Page 1 The Toro Company reserves the right to change product specifications or this publication without notice. IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine.
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Page 3: Table Of Contents
Table Of Contents Chapter 1 - - Safety Chapter 6 - - Drive Train Safety Instructions ......1 -- 2 Specifications .
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Page 5 Workman HD Circuit Drawings ....11 -- 6 Workman HDX Circuit Drawings ... . . 11 -- 8 Workman HDX--D Circuit Drawings .
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Page 7: Safety Instructions 1
Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS ..... . Before Operating ......While Operating .
Page 8: Safety Instructions
Additional copies of the Operator’s Manual are available on the internet at www.Toro.com. B. Do not remove vehicle fuel tank cap while engine is hot or running. 2. Keep all shields, safety devices and decals in place.
Page 9: While Operating
While Operating 1. Sit on the operator seat when starting and operating 4. Do not touch engine, exhaust system components, the vehicle. transaxle or radiator (if equipped), while engine is run- ning or soon after it is stopped. These areas could be hot 2.
Page 10: Maintenance And Service
Hydraulic 16.To ensure optimum performance and continued fluid escaping under pressure can penetrate skin and safety of the vehicle, use genuine Toro replacement cause injury. Fluid accidentally injected into the skin parts and accessories. Replacement parts and acces-...
Page 11: Jacking Vehicle
Jacking Vehicle WARNING When changing attachments, tires or perform- ing other service, use correct jacks, hoists and jack stands. Always chock or block the wheels and use jack stands to support the vehicle. If the vehicle is not properly supported by jack stands, the vehicle may move or fall resulting in personal injury.
Page 12: Safety And Instruction Decals
Using Bed Safety Support Many of the procedures shown in this manual re- quire raising and lowering the bed. The following precautions must be taken or serious injury or death could result. WARNING Before servicing or making adjustments to the vehicle, stop engine, engage parking brake and remove key from ignition switch.
Page 13: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ....... EQUIVALENTS AND CONVERSIONS .
Page 14: Equivalents And Conversions
Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - - 2 Workman HD Series...
Page 15: Torque Specifications
For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
Page 16 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 17 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws and Studs with Class 10.9 Bolts, Screws and Studs with Thread Size Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
Page 18 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb...
Page 19: General Information 3
......BRIGGS & STRATTON/DAIHATSU REPAIR MANUAL FOR 3--CYLINDER, LIQUID--COOLED, GASOLINE ENGINES EFI TROUBLESHOOTING GUIDE FOR 3--CYLINDER, LIQUID--COOLED, GASOLINE ENGINES Rev. A Workman HDX Page 3 - - 1 Briggs/Daihatsu Gasoline Engine...
Page 20: Specifications
3.5 U.S. quarts (3.3 liters) with filter Water Pump Belt driven centrifugal type Cooling System Capacity 4.0 U.S. quarts (3.8 liters) Starter 12 VDC Alternator/Regulator 12 VDC 60 Amp Dry Weight (approximate) 137 pounds (62 kilograms) Briggs/Daihatsu Gasoline Engine Page 3 - - 2 Workman HDX...
Page 21: General Information
Toro distributor. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman HDX vehicle. Refer to the Operator’s Manual for additional information when ser- vicing the vehicle. 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.
Page 22 Engine Electronic Controller The engine that is used in the Workman HDX uses an IMPORTANT: Before performing any welding on the electronic controller for engine management and also to vehicle, disconnect the battery cables from the bat- provide inputs for the gauge cluster on the machine. All...
Page 23: Adjustments
Figure 3 10.After engine speed adjustments are complete, lower the bed or install attachment(s). 1. Governor link 2. Idle speed screw Workman HDX Page 3 - - 5 Briggs/Daihatsu Gasoline Engine...
Page 24: Engine Diagnostics
Engine Diagnostics Check Engine Light The Workman HDX is equipped with a check engine 5. After necessary service has been performed, dis- light that indicates if the engine electronic controller is connect service shunt leads and insert shunt leads into functioning correctly.
Page 25 Cylinder #2 ignition coil 3 -- 9 Cylinder #3 ignition coil 4 -- 1 Fuel pump relay 4 -- 5 Oxygen heater 5 -- 8 75 ohm resister (or circuit wiring) Workman HDX Page 3 - - 7 Briggs/Daihatsu Gasoline Engine...
Page 26: Service And Repairs
7. Air cleaner assembly 2. Hose clamp (4 used) 5. Air inlet hood 8. Flange nut (2 used) 3. Air intake hose 6. Air cleaner hose 9. Flange head screw (2 used) Briggs/Daihatsu Gasoline Engine Page 3 - - 8 Workman HDX...
Page 27 2. Upper housing 5. Lower housing tioned downward. 3. Element 6. Vacuator valve 2. Lower or install bed or attachment(s). Workman HDX Page 3 - - 9 Briggs/Daihatsu Gasoline Engine...
Page 28 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 Gasoline Engine Page 3 - - 10 Workman HDX...
Page 29 (item 18) to secure fuel tank. 5. Lower or install the bed or other attachment(s). 6. Fill fuel tank. Check for fuel leakage and correct if found. Workman HDX Page 3 - - 11 Briggs/Daihatsu Gasoline Engine...
Page 30: Fuel Pump
2. Hose clamp 7. Washer head screw (2 used) 11. Fuel pump/sender assembly 3. Rollover valve 8. Grommet 12. Retainer plate 4. Fuel filter 9. Fuel tank 13. Fuel hose 5. Gasket Briggs/Daihatsu Gasoline Engine Page 3 - - 12 Workman HDX...
Page 31 Secure fuel hose with hose clamp. 6. Connect vehicle wire harness connectors to fuel pump/sender assembly on fuel tank. 7. Remove bed support from lift cylinder and lower bed. Workman HDX Page 3 - - 13 Briggs/Daihatsu Gasoline Engine...
Page 32 8. Flange nut (8 used) 13. Carriage bolt (2 used) 4. Hex nut (4 used) 9. Flange head screw (2 used) 14. Flange head screw (4 used) 5. Exhaust tube 10. Mount plate Briggs/Daihatsu Gasoline Engine Page 3 - - 14 Workman HDX...
Page 33 (item 8) that secure muffler to shift cable mount bracket. E. Carriage bolts (item 13) and flange nuts (item 8) that secure muffler to mount plate. 3. Lower or install bed or attachment(s). Workman HDX Page 3 - - 15 Briggs/Daihatsu Gasoline Engine...
Page 34 12. Flange head screw 19. Flat washer (2 used) 6. Hose (radiator to coolant reservoir) 13. Flange head screw (4 used) 20. RH frame rail 7. Hose 14. Clip (2 used) Briggs/Daihatsu Gasoline Engine Page 3 - - 16 Workman HDX...
Page 35 5. Flange screw (7 used) and remove from vehicle. 12.Plug all radiator and hose openings to prevent con- tamination. 13.If necessary, remove components from radiator as- sembly using Figure 14 as a guide. Workman HDX Page 3 - - 17 Briggs/Daihatsu Gasoline Engine...
Page 36: Engine
35. R- -clamp 11. Square key 24. Coupling 36. Washer head screw 12. Pump/engine mount 25. Upper radiator hose 37. Flange head screw (8 used) 13. Flange head screw (4 used) Briggs/Daihatsu Gasoline Engine Page 3 - - 18 Workman HDX...
Page 37: Engine Removal
3. R- -clamp 7. Engine mount assembly assembly purposes. 4. Engine support G. Six (6) harness wires from ignition coils. H. All harness connectors from engine sensors and fuel injectors. Workman HDX Page 3 - - 19 Briggs/Daihatsu Gasoline Engine...
Page 38 14.Put blocking under transaxle to prevent the transaxle from moving during engine removal. 15.Loosen and remove two (2) flange nuts, snubbing washers and cap screws that secure engine mount to engine support (Fig. 17). Briggs/Daihatsu Gasoline Engine Page 3 - - 20 Workman HDX...
Page 39: Engine Installation
10.Remove plugs from hydraulic hoses and gear pump fittings. Connect hydraulic hoses to gear pump (see Hy- draulic Hose and Tube Installation in the General Infor- mation section of Chapter 9 -- Hydraulic System). Workman HDX Page 3 - - 21 Briggs/Daihatsu Gasoline Engine...
Page 40: Engine Throttle Bracket
3. Governor spring 9. Grease fitting 14. Throttle bracket 4. Lock nut 10. Shoulder bolt 15. Governor link rod 5. Ball joint 11. Bellcrank 16. Throttle return spring 6. Accelerator cable Briggs/Daihatsu Gasoline Engine Page 3 - - 22 Workman HDX...
Page 41 (see Operator’s Manual). If needed, adjust accelerator cable. Figure 21 1. Engine governor lever 3. Spring mounting slot 2. Governor spring 4. Governor link rod Workman HDX Page 3 - - 23 Briggs/Daihatsu Gasoline Engine...
Page 42: Efi System
This sensor is a NTC (negative temperature coefficient) type. At cold temperatures the NTC type sensor’s resist- ance is very high, but reduces as air temperature in- creases. Briggs/Daihatsu Gasoline Engine Page 3 - - 24 Rev. A Workman HDX...
Page 43 This sensor provides the most accurate signal within a temperature range window normally seen dur- Figure 25 ing most engine loads and RPM’s. Rev. A Workman HDX Page 3 - - 25 Briggs/Daihatsu Gasoline Engine...
Page 44 ECU that the engine number 1 cylinder is at top dead center. The ECU can now begin its sequence and follow through the engine’s firing order until the last injector has been opened. Figure 28 Briggs/Daihatsu Gasoline Engine Page 3 - - 26 Rev. A Workman HDX...
Page 45: Efi Troubleshooting
Information on EFI troubleshooting is in the EFI Trouble- shooting Guide that is included at the end of this section. Use this information when troubleshooting a problem that affects the engine EFI system. Rev. A Workman HDX Page 3 - - 27 Briggs/Daihatsu Gasoline Engine...
