WorkmanR 3000/4000 Series

WorkmanR 3000/4000 Series
PART NO. 03126SL (Rev.D)
Service Manual
(Serial No. 240000001 and Above)
WorkmanR 3000/4000 Series
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 OPERATING,
MAINTENANCE
AND
ADJUSTMENT
INSTRUCTIONS. Space is provided in Chapter 2 of this
book to insert the Operator’s Manuals and Parts Catalogs 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.
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. 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 repair of the machine.
IMPORTANT: The IMPORTANT notice will give important instructions which must be followed to prevent damage to systems or components on the
machine.
E The Toro Company -- 2003, 2004, 2006, 2007, 2011
This page is intentionally blank.
Workman 3000/4000 Series
General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 6
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 6 -- 10
Chapter 2 -- Product Records and Maintenance
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
2
-----
1
2
3
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 & 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 6
BRIGGS & STRATTON/DAIHATSU REPAIR MANUAL
FOR 3--CYLINDER, LIQUID--COOLED, DIESEL EN-
GINES
Chapter 5 -- Kohler Gasoline Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . .
7
7
7
7
-----
2
3
4
8
Chapter 8 -- Electrical System
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . 8 -- 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 3
Electrical System Quick Checks . . . . . . . . . . . . . . 8 -- 5
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 7
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 8 -- 17
Chapter 9 -- Hydraulic System
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 3
General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 4
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 9 -- 6
Hydraulic Circuit Operation . . . . . . . . . . . . . . . . . . 9 -- 8
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 10
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 12
Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 15
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 9 -- 25
SAUER/DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Hydraulic
System
Electrical
System
Chassis
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3
KOHLER ENGINE SERVICE MANUAL
Chapter 7 -- Chassis
Briggs/Daihatsu
Diesel Engine
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2
Kohler
Gasoline Engine
Chapter 6 -- Drive Train
Drive Train
Chapter 1 -- Safety
Briggs/Daihatsu Product Records
Gasoline Engine and Maintenance
Safety
Table Of Contents
Workman 3000/4000 Series
This page is intentionally blank.
Workman 3000/4000 Series
Chapter 10 -- Front Wheel Drive (4WD)
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . 10 -- 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 10 -- 4
Chapter 11 -- Electrical Schematics
Vehicle Electrical Schematics . . . . . . . . . . . . . . . 11 -- 3
Wire Harness Drawings . . . . . . . . . . . . . . . . . . . 11 -- 10
Workman 3000/4000 Series
Rev. C
Electrical
Schematics
Front Wheel
Drive (4WD)
Table Of Contents
This page is intentionally blank.
Workman 3000/4000 Series
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . .
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance and Service . . . . . . . . . . . . . . . . . . . .
Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Using Bed Safety Support . . . . . . . . . . . . . . . . . . . .
Workman 3000/4000 Series
2
2
3
4
5
6
Page 1 – 1
Safety
Safety
Chapter 1
Safety Instructions
The Workman 3000/4000 series vehicles are designed
and tested to offer safe service when operated and
maintained properly. Although hazard control and accident prevention are partially dependent upon the design
and configuration of the vehicle, these factors are also
dependent upon the awareness, concern, and proper
training of the personnel involved in the operation, transport, maintenance, and storage of the vehicle. Improper
use or maintenance of the vehicle can result in injury or
death. To reduce the potential for injury or death, comply
with the following safety instructions.
WARNING
To reduce the potential for injury or death, comply with the following safety instructions.
Before Operating
1. Read and understand the contents of the Operator’s
Manual and Operator’s Video before starting and operating the vehicle. Become familiar with the controls and
know how to stop the vehicle and engine quickly. A replacement Operator’s Manual is available on the Internet at www.Toro.com.
4. Since fuel used in Workman vehicles is highly flammable, handle it carefully:
2. Keep all shields, safety devices, and decals in place.
If a shield, safety device, or decal is defective, illegible
or damaged, repair or replace it before operating the vehicle. Also tighten any loose nuts, bolts or screws to ensure vehicle is in safe operating condition.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless clutch pedal is depressed. 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
Page 1 -- 2
A. Store fuel in containers specifically designed for
this purpose.
B. 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.
Rev. D
Workman 3000/4000 Series
1. Sit on the seat when starting and operating the vehicle.
4. Do not touch engine, radiator, muffler or exhaust pipe
while engine is running or soon after it is stopped. These
areas could be hot enough 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.
B. Disengage PTO (if so equipped) and return hand
throttle lever to OFF position (if so equipped).
A. Stop movement of the vehicle.
B. Lower bed.
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. Move shift lever to NEUTRAL and depress clutch
pedal. Keep foot off accelerator pedal.
D. Set parking brake and remove key from ignition
switch.
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 adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
Workman 3000/4000 Series
Page 1 – 3
Safety
Safety
While Operating
Maintenance and Service
1. Before servicing or making adjustments, turn all accessories 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 heater 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 leaks in hydraulic 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 doctor familiar with this form of injury or gangrene may result.
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 lever 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 desired, 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.
11. Shut engine off before checking or adding oil to the
engine crankcase.
12.Disconnect battery before servicing the vehicle. Disconnect negative (–) battery cable first and positive (+)
cable last. If battery voltage is required for troubleshooting 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 accessories made by other manufacturers may result in nonconformance with safety standards, and the warranty
may be voided.
16.When raising the vehicle to change tires or to perform 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 supported by blocks or jack stands, the vehicle may move
or fall, which may result in personal injury (see Jacking
Instructions in Operator’s Manual).
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 bystanders away.
10.Do not overspeed the engine by changing governor
setting. To assure safety and accuracy, check maximum
engine speed.
Safety
Page 1 – 4
Workman 3000/4000 Series
Safety
Jacking Vehicle
WARNING
When changing attachments, tires or performing other service, use the correct blocks, hoists
and jacks. Always chock or block the wheels
and use jack stands or solid wood blocks to
support the vehicle. If the vehicle is not properly
supported by blocks or jack stands, the vehicle
may move or fall resulting in personal injury.
1
Figure 1
1. Do not start engine while vehicle is on jack, because
engine vibration or wheel movement could cause vehicle to slip off jack.
1. Front jacking point
2. Do not work under vehicle without jack stands supporting it. The vehicle could slip off jack, injuring any one
beneath it.
3. The jacking point at the front of the vehicle is under
the front center frame support and at the rear it is under
the axle tube.
4. When jacking up front of vehicle, always place a
wood block (or similar material) between jack and vehicle frame support.
Workman 3000/4000 Series
Page 1 -- 5
1
1
Figure 2
1. Rear jacking point
Safety
Using Bed Safety Support
Many of the procedures shown in this manual require raising and lowering the bed. The following
precautions must be taken or serious injury or
death could result.
1
WARNING
Before servicing or making adjustments to the
vehicle, stop engine, set parking brake and remove key from ignition switch. Any load material must be removed from bed or other attachment before working under raised bed. Never
work under a raised bed without positioning
bed safety support on a fully installed cylinder
rod.
3
2
After work is completed, remove bed safety support, insert into storage brackets on back of ROPS
panel and lower bed.
Figure 3
1. Bed safety support
2. Cylinder barrel
1. Raise bed until lift cylinders are fully extended.
3. Bed
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 cylinder: cylinder and bed damage may occur.
Safety
Page 1 – 6
Workman 3000/4000 Series
Chapter 2
Product Records
and Maintenance
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . .
Decimal and Millimeter Equivalents . . . . . . . . . . . .
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . .
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . .
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and Steel
Fasteners (Inch Series Fasteners) . . . . . . . . . . .
Standard Torque for Dry, Zinc Plated, and Steel
Fasteners (Metric Fasteners) . . . . . . . . . . . . . . .
Other Torque Specifications . . . . . . . . . . . . . . . . . .
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
2
2
2
3
3
4
5
6
6
7
Product Records
Insert Operator’s Manual and Parts Catalog for your
Workman at the end of this chapter. Refer to Operator’s
Manual for recommended maintenance intervals. Additionally, 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
0.09375
Product Records and Maintenance
Page 2 -- 2 Rev. D
Workman 3000/4000 Series
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 specified 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 Service 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, hardness of the surface underneath the fastener’s head, or
similar condition which affects the installation.
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 aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
The standard method of verifying torque shall be performed 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.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Inch Series Bolts and Screws
Workman 3000/4000 Series
Class 10.9
Metric Bolts and Screws
Page 2 – 3
Product Records and Maintenance
Product Records
and Maintenance
Torque Specifications
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series Fasteners)
Thread Size
Grade 1, 5, &
8 with Thin
Height Nuts
SAE Grade 1 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
in–lb
in–lb
N–cm
10 + 2
13 + 2
147 + 23
# 6 – 32 UNC
# 6 – 40 UNF
# 8 – 32 UNC
13 + 2
25 + 5
# 10 – 24 UNC
30 + 5
SAE Grade 8 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
in–lb
N–cm
in–lb
N–cm
15 + 2
170 + 20
23 + 2
260 + 20
17 + 2
190 + 20
25 + 2
280 + 20
29 + 3
330 + 30
41 + 4
460 + 45
31 + 3
350 + 30
43 + 4
485 + 45
42 + 4
475 + 45
60 + 6
675 + 70
48 + 4
540 + 45
68 + 6
765 + 70
282 + 30
# 8 – 36 UNF
18 + 2
SAE Grade 5 Bolts, Screws, Studs, &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
339 + 56
# 10 – 32 UNF
1/4 – 20 UNC
48 + 7
53 + 7
599 + 79
100 + 10
1125 + 100
140 + 15
1580 + 170
1/4 – 28 UNF
53 + 7
65 + 10
734 + 113
115 + 10
1300 + 100
160 + 15
1800 + 170
5/16 – 18 UNC
115 + 15
105 + 17
1186 + 169
200 + 25
2250 + 280
300 + 30
3390 + 340
5/16 – 24 UNF
138 + 17
128 + 17
1446 + 192
225 + 25
2540 + 280
325 + 30
3670 + 340
ft–lb
ft–lb
N–m
ft–lb
N–m
ft–lb
N–m
3/8 – 16 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 4
58 + 5
3/8 – 24 UNF
17 + 2
18 + 2
24 + 3
35 + 3
47 + 4
50 + 4
68 + 5
7/16 – 14 UNC
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
7/16 – 20 UNF
29 + 3
29 + 3
39 + 4
55 + 5
75 + 7
77 + 7
104 + 9
1/2 – 13 UNC
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
105 + 10
142 + 14
1/2 – 20 UNF
32 + 3
53 + 7
72 + 9
85 + 8
115 + 11
120 + 10
163 + 14
5/8 – 11 UNC
65 + 10
88 + 12
119 + 16
150 + 15
203 + 20
210 + 20
285 + 27
5/8 – 18 UNF
75 + 10
95 + 15
129 + 20
170 + 15
230 + 20
240 + 20
325 + 27
3/4 – 10 UNC
93 + 12
140 + 20
190 + 27
265 + 25
359 + 34
375 + 35
508 + 47
3/4 – 16 UNF
115 + 15
165 + 25
224 + 34
300 + 25
407 + 34
420 + 35
569 + 47
7/8 – 9 UNC
140 + 20
225 + 25
305 + 34
430 + 45
583 + 61
600 + 60
813 + 81
7/8 – 14 UNF
155 + 25
260 + 30
353 + 41
475 + 45
644 + 61
660 + 60
895 + 81
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
Product Records and Maintenance
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
Page 2 – 4
Workman 3000/4000 Series
Thread Size
Class 8.8 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 8 or Stronger Nuts)
Class 10.9 Bolts, Screws, and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
M5 X 0.8
57 + 5 in–lb
640 + 60 N–cm
78 + 7 in–lb
885 + 80 N–cm
M6 X 1.0
96 + 9 in–lb
1018 + 100 N–cm
133 + 13 in–lb
1500 + 150 N–cm
M8 X 1.25
19 + 2 ft–lb
26 + 3 N–m
27 + 2 ft–lb
36 + 3 N–m
M10 X 1.5
38 + 4 ft–lb
52 + 5 N–m
53 + 5 ft–lb
72 + 7 N–m
M12 X 1.75
66 + 7 ft–lb
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 N–m
M20 X 2.5
325 + 33 ft–lb
440 + 45 N–m
450 + 37 ft–lb
610 + 50 N–m
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
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
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
Page 2 – 5
Product Records and Maintenance
Product Records
and Maintenance
Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners)
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Recommended Torque
Thread Size
Recommended Torque**
Thread Size
Square Head
Hex Socket
1/4 – 20 UNC
140 + 20 in–lb
73 + 12 in–lb
5/16 – 18 UNC
215 + 35 in–lb
145 + 20 in–lb
3/8 – 16 UNC
35 + 10 ft–lb
18 + 3 ft–lb
1/2 – 13 UNC
75 + 15 ft–lb
50 + 10 ft–lb
7/16 – 20 UNF
Grade 5
65 + 10 ft–lb
88 + 14 N–m
1/2 – 20 UNF
Grade 5
80 + 10 ft–lb
108 + 14 N–m
M12 X 1.25
Class 8.8
80 + 10 ft–lb
108 + 14 N–m
M12 X 1.5
Class 8.8
80 + 10 ft–lb
108 + 14 N–m
** For steel wheels and non–lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23, or Type F
Thread Size
Baseline Torque*
No. 6 – 32 UNC
20 + 5 in–lb
No. 8 – 32 UNC
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
Threads per Inch
Baseline Torque*
Type A
Type B
No. 6
18
20
20 + 5 in–lb
30 + 5 in–lb
No. 8
15
18
30 + 5 in–lb
No. 10 – 24 UNC
38 + 7 in–lb
No. 10
12
16
38 + 7 in–lb
1/4 – 20 UNC
85 + 15 in–lb
No. 12
11
14
85 + 15 in–lb
5/16 – 18 UNC
110 + 20 in–lb
3/8 – 16 UNC
200 + 100 in–lb
* Hole size, material strength, material thickness & finish
must be considered when determining specific torque
values. All torque values are based on non–lubricated
fasteners.
Conversion Factors
in–lb X 11.2985 = N–cm
ft–lb X 1.3558 = N–m
Product Records and Maintenance
N–cm X 0.08851 = in–lb
N–m X 0.7376 = ft–lb
Page 2 – 6
Workman 3000/4000 Series
Maintenance
Workman 3000/4000 Series
Page 2 – 7
Product Records
and Maintenance
Maintenance procedures and recommended service intervals for the Workman 3000/4000 are covered in the
Operator’s Manual. Refer to that publication when performing regular equipment maintenance. Several maintenance procedures have break–in intervals identified in
the Operator’s Manual. Refer to the Engine Operator’s
Manual for additional engine specific maintenance procedures.
Product Records and Maintenance
This page is intentionally blank.
Product Records and Maintenance
Page 2 – 8
Workman 3000/4000 Series
Chapter 3
Briggs/Daihatsu Gasoline Engine
Table of Contents
Briggs/Daihatsu
Gasoline Engine
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Adding Oil to Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Engine Speed Adjustment . . . . . . . . . . . . . . . . . . . . 4
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump Driveshaft Service . . . . . . . . . . . . . . . . . . . . . 8
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Throttle Bracket . . . . . . . . . . . . . . . . . . . . . 20
BRIGGS & STRATTON/DAIHATSU REPAIR MANUAL
FOR 3–CYLINDER, LIQUID–COOLED, GASOLINE
ENGINES
Introduction
This Chapter gives information about specifications and
repair of the Briggs & 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 troubleshooting, testing, disassembly, and reassembly is
identified in the Briggs & Stratton/Daihatsu Repair
Manual that is included at the end of this section.
Workman 3200/4200
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Briggs & Stratton/Daihatsu
Repair Manual. The use of some specialized test equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may
dictate that the work be done at an engine repair facility.
Service and repair parts for Briggs & Stratton/Daihatsu
3LC gasoline engines are supplied through your local
Toro distributor.
Page 3 – 1
Briggs/Daihatsu Gasoline Engine
Specifications
Item
Description
Make / Designation
Briggs & Stratton/Daihatsu, 4–stroke,
Liquid Cooled, OHV Gasoline
Number of Cylinders
3
Bore x Stroke mm (in.)
72 x 78 (2.834 x 3.07)
Total Displacement cc (cu. in.)
952 (58.1)
Compression Ratio
8.6:1
Firing Order
1 (front) – 2 – 3
Dry Weight (approximate) kg (lb.)
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
Briggs/Daihatsu Gasoline Engine
12 VDC 40 AMP
Page 3 – 2
Workman 3200/4200
General Information
Adding Oil to Engine
Briggs/Daihatsu
Gasoline Engine
When adding oil to the engine, maintain clearance between the oil fill device and the oil fill opening in the valve
cover (Fig. 1). This clearance is necessary to allow venting when adding engine oil which will prevent oil from
running into the breather tube and intake system.
Figure 1
Workman 3200/4200
Page 3 – 3
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
1
2. Raise the bed or remove attachment(s) to allow access to engine. If bed is raised, place safety support on
lift cylinder (see Operator’s Manual).
3
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 governor 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:
Figure 2
1. Engine governor lever
2. Governor spring
3. Spring mounting slot
NOT EQUIPPED WITH GOVERNOR
SPRING ADJUSTING ROD
A. Remove return spring from throttle bracket and
bellcrank. Disconnect throttle cable from balljoint on
bellcrank.
4
6
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 bellcrank. Connect throttle cable to balljoint on bellcrank.
3
1
5
Figure 3
1. Governor spring
2. Bellcrank
3. Engine governor lever
4. High idle stop screw
5. Low idle stop screw
6. Return spring
EQUIPPED WITH GOVERNOR
SPRING ADJUSTING ROD
6
4
3
6. Check operation and adjustment of accelerator
cable (see Operator’s Manual). If needed, adjust accelerator cable.
7. Start and run engine until engine is at normal operating temperature. Make sure that carburetor choke is fully open.
2
1
2
5
(0.125” (3.2 mm)
Figure 4
1. Governor spring
2. Bellcrank
3. Engine governor lever
Briggs/Daihatsu Gasoline Engine
Page 3 – 4
Rev. B
4. High idle stop screw
5. Low idle stop screw
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 carburetor to obtain 1100 + 50 RPM (Fig. 6).
7
6
5
4
8
10.After engine speed adjustments are complete, lower
the bed or install attachment(s).
3
1
2
Figure 5
1.
2.
3.
4.
Throttle bracket
High idle stop screw
Idle stop screw
Governor spring
5.
6.
7.
8.
Bellcrank
Jam nut
Return spring
Adj rod (if equipped)
1
2
3
Figure 6
1. Governor link
2. Idle speed screw
Workman 3200/4200
Page 3 – 5 Rev. B
3. Carburetor
Briggs/Daihatsu Gasoline Engine
Briggs/Daihatsu
Gasoline Engine
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 after adjusting high idle stop screw.
6
Service and Repairs
Radiator
20
21
26
1
25
22
19
18
16
RIGHT
FRONT
23 24
17
15
14
13
12
2
3
11
10
4
5
6
7
8
9
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
9.
Hydraulic pump
Carriage screw (4 used)
Fan hub/pulley
Fan shroud
Lower radiator hose
Hose clamp
Radiator
Lock nut (4 used)
Cap screw (4 used)
Briggs/Daihatsu Gasoline Engine
10.
11.
12.
13.
14.
15.
16.
17.
18.
Flange nut (4 used)
Magnetic catch (2 used)
Radiator cap
Hose (to coolant reservoir)
Cap screw (4 used)
Hose clamp
Upper radiator hose
Screw (2 used)
Flat washer
Page 3 – 6
19.
20.
21.
22.
23.
24.
25.
26.
Lock nut (4 used)
Handle
Radiator cover/screen
Cap screw (4 used)
Lock washer (4 used)
Fan
Idler pulley
Mount plate
Workman 3200/4200
Removal (Fig. 5)
Installation (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.
1. Remove plugs from radiator and hoses placed during the removal procedure.
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 radiator.
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 clearance exists between shroud and fan at all points.
CAUTION
5. Connect upper and lower hoses to the radiator.
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
6. Make sure radiator drain is closed. Fill radiator with
coolant (see Operator’s Manual).
7. Install the radiator screen.
Ethylene–glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly
labeled container away from children and pets.
8. Lower or install bed or other attachment(s).
4. Remove the radiator cap. Drain radiator into a suitable container using the radiator drain located on the
lower right corner of the radiator.
5. Disconnect upper and lower radiator hoses from the
radiator.
6. Disconnect reservoir hose (item 13) from the radiator
filler neck.
7. Detach fan shroud from the radiator by removing four
(4) cap screws, flat washers and lock nuts. Position
shroud away from radiator.
8. Remove four (4) cap screws and flange nuts that secure the radiator to the frame. Pull radiator from the vehicle.
9. Plug all radiator and hose openings to prevent contamination.
Workman 3200/4200
Page 3 – 7
Briggs/Daihatsu Gasoline Engine
Briggs/Daihatsu
Gasoline Engine
4. Connect reservoir hose (item 11) to the radiator filler
neck.
Pump Driveshaft Service
11
18
RIGHT
14
9
12
FRONT
14
11
12
13
10
100 to 130 in–lb
(11.3 to 14.7 N–m)
15
17
16
13
8
7
3
9
6
6
ANTISIEZE
LUBRICANT
5
1
15
4
2
Figure 6
1.
2.
3.
4.
5.
6.
Lock nut
Flat washer
Woodruff key
Pump drive belt
Pulley
Bearing
Briggs/Daihatsu Gasoline Engine
7.
8.
9.
10.
11.
12.
Bearing spacer
Shaft
Lock nut (6 used)
Frame support bracket
Cap screw (4 used)
Coupling spacer (4 used)
Page 3 – 8
13.
14.
15.
16.
17.
18.
Coupling spacer (4 used)
Rubber coupling
Flat washer (4 used)
Cap screw (2 used)
Cap screw (2 used)
Driveshaft
Workman 3200/4200
Removal (Fig. 6)
Installation (Fig. 6)
1. Park vehicle on a level surface, raise and support
bed (if installed), shut engine off and engage the parking
brake.
1. To install bearings (Item 6) into frame support bracket:
A. Install pulley side bearing into support bracket by
pressing on bearing outer race until bearing contacts
shoulder in support bracket.
2. Disassemble driveshaft using Figure 6 as a guide.
3. Do not reuse bearings (Item 6) if they have been removed from frame support bracket. Replace with new
bearings.
