever 3 Lock nut 2 Idle speed screw Figure 3 3 Lock nut Speed control lever 2 High speed screw Workman 3300 D 4300 D gt 5 a E Q a This page is intentionally blank Workman 3300 D 4300 D Page 4 5 Briggs Daihatsu Diesel Engine Service and Repairs Radiator 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 Fan shroud 13 Hose to coolant reservoir 22 Cap screw 4 used 5 Lower radiator hose 14 Cap screw 4 used 23 Lock washer 4 used 6 Hose clamp 15 Hose clamp 24 Fan 7 Radiator 16 Upper radiator hose 25 Idler
225. ot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance 2 2 Rev D Workman 3000 4000 Series Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant Loctite degree of lubrication on the fastener presence of a prevailing torque feature hard ness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 5 Grade 1 Inch Series Bolts and Screws Workman 3000 4000 Series Page 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into a
226. otate the steering wheel in both directions lower or support the bed and operate other hydraulic accessories 3 Disconnect hydraulic hoses from lift cylinder Install caps or plugs in hoses to prevent contamination and leakage of hydraulic oil Install plugs in cylinder ports 4 Remove lynch pin and clevis pin that secure lift cylin der to bed 5 Remove cotter pin that secures lift cylinder to engine support 6 Remove lift cylinder from vehicle Workman 3000 4000 Series Page 9 43 Installation Fig 37 1 Make sure that lift cylinder is fully retracted 2 Position lift cylinder to vehicle Secure lift cylinder to bed with clevis pin and lynch pins and to engine support with cotter pin 3 Remove plugs and or caps from hydraulic hoses and cylinder ports Connect hydraulic hoses to lift cylinder 4 Start the engine operate at idle speed and raise and lower bed until air is out of hydraulic system 5 Stop the engine and check oil level in transaxle see Operator s Manual Add Dexron III ATF if necessary Hydraulic System 2 FE 0 Y gt Lift Cylinder Service 60 to 75 ft lb 81 to 102 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 Piston 10 Seal Disassembly Fig 38 1 Pump oil out of cylinder into a drain pan by slowly moving piston back and forth 2 Bef
227. otter pin and slotted nut from affected tie rod end 3 Use a suitable puller to disconnect rod end from spindle or pitman arm 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 Workman 3000 4000 Series Page 7 25 Rev A 7 Pitman arm 8 Steering cylinder 9 Spindle RH shown Installation Fig 16 1 Install new tie rod end to tie rod Thread in the same number of revolutions as the old one took to remove 2 Make sure that tie rod end shaft and spindle or pit man arm are thoroughly cleaned 3 Insert tie rod end shaft to spindle or pitman arm and secure with slotted nut Tighten slotted nut to a torque from 45 to 55 ft lb 61 to 75 N m If necessary to install cotter pin tighten nut further and secure assembly with cotter pin 4 Tighten jam nut to secure tie rod end to tie rod Torque jam nuts to 50 ft Ib 68 N m after adjustment is complete Make sure that the tie rod ends are aligned with each other as the jam nuts are being tightened 5 Check front wheel alignment see Front Wheel Align ment in this section Adjust as necessary 6 Grease tie rod end see Operator s Manual Chassis Front Wheel Alignment 1 Before inspecting or adjusting front wheel alignment check that when fully retracted the steering cylinder has a length as shown in Figure 17 If the retracted cylinder leng
228. p Performance 7 9 GPM 30 LPM at 1 500 PSI 103 4 Bar Optional High Flow Hydraulic Kit Hydraulic Filter Automotive 10 micron spin on cartridge type 25 PSI by pass valve 100 mesh strainer in reservoir NOTE Vehicles that are equipped with the optional High Flow Hydraulic Kit have two independent hydraulic systems Each of these hydraulic systems include a belt driven hydraulic gear pump reservoir filter and controls Maintenance troubleshooting and repair of each hy draulic system need to be performed independently 9 0 EA o Workman 3000 4000 Series 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 condi tions or mishandling during operation or maintenance These conditions can cause damage or premature dete rioration 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 tight en the hose swivel nut onto the fitting with the other Hydraulic Fitting Installation O Ring Face Seal 1 Make sure both threads and sealing surfaces ar
229. per 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 Incorrect brake lining material Restricted brake lines or hoses Brake pedal linkage binding Wheel locks Contaminated brake linings Loose or damaged brake linings Wheel cylinder sticking Incorrect wheel bearing adjustment Brakes fade Overheated brake drums Saturated brake linings Chatter at fast speeds Shoe lock Machining grooves in contact face of brake drums Brakes do not self adjust Adjuster bolt seized in thread Adjuster lever does not engage star wheel Workman 3000 4000 Series Page 7 7 Chassis 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 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 ft lb 61 to 88 at intervals recommended in Operator s Manual Figure 2 1 Wheel assembly 2 Wheel nut 5 used Chassis Page 7 8 Workman 3000 4000 Series This page is intentionally blank Workman 3000 4000 Series Page 7 9 Chassis Front Wheel Assembly 2 Wheel Drive 45 to 65 ft lb See tightening procedure in text ACCESS HOLE Loctite 6
230. place drum if lim itis exceeded Workman 3000 4000 Series Page 7 15 B Replace drums if they are cracked or heat spotted C Scoring grooves taper out of round and glazing can be machined out as long as the oversize limit is not exceeded Minor scoring or glazing can be re moved with sand paper IMPORTANT If one drum is machined the drum on the opposite side should be machined to the same diameter to maintain equal braking forces D Wipe braking surface of drum after machining with a cloth soaked in denatured alcohol 2 Inspect brake shoe and lining set 13 IMPORTANT Shoe and lining sets should be re placed for both wheels on the axle Equal braking forces must be maintained A Replace if linings are excessively worn or dam aged Oil grease or brake fluid contamination is not acceptable B Replace if shoe webbing show signs of overheat ing as indicated by a slight blue color 3 Inspect hold down washer 22 hold down spring 23 and hold down pin 26 Replace parts if rusted cor roded or bent Replace washers and springs if they are unable to lock onto the pin 1 Upper shoe spring 5 Brake shoe 2 Adjuster spring 6 Adjuster assembly 3 Lower shoe spring Brake cylinder assy 4 Hold down washer 8 Pawl Chassis 4 Inspect upper shoe spring 14 lower shoe spring 15 and adjuster spring 20 A Replace if springs show signs of overheating as indicated by a slight blue color
231. r Wire Harness Drawing Serial Number Below 260000000 CLUTCH SWITCH PTO KIT PTO SHUNT TRANSMISSION 3RD GEAR SWITCH TRANSMISSION HI LO SWITCH FUEL SOL PROTECTION START FUSIBLE LINK ALTERNATOR BED LIFT amp BED LIFT 8 PROTECTION OVER ARNESS REMOTE HYD REMOTE HYD 1 3 VERTICAL 1 3 VERTICAL OIL PRESSURE SHUNT LIFT SHUNT LIFT KIT SWITCH ODE TEMP SWITCH TEMP SENDER p22 Pl As J i 2 pis A sl pial A enl A 8 P20 pg B 45 x a m RED x 5 PINK 3 I YELLOW RED Je 5 BLACK PINK 3 WHITE a GRAY xz J4 96 343 mi RED gt Ae BLUE WHITE 4 A 8 PINK BLACK PINK P T 8 BLACK BLACK Pn 5 BLACK 3 RED m 2 8 RED BLACK m PIS BLACK WHITE BLACK 8 BROWN RED BLACK RED BLACK E SP3 8
232. r driven trochoid type Crankcase Oil Capacity liter U S qt 3 3 3 5 with filter Water Pump Belt driven centrifugal type Cooling System Capacity liter U S qt 3 8 4 0 Starter 12 VDC 1 2KW Alternator Regulator 12 VDC 40 AMP Briggs Daihatsu Diesel Engine Page 4 2 Workman 3300 D 4300 D 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 Workman 3300 D 4300 D Page 4 3 Note Clearance N Note Note een Figure 1 Briggs Daihatsu Diesel Engine 5 2 a 5 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 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 A Lo