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Page 47: Engines
..... BRIGGS & STRATTON/DAIHATSU REPAIR MANUAL FOR 3--CYLINDER, LIQUID--COOLED, DIESEL ENGINES Workman HDX--D Briggs/Daihatsu Diesel Engine Page 4 - - 1...
Page 48: Specifications
Water Pump Belt driven centrifugal type Cooling System Capacity 4.0 U.S. quarts (3.7 liters) Starter 12 VDC 1.2 KW Alternator/Regulator 12 VDC 60 Amp Dry Weight (approximate) 196 pounds (89 kilograms) Briggs/Daihatsu Diesel Engine Workman HDX--D Page 4 - - 2...
Page 49: General Information
Toro distributor. Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman HDX--D vehicle. Refer to the Operator’s Manual for additional information when ser- vicing the vehicle. 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.
Page 50: Adjustments
B. Adjust high speed screw to obtain 3600 + 50 RPM. C. Tighten lock nut. Recheck high idle speed. Figure 3 1. Speed control lever 3. Lock nut 2. High speed screw Briggs/Daihatsu Diesel Engine Workman HDX--D Page 4 - - 4...
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Page 52: Service And Repairs
8. Frame 2. Air cleaner hose 6. Engine 9. Flange head screw (2 used) 3. Air inlet hood 7. Air intake hose 10. Flange nut (2 used) 4. Air cleaner assembly Briggs/Daihatsu Diesel Engine Workman HDX--D Page 4 - - 6...
Page 53 2. Upper housing 5. Lower housing downward. 3. Air filter element 6. Vacuator valve 2. Lower or install bed or attachment(s). Workman HDX--D Briggs/Daihatsu Diesel Engine Page 4 - - 7...
Page 54: Fuel Tank
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 Workman HDX--D Page 4 - - 8...
Page 55 (item 7) to secure fuel tank. 5. Lower or install the bed or other attachment(s). 6. Fill fuel tank. Check for fuel leakage and correct if found. Workman HDX--D Briggs/Daihatsu Diesel Engine Page 4 - - 9...
Page 56: Exhaust System
8. Flange nut (8 used) 13. Carriage bolt (2 used) 4. Hex nut (4 used) 9. Flange head screw (2 used) 14. Flange head screw (4 used) 5. Exhaust tube 10. Mount plate Briggs/Daihatsu Diesel Engine Workman HDX--D Page 4 - - 10...
Page 57 (item 8) that secure muffler to shift cable mount bracket. E. Carriage bolts (item 13) and flange nuts (item 8) that secure muffler to mount plate. 3. Lower or install bed or attachment(s). Workman HDX--D Briggs/Daihatsu Diesel Engine Page 4 - - 11...
Page 58: Radiator
5. Hose clamp (4 used) 12. Flange head screw 18. Washer head screw 6. Hose (radiator to coolant reservoir) 13. Flange head screw (4 used) 19. Flat washer (2 used) 7. Hose Briggs/Daihatsu Diesel Engine Workman HDX--D Page 4 - - 12...
Page 59 5. Flange screw (7 used) and remove from vehicle. 12.Plug all radiator and hose openings to prevent con- tamination. 13.If necessary, remove components from radiator us- ing Figure 10 as a guide. Workman HDX--D Briggs/Daihatsu Diesel Engine Page 4 - - 13...
Page 60: Engine
35. R- -clamp 11. Square key 24. Coupling 36. Washer head screw 12. Pump/engine mount 25. Upper radiator hose 37. Flange head screw (8 used) 13. Flange head screw (4 used) Briggs/Daihatsu Diesel Engine Workman HDX--D Page 4 - - 14...
Page 61: Engine Removal
7. Engine mount assembly 8. Disconnect accelerator cable ball joint from throttle 4. Engine support lever (see Engine Throttle Bracket Disassembly in this section). Position accelerator cable away from engine. Workman HDX--D Briggs/Daihatsu Diesel Engine Page 4 - - 15...
Page 62: Engine Installation
Torque fasteners to values identified in Figure 11. 16.Remove six (6) cap screws that secure clutch bell housing to engine. Note location of two (2) harness brackets as caps screws are being removed (Fig. 14). Briggs/Daihatsu Diesel Engine Workman HDX--D Page 4 - - 16...
Page 63 11. On 4WD vehicles, install differential drive shaft (see Differential Driveshaft Installation in the Service and Re- pairs section of Chapter 10 -- Front Wheel Drive (4WD)). Workman HDX--D Briggs/Daihatsu Diesel Engine Page 4 - - 17...
Page 64: Engine Throttle Bracket
(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 Workman HDX--D Page 4 - - 18...
Page 65: Specifications
Chapter 5 Kohler Gasoline Engine Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
Page 66: Specifications
Specifications Item Description Make / Designation Kohler, CH23S, 4--stroke, V--Twin Air Cooled, OHV Number of Cylinders Bore x Stroke 3.15 in x 2.64 in (80 mm x 67 mm) Total Displacement 41.1 in (674 cc) Compression Ratio 8.5:1 Governor Mechanical Idle Speed (no load) 1200 + 100 RPM High Idle (no load)
Page 67: General Information
General Information This Chapter gives information about specifications and Most repairs and adjustments require tools which are repair of the Kohler engine used in the Workman HD. commonly available in many service shops. Special tools are described in the Kohler Command Engine Ser- General engine maintenance procedures are described vice Manual.
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Page 69 Service and Repairs Cooling System To ensure proper engine cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. NOTE: Perform this maintenance procedure at the in- terval specified in the Operator’s Manual. IMPORTANT: The engine that powers the Workman HD vehicle is air- -cooled.
Page 70 Fuel Tank 175 to 200 in- -lb (20 to 22 N- -m) TO PURGE PORT TO ENGINE RIGHT FRONT Figure 2 1. Fuel hose (fuel supply) 11. Fuel sender 21. Gasket 2. Fuel hose 12. Carbon cannister 22. Hose clamp 3.
Page 71 Fuel Tank Removal (Fig. 2) 1. Park 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. 3.
Page 72 Exhaust System RIGHT FRONT Figure 4 1. Flange head screw (4 used) 6. Flange head screw (3 used) 11. Flange head screw 2. Exhaust manifold 7. Flange head screw 12. Shift cable mount bracket 3. Hex nut (4 used) 8. Bracket 13.
Page 73 Removal (Fig. 4) Installation (Fig. 4) 1. Park vehicle on a level surface and engage parking 1. Replace any removed gaskets. brake. Stop the engine and remove key from ignition 2. Using Figure 4 as a guide, fit all exhaust components switch.
Page 74 Engine RIGHT FRONT Antiseize Lubricant 35 to 40 ft- -lb (48 to 55 N- -m) Antiseize Lubricant Figure 5 1. Lock nut 17. Flange nut 33. Choke cable 2. Flat washer 18. Clutch adapter 34. Flange nut (4 used) 3. Pulley 19.
Page 75 Engine Removal (Fig. 5) 1. Park 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. 3.
Page 76 2. Check pilot bearing (item 23) for smooth rolling and 7. Secure engine to engine mount with four (4) flange noise. Check (sealed) bearing for grease leakage. Re- nuts (item 34) and flange head screws (item 36). place bearing if necessary. Remove pilot bearing from 8.
Page 77: Adjustments
Chapter 6 Drive Train Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Drive Train Operation .
Page 78: Specifications
Specifications Item Specification Transaxle Oil Dexron III ATF Transaxle Oil Capacity 8 U.S. quart (7.6 liter) system capacity Drive Train Page 6 - - 2 Workman HD Series...
Page 79: General Information
General Information Drive Train Operation Workman HD series vehicles are equipped with a Toro designed transaxle with 3 forward speeds, 1 reverse Optional PTO speed and a differential lock. Hi--Lo range gives an effec- tive 6 forward and 2 reverse speeds.
Page 80: Special Tools
Special Tools Order special tools from your Toro Distributor. Clutch Alignment Tool Use clutch alignment tool to align clutch friction disk to engine flywheel before tightening pressure plate cap screws. Toro Part Number: TOR6002 Figure 2 Drive Train Page 6 - - 4...
Page 81: Pto Cable Adjustment
Adjustments PTO Cable Adjustment (If Equipped) 1. Remove clevis pin that secures PTO cable to PTO le- ver arm. 2. Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in PTO lever arm. 3. Tighten jam nut making sure that holes in clevis and lever arm still align.
Page 82: Troubleshooting
Troubleshooting Clutch Problem Possible Causes Clutch slips. Clutch pedal out of adjustment. Excessive wear of clutch disc facing. Hardening of clutch disc facing, or adhesion of oil. Weak or broken clutch diaphragm spring. Damaged pressure plate or flywheel. Clutch operation erratic or rough. Improper installation of clutch cover assembly.
Page 83 Clutch (Continued) Problem Possible Causes Clutch drags or does not release. Control cable loose or out of adjustment. Bent or broken clutch diaphragm spring tip. Damaged or distorted clutch disc. Worn or rusted clutch disc spline. Damaged pressure plate or flywheel. Damaged release bearing.
Page 84: Transaxle
Transaxle Problem Possible Causes Noisy operation. Low oil level in transaxle. Damaged or worn bearings. Gears worn, scuffed or broken. Excessive end play in countershaft. Gears loose on shaft. Excessive wear of differential side gear liners and pinion liners. Excessive wear of splined slider on axle drive joints. Difficult shifting.
Page 85 Transaxle (Continued) Problem Possible Causes Transaxle slips out of gear. Shift linkage out of adjustment. Gear loose on shaft. Gear teeth worn. Excessive end play in gears. Lack of spring pressure on shift fork detent ball. Badly worn bearings. Overheating of transaxle. Oil level too high.
Page 86: Service And Repairs
Service and Repairs Shift Cable Replacement RIGHT FRONT Figure 4 1. Shift knob 8. Clevis pin 14. Lock nut 2. Jam nut 9. Shift lever 15. Lever support 3. Boot seal 10. Shift link 16. Hex nut (2 used) 4. Shift cable 11.
Page 87 6. Remove shift cable from transaxle shift lever (Fig. 6): A. Remove hair 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. 7.
Page 88: Driveshaft