C. Install second bearing into bracket by pressing on
the bearing outer race until bearing inner race contacts spacer.
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.
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 N–m).
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).
Workman 3200/4200
Page 3 – 9
Briggs/Daihatsu Gasoline Engine
Briggs/Daihatsu
Gasoline Engine
B. Place the bearing spacer (Item 7) into bracket cavity.
Fuel Tank
6
7
8
9
5
4
2
10
3
11
13
12
Sender
Ground
Wire
Thread Sealant
1
27
14
24
18
17
19
15
20
RIGHT
26
21
16
23
22
FRONT
25
13
Figure 7
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Fuel tank
Fuel tank cap
Gasket
Fuel sender
Lock washer (5 used)
Screw (5 used)
Hex nut
Lock washer
Wire harness
Spacer
Fuel fitting
Hose clamp
Fuel hose (to fuel filter)
Clamp
Flange nut (2 used)
Flange nut (2 used)
Rear fuel tank support
Cap screw (2 used)
19.
20.
21.
22.
23.
24.
25.
26.
27.
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
DANGER
Because gasoline is highly flammable, use caution when storing or handling it. Do not smoke
while filling the fuel tank. Do not fill fuel tank
while engine is running, hot, or when vehicle is in
an enclosed area. Always fill fuel tank outside
and wipe up any spilled fuel before starting the
engine. Store fuel in a clean, safety–approved
container and keep cap in place. Use fuel for the
engine only; not for any other purpose.
Briggs/Daihatsu Gasoline Engine
Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check lines for deterioration, damage, leaks, or loose connections. Replace
hoses, clamps, and connections as necessary.
Page 3 – 10
Workman 3200/4200
Fuel Tank Removal (Fig. 7)
Fuel Tank Installation (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.
1. Check felt straps (item 23) and replace if worn or
damaged.
3. Disconnect negative battery cable first and then positive 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.
IMPORTANT: When positioning fuel tank to vehicle,
make sure that hydraulic lift cylinder does not contact tank.
2. Position fuel tank to tank straps and fuel tank supports. 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.
4. Disconnect fuel hose (item 13) from fuel filter located
on right frame rail. Drain fuel from the fuel tank into a
suitable container.
A. Connect blue/white wire with ring terminal to the
center fuel sender terminal and secure with lock
washer and hex nut.
NOTE: To prevent fuel leakage, do not loosen lower nut
on fuel sender stud.
B. Connect black (ground) wire with the screw (item
6) that is closest to the frame rail.
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.
C. Apply skin–over grease to the wire terminal connections and cover center terminal with harness
boot.
5. Connect fuel hose from tank outlet to fuel filter and
secure with clamp.
7. Remove fuel tank from vehicle.
CAUTION
Connecting battery cables to the wrong battery
post could result in personal injury and/or damage to the electrical system.
6. Position battery in vehicle (see 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.
Workman 3200/4200
Page 3 – 11
Briggs/Daihatsu Gasoline Engine
Briggs/Daihatsu
Gasoline Engine
2. Raise or remove the bed or other attachment(s). If
bed is raised, place safety support on lift cylinder (see
Operator’s Manual).
Air Cleaner System
1
3
4
2
RIGHT
13
14
5
FRONT
6
8
2 12
11
7
10
VACUATOR
DIRECTION
8
9
Figure 8
1.
2.
3.
4.
5.
Engine
Hose clamp
Air intake hose
Radiator hose
Air inlet hood
Briggs/Daihatsu Gasoline Engine
6.
7.
8.
9.
10.
Air cleaner hose
Air cleaner assembly
Flange nut (2 used)
Clamp
Mounting band
Page 3 – 12
11.
12.
13.
14.
Mount bracket
Cap screw (2 used)
Flange nut (2 used)
R–clamp
Workman 3200/4200
Removal (Fig. 8)
1
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
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
3. Remove air cleaner components as needed using
Figures 8 and 9 as guides.
4
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 vacuator valve on the air cleaner assembly should be positioned downward.
5
6
IMPORTANT: Any leaks in the air filter system will
cause serious engine damage. Make sure daily that
all air cleaner components are in good condition
and are properly secured during reassembly.
Figure 9
1. Plug
2. Upper housing
3. Element
4. Gasket
5. Lower housing
6. Vacuator valve
2. Lower or install bed or attachment(s).
Workman 3200/4200
Page 3 – 13
Briggs/Daihatsu Gasoline Engine
Briggs/Daihatsu
Gasoline Engine
Installation (Fig. 8)
Exhaust System
11
14
15
13
1
12
16
11
2
10
4
9
7
8
Loctite #242
17
3
5
3
RIGHT
6
FRONT
Figure 10
1.
2.
3.
4.
5.
6.
Engine
Stud (4 used)
Exhaust gasket
Hex nut (4 used)
Exhaust manifold
Socket head screw (4 used)
Briggs/Daihatsu Gasoline Engine
7.
8.
9.
10.
11.
12.
Cap screw (2 used)
Flange nut (4 used)
Cap screw
Hardened washer
Flange nut (4 used)
Carriage bolt (2 used)
Page 3 – 14
13.
14.
15.
16.
17.
Mount plate
Cap screw
Muffler
Transaxle
Shift cable mount bracket
Workman 3200/4200
Removal (Fig. 10)
Installation (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.
1. Replace any removed gaskets.
3. Remove exhaust system components as needed using Figure 10 as a guide.
3. Using Figure 10 as a guide, fit all exhaust components to vehicle before tightening any fasteners. When
securing exhaust, tighten fasteners in the following order:
A. Hex nuts (item 4) that secure exhaust manifold to
engine.
4. Discard gaskets and thoroughly clean flange surfaces of manifold and muffler.
B. Cap screw (item 9) with washer (item 10) that secures muffler to transaxle.
C. Socket head screws (item 6) and flange nuts
(item 8) that secure muffler to manifold.
D. Cap screws (item 7) and flange nuts (item 11) that
secure muffler to shift cable mount bracket.
E. Carriage bolts (item 12) and flange nuts (item 11)
that secure muffler to mount plate.
4. Lower or install bed or attachment(s).
Workman 3200/4200
Page 3 – 15
Briggs/Daihatsu Gasoline Engine
Briggs/Daihatsu
Gasoline Engine
2. Raise or remove the bed or other attachment(s). If
bed is raised, place safety support on lift cylinder (see
Operator’s Manual).
2. If cap screw (item 9) was removed, apply Loctite
#242 (or equivalent) to threads during installation.
Engine
12
13
11
32
6
10
7
14
9
8
4
33
3
2
5
1
16
15
17
18
19
20
21
27
RIGHT
22
FRONT
23
26
31
29
24
25
28
30
Figure 11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Engine
Hex nut
Lock washer
Flat washer
Wire harness alternator lead
Fuel hose
Hose clamp
Hose clamp
Air intake hose
Throttle bracket
Lock nut
Briggs/Daihatsu Gasoline Engine
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Ball joint
Accelerator cable
Bellcrank
Upper radiator hose
Hose clamp
Engine mount
Lock washer (8 used)
Cap screw (8 used)
Fusible link harness
Positive battery cable
Lock washer
Page 3 – 16
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
Hex nut
Wire harness solenoid lead
Lower radiator hose
Hose clamp
Hex nut
Engine cover
Washer
Cap screw
Cap screw
Return spring
Governor spring
Workman 3200/4200
Engine Removal (Fig. 11)
1
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.
3
5
2. Raise or remove the bed or other attachment(s) to
gain access to engine. If bed is raised, place safety support on lift cylinder (see Operator’s Manual).
3
4
4
3. Disconnect negative (–) and then positive (+) battery
cables at the battery.
6
7
4. Remove exhaust manifold from vehicle (see Exhaust System Removal in this section).
8
7
5. Loosen hose clamp that secures air intake hose to
carburetor. Remove intake hose from carburetor.
6
5
2
6. Disconnect fuel hose from carburetor on engine.
Plug end of fuel hose to prevent contamination and fuel
spillage. Position disconnected fuel hose away from engine.
7. Note location of cable ties used to secure wire leads.
Label and disconnect electrical leads that attach to engine:
10
Briggs/Daihatsu
Gasoline Engine
9
Figure 12
1.
2.
3.
4.
5.
Engine pulley
Cap screw (4 used)
Coupling spacer (4 used)
Rubber coupling
Lock nut (6 used)
6.
7.
8.
9.
10.
Coupling spacer (4 used)
Flat washer (4 used)
Cap screw (2 used)
Hyd. pump driveshaft
Cap screw (2 used)
1
A. Battery cable and fusible link harness from starter
solenoid stud.
1
2
2
4
B. Double wire from spade terminal on starter solenoid.
3
6
4
C. Wires from oil pressure switch, temperature
sender (on water pump housing) and high temperature switch.
5
7
6
D. Harness connector and wire with ring terminal
from alternator.
7
E. Wires from fuel solenoid and choke assembly on
carburetor.
7
6
F. Six wires from ignition coils.
9
8
G. Two harness connectors from ignition controller.
7
H. Harness connector from crankshaft sensor.
6
10
8. Disconnect accelerator cable from bellcrank on engine. Position accelerator cable away from engine.
9
Figure 13
9. Drain coolant from radiator (see Operator’s Manual).
Loosen hose clamps and remove upper and lower radiator hoses from engine. Position hoses away from engine.
1.
2.
3.
4.
5.
Cap screw
Flat washer
R–clamp
Spacer
Engine mount
6.
7.
8.
9.
10.
Snubbing washer
Engine mount
Engine support
Lock nut
Guard (2 used)
10.Remove four (4) cap screws (item 2) and lock nuts
(item 5) that fasten both ends of hydraulic pump driveshaft 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.
2
3
1
12.On 4WD vehicles, remove differential drive shaft
(see Differential Driveshaft in the Service and Repairs
section of Chapter 10 – Front Wheel Drive (4WD)).
2
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).
4
5
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 being 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 engine out of chassis. Move engine forward before lifting
to disengage transaxle input shaft from clutch.
2
3
Figure 14
1. Bell housing
2. Cap screw (6 used)
3. Harness bracket
4. Flat washer (3 used)
5. Dowel pins (2 used)
18.Note location and retrieve two (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 necessary, 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 correct oil (see Operator’s Manual).
5. Adjust accelerator cable (see Operator’s Manual).
6. Check engine speed (both idle and high idle) and adjust if necessary (see Engine Speed Adjustment in Adjustments section of this chapter)
Briggs/Daihatsu Gasoline Engine
Page 3 – 18
Workman 3200/4200
Briggs/Daihatsu
Gasoline Engine
This page is intentionally blank.
Workman 3200/4200
Page 3 – 19
Briggs/Daihatsu Gasoline Engine
Engine Throttle Bracket
5
4
6
2
7
3
8
2
9
11
10
12
1
17
16
15
13
14
RIGHT
FRONT
Figure 17
1.
2.
3.
4.
5.
6.
Engine
Jam nut
Return spring
Lock nut
Ball joint
Accelerator cable
Briggs/Daihatsu Gasoline Engine
7.
8.
9.
10.
11.
12.
Lock washer (3 used)
Flange head screw (3 used)
Grease fitting
Shoulder bolt
Bellcrank
Governor spring
Page 3 – 20 Rev. B
13.
14.
15.
16.
17.
Idle stop screw
High idle stop screw
Throttle bracket
Lock nut
Spring adjusting rod (if equipped)
Workman 3200/4200
Disassembly (Fig. 17)
1. Remove throttle bracket components from engine as
needed using Figures 17, 18 and 19 as guides.
NOT EQUIPPED WITH GOVERNOR
SPRING ADJUSTING ROD
4
Assembly (Fig. 17)
1. Install removed throttle bracket components to engine using Figures 17, 18 and 19 as guides.
6
2
3
3. Lubricate bellcrank grease fitting after assembly.
4. Check engine speed (both idle and high idle) and adjust if necessary (see Engine Speed Adjustment in Adjustments 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.
5
Figure 18
1. Governor spring
2. Bellcrank
3. Engine governor lever
4. High idle stop screw
5. Low idle stop screw
6. Return spring
EQUIPPED WITH GOVERNOR
SPRING ADJUSTING ROD
6
4
3
1
2
5
(0.125” (3.2 mm)
Figure 19
1. Governor spring
2. Bellcrank
3. Engine governor lever
4. High idle stop screw
5. Low idle stop screw
6. Spring adjusting rod
2
1
3
Figure 20
1. Engine governor lever
2. Governor spring
Workman 3200/4200
Page 3 – 21 Rev. B
3. Spring mounting slot
Briggs/Daihatsu Gasoline Engine
Briggs/Daihatsu
Gasoline Engine
1
2. If removed, attach governor spring to bellcrank on
throttle bracket and outer most slot in engine governor
lever (Fig. 20).
This page is intentionally blank.
Briggs/Daihatsu Gasoline Engine
Page 3 – 22
Workman 3200/4200
Chapter 4
Briggs/Daihatsu Diesel Engine
Table of Contents
Briggs/Daihatsu
Diesel Engine
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Adding Oil to Engine . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Adjust Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . 4
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pump Driveshaft Service . . . . . . . . . . . . . . . . . . . . . 8
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Air Cleaner System . . . . . . . . . . . . . . . . . . . . . . . . . 12
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Throttle Bracket . . . . . . . . . . . . . . . . . . . . . 20
BRIGGS & STRATTON/DAIHATSU REPAIR MANUAL
FOR 3–CYLINDER, LIQUID–COOLED, DIESEL ENGINES
Introduction
This Chapter gives information about specifications and
repair of the Briggs and Stratton/Daihatsu 3LC diesel
engine used in the Workman 3300–D and 4300–D.
General engine maintenance procedures are described
in your Operator’s Manual. Information on engine troubleshooting, testing, disassembly, and reassembly is
identified in the Briggs & Stratton/Daihatsu Repair Manual that is included at the end of this section.
Workman 3300–D/4300–D
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Briggs & Stratton/Daihatsu
Repair Manual. The use of some specialized test equipment is explained. However, the cost of the test equipment and the specialized nature of some repairs may
dictate that the work be done at an engine repair facility.
Service and repair parts for Briggs and Stratton/Daihatsu 3LC diesel engines are supplied through your local
Toro distributor.
Page 4 – 1
Briggs/Daihatsu Diesel Engine
Specifications
Item
Description
Make / Designation
Briggs & Stratton/Daihatsu, 4–stroke,
Liquid Cooled, OHV Diesel
Number of Cylinders
3
Bore x Stroke mm (in.)
72 x 78 (2.834 x 3.07)
Total Displacement cc (cu. in.)
952 (58.1)
Compression Ratio
24.0:1
Firing Order
1 (front) – 2 – 3
Dry Weight (approximate) kg (lb.)
78 (172)
Fuel
Grade No. 2–D 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
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 1.2 KW
Alternator/Regulator
12 VDC 40 AMP
Briggs/Daihatsu Diesel Engine
Page 4 – 2
Workman 3300–D/4300–D
General Information
Adding Oil to Engine
Briggs/Daihatsu
Diesel Engine
When adding oil to the engine, maintain clearance between the oil fill device and the oil fill opening in the valve
cover (Fig. 1). This clearance is necessary to allow venting when adding engine oil which will prevent oil from
running into the breather tube and intake system.
Figure 1
Workman 3300–D/4300–D
Page 4 – 3
Briggs/Daihatsu Diesel Engine
Adjustments
Adjust Engine Speed
1. Park vehicle on a level surface, engage parking
brake and place gear shift lever in neutral.
3
2
1
2. Raise the bed or remove attachment(s) to allow access 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).
Figure 2
1. Speed control lever
2. Idle speed screw
3. Lock nut
A. Loosen lock nut on idle speed screw.
B. Adjust idle speed screw to obtain 1500 + 50 RPM.
C. Tighten lock nut. Recheck idle speed.
6. Increase engine speed to high idle. Use a tachometer 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.
2
B. Adjust high speed screw to obtain 3600 + 50
RPM.
C. Tighten lock nut. Recheck high idle speed.
Briggs/Daihatsu Diesel Engine
1
3
Figure 3
1. Speed control lever
2. High speed screw
Page 4 – 4
3. Lock nut
Workman 3300–D/4300–D
Briggs/Daihatsu
Diesel Engine
This page is intentionally blank.
Workman 3300–D/4300–D
Page 4 – 5
Briggs/Daihatsu Diesel Engine
Service and Repairs
Radiator
20
21
26
1
25
22
19
18
16
RIGHT
FRONT
23 24
17
15
14
13
12
2
3
11
10
4
5
6
7
8
9
Figure 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
Hydraulic pump
Carriage screw (4 used)
Fan hub/pulley
Fan shroud
Lower radiator hose
Hose clamp
Radiator
Lock nut (4 used)
Cap screw (4 used)
Briggs/Daihatsu Diesel Engine
10.
11.
12.
13.
14.
15.
16.
17.
18.
Flange nut (4 used)
Magnetic catch (2 used)
Radiator cap
Hose (to coolant reservoir)
Cap screw (4 used)
Hose clamp
Upper radiator hose
Screw (2 used)
Flat washer
Page 4 – 6
19.
20.
21.
22.
23.
24.
25.
26.
Lock nut (4 used)
Handle
Radiator cover/screen
Cap screw (4 used)
Lock washer (4 used)
Fan
Idler pulley
Mount plate
Workman 3300–D/4300–D
Removal (Fig. 4)
Installation (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.
1. Remove plugs from radiator and hoses placed during the removal procedure.
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 radiator.
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 clearance exists between shroud and fan at all points.
4. Connect reservoir hose (item 11) to the radiator filler
neck.
CAUTION
5. Connect upper and lower hoses to the radiator.
Do not open radiator cap or drain coolant if the
radiator or engine is hot. Pressurized, hot coolant can escape and cause burns.
6. Make sure radiator drain is closed. Fill radiator with
coolant (see Operator’s Manual).
8. Lower or install bed or other attachment(s).
4. Remove the radiator cap. Drain radiator into a suitable container using the radiator drain located on the
lower right corner of the radiator.
5. Disconnect upper and lower radiator hoses from the
radiator.
6. Disconnect reservoir hose (item 13) from the radiator
filler neck.
7. Detach fan shroud from the radiator by removing four
(4) cap screws, flat washers and lock nuts. Position
shroud away from radiator.
8. Remove four (4) cap screws and flange nuts that secure the radiator to the frame. Pull radiator from the vehicle.
9. Plug all radiator and hose openings to prevent contamination.
Workman 3300–D/4300–D
Page 4 – 7
Briggs/Daihatsu Diesel Engine
Briggs/Daihatsu
Diesel Engine
7. Install the radiator screen.
Ethylene–glycol antifreeze is poisonous. Dispose of coolant properly, or store it in a properly
labeled container away from children and pets.
Pump Driveshaft Service
11
18
RIGHT
14
9
12
FRONT
14
11
12
13
10
100 to 130 in–lb
(11.3 to 14.7 N–m)
15
17
16
13
8
7
3
9
6
6
ANTISIEZE
LUBRICANT
5
1
15
4
2
Figure 5
1.
2.
3.
4.
5.
6.
Lock nut
Flat washer
Woodruff key
Pump drive belt
Pulley
Bearing
Briggs/Daihatsu Diesel Engine
7.
8.
9.
10.
11.
12.
Bearing spacer
Shaft
Lock nut (6 used)
Frame support bracket
Cap screw (4 used)
Coupling spacer (4 used)
Page 4 – 8
13.
14.
15.
16.
17.
18.
Coupling spacer (4 used)
Rubber coupling
Flat washer (4 used)
Cap screw (2 used)
Cap screw (2 used)
Driveshaft
Workman 3300–D/4300–D
Removal (Fig. 5)
Installation (Fig. 5)
1. Park vehicle on a level surface, raise and support
bed (if installed), shut engine off and engage the parking
brake.
1. To install bearings (Item 6) into frame support bracket:
A. Install pulley side bearing into support bracket by
pressing on bearing outer race until bearing contacts
shoulder in support bracket.
2. Disassemble driveshaft using Figure 5 as a guide.
3. Do not reuse bearings (Item 6) if they have been removed from frame support bracket. Replace with new
bearings.
B. Place the bearing spacer (Item 7) into bracket cavity.
C. Install second bearing into bracket by pressing on
the bearing outer race until bearing inner race contacts spacer.
Inspection
1. Inspect frame support bracket for wear or damage.
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 N–m).
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).
Workman 3300–D/4300–D
Page 4 – 9
Briggs/Daihatsu Diesel Engine
Briggs/Daihatsu
Diesel Engine
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.
Fuel Tank
6
7
8
RIGHT
10
9
Sender
Ground
Wire
5
FRONT
4
13
11
3
12
19
2
20
13
18
29
Thread Sealant
14
1
17
22
30
29
21
23
24
28
25
16
32
15
27
31
33
26
Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Fuel tank
Fuel tank cap
Gasket
Fuel sender
Lock washer (5 used)
Screw (5 used)
Hex nut
Lock washer
Spacer
Wire harness lead
Fuel fitting
Hose clamp
Fuel hose (to fuel filter)
Clamp
Flange nut (2 used)
Flange nut (2 used)
Fuel hose (return from engine)
Hose clamp
Fitting
Bushing
Rear fuel tank support
Cap screw (2 used)
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
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
DANGER
Because diesel fuel is highly flammable, use caution when storing or handling it. Do not smoke
while filling the fuel tank. Do not fill fuel tank
while engine is running, hot, or when vehicle is in
an enclosed area. Always fill fuel tank outside
and wipe up any spilled fuel before starting the
engine. Store fuel in a clean, safety–approved
container and keep cap in place. Use fuel for the
engine only; not for any other purpose.
Briggs/Daihatsu Diesel Engine
Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check lines for deterioration, damage, leaks, or loose connections. Replace
hoses, clamps, and connections as necessary.
Page 4 – 10
Workman 3300–D/4300–D
Fuel Tank Removal (Fig. 6)
Fuel Tank Installation (Fig. 6)
1. Put vehicle on a level surface and engage parking
brake. Stop the engine and remove key from ignition
switch. Allow engine to cool.
1. Check felt straps (item 27) and replace if worn or
damaged.
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 positive 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.
IMPORTANT: When positioning fuel tank to vehicle,
make sure that hydraulic lift cylinder does not contact tank.
2. Position fuel tank to tank straps and fuel tank supports. 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.
A. Connect blue/white wire with ring terminal to the
center fuel sender terminal and secure with lock
washer and hex nut.