233. r part if its condi tion could affect the operation of the front differential as sembly Clean flange surfaces of any sealant oil and dirt Fig 26 2 Inspect needle bearings 34 for wear and damage Replace bearings if needles are bent do not rotate free ly or do not remain in the bearing cage Replace oil seal 33 if it is cracked nicked torn or distorted such that it would not hold a proper seal Fig 27 Front Wheel Drive AWD Page 10 20 Figure 25 Figure 27 Workman 4000 Series 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 lt z Drive 4 0 IMPORTANT The ring gear 32 and pinion gear 8 must be replaced as a matched set 4 Inspect bevel side gears 5 pinion gear shafts 6 pinion gear 8 and ring gear 32 for abnormal wear or damage Replace any gear that is worn or damaged Cracked broken missing or chipped gear teeth are not acceptable Fig 29 IMPORTANT If any part of a bearing needs replace Figure 28 ment both bearing cone and cup must be replaced 5 Replace bearing cones 9 22 or 29 and corre sponding bearing cups 10 23 or 30 if any of the follow ing conditions occur Fig 30 and 31 A Spalling or pitting on roller or cone contact sur faces Corrosion
234. radles with four cap screws 11 Torque cap screws from 30 to 45 ft lb 41 to 61 Fig 46 Front Wheel Drive AWD Page 10 26 Figure 45 Figure 46 Workman 4000 Series 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 If backlash does not meet specifications move shims 31 from one side of the differential case 27 to the other until the correct backlash is attained 13 Check ring to pinion gear engagement see Ring and Pinion Gear Engagement in this chapter of the manual 14 If the needle bearings 34 were removed press two new bearings into the front housing 2 Press new oil seals into housing Fig 48 15 Make sure flange surface of carrier assembly 15 is clean and free of any sealant dirt and oil Apply thin bead of non acidic silicon sealer along the entire flange surface of the carrier assembly Fig 49 16 Make sure flange surface of front housing 2 is clean and free of any sealant dirt and oil Attached front hous ing to the carrier assembly 15 using alignment pins 3 as guides Secure housing to assembly with eight cap screws 16 Torque cap screws from 15 to 20 ft lb 20 to 27 using a criss cross pattern Fig 50 m M FLANGE SURFACE E 4 FLANGE j SU
235. rake assembly RH shown 10 Cap screw Front Wheel Drive AWD Page 10 12 APPLY GREASE TO SPLINES 20 21 22 23 24 25 26 Jam nut LH thread 28 Wheel bearing spacer Hardened washer Hex flange nut Tie rod end RH thread Cotter pin Jam nut RH thread Tie rod Tie rod end LH thread Workman 4000 Series Removal Fig 8 LEVERAGE 1 Remove wheel stub axle and axle housing from the CV joint and front suspension see Front Wheel And Axle Housing Assembly in this section 2a gt os IMPORTANT Make sure not to damage the oil seal on the front differential with the pry bars when re moving the CV joints 2 Use two small pry bars 180 apart to leverage the CV joint out of the front differential Use even pressure on both pry bars Fig 9 Figure 9 IMPORTANT With damaged CV joints there is the 1 CV joint 2 Front differential possibility that the wheel bearings may be damaged as well It is recommended that the wheel bearings be inspected when CV joints are replaced 3 Inspect front wheel bearings see Inspection in Front Wheel And Axle Housing Assembly in this section Installation Fig 8 1 If necessary install a new circular clip onto the splined inboard end of the CV joint 2 Grease splines of CV joint with No 2 general pur pose lithium base grease 3 Insert end of CV joint into the front differential until a snap is heard Pull ou
236. re commonly available in many service shops Special tools are described in the Kohler Engine Service Manu al The use of some specialized test equipment is ex plained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Kohler engines are supplied through your local Kohler dealer or distributor Kohler Gasoline Engine 1c C O g 7 6 Specifications Item Description Make Designation Kohler 235 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 Ib Fuel Unleaded Regular Gasoline Minimum 87 Octane Fuel Tank Capacity 26 liters 7 U S gal Governor Mechanical Idle Speed no load 1200 100 RPM High Idle no load 3600 50 RPM Engine Oil See Operator s Manual Oil Pump Gear driven trochoid type Crankcase Oil Capacity 1 9 liters 2 U S qt with filter Starter 12 VDC Kohler Gasoline Engine Page 5 2 Workman 3100 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 kep
237. re 3 1 Bed safety support 3 Bed 1 Raise bed until lift cylinders are fully extended Zu Cylinder parrel 2 Remove bed safety support from storage brackets on back of ROPS panel 3 Push bed safety support onto cylinder rod making sure support end tabs rest on end of cylinder barrel and on cylinder rod end Fig 3 4 To store bed safety support remove support from cylinder and insert into storage brackets on back of ROPS panel 5 Always install or remove bed safety support from outside of bed 6 Do not try to lower bed with bed safety support on cyl inder cylinder and bed damage may occur Safety Page 1 6 Workman 3000 4000 Series Chapter 2 TORO Product Records and Maintenance oc Table of Contents 85 55 PRODUCT 6 1 EQUIVALENTS AND CONVERSIONS 2 Decimal and Millimeter Equivalents 2 U S to Metric Conversions 2 TORQUE SPECIFICATIONS 3 Fastener Identification 3 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Fasteners 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 MAINTENANCE 7 Product Records Insert Operator s Manual and Parts Catalog for your Workman at
238. re 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 NOTE Remove bearing cone 9 from the pinion gear shaft 8 only if it needs replacing see Inspection 12 Press pinion gear shaft 8 out of the bearing cone 9 using bearing press Make sure shaft does not drop to the floor Fig 22 NOTE Remove bearing cup 23 from the carrier hous ing 15 only if it needs replacing see Inspection 13 Press bearing cup 23 from the carrier assembly 15 Fig 23 Figure 23 Workman 4000 Series Page 10 19 Front Wheel Drive AWD 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 24 NOTE Remove needle bearing 34 from the front housing 2 only if it needs replacing see Inspection 15 Remove oil seal 33 Press needle bearing 34 from the front housing 2 Fig 25 Inspection Fig 11 1 Inspect front housing 2 and carrier assembly 15 for cracks and damage Replace eithe
239. re supply 90 hydraulic fitting Workman 3000 4000 Series 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 Chassis 3 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter Figure 25 1 Lift lever 3 Link rod Before performing any service or repair on hy 2 Clevis 4 Lift valve spool draulic system components relieve system pressure to avoid injury from pressurized hy draulic 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 4 Label and disconnect hydraulic hoses from lift valve Install caps or plugs in hoses to prevent contamination and leakage of hydraulic oil Install plugs in valve ports 5 Remove lift valve from vehicle using Figure 24 as a guide Installation Fig 24 1 Install lift valve to vehicle using Figure 24 as a guide Make sure that lift lever can be moved in control plate slot to allow correct operation of lift lock Readjust loca tion of clevis on link rod if needed Fig 25 2 Replace o rings on hydraulic hoses and fittings Re move caps and plugs from hos
240. required slide driveshaft from transaxle 9 If bearings are being serviced remove axle housing 15 from vehicle A Remove brake assembly from axle housing see Brake Service in Service and Repairs Section of Chapter 7 Chassis B Remove three 3 cap screws with washers that secure axle housing to vehicle frame Remove axle housing NOTE Upper cap screw for LH axle hous ing is shorter than other cap screws used to secure axle housing to frame Bearing Service Fig 8 1 Inspect bearings and replace if necessary If outer bearing is removed from stub axle bearing set must be replaced 2 Remove bearing seal from back of axle housing 3 Remove inner bearing cone Slide bearing spacer from axle housing noting orientation of bearing spacer step away from stub axle flange 4 Press inner and outer bearing cups from housing Press outer bearing cone from stub axle 5 Clean all parts thoroughly before reassembly 6 Position inner and outer bearing cups to axle hous ing 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