Driveshaft 35 to 40 ft- -lb (48 to 55 N- -m) 170 to 180 ft- -lb (231 to 244 N- -m) 35 to 40 ft- -lb (48 to 55 N- -m) Antiseize Lubricant 40 to 45 ft- -lb (55 to 61 N- -m) Loctite #271 RIGHT Antiseize...
Page 89 Removal (Fig. 7) 1. Park vehicle on a level surface, shut engine off and remove key from ignition switch. 2. For driveshaft to be serviced, remove wheel, brake caliper, brake rotor and wheel hub (see Wheel Hub Re- moval in the Service and Repairs section of Chapter 7 -- Chassis).
Page 90: Driveshaft Cross And Bearing Service
Driveshaft Cross and Bearing Service 1. Remove driveshaft from vehicle (see Driveshaft Re- 5. Lubricate grease fittings until grease purges from moval in this section). bearing cups. Make sure to grease all cross fittings. IMPORTANT: When placing yoke in vise, clamp 6.
Page 91: Pto Removal And Installation (If Equipped)
PTO Removal and Installation (If Equipped) PTO Removal 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Remove clevis pin to disconnect PTO control cable clevis from lever arm on PTO.
Page 92: Transaxle
Transaxle RIGHT FRONT Figure 12 1. Transaxle assembly 8. Shift arm 14. Shift arm plate 2. Snubbing washer (4 used) 9. Lock nut (3 used) 15. O- -ring 3. Isolation mount assembly (2 used) 10. Shift cable mount bracket 16. Suction hose 4.
Page 93: Transaxle Removal
Transaxle Removal (Fig. 12) 1. Park vehicle on a level surface. Stop the engine and remove key from ignition switch. Remove the bed or oth- er attachment(s). Allow transaxle and engine to cool. 2. Disconnect negative (--) battery cable from battery first.
Page 94: Transaxle Installation
16.Put blocking under engine for support. Support trans- axle with a floor jack or suspend transaxle from vehicle frame rails. 17.Remove isolation mount assemblies and transaxle mounts (Fig. 16). 18.Remove driveshaft clamp bolts, then slide transaxle side--to--side to disconnect each driveshaft from axle shafts on transaxle.
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Page 96: Clutch Service
Clutch Service RIGHT FRONT 5 to 7 ft- -lb (7 to 9 N- -m) Antiseize lubricant Antiseize lubricant Figure 19 1. Spring pin 6. Bushing 11. Lock washer (6 used) 2. Throw out bearing 7. Spring pin (2 used) 12. Pressure plate 3.
Page 97 Clutch Disassembly and Inspection (Fig. 19) 3. Install pressure plate. Install and tighten six (6) cap screws and lock washers a little at a time, working in a 1. Insert clutch alignment tool (see Special Tools) in en- diagonal sequence. Torque screws from 5 to 7 ft- -lb (7 gine flywheel pilot bearing hole to keep clutch disk from to 9 N- -m).
Page 98: Transaxle Service
Transaxle Service Transaxle Disassembly NOTE: Item numbers in figures are shown in order of disassembly; for example, remove item 1 first, then item 2, etc. assemble transaxle in reverse order; for example, install item 1 last. 1. Remove extension spring (item 1). 2.
Page 99 7. Loosen and remove fifteen (15) flange head screws and separate center plate from transaxle case. Note dowel pins in transaxle case. Remove seal cap (item 1), shims (items 2 and 4) and snap ring (item 3) from center plate. Figure 27 FRONT DRIVE SHAFT...
Page 100 11. Remove, all at the same time, reduction shaft as- sembly (item 1), 2nd--3rd shift assembly (item 2), coun- tershaft assembly (item 3) and High--Low shift assembly (item 4). Figure 31 12.Loosen five (5) flange head screws (item 1) and re- move L.H.
Page 101 16.Remove differential gear assembly (item 1) together with fork shaft assembly (item 2). Figure 35 17.Remove washer (item 1) from inside of transaxle case. NOTE: Washer may stick to fork shaft when re- moved in step 16. Figure 36 Workman HD Series Page 6 - - 25 Drive Train...
Page 102 18.To remove shift arms: A. Loosen and remove nut (item 1). Remove 2nd--3rd shift arm (item 2) together with shift arm plate (item 3), spring (item 4), locknut (item 5), wash- er (item 6) and cap screw (item 7). B. Loosen and remove locknut (item 8) from both 1st--Rev.
Page 103 20.Remove oil cap (item 1) and O--ring from transaxle case if necessary. 21.Remove air breather (item 2) if necessary. Figure 40 22.Loosen four (4) flange head screws (item 1) and re- move upper cover (item 2) from transaxle case. Figure 41 Workman HD Series Page 6 - - 27 Drive Train...
Page 104 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 0.0709 in. (1.8 mm) thick. C.
Page 105 24.Disassemble reduction shaft assembly: A. Use a bearing puller to remove bearing (item 1) from reduction shaft. B. Remove gear (item 2), helical gear (item 3), collar (item 4) and gear (item 5). C. Use a bearing puller to remove bearing (item 6). D.
Page 106 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 46 26.Disassemble countershaft assembly: A.
Page 107 27.Disassemble fork shaft assemblies: A. Remove lock pin (item 1) from 2nd--3rd fork shaft assembly. B. Remove shift fork (item 2) from fork shaft. C. Remove lock pin (item 1) from 1st--R fork shaft assembly. D. Remove fork (item 2) from fork shaft. Figure 49 28.Disassemble Hi--Lo fork shaft assembly: A.
Page 108 30.Disassemble differential fork shaft assembly: A. Remove O--ring (item 1) from fork shaft. B. Remove snap ring (item 2), washer (item 3) and spring (item 4). C. Remove fork (item 5). D. Remove lock pin (item 6) if necessary. Figure 53 31.Disassemble axle shaft assemblies: A.
Page 109: Transaxle Inspection
Transaxle Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. 3. Inspect synchronizer ring: A. Inspect the chamfer for excessive wear or dam- age. B. Inspect inner tapered area for excessive wear or damage.
Page 110 6. Inspect hub, shifter, synchro key and synchro spring: A. Inspect hub for worn or damaged spline. B. Inspect shifter for chipping or damaged chamfer. C. Inspect synchro keys for wear or damage. D. Inspect synchro springs for wear or damage. E.
Page 111 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 (Figs. 60 and 61). UNDAMAGED GROOVE Figure 60 DAMAGED GROOVE EDGES Figure 61 Workman HD Series...
Page 112 10.Inspect reduction shaft for wear or damage. If O.D. of needle bearing area is less than 0.864 in. (21.95 mm) or 0.982 in. (24.95 mm), replace the reduction shaft. Figure 62 11. Inspect countershaft for wear or damage. If O.D. of inner portion is less than 1.100 in.
Page 113: Transaxle Assembly
Transaxle Assembly NOTE: Item numbers in figures are shown in reverse order of assembly; for example, when assembling, 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.
Page 114 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 and 12). B. Install side gear liners (item 14), side gears (items 13 and 12), pinion liners (item 11) and pinion gears (item 10).
Page 115 6. Assemble Hi--Lo fork shaft: A. Install E--ring (item 4) onto fork shaft (item 5). B. Insert spring (item 3) and steel ball (item 2) into fork (item 1). C. Insert fork shaft into fork. Put moly disulfide grease onto the shaft before installing. 7.
Page 116 8. Assemble countershaft: A. Use a press to install 2 new bearings (item 15) onto countershaft. B. Install collar (item 14) and snap ring (item 13). C. Install washer (item 12) and gear (item 11). Apply moly disulfide grease into bushing of countershaft gear before installing.
Page 117 9. Assemble synchro hub: A. Install 3 keys (item 1) into grooves of hub (item 2). Figure 75 B. Install shifter (item 1) onto hub (item 2). Figure 76 C. Insert two (2) springs (item 3) into hub. Pay atten- tion to direction of spring.
Page 118 10.Assemble reduction shaft: A. Install washer(s) (item 17), 2 needle bearings (item 16) and gear (item 15) onto reduction shaft (item 18). Apply moly disulfide grease to washer and needle bearings before installing. Oil groove on washer must face the gear. B.
Page 119 11. Assemble reverse shaft: A. Install gear (item 2) onto reverse shaft. B. Use a press to install bearings (item 3 and 1). Figure 81 12.Assemble main shaft: A. Install gear (item 18), gear (item 17) and snap ring (item 16). B.
Page 120 13.Assemble shift arms: 230 to 240 in- -lb 230 to 240 in- -lb (26 to 27 N- -m) (26 to 27 N- -m) A. Install three (3) new oil seals (item 12) into trans- axle case. Apply multi--purpose grease on lips of oil seals before installing.
Page 121 16.Assemble reduction shaft and countershaft together with R--1 fork shaft and Hi--Lo fork shaft. Figure 87 17.Insert reduction shaft and countershaft assembly into transaxle case. Insert heads of shift arms into grooves of forks when installing them. Figure 88 18.Assemble main shaft together with 2--3 fork shaft. Figure 89 19.Insert main shaft and 2--3 fork shaft assembly into transaxle case.
Page 122 20.Install reverse shaft (item 1) into transaxle case. Ro- tate main shaft and reverse shaft gears to mesh gears when installing. Figure 91 FRONT DRIVE 21.On 4WD vehicles, install bearing to gear case (see SHAFT item 2 of Fig. 91) and center plate. Install front drive shaft BEARING (CENTER PLATE) and 41T gear to the gear case.
Page 123 NOTE: The thickest shim of the shim set (item 2) should be positioned against the snap ring (Fig. 94). 23.Insert tabbed shim (item 4) against the bearing. In- sert shim set (item 2) against the tabbed shim. Use thick- est shims in set possible, that will permit installation of the snap ring.
Page 124 25.Measure countershaft end play. Rotate one of the axle shafts back and forth to take up all back lash. Rotat- ing the shaft in one direction will pull the shaft and bear- ing away from the snap ring. Rotate axle shaft in this direction, then measure space between the snap ring and shim (set) with a feeler gauge.
Page 125 27.Install fork shaft case: A. Insert spindle (item 1) between fork shafts. Figure 99 B. Insert two (2) steel balls (item 2) and two (2) springs (item 1) into the grooves. Figure 100 C. Apply silicone sealant to mating surface of fork shaft case (item 3).