5. Loosen hose clamp and remove return hose (item
17) from fitting on top of tank.
B. Connect black (ground) wire with the screw (item
6) that is closest to the frame rail.
NOTE: To prevent fuel leakage, do not loosen lower nut
on fuel sender stud.
C. Apply skin–over grease to the wire terminal connections and cover center terminal with harness
boot.
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.
5. Connect return hose to fitting on top of tank and secure with clamp.
6. Connect fuel hose from tank outlet to fuel filter and
secure with clamp.
8. Remove fuel tank from vehicle.
CAUTION
Connecting battery cables to the wrong battery
post could result in personal injury and/or damage to the electrical system.
7. Position battery in vehicle (see 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.
Workman 3300–D/4300–D
Page 4 – 11
Briggs/Daihatsu Diesel Engine
Briggs/Daihatsu
Diesel Engine
4. Connect electrical wiring to the fuel sender.
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.
Air Cleaner System
1
3
4
2
RIGHT
13
14
5
FRONT
6
8
2 12
11
7
10
VACUATOR
DIRECTION
8
9
Figure 7
1.
2.
3.
4.
5.
Engine
Hose clamp
Air intake hose
Radiator hose
Air inlet hood
Briggs/Daihatsu Diesel Engine
6.
7.
8.
9.
10.
Air cleaner hose
Air cleaner assembly
Flange nut (2 used)
Clamp
Mounting band
Page 4 – 12
11.
12.
13.
14.
Mount bracket
Cap screw (2 used)
Flange nut (2 used)
R–clamp
Workman 3300–D/4300–D
Removal (Fig. 7)
1
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
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
3. Remove air cleaner components as needed using
Figure 7 and 8 as guides.
4
Installation (Fig. 7)
Figure 8
1. Plug
2. Upper housing
3. Element
4. Gasket
5. Lower housing
6. Vacuator valve
2. Lower or install bed or attachment(s).
Workman 3300–D/4300–D
Page 4 – 13
Briggs/Daihatsu Diesel Engine
Briggs/Daihatsu
Diesel Engine
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 vacuator valve on the air cleaner assembly should be positioned downward.
5
6
IMPORTANT: Any leaks in the air filter system will
cause serious engine damage. Make sure daily that
all air cleaner components are in good condition
and are properly secured during reassembly.
Exhaust System
11
14
15
13
1
12
16
11
2
10
4
9
7
8
Loctite #242
17
3
5
3
RIGHT
6
FRONT
Figure 9
1.
2.
3.
4.
5.
6.
Engine
Stud (4 used)
Exhaust gasket
Hex nut (4 used)
Exhaust manifold
Socket head screw (4 used)
Briggs/Daihatsu Diesel Engine
7.
8.
9.
10.
11.
12.
Cap screw (2 used)
Flange nut (4 used)
Cap screw
Hardened washer
Flange nut (4 used)
Carriage bolt (2 used)
Page 4 – 14
13.
14.
15.
16.
17.
Mount plate
Cap screw
Muffler
Transaxle
Shift cable mount bracket
Workman 3300–D/4300–D
Removal (Fig. 10)
Installation (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.
1. Replace any removed gaskets.
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 using Figure 10 as a guide.
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 components to vehicle before tightening any fasteners. When
securing exhaust, tighten fasteners in the following order:
A. Hex nuts (item 4) that secure exhaust manifold to
engine.
4. Discard gaskets and thoroughly clean flange surfaces of manifold and muffler.
B. Cap screw (item 9) with washer (item 10) that secures muffler to transaxle.
D. Cap screws (item 7) and flange nuts (item 11) that
secure muffler to shift cable mount bracket.
E. Carriage bolts (item 12) and flange nuts (item 11)
that secure muffler to mount plate.
4. Lower or install bed or attachment(s).
Workman 3300–D/4300–D
Page 4 – 15
Briggs/Daihatsu Diesel Engine
Briggs/Daihatsu
Diesel Engine
C. Socket head screws (item 6) and flange nuts
(item 8) that secure muffler to manifold.
Engine
25
21
27
22
23
24
26
28 29
30
20
19
31
18
1
17
16
2
15
14
9
RIGHT
FRONT
13
3
5
7
12
10
11
8
6
5
4
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Engine
Fusible link harness
Positive battery cable
Wire harness solenoid lead
Lock washer
Hex nut
Hose clamp
Lower radiator hose
Hex nut
Engine cover
Cap screw
Briggs/Daihatsu Diesel Engine
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Washer
Cap screw
Lock washer (8 used)
Cap screw (8 used)
Engine mount
Hose clamp
Upper radiator hose
Throttle bellcrank
Accelerator cable
Ball joint
Page 4 – 16
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
Throttle bracket
Air intake hose
Hose clamp
Fuel supply hose
Hose clamp
Fuel hose (return)
Wire harness alternator lead
Lock washer
Hex nut
Flat washer
Workman 3300–D/4300–D
Engine Removal (Fig. 10)
1
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.
3
5
2. Raise or remove the bed or other attachment(s) to
gain access to engine. If bed is raised, place safety support on lift cylinder (see Operator’s Manual).
3
4
4
3. Disconnect negative (–) and then positive (+) battery
cables at the battery.
6
7
4. Remove exhaust manifold from vehicle (see Exhaust System Removal in this section).
9
8
7
5. Loosen hose clamp that secures air intake hose to
engine. Remove intake hose from engine.
6
5
2
7. Note location of cable ties used to secure wire leads.
Label and disconnect electrical leads that attach to engine:
Figure 11
1.
2.
3.
4.
5.
Engine pulley
Cap screw (4 used)
Coupling spacer (4 used)
Rubber coupling
Lock nut (6 used)
6.
7.
8.
9.
10.
Coupling spacer (4 used)
Flat washer (4 used)
Cap screw (2 used)
Hyd. pump driveshaft
Cap screw (2 used)
1
A. Battery cable and fusible link harness from starter
solenoid stud.
1
2
2
4
B. Double wire from spade terminal on starter solenoid.
3
6
4
C. Wires from oil pressure switch, temperature
sender on water pump housing and high temperature switch.
5
7
6
D. Harness connector and wire with ring terminal
from alternator.
7
E. Harness connector with ring terminal from glow
plug connector.
7
6
F. Harness connector from fuel solenoid on injection pump.
9
8
G. Harness connector from crankshaft sensor.
7
6
8. Disconnect accelerator cable from throttle lever on
engine. Position accelerator cable away from engine.
9. Drain coolant from radiator (see Operator’s Manual).
Loosen hose clamps and remove upper and lower radiator hoses from engine. Position hoses away from engine.
10
9
Figure 12
1.
2.
3.
4.
5.
Cap screw
Flat washer
R–clamp
Spacer
Engine mount
6.
7.
8.
9.
10.
Snubbing washer
Engine mount
Engine support
Lock nut
Guard (2 used)
10.Remove four (4) cap screws (item 2) and lock nuts
(item 5) that fasten both ends of hydraulic pump driveshaft 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
Briggs/Daihatsu
Diesel Engine
6. Disconnect fuel hose from fuel injection pump on engine. Plug end of fuel hose to prevent contamination and
fuel spillage. Position disconnected fuel hose away from
engine.
10
11. Remove any clamps and cable ties used to attach
wiring harness, hoses or cables to the engine.
2
3
1
12.On 4WD vehicles, remove differential drive shaft
(see Differential Driveshaft in the Service and Repairs
section of Chapter 10 – Front Wheel Drive (4WD)).
2
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).
4
5
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 being 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 engine out of chassis. Move engine forward before lifting
to disengage transaxle input shaft from clutch.
2
3
Figure 13
1. Bell housing
2. Cap screw (6 used)
3. Harness bracket
4. Flat washer (3 used)
5. Dowel pins (2 used)
18.Note location and retrieve two (2) dowel pins from
bell housing (Fig. 13).
19.If necessary, remove engine mount from engine.
20.If pressure plate and clutch disc removal is necessary, 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 correct oil (see Operator’s Manual).
5. Adjust accelerator cable (see Operator’s Manual).
6. Check engine speed (both idle and high idle) and adjust if necessary (see Adjust Engine Speed in Adjustments section of this chapter)
Briggs/Daihatsu Diesel Engine
Page 4 – 18
Workman 3300–D/4300–D
Briggs/Daihatsu
Diesel Engine
This page is intentionally blank.
Workman 3300–D/4300–D
Page 4 – 19
Briggs/Daihatsu Diesel Engine
Engine Throttle Bracket
8
7
9
7
6
10
5
4 3
1
12
11
2
13
5
14
15
5
16
RIGHT
FRONT
Figure 14
1.
2.
3.
4.
5.
6.
Engine
Lock nut
Cap screw
Cap screw
Lock nut
Lock nut
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
Ball joint
Jam nut
Threaded rod
Accelerator cable
Return spring
Shoulder bolt
Grease fitting
Throttle bellcrank
Throttle bracket
Engine mount
Disassembly (Fig. 14)
Assembly (Fig. 14)
1. Remove throttle bracket components from engine as
needed using Figure 14 as a guide.
1. Install removed throttle bracket components to engine 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 accelerator cable.
4. Check engine speed (both idle and high idle) and adjust if necessary (see Adjust Engine Speed in Adjustments section of this chapter)
Briggs/Daihatsu Diesel Engine
Page 4 – 20
Workman 3300–D/4300–D
Chapter 5
Kohler Gasoline Engine
Table of Contents
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KOHLER ENGINE SERVICE MANUAL
1
2
3
3
4
6
8
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 troubleshooting, testing, disassembly, and reassembly is
identified in the Kohler Engine Service Manual that is included at the end of this section.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Kohler Engine Service Manual. The use of some specialized test equipment is explained. However, the cost of the test equipment and the
specialized nature of some repairs may dictate that the
work be done at an engine repair facility.
Service and repair parts for Kohler engines are supplied
through your local Kohler dealer or distributor.
Workman 3100
Page 5 – 1
Kohler Gasoline Engine
Kohler
Gasoline Engine
Introduction
Specifications
Item
Description
Make / Designation
Kohler, CH23S, 4–stroke, V–Twin
Air Cooled, OHV
Number of Cylinders
2
Bore x Stroke
80 mm x 67 mm (3.15” x 2.64”)
Total Displacement
674 cc (41.1 cu. in.)
Compression Ratio
8.5:1
Dry Weight (approximate)
41 kg (90 lb.)
Fuel
Unleaded, Regular Gasoline (Minimum 87 Octane)
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
Kohler Gasoline Engine
12 VDC
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 kept clean at all times.
1
NOTE: Perform this maintenance procedure at the interval specified in the Operator’s Manual.
3
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 engine overheating and engine damage.
2
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).
Figure 1
1. Cylinder head
2. Grass screen
3. Blower housing
Kohler
Gasoline Engine
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 necessary.
IMPORTANT: Never operate engine without the
blower housing installed. Overheating and engine
damage will result.
5. Make sure grass screen and blower housing are reinstalled to the engine if removed.
Workman 3100
Page 5 – 3
Kohler Gasoline Engine
Fuel Tank
6
7
8
9
5
4
2
10
3
11
13
12
Sender
Ground
Wire
Thread Sealant
1
14
24
26
17
18
19
15
20
RIGHT
21
16
23
FRONT
22
25
13
Figure 2
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
Fuel tank
Fuel tank cap
Gasket
Fuel sender
Lock washer (5 used)
Screw (5 used)
Hex nut
Lock washer
Wire harness
Spacer
Fuel fitting
Hose clamp
Fuel line
Clamp
Flange nut (2 used)
Flange nut (2 used)
Rear fuel tank support
Cap screw (2 used)
19.
20.
21.
22.
23.
24.
25.
26.
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
DANGER
Because gasoline is highly flammable, use caution when storing or handling it. Do not smoke
while filling the fuel tank. Do not fill fuel tank
while engine is running, hot, or when vehicle is in
an enclosed area. Always fill fuel tank outside
and wipe up any spilled fuel before starting the
engine. Store fuel in a clean, safety–approved
container and keep cap in place. Use fuel for the
engine only; not for any other purpose.
Kohler Gasoline Engine
Check fuel lines and connections periodically as recommended in the Operator’s Manual. Check lines for deterioration, damage, leaks, or loose connections. Replace
hoses, clamps, and connections as necessary.
Page 5 – 4
Workman 3100
Fuel Tank Removal (Fig. 2)
Fuel Tank Installation (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.
1. Check felt straps (item 23) and replace if worn or
damaged.
IMPORTANT: Review safety information regarding
fuel handling in the Operator’s Manual and Chapter
2 – Safety.
3. Disconnect negative battery cable first and then positive battery cable. Remove battery from vehicle (see
Operator’s Manual).
IMPORTANT: Make sure that hydraulic lift cylinder
does not contact fuel tank.
2. Position fuel tank to tank straps and fuel tank supports. 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.
4. Disconnect fuel line (item 13) from fuel filter on right
side frame rail. Drain fuel from the fuel tank into a suitable container.
A. Connect blue/white wire with ring terminal to the
center fuel sender terminal and secure with lock
washer and hex nut.
NOTE: To prevent fuel leakage, do not loosen lower nut
on fuel sender stud.
B. Connect black (ground) wire with the screw (item
6) that is closest to the frame rail.
5. Disconnect electrical wiring from the fuel sender on
the fuel tank.
C. Apply skin–over grease to the wire terminal connections and cover center terminal with harness
boot.
6. Loosen socket head screws (item 21) and lock nuts
(item19) to allow tank straps to be unhooked from fuel
tank supports.
5. Connect fuel line from tank outlet to fuel filter and secure with clamp.
7. Remove fuel tank from vehicle.
CAUTION
Connecting battery cables to the wrong battery
post could result in personal injury and/or damage to the electrical system.
6. Position battery in vehicle (see 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.
Workman 3100
Page 5 – 5
Kohler Gasoline Engine
Kohler
Gasoline Engine
2. Raise or remove the bed or other attachment(s). If
bed is raised, place safety support on lift cylinder (see
Operator’s Manual).
Exhaust System
15
5
16
14
13
12
5
17
12
11
10
6
Loctite #242
5
18
8
4
7
RIGHT
3
FRONT
2
9
1
Figure 3
1.
2.
3.
4.
5.
6.
Socket head screw (4 used)
Exhaust manifold
Hex nut (3 used)
Exhaust gasket (2 used)
Flange nut
Screw
Kohler Gasoline Engine
7.
8.
9.
10.
11.
12.
Cap screw
Bracket
Muffler gasket
Flange nut (4 used)
Cap screw
Hardened washer
Page 5 – 6
13.
14.
15.
16.
17.
18.
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.
3. Using Figure 3 as a guide, fit all exhaust components
to vehicle before tightening any fasteners. When securing exhaust, tighten fasteners in the following order:
A. Hex nuts (item 3) that secure manifold to engine.
2. Raise or remove the bed or other attachment(s). If
bed is raised, place safety support on lift cylinder (see
Operator’s Manual).
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.
3. Remove exhaust system components as needed using Figure 3 as a guide.
D. Cap screws (item 17) and flange nuts (item 5) that
secure muffler to shift cable mount bracket.
4. Discard gaskets and thoroughly clean flange surfaces of manifold and muffler.
E. Carriage screws (item 13) and flange nuts (item
5) that secure muffler to mount plate.
Installation (Fig. 3)
1. Replace any removed gaskets.
F. Screw (item 6) and flange nut (item 5) that secures exhaust manifold to bracket (item 8).
4. Lower or install bed or attachment(s).
Kohler
Gasoline Engine
2. If cap screw (item 11) was removed, apply Loctite
#242 (or equivalent) to threads during installation.
Workman 3100
Page 5 – 7
Kohler Gasoline Engine
Engine
26
Anti–seize
Lubricant
15
14
16
13
17
18
12
23
25
24
22
11
27
21
10
9
7
19
28
8
29
7
30
6
31
5
32
20
33
43
35 to 41 ft–lb
(47 to 56 N–m)
Anti–seize
Lubricant
35
4
34
3
36
2
37
1
38
RIGHT
FRONT
42
41
39
40
Figure 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Lock nut
Flat washer
Pulley
Woodruff key
Flange nut
Cap screw
Jam nut
Cap screw
Throttle bracket
Lock nut
Throttle lever
Spring
Accelerator cable ball joint
Socket head screw
Shoulder bolt
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
Choke lever
Choke cable
Accelerator cable
Cap screw (2 used)
Lock nut
Flat washer (4 used)
Lock washer (4 used)
Cap screw (4 used)
Woodruff key
Pin (3 used)
Cap screw (6 used)
Lock washer (6 used)
Pressure plate
Clutch disc
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.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
Pilot bearing
Socket head screw
Washer
Flywheel
Clutch adapter
Nut
Positive battery cable
Lock nut (4 used)
Flat washer (4 used)
Engine mount
Cap screw (4 used)
Lock washer
Pump drive belt
Engine assembly
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 Remove Exhaust System in this section).
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
Workman 3100
5. Disconnect fuel line from fuel pump on engine. Plug
end of fuel line to prevent contamination and fuel spillage. Position disconnected fuel line away from engine.
2
3
6. Disconnect and label electrical leads that attach to
engine and engine accessories.
4
5
1
7. Loosen fasteners that secure hydraulic pump to engine mount (Fig. 5). Rotate pump to allow drive belt (Item
42) to be removed from pump and engine pulley.
6
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
4. Pump drive belt
5. Carriage screw
6. Cap screw
13.Loosen and remove four (4) lock nuts (Item 37), flat
washers (Item 38) and cap screws (Item 40) that secure
engine to engine mount. Locate and retrieve lock washer (Item 41) from cap screw on right front corner of engine.
5
4
3
14.Remove four (4) cap screws with lock washers that
secure clutch bell housing to engine (Fig. 6).
Kohler
Gasoline Engine
12.Attach hoist or block and tackle to engine for support.
1. Hydraulic pump
2. Lock nut (2 used)
3. Engine mount
2
1
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 engine out of chassis. Move engine forward before lifting
to disengage transaxle input shaft from clutch.
6
16.Note location and retrieve two (2) bushings (Fig. 6,
item 2) from bell housing.
7
17.If necessary, remove hydraulic pump drive pulley
from stub shaft on flywheel side of engine. Locate and
retrieve woodruff key.
18.If pressure plate and clutch disc removal is necessary, see Clutch Disassembly and Inspection in Chapter
6 – Drive Train.
Figure 6
1.
2.
3.
4.
Engine
Bushing (2 used)
Clutch bell housing
Lock washer (4 used)
5. Cap screw (4 used)
6. Transaxle
7. Clutch adapter
Flywheel and Pilot Bearing Inspection
1. Inspect flywheel (Item 33) surface for stepped wear,
streaking or seizure and replace if necessary. Check flywheel 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. Replace bearing if necessary. Remove pilot bearing by
backing out socket head cap screw that attaches flywheel to crankshaft. Do not reuse bearing if removed.
Workman 3100
Page 5 – 9
Kohler Gasoline Engine
5. If shoulder bolt (Item 15) was removed, apply anti–
seize lubricant to bolt shoulder before installing.
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 engine, apply antiseize lubricant on shaft surface before
installing pulley.
6. Install a new engine oil filter. Fill engine with the correct oil (see Operator’s Manual).
7. Install and adjust hydraulic pump drive belt (see Operator’s Manual).
8. Adjust accelerator and choke cables (see Operator’s
Manual).
9. Lower or install bed or attachment(s).
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
Workman 3100
Chapter 6
Drive Train
Table of Contents
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Take–Off (PTO) Service . . . . . . . . . . . . . . . 54
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Drive Train
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Clutch Alignment Tool . . . . . . . . . . . . . . . . . . . . . . . . 4
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PTO Cable Adjustment . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 10
Shift Cable Replacement . . . . . . . . . . . . . . . . . . . . . 10
Stub Axle and Drive Shaft Service . . . . . . . . . . . . . 12
Drive Shaft Universal Joint Service . . . . . . . . . . . . 14
P.T.O. Removal and Installation (If Equipped) . . . 15
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 reverse 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 transmission 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 independent rear suspension and Dedion type rear axle isolate
the mid–mounted engine/transaxle assembly from the
terrain.
The transaxle housing also functions as the hydraulic
system reservoir.
Transaxle
Figure 1
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 III ATF
8 quart U.S. (7.6 liter) system capacity
Drive Train
Transaxle Oil Capacity
Workman 3000/4000 Series
Page 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.
4
3
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 adjustment.
2
1
Figure 3
3. Clevis pin
4. Clevis jam nut
Drive Train
1. PTO lever arm
2. PTO cable
Workman 3000/4000 Series
Page 6 – 5
Drive Train
Troubleshooting
Clutch
Problem
Possible Causes
Clutch slips.
Excessive wear of clutch disc facing.
Clutch pedal out of adjustment.
Hardening of clutch disc facing, or adhesion of oil.
Weak or broken clutch diaphragm spring.
Damaged pressure plate or flywheel.
Clutch operation erratic or rough.
Improper installation of clutch cover assembly.
Damaged clutch disc.
Excessive wear of clutch disc facing.
Weak or broken clutch torsion spring.
Damaged or broken clutch pressure plate.
Bent or broken clutch diaphragm spring tip.
Dirty or improperly lubricated clutch disk spline.
Damaged or distorted flywheel.
Damaged release bearing.
Clutch noisy.
Improper installation of clutch cover assembly.
Excessive wear 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)
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.
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.
Drive Train
Loose or worn front wheel bearings.
Workman 3000/4000 Series
Page 6 – 7
Drive Train
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.
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 shifter is loose.
Sliding gear tight on shaft or splines.
Synchronizing unit damaged.
Sliding gear teeth damaged.
Synchronizer keys damaged.
Gears make clashing noise when shifting.
Shifting too fast.
Excessive wear of synchro rings.
Excessive wear of differential side gear liners and
pinion liners.
Damaged synchro springs and/or 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)
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.
Excessive hydraulic load.
Drive Train
See Chapter 9 – Hydraulic System.
Workman 3000/4000 Series
Page 6 – 9
Drive Train
Service and Repairs
Shift Cable Replacement
1
2
19
4
3
18
6
7
5
8
9
7
10
8
6
11
11
10
17
16
15
12
4
RIGHT
FRONT
180 to 210 in–lb
(20.3 to 23.7 N–m)
13
14
Figure 4
1.
2.
3.
4.
5.
6.
7.