241. rom 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 num bers on both gears are etched for verification When using a new gear set make sure the matching num bers are verified before using Fig 33 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 Front Wheel Drive AWD Page 10 24 Figure 36 Figure 38 Workman 4000 Series 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 lt a Drive 4 0 The torque required to rotate the shaft of the ion gear should be from 7 to 12 in lb 8 to 14 kg cm Fig 39 C If the torque required to rotate the shaft of the pin s ion gear is more than specified in step B remove lock Figure 39 nut washer coupler flange bearing cone 22 and shim 21 from the shaft of the pinion gear Increase shim thickness to decrease bearing preload D If the torque required to rotate the pinion gear shaft is less than specified in step B remove lock nut washer coupler flange bearin
242. roximate kg Ib 62 137 Carburetor Single barrel float feed 12 VDC shut off solenoid Fuel Pump 12 VDC Fuel Unleaded regular grade 87 octane minimum Fuel Tank Capacity liter U S gal 26 7 Governor Mechanical Idle Speed no load 1100 50 RPM High Idle no load 3600 50 RPM Engine Oil API Service Classification SH or better see Operator s Manual for viscosity Oil Pump Gear driven trochoid type Crankcase Oil Capacity liter U S qt 3 3 3 5 with filter Water Pump Belt driven centrifugal type Cooling System Capacity liter U S qt 3 8 4 0 Starter 12 VDC Alternator Regulator 12 VDC 40 AMP Briggs Daihatsu Gasoline Engine Page 3 2 Workman 3200 4200 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 Note serene Note ana i 2 sD Dg x Note een Figure 1 Workman 3200 4200 Page 3 3 Briggs Daihatsu Gasoline Engine 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
243. rs nicks scratches or any foreign material 2 Always replace the O ring seal when this type of fit ting shows signs of leakage 3 Lubricate the O ring with a light coating of oil FORE 4 Turn back the jam nut as far as possible Make sure iti Back up Washer the back up washer is not loose and is pushed up as far as possible Step 1 O Ring 5 Install the fitting into the port and tighten finger tight Figure 5 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 Size F F F T 4 1 4 in nominal hose or tubing 1 00 0 25 6 3 8 in 1 50 0 25 8 1 2 in 1 50 0 25 10 5 8 in 1 50 0 25 Figure 6 12 3 4 in 1 50 0 25 2 16 1 in 1 50 0 25 2 Workman 3000 4000 Series 9 5 Hydraulic System Hydraulic Schematics Vehicle Hydraulic Schematic 3NT1VA ELAN INO Lf NI SZ 9L 3051 WW 1 86 041 3808 WW 1 61 NI 05 SOMNVHGAH SYXIL 2 SHSQNMAO 141 QM IND NI 71 999 15 WN 97 NIOSZ 3HO8 WIN 6 51 NI 829 aou SOMNVHGAH SYXIL H3QNITAO SNIH33IS SSWdAd 15 S2 M NY
244. rt 4 Start engine and apply pressure to rod end of cylinder i e put hydraulic lift lever in LOWER position 5 If any oil comes out of open cylinder port cylinder has an internal leak Repair or replace cylinder 6 Reconnect hose disconnected in step 3 after test or repairs are complete 9 N EFA o Workman 3000 4000 Series 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 6 0 833 ENGINE F SOLENOID SPEED ACTIVATED BYPASS VALVE ENERGIZED RELIEF VALVE 2000 PSI IN TANK SUCTION of STRAINER 100 MESH RETURN FILTER OIL COOLER 10 MICRON WITH 4 GALLON RESERVOIR 25 PSI BYPASS Figure 18 Figure 19 1 Pressure coupler 2 Return coupler Hydraulic System Page 9 22 Workman 3000 4000 Series Procedure for High Flow Hydraulic Kit Optional Gear Pump Flow and System Relief Pressure Test 1 Make sure hydraulic oil is at normal operating tem perature by operating the vehicle for approximately 10 minutes 2 Park vehicle on a level surface raise and support bed if installed shut engine off and engage the parking brake After turning engine off operate all hydraulic con trols to relieve hydraulic system pressure 3 Make sure that drive belt for High Flow Kit gear pump is adjusted properly see Kit
245. rt Hyd hose to control valve E port Hyd hose to control valve T port Removal Fig 27 1 2 Remove steering wheel see Steering Wheel Re 20 to 26 ft lb 28 to 35 N m 222 Anti seize Lubricant Bulkhead fitting to valve L port 3 Remove cable ties that secure steering hose cover Figure 27 Hyd hose to control valve R port 15 Bulkhead fitting to valve R port Hyd hose to control valve L port 16 Bulkhead fitting to valve T port Cap screw 4 used 17 Bulkhead fitting to valve P port Dust cover 18 Bulkhead fitting to valve E port Steering hose cover 19 Hyd hose to steer cyl shaft end Cable tie 20 Hyd hose to steer cyl barrel end to hydraulic hoses Remove cover from hoses Park vehicle on a level surface shut engine off and engage the parking brake 4 Read the General Precautions for Removing and Installing Hydraulic System Components at the begin ning of the Service and Repairs section of this chapter moval in the Service and Repairs section of Chapter 7 Chassis Hydraulic System Page 9 34 Rev C Workman 3000 4000 Series Before performing any service or repair on hy draulic system components relieve system pressure to avoid injury from pressurized hy draulic 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 Raise dash to ga
246. rt diator hoses from engine Position hoses away from en 4 Spacer 6 gine 5 Engine mount 10 Guard 2 used 10 Remove four 4 cap screws item 2 and lock nuts item 5 that fasten both ends of hydraulic pump drive shaft to rubber couplers Fig 12 Locate and retrieve coupling spacers item 3 Remove driveshaft Workman 3200 4200 Page 3 17 Briggs Daihatsu Gasoline Engine 11 Remove any clamps and cable ties used to attach wiring harness hoses or cables to the engine 12 0n 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 14 Attach hoist or block and tackle to engine for support 15 Loosen and remove two 2 locknuts Item 9 and cap screws Item 1 that secure engine mount to engine support Fig 13 Locate and retrieve flat washers item 2 spacers item 4 and snubbing washers item 6 16 Remove six 6 cap screws that secure clutch bell housing to engine Note location of three 3 flat washers and three 3 harness brackets as caps screws are be ing removed Fig 14 17 Use a hoist or block and tackle to remove engine from chassis One person should operate hoist or block and tackle and the other person should help guide en gine out of chassis Move engine forward before lifting to disengage transaxle input shaft from clutch 18 Note location and retrieve t
247. s axle install as follows A Make sure contact surfaces between the adapter plate and transaxle are free of dirt debris and oil B Apply Loctite 59375 black silicone sealant or equivalent to the back side of the adapter plate C Secure adapter plate to the transaxle with four screws 15 Make sure not to get sealant into the threaded holes of the transaxle 3 Coat front drive shaft 19 and adapter plate 14 lightly with Dexron III ATF Slide cage and roller assem bly as a complete assembly see Fig 62 slowly onto the front drive shaft Make sure large base end of the cage is installed first 4 Position housing and race 5 over the cage and roll er assembly Make sure assembly parts are positioned properly by pushing the clutch towards the transaxle and feeling for spring 11 compression Figure 66 1 Garter spring 2 Cage Figure 67 1 Thrust bearing 3 Spring 2 Thrust washer 4 Cam Figure 68 1 Cam 3 Roller 2 Cage 4 Garter spring Front Wheel Drive AWD Page 10 34 Workman 4000 Series IMPORTANT Make sure retaining ring 3 is proper ly 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 5 Secure clutch to front drive shaft 19 with retaining ring 3 IMPORTANT Make sure rubber side of the seal plug 2 faces towards the clutch when installing 6 Insert seal plug 2 into the housing a