Page 126 29.Install differential gear assembly (item 1) together with fork shaft (item 2) onto transaxle case. Figure 103 Figure 104 30.Install side cover: A. Insert two (2) dowel pins onto transaxle case. B. Apply silicone sealant onto mating surface of side cover.
Page 127 32.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 installed against the bearing. Figure 107 C.
Page 128 34.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 110 35.Apply silicone sealant to mating surface of upper cover (item 2). Pay attention to direction of cover and install.
Page 129 36.Apply multi--purpose grease to O--ring and insert O-- ring into groove of transaxle case. Install cover and se- cure with nut (item 2) with lockwasher and five (5) cap screws (item 1). Torque fasteners from 11 to 13 ft- -lb (15 to 17 N- -m).
Page 130 Power Take- -Off (PTO) Service (If Equipped) 18 to 22 ft- -lb (24.5 to 29.5 N- -m) Figure 114 1. PTO cover 13. Shift collar 25. Intermediate shaft 2. Cap screw (4 used) 14. Gear (29T) 26. Gear (37T) 3. Lock washer (7 used) 15.
Page 131 6. Remove PTO output shaft assembly (item 1) from PTO housing. Remove oil seal from PTO cover. Figure 115 7. Remove intermediate shaft assembly (item 1) from PTO housing. Remove intermediate gear (item 2). Re- move bearing (item 3) from housing if necessary. Figure 116 Figure 117 Workman HD Series...
Page 132 8. Remove PTO input shaft from PTO housing: Moly disulfide A. Shift PTO to ”ON” position. grease B. Remove two (2) retaining rings (items 1 and 2) from PTO housing. C. Slide input shaft assembly (item 3) toward PTO shaft side. D.
Page 133 10.Disassemble PTO intermediate shaft: A. Use a bearing puller to remove bearing (item 1) if necessary. Figure 121 11. Disassemble PTO output shaft: A. Use a bearing puller to remove bearing (item 1). B. Remove gear (item 2) and retaining ring (item 3). C.
Page 134 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 0.039 in. (1.0 mm). Figure 125 4.
Page 135 Assembly (Fig. 114) NOTE: Item numbers in figures are shown in reverse order of assembly; for example, when assembling, install item 1 last. 1. Clean gasket material from mating surfaces of hous- ing and cover. IMPORTANT: Be careful not to damage mating sur- faces when removing gasket material.
Page 136 4. Assemble PTO output shaft: A. If bearing (item 6) was removed, use a press to install bearing onto output shaft. B. Install washer (item 5) and retaining ring (item 4). C. Install retaining ring (item 3) and gear (item 2). D.
Page 137 7. Install PTO input shaft sub--assembly: A. Insert shifter block (item 9) onto pin of shift arm. Apply moly disulfide grease onto both sides of block before installing. B. Put shift collar of PTO input shaft sub--assembly (item 3) on the shifter block. C.
Page 138 8. Install PTO intermediate shaft sub--assembly: A. If removed during disassembly, insert bearing (item 3) into PTO housing. Figure 140 B. Put gear (item 2) on mating gear. C. Move gear until bores of gear and bearing line up. D. Insert intermediate shaft sub--assembly (item 1). Apply grease to intermediate shaft to aid assembly.
Page 139 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. Secure cover with cap screws, nut and lock washers.
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Page 141 Chapter 7 Chassis Table of Contents SPECIFICATIONS ......Brake Master Cylinder ..... . GENERAL INFORMATION .
Page 142: Specifications
Specifications Item Specification Front tire 20” x 9” -- 12, 6 ply Maximum front tire pressure 32 PSI (220 kPa) Front wheel alignment 0 + 0.120 in. (0 + 3 mm) Rear tire 24” x 12” -- 12, 6 ply Maximum rear tire pressure 18 PSI (124 kPa) Wheel nut torque...
Page 143: General Information
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Opera- tor’s Manual for additional information when servicing the vehicle. Tire Pressure 1. Tire pressure should be determined by the payload carried.
Page 144: Special Tools
Special Tools Compression Spring Tool Use to remove and install the two (2) front suspension compression springs. 5” Quantity Item 1/2” x 20” threaded steel rods 1/2” nuts 5” 1/2” flat washers 20” Figure 1 Chassis Page 7 - - 4 Workman HD Series...
Page 145: Troubleshooting
Troubleshooting Suspension and Steering Problem Possible Causes Front end noise. Loose or worn front wheel bearings. Worn front shock absorbers. Worn stabilizer link bushings. Loose steering components (e.g. tie rods, steering cylinder). Worn control arm bushings. Tire pressure low (4WD vehicles). Worn tires (4WD vehicles).
Page 146: Brakes
Suspension and Steering (Continued) Problem Possible Causes Hard steering. Loose, worn or glazed hydraulic pump drive belt (Workman HD vehicles). Binding or damaged steering linkage. Low or uneven tire pressure. Low hydraulic pressure (see Chapter 9 -- Hydraulic System). Damaged or binding steering cylinder. Worn or damaged steering control valve.
Page 147 Brakes (Continued) Problem Possible Causes Brakes pulling. Incorrect tire pressure. Contaminated brake pads. Front end is out of alignment. Bent or damaged brake rotors. Damaged brake hoses. Parking brake caliper or cable is sticking or damaged. Unmatched tires on same axle. Dragging brakes.
Page 148: Service And Repairs
Service and Repairs Wheel Assembly 35 to 40 ft- -lb (48 to 55 N- -m) 35 to 40 ft- -lb (48 to 55 N- -m) 80 to 90 ft- -lb (109 to 122 N- -m) RIGHT FRONT 80 to 90 ft- -lb (109 to 122 N- -m) Figure 2 1.
Page 149 Removal (Fig. 2) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Partially loosen wheel lug nuts that secure wheel to be removed, then jack up and support vehicle (see Jack- ing Vehicle in the Safety Instructions section of Chapter 1 -- Safety).
Page 150: Brake System
Brake System 35 to 40 ft- -lb (48 to 55 N- -m) 35 to 40 ft- -lb (48 to 55 N- -m) 80 to 90 ft- -lb (109 to 122 N- -m) RIGHT 80 to 90 ft- -lb FRONT (109 to 122 N- -m) Figure 4 1.
Page 151 5. On rear axle, remove parking brake assembly from 4. Slide brake caliper onto brake rotor. Make sure that brake rotor: rotor is between brake pads. A. Remove two (2) flange head screws that secure 5. Align caliper with mounting holes. Secure caliper parking brake bracket to rear axle.
Page 152: Brake Caliper Service
Brake Caliper Service Disassembly (Fig. 5) 1. Remove anti--rattle clip from caliper, pins and brake pads. 2. Remove pins from caliper by prying with a flat blade screwdriver through loop in pins. 3. Slide brake pads from caliper. For assembly pur- poses, note orientation of inner and outer pads as the pads are not the same.
Page 153: Parking Brake Caliper Service
Parking Brake Caliper Service Disassembly (Fig. 6) 1. Remove carrier side brake pad and pad support from caliper. 2. Remove cam side brake pad and pad support from caliper. 3. Replace the brake pads if the friction material is worn to less than 0.135”...
Page 154: Bleed Brake System
Bleed Brake System 1. Remove hood to access brake master cylinder (see Hood Removal in this section). Make sure that brake fluid level is correct. Bleeder valve 2. Connect a suitable transparent hose to bleeder valve on left rear wheel caliper and submerge other end of hose in a clean glass container partially filled with clean brake fluid.
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Page 156: Brake Master Cylinder
Brake Master Cylinder RIGHT FRONT Figure 8 1. Brake master cylinder 5. Brake pedal 9. Cotter pin 2. Flange head screw (2 used) 6. Flange bushing 10. Shoulder screw 3. Clevis pin 7. Flange nut 11. Brake shaft 4. Grease fitting 8.
Page 157 Removal (Fig. 8) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Remove hood to access brake master cylinder (see Hood Removal in this section). 3. Remove cotter pin from the clevis pin that connects master cylinder to brake pedal.
Page 158: Brake Master Cylinder Service
Brake Master Cylinder Service Disassembly (Fig. 10) 1. Thoroughly clean outside of master cylinder before disassembly. 2. Remove reservoir and flange seal. Push in on the push rod (item 8) so the stop pin (item 3) can be re- moved. 3.
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Page 160: Parking Brake Cable
Parking Brake Cable RIGHT FRONT Figure 11 1. Parking brake lever handle 7. Bellcrank 13. Socket head screw (3 used) 2. Parking brake lever 8. Cap screw 14. Cable clamp 3. Spacer 9. Hair pin 15. Parking brake cable 4. Curved washer 10.
Page 161 8. Disconnect brake cable from cable equalizer bracket (Fig. 13). 9. Note routing of parking brake cable and location of cable ties used to secure brake cable to vehicle frame. Remove brake cable from vehicle. Installation (Fig. 11) 1. Route new brake cable in same location as before and secure with cable ties.
Page 162: Wheel Hub
Wheel Hub 35 to 40 ft- -lb (48 to 55 N- -m) RIGHT FRONT 170 to 180 ft- -lb (231 to 244 N- -m) 35 to 40 ft- -lb (48 to 55 N- -m) 35 to 40 ft- -lb (48 to 55 N- -m) 35 to 40 ft- -lb 80 to 90 ft- -lb (48 to 55 N- -m)
Page 163 Removal (Fig. 14) Installation (Fig. 14) 1. Park vehicle on a level surface, shut engine off and 1. If front wheel hub is being replaced, install cap screw remove key from ignition switch. (item 22), washers (items 18 and 21) and lock nut (item 20) to new hub.
Page 164: Steering Assembly
Steering Assembly 40 to 50 ft- -lb 80 to 90 ft- -lb (55 to 67 N- -m) (109 to 122 N- -m) 35 to 40 ft- -lb (48 to 55 N- -m) 35 to 40 ft- -lb (48 to 55 N- -m) 35 to 40 ft- -lb RIGHT (48 to 55 N- -m)
Page 165 Disassembly (Fig. 15) 45 to 55 ft- -lb 70 to 80 ft- -lb (61 to 74 N- -m) 1. Park vehicle on a level surface, shut engine off, re- (94 to 109 N- -m) move key from ignition switch and apply parking brake. 2.