Shift knob
Jam nut
Boot seal
Shift cable
Shift pin
Jam nut
Cotter pin
Drive Train
8.
9.
10.
11.
12.
13.
Clevis pin
Shift lever
Shift link
Cable clevis
Cap screw
Lower shift boot
Page 6 – 10
14.
15.
16.
17.
18.
19.
Lock nut
Lever support
Hex nut (2 used)
Shift stop bolt (2 used)
Screw (3 used)
Cable clamp
Workman 3000/4000 Series
Removal (Fig. 4)
1. Remove knobs from control levers, then remove center console shift boot and control plate (Fig. 5).
2. Remove three screws (Item 18) and cable clamp
(Item 19) that secure shift cables to lever support.
3. Remove cotter pin and clevis pin that secure shift
cable clevis to shift link (Item 10) on shifter in operator
platform.
4. Loosen jam nut that retains clevis to shift cable and
remove clevis from cable.
1
2
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.
Figure 5
1. Shift boot
2. Control plate
B. Loosen jam nuts on bulkhead fitting of cable.
.390 to .510 in.
(9.9 to 13 mm)
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)
3
4
2
1
1. Route cable in same location as before.
Figure 6
2. Install cable clevis on shift cable. Adjust cable clevis
as shown in Figure 6. Tighten jam nut to secure clevis to
cable.
1. Clevis
2. Shift cable
3. Clamp
4. Shift stop bolt
3
4. Secure shift cables to lever support with cable clamp
(Item 19) and three screws (Item 18).
Drive Train
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.
3
2
5. Spread jam nuts on bulkhead fitting of cable (Fig. 7).
With cable properly routed to transaxle, install cable
bulkhead fitting to shift cable mount bracket on transaxle
and tighten jam nuts.
6. Install cable ties in the original locations to secure
shift cables to vehicle.
1
Figure 7
1. First–Reverse
2. 2nd–3rd
3. Bulkhead jam nut
7. Adjust shift cables (see Operator’s Manual) and secure cable clevis to transaxle shift lever with clevis pin
and cotter pin.
8. Check adjustment of shift stop bolts. Move shift lever
forward until lever stops. Hold lever in stopped position
and adjust stop bolt so that head just contacts lever.
Tighten hex nut on stop bolt.
9. Install shift boot, control plate and control lever
knobs.
Workman 3000/4000 Series
Page 6 – 11
Drive Train
Stub Axle and Drive Shaft Service
25
40 to 60 ft–lb
(54 to 81 N–m)
29
28
16
24
8
23
27
12
22
26
11
Loctite #680
10
21
35 to 42 ft–lb
(47 to 57 N–m)
220 to 250 ft–lb
(298 to 339 N–m)
9 7
6
20
15
19
18
45 to 65 ft–lb
(61 to 88 N–m)
17
13
RIGHT
4
5
14
200 to 250 in–lb
(22.6 to 28.3 N–m)
8
2
1
ACCESS HOLE
FRONT
3
Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Flange nut
Wheel nut (5 used per wheel)
Wheel assembly
Brake drum
Stub axle
Lock washer (5 used per wheel)
Hex bolt (5 used per wheel)
Bearing
Bearing spacer
Cap screw (4 used per brake)
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
Lock washer (4 used per brake)
Brake assembly
Parking brake cable
Cable clip
Axle housing
Seal
End yoke
Yoke strap (2 used per yoke)
Bolt (2 used per strap)
Hardened washer
21.
22.
23.
24.
25.
26.
27.
28.
29.
Flange head screw
Thrust washer
Cap screw
Cap screw
Rear axle
Drive shaft
Flange nut
Hardened washer
Cap screw
1. Loosen wheel nuts.
5. Remove the yoke straps (18) securing driveshaft
bearing cross to the end yoke (17), then disconnect driveshaft from the end yoke.
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.
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.
Disassembly (Fig. 8)
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 adjuster 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 easier 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
Page 6 – 12 Rev. B
Figure 9
Workman 3000/4000 Series
7. Carefully slide stub axle from axle housing.
Assembly (Fig. 8)
8. If required, slide driveshaft from transaxle.
1. If driveshaft was removed from transaxle, apply anti–
seize lubricant to transaxle shaft. Slide driveshaft clamp
end onto splined transaxle shaft.
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 housing 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).
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 shorter 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 housing. Be careful not to damage the bearing seal during
installation.
5. Slide end yoke onto stub axle shaft.
4. Press inner and outer bearing cups from housing.
Press outer bearing cone from stub axle.
IMPORTANT:Flange nut (1) should be replaced
whenever it is removed.
5. Clean all parts thoroughly before reassembly.
6. Insert 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).
6. Position inner and outer bearing cups to axle housing. Press bearing cups into housing until they seat
against the housing shoulder.
7. Pack bearings with lithium based grease.
8. Position outer bearing cone, wide end first, onto stub
axle. Press bearing onto stub axle putting pressure on
inner race of bearing.
9. Insert stub axle with bearing into axle housing. Fill
housing with grease.
10.Insert bearing spacer onto stub axle inside housing.
NOTE: The stepped end of bearing spacer should be
positioned away from stub axle flange.
11. Insert inner, greased bearing, small end first, onto
stub axle inside housing.
IMPORTANT: The bearing seal must be pressed in
so it is flush with the end of the axle housing. The lip
of the seal must be toward the bearing.
12.Install new seal over shaft and into housing with the
seal lip inward. Be careful not to damage the seal during
installation.
Workman 3000/4000 Series
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 in–lb (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 N–m).
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 N–m).
12.Lower vehicle to ground.
Page 6 – 13 Rev. B
Drive Train
Drive Train
9. If bearings are being serviced, remove axle housing
(15) from vehicle:
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 removing and installing bearings to prevent bending.
3. While supporting yoke, use a press to remove cross
and bearings (Item 2).
7
6
4. To install new cross and bearings:
5
A. Apply a coating of grease to bearing bores.
4
B. Press one bearing partially into yoke (Item 3).
2
3
C. Insert cross into yoke and bearing.
1
D. Hold cross in alignment and press bearing in until
it hits the yoke.
Figure 10
E. Install snap ring into groove by first bearing cap
installed.
F. Place second bearing into yoke bore and onto
cross shaft. Press second bearing into yoke.
1.
2.
3.
4.
Snap ring
Cross and bearings
End yoke
Yoke and hub
5. Seal
6. Shaft
7. Tube yoke
G. Tap axle yoke outward with hammer and alignment punch to allow 2nd snap ring to fit. Install snap
ring.
H. Repeat procedure for other yoke.
I. Grease cross until grease comes out of all four (4)
cups.
Drive Train
Page 6 – 14
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.
3
2. Disconnect and label electrical lead that attaches to
PTO switch.
2
1
3. Disconnect hydraulic hose from fitting on PTO. Put labels on hydraulic hoses for proper reassembly. Put caps
or plugs on all open hoses or fittings to prevent contamination. Label hoses and fittings for proper reinstallation.
4. Loosen cap screws and remove nut with washer. Separate P.T.O. and O–ring from transaxle case. Locate and
remove two alignment pins.
Figure 11
1. PTO lever arm
2. Cable clevis
3. Hydraulic hose
PTO Installation
1. Apply multi–purpose grease to O–ring and insert O–
ring into groove of transaxle case. Insert 2 alignment
pins in transaxle case.
11 to 13 ft–lb
(15 to 17 N–m)
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.
Drive Train
4. Connect PTO switch electrical lead.
5. Loosen clevis jam nut and adjust clevis so clevis hole
aligns with hole in PTO arm.
6. Reinstall clevis pin and tighten jam nut after doing adjustment.
Figure 12
1. PTO assembly
Workman 3000/4000 Series
Page 6 – 15
2. Alignment pins
Drive Train
Transaxle
2
6
3
5
7
8
4
3
9
10
2
11
1
12
Loctite #242
13
RIGHT
14
Loctite #242
FRONT
15
Figure 13
1.
2.
3.
4.
5.
Transaxle assembly
Snubbing washer (4 used)
Isolation mount assembly (2 used)
Transaxle mount (2 used)
Lock nut (4 used)
Drive Train
6.
7.
8.
9.
10.
Cap screw (2 used)
Cap screw (4 used)
Shift arm
Nut (3 used)
Hardened washer (3 used)
Page 6 – 16
11.
12.
13.
14.
15.
Shift lever (2 used)
Differential lock lever
Strainer
Shift cable mount bracket
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 other attachment(s). Allow engine and radiator to cool.
1
3
2. Disconnect negative (–) battery cable from battery
first. Then disconnect positive (+) battery cable from battery.
2
3. Remove drain plug from bottom of transaxle (Fig. 14)
and allow oil to drain into a drain pan. Install drain plug.
4. Note orientation of 90o fitting connected to strainer
on side of transaxle. Remove hydraulic hose and 90o fitting from strainer (Fig. 14).
5. Remove muffler (see Muffler Removal in Engine
Chapter).
Figure 14
3. 90o fitting
1. Drain plug
2. Strainer
6. Remove hydraulic filter assembly and bracket.
7. Disconnect and label electrical leads that attach to
transaxle and PTO.
1
8. Disconnect clutch cable from clutch release lever,
then loosen jam nut to remove clutch cable from support
bracket (Fig. 15).
2
3
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).
Figure 15
1. Clutch cable
2. Clutch release lever
3. Support bracket
Drive Train
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. Position 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 Repairs section of Chapter 10 – Front Wheel Drive (4WD)).
1
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 fittings to prevent contamination.
14.Remove PTO, if equipped, from top of transaxle (see
PTO Removal and Installation).
2
Figure 16
1. Differential lock cable
2. Differential lock lever
15.Block front wheels. Jack–up rear of vehicle under
rear axle and install jack stands so transaxle can be removed by sliding out from under rear axle (see Jacking
Information in Operator’s Manual).
Workman 3000/4000 Series
Page 6 – 17
Drive Train
16.Put blocking under engine for support. Support transaxle with a floor jack or suspend transaxle from vehicle
frame rails.
17.Remove transaxle isolation mounts and mount
brackets (Fig. 17).
18.Remove drive shaft clamp bolts, then slide transaxle
side–to–side to disconnect each drive shaft from axle
shafts on transaxle.
1
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.
2
2
19.Remove cap screws securing clutch bell housing to
engine. Note location of washers and harness brackets.
Figure 17
1. Mounting brackets
2. Drive shaft
21.Note location and retrieve dowel pins from bell housing.
4
Installation
1. To install the transaxle, perform Transaxle Removal
procedure in reverse order noting the following:
3
IMPORTANT: Workman 3100 (air cooled, gasoline
engine) vehicles require application of silicone sealant to mating surface of bell housing and clutch
adapter plate on engine. This will 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 N–m).
2
1
Figure 18
1. First–Reverse
2. High–Low
3. 2nd–3rd
4. PTO clutch
200 to 280 in–lb
(22.6 to 31.6 N–m)
200 to 280 in–lb
(22.6 to 31.6 N–m)
B. Apply Loctite #242 (or equivalent) to the threads
of cap screws used to secure the control cable support 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 in–lb (22.6 to
31.6 N–m) while holding lever to prevent torque
transfer into transaxle (Fig. 19).
Apply Loctite 680
to threads and tapers
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).
Figure 19
4. If equipped with PTO, adjust PTO cable (see PTO
Cable Adjustment in the Adjustments section of this
chapter).
Drive Train
Page 6 – 18
Workman 3000/4000 Series
Drive Train
This page is intentionally blank.
Workman 3000/4000 Series
Page 6 – 19
Drive Train
Clutch Service
Silicone sealant
(Workman 3100 only)
5
RIGHT
8
14
FRONT
9
5 to 7 ft–lb
(7 to 9 N–m)
12
11
6
10
13
7
2
4
6
1
9
3
Figure 20
1.
2.
3.
4.
5.
Spring pin
Throw out bearing
Release guide
Clutch release fork
Clutch release shaft
6.
7.
8.
9.
10.
11.
12.
13.
14.
Bushing
Spring pin (2 used)
Bell housing
Oil seal
Cap screw (6 used)
Lock washer (6 used)
Pressure plate
Clutch disc
Spring
5. During assembly, apply anti–seize lubricant to the
following:
Clutch Release Mechanism (Fig. 20)
1. Remove transaxle (See Transaxle Removal in this
section).
2. Inspect main shaft of transaxle for wear or damaged
splines.
3. Remove roll pin (Item 1), then remove throw out
bearing (Item 2). Inspect bearing and replace if it is loose
on the sleeve, if it appears burned or is worn. Make sure
bearing slides freely on release guide (Item 3).
A. Fill annular groove of release bearing and coat remainder of bearing bore.
B. Apply thin coat to outside diameter of release
guide.
C. Apply thin coat to fingers of clutch release fork.
D. Remove any excess lubricant before final assembly.
4. Inspect clutch fork (Item 4), release shaft (Item 5),
and bushings (Item 6) for wear or damage. Inspect extension spring (Item 14). Replace worn or damaged
parts. Replace seals (Item 9).
Drive Train
Page 6 – 20
Workman 3000/4000 Series
Clutch Disassembly and Inspection (Fig. 20)
1. Insert clutch alignment tool (see Special Tools) in flywheel pilot bearing hole to keep clutch disk from falling
off (Fig. 21).
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--lb (7 to
9 N--m). Remove alignment tool from flywheel bearing.
2. Loosen pressure plate screws (Item 10) in a diagonal
sequence.
Clutch Alignment Tool
3. Remove cap screws, washers (Item 11) and pressure plate (Item 12), then slide out the transaxle main
shaft and remove clutch disk (Item 13). Note orientation
of clutch disk as it is removed (Fig. 22).
4. Inspect diaphragm spring end of pressure plate for
wear and uneven height. Replace if wear is evident or if
height difference exceeds 0.020 in. (0.5 mm).
Figure 21
5. Check pressure plate surface for wear, cracks and
color change.
6. Check strap plate rivets for looseness and replace
pressure plate if loose.
Clutch Disc
7. Check clutch disk facing for loose rivets, uneven contact, deterioration due to seizure, adhesion of oil or
grease. Replace clutch disk if damaged.
Engine
Flywheel
Side
Pressure
Plate Side
8. Measure rivet sink and replace clutch disk if out of
specification (Fig. 24).
Clutch disk thickness
standard value
0.307 to 0.339 in. (7.8 to 8.6
mm)
Clutch disk rivet sink
0.012 in. (0.3 mm) minimum
Figure 22
Pressure plate
Drive Train
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 excessive play in rotating direction.
11. Inspect flywheel surface for stepped wear, streaking
or seizure. Replace if necessary. Clean any oil or rust
from flywheel surface with light abrasive. Check flywheel
runout and replace if runout exceeds 0.005 in. (0.13
mm).
Diaphragm spring
Torsion spring
Figure 23
Rivet sink
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 position clutch disk on flywheel.
Workman 3000/4000 Series
Page 6 -- 21 Rev. C
Figure 24
Drive Train
Transaxle Service
Disassembly
NOTE: Item numbers in figures are shown in order of
disassembly; for example, remove Item 1 first, then Item
2, etc. Reassemble in reverse order; for example, install
Item 1 last.
1
1. Remove extension spring (Item 1).
2. Loosen cap screws (Item 2) and remove bell housing
assembly from transaxle.
2
3. Thoroughly clean outside surface of transaxle.
Figure 25
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 cover as steel
balls inside are spring loaded.
2
1
Figure 26
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.
2
6. Inspect fork shaft case for cracks or damage and replace if necessary.
3
1
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. Remove seal cap (Item 1), shims (Item 2 and 4) and snap
ring (Item 3) from center plate.
3
4
1
2
Figure 28
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.
FRONT DRIVE
SHAFT
BEARING
(CENTER PLATE)
BEARING
(GEAR CASE)
41T GEAR
Figure 29
Drive Train
9. Remove reverse shaft (Item 1) from transaxle case.
1
2
Figure 30
2
10.Remove main shaft assembly (Item 1) together with
fork shaft assembly (Item 2) from transaxle case.
1
Figure 31
Workman 3000/4000 Series
Page 6 – 23
Drive Train
11. Remove, all at the same time, reduction shaft assembly (Item 1), 2nd–3rd shift assembly (Item 2), countershaft assembly (Item 3) and High–Low shift assembly
(Item 4).
2
4
1
3
Figure 32
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.
Figure 33
13.Remove roll pin from differential lock lever. Remove
lever (Item 1) from shaft. Loosen cap screws (Item 2)
and remove L.H. side cover (Item 3) from transaxle
case.
2
14.Inspect side cover for cracks or damage and replace
if necessary.
3
1
Figure 34
15.Loosen cap screws (Item 1) and remove R.H. axle
shaft assembly (Item 2) from transaxle case.
1
2
Drive Train
Page 6 – 24
Figure 35
Workman 3000/4000 Series
16.Remove differential gear assembly (Item 1) together
with fork shaft assembly (Item 2).
1
2
Figure 36
17.Remove washer (Item 1) from inside of transaxle
case. NOTE: Washer may stick to fork shaft when removed in step 16.
1
Drive Train
Figure 37
Workman 3000/4000 Series
Page 6 – 25
Drive Train
18.To remove shift arms:
1
2
A. Loosen and remove nut (Item 1). Remove washer (Item 2) and 2nd–3rd shift arm (Item 3) together
with shift arm plate (Item 4), spring (Item 5), locknut
(Item 6), washer (Item 7) and cap screw (Item 8).
B. 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.
4
6
8
7
5
3
9
10
11
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 38
14
12
13
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.
2
3
1
Figure 40
Drive Train
Page 6 – 26
Workman 3000/4000 Series
20.Remove oil cap (Item 1) and O–ring from transaxle
case if necessary.
1
21.Remove air breather (Item 2) if necessary.
2
Figure 41
22.Loosen cap screws (Item 1) and remove upper cover
(Item 2) from transaxle case.
2
1
Drive Train
Figure 42
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).
Figure 43
E. Remove snap ring (Item 7).
F. Remove shifter (Item 8) together with spring, hub
and 3 keys.
G. Remove key (Item 9).
1
2
3 5
4
8
6
15
16
1817
14
9
H. Remove snap ring (Item 10).
19
I. 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.
10
6
11
12
13
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).
7
Figure 44
Drive Train
Page 6 – 28
Workman 3000/4000 Series
24.Disassemble reduction shaft assembly:
1
A. Use a bearing puller to remove bearing (Item 1)
from reduction shaft.
5
3
15
14
13
10
7
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. Remove washer (Item 7), needle bearing (Item 9)
and gear (Item 8).
4
2
18
E. Remove spacer (Item 10).
17
16
F. Remove snap ring (Item 11).
12
11
8
6
9
G. Remove shifter (Item 12) together with spring,
hub and 3 keys.
Figure 45
H. Remove key (Item 13).
I. Remove synchro ring (Item 14) from gear (Item
15).
J. Remove gear (Item 15), needle bearing (Item 16)
and thrust washer (Item 17). Inspect needle bearing
and replace if necessary. Measure thickness of
thrust washer. Replace thrust washer if thickness is
less than .0709 in. (1.8 mm).
14
12
15
13
17
16
8
18
97
6
11
5
3
4
Drive Train
1
2
Figure 46
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 (Item 6) and thrust washer (Item
7). Inspect inner for wear and damage. Replace in
ner if O.D. is less than 1.258 in. (31.95 mm). Measure
thickness of thrust washer. Replace thrust washer if
thickness is less than .0709 in. (1.8 mm).
E. Remove 2 snap rings (Item 8).
F. Remove Hi–Lo shifter (Item 9) and collar spline
(Item 10).
Figure 48
G. Remove gear (Item 11). Inspect bushing for wear
and damage. Replace gear if I.D. exceeds 1.184 in.
(30.08 mm).
16
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)
I. Use a bearing puller to remove 2 bearings (Item
15).
1
2
3
4
6
5
7
8
9
8
10
12
11
13
14
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.
Figure 50
28.Disassemble Hi–Lo fork shaft assembly:
5
1
A. Remove shift fork (Item 1), steel ball (Item 2) and
spring (Item 3) from Hi–Lo shift fork assembly.
4
B. Remove E–ring (Item 4).
3
2
Figure 51
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).
Drive Train
D. Loosen screws (Item 5) from ring gear.
E. Remove ring gear (Item 6) from differential case
and remove 2 dowel pins (Item 7).
F. Drive lock pin (Item 8) out of pinion shaft (Item 9).
G. Remove pinion shaft (Item 9) from differential
case.
H. Remove 2 differential pinions (Item 10) and 2 liners (Item 11).
I. Remove L.H. side gear (Item 12), R.H. side gear
(Item 13) and 2 liners (Item 14).
Figure 52
11
2
3
10
4
6
9
7
8
12
14
14
13
10
11
1
5
1
Figure 53
Workman 3000/4000 Series
Page 6 – 31
Drive Train
30.Disassemble differential fork shaft assembly:
A. Remove O–ring (Item 1) from fork shaft.
B. Remove snap ring (Item 2), washer (Item 3) and
spring (Item 4).
C. Remove fork (Item 5).
D. Remove lock pin (Item 6) if necessary.
Figure 54
31.Disassemble axle shaft assemblies:
A. Remove O–ring (Item 1) from differential carrier.
B. Remove snap ring (Item 2).
C. Remove L.H. axle shaft assembly (Item 3).
D. Remove snap ring (Item 4) and washer (Item 5).
E. Use a bearing puller to remove bearing (Item 6)
from axle shaft.
L.H. SHAFT
F. Remove oil seal (Item 7) from differential carrier
(Item 8).
G. Remove R.H. axle shaft assembly (Item 1) from
seal cover.
H. Remove snap ring (Item 2) and washer (Item 3)
from axle shaft.
I. Use a bearing puller to remove bearing (Item 4).
R.H. SHAFT
J. Remove oil seal (Item 5) from seal cover.
Figure 55
Drive Train
Page 6 – 32
Workman 3000/4000 Series
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.
C. Measure the clearance between synchronizer
ring and synchro gear in three equally spaced points.
If clearance is less than .0195 in. (0.5 mm) replace
the synchronizer ring.
4. Inspect synchro gears:
Figure 56
A. Inspect the cone surface for roughness, material
transfer (brass color material) or damage.
B. Inspect the spline chamfer for excessive chipping
or damage.