248. s 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 me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 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 gt RAF Figure 3 Electrical System Page 8 2 Rev D Workman 3000 4000 Series Troubleshooting For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and com ponents used on this vehicle see Vehicle Electrical Schematics in Chapter 11 Remove all jewelry especially rings and watches before doing any electrical trouble If the vehicle has any interlock switches by passed they shooting or testing Disconnect the battery must be reconnected for proper troubleshooting and cables unless the test requires battery voltage safety Starter cranks but should not with clutch pedal Clutch switch out of adjustment or faulty released Starter cranks but should not w
249. sary see Clutch Disassembly and Inspection in Chapter 2 Bushing 2 used 6 Transaxle 6 Drive Train 3 Clutch bell housing 7 Clutch adapter 4 Lock washer 4 used Flywheel and Pilot Bearing Inspection 1 Inspect flywheel Item 33 surface for stepped wear streaking or seizure and replace if necessary Check fly wheel runout and replace if runout exceeds 005 in 0 13 mm 2 Check pilot bearing Item 30 for smooth rolling and noise Check sealed bearing for grease leakage Re place bearing if necessary Remove pilot bearing by backing out socket head cap screw that attaches fly wheel to crankshaft Do not reuse bearing if removed Workman 3100 Page 5 9 Kohler Gasoline Engine Engine Installation Fig 4 1 Install flywheel Item 33 and or pilot bearing Item 30 if removed Torque socket head cap screw Item 31 from 35 to 41 ft lb 47 to 56 N m to secure flywheel to engine crankshaft 2 If pressure plate and clutch disc were removed see Installing Clutch Disc and Cover in the Repairs section of Chapter 6 Drive Train 3 If hydraulic pump drive pulley was removed from en gine apply antiseize lubricant on shaft surface before installing pulley 4 To install the engine perform Engine Removal steps in reverse order Scrape RTV sealant off engine bell housing surface Apply new sealant in same area during engine installation Kohler Gasoline Engine Page 5 10 5 If shoulder bolt Item 15 was remov
250. sert flange head screw through end yoke and stub axle Install new flange nut onto screw Torque flange nut from 220 to 250 ft lb 298 to 339 N m 7 Position driveshaft cross to the end yoke Install the straps to secure driveshaft bearing cross to the end yoke Torque bolts from 200 to 250 22 6 to 28 3 N m 8 Lubricate driveshaft grease fittings see Operator s Manual 9 Secure drive shaft to transaxle shaft Fig 9 A Align mounting holes in driveshaft with relief in transaxle shaft B Install cap screws hardened washers and flange nuts to secure driveshaft to transaxle shaft Torque fasteners from 35 to 42 ft lb 47 to 57 10 Install brake drum and wheel see Brake Service in Service and Repairs Section of Chapter 7 Chassis 11 Tighten wheel nuts to a torque of 45 to 65 ft lb 61 to 88 12 Lower vehicle to ground Drive Train 2 e 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 4 To install new cross and bearings A Apply a coating of grease to bearing bores B Press one bearing partially into yoke Item 3 C Insert cross into yoke and bearing D Hold cross in alignment and
251. sert pinion shaft 9 Grease the shaft to aid assembly E Assemble lock pin Item 8 Drive the pin to the 2 approximate center location of the pinion mate shaft Pay attention to direction of slit in lock pin F Check for smooth revolution of pinion gears and side gears G Completely clean oil from threads in ring gear Item 6 NOTE Ring gear and countershaft are supplied in matched sets only H Insert 2 dowel pins Item 7 onto ring gear Item 6 18 5 to 22 ft lb 24 5 to 29 5 N m 1 Completely clean oil from threads of cap screws Item 5 NOTE It is recommended that whenever the ring gear screws are removed that they be replaced with new screws J Apply Loctite to threads of cap screws K Clean oil from contact surface of differential case and ring gear L Drive ring gear onto differential case M Tighten cap screws to a torque from 18 5 to 22 ft Ib 24 5 to 29 5 N Use a press to install bearing Item 1 onto differ ential case O Install slider Item 4 Put moly disulfide grease onto sliding area of differential case before installing P Use a press to install bearing Item 3 Q Install snap ring Item 2 Figure 71 Drive Train Page 6 38 Workman 3000 4000 Series 6 Assemble Hi Lo fork shaft A Install E ring 4 onto fork shaft Item 5 B Insert spring Item 3 and steel ball Irem 2 into fork Item 1 C Insert fork shaft
252. shing area for scoring or damage BUSHING Figure 129 6 Inspect surface of oil seal area on output shaft for wear or damage OIL SEAL Figure 130 Drive Train Page 6 58 Workman 3000 4000 Series 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 2 Make sure all parts are free of dirt and dust 3 Assemble shift arm Figure 131 A Install two 2 new O rings Item 1 onto shift arm Apply moly disulfide grease to O rings before instal ling B Apply moly disulfide grease to arm pin and shaft Install shift arm into PTO housing pc Install shift lever onto shift arm E Drive lock pins into shift lever and shift arm Pay attention to direction of slit in lock pins Figure 132 x o 2 Figure 133 Workman 3000 4000 Series Page 6 59 Drive Train 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 Use a press to install bearing Item 1 Figure 135 5 Use a press to install bearing Item 1 onto in
253. sion springs before dis assembling the front suspension 4 Install a compression spring tool rod through holes in each spring cradle Item 1 then install nuts and washers on 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 op posite ends so cap screws Item 7 can be removed 5 Remove lock nut Item 3 and cap screw Item 4 from lower end of each stabilizer link Item 5 Workman 3000 4000 Series Page 7 27 7 Cap screw 8 Control arm tower 9 Spring pivot sleeve 6 Remove lock nut Item 6 and cap screw Item 7 se curing each spring cradle to control arm towers Item 8 then remove springs and cradles along with the stabiliz er links 7 Reverse this procedure to install springs Install compression spring tool before disassembling Figure 20 Chassis 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 Insert spacer into ram lower end of shock absorber 3 Install inner washer onto stud above control arm 4 Install new shock absorber with ram end down and secure upper end with outer washer and lock nut 5 Insert capscrew down through angled h
254. ss hole in brake drum aligns with hole in front hub Workman 3000 4000 Series Page 7 11 8 Adjust brake shoes A Align access hole in brake drum with adjuster bolt on adjuster assembly B Rotate adjusting bolt to increase adjuster length until brake shoes contact brake drum C Back off adjuster until drum rotates freely 9 Install wheel Secure with wheel nuts Tighten lug nuts in a crossing pattern to a torque from 45 to 65 ft lb 61 to 88 After reassembly check the brakes in a wide open level area that is free of other persons and obstructions 10 Check brake operation Chassis Rear Wheel Assembly 40 to 60 ft lb 54 to 81 12 0 11 41 9 X 200 to 250 22 6 to 28 3 N m ACCESS HOLE Pd Loctite 4680 220 to 250 ft Ib 298 to 339 N m 45 to 65 ft lb 61 to 88 Figure 4 1 Flange nut 10 Cap screw 4 used per brake 19 Bolt 2 used per strap 2 Wheel nut 5 used per wheel 11 Lock washer 4 used per brake 20 Hardened washer 3 Wheel assembly 12 Brake assembly 21 Flange head screw 4 Brake drum 13 Parking brake cable 22 Thrust washer 5 Stub axle 14 Cable clip 23 Cap screw 6 Lock washer 5 used per wheel 15 Axle housing 24 Cap screw 7 Hex bolt 5 used per wheel 16 Seal 25 Rear axle 8 Bearing 17 End yoke 26 Drive shaft 9 Bearing spacer 18 Yoke strap 2 used per yoke For rear wheel assembly service procedures see
255. t from flywheel surface with light abrasive Check flywheel runout and replace if runout exceeds 0 005 in 0 13 mm 12 Inspect flywheel pilot bearing for wear or damage and replace if necessary Installing Clutch Disk and Pressure Plate 1 Apply a coating of grease to clutch disk spline then use a brush to rub it in Wipe off any excess grease 2 Use clutch alignment tool see Special Tools to posi tion clutch disk on flywheel Workman 3000 4000 Series Page 6 21 Rev C 3 Install pressure plate Install and tighten six cap screws and lock washers a little at a time working in a diagonal sequence Torque screws from 5 to 7 ft Ib 7 to 9 N m Remove alignment tool from flywheel bearing Clutch Alignment Tool Engine Flywheel Side Pressure Plate Side Pressure plate Diaphragm spring Torsion spring Rivet sink Figure 24 Drive Train 2 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 Loosen cap screws Item 2 and remove bell housing assembly from transaxle 3 Thoroughly clean outside surface of transaxle 4 Loosen cap screws Item 1 and remove fork shaft case Item 2 from center plate Note location of longer cap screw Be careful when removing cov