Page 166 2. If steering linkage (item 19) and center link (item 20) B. Apply Loctite #271 (or equivalent) to threads of assembly was removed from vehicle: inner tie rod end. Thread tie rod into center link and torque from 70 to 80 ft- -lb (94 to 109 N- -m). A.
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Page 168: Front Control Arms
Front Control Arms 40 to 50 ft- -lb (55 to 67 N- -m) 70 to 80 ft- -lb (94 to 109 N- -m) RIGHT FRONT Figure 18 1. LH upper control arm 6. Flange nut (4 used) 11. Ball joint 2.
Page 169 Removal (Fig. 18) Installation (Fig. 18) 1. Assemble control arm. WARNING A. Press ball joint into control arm and secure with retaining ring. Make sure that grease fitting is in ball joint. FRONT SUSPENSION IS SPRING LOADED! To prevent possible personal injury, use special B.
Page 170: Front Compression Spring Service
Front Compression Spring Service RIGHT FRONT Figure 19 1. Spring cradle (2 used) 5. Stabilizer link 8. LH control arm tower 2. Compression spring (2 used) 6. Lock nut 9. Spring pivot sleeve 3. Flange nut 7. Cap screw 10. RH control arm tower 4.
Page 171 Disassembly (Fig. 19) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Remove seat base to gain access to front suspen- sion assembly (see Seat Base Removal in this section). 3.
Page 172: Front Shock Absorber
Front Shock Absorber Removal (Figs. 22 and 23) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Remove lower and upper lock nuts, then remove shock absorber and washers. Note that washers on up- per end of shock absorber are different.
Page 173: Rear Shock Absorber
Rear Shock Absorber Removal (Fig. 25) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. NOTE: The three (3) flat washers used to retain shock absorber to vehicle are different. Note location of each washer during removal.
Page 174: Rear Leaf Spring
Rear Leaf Spring See tightening RIGHT procedure in text FRONT Figure 26 1. Washer (4 used per plate) 6. Rear axle 11. Spring plate (2 used) 2. Spring mount (LH shown) 7. Axle bumper (2 used) 12. Rubber bushing (6 used per spring) 3.
Page 175 7. Remove two (2) lock nuts (item 14) and flange head NOTE: During leaf spring installation, make sure axle screws (item 4) securing spring mount (item 2) to frame and spring plate are centered on leaf spring knob. rail, then remove leaf spring assembly. 5.
Page 176: Front Wheel Alignment
Front Wheel Alignment 1. Rotate steering wheel to center the pitman arm with the vehicle to ensure correct front wheel alignment mea- surement. FRONT OF VEHICLE 2. With the pitman arm centered, measure center to center distance (at axle height) between the front Center- -to- -center wheels at both front and rear of the wheels (Fig.
Page 177: Steering Wheel
Steering Wheel Removal (Fig. 28) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. RIGHT FRONT 2. Carefully remove steering wheel cover from steering wheel. 20 to 25 ft- -lb 3.
Page 178: Seat Base
Seat Base 12 in- -lb (maximum) (1.3 N- -m) RIGHT FRONT Figure 29 1. LH (operator) seat 9. Flange nut (9 used) 17. Socket head screw 2. RH (passenger) seat 10. U- -clip nut (8 used) 18. Spacer 3. Washer head screw (12 used) 11.
Page 179 Removal (Fig. 29) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and apply the parking brake. Remove key from ignition switch. 2. Remove six (6) carriage screws and flange nuts that secure ROPS cover to ROPS frame. Remove cover from vehicle (Fig.
Page 180: Hood
Hood RIGHT FRONT Figure 31 1. Hood 4. Bumper 7. Operator frame 2. Clip (3 used per headlight) 5. Bumper bracket 8. Hood attachment tab 3. Headlight (2 used) 6. Cover Removal (Fig. 31) Installation (Fig. 31) 1. Park vehicle on a level surface, shut engine off and 1.
Page 181: Electrical Schematics 8
TROUBLESHOOTING ......Thermal Fan Switch (Workman HDX and ELECTRICAL SYSTEM QUICK CHECKS ..
Page 182: Electrical Schematics
The digital multimeter can test electrical components and circuits for current (amps), resistance (ohms) or voltage. Obtain this tool locally. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 183 Aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply battery terminal protector after the battery cable has been secured to the battery terminal. Toro Part Number: 107- -0392 Figure 4 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte.
Page 184: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and com- CAUTION ponents used on this vehicle (see electrical schematics and drawings in Chapter 11 -- Electrical Drawings). Remove all jewelry, especially rings and If the vehicle has any interlock switches by--passed, they watches, before doing any electrical trouble- must be reconnected for proper troubleshooting and...
Page 185 Condition Possible Cause Starter cranks, but should not, with hydraulic lift lever Lift lever interlock switch out of adjustment. out of the neutral position. Lift lever interlock switch faulty. Starter cranks, but should not, with rear PTO (if Rear PTO switch faulty. equipped) engaged.
Page 186: Electrical System Quick Checks
ON and record the multimeter results. Use a digital multimeter and/or inductive Ammeter (AC/ The Workman HDX--D glow plug system should have a DC Current Transducer). Properly connect the ammeter reading of approximately nine (9) amps per glow plug to the digital multimeter (refer to manufacturers’...
Page 187: Verify Interlock System Operation
Verify Interlock System Operation The purpose of the interlock system is to prevent the en- To verify operation of hydraulic lift lever interlock gine from cranking or starting unless the clutch pedal is switch: depressed (all models), the hydraulic lift lever is in the 1.
Page 188: Component Testing
Component Testing This section will define electrical component operation NOTE: Electrical troubleshooting of any 12 volt power and supply test procedures that can be performed on connection can also be performed through voltage drop those components. tests without disconnecting the component. For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION...
Page 189: Gauge Cluster
The fuel level gauge displays the approximate amount of fuel remaining in the fuel tank. Additionally, a red LED The glow light LED on Workman HDX--D vehicles illumi- will illuminate when the fuel tank is low and the LED will nates whenever the engine glow plugs are energized.
Page 190: Fuses
Fourth Row RH: Protects power supply for 4WD differ- ential (vehicles with 4WD). On Workman HDX and HDX--D vehicles, an additional 30 amp fuse is located in a fuse holder near the cooling fan. This fuse protects the power supply for the radiator fan.
Page 191: Headlight Switch
Headlight Switch This headlight switch allows the headlights to be turned on and off and is located on the dash (Fig. 10).. Testing The headlight switch terminals are marked as shown in Figure 11. The circuitry of the headlight switch is shown in the chart below.
Page 192: Clutch Switch
Clutch Switch The clutch switch is a normally open proximity switch that is attached to the frame under the dash (Fig. 13). The switch is in its normal open position as long as the clutch pedal is released (clutch engaged). When the clutch pedal is depressed (clutch disengaged), the pedal is positioned close to the clutch switch causing the switch to close.
Page 193: Hydraulic Lift Lever Interlock Switch
Hydraulic Lift Lever Interlock Switch The lift lever interlock switch is a normally open proximity switch that is attached to the control lever support (Fig. 14). The interlock switch is in its normal open position whenever the hydraulic lift lever is moved away from the neutral position.
Page 194: 3Rd -- High Lockout Key Switch
3rd - - High Lockout Key Switch The 3rd -- High lockout key switch has two positions: SLOW (turtle) and FAST (rabbit). This switch is located on the dash (Fig. 16). Testing The switch terminals are identified as shown in Figure 17.
Page 195: Transaxle Switches
Transaxle Switches 2- -3 Lockout Switch The transaxle 2--3 Lockout switch is located on the top of the transaxle (Fig. 18). The switch is closed in 2nd gear and open in 3rd gear. To test the switch, disconnect the wire harness connec- tor from the switch.
Page 196: Power Relay (Four Terminals)
HDX MODELS near the rear axle (Fig. 19). Besides the main power relay, Workman HDX--D ve- hicles (diesel engine) use an additional power relay to supply electrical power to the glow plugs. The glow plug controller determines when the glow relay is energized.
Page 197: Relay (Five Terminals)
6. Connect multimeter (ohms setting) leads to relay ter- minals 30 and 87A. Apply +12 VDC to terminal 85. The The fan relay on Workman HDX and HDX--D vehicles relay should make and break continuity between termi- causes the engine cooling fan to rotate when the relay nals 30 and 87A as +12 VDC is applied and removed is energized.
Page 198: Diodes
Diodes A diode is used for starting circuit protection from voltage spikes that occur when the starter solenoid is de--ener- gized. If a vehicle is equipped with the optional High Flow Hy- draulics Kit, an additional diode is used for circuit protec- tion from voltage spikes that occur when the Kit hydraulic solenoid is de--energized.
Page 199: Fusible Link
Fusible Link A Workman HD series vehicle uses three (3) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the ve- hicle wire harness (Fig. 24). If any of these links should fail, current to the protected circuit will cease.
Page 200: Fuel Gauge Sender