C. Inspect I.D. of synchro gear for excessive wear or
scoring. If synchro gears have the following I.D., re-
place the synchro gear:
I.D. exceeds 1.027 in. (26.08 mm)
I.D. exceeds 1.145 in. (29.08 mm)
5. On 4WD units, inspect 41T gear and front drive
shaft (Fig. 57):
A. Inspect gear teeth for roughness, material transfer (brass color material) or damage.
FRONT DRIVE
SHAFT
BEARING
(CENTER PLATE)
BEARING
(GEAR CASE)
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.
41T GEAR
Figure 57
Workman 3000/4000 Series
Page 6 – 33
Drive Train
Drive Train
22T, 25T, 40T
49T
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. The shifter should move freely on the hub.
F. Measure the clearance between shifter groove
and fork. Replace shift fork, if the clearance exceeds
.039 in. (1.0 mm).
Figure 58
7. Inspect main shaft:
A. Inspect main shaft for worn or damaged surface.
If O.D. of needle bearing surface is less than .864 in.
(21.95 mm), replace the main shaft.
B. Inspect lip portion of oil seal for wear or damage.
C. Insert spline in clutch disk and check for excessive looseness and free sliding of clutch disk hub.
Figure 59
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).
3
4
1
2
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
Figure 61
DAMAGED
GROOVE EDGES
Drive Train
Figure 62
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.
Figure 63
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.
Figure 64
12.Inspect differential:
A. Inspect pinion shaft for excessive wear or damage. If O.D. is less than .707 in. (17.95 mm), replace
the pinion shaft.
B. Measure thickness of pinion liners. If thickness is
less than .035 in. (0.9 mm), replace the pinion liners.
C. Measure thickness of side gear liners. If thickness is less than .043 in. (1.1 mm), replace the side
gear liners.
D. Inspect the gear contact condition between spiral
bevel pinion and ring gear.
E. Inspect differential case for wear in side gears
and pinion shaft mating area. Replace the case if machined surfaces are scored or if the pinion shaft fits
loosely in the bore.
Drive Train
Page 6 – 36
Figure 65
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 before reassembling. Make sure all parts are clean and
free of dirt and dust.
IMPORTANT: Be careful not to damage mating surfaces when removing gasket material.
2. Assemble L.H. axle shaft:
A. Install new oil seal (Item 7) into differential carrier.
B. Use a press to install bearing (Item 6) onto L.H.
axle shaft.
C. Install washer (Item 5) and snap ring (Item 4).
D. Install L.H. axle shaft assembly into differential
carrier.
L.H. SHAFT
E. Install snap ring (Item 2).
F. 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.
R.H. SHAFT
C. Use a press to install bearing (Item 4) onto R.H.
axle shaft.
D. Install washer (Item 3) and snap ring (Item 2).
E. Install R.H. axle shaft assembly into seal cover
(Item 7).
Figure 66
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.
ARM
B. 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 O–ring before installing.
Figure 67
Workman 3000/4000 Series
Page 6 – 37
Drive Train
Drive Train
B. Insert washer (Item 6).
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. Insert pinion shaft (Item 9). Grease the shaft to
aid assembly.
E. Assemble lock pin (Item 8). Drive the pin to the
approximate center location of the pinion mate shaft.
Pay attention to direction of slit in lock pin.
Figure 68
F. Check for smooth revolution of pinion gears and
side gears.
11
2
3
10
4
9
6
G. Completely clean oil from threads in ring gear
(Item 6).
7
NOTE: Ring gear and countershaft are supplied in
matched sets only.
H. Insert 2 dowel pins (Item 7) onto ring gear (Item
6).
8
12
14
14
13
10
18.5 to 22 ft–lb
(24.5 to 29.5 N–m)
I. Completely clean oil from threads of cap screws
(Item 5).
NOTE: It is recommended that whenever the ring
gear screws are removed that they be replaced with
new screws.
11
1
5
1
Figure 69
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–
lb (24.5 to 29.5 N–m).
Figure 70
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:
5
A. Install E–ring (Item 4) onto fork shaft (Item 5).
1
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. Assemble R–1 and 2–3 fork shaft:
4
3
2
Figure 72
A. Insert R–1 fork shaft (Item 2) into R–1 fork (Item
3).
B. Drive lock pin (Item 1) into fork and fork shaft. Pay
attention to direction of slit in lock pin.
C. Insert 2–3 fork shaft (Item 2) into 2–3 fork (Item 3).
D. Drive lock pin (Item 1) into fork and fork shaft. Pay
attention to direction of slit in lock pin.
Drive Train
Figure 73
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 inner (Item 6). Oil groove on washer must face the
gear.
Figure 74
G. Install gear (Item 5).
H. Install washer (Item 4) and snap ring (Item 3). Oil
groove on washer must face the gear.
16
I. Install washer (Item 2) and a new bearing (Item 1)
using a press.
1
2
3
4
6
5
7
8
9
8
10
12
11
13
14
15
Figure 75
Drive Train
Page 6 – 40
Workman 3000/4000 Series
9. Assemble synchro hub:
A. Install 3 keys (Item 1) into grooves of hub (Item 2).
1
2
Figure 76
B. Install shifter (Item 1) onto hub (Item 2).
1
2
Figure 77
Drive Train
C. Insert 2 springs (Item 3) into hub. Pay attention to
direction of spring.
Figure 78
Figure 79
Workman 3000/4000 Series
Page 6 – 41
Drive Train
10.Assemble reduction shaft:
1
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.
5
3
15
14
13
10
7
B. Install synchro ring (Item 14) onto gear (Item 15).
Apply Dexron III transmission oil on cone face of gear
before installing synchro ring.
C. Insert key (Item 13) onto reduction shaft.
4
2
18
17
16
12
11
8
D. Install synchro hub sub–assembly (Item 12).
6
9
E. Install snap ring (Item 11).
Figure 80
F. Install spacer (Item 10) onto gear (Item 8).
G. Insert needle bearings (Item 9) into gear (Item 8).
H. Install washer (Item 7). Oil groove on washer
must face the gear.
I. Use a press to install bearing (Item 6).
14
12
15
13
17
16
8
18
97
6
11
5
1
2
3
4
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).
B. Install gear (Item 15).
C. Use a press to install bearing (Item 14).
D. Install washer (Item 13) and 2 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.
Figure 83
E. Install gear (Item 11) and snap ring (Item 10).
1
G. Insert key (Item 9).
2
3
5
4
6
8
17
18
15
16
14
9
Drive Train
F. Install synchro ring (Item 6) onto gear (Item 11).
Apply Dexron III transmission oil on cone face of gear
before installing synchro ring.
19
H. Install synchro hub sub–assembly (Item 8).
10 6
I. Install snap ring (Item 7).
11
12
13
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.
7
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:
A. Install 3 new oil 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).
1
2
200 to 280 in–lb
(22.6 to 31.6 N–m)
200 to 280 in–lb
(22.6 to 31.6 N–m)
8
7
5
4
6
3
9
10
11
Apply Loctite 680
to threads and tapers
9
10
11
C. Apply Loctite #680 (or equivalent) to threads and
tapers of shift fork arms.
D. Install 2 shift arms (Item 11). Install shift arm assembly (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 in–lb (22.6 to 31.6 N–m).
Figure 85
14
12
13
Figure 86
14.Install oil cap (Item 1) with O–ring. Apply multi–purpose grease to O–ring.
1
2
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 88
Drive Train
Figure 89
17.Install main shaft together with 2–3 fork shaft. Insert
head of shift arm into groove of fork while installing.
Figure 90
Figure 91
Workman 3000/4000 Series
Page 6 – 45
Drive Train
18.Install reverse shaft (Item 1). Rotate main shaft and
reverse shaft gears to mesh gears when installing.
1
2
Figure 92
19.On 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.
FRONT DRIVE
SHAFT
BEARING
(CENTER PLATE)
BEARING
(GEAR CASE)
41T GEAR
Figure 93
20.Install center plate:
A. Insert 2 dowel pins into transaxle case.
B. Apply silicone sealant onto mating surface of
center plate.
C. Position center plate to transaxle.
D. Install and tighten cap screws to a torque from
18.5 to 22 ft–lb (24.5 to 29.5 N–m).
E. Apply multi–purpose grease onto lips of oil seal,
then insert oil seal flush with face of housing.
F. Apply moly disulfide grease to spline of main
shaft for clutch disk hub.
Drive Train
Page 6 – 46
Figure 94
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. Insert 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).
3
4
1
2
Figure 95
5
22.Install snap ring into the groove of the bearing housing (Fig. 96 and 97).
3
1
6
4
2
Figure 96
4. Snap ring
5. Center plate
6. Sealing cap
Drive Train
1. Countershaft
2. Bearing
3. Shims
Figure 97
Workman 3000/4000 Series
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. Rotating the shaft in one direction will pull the shaft and bearing 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 in. (0.00 to 0.10 mm)
(Fig. 98).
IMPORTANT: If end play is too large, replace shim/
shim set (item 2) in steps 21 and 22 with thicker
shims to reduce endplay.
Figure 98
24.Insert sealing cap (Item 1) flush with face of housing.
Make sure not to insert sealing cap too far. Pay attention
to direction of sealing cap.
1
Figure 99
Drive Train
Page 6 – 48
Workman 3000/4000 Series
25.Install fork shaft case:
A. Insert spindle (Item 1) between fork shafts.
1
Figure 100
B. Insert 2 steel balls (Item 2) and 2 springs (Item 1)
into the grooves.
1
2
Figure 101
C. Apply silicone sealant to mating surface of fork
shaft case.
2
Drive Train
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 N–m). Check operation of shifters and detent.
1
Figure 102
26.Insert a washer (Item 1) into housing of transaxle
case. Apply moly disulfide grease to washer before
installing.
1
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.
Figure 104
1
2
Figure 105
28.Install side cover:
A. Insert 2 dowel pins onto transaxle case.
B. Apply silicone sealant onto mating surface of side
cover.
C. Install side cover. Tighten cap screws to a torque
from 18.5 to 22 ft–lb (24.5 to 29.5 N–m).
Figure 106
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 18.5 to 22 ft–lb
(24.5 to 29.5 N–m).
Drive Train
Page 6 – 50
1
2
Figure 107
Workman 3000/4000 Series
30.Install L.H. axle shaft assembly:
A. Thoroughly clean mating surface of differential
carrier and side cover (Item 1).
1
B. Insert selected shims (Item 2) into housing of side
cover. NOTE: The thickest shim should be inserted
against the bearing.
2
Figure 108
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).
1
Figure 109
Drive Train
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
Figure 110
Drive Train
32.Install differential lock arm (Item 1) onto fork shaft. Insert lock pin into fork shaft and arm. Pay attention to
direction of slit in lock pin.
1
Figure 111
33.Apply silicone sealant to mating surface of upper
cover (Item 2). Pay attention to direction of cover and
install. Tighten cap screws (Item 1) to a torque from 18.5
to 22 ft–lb (24.5 to 29.5 N–m).
2
1
Figure 112
Drive Train
Page 6 – 52
Workman 3000/4000 Series
34.Apply multi–purpose grease to O–ring and insert O–
ring into groove of transaxle case. If installing P.T.O., insert 2 dowel pins in transaxle case. Install P.T.O. or
cover. Tighten nut with lockwasher (Item 2) and cap
screws (Item 1) to a torque from 11 to 13 ft–lb (15 to 17
N–m).
2
3
1
Figure 113
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 N–m).
1
36.Install extension spring (Item 1).
2
Drive Train
Figure 114
Workman 3000/4000 Series
Page 6 – 53
Drive Train
Power Take–Off (P.T.O.) Service
33
34
35
3
32
28
26
29
30
1
31
17
25
2
3
24
27
11
18 to 22 ft–lb
(24.5 to 29.5 N–m)
2
4
17
5
3
6
22
21
8
7
9
20
23
19
17
12
11
10
13
14
18
16
15
Figure 115
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
PTO cover
Cap screw (4 used)
Lock washer (7 used)
Cap screw (3 used)
O–ring
Shift arm
Shifter block
Spring
Ball
Retaining ring
Bearing
Input shaft
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
Shift collar
Gear (29T)
Bushing
Thrust washer
Bearing
Retaining ring
Shift lever
Spring pin
Spring pin
Alignment pin (2 used)
PTO housing
Gear (27T)
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
Intermediate shaft
Gear (37T)
Retaining ring
Retaining ring
Thrust washer
Bearing
Oil seal
Output shaft
Stud
Lock washer
Hex nut
Disassembly (Fig. 115)
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. Put vehicle on a level surface. Stop the engine and
remove key from ignition switch. Remove the bed or other attachment(s). Allow engine and radiator to cool.
2. Remove PTO from top of transaxle (see PTO Removal 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.
1
Figure 117
6. Remove intermediate shaft assembly (Item 1) from
PTO housing. Remove intermediate gear (Item 2). Remove bearing (Item 3) from housing if necessary.
2
1
Drive Train
Figure 118
3
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.
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.
Figure 120
H. Release shift arm (Item 8) from shifter block (Item
9).
8
I. Remove input shaft assembly.
6
3
7
Figure 121
8. Disassemble PTO input shaft:
A. Remove shift collar (Item 1).
2
1
B. Remove 2 steel balls (Item 2) and spring (Item 3).
3
2
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.
1
Figure 123
10.Disassemble PTO output shaft:
A. Use a bearing puller to remove bearing (Item 1).
B. Remove gear (Item 2) and retaining ring (Item 3).
C. Remove retaining ring (Item 4) and thrust washer
Item 5).
D. Use a bearing puller to remove bearing (Item 6) if
necessary.
Figure 124
4
Drive Train
5
6
7
3
1
2
Figure 125
11. Disassemble shift arm:
A. Remove two (2) lock pins from shift arm.
B. Remove two (2) O–rings (Item 1).
1
Figure 126
Workman 3000/4000 Series
Page 6 – 57
Drive Train
Inspection
1. Thoroughly clean and dry all parts.
2. Use emery cloth to remove nicks and burrs from all
parts.
3. Measure clearance between groove on shift collar
and shifter block. Replace shifter block if clearance exceeds .039 in. (1.0 mm).
Figure 127
4. Measure I.D. of input shaft bushing (Item 1). Replace
bushing if I.D. exceeds .673 in. (17.10 mm).
1
Figure 128
5. Measure O.D. of bushing area on input shaft. Replace shaft if O.D. is less than .667 in. (16.95 mm). Inspect surface of bushing area for scoring or damage.
Figure 129
6. Inspect surface of oil seal area on output shaft for
wear or damage.
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 housing and cover.
3
2
1
IMPORTANT: Be careful not to damage mating surfaces when removing gasket material.
2. Make sure all parts are free of dirt and dust.
3. Assemble shift arm:
Figure 131
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.
C. Install shift arm into PTO housing.
D. 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.
Drive Train
Figure 132
5
Figure 133
Workman 3000/4000 Series
Page 6 – 59
Drive Train
4. Assemble PTO output shaft:
5
6
4
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).
7
D. Use a press to install bearing (Item 1).
3
1
2
Figure 134
Figure 135
5. Use a press to install bearing (Item 1) onto intermediate shaft.
1
Figure 136
6. Assemble PTO input shaft:
A. Insert spring (Item 3) and two (2) steel balls (Item
2) into hole.
2
1
B. Insert shift collar (Item 1) onto input shaft.
3
C. Move shift collar to ”ON” position.
2
Figure 137
Drive Train
Page 6 – 60
Workman 3000/4000 Series
7. Install PTO input shaft sub–assembly:
7
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. Install gear (Item 7) with bushing and thrust wash
er (Item 6) onto input shaft after sliding the assembly
toward PTO shaft side. Apply moly disulfide grease
to bushing of gear and thrust washer before instal
ling.
3
6
5
4
Figure 138
D. Slide two (2) bearings (Items 5 and 4) onto input
shaft.
E. Install two (2) retaining rings (Items 2 and 1).
3
Drive Train
Figure 139
6
7
Figure 140
Moly disulfide
grease
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.
3
Figure 142
B. Put gear (Item 2) on mating gear.
C. Move gear until bores of gear and bearing line up.
D. Insert intermediate shaft sub–assembly (Item 1).
Apply grease to intermediate shaft to aid assembly.
2
1
Figure 143
9. Insert PTO shaft assembly (Item 1) into bearing
housing of PTO housing.
1
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).
Figure 145
Drive Train
11. Install PTO to transaxle (see PTO Removal and
Installation in this chapter).
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
Chassis
Table of Contents
Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . .
Brake Master Cylinder Service . . . . . . . . . . . . . . .
Parking Brake Cable Replacement . . . . . . . . . . .
Steering Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Arm Ball Joint Replacement . . . . . . . . . .
Tie Rod End Replacement . . . . . . . . . . . . . . . . . .
Front Wheel Alignment . . . . . . . . . . . . . . . . . . . . .
Front Compression Spring Service . . . . . . . . . . .
Front Shock Absorber Replacement . . . . . . . . . .
Rear Shock Absorber Replacement . . . . . . . . . .
Rear Leaf Spring Replacement . . . . . . . . . . . . . .
Seat Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
21
22
23
24
25
26
27
28
29
30
32
Chassis
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4
Suspension and Steering . . . . . . . . . . . . . . . . . . . . 4
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 8
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front Wheel Assembly (2 Wheel Drive) . . . . . . . 10
Rear Wheel Assembly . . . . . . . . . . . . . . . . . . . . . . 12
Brake Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wheel Brake Cylinder Service . . . . . . . . . . . . . . . 17
Bleeding the Brakes . . . . . . . . . . . . . . . . . . . . . . . . 18
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 N–m)
Brake fluid
DOT 3
Tire Pressure
1. Tire pressure needed is determined by the payload
carried.
2. The lower the air pressure, the less the compaction,
and tire marks are minimized. Lower pressure should
not be used for heavy payloads at high speeds. Tire
damage may result.
3. High pressure should be used for heavier payloads
at higher speeds. Do not exceed maximum tire pressure.
4. See 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
compression springs.
Qty.
5”
Item
2
1/2” x 20” threaded steel rods
4
1/2” nuts
4
1/2” flat washers
5”
20”
Chassis
Figure 1
Workman 3000/4000 Series
Page 7 – 3
Chassis
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).
Rear end noise.
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).
Excessive steering play.
Loose or worn front wheel bearings.
Loose or worn steering linkage.
Worn tie rod ends.
Front wheel shimmy.
Loose or worn front wheel bearings.
Tires out of round or uneven tire wear.
Worn tie rod ends.
Incorrect front wheel alignment (toe–in).
Worn shock absorbers.
Instability (wander).
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 ball joints.
Chassis
Page 7 – 4
Workman 3000/4000 Series
Suspension and Steering (Continued)
Problem
Possible Causes
Hard steering.
Loose, worn or glazed hydraulic pump drive belt.
Binding or damaged steering linkage.
Low or uneven tire pressure.
Low hydraulic pressure (see Chapter 9 – Hydraulic
System).
Damaged or binding steering cylinder.
Worn or damaged steering control valve.
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.
Chassis
Worn or damaged brake components.
Workman 3000/4000 Series
Page 7 – 5
Chassis
Brakes
Problem
Possible Causes
Brake pedal goes to floor.
Incorrectly adjusted brakes.
Low brake fluid level.
Air in brake system.
Leaking wheel cylinder(s).
Loose or broken brake lines.
Leaking or worn brake master cylinder.
Excessively worn brake shoes or drums.
Spongy brake pedal.
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)
Problem
Possible Causes
Dragging brakes.
Improper brake or parking brake adjustment.
Parking brake engaged.
Weak or broken brake shoe return spring.
Binding brake pedal.
Sticking brake master cylinder.
Saturated brake linings.
Bent or out of round brake drums.
Hard brake pedal.
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.
Surge at slow speeds.
Chatter at fast speeds.
Bent or out of round brake drums.
Shoe lock.
Machining grooves in contact face of brake drums.
Weak hold down springs.
Brakes do not self adjust.
Adjuster bolt seized in thread.
Workman 3000/4000 Series
Page 7 – 7
Chassis
Adjuster lever does not engage star wheel.
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 N–m).
WARNING
Failure to maintain proper wheel nut torque
could result in failure or loss of wheel and may
result in personal injury. Torque front and rear
wheel nuts from 45 to 65 ft–lb (61 to 88 N–m) at
intervals recommended in Operator’s Manual.
Figure 2
1. Wheel assembly
Chassis
Page 7 – 8
2. Wheel nut (5 used)
Workman 3000/4000 Series
Chassis
This page is intentionally blank.
Workman 3000/4000 Series
Page 7 – 9
Chassis
Front Wheel Assembly (2 Wheel Drive)
3
5
1
45 to 65 ft–lb
(61 to 88 N–m)
6
Loctite #680
2
8
40 to 60 ft–lb
(54 to 81 N–m)
10
4
9
11
12
See tightening
procedure in text
13
17
18
19
20
7
RIGHT
14
ACCESS HOLE
15
16
FRONT
Figure 3
1.
2.
3.
4.
5.
6.
7.
Dust cap
Cotter pin
Nut retainer
Jam nut
Tab washer
Wheel nut (5 used per wheel)
Wheel assembly
8.
9.
10.
11.
12.
13.
14.
Brake drum
Outer bearing cone
Outer bearing cup
Front hub
Lock washer (5 used per wheel)
Hex bolt (5 used per wheel)
Inner bearing cup
15.
16.
17.
18.
19.
20.
Inner bearing cone
Bearing seal
Cap screw (4 used per brake)
Lock washer (4 used per brake)
Brake assembly (RH shown)
Spindle (RH shown)
NOTE: For Workman 4000 Series front wheel service
procedures, see Front Wheel and Axle Housing Assembly in the Service and Repairs section of Chapter 10 –
Front Wheel Drive (4WD).
4. Pull seal out of wheel hub and discard seal. Remove
inner bearing cone from wheel hub. Check bearing cups
for wear, pitting or other damage. Replace worn or damaged parts.
Disassembly (Fig. 3)
Assembly (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.
1. If hex bolts and lock washers were removed from the
from hub:
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 adjuster assembly. Use a hooked piece of wire to pull pawl
away from star wheel, then turn star wheel.
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. Remove brake drum from front hub.
2. If bearing cups were removed from hub, press new
cups into hub until they seat against inside shoulder of
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.
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.
Chassis
Page 7 – 10
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.
8. Adjust brake shoes:
A. Align access hole in brake drum with adjuster bolt
on adjuster assembly.
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 N–m). 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–lb (12 to 17 kg–cm). Position nut retainer 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 access hole in
brake drum aligns with hole in front hub.