256. t 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 Briggs Daihatsu Gasoline Engine 5 Do Engine Hex nut Lock washer Flat washer Wire harness alternator lead Fuel hose Hose clamp Hose clamp Air intake hose 10 Throttle bracket 11 Lock nut Briggs Daihatsu Gasoline Engine Figure 11 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 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 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 3 Disconnect negative and then positive battery cables at the battery 4 Remove exhaust manifold from vehicle see Ex haust System Removal in this section 5 5 5 Loosen h
257. t 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 Operating the engine with dirty or plugged cooling fins a blocked grass screen or a plugged or dirty blower housing will result in en gine overheating and engine damage 1 Park vehicle on a level surface stop engine engage parking brake and remove key from the ignition switch 2 Raise or remove the bed or other attachment s If bed is raised place safety support on lift cylinder see Operator s Manual IMPORTANT Never clean engine with pressurized water Water could enter and contaminate the fuel system 3 Clean cooling fins on both cylinder heads 4 Clean grass screen and blower housing of dirt and debris Fig 1 Remove screen and housing if neces sary IMPORTANT Never operate engine without the blower housing installed Overheating and engine damage will result 5 Make sure grass screen and blower housing are re installed to the engine if removed 1 Cylinder head 2 Grass screen Workman 3100 Page 5 3 Figure 1 3 Blower housing Kohler Gasoline Engine 1c Ss 9 7 6 Fuel Tank Figure 2 1 Fuel tank 10 Spacer 19 2 Fuel tank cap 11 Fuel fitting 20 3 Gasket 12 Hose clamp 21 4 Fuel sender 13 Fuel line 22 5 Lock washer 5 used 14 Clamp 23 6 Screw
258. t run ning or if the charging circuit is not operating properly during operation Test the lamp by disconnecting the wires and applying 12 VDC between the lamp wiring ter minals Glow Light Diesel Engine The glow light should be on when the ignition key switch is in the HUN position and the glow switch is ON Test the lamp by disconnecting the wires and applying 12 VDC between the lamp wiring terminals Hourmeter Test the hourmeter by connecting a 12 volt battery so the positive battery terminal is connected to the positive terminal on the hourmeter Connect the negative bat tery terminal to the negative terminal on the hourmet er 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 Figure 13 1 Battery Temperature Gauge and Fuel Level Gauge To test a gauge use a commercial gauge tester If a com mercial gauge tester is not available substitute a new gauge or test the sending unit 2i Figure 14 4 Hourmeter 5 Temperature gauge 6 Fuellevel gauge 1 Oil pressure light 2 Charging light 3 Glow light Workman 3000 4000 Series High Temperature Shutdown Switch Briggs Daihatsu Gas and Diesel Engine The high temperature shutdown switch is threaded into the thermostat housing Fig 15 There is a blue wire at tached to the switch Testing Make sure engine is cool before removing
259. te 4 Lower or install bed or attachment s Briggs Daihatsu Diesel Engine 5 2 a gt Engine Engine Fusible link harness Positive battery cable Wire harness solenoid lead Lock washer Hex nut Hose clamp Lower radiator hose Hex nut 10 Engine cover 11 Cap screw Briggs Daihatsu Diesel Engine Figure 10 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 3300 D 4300 D 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 3 Disconnect negative and then positive battery cables at the battery 4 Remove exhaust manifold from vehicle see Ex haust System Removal in this section 5 Loosen hose clamp that secures air intake hose to engine Remove intake hose from
260. tem 17 and gently tap housing with a soft face hammer to loosen from stator Item 8 Be careful not to drop any parts or disengage gear mesh 5 Before removing gears Item 11 apply marking dye to mating teeth to retain gear timing and location when reassembling 6 Remove and discard the pressure plate seal Item 15 back up seal Item 14 and wear plate seal Item 21 as the pump is disassembled 7 Press drive shaft and bearing assembly Item 6 22 4 out of stator Item 8 Remove crescent rings Item 4 and then remove bearing from drive shaft Inspection 1 Wash all parts in cleaning solvent 2 Check all parts for burrs scoring nicks etc 3 Check bearings Item 12 in stator and gear end housing for excessive wear or scoring Replace the bearings if necessary Replace wear plate Item 10 if it appears scored then stone face of gears Replace gears Item 11 if excessively worn or damaged 4 Check bearing Item 22 for smooth operation Re place bearing if loose on shaft or noisy when rotated 5 Inspect square key Item 5 shear pin Item 7 ball key Item 23 and keyways in shafts for wear or damage Replace parts as necessary Workman 3000 4000 Series Page 9 29 Assembly Fig 23 1 Install one crescent ring Item 4 on inside portion of driveshaft Item 6 then install bearing Item 22 and other crescent ring Install driveshaft and bearing as sembly into stator Item 8 2 Apply Dexron
261. termedi ate shaft o Figure 136 6 Assemble PTO input shaft A Insert spring Item 3 and two 2 steel balls Item 2 into hole B Insert shift collar Item 1 onto input shaft PT C Move shift collar to ON position FL Figure 137 Drive Train Page 6 60 Workman 3000 4000 Series 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 g Item 3 on the shifter block C Install gear Item 7 with bushing and thrust wash o er Item 6 onto input shaft after sliding the assembly toward PTO shaft side Apply moly disulfide grease to bushing of gear and thrust washer before instal ling Figure 138 D Slide two 2 bearings Items 5 4 onto input shaft E Install two 2 retaining rings Items 2 and 1 o gt Moly disulfide grease Ls EE f Figure 141 Workman 3000 4000 Series Page 6 61 Drive Train 8 Install PTO intermediate shaft sub assembly A If removed during disassembly insert bearing Item 3 into PTO housing B Put gear Item 2 on mating gear C Move gear until bores of gear and bearing line up D Insert intermediate shaft sub assembly Item 1 Apply grease to intermediate shaft to aid assembly Figur
262. th is incorrect see Steering Cylinder Installation in Service and Repair section of Chapter 9 Hydraulic System for steering cylinder ball joint installation proce dure 2 With steering cylinder mounted in vehicle rotate steering wheel to extend steering cylinder to a length of 17 320 43 99 cm between the centers of the cylinder ball joints Fig 18 This steering cylinder length will cen ter the Pitman arm with the vehicle to ensure correct front wheel alignment measurement 3 With the Pitman arm centered measure center to center distance at axle height between the front wheels at both front and rear ofthe wheels Fig 19 The front measurement must be 0 125 to 0 375 inch 3 18 to 9 53 mm greater than the rear measurement toe out 4 If adjustment is needed loosen jam nuts on front tie rod ends and rotate tie rod s to change alignment Torque jam nuts to 50 ft Ib 68 N m after adjustment is complete Make sure that the tie rod ends are aligned with each other as the jam nuts are being tightened 5 After alignment has been checked and or adjusted check for component interference as steering wheel is turned from lock to lock A lf atie rod contacts the Pitman arm adjust steer ing cylinder ball joint location B If tie rod ends contact spindles adjust both tie rods equally to re center steering C After any adjustment re check front wheel align ment Additionally make sure that all jam nuts are properly