The fuel gauge sender is located in the fuel tank (Fig. 8. After testing, install sender into fuel tank and secure 26). The fuel gauge sender on Workman HDX vehicles with gasket and fuel sender cap. Secure fuel hoses to fit-...
Page 201: Fuel Pump (Workman Hdx)
6. If fuel pump pressure is low, make sure that electrical power is available to pump and then consider a clogged The electric fuel pump used on Workman HDX vehicles fuel filter or faulty fuel pump (see Fuel Pump in the Ser-...
Page 202: Temperature Sender (Workman Hdx And Hdx--D)
Temperature Sender (Workman HDX and HDX- -D) The temperature sender is threaded into the water pump 7. Install switch to the water pump. housing on the engine (Fig. 30). The resistance of the temperature sender reduces as the engine coolant tem- A.
Page 203 Thermal Fan Switch (Workman HDX and HDX- -D) The thermal fan switch is threaded into the thermostat 7. Install fan switch to the water pump. housing on the engine (Fig. 32). The fan switch is a nor- mally open switch that closes when the engine coolant A.
Page 204: Speed Sensor (Workman Hdx And Hdx--D)
Speed Sensor (Workman HDX and HDX- -D) The speed sensor is attached to the upper transaxle cover (Fig. 34). It uses a magnetically based, Hall Effect integrated circuit. As the differential in the transaxle turns, the sensor accurately senses the movement of the differential ring gear teeth passing by the sensor.
Page 205: Glow Plug Timer (Workman Hdx--D)
Glow Plug Timer (Workman HDX- -D) The glow plug timer is attached to the relay bracket un- der the right side of the bed near the rear axle (Fig. 36). NOTE: Refer to electrical schematic and circuit draw- ings in Chapter 11 -- Electrical Drawings when trouble- shooting the glow plug timer.
Page 206: Delay Timer (Vehicles With 4Wd)
Delay Timer (Vehicles with 4WD) To delay the re--engagement of the 4WD differential clutch when shifting, the 4WD engage circuit includes a one second delay timer. On some early production ve- hicles, the delay timer is located near the differential electrical connector.
Page 207: Hydraulic Solenoid Valve Coil
Hydraulic Solenoid Valve Coil (Vehicles with High Flow Hydraulics Kit) Vehicles equipped with the High Flow Hydraulics Kit use a hydraulic solenoid valve coil for system control (Fig. 41). When the solenoid coil is energized, hydraulic valve RIGHT shift occurs to provide hydraulic flow for the attachment. FRONT Testing of the coil can be done with the coil installed on the hydraulic manifold valve.
Page 208: Rear Pto Switch (Optional Kit)
Rear PTO Switch (Optional Kit) On vehicles equipped with the optional rear PTO kit, the rear PTO switch is located in the rear PTO housing mounted on the top of the transaxle. The Rear PTO switch is normally closed and opens when the PTO is en- gaged.
Page 209: Service And Repairs
A. Clean battery by washing entire case with a solu- tion of baking soda and water. Rinse with clear water. B. Coat battery posts and cable connectors with Bat- tery Terminal Protector (Toro Part No. 107--0392) or petroleum jelly to prevent corrosion. Workman HD Series...
Page 210: Battery Service
6. Coat battery posts and cable connectors with Battery Terminal Protector (Toro Part No. 107--0392) or petro- leum jelly to prevent corrosion. 7. Make sure that battery retainer secures battery in place.
Page 211: Battery Testing
Battery Testing C. Make sure battery terminals are free of corrosion. 1. If battery filler caps are removable, conduct a D. If battery filler caps are removable, measure the hydrometer test of the battery electrolyte. temperature of the center cell. IMPORTANT: Make sure the area around the cells is E.
Page 212: Battery Charging
Battery Charging Battery Battery Charge Level Reserve (Percent of Fully Charged) To minimize possible damage to the battery and to allow Capacity Capacity the battery to be fully charged, the slow charging method (Minutes) is presented here. This charging method can be accom- 80 or 3.8 hrs 7.5 hrs...
Page 213: Headlights
Headlights 3. Install hood (see Hood Installation in the Service and Repairs section of Chapter 7 -- Chassis). Make sure to CAUTION connect the wire harness connector to the headlight dur- ing hood installation. The Workman headlights use a halogen bulb that becomes extremely hot when in operation.
Page 214: Tail Lamps
Tail Lamps Disassemble and assemble tail lamp using Fig. 46 as a guide. Figure 46 1. Screw (2 used) 3. Bulb 2. Lens 4. Gasket Electrical System Page 8 - - 34 Workman HD Series...
Page 215: General Information 9
... . Hydraulic Hose and Tube Installation ..Gear Pump (Workman HDX and HDX--D) ..Hydraulic Fitting Installation .
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Page 217: Specifications
Specifications Item Description Hydraulic Pump (Workman HDX and HDX--D) Casappa positive displacement gear type pump Displacement (per revolution) 0.325 in (5.3 cc) Hydraulic Pump (Workman HD) Casappa positive displacement gear type pump Displacement (per revolution) 0.378 in (6.2 cc) System Relief Pressure...
Page 218: General Information
Installation in this section). If the hose has an elbow at one end, tighten the swivel nut on that end before tight- ening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).
Page 219: Hydraulic Hose And Tube Installation
Hydraulic Hose and Tube Installation (O- -Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ C. Use a second wrench to tighten the nut to the cor- tube and the fitting are free of burrs, nicks, scratches or rect Flats From Wrench Resistance (F.F.W.R.).
Page 220 Hydraulic Fitting Installation (SAE Straight Thread O- -Ring Fitting into Component Port) Non- -Adjustable Fitting (Fig. 4) 5. If a torque wrench is not available, or if space at the port prevents use of a torque wrench, an alternate meth- 1.
Page 221 Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. As a preventative measure against leakage, it is rec- ommended that the O--ring be replaced any time the connection is opened.
Page 222: Hydraulic Schematics
Hydraulic Schematics Vehicle Hydraulic Schematic Hydraulic System Page 9 - - 8 Workman HD Series...
Page 223: High Flow Hydraulics Kit (If Equipped) Schematic
High Flow Hydraulics Kit (If Equipped) Schematic Workman HD Series Page 9 - - 9 Hydraulic System...
Page 224: Hydraulic Circuit Operation
Hydraulic Circuit Operation Steering Circuit The hydraulic gear pump supplies flow for the steering Fluid leaving the steering cylinder flows back through circuit and for raising and lowering the bed. Pump output the spool valve, then out the T port and returns to the hy- flows to the steering control valve before reaching the lift draulic reservoir (transaxle).
Page 225: Raise And Lower Bed
Raise and Lower Bed The hydraulic gear pump supplies flow for the steering When the control valve lever is released, spring action circuit and for raising and lowering the bed. Pump output returns the lift valve spool to the center position and lift flows through the steering control valve and then to the cylinder movement is stopped.
Page 226: High Flow Hydraulic Circuit
High Flow Hydraulic Circuit On Workman HDX and HDX--D vehicles that are High Flow Circuit ON (Fig. 10) equipped with the high flow hydraulics kit, a second gear When the rocker switch is in the ON position, the man- pump is directly coupled to the standard gear pump. This ifold solenoid operated relief valve (SVRV) is energized.
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Page 228: Special Tools
Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 229: Hydraulic Test Fitting Kit
It is recommended that O--rings be replaced whenever a hydraulic connec- tion is loosened. Toro Part Number: 16- -3799 Figure 14 Male Coupler (For High Flow Hydraulics Kit) Male coupler that fits into the High Flow Hydraulics Kit female coupler.
Page 230: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic system ued use of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equip- could lead to extensive internal component damage. ment and a thorough understanding of the complete hy- The charts that follow contain information to assist in draulic system.
Page 231 Problem Possible Cause Bed does not lift or lifts very slowly. Excessive load in bed. Oil level in transaxle is low. Engine RPM is low. Incorrect oil in system (see oil recommendations in Operator’s Manual). Lift cylinder pivots or bed pivots are binding or damaged. Hydraulic pump drive belt is loose (Workman HD vehicles).
Page 232 Problem Possible Cause Difficulty in connecting or discon- Hydraulic pressure is not relieved (coupler under pressure -- engine necting quick couplers. running). Hydraulic lift valve is not in neutral (centered) position. Hydraulic attachment does not func- Quick couplers are not fully engaged. tion.
Page 233: Testing
Testing The most effective method for isolating problems in the 1. Thoroughly clean the vehicle before disconnecting or hydraulic system is by using hydraulic test equipment disassembling any hydraulic components. Always keep such as pressure gauges and flow meters in the circuits in mind the need for cleanliness when working on hy- during various operational checks (see Special Tools draulic equipment.
Page 234: Gear Pump Flow And System Relief Pressure
Gear Pump Flow and System Relief Pressure (Workman HDX and HDX- -D) STEERING CONTROL TESTER VALVE LIFT CYLINDERS Figure 16 NOTE: This test procedure is for the single gear pump WORKMAN HDX and HDX- -D used on Workman HDX and HDX--D vehicles. If vehicle...
Page 235 Procedure for Gear Pump Flow and System Relief 7. While watching tester pressure gauges, slowly close Pressure Test (Workman HDX and HDX- -D) flow control valve on the tester until 1500 PSI (103 bar) is obtained on gauge. Verify that engine speed contin- 1.