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 N–m).
CAUTION
After reassembly, check the brakes in a wide
open, level area that is free of other persons and
obstructions.
Chassis
10.Check brake operation.
Workman 3000/4000 Series
Page 7 – 11
Chassis
Rear Wheel Assembly
25
40 to 60 ft–lb
(54 to 81 N–m)
16
24
8
23
12
11
22
Loctite #680
10
26
220 to 250 ft–lb
(298 to 339 N–m)
9 7
21
6
15
20
19
18
FRONT
45 to 65 ft–lb
(61 to 88 N–m)
17
13
RIGHT
4
5
14
200 to 250 in–lb
(22.6 to 28.3 N–m)
8
2
1
ACCESS HOLE
3
Figure 4
1.
2.
3.
4.
5.
6.
7.
8.
9.
Flange nut
Wheel nut (5 used per wheel)
Wheel assembly
Brake drum
Stub axle
Lock washer (5 used per wheel)
Hex bolt (5 used per wheel)
Bearing
Bearing spacer
10.
11.
12.
13.
14.
15.
16.
17.
18.
Cap screw (4 used per brake)
Lock washer (4 used per brake)
Brake assembly
Parking brake cable
Cable clip
Axle housing
Seal
End yoke
Yoke strap (2 used per yoke)
19.
20.
21.
22.
23.
24.
25.
26.
Bolt (2 used per strap)
Hardened washer
Flange head screw
Thrust washer
Cap screw
Cap screw
Rear axle
Drive shaft
For rear wheel assembly service procedures, see 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
Chassis
This page is intentionally blank.
Workman 3000/4000 Series
Page 7 – 13
Chassis
Brake Service
2
49 to 97 in–lb
(5.5 to 11 N–m)
8
1
7
13
26
25
5
4
3
11
6
9
12
10
10
24
12
11
14
16
17
18
21
13
15
27
19
20
23
22
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
9.
Cap screw and lock washer (2 used)
Backing plate
Plug
Bleed screw
Bleed screw cap
Brake cylinder body
Parking brake lever
Pin
Spring
Chassis
10.
11.
12.
13.
14.
15.
16.
17.
18.
L–type seal
Piston
Dust cover
Brake shoe
Upper shoe spring
Lower shoe spring
Female push rod
Bolt adjuster
Adjuster sleeve
Page 7 – 14
19.
20.
21.
22.
23.
24.
25.
26.
27.
Pawl
Adjuster spring
Pawl pin
Hold down washer (2 used)
Hold down spring (2 used)
Pipe guide
Inspection plug
Hold down pin (2 used)
Adjuster assembly
Workman 3000/4000 Series
B. Replace drums if they are cracked or heat
spotted.
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.
NOTE: It may be necessary to back off adjuster to remove brake drum. To back off adjuster, rotate brake
drum until access hole lines up with bolt adjuster on adjuster assembly. Use a hooked piece of wire to pull pawl
away from bolt adjuster, then turn bolt adjuster.
3. Remove brake drum.
4. If servicing front brakes, remove wheel hub from vehicle (see Front Wheel Assembly (2 Wheel Drive) in this
section for series 3000 Workman vehicle or see Front
Wheel and Axle Housing Assembly in the Service and
Repairs section of Chapter 10 – Front Wheel Drive
(4WD) for series 4000 Workman vehicle).
5. If servicing rear brakes, remove stub axle from vehicle (see Stub Axle and Drive Shaft Service in the Service and Repairs section of Chapter 6 – Drive Train).
6. Remove upper shoe spring (14), adjuster spring (20)
and then lower shoe spring (15).
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 replaced for both wheels on the axle. Equal braking
forces must be maintained.
A. Replace if linings are excessively worn or damaged. Oil, grease or brake fluid contamination is not
acceptable.
B. Replace if shoe webbing show signs of overheating 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, corroded or bent. Replace washers and springs if they are
unable to lock onto the pin.
NOTE: The adjuster assembly (27) consists of the female push rod (16), bolt adjuster (17) and adjuster
sleeve (18).
7. Remove hold down washers (22) and hold down
springs (23) from the hold down pins (26). Remove
brake shoes (13), pawl (19) and adjuster assembly (27).
7
1
4
4
8. If servicing rear brakes, disengage parking brake
cable from parking brake lever.
9. See Brake Cylinder Service in this section for information on brake cylinder disassembly, inspection and
assembly procedures.
8
6
2
3
Chassis
2. If servicing rear brakes, loosen set screw on parking
brake control lever knob. Turn knob on parking brake lever counterclockwise all the way to loosen parking brake
cable adjustment.
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 removed with sand paper.
10.If needed, remove brake backing plate from vehicle
by removing four cap screws and lock washers.
1. Clean and inspect brake drum any time they are removed for brake service.
A. Check drum diameter at a minimum of three locations. Diameter should not exceed the over size limit
cast into the outside of the drum. Replace drum if limit is exceeded.
Workman 3000/4000 Series
5
5
Inspection
Figure 6
1.
2.
3.
4.
Page 7 – 15
Upper shoe spring
Adjuster spring
Lower shoe spring
Hold down washer
5.
6.
7.
8.
Brake shoe
Adjuster assembly
Brake cylinder assy
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. 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 removed by sanding lightly with emery cloth.
B. Replace if cracked, warped or excessively
rusted.
11. If servicing front brakes, install wheel hub to vehicle
(see Front Wheel Assembly (2 Wheel Drive) in this section for series 3000 Workman vehicle or see Front
Wheel and Axle Housing Assembly in the Service and
Repairs section of Chapter 10 – Front Wheel Drive
(4WD) for series 4000 Workman vehicle).
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 adjuster.
6. Inspect female push rod (16), bolt adjuster (17) and
adjuster sleeve (18) for rust, corrosion, bending and fatigue. Replace parts as necessary.
B. Rotate bolt adjuster to increase adjuster length
until brake shoes contact brake drum.
Assembly (Fig. 5 and 6)
C. Back off adjuster until drum rotates freely.
1. If backing plate was removed from vehicle, secure
backing plate to vehicle with four cap screws and lock
washers.
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 N–m).
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
brake 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
CAUTION
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
16.After servicing brakes, start the engine and depress
brake pedal several times while vehicle is moving in reverse.
17.Adjust parking brake (see 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.
Page 7 – 16
Workman 3000/4000 Series
Wheel Brake Cylinder Service
Disassembly
1. Disassemble brakes as described in Brake Service.
5
2. If brake line is still attached to brake cylinder, disconnect brake line from cylinder. Put a cap on brake line to
prevent contamination of system and brake fluid leakage.
6
7
1
4
1
3. Remove two (2) cap screws and lock washers that
secure brake cylinder to brake backing plate. Remove
brake cylinder assembly.
3
2
4. Remove dust covers, pistons, L–type seals and
spring from brake cylinder body (Fig. 7). Discard dust
covers and seals.
Figure 7
1.
2.
3.
4.
Inspection
3
2
Dust cover (2 used)
Piston (2 used)
L–type seal (2 used)
Spring
5. Bleed screw
6. Bleed screw cap
7. Brake cylinder body
CAUTION
Use eye protection such as goggles when using
compressed air.
1. Clean all metal parts with isopropyl alcohol, then
clean out and dry grooves and passageways with compressed air. Make sure brake cylinder bore and component pieces are thoroughly clean.
2. Check cylinder bore and pistons and spring for damage or excessive wear. Replace brake cylinder assembly if signs of pitting, scoring or cracks are evident.
Assembly
1. Apply a film of clean brake fluid to new L–type seals
and then install seals onto pistons.
Chassis
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 N–m).
5. Connect brake line to brake cylinder.
6. Reassemble brakes (see Brake Service in this section).
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
4. Repeat procedure until a continuous flow of brake
fluid, with no air bubbles, is released from bleeder valve.
Make sure fluid level is maintained in brake fluid reservoir at all times.
Figure 8
5. Complete steps 1 – 4 for left rear, right front and left
front brakes.
CAUTION
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
6. After bleeding of brakes is completed, road test vehicle to make sure brakes are operating correctly and
pedal is solid.
Chassis
Page 7 – 18
Workman 3000/4000 Series
Chassis
This page is intentionally blank.
Workman 3000/4000 Series
Page 7 – 19
Chassis
Brake Master Cylinder
2
RIGHT
1
FRONT
3
4
5
6
Figure 9
1. Brake master cylinder
2. Cap screw (2 used)
3. Clevis pin
4. Cotter pin
5. Flange nut (2 used)
6. Brake pedal
Removal (Fig. 9)
Installation (Fig. 9)
1. Remove cotter pin from the clevis pin that connects
master cylinder to brake pedal.
1. Position master cylinder to vehicle frame and secure
with two (2) cap screws and flange nuts.
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.
2. Remove plugs from brake lines. Install brake lines to
master cylinder.
3. Remove two (2) cap screws and flange nuts that secure master cylinder to vehicle frame.
3. Make sure that master cylinder push rod is fully extended. Connect push rod clevis to brake pedal with clevis pin and cotter pin.
4. Bleed brakes (see Bleed Brake System).
4. Pull master cylinder from vehicle.
CAUTION
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
5. Check brake operation.
Chassis
Page 7 – 20
Workman 3000/4000 Series
Brake Master Cylinder Service
Disassembly (Fig. 10)
4
1. Remove reservoir and flange seal. Push in on the
push rod so the stop pin can be removed.
5
2. Disconnect lower end of the dust cover from the
housing.
6
3. Push in on the push rod and remove circlip, then remove push rod with dust cover and clevis. Remove retainer washer.
4. Remove primary piston assembly and secondary
piston assembly from cylinder housing.
7
11
8
9
12
10
Inspection
1. Clean all metal parts with isopropyl alcohol, then
clean out and dry grooves and passageways with compressed air. Make sure cylinder bore and component
pieces are thoroughly clean.
2. Check cylinder bore, pistons, and springs for damage or excessive wear. Replace brake cylinder assembly if signs of pitting, scoring, or cracks are evident in
cylinder bore.
Assembly (Fig. 10)
1
2
3
Figure 10
1.
2.
3.
4.
5.
6.
Master cylinder reservoir
Flange seal
Stop pin
Clevis
Nut
Dust cover
7.
8.
9.
10.
11.
12.
Push rod
Circlip
Retainer washer
Primary piston assy.
Secondary piston assy.
Cap assembly
1. Apply a film of clean brake fluid to cylinder bore and
piston assemblies.
2. Install secondary piston assembly and primary piston 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.
Workman 3000/4000 Series
Page 7 – 21
Chassis
5. Push in on push rod so stop pin can be installed to
retain secondary piston assembly, then install flange
seal and reservoir.
Chassis
Parking Brake Cable Replacement
Removal (Fig. 11)
7. Install center console control plate and control lever
knobs.
1. Remove brake handle from parking brake lever.
Loosen set screw on parking brake control lever knob.
Turn knob on parking brake lever counterclockwise all
the way to loosen brake cable adjustment.
8. Adjust parking brake lever (see Operator’s Manual)
and check operation of brakes before using the vehicle.
8
2. Remove knobs from control levers and then remove
center console control plate to gain access to parking
brake cables.
7
4
9
10
3. Jack up and support rear of vehicle (see Jacking Instructions in Operator’s Manual).
5
6
3
2
4. Remove rear wheel and brake drum (see Brake Service in this section).
5. Disconnect cable from rear brake (Fig. 12):
1
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 lever support bracket (Fig. 11).
11
Figure 11
1.
2.
3.
4.
5.
6.
7. Disconnect brake cable from brake equalizer plate
(Fig. 13).
7.
8.
9.
10.
11.
Parking brake lever
Cable equalizer bracket
Cotter pin
Clevis pin
Retaining ring (2 used)
LH brake cable
RH brake cable
Washer
Bellcrank
Brake handle
Lever support bracket
1
4
2
8. Note routing of parking brake cable and location of
cable ties 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 lever. Install brake cable clip to secure cable to backing
plate (Fig. 12).
3
Figure 12
1. Rear brake backing plate
2. Parking brake lever
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. Brake shoe grooves
4. Brake cable clip
3
3. Route brake cable in same location as before and secure with cable ties. Start from rear of vehicle and work
towards front.
1
2
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).
1
Figure 13
1. Brake cable
2. Retaining ring
3. Equalizer bracket
6. Lower vehicle to ground.
Chassis
Page 7 – 22
Workman 3000/4000 Series
Steering Wheel
Removal (Fig. 14)
3
1
1. Carefully remove steering wheel cover from steering
wheel.
2
2. Remove hex nut and lock washer that secure steering wheel to steering control valve.
5
20 to 26 ft–lb
(28 to 35 N–m)
3. Pull steering wheel from control valve.
Installation (Fig. 14)
4
1. Apply anti–seize lubricant to shaft of control valve.
Anti–seize
Lubricant
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 N–m).
4. Install steering wheel cover.
Figure 14
4. Steering control valve
5. Frame
Chassis
1. Steering wheel
2. Lock washer
3. Hex nut
Workman 3000/4000 Series
Page 7 – 23 Rev. B
Chassis
Control Arm Ball Joint Replacement
8
3
5
6
7
9
12
2
80 to 90 ft–lb
(108 to 122 N–m)
1
10
9
7
11
6
4
RIGHT
FRONT
11
5
8
9
10
Figure 15
1.
2.
3.
4.
Cotter pin
Slotted hex nut
Upper control arm (RH shown)
Lower control arm (RH shown)
5.
6.
7.
8.
Snap ring
Ball joint
Ball joint seal
Grease fitting
Flange bushing
Cap screw
Lock nut
Spindle (RH, 2WD shown)
Installation (Fig. 15)
Removal (Fig. 15)
1. Press new ball joint into control arm. Install snap ring
to secure ball joint.
WARNING
FRONT SUSPENSION IS SPRING LOADED! To
prevent possible personal injury, use special
tool to remove compression springs before disassembling the front suspension.
1. If servicing upper ball joint or control arm, remove
front compression springs (see Front Compression
Spring Service in this section). NOTE: Front compression springs do not need to be removed if servicing only
the lower ball joint or lower control arm.
2. Remove cotter pin and slotted nut that secure affected ball joint to spindle. Separate ball joint from
spindle. Inspect ball joint seal and replace if damaged.
3. Remove control arm.
4. Remove snap ring. Press ball joint out of control arm.
Chassis
9.
10.
11.
12.
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 further 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).
Page 7 – 24
Workman 3000/4000 Series
Tie Rod End Replacement
9
8
1
45 to 55 ft--lb
(61 to 75 N--m)
7
2
3
4
5
RIGHT
FRONT
50 ft--lb
(68 N--m)
2
6
45 to 55 ft--lb
(61 to 75 N--m)
Figure 16
4. Tie rod
5. Jam nut (LH thread)
6. Tie rod end (LH thread)
7. Pitman arm
8. Steering cylinder
9. Spindle (RH shown)
Removal (Fig. 16)
Installation (Fig. 16)
1. Loosen jam nut that secures affected tie rod end to
tie rod.
1. Install new tie rod end to tie rod. Thread in the same
number of revolutions as the old one took to remove.
2. Remove cotter pin and slotted nut from affected tie
rod end.
2. Make sure that tie rod end shaft and spindle or pitman arm are thoroughly cleaned.
3. Use a suitable puller to disconnect rod end from
spindle or pitman arm.
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. 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.
4. Tighten jam nut to secure tie rod end to tie rod.
Torque jam nuts to 50 ft--lb (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 Alignment in this section). Adjust as necessary.
6. Grease tie rod end (see Operator’s Manual).
Workman 3000/4000 Series
Page 7 -- 25 Rev. A
Chassis
Chassis
1. Tie rod end
2. Cotter pin
3. Jam nut
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
length is incorrect, see Steering Cylinder Installation in
Service and Repair section of Chapter 9 -- Hydraulic
System for steering cylinder ball joint installation procedure.
CYLINDER LENGTH WHEN FULLY RETRACTED
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 center 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 of the 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).
14.520” (36.88 cm) for 2WD
15.040” (38.20 cm) for 4WD
Figure 17
Cylinder Length to Center the Pitman Arm
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--lb (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.
17.320” (43.99 cm)
Figure 18
5. After alignment has been checked and/or adjusted,
check for component interference as steering wheel is
turned from lock to lock.
A. If a tie rod contacts the Pitman arm, adjust steering cylinder ball joint location.
FRONT OF VEHICLE
Center--to--center
Distance
B. If tie rod ends contact spindles, adjust both tie
rods equally to re--center steering.
C. After any adjustment, re--check front wheel alignment. Additionally, make sure that all jam nuts are
properly torqued.
Center--to--center
Distance
Figure 19
Chassis
Page 7 -- 26
Rev. A
Workman 3000/4000 Series
Front Compression Spring Service
COMPRESSION SPRING TOOL
TOP VIEW
20I
Control arm tower
(4) 1/2I flat washers
5I
Compression
spring tool rod
(2) 1/2I steel rods
8
Spring cradle
5I
(4) 1/2I nuts
Compression
spring
9
1
6
7
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.
5
2
4
3
Figure 19
1. Spring cradle
2. Spring
3. Lock nut
4. Cap screw
5. Stabilizer link
6. Lock nut
1. Remove seat base to gain access to front suspension assembly (see Seat Base removal in this section).
2. Jack up front of vehicle and secure with jack stands
(see Jacking Instructions in Operator’s Manual). Remove front wheels.
7. Cap screw
8. Control arm tower
9. Spring pivot sleeve
6. Remove lock nut (Item 6) and cap screw (Item 7) securing each spring cradle to control arm towers (Item 8),
then remove springs and cradles along with the stabilizer links.
7. Reverse this procedure to install springs.
Chassis
3. Remove front shock absorbers.
WARNING
FRONT SUSPENSION IS SPRING LOADED! To
prevent possible personal injury, use special
tool to remove compression springs before disassembling the front suspension.
4. Install a compression spring tool rod through holes
in each spring cradle (Item 1), then install nuts and
washers on both ends of each rod. Tighten one nut on
each rod to secure springs (Item 2). NOTE: Extended
portion of each compression spring tool must be on opposite ends so cap screws (Item 7) can be removed.
Install compression
spring tool before
disassembling
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
Figure 20
Chassis
Front Shock Absorber Replacement
1. Remove lower and upper lock nuts, then remove
shock absorber and washers. Note that washers on upper end of shock absorber are different. Washers on
lower end of shock are identical.
10
2. Insert two (2) new rubber bushings into each end of
new shock absorber. Insert spacer into ram (lower) end
of shock absorber.
7
6
5
3. Install inner washer onto stud above control arm.
1
4. Install new shock absorber with ram end down and
secure upper end with outer washer and lock nut.
4
3
8
5. Insert capscrew down through angled hole 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.
2
1
8
9
Figure 21
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Rubber bushing
Spacer
Inner washer
Shock absorber
Outer washer
Lock nut
Cap screw
Washer
Lock nut
Control arm tower
Shock absorber
Figure 22
Chassis
Page 7 – 28
Workman 3000/4000 Series
Rear Shock Absorber Replacement
1. Remove lower and upper lock nuts, then remove
shock absorber and washers from vehicle.
2
2. Insert two (2) new rubber bushings into each end of
new shock absorber.
1
4
5
3. Install one large washer onto each shock absorber
mounting stud.
3
4. Install new shock absorber with ram end down. Secure each end with with large washer and lock nut.
2
5
1
4
Figure 23
1. Rubber bushing
2. Large washer
3. Shock absorber
4. Large washer
5. Lock nut
Shock absorber
Chassis
Figure 24
Workman 3000/4000 Series
Page 7 – 29
Chassis
Rear Leaf Spring Replacement
1
2
3
3
2
12
1
1
4
5
7
6
8
9
13
RIGHT
10
11
FRONT
3
See tightening procedure in text
14
Figure 25
1.
2.
3.
4.
5.
Lock nut
Spring shackle
Rubber bushing
Axle bumper
Hex nut
6.
7.
8.
9.
10.
Lock nut (4 used per spring)
Washer (4 used per spring)
Spring plate
Leaf spring
Flange head screw (2 per mount)
11.
12.
13.
14.
Spring mount
Flange nut (2 per mount)
Rear axle
Carriage screw (4 used per spring)
IMPORTANT: For proper vehicle performance, always replace the springs on both sides of the vehicle.
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.
Removal (Fig. 25)
4. Remove two (2) lock nuts (Item 1) from spring
shackles (Item 2). Remove spring shackles.
1. Jack up and support rear of vehicle (See Jacking Instructions in Operator’s Manual). Remove rear
wheel(s).
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.
2. Support frame side rails so rear axle can be removed.
Chassis
Page 7 – 30
Workman 3000/4000 Series
Installation (Fig. 25)
1. Before installing new leaf spring, insert four (4) rubber bushings (Item 3) into leaf spring. Insert two (2) rubber bushings into frame side rail.
Make sure axle and
plate are centered
on leaf spring knob
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 finger tight. Tighten lock nuts (Item 6). Leave flange nuts
(Item 12) that secure spring mount to frame rail finger
tight.
Figure 26
4. Install spring plate (Item 8) to top of spring, then secure axle to spring with carriage bolts (Item 14), washers
(Item 7) and lock nuts (Item 6). NOTE: Make sure axle
and plate are centered on leaf spring knob (Fig. 26).
5. Tighten lock nuts (Item 6) in a crossing pattern until
spring plate, leaf spring and axle contact. Tighten flange
nuts (Item 12) securing spring mount to frame rail. Tighten lock nuts (Item 6) securing axle and clamp plate to
leaf spring using a crossing pattern and the following
torque values:
A. Tighten lock nuts from 20 to 30 ft–lb (27 to 41
N–m) in a crossing pattern.
B. Tighten lock nuts from 50 to 60 ft–lb (68 to 81
N–m) in a crossing pattern.
C. Retighten lock nuts from 50 to 60 ft–lb (68 to 81
N–m).
6. Install rear wheels (see Wheel Installation in this section).
Workman 3000/4000 Series
Chassis
7. Lower vehicle to ground.
Page 7 – 31
Chassis
Seat Base
1
6
4
2
5
3
11
10
8
9
7
RIGHT
FRONT
Figure 27
1.
2.
3.
4.
Passenger seat
Screw (6 used)
Control plate
Hose to radiator
Chassis
5.
6.
7.
8.
Coolant reservoir
Operator seat
Lock nut
Flat washer
Page 7 – 32
9. Cap screw
10. Seat base
11. Socket head screw (4 used per seat)
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.