263. than 0 1 amp If the reading is 0 1 amp or more the unit s electri cal system should be tested and repaired 8 Connect negative ground cable connector to the negative battery post Tighten cap screw and nut with two wrenches Charging To minimize possible damage to the battery and to allow the battery to be fully charged the slow charging method is presented here This charging method can be accom plished with a constant current battery charger which is available in most shops Follow the manufacturer s instructions when us ing a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 If battery filler caps are removable check the electro lyte 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 Specific Open Circuit Level Gravity Voltage 100 1 265 12 68 3 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Workman 3000 4000 Series Page 8 19 Battery Reserve Capacity Battery Charge Level Percent of Fully Charged inte 80 or less 3 8hrs 7 5hrs 11 3hrs 15 hrs 3 amps 3amps amps 3
264. the end of this chapter Refer to Operator s Manual for recommended maintenance intervals Addi tionally insert Installation Instructions Operator s Manuals Parts Catalogs and Service Manuals for any accessories that have been installed on your Workman at the end of this section Workman 3000 4000 Series Page 2 1 Product Records and Maintenance Equivalents and Conversions Decimal and Millimeter Equivalents Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 5
265. the pinion gear 8 Fig 34 Workman 4000 Series 9 3000 0003 0002 cup d 222221 EE MN gm Page 10 23 H Figure 3 Front Wheel Drive AWD lt E Drive 4 0 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 If anew carrier assembly 15 is being installed pro ceed as follows A Press bearing cup 10 into the assembly with out any shims 14 B Place pinion gear 8 with bearing cone 9 installed into the carrier assembly and bearing cup C Measure and note distance from the centerline of the ring gear to the bottom of the pinion gear teeth us ing a depth micrometer Fig 32 and 37 D Note shimming dimension on the pinion gear Fig 33 If the dimension is positive add the di mension to 3 750 inch If the dimension is nega tive subtract the dimension from 3 750 inch For Example If the pinion gear shaft is etched 4 Add 0 004 to 3 750 to get 3 754 inch If the pinion gear shaft is etched 4 Subtract 0 004 from 3 750 to get 3 746 inch E Now determine the difference between the mea surement taken in a step C and the value calculated in step D This difference is the new shim thickness F Remove bearing cup f
266. ting 6 6 Service and Repairs 6 10 Chapter 7 Chassis Specifications 7 2 Special Tools 7 3 Troubleshooting 7 4 Service and Repairs 7 8 Chapter 8 Electrical System Electrical Schematics Special Tools Troubleshooting Electrical System Quick Checks Component Testing Service and Repairs Chapter 9 Hydraulic System Specifications General Information Hydraulic Schematics Hydraulic Circuit Operation Special Tools Troubleshooting Testinig Service and Repairs SAUER DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Briggs Daihatsu Product Records Kohler Briggs Daihatsu Gasoline Engine Drive Train D Hydraulic Gasoline Engine and Maintenance Diesel Engine This page is intentionally blank Workman 3000 4000 Series Table Of Contents 52 52 Chapter 10 Front Wheel Drive 4WD Specifications Soe cee 10 2 General Information 10 3 a Service and Repairs 10 4 88 Chapter 11 Electrical Schematics 88
267. tite 680 to threads and tapers C Apply Loctite 680 or equivalent to threads and tapers of shift fork arms D Install 2 shift arms Item 11 Install shift arm as sembly Items 8 7 6 5 4 3 E Install washers Items 10 and 2 and locknuts Items 9 and 1 Tighten shift arm retaining locknuts to a torque from 200 to 280 22 6 to 31 6 14 Install oil cap Item 1 with O ring Apply multi pur pose grease to O ring 15 If removed install air breather Item 2 Use sealing tape on threads of air breather Figure 87 Drive Train Page 6 44 Workman 3000 4000 Series 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 89 17 Install main shaft together with 2 3 fork shaft Insert head of shift arm into groove of fork while installing Drive Train Figure 90 Figure 91 Workman 3000 4000 Series Page 6 45 Drive Train 18 Install reverse shaft Item 1 Rotate main shaft and reverse shaft gears to mesh gears when installing 19 4WD vehicles install bearing to gear case see Item 2 of Fig 92 and center plate Install front drive shaft and 41T gear to the gear case BEARING CENTER PLATE BEARING GEAR CASE 20 Install center plate A Insert 2 dowel pins into transaxle case B Apply silicone sealant onto mating surface of center plate C Positi
268. to cause burns 2 Before starting the engine 5 Before getting off the seat A Sit on operator s seat and engage the parking brake A Stop movement of the vehicle B Disengage PTO if so equipped and return hand B Lower bed throttle lever to OFF position if so equipped C Shut engine off and wait for all movement to stop C On TC models make sure that hydraulic lever is in the neutral position D Set parking brake and remove key from ignition switch D Move shift lever to NEUTRAL and depress clutch pedal Keep foot off accelerator pedal E Do not park on slopes unless wheels are chocked or blocked E Turn ignition key to START 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly Workman 3000 4000 Series Page 1 3 Safety Maintenance and Service 1 Before servicing or making adjustments turn all ac cessories off put traction pedal in neutral stop engine set parking brake and remove key from the switch 2 Make sure vehicle is in safe operating condition by keeping all nuts bolts and screws tight 3 Never store the vehicle or fuel container inside where there is an open flame such as near a water heat er or furnace 4 Make sure all hydraulic line connectors are tight and that all hydraulic hoses and lines are in good condition before applying pressure to the system 5 Keep body and hands away from pin hole le
269. tor 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 se cure the radiator to the frame Pull radiator from the ve hicle 9 Plug all radiator and hose openings to prevent con tamination Workman 3200 4200 Page 3 7 Installation Fig 5 1 Remove plugs from radiator and hoses placed dur ing the removal procedure 2 Position radiator to the frame Secure radiator to the vehicle with four 4 cap screws and flange nuts 3 Attach fan shroud to the radiator with four 4 cap screws flat washers and lock nuts Make sure that clear ance exists between shroud and fan at all points 4 Connect reservoir hose item 11 to the radiator filler neck 5 Connect upper and lower hoses to the radiator 6 Make sure radiator drain is closed Fill radiator with coolant see Operator s Manual 7 Install the radiator screen 8 Lower or install bed or other attachment s Briggs Daihatsu Gasoline Engine 5 9 Pump Driveshaft Service RIGHT A FRONT 100 to 130 in Ib 11 3 to 14 7 N m ANTISIEZE LUBRICANT Figure 6 1 Locknut 7 Bearing spacer 13 Coupling spacer 4 used 2 Flat washer 8 Shaft 14 Rubber coupling
270. torqued Chassis 7 26 Rev A CYLINDER LENGTH WHEN FULLY RETRACTED 14 520 36 88 cm for 2WD 15 040 38 20 cm for 4WD Figure 17 Cylinder Length to Center the Pitman Arm 17 320 43 99 3 Figure 18 FRONT OF VEHICLE Center to center Distance a Center to center Distance Figure 19 Workman 3000 4000 Series Front Compression Spring Service TOP VIEW Control arm tower gt Compression spring tool rod Spring cradle Tees e Compression 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 Extended portion should be on nut side of cap screw COMPRESSION SPRING TOOL dol 20 4 1 2 flat washers 5 4 1 2 nuts Figure 19 4 Cap screw 5 Stabilizer link 6 Lock nut 1 Spring cradle 2 Spring 3 Lock nut 1 Remove seat base to gain access to front suspen sion assembly see Seat Base removal in this section 2 Jack up front of vehicle and secure with jack stands see Jacking Instructions in Operator s Manual Re move front wheels 3 Remove front shock absorbers FRONT SUSPENSION IS SPRING LOADED To prevent possible personal injury use special tool to remove compres