Page 236 Gear Pump Flow and System Relief Pressure (Workman HD) STEERING CONTROL TESTER VALVE LIFT CYLINDERS Figure 18 NOTE: This test procedure is for the belt driven gear FRONT WORKMAN HD pump used on Workman HD vehicles. GEAR PUMP Figure 19 1.
Page 237 Procedure for Gear Pump Flow and System Relief 8. While watching tester pressure gauges, slowly close Pressure Test (Workman HD) flow control valve on the tester until 1500 PSI (103 bar) is obtained on gauge. Verify that pump speed continues 1.
Page 238 Steering Control Valve and Steering Cylinder (ROTATED FOR RIGHT TURN) PLUG STEERING CYLINDER STEERING CONTROL VALVE LIFT CYLINDERS Figure 20 Hydraulic System Page 9 - - 24 Workman HD Series...
Page 239 Procedure for Steering Control Valve and Steering WARNING Cylinder Test 1. Make sure hydraulic oil is at normal operating tem- perature by operating the vehicle for approximately ten Keep body and hands away from disconnected (10) minutes. hoses and fittings that might eject hydraulic fluid under high pressure.
Page 240 Lift Cylinder Internal Leakage STEERING CYLINDER STEERING CONTROL VALVE (IN LOWER POSITION) LIFT CYLINDERS PLUG Figure 21 Hydraulic System Page 9 - - 26 Workman HD Series...
Page 241 Procedure for Lift Cylinder Internal Leakage Test Disconnect and plug this hose 1. Shut off engine and engage parking brake. ANY oil flow or droplets from this fitting indicates internal leak CAUTION Prevent personal injury and/or damage to equip- ment. Read all WARNINGS, CAUTIONS and Pre- cautions for Hydraulic Testing at the beginning of this section.
Page 242 Figure 23 NOTE: This test procedure is for the rear gear pump section on Workman HDX and HDX--D vehicles that are equipped with the High Flow Hydraulics Kit. For testing the front pump section on vehicles with this kit, refer to the Gear Pump Flow and System Relief Pressure (Work- man HDX and HDX--D) Test.
Page 243 Procedure for High Flow Hydraulics Kit (If 7. With High Flow Kit switch still in the ON position, Equipped) Gear Pump Flow and System Relief Pres- watch tester pressure gauges while slowly closing flow sure Test control valve on the tester until 1500 PSI (103.4 bar) is obtained on gauge.
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Page 245: Service And Repairs
Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components After Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- 1. Check oil level in the transaxle and add correct oil if tem, park vehicle on a level surface, engage parking necessary.
Page 246 Gear Pump (Workman HDX and HDX- -D) 25 to 30 ft- -lb (33 to 40 N- -m) RIGHT LOCTITE #242 FRONT 25 to 30 ft- -lb (33 to 40 N- -m) LOCTITE #242 HIGH FLOW GEAR PUMP 25 to 30 ft- -lb...
Page 247 Removal (Fig. 25) Installation (Fig. 25) 1. Park vehicle on a level surface, raise and support bed 1. If fittings were removed from gear pump, lubricate (if installed), shut engine off and engage parking brake. and place new O--rings onto fittings. Install fittings into Remove key from the ignition switch.
Page 248 Gear Pump (Workman HD) Removal (Fig. 26) 3. After installing the pump and connecting hydraulic hoses, install belt and adjust belt tension (see Opera- 1. Park vehicle on a level surface, raise and support bed tor’s Manual). (if installed), shut engine off and engage the parking brake.
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Page 250 16. Lock washer (4 used) NOTE: If vehicle is equipped with High Flow Hydraulics NOTE: The Workman HDX and HDX--D gear pump in- Kit, refer to High Flow Hydraulics Kit Gear Pump Service cludes a rear flange that will allow the installation of a later in this section.
Page 251 Disassembly (Fig. 28) 1. Plug pump ports and clean the outside of the pump MARKER LINE thoroughly. After cleaning, remove plugs and drain 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.
Page 252 Assembly (Fig. 28) NOTE: When assembling the pump, check the marker line on each part to make sure the pump components are properly aligned during assembly (Fig. 29). 1. Lubricate O--rings, pressure seals, back--up seals and thrust plate grooves with a thin coat of petroleum jel- ly.
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Page 254 Gear Pump Service (Vehicles with High Flow Hydraulics Kit) 220 in- -lb HIGH FLOW HYDRAULICS KIT GEAR PUMP (25 N- -m) 220 in- -lb (25 N- -m) Figure 31 1. Retaining ring 12. Thrust plate 22. Washer (4 used) 2. Shaft seal 13.
Page 255 The gear pump assembly used on Workman HDX and HDX--D vehicle equipped with the High Flow Hydraulics Kit is shown in Figure 31. When servicing this gear RIGHT pump, follow the procedure for Gear Pump Service in FRONT this section and the following: 1.
Page 256: Lift Valve
Lift Valve RIGHT FRONT Figure 33 1. Lift valve 8. Lift lever 15. Hyd. tube (to female quick fitting) 2. O- -ring 9. Clevis pin 16. 90 hydraulic fitting 3. Tee fitting 10. Hairpin 17. O- -ring 4. Hyd. tube (steering circuit return) 11.
Page 257 Removal (Fig. 33) 2. Install lift valve to vehicle using Figure 33 as a guide. 1. Park vehicle on a level surface, raise and support bed 3. Replace O--rings on hydraulic hoses and fittings. Re- (if installed), shut engine off and engage the parking move caps and plugs from hoses and fittings.
Page 258: Lift Valve Service
Lift Valve Service Disassembly (Fig. 35) 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.
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Page 260 Steering Control Valve 20 to 25 ft- -lb (28 to 33 N- -m) RIGHT FRONT Antiseize Lubricant Figure 36 1. Lock nut 8. Hyd hose (to control valve R port) 15. Bulkhead fitting (to valve R port) 2. Flat washer 9.
Page 261 CAUTION 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 FRONT OF VEHICLE ignition switch, rotate the steering wheel in both directions, lower or support the bed and operate other hydraulic accessories.
Page 262: Sauer/Danfoss Steering Unit Type Ospm Service Manual
Steering Control Valve Service 20 to 24 ft- -lb (27 to 33 N- -m) Figure 39 1. Sleeve 9. Dust seal ring 16. Outer gearwheel 2. Cross pin 10. Housing 17. End cover 3. Ring 11. Cardan shaft 18. O- -ring (5 used) 4.
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Page 264: Steering Cylinder
Steering Cylinder 40 to 50 ft- -lb 80 to 90 ft- -lb (55 to 67 N- -m) (109 to 122 N- -m) 35 to 40 ft- -lb (48 to 55 N- -m) 35 to 40 ft- -lb (48 to 55 N- -m) 35 to 40 ft- -lb RIGHT (48 to 55 N- -m)
Page 265 Removal (Fig. 40) 3. Remove caps and plugs from hoses and fittings. Install new O--rings on hydraulic fittings. Connect hy- 1. Park vehicle on a level surface, shut engine off and draulic hoses to steering cylinder (see Hydraulic Hose engage the parking brake. Remove key from the ignition and Tube Installation in the General Information section switch.
Page 266: Steering Cylinder Service
Steering Cylinder Service Figure 42 1. Rear shaft 6. Rear head 11. Dust seal 2. Wear ring 7. O- -ring 12. Barrel 3. Seal 8. Back- -up ring 13. Front shaft 4. O- -ring 9. Retaining ring 14. Roll pin 5.
Page 267 Inspection 4. Slide front shaft onto rear shaft and align roll pin holes in shafts. Install new roll pin to secure shafts. 1. Wash all cylinder parts in clean solvent. Dry parts with compressed air. Do not wipe parts dry with paper IMPORTANT: Prevent damage when clamping the towels or cloth.
Page 268: Lift Cylinder
Lift Cylinder RIGHT FRONT Figure 43 1. Bed frame 5. Hydraulic hose 9. Engine support 2. O- -ring 6. Lift cylinder (LH shown) 10. Frame rail (LH shown) 3. 90 hydraulic fitting 7. Hydraulic hose 11. Clevis pin 4. O- -ring 8.
Page 269 Removal (Fig. 43) Installation (Fig. 43) 1. Park vehicle on a level surface, lower bed until clevis 1. If fittings were removed from lift cylinder, lubricate pins that secure lift cylinder to bed are loose in the bed and place new O--rings onto fittings. Install fittings into slots.
Page 270: Lift Cylinder Service
Lift Cylinder Service 60 to 75 ft- -lb (81 to 102 N- -m) Figure 44 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.
Page 271 Assembly (Fig. 44) 4. Lubricate head and piston with clean Dexron III ATF. Slide shaft assembly carefully into cylinder barrel. 1. Make sure all parts are clean before assembly. IMPORTANT: Prevent damage when clamping the 2. Coat new O--rings, piston seal, wear ring, shaft seal, cylinder’s barrel into a vise;...
Page 272 Hydraulic Manifold (High Flow Hydraulics Kit) Removal (Fig. 45) 1. Park vehicle on a level surface, raise and support bed RIGHT (if installed), shut engine off and engage the parking FRONT brake. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of the Service and Repairs section of this chapter.
Page 273 5. Visually inspect cartridge valve for damaged sealing Installation (Fig. 45) surfaces and contamination. 1. If fittings were removed from manifold, lubricate and A. Contamination may cause valves to stick or hang place new O--rings onto fittings. Install fittings into man- up.
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Page 275 Front Differential Assembly ....HILLIARD FRONT DRIVE DIFFERENTIAL PARTS and SERVICE MANUAL Rev. A Workman HDX/HDX--D Page 10 - - 1 Front Wheel Drive (4WD)
Page 276: Specifications
Specifications Item Description Differential Oil Capacity 8.5 fl oz (250 ml) Differential Oil Type Mobil 424 Hydraulic Oil Front Wheel Drive (4WD) Page 10 - - 2 Workman HDX/HDX--D...
Page 277: General Information
The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Opera- tor’s Manual for additional information when servicing the vehicle. Workman HDX/HDX--D Page 10 - - 3 Front Wheel Drive (4WD)
Page 278: Service And Repairs