1
5
4. Remove 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 secure each front corner of seat base to frame.
2
4
6. Disconnect radiator overflow tank hose at radiator
and plug the hose.
3
Figure 28
7. Carefully lift seat base from vehicle.
1. ROPS frame
2. Cap screw (4 used)
3. LH ROPS receiver
Installation (Fig. 27)
4. Flange nut (4 used)
5. RH ROPS receiver
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.
Chassis
4. Install ROPS to vehicle with four (4) cap screws and
flange nuts (Fig. 28).
Workman 3000/4000 Series
Page 7 – 33
Chassis
This page is intentionally blank.
Chassis
Page 7 – 34
Workman 3000/4000 Series
Chapter 8
Electrical System
Table of Contents
Start Relay (Kohler Engine) . . . . . . . . . . . . . . . . . . 11
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Indicator Lights and Gauges . . . . . . . . . . . . . . . . . . 12
High Temperature Shutdown Switch (Briggs/
Daihatsu Gas and Diesel Engine) . . . . . . . . . . . 13
Fuel Gauge Sender . . . . . . . . . . . . . . . . . . . . . . . . . 14
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Glow Plug Switch (Briggs/Daihatsu Diesel
Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Diodes (Briggs/Daihatsu Gas and Diesel
Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Diode Assembly (Kohler Engine) . . . . . . . . . . . . . . 16
Rear PTO Switch (Optional) . . . . . . . . . . . . . . . . . . 16
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 17
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Headlamp Replacement . . . . . . . . . . . . . . . . . . . . . 20
Tail Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . 20
Electrical
System
ELECTRICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . . 5
Battery Test (Open Circuit Test) . . . . . . . . . . . . . . . . 5
Charging System Test . . . . . . . . . . . . . . . . . . . . . . . . 5
Verify Interlock System Operation . . . . . . . . . . . . . . 6
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . . 7
Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Clutch Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Transaxle Lockout Switches . . . . . . . . . . . . . . . . . . . 9
3rd–High Lockout Key Switch . . . . . . . . . . . . . . . . . . 9
Start (Briggs/Daihatsu Gas and Diesel Engine)
and Fuel Pump (Briggs/Daihatsu Gas
Engine) Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Glow Relay (Briggs/Daihatsu Diesel Engine) . . . . 11
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 circuits and electrical components when the
current is off.
Figure 1
Multimeter
The meter can test electrical components and circuits for
current, resistance, or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 2
Skin--Over Grease
Special non--conductive grease (Toro Part No.
TOR50547) which forms a light protective skin which
helps waterproof electrical switches and contacts.
Figure 3
Electrical System
Page 8 -- 2
Rev. D
Workman 3000/4000 Series
Troubleshooting
For effective troubleshooting and repairs, you must have
a good understanding of the electrical circuits and components used on this vehicle (see Vehicle Electrical
Schematics in Chapter 11).
CAUTION
Remove all jewelry, especially rings and
watches, before doing any electrical troubleshooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
If the vehicle has any interlock switches by–passed, they
must be reconnected for proper troubleshooting and
safety.
Condition
Possible Cause
Starter cranks, but should not, with clutch pedal
released.
Clutch switch out of adjustment or faulty.
Starter cranks, but should not, with PTO engaged.
PTO switch faulty.
Starter solenoid clicks, but starter will not crank.
(If solenoid clicks, problem is not in interlock system.)
Low battery charge.
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.
”I” terminal wire of ignition key switch loose, corroded
or damaged.
Engine or fuel system problem (see appropriate
Engine chapter).
Electrical
System
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.
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 loose, 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
switch in Slow position and transaxle in
3rd gear and High range.
3rd–High lockout key switch faulty.
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.
Voltage Measured
Battery Charge Level
12.68 v (or higher)
Fully charged (100%)
Set the multimeter to the DC volts setting. The battery
should be at a temperature of 60o to 100o F (16o to 38o
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 (–) meter lead to the negative battery post.
12.45 v
75% charged
12.24 v
50% charged
12.06 v
25% charged
11.89 v
0% charged
NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional
and more accurate information (see Battery Service in
Service and Repairs section of this Chapter).
Charging System Test
This is a simple test used to determine if a charging system is functioning. It will tell you if a charging system has
an output, but not its capacity.
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):
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 running.
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage
= 12.30 v
Battery Voltage after 3 Minute Charge
= 12.80 v
Difference
= +0.50 v
Electrical
System
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
Electrical System
Verify Interlock System Operation
The purpose of the interlock system is to prevent the engine from cranking 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.
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.
CAUTION
Check the operation of the interlock switches
daily for proper operation. Replace any malfunctioning switches before operating the machine.
To verify clutch interlock switch operation:
1. Sit on 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
To verify operation of hydraulic lift interlock switch
(TC models):
3. Depress clutch pedal and rotate ignition key clockwise to START position.
4. If engine cranks or starts, there is a malfunction in the
interlock system that must be repaired before operating
vehicle.
To verify rear PTO interlock switch (if equipped) operation:
1. Sit on 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.
2. Engage rear PTO.
3. Depress clutch pedal and rotate ignition key clockwise to START position.
4. If engine cranks or starts, there is a malfunction in the
interlock system that must be repaired before operating
vehicle.
Page 8 -- 6 Rev. D
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.
NOTE: Electrical troubleshooting of any 12 Volt power
connection can also be performed through voltage drop
tests without disconnection of the component.
For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the
circuit (e.g. unplug the clutch switch connector before
doing a continuity check).
CAUTION
When testing electrical components for continuity with a volt–ohm meter or continuity tester,
make sure that power to the circuit has been disconnected.
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.
Y
A
B
S
I
X
Figure 4
1. OFF
CONTINUITY
AMONG
TERMINALS
NONE
2. RUN
B+A+I
3. START
B+S+I
OTHER
CIRCUITS
MADE
NONE
X+Y
NONE
Figure 5
Workman 3000/4000 Series
Page 8 – 7
Electrical System
Electrical
System
POSITION
Clutch Switch
The clutch switch is normally open and closes when the
clutch pedal is depressed. The clutch switch is attached
to a bracket on the left side of the clutch bell housing (Fig.
6).
Test the switch by disconnecting the wiring connector
and connecting a continuity tester across the two terminals. With the engine off, depress the clutch pedal completely – there should be an indication of continuity.
Release the clutch pedal – there should be no continuity.
1
For clutch switch adjustment procedure, see Clutch
Pedal Adjustment in Chapter 6 – Drive Train.
Figure 6
1. Clutch switch
Brake Switch
The brake switch is normally open and closes when the
brake pedal is depressed. The closed switch allows a
current path to the stop light.
Test the switch by disconnecting the wiring connector
and connecting a continuity tester across the two terminals. With the engine off, depress the brake pedal –
there should be an indication of continuity. Release the
brake pedal – there should be no continuity.
1
Figure 7
1. Brake switch
Electrical System
Page 8 – 8
Workman 3000/4000 Series
Transaxle Lockout Switches
2–3 Lockout Switch
1
The transaxle 2–3 Lockout switch is closed in 2nd gear
and open in 3rd gear.
Test the switch by disconnecting the wiring connector
and connecting a continuity tester across the two terminals. 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
2
The transaxle High–Low Lockout switch is closed in Low
range and open in High range.
Test the switch by disconnecting the wiring connector
and connecting a continuity tester across the two terminals. With the engine off, move shifter to Low range –
there should be an indication of continuity. Move shift lever to High range – there should be no continuity.
Figure 8
1. 2–3 lockout switch
2. Hi–Low lockout switch
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 connecting 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.
Electrical
System
Figure 9
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 gasoline engine are identical. These relays are attached to
the frame near the hydraulic oil filter.
Testing
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this value from the measured value of the component you are
testing.
86
87A
87
1. Disconnect the harness connector from the relay that
is to be tested.
2. Using a multimeter (ohms setting), measure coil resistance between terminals 85 and 86 (Fig. 10). Resistance should be between 70 and 90 ohms.
85
30
Figure 10
3. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
4. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
5. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between terminals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
6. Disconnect voltage and multimeter leads from the
relay terminals. Reconnect relay to vehicle wire harness.
Electrical System
Page 8 – 10
Workman 3000/4000 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 Workman. On machines with serial numbers below
260000000, two of the four relay connections are secured 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).
86
87
85
30
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.
87
85
30
86
Figure 11
86
87
30
85
85
30
2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
86
87
Figure 12
3. Disconnect voltage and leads from the terminals.
Start Relay (Kohler Engine)
The start relay used on Workman vehicles with a Kohler
engine is attached to the frame near the hydraulic oil filter.
5. Disconnect voltage and multimeter leads from the
relay terminals. Reconnect relay to vehicle wire harness.
Testing
2. Connect multimeter (ohms setting) leads to relay terminals 30 and 87 (Fig. 13). Ground terminal 86 and apply
+12 VDC to terminal 85. The relay should make and
break continuity between terminals 30 and 87 as +12
VDC is applied and removed from terminal 85.
86
87A
87
87
86
87A
85
30
85
3. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
30
Electrical
System
1. Disconnect the harness connector from the relay that
is to be tested.
Figure 13
4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. Apply +12 VDC to terminal 85. The
relay should make and break continuity between terminals 30 and 87A as +12 VDC is applied and removed
from terminal 85.
Workman 3000/4000 Series
Page 8 -- 11 Rev. C
Electrical System
Battery
Use a digital multi meter to measure the voltage between
the battery terminals.
If the voltage is less than 12.3 Volts DC, the battery
should be charged.
NOTE: Regulated battery voltage will increase to
approximately 13.5 Volts when the engine is running.
1
Figure 13
1. Battery
Indicator Lights and Gauges
Oil Pressure Light
Temperature Gauge and Fuel Level Gauge
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 operation – oil pressure below 7 psi (0.5 kg/cm2).Test the lamp
by disconnecting the wires and applying 12 VDC. between the lamp wiring terminals.
To test a gauge, use a commercial gauge tester. If a commercial gauge tester is not available, substitute a new
gauge or test the sending unit.
2
Charging Light (Liquid Cooled Engines)
The charging light should come on when the ignition key
switch is in the “RUN” position with the engine not running 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 terminals.
1
3
6
4
5
Glow Light (Diesel Engine)
The glow light should be on when the ignition key switch
is in the “RUN” position and the glow switch is “ON”. Test
the lamp by disconnecting the wires and applying 12
VDC. between the lamp wiring terminals.
Figure 14
1. Oil pressure light
2. Charging light
3. Glow light
4. Hourmeter
5. Temperature gauge
6. Fuel level gauge
Hourmeter
Test the hourmeter by connecting a 12 volt battery so the
positive (+) battery terminal is connected to the positive
terminal on the hourmeter. Connect the negative (–) battery terminal to the negative (–) terminal on the hourmeter. The hour meter should move 1/10 of an hour in six
minutes as 12 VDC. is applied between the terminals.
Electrical System
Page 8 – 12
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 attached to the switch.
1
2
Testing
CAUTION
Make sure engine is cool before removing the
temperature switch.
1. Lower coolant level in the engine and remove the
temperature shutdown switch.
2. Put switch in a container of oil with a thermometer
and slowly heat the oil (Fig. 16).
Figure 15
1. Temp. shutdown switch
2. Thermostat housing
CAUTION
VOA
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 238oF (114oC).
Figure 16
4. Allow oil to cool while observing temperature. The
temperature switch should open at about 232oF (111oC).
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.
Electrical
System
7. Fill engine cooling system (see Operator’s Manual).
Workman 3000/4000 Series
Page 8 – 13
Electrical System
Fuel Gauge Sender
Disconnect wire and remove the fuel gauge sender from
the fuel tank.
1
CAUTION
Make sure sending unit is completely dry (no fuel
on it) before testing. Perform test away from the
tank to prevent an explosion or fire from sparks.
Install an ohm meter between the terminal and base.
With arm completely down (empty position), resistance
should be 240–260 ohms.
With arm completely up (full position), resistance should
be 29–34 ohms.
Figure 17
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
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
ON
2+3
5+6
OFF
1+2
4+5
1
Figure 18
1. Headlight switch
4
5
6
1
2
3
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.
3
2
1
6
5
4
Figure 20
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
OFF
2+3
5+6
MOMENTARY
ON
1+2
4+5
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–energized. Diode D1 is in the optional hydraulic circuit and D2
is in the starting circuit.
2
These diodes plug into the vehicle wiring harness at various locations (see appropriate vehicle electrical schematic in Chapter 11 – Electrical Schematics).
3
1
Testing
Figure 21
1. Diode
2. Male terminal
3. Female terminal
Multimeter
Red Lead (+)
on Terminal
Multimeter
Black Lead (–)
on Terminal
Continuity
Female
Male
YES
Male
Female
NO
Electrical
System
The diodes can be individually tested using a digital
multimeter (diode test or ohms setting) and the table to
the right.
Workman 3000/4000 Series
Page 8 – 15
Electrical System
Diode Assembly (Kohler Engine)
The diode assembly on Kohler powered Workman vehicles is used for circuit protection from voltage spikes
that occur when the starter solenoid is de–energized.
2
The diode assembly plugs into the vehicle wiring harness (see Workman 3100 electrical schematic in Chapter 11 – Electrical Schematics).
3
1
Testing
Figure 22
The diode assembly can be tested using a digital multimeter (diode test or ohms setting) and the table to the
right.
1. Diode
2. Male terminal
3. Female terminal
Multimeter
Multimeter
Black Lead (–)
Red Lead (+)
on
on
Terminal Blade Terminal Blade
Continuity
Male
Female
YES
Female
Male
NO
Rear PTO Switch (Optional)
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 engaged.
1
Test the switch by disconnecting the wiring connector
and connecting a continuity tester across the two terminals. With the engine off, move PTO lever to OFF position – there should be an indication of continuity. Move
PTO lever to ON – there should be no continuity.
Figure 23
1. Rear PTO switch
Electrical System
Page 8 – 16
Workman 3000/4000 Series
Service and Repairs
Battery Service
The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can
be prevented.
CAUTION
When working with batteries, use extreme caution to avoid slashing or spilling electrolyte.
Electrolyte can destroy clothing and burn skin or
eyes. Always wear safety goggles and a face
shield when working with batteries.
1
Figure 24
1. Battery
Battery Specifications (Liquid Cooled Engines)
Inspection, Maintenance, and Testing
BCI Group 34 Battery:
690 Amp Cold Cranking Performance at 0o F (–18o C)
100 minute Reserve Capacity at 80o F (27o C)
1. Perform following inspections and maintenance:
A. Check for cracks. Replace battery if cracked or
leaking.
Battery Specifications (Air Cooled Engines)
BCI Group 26 Battery:
525 Amp Cranking Performance at 0o F (–18o C)
80 min. Reserve Capacity at 80o F (27o C)
B. Check battery terminal posts for corrosion. Use
wire brush to clean corrosion from posts.
Electrolyte Specific Gravity
IMPORTANT: Before cleaning the battery, tape or
block vent holes to the filler caps and make sure the
caps are on tightly.
Removal (Fig. 24)
IMPORTANT: Be careful not to damage terminal
posts or cable connectors when removing the battery cables.
1. Remove battery cover from the frame. Loosen battery retainer securing the back of the battery to the battery 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.
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, or overfilling.
Also, check battery case for dirt and oil. Clean the
battery with a solution of baking soda and water, then
rinse it with clean water.
D. Check that the cover seal is not broken away. Replace 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 sufficient mixing of the electrolyte.
4. Remove battery from the battery compartment to a
service area to allow better access for service.
Workman 3000/4000 Series
Page 8 – 17
Electrical System
Electrical
System
Fully charged: 1.250 – 1.280
Discharged: less than 1.240
2. If battery filler caps are removable, conduct a
hydrometer test of the battery electrolyte.
D. If battery filler caps are removable, measure the
temperature of the center cell.
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
E. Connect a battery load tester to the battery terminals following the manufacturer’s instructions.
Connect a digital multimeter to the battery terminals.
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 temperature of the cell.
B. Temperature correct each cell reading. For each
10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the
specific gravity reading. For each 10oF (5.5oC) below
80oF (26.7oC) subtract 0.004 from the specific gravity
reading.
Example: Cell Temperature
100oF
Cell Gravity
1.245
100oF minus 80oF equals 20oF
(37.7oC minus 26.7oC equals 11.0oC)
20oF multiply by 0.004/10oF equals 0.008
(11oC multiply by 0.004/5.5oC equals 0.008)
ADD (conversion above)
0.008
Correction to 80oF (26.7oC)
1.253
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the battery. Charge at the recommended rate and time given
in Charging or until all cells specific gravity is 1.225
or greater with the difference in specific gravity between the highest and lowest cell less than 0.050. If
these charging conditions can not be met, replace
the battery.
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 battery load tester is required to perform this test.
F. Apply a test load of one half the Cranking Performance (see Battery Specifications) rating of the battery for 15 seconds.
G. Take a voltage reading at 15 seconds, then remove the load.
H. Using the table below, determine the minimum
voltage for the cell temperature reading.
Minimum
Voltage
Battery Electrolyte
Temperature
9.6
70oF (and up)
21.1oC (and up)
9.5
60oF
15.6oC
9.4
50oF
10.0oC
9.3
40oF
4.4oC
9.1
30oF
–1.1oC
8.9
20oF
–6.7oC
8.7
10oF
–12.2oC
8.5
0oF
–17.8oC
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the minimum, return the battery to service.
Installation (Fig. 24)
IMPORTANT: To prevent possible electrical problems, install only a fully charged battery.
1. Make sure ignition and all accessories are off.
2. Make sure battery compartment is clean and repainted if necessary.
CAUTION
Follow the manufacturer’s instructions when using a battery tester.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.4 VDC, recharge the battery.
B. If the battery has been charged, apply a 150 amp
load for 15 seconds to remove the surface charge.
Use a battery load tester following the manufacturer’s instructions.
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.
C. Make sure battery terminals are free of corrosion.
Electrical System
Page 8 – 18
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 than 0.1
amp. If the reading is 0.1 amp or more, the unit’s electrical 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 accomplished with a constant current battery charger which is
available in most shops.
Battery
Reserve
Capacity
(Minutes)
Battery Charge Level
(Percent of Fully Charged)
75%
50%
25%
0%
80 or less
3.8 hrs
@
3 amps
7.5 hrs
@
3 amps
11.3 hrs
@
3 amps
15 hrs
@
3 amps
81 to 125
5.3 hrs
@
4 amps
10.5 hrs
@
4 amps
15.8 hrs
@
4 amps
21 hrs
@
4 amps
126 to
170
5.5 hrs
@
5 amps
11 hrs
@
5 amps
16.5 hrs
@
5 amps
22 hrs
@
5 amps
171 to
250
5.8 hrs
@
6 amps
11.5 hrs
@
6 amps
17.3 hrs
@
6 amps
23 hrs
@
6 amps
above
250
6 hrs
12 hrs
18 hrs
24 hrs
@
@
@
@
10 amps 10 amps 10 amps 10 amps
CAUTION
CAUTION
Follow the manufacturer’s instructions when using a battery charger.
Do not charge a frozen battery because it can explode and cause injury. Let the battery warm to
60_F (15.5_ C) before connecting to a charger.
NOTE: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
Charge the battery in a well–ventilated place to
dissipate gases produced from charging. These
gases are explosive; keep open flame and electrical spark away from the battery. Do not smoke.
Nausea may result if the gases are inhaled. Unplug the charger from the electrical outlet before
connecting or disconnecting the charger leads
from the battery posts.
1. If battery filler caps are removable, check the electrolyte level in each cell. If the level is below the tops of the
plates in any cell, fill all cells with distilled water so that
plates are just covered with electrolyte.
2. Determine the battery charge level from either its
open circuit voltage or specific gravity (if filler caps are
removable).
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
1.265
12.68
75%
1.225
12.45
50%
1.190
12.24
25%
1.155
12.06
0%
1.120
11.89
4. Following the manufacturer’s instructions, connect the charger cables to the battery. Make sure a good
connection is made.
5. Charge the battery following the manufacturer’s
instructions.
3. Determine the charging time and rate using the
manufacturer’s battery charger instructions or the
following table.
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 freely
at a low charging rate and there is less than a 0.003
change in specific gravity for three consecutive readings.
8. If battery filler caps are removable, check the electrolyte level in each cell. Adjust electrolyte level if needed.
Workman 3000/4000 Series
Page 8 – 19
Electrical System
Electrical
System
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.
Headlight Replacement
Disassemble and assemble headlight as follows:
1
1. Set parking brake, turn ignition off, and remove key.
2. Reach beneath dash and disconnect the wiring harness connector from the headlight.
3. From beneath the dash, push headlight out of the
hood.
4. Remove rubber seal from around the headlight. Discard 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.
3
2
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.
Figure 25
1. Front hood
2. Headlight
3. Headlight mount
7. Connect the wiring harness connector to the headlight.
Tail Lamp Replacement
Disassemble and assemble tail lamp using Fig. 26 as a
guide.
The tail lamp uses a standard #1157 12volt bulb.
1
2
3
4
Figure 26
1. Screw (2 used)
2. Lens
Electrical System
Page 8 – 20
3. Bulb
4. Gasket
Workman 3000/4000 Series
Chapter 9
Hydraulic System
Table of Contents
SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . 25
General Precautions for Removing and Installing
Hydraulic System Components . . . . . . . . . . . . . 25
Check Hydraulic Lines and Hoses . . . . . . . . . . . . 25
Gear Pump (Vehicles With Liquid Cooled
Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Gear Pump (Vehicles With Air Cooled Engine) . 27
Gear Pump Service Barnes Gear Pump) . . . . . . 28
Gear Pump Service (Casappa Gear Pump) . . 29.1
Lift Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Lift Valve Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . 34
Steering Control Valve Service . . . . . . . . . . . . . . . 36
Steering Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Steering Cylinder Service . . . . . . . . . . . . . . . . . . . 40
Lift Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Lift Cylinder Service . . . . . . . . . . . . . . . . . . . . . . . . 44
Hydraulic Manifold (Optional High Flow
Hydraulic Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
SAUER/DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
Hydraulic
System
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Hydraulic Fitting Installation . . . . . . . . . . . . . . . . . . . 4
HYDRAULIC SCHEMATICS . . . . . . . . . . . . . . . . . . . . 6
Vehicle Hydraulic Schematic . . . . . . . . . . . . . . . . . . 6
High Flow Hydraulic Kit (Optional) Schematic . . . 7
HYDRAULIC CIRCUIT OPERATION . . . . . . . . . . . . . 8
Steering Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Raise and Lower Bed . . . . . . . . . . . . . . . . . . . . . . . . 9
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic Pressure Test Kit . . . . . . . . . . . . . . . . . . 10
Hydraulic Tester (Pressure and Flow) . . . . . . . . . 10
Hydraulic Test Fitting Kit . . . . . . . . . . . . . . . . . . . . . 11
Male Coupler (For Optional High Flow
Hydraulic Kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 12
TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Test No. 1: Gear Pump Flow and System Relief
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Test No. 2: Steering Control Valve and Steering
Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Test No. 3: Lift Cylinder Internal Leakage . . . . . . 20
Test No. 4: High Flow Hydraulic Kit (Optional)
Gear Pump Flow and Relief Pressure . . . . . . . 22
Workman 3000/4000 Series
Page 9 -- 1 Rev. D
Hydraulic System
This page is intentionally blank.