271. torted flywheel Damaged release bearing Clutch noisy Improper installation of clutch cover assembly Excessive wear of clutch disc facing Worn clutch disc spline Weak or broken clutch torsion spring Damaged pilot bushing Damaged release bearing Drive Train Page 6 6 Workman 3000 4000 Series Clutch Continued 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 Clutch chatters Worn or damaged clutch disc facing Oil adhered to clutch disc facing Uneven height of diaphragm spring Weak or damaged clutch torsion spring Damaged pressure plate or flywheel Damaged clutch release bearing Loose or worn front wheel bearings o gt Workman 3000 4000 Series Page 6 7 Drive Train Transaxle 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 Clutch not releasing Shift cable out of adjustment Shift cable damaged Shifter cap screw loose at operator station Loose shift lever on transaxle Cable clamp securing cables near sh
272. transaxle case IMPORTANT When installing PTO assembly make sure O ring is properly positioned in groove 2 Install PTO to transaxle Tighten cap screws and nut with lockwasher to a torque from 11 to 13 ft lb 15 to 17 N m 3 Install hydraulic hose to fitting on PTO 4 Connect PTO switch electrical lead 5 Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in PTO arm x o gt 6 Reinstall clevis pin and tighten jam nut after doing ad justment Figure 12 1 assembly 2 Alignment pins Workman 3000 4000 Series Page 6 15 Drive Train Transaxle Loctite 242 Figure 13 1 Transaxle assembly 6 Cap screw 2 used 2 Snubbing washer 4 used 7 Cap screw 4 used 3 Isolation mount assembly 2 used 8 Shift arm 4 Transaxle mount 2 used 9 Nut 3 used 5 Lock nut 4 used 10 Hardened washer 3 used Drive Train Page 6 16 11 Shift lever 2 used 12 Differential lock lever 13 Strainer 14 Shift cable mount bracket 15 Negative battery cable Workman 3000 4000 Series 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 3 Remove drain plug from bottom of transaxle Fig 14 and allow oil to drain i
273. turn 5 If either of these performance tests indicate a steer ing problem determine if the steering cylinder is faulty using the following procedure A Park vehicle on a level surface B With the engine running turn the steering wheel to the right clockwise until the steering cylinder rod is fully extended C Turn engine off and engage the parking brake D Read Precautions for Hydraulic Testing E Clean and remove hydraulic hose from the fitting on the rod end of the steering cylinder Plug the end of the disconnected hose Fig 15 Workman 3000 4000 Series Page 9 19 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 es caping 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 cylin der 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
274. tward on CV joint as close as possible to the front differential to make sure that the CV joint is properly snapped into place 4 Reassemble axle housing stub axle and wheel to the CV joint and front suspension see Front Wheel And Axle Housing Assembly in this section Workman 4000 Series Page 10 13 Front Wheel Drive AWD Front Differential 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 R clamp CONC PON a Front Wheel Drive AWD 14 15 16 17 18 Cap screw 4 used 20 21 Lock washer 4 used 23 24 25 26 Figure 10 Front brake hose Cap screw 2 used per control arm Lock nut 2 used per control arm Mount assembly 4 used Snubbing washer 8 used Front differential Differential rear mount Cap screw 4 used Differential drive shaft Upper ball joint Socket hex head screw 6 used Page 10 14 Differential front bracket Cap screw 3 used Lock washer 3 used Cap screw Lock nut Lower control arm Cap screw Cotter pin Support bracket RH shown Cap screw 3 used per bracket Flange nut 3 used per bracket Axle housing RH shown Workman 4000 Series Removal Fig 10 1 Park vehicle on a level surface Make sure engine is off Set parking brake and block rear w
275. ultimeter ohms setting leads to relay ter minals 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 3 Disconnect voltage from terminal 85 and multimeter lead from terminal 87 Figure 13 2 E o 4 Connect multimeter ohms setting leads to relay ter minals 30 and 87A Apply 12 VDC to terminal 85 The relay should make and break continuity between termi nals 30 and 87A as 12 VDC is applied and removed from terminal 85 Workman 3000 4000 Series 8 11 Rev 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 Indicator Lights and Gauges Oil Pressure Light The oil pressure lamp should come on when the ignition key switch is in the RUN position with the engine not running or if the oil pressure switch closes during opera tion oil pressure below 7 psi 0 5 kg cm Test the lamp by disconnecting the wires and applying 12 VDC be tween the lamp wiring terminals Charging Light Liquid Cooled Engines The charging light should come on when the ignition key switch is in the RUN position with the engine no
276. uous flow of brake fluid with no air bubbles is released from bleeder valve Make sure fluid level is maintained in brake fluid res ervoir at all times Figure 8 5 Complete steps 1 4 for left rear right front and left front brakes 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 ve hicle to make sure brakes are operating correctly and pedal is solid Chassis Page 7 18 Workman 3000 4000 Series This page is intentionally blank Workman 3000 4000 Series Page 7 19 Chassis Brake Master Cylinder Figure 9 3 Clevis pin 4 Cotter pin 1 Brake master cylinder 2 Cap screw 2 used Removal Fig 9 1 Remove cotter pin from the clevis pin that connects master cylinder to brake pedal 2 Clean hydraulic brake line area of master cylinder to prevent contamination Remove both brake lines from master cylinder Cap ends of brake lines and position them away from master cylinder 3 Remove two 2 cap screws and flange nuts that se cure master cylinder to vehicle frame 4 Pull master cylinder from vehicle Chassis Page 7 20 5 Flange nut 2 used 6 Brake pedal Installation Fig 9 1 Position master cylinder to vehicle frame and secure with two 2 cap screws and flange nuts 2 Remove plugs from brake lines Install brake lines to master cyl
277. ure should be sufficient to engage the dowel pins 11 Align marker line on the body and rear flange Hydraulic System 2 5 c LE gt 2 D gt 72 12 Carefully install rear flange onto pump assembly 13 Install the four 4 screws item 17 with lock washers and hand tighten IMPORTANT Prevent damage when clamping the pump into a vise clamp on the front cover only Also use a vise with soft jaws 14 Place front cover of the pump into a vise with soft jaws and alternately torque the cap screws 220 25 N m Hydraulic System Page 9 29 3 Rev D 15 Remove pump from vise 16 Place a small amount of clean Dexron III ATF in the inlet of the pump and rotate the drive shaft away from the inlet one revolution If any binding is noted disassemble the pump and check for assembly problems Workman 3000 4000 Series This page is intentionally blank 2 FE Ga gt Workman 3000 4000 Series Page 9 29 4 Rev D Hydraulic System Lift Valve NO ON Lift valve O ring Tee fitting Hyd hose steering circuit return O ring Hyd hose return to hydraulic filter Flange nut Hydraulic System Figure 24 Lift lever Clevis pin Hairpin Jam nut Link rod Clevis Hyd hose to male quick fitting Page 9 30 Hyd hose to female quick fitting 90 hydraulic fitting O ring Hydraulic adapter Cap screw Hyd hose pressu
278. used to secure brake cable Remove brake cable from vehicle Installation Fig 11 1 Connect brake cable to rear brake by inserting cable through brake backing plate and into parking brake le ver Install brake cable clip to secure cable to backing plate Fig 12 2 After installing cable to rear brake check to make sure bottoms of brake shoes are seated in grooves at bottom of backing plate 3 Route brake cable in same location as before and se cure with cable ties Start from rear of vehicle and work towards front 4 Install brake cable end to brake equalizer on parking brake lever Secure brake cable to lever support bracket with retaining ring Fig 13 5 Install rear brake drum and rear wheel see Brake Service in this section 6 Lower vehicle to ground Chassis Page 7 22 7 Install center console control plate and control lever knobs 8 Adjust parking brake lever see Operator s Manual and check operation of brakes before using the vehicle Retaining ring 2 used LH brake cable 11 Lever support bracket Figure 11 1 Parking brake lever 7 RH brake cable 2 Cable equalizer bracket 8 Washer 3 Cotter pin 9 Bellcrank 4 Clevis pin 10 Brake handle 5 6 Figure 12 1 Rear brake backing plate 3 Brake shoe grooves 2 Parking brake lever 4 Brake cable clip Figure 13 3 Equalizer bracket 1 Brake cable 2 Retaining ring Workman 3000 4000 Series Steering Wheel Remo