(see Brake System Disas- sembly in the Service and Repairs section of Chapter 7 5. Remove axle spacer (item 10) from CV axle. -- Chassis). Front Wheel Drive (4WD) Page 10 - - 4 Workman HDX/HDX--D...
Page 279 Torque wheel lug nuts from 80 to 90 ft- -lb (109 to 122 N- -m). 9. Make sure that wheel lug nuts are properly tight- ened. Workman HDX/HDX--D Page 10 - - 5 Front Wheel Drive (4WD)
Page 280 4. Accelerate vehicle at an angle over a ramp or up a hill. A clunking noise indicates a worn inboard CV axle joint. 5. If any CV axle components are worn or damaged, the CV axle assembly must be replaced. Front Wheel Drive (4WD) Page 10 - - 6 Workman HDX/HDX--D...
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Page 282: Differential Driveshaft
ANTISEIZE LUBRICANT ANTISEIZE LUBRICANT Figure 4 1. Transaxle 4. Driveshaft 6. CV axle assembly 2. Cap screw 5. Differential assembly 7. Flange head screw (4 used) 3. Flat washer Front Wheel Drive (4WD) Page 10 - - 8 Workman HDX/HDX--D...
Page 283 4. Secure driveshaft yokes with cap screw and flat Figure 6 washer. 1. Driveshaft slip yoke 2. Transaxle shaft 5. Lubricate differential driveshaft grease fittings. Workman HDX/HDX--D Page 10 - - 9 Front Wheel Drive (4WD)
Page 284: Driveshaft Cross And Bearing Service
E. Thoroughly clean and inspect all components. binding. 3. Install driveshaft to vehicle (see Differential Drive- shaft Installation in this section). Front Wheel Drive (4WD) Page 10 - - 10 Workman HDX/HDX--D...
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Page 286: Front Differential
14. Slotted hex nut 4. Flange head screw (4 used) 10. Axle spacer 15. Cotter pin 5. Driveshaft 11. Flange head screw 16. Knuckle (LH shown) 6. Cap screw Front Wheel Drive (4WD) Page 10 - - 12 Workman HDX/HDX--D...
Page 287 IMPORTANT: Make sure to not damage brake lines, electrical harness, control cables or other parts while installing the differential to the vehicle. 1. Position differential to the vehicle frame. Workman HDX/HDX--D Page 10 - - 13 Front Wheel Drive (4WD)
Page 288: Front Differential Service
35. Internal retaining ring 11. Plug clip 24. Oil seal (2 used) 36. Thrust bearing 12. Coil 25. Female output hub 37. O- -ring 13. Torsion spring Rev. A Front Wheel Drive (4WD) Page 10 - - 14 Workman HDX/HDX--D...
Page 289: Front Differential Disassembly
(Fig. 13). If the bushing is excessively worn, the gear case must be replaced. The bushing is not serviced sep- arately. Figure 13 1. Pinion bushing 2. Gear case Rev. A Workman HDX/HDX--D Page 10 - - 15 Front Wheel Drive (4WD)
Page 290 8. Lift the roller cage assembly from the center of the ring gear (Fig. 16). Note: the rollers are loose in the cage and may fall out when removed. Figure 16 1. Roller cage assembly 2. Roller Rev. A Front Wheel Drive (4WD) Page 10 - - 16 Workman HDX/HDX--D...
Page 291 Take care to not damage the oil seal in the gear case during hub removal. Figure 19 1. Drift 3. Oil seal 2. Gear case Rev. A Workman HDX/HDX--D Page 10 - - 17 Front Wheel Drive (4WD)
Page 292 1. Male output hub 2. Armature plate NOTE: For additional front differential information, see the Hilliard Front Drive Differential Parts and Service Manual at the end of this chapter. Rev. A Front Wheel Drive (4WD) Page 10 - - 18 Workman HDX/HDX--D...
Page 293: Front Differential Assembly
(Fig. 25). Make sure that retaining ring is fully seated into groove in cover plate. Figure 25 1. Male output hub 2. Gear spacer Rev. A Workman HDX/HDX--D Page 10 - - 19 Front Wheel Drive (4WD)
Page 294 Place the rollers in the roller cage slots and press them out toward the ring gear bore. Figure 28 1. Roller cage assembly 3. Torsion spring 2. Ring gear notch Rev. A Front Wheel Drive (4WD) Page 10 - - 20 Workman HDX/HDX--D...
Page 295 This proper backlash should be achieved after the set screw has been turned counter--clock- wise from 1/4 to 1/2 of a turn. Figure 31 1. Cover plate 2. Set screw Rev. A Workman HDX/HDX--D Page 10 - - 21 Front Wheel Drive (4WD)
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Page 297 ......Rear Wire Harness Drawing: Workman HD ..Rear Wire Harness Drawing: Workman HDX . . . Rear Wire Harness Drawing: Workman HDX--D...
Page 298 This page is intentionally blank. Electrical Drawings Page 11 - - 2 Workman HD Series...
Page 299 3rd - - HIGH LOCKOUT SWITCH (SLOW) (OPTIONAL KIT) LIFT LEVER (OPTIONAL KIT) (OPTIONAL KIT) INTERLOCK SWITCH MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) LEFT FRONT ELECTRIC TURN/RUNNING BRAKE KIT LIGHT (OPTIONAL KIT) (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) TURN SIGNAL FLASHER...
Page 300 TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) HAZARD FLASHER (OPTIONAL KIT) (OPTIONAL KIT) Workman HDX Briggs/Daihatsu Gasoline Engine Vehicle Electrical Schematic All relays and solenoids are shown as de- - energized. Page 11 - - 4...
Page 301 TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) HAZARD FLASHER Workman HDX--D (OPTIONAL KIT) (OPTIONAL KIT) Briggs/Daihatsu Diesel Engine Vehicle Electrical Schematic All relays and solenoids are shown as de- - energized. Page 11 - - 5...
Page 302 3rd - - HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER (OPTIONAL KIT) INTERLOCK SWITCH (LIFT LEVER IN NEUTRAL) (OPTIONAL KIT) (OPTIONAL KIT) MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) LEFT FRONT ELECTRIC TURN/RUNNING BRAKE KIT LIGHT (OPTIONAL KIT) (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT)
Page 303 3rd - - HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER (OPTIONAL KIT) INTERLOCK SWITCH (LIFT LEVER IN NEUTRAL) (OPTIONAL KIT) (OPTIONAL KIT) MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) LEFT FRONT ELECTRIC TURN/RUNNING BRAKE KIT LIGHT (OPTIONAL KIT) (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT)
Page 304 TURN/RUNNING (OPTIONAL KIT) LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL Workman HDX FLASHER (OPTIONAL KIT) Start Circuits HAZARD FLASHER Ignition Switch in START Position (OPTIONAL KIT) (OPTIONAL KIT) Transmission in Neutral Clutch Pedal Depressed...
Page 305 LIGHT (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) Workman HDX HAZARD FLASHER Run Circuits (OPTIONAL KIT) (OPTIONAL KIT) Ignition Switch in RUN Position Transmission in Neutral Power Current Control Current Indication Current...
Page 306 (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) Workman HDX--D HAZARD Glow Plug Circuits FLASHER (OPTIONAL KIT) Ignition Switch in RUN Position (OPTIONAL KIT) Transmission in Neutral Power Current Control Current Indication Current...
Page 307 BRAKE KIT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN Workman HDX--D SIGNAL FLASHER Start Circuits (OPTIONAL KIT) Ignition Switch in START Position HAZARD FLASHER (OPTIONAL KIT) Transmission in Neutral (OPTIONAL KIT) Clutch Pedal Depressed...
Page 308 (OPTIONAL KIT) (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT) Workman HDX--D HAZARD Run Circuits FLASHER (OPTIONAL KIT) Ignition Switch in RUN Position (OPTIONAL KIT) Transmission in Neutral Power Current Control Current Indication Current...
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Page 310 3RD HIGH LOCKOUT SWITCH Workman HD Series (All Models) Front Wire Harness Drawing Page 11 - - 14...
Page 311 3RD- -HIGH LOCKOUT SWITCH ORANGE PINK RED/BLACK YELLOW ORANGE WHITE BLUE GREEN VIOLET GREEN BLUE YELLOW ORANGE YELLOW BLUE PINK GRAY BLACK YELLOW GRAY RED/BLACK BROWN GREEN ORANGE WHITE/BLACK BLACK PINK YELLOW WHITE/BLACK BLACK BLACK BLACK GREEN GREEN GREEN ORANGE ORANGE BLACK GREEN...
Page 312 LIFT LEVER INTERLOCK SWITCH Workman HD Kohler Gasoline Engine Rear Wire Harness Drawing Page 11 - - 16...
Page 313 LIFT LEVER INTERLOCK SWITCH 3RD--HIGH LOCKOUT ORANGE WHITE GREEN ORANGE BLUE GRAY RED/BLACK BROWN GREEN BLACK ORANGE WHITE/BLACK BLACK BLACK YELLOW BLACK ORANGE BLACK WHITE BLACK ORANGE BLACK Workman HD Kohler Gasoline Engine Rear Wire Harness Diagram Page 11 - - 17...
Page 314 A SMALL WIRE HARNESS IS CONNECTED TO THE P20 HARNESS CONNECTOR FOR THE DELAY TIMER AND DIFFERENTIAL DELAY RELAY. THIS WIRE HARNESS IS DEPICTED BELOW. TO HARNESS P20 CONNECTOR Workman HDX Briggs/Daihatsu Gasoline Engine Rear Wire Harness Drawing Page 11 - - 18...
Page 315 YELLOW GRAY ORANGE RED/BLACK BROWN GREEN BLACK ORANGE WHITE/BLACK BLACK BLACK YELLOW BLACK BLACK BLACK BLACK YELLOW BLUE YELLOW BLUE ORANGE BLACK GREEN GREEN ORANGE BLACK Workman HDX Briggs/Daihatsu Gasoline Engine Rear Wire Harness Diagram Page 11 - - 19...
Page 316 A SMALL WIRE HARNESS IS CONNECTED TO THE P20 HARNESS CONNECTOR FOR THE DELAY TIMER AND DIFFERENTIAL DELAY RELAY. THIS WIRE HARNESS IS DEPICTED BELOW. TO HARNESS P20 CONNECTOR Workman HDX--D Briggs/Daihatsu Diesel Engine Rear Wire Harness Drawing Page 11 - - 20...
Page 317 RED/BLACK BROWN GREEN BLACK ORANGE WHITE/BLACK BLACK BLACK BLACK YELLOW BLACK BLACK PINK GRAY VIOLET BLACK YELLOW BLUE YELLOW PINK ORANGE YELLOW VIOLET BLUE ORANGE GREEN Workman HDX--D Briggs/Daihatsu Diesel Engine Rear Wire Harness Diagram Page 11 - - 21...

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Workman hd Workman hdx--d

Toro Workman HDX Service Manual

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Chapter 1 -- Safety

Chapter 2 -- Product Records and Maintenance

Chapter 3 Briggs/Daihatsu Gasoline Engine

Chapter 4 Briggs/Daihatsu Diesel Engine

Chapter 5 -- Kohler Gasoline Engine

Chapter 6 -- Drive Train

Chapter 6 Drive Train

Chapter 7 -- Chassis

Chapter 7 Chassis

Chapter 8 Electrical System

Chapter 9 Hydraulic System

Chapter 10 Front Wheel Drive (4Wd)

Quick Links

Chapters

Troubleshooting

Related Manuals for Toro Workman HDX

Summary of Contents for Toro Workman HDX