279. using a vise to avoid scratching or distorting any parts 3 Put cylinder in a vise so shaft end is facing up 4 Use a spanner wrench to rotate head Item 6 and re move retaining ring Item 9 Grasp end of shaft and use a twisting and pulling motion to carefully extract the pis ton shaft and head assembly from the barrel 5 Remove cylinder from vise 6 Remove lock nut Item 1 from shaft then remove pis ton Item 5 and head Item 6 Remove and discard seals o rings wear ring and wiper from piston and head Hydraulic System Page 9 40 Spanner wrench Retaining ring Figure 35 Removing retaining ring Workman 3000 4000 Series 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 2 Inspect inside of barrel for scoring pitting or out of round and replace if worn or damaged Assembly Fig 34 1 Use a new seal kit to replace all seals o rings wear ring and wiper to piston and head Apply clean Dexron ATF to all seal kit components before installing 2 Install head Item 6 with new seals onto shaft Item 13 Install piston Item 5 with new seals and back ups onto shaft Install piston onto shaft and secure with lock nut Item 1 Torque lock nut from 30 to 36 ft lb 41 to 49 N m 3 Coat all cylinder parts with clean Dexron III ATF Slide shaft assembly and head into barrel bei
280. ust 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 Pitman arm 14 Slotted hex nut 5 Hyd hose from steering valve R 10 Slotted hex nut 15 Ball joint Hydraulic System Page 9 38 Workman 3000 4000 Series Removal Fig 31 1 Park vehicle on a level surface shut engine off and ie engage the parking brake 2 Read the General Precautions for Removing and 7 Installing Hydraulic System Components at the begin 8 ning of the Service and Repairs section of this chapter Before performing service or repair hy draulic system components relieve system pressure to avoid injury from pressurized hy draulic oil Stop the engine remove key from the 3 6 ignition switch rotate the steering wheel in both directions lower or support the bed and operate other hydraulic accessories Figure 32 3 Label and disconnect hydraulic hoses from steering nei NS fitting ae fitting cylinder Install caps or plugs in hoses to prevent con 3 O ring 7 Balljoint tamination and leakage of hydraulic oil Install plugs in 4 O ring 8 Jam nut cylinder ports 4 Remove steering cylinder from vehicle using Figures CYLINDER LENGTH WHEN FULLY RETRACTED 31 and 32 as guides Installation Fig 31 1 If ball joint was removed from cylinder shaft fully re p tract cylinder shaft and thread ball joint onto shaft
281. val 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 3 Pull steering wheel from control valve Installation Fig 14 1 Apply anti seize lubricant to shaft of control valve 2 Slide steering wheel onto control valve shaft 3 Secure steering wheel with lock washer and hex nut Torque hex nut from 20 to 26 ft lb 28 to 35 4 Install steering wheel cover 1 Steering wheel 2 Lock washer 3 Hexnut Workman 3000 4000 Series Page 7 23 Rev B 20 to 26 ft Ib 28 to 35 N m Anti seize Lubricant Figure 14 4 Steering control valve 5 Frame Chassis Control Arm Ball Joint Replacement 2 80 to 90 ft lb 10810122N m 9 Figure 15 Snap ring Ball joint Ball joint seal Grease fitting 1 Cotter pin 2 Slotted hex nut 3 Upper control arm RH shown 4 Lower control arm RH shown oom Removal Fig 15 FRONT SUSPENSION IS SPRING LOADED To prevent possible personal injury use special tool to remove compression springs before dis assembling 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 compres sion springs do not need to be removed if servicing only the lower ball joint or lower control arm 2 Remove cotter p
282. w or uneven tire pressure Low hydraulic pressure see Chapter 9 Hydraulic System Damaged or binding steering cylinder Worn or damaged steering control valve Incorrect front wheel alignment Vehicle pulls to one side when not braking Low or uneven tire pressure Broken or weak rear leaf spring Incorrect front wheel alignment Damaged or bent suspension or steering component Worn or damaged brake components Workman 3000 4000 Series 7 5 Chassis Brakes 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 Air in brake system Excessively worn or cracked brake drums Broken or worn brake pedal pivot bushing Brakes pulling Incorrect tire pressure Contaminated brake linings Front end out of alignment Incorrect brake adjustment Distorted brake shoes Restricted brake lines or hoses Broken rear spring Unmatched tires on same axle Squealing brakes Glazed brake lining Saturated brake lining Weak or broken shoe return spring Weak or broken shoe retaining spring Distorted brake shoes Bent support plate Dust in brake drums and brakes Scored brake drums Out of round drums Chassis Page 7 6 Workman 3000 4000 Series Brakes Continued Dragging brakes Impro
283. wo 2 dowel pins from bell housing Fig 14 19 If necessary remove engine mount from engine 20 If pressure plate and clutch disc removal is neces sary see Clutch Disassembly and Inspection in Chapter 6 Drive Train Engine Installation Fig 11 1 If pressure plate and clutch disc were removed see Installing Clutch Disc and Cover in the Repairs section of Chapter 6 Drive Train 2 If removed secure engine mount to engine with eight 8 cap screws and lock washers 3 To install the engine perform Engine Removal steps in reverse order 4 Install a new engine oil filter Fill engine with the cor rect oil see Operator s Manual 5 Adjust accelerator cable see Operator s Manual 6 Check engine speed both idle and high idle and ad just if necessary see Engine Speed Adjustment in Ad justments section of this chapter Briggs Daihatsu Gasoline Engine Page 3 18 Figure 14 1 Bell housing 2 Cap screw 6 used 3 Harness bracket 4 Flat washer 3 used 5 Dowel pins 2 used Workman 3200 4200 Workman 3200 4200 This page is intentionally blank Page 3 19 Briggs Daihatsu Gasoline Engine BE 5 as 9 mo Engine Throttle Bracket Figure 17 1 Engine 7 Lock washer 3 used 13 Idle stop screw 2 nut 8 Flange head screw 3 used 14 High idle stop screw 3 Return spring 9 Grease fitting 15 Throttle bracket 4 Lock nut 10 Shoulder bolt 16 L
284. zer ring and synchro gear in three equally spaced points If clearance is less than 0195 in 0 5 mm replace the synchronizer ring Inspect synchro gears A Inspect the cone surface for roughness material transfer brass color material or damage B Inspect the spline chamfer for excessive chipping or damage Inspect I D of synchro gear for excessive wear scoring If synchro gears have the following l D re place the synchro gear 22T 25T 40 1 0 exceeds 1 027 in 26 08 mm 49T 1 0 exceeds 1 145 29 08 mm On 4WD units inspect 41T gear and front drive shaft Fig 57 Workman 3000 4000 Series A Inspect gear teeth for roughness material trans fer brass color material or damage B Inspect spline chamfer for excessive chipping or damage C Inspect I D of gear for excessive wear or scoring Gear should fit snuggly on shaft BEARING CENTER PLATE Page 6 33 Figure 56 FRONT DRIVE SHAFT 41T GEAR Figure 57 BEARING GEAR CASE Drive Train Drive Train 6 Inspect hub shifter synchro key and synchro spring A Inspect hub for worn or damaged spline Inspect shifter for chipping or damaged chamfer B C Inspect synchro keys for wear or damage D Inspect synchro springs for wear or damage SPRING E The shifter should move freely on the hub SHIFTER CLEARANCE F Measure the clearance between shifter groove and fork Replace shift fork if the

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