Hydraulic System
Page 9 – 2
Workman 3000/4000 Series
Specifications
Item
Description
Hydraulic Pump
Positive Displacement Gear Pump
Pump Performance
4 GPM (15 LPM) at 1,500 PSI (103.4 Bar)
System Relief Pressure
1,800 PSI (124.1 Bar)
Lift Control Valve
Three position control valve
Spring return to neutral
Ball checks to maintain load
Hydraulic Oil
Dexron III ATF
Reservoir (Transaxle)
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 Pump
Positive Displacement Gear Pump
Optional High Flow Hydraulic Kit Pump Performance
7.9 GPM (30 LPM) at 1,500 PSI (103.4 Bar)
Optional High Flow Hydraulic Kit System Relief Pressure
2,000 PSI (137.9 Bar)
Optional High Flow Hydraulic Kit Hydraulic Oil
Multigrade Hydraulic Fluid – ISO VG 46
Optional High Flow Hydraulic Kit Reservoir
4.5 U.S. gallon (17 Liter) capacity
Optional High Flow Hydraulic Kit Hydraulic Filter
Automotive, 10 micron spin–on cartridge type
25 PSI by–pass valve
100 mesh strainer in reservoir
Hydraulic
System
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 hydraulic system need to be performed independently.
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 conditions, or mishandling during operation or maintenance.
These conditions can cause damage or premature deterioration. Some hoses are more susceptible to these
conditions than others. Inspect the hoses frequently for
signs of deterioration or damage.
When replacing a hydraulic hose, be sure that the hose
is straight (not twisted) before tightening the fittings. This
can be done by observing the imprint on the hose. Use
two wrenches; hold the hose straight with one and tighten the hose swivel nut onto the fitting with the other.
WARNING
Before disconnecting or performing any work
on hydraulic system, relieve all pressure in
system. Stop engine; lower or support box
and/or other attachment(s).
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands,
to search for leaks. Hydraulic fluid escaping
under pressure can have sufficient force to
penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgically removed within a few hours by a doctor
familiar with this type of injury. Gangrene may
result from such an injury.
Hydraulic Fitting Installation
O–Ring Face Seal
Nut
1. Make sure both threads and sealing surfaces are
free of burrs, nicks, scratches, or any foreign material.
Body
Sleeve
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.
Seal
3. Lubricate the O–ring with a light coating of oil.
4. Put the tube and nut squarely into position on the face
seal end of the fitting and tighten the nut until finger tight.
Figure 1
5. Mark the nut and fitting body. Hold the body with a
wrench. Use another wrench to tighten the nut to the correct Flats From Finger Tight (F.F.F.T.). The markings on
the nut and fitting body will verify that the connection has
been tightened.
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Final
Position
F.F.F.T.
0.75 + 0.25
0.75 + 0.25
0.75 + 0.25
1.00 + 0.25
0.75 + 0.25
0.75 + 0.25
Mark Nut
and Body
Extend Line
Finger Tight
Initial
Position
After Proper Tightening
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 fitting shows signs of leakage.
O–Ring
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.
5. Tighten the fitting to the correct Flats From Finger
Tight (F.F.F.T.).
Size
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
NOTE: Installation torque values for non–adjustable fittings are listed in Figure 4. These torque values should
only be used when a fitting can be accessed with a socket. Use of an offset wrench (e.g. crowfoot wrench) will affect torque wrench accuracy and should not be used.
Figure 3
Fitting Size
Installation Torque
4
9–10 ft–lb (12–13 N–m)
6
20–21 ft–lb (27–28 N–m)
8
35–37 ft–lb (47–50 N–m)
10
60–66 ft–lb (81–89 N–m)
12
81–87 ft–lb (110–117 N–m)
16
121–131 ft–lb (164–177 N–m)
Figure 4
SAE Straight Thread O–Ring Port – 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 fitting shows signs of leakage.
Lock Nut
3. Lubricate the O–ring with a light coating of oil.
4. Turn back the jam nut as far as possible. Make sure
the back up washer is not loose and is pushed up as far
as possible (Step 1).
Back–up Washer
O–Ring
Figure 5
5. Install the fitting into the port and tighten finger tight
until the washer contacts the face of the port (Step 2).
6. To put the fitting in the desired position, unscrew it by
the required amount, but no more than one full turn (Step
3).
7. Hold the fitting in the desired position with a wrench
and turn the jam nut with another wrench to the correct
Flats From Finger Tight (F.F.F.T.) (Step 4).
4 (1/4 in. nominal hose or tubing)
6 (3/8 in.)
8 (1/2 in.)
10 (5/8 in.)
12 (3/4 in.)
16 (1 in.)
Workman 3000/4000 Series
Step 3
Step 2
Step 4
F.F.F.T.
1.00 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
1.50 + 0.25
Page 9 – 5
Hydraulic
System
Size
Step 1
Figure 6
Hydraulic System
Hydraulic System
Page 9 – 6
100 MESH
STRAINER
TRANSAXLE
RESERVOIR
10 MICRON
RETURN FILTER
W/25 PSI BYPASS
(6.36 CC/REV)
.769 ENGINE SPEED
PUMP
BARNES
.388 IN 3 /REV
E
T
P
STEERING UNIT
SAUER OSPM – PB
3
3.05 IN /REV (50 CC/REV)
1800 PSI RELIEF
R
L
PARKER
VY13 VALVE
LIFT CYLINDERS (2)
TEXAS HYDRAULICS
ROD .750 IN (19.1 MM)
BORE 1.50 IN (38.1 MM)
STROKE 16.25 IN (41.3 CM)
STEERING CYLINDER
TEXAS HYDRAULICS
ROD .625 IN (15.9 MM)
BORE 1.750 IN (44.5 MM)
STROKE 5.56 IN (14.1 CM) 2WD
4.47 IN (11.4 CM) 4WD
Hydraulic Schematics
Vehicle Hydraulic Schematic
Workman 3000/4000 Series
Hydraulic
System
IN TANK
SUCTION
STRAINER
100 MESH
Workman 3000/4000 Series
Page 9 – 7
4 GALLON
RESERVOIR
OIL COOLER
RELIEF VALVE
2000 PSI
SOLENOID
ACTIVATED
BYPASS VALVE
RETURN FILTER
10 MICRON WITH
25 PSI BYPASS
HYDRAULIC
GEAR PUMP
.610 IN 3 /REV
(10 CC/REV)
.833 ENGINE SPEED
QUICK DISCONNECT
COUPLINGS
High Flow Hydraulic Kit (Optional) Schematic
Hydraulic System
Hydraulic Circuit Operation
Steering Circuit
Left Turn
When a left turn is made with the engine running, the
turning of the steering wheel positions the spool valve so
that flow goes through the top of the spool. Flow entering
the steering control valve at the P port passes through
the rotary meter and is directed out the L port. Pressure
contracts the steering cylinder for a left turn. The rotary
meter ensures that the oil flow to the cylinder is proportional to the amount of the turning on the steering wheel.
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 entering the steering control valve at the P port passes
through the rotary meter and is directed out port R. Pressure 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 through the
spool valve, then out the T port and to the hydraulic reservoir (transaxle).
The steering wheel and steering control valve return to
the neutral position when turning is completed.
1800
PSI
L
R
STEERING CYLINDER
PISTON MOVEMENT
R
L
R
L
Right Turn
STEERING CYLINDER
PISTON MOVEMENT
STEERING CYLINDER
NO PISTON MOVEMENT
P
E
1800
PSI
T
P
E
1800
PSI
T
P
The steering wheel and steering control valve return to
the neutral position when turning is completed.
E
When the steering wheel is not being turned with the engine running (hydraulic pump being rotated), flow enters
the steering control valve at the P port and by–passes
the rotary meter and steering cylinder. Flow leaves the
control valve through the E port and is directed to the lift
valve.
Fluid leaving the steering cylinder flows back through
the spool valve, then out the T port and returns to the hydraulic reservoir (transaxle).
T
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.
STEERING
STEERING
STEERING
CONTROL
CONTROL
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 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
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 cylinder shafts. At the same time, the pistons push the hydraulic fluid in the rod end of the lift cylinders out and
through the lift valve to the reservoir (transaxle).
LIFT CYLINDERS (2)
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
PISTON MOVEMENT
LIFT VALVE
(IN RAISE POSITION)
RAISE BED
LIFT VALVE
(IN LOWER POSITION)
LOWER BED
Hydraulic
System
Figure 8
Workman 3000/4000 Series
Page 9 – 9
Hydraulic System
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 and 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 circuit 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 included with this kit.
Hydraulic System
Page 9 -- 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 system.
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.
1
Figure 12
Hydraulic
System
1. Male coupler
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 equipment and a thorough understanding of the complete hydraulic system.
A hydraulic system with an excessive increase in heat or
noise is a potential failure. Should either of these conditions be noticed, immediately stop the vehicle, turn off
the engine, locate the cause of the trouble and correct
it before allowing the vehicle to be used again. Contin-
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 precautions and specific test procedures.
Problem
Possible Cause
Hydraulic oil leaks.
Fitting(s), hose(s), or tube(s) are loose or damaged.
O--ring(s) or seal(s) are missing or damaged.
Squealing noise.
Hydraulic lift valve held in raise or lower position (hydraulic oil flowing over relief valve).
Hydraulic oil is overheating.
Oil level in transaxle is incorrect.
Hydraulic oil is contaminated or incorrect oil (use Dexron III ATF).
Kinked or severely bent hose or tubing.
Hydraulic oil going over relief valve excessively (too heavy a load
on hydraulic system or quick coupler disconnected with lift valve
engaged).
Suction screen in transaxle is loose or clogged.
Worn or damaged hydraulic gear pump (Note: entire hydraulic system affected).
Transaxle or drive train problem (see Drive Train -- Chapter 7).
Bed does not lift or lifts too slowly.
Excessive load in bed.
Oil level in transaxle is low.
Engine RPM is low.
Incorrect oil in system (use Dexron III ATF).
Lift cylinder pivots or bed pivots are binding or damaged.
Hydraulic pump drive belt loose.
Lift cylinder(s) worn or damaged.
Sheared key on gear pump shaft (Note: entire hydraulic system
affected).
Low gear pump flow or pressure (see TEST NO. 1) (Note: entire
hydraulic system affected).
Hydraulic System
Page 9 -- 12
Workman 3000/4000 Series
Problem
Possible Cause
Lift cylinders extend with valve in
neutral position.
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).
Bed drops from raised position with
lift valve in centered position.
Improperly positioned valve.
Lift valve worn or damaged.
Internal leakage of lift cylinder(s).
Lift cylinder hydraulic lines or fittings leaking.
Steering inoperative or sluggish
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 NO. 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).
Hydraulic
System
Gear pump is worn or damaged (Note: entire hydraulic system affected).
Workman 3000/4000 Series
Page 9 -- 13
Hydraulic System
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Difficulty in connecting or disconnecting quick couplers.
Pressure not relieved (coupler under pressure – engine running).
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 damaged (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.)
CAUTION
Failure to use gauges with recommended pressure (psi) rating as listed in test procedures
could result in damage to gauge and possible
personal injury from leaking hot oil.
Before Performing Hydraulic Tests
All obvious areas such as oil supply, filter, binding linkage, loose fasteners, or improper adjustments must be
checked before assuming that a hydraulic component is
the source of the problem being experienced.
Precautions For Hydraulic Testing
3. The engine must be 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 hydraulic 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 using tester with pressure and flow capabilities).
7. Install fittings finger tight, far enough to insure that
they are not cross–threaded, before tightening the fittings 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 and adjust the oil level in the transaxle after
connecting hydraulic test equipment.
WARNING
Before disconnecting or performing any work
on the hydraulic system, all pressure in the
system must be relieved by stopping the engine,
rotating the steering wheel in both directions,
lowering or supporting the bed and operating
other hydraulic accessories.
10.All hydraulic tests should be made with the hydraulic
oil at normal operating temperature.
11. After testing is completed, check and adjust the oil
level in the transaxle before returning the vehicle to service.
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
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 hydraulic equipment. Contamination will cause excessive
wear of hydraulic components.
Workman 3000/4000 Series
Page 9 – 15
Hydraulic
System
2. Put caps or plugs on any hydraulic lines left open or
exposed during testing or removal of components.
Hydraulic System
TEST NO. 1: Gear Pump Flow and System Relief Pressure
STEERING CONTROL
L
P
STEERING
CYLINDER
T
E
R
TESTER
LIFT CYLINDERS
GEAR
PUMP
FILTER
STRAINER
LIFT VALVE
TRANSAXLE
RESERVOIR
Figure 13
1
2
3
Figure 14
1. Gear pump
2. Pressure hose
Hydraulic System
3. Suction hose
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 temperature 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 controls to relieve hydraulic system pressure.
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 continues to be correct (2700 RPM). Record flow meter
reading.
GAUGE READING TO BE: Flow should be approximately 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:
3. Make sure that gear pump drive belt is adjusted properly (see Operator’s Manual).
A. Slipping pump drive belt.
B. Worn or stuck relief valve.
CAUTION
C. Pump suction line restriction.
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
IMPORTANT: Make sure that the oil flow indicator
arrow on the flow meter is showing that the oil will
flow from the pump, through the tester, and into the
hydraulic hose.
4. With the engine off, clean hose fitting and disconnect
the pressure hose from the gear pump (Fig. 14). Install
tester with pressure gauges and flow meter in series between the gear pump and the disconnected hose. Make
sure the tester flow control valve is open.
5. Make sure the hydraulic reservoir (transaxle) is full
after connecting the tester.
D. Gear pump needs to be repaired or replaced.
11. 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 reading. 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 steering lock) and holding momentarily.
D. System pressure should be approximately 1800
PSI (124.1 Bar) as the relief valve lifts. Return steering wheel to the center position.
CAUTION
The engine must be running to perform hydraulic tests. To guard against possible personal injury, engage parking brake and keep clothing,
hands, feet, face and other parts of the body
away from fan and other moving parts.
E. Release accelerator pedal to allow engine to return to low idle and turn off vehicle. Record test results.
12.If relief pressure is incorrect, inspect for:
A. Slipping pump drive belt.
6. After installing tester, start engine and run at idle
speed. Check for hydraulic leakage and correct before
proceeding with test.
B. Worn or stuck relief valve.
13.Remove tester and reinstall disconnected hose.
IMPORTANT: In this test, the flow tester is positioned before the relief valve. Pump damage can occur if the oil flow is fully restricted.
Workman 3000/4000 Series
Page 9 – 17
Hydraulic
System
7. Start engine and adjust engine speed with accelerator pedal so pump speed is 2700 RPM (engine speed
approximately 3600 RPM). Verify pump speed with a
phototac.
Hydraulic System
TEST NO. 2: Steering Control Valve and Steering Cylinder
STEERING CONTROL
(RIGHT TURN)
PLUG
L
P
STEERING
CYLINDER
T
E
R
LIFT CYLINDERS
GEAR
PUMP
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 temperature 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 proceeding 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 surface.
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 movement 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
turn.
5. If either of these performance tests indicate a steering problem, determine if the steering cylinder is faulty
using the following procedure.
WARNING
Keep body and hands away from disconnected
hoses and fittings that might eject hydraulic fluid
under high pressure. Use paper or cardboard,
not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force
to penetrate the skin and cause serious injury. If
fluid is injected into the skin, it must be surgically
removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
IMPORTANT: Do not turn steering wheel to the
left (counterclockwise) as system damage may
occur.
F. With the engine off, continue turning the steering
wheel to the right (clockwise) with the steering cylinder fully extended. Observe the open fitting on the
steering cylinder as the wheel is turned. If oil comes
out of the fitting while turning the steering wheel to the
right, the steering cylinder has internal leakage and
must be repaired or replaced.
G. Remove plug from the disconnected hydraulic
hose. Reconnect hose to the steering cylinder.
6. If steering problem exists and the steering cylinder,
gear pump flow and system relief pressure (see Test No.
1) tested acceptably, steering control valve requires service (see Steering Control Valve and Steering Control
Valve Service).
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.
Hydraulic
System
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
Hydraulic System
TEST NO. 3: Lift Cylinder Internal Leakage
STEERING CONTROL
L
P
STEERING
CYLINDER
T
E
R
LIFT CYLINDERS
LIFT VALVE
(IN LOWER POSITION)
GEAR
PUMP
PLUG
FILTER
STRAINER
TRANSAXLE
RESERVOIR
Figure 16
Hydraulic System
Page 9 – 20
Workman 3000/4000 Series
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 equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
2. Remove all pressure from cylinder by fully retracting
it (i.e. put hydraulic lift lever in LOWER position).
Pressure is applied
to this port
Figure 17
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 port.
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.
Hydraulic
System
6. Reconnect hose disconnected in step 3 after test or
repairs are complete.
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
.610 IN 3/REV
.833 ENGINE
SPEED
TESTER
SOLENOID
ACTIVATED
BYPASS VALVE
(ENERGIZED)
RELIEF VALVE
2000 PSI
IN TANK
SUCTION
STRAINER
100 MESH
RETURN FILTER
10 MICRON WITH
25 PSI BYPASS
4 GALLON
RESERVOIR
OIL COOLER
Figure 18
2
1
Figure 19
1. Pressure coupler
Hydraulic System
2. Return coupler
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 temperature 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 controls to relieve hydraulic system pressure.
3. Make sure that drive belt for High Flow Kit gear pump
is adjusted properly (see Kit Installation Instructions).
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 pump speed continues to be 3000
RPM. Record flow meter reading.
GAUGE READING TO BE: Flow should be approximately 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.
CAUTION
C. Pump suction line restriction.
Prevent personal injury and/or damage to equipment. Read all WARNINGS, CAUTIONS, and Precautions for Hydraulic Testing at the beginning
of this section.
IMPORTANT: Make sure that the oil flow indicator
arrow on the flow meter is showing that the oil will
flow from the pressure coupler, through the tester,
and into the return (tank) coupler (Fig. 19).
D. Gear pump needs to be repaired or replaced.
11. 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.
4. With the engine off, install tester with pressure
gauges and flow meter in series between the quick disconnect couplings. Make sure the tester flow control
valve is open.
IMPORTANT: Close flow control valve on tester
only enough to get a system relief pressure reading.
5. Make sure the Hydraulic Kit reservoir is full after connecting the tester.
C. Watch pressure gauge carefully while slowly closing the tester flow control valve until the relief valve
opens.
D. System pressure should be approximately 2000
PSI (137.9 Bar) as the relief valve lifts.
CAUTION
The engine must be running to perform hydraulic tests. To guard against possible personal injury, engage parking brake and keep clothing,
hands, feet, face and other parts of the body
away from fan and other moving parts.
E. Open tester flow control valve, release accelerator pedal to allow engine to return to low idle and turn
Kit switch OFF. Turn off vehicle. Record test results.
12.If relief pressure is incorrect, inspect for:
A. Slipping pump drive belt.
6. After installing tester, start engine and run at idle
speed. Turn hydraulic kit switch ON and check for hydraulic leakage from connections. Correct before proceeding with test.
B. Worn, stuck or out of adjustment relief valve.
13.Remove tester from quick disconnect couplings.
Hydraulic
System
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
Hydraulic System
This page is intentionally blank.
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
After Repair or Replacement of Components
1. Before removing any parts from the hydraulic system, park vehicle on a level surface, engage parking
brake, and stop engine. Remove key from the ignition
switch.
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 contaminated.
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.
2. Lubricate O--rings and seals with clean hydraulic oil
before installing hydraulic components.
3. Make sure caps or plugs are removed from the hydraulic tubes, hydraulic fittings, and components before
reconnecting.
4. Use proper tightening methods when installing hydraulic hoses and fittings (see Hydraulic Fitting Installation in the General Information section of this chapter).
CAUTION
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
5. After disconnecting or replacing any hydraulic components, operate vehicle functions slowly until air is out
of system.
6. Check for hydraulic oil leaks. Shut off engine and correct leaks if necessary. Check oil level in transaxle and
add correct oil if necessary.
3. Put caps or plugs on any hydraulic lines, hydraulic fittings, and components left open or exposed to prevent
contamination.
4. Put labels on disconnected hydraulic lines and hoses
for proper installation after repairs are completed.
5. Note the position of hydraulic fittings (especially elbow fittings) on hydraulic components before removal.
Mark parts if necessary to make sure they will be aligned
properly when reinstalling hydraulic hoses and tubes.
Check Hydraulic Lines and Hoses
Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
the skin and cause serious injury. If fluid is injected into the skin, it must be surgically removed within a few hours by a doctor familiar
with this type of injury. Gangrene may result from
such an injury.
Workman 3000/4000 Series
Page 9 -- 25 Rev. D
Hydraulic
System
WARNING
Check hydraulic lines and hoses daily for leaks, kinked
lines, loose mounting supports, wear, loose fittings,
weather deterioration and chemical deterioration. Make
all necessary repairs before operating.
Hydraulic System
Gear Pump (Vehicles with Liquid Cooled Engine)
Removal (Fig. 20)
3. Check oil level in transaxle (see Operator’s Manual).
Add Dexron III ATF if necessary.
1. Park vehicle on a level surface, raise and support bed
(if installed), shut engine off and engage parking brake.
2. Loosen pump drive belt and remove belt from pump
pulley (see Operator’s Manual).
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.
3. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
ANTISIEZE
LUBRICANT
27 to 33 in–lb
(3 to 3.7 N–m)
12
2
1
CAUTION
13
11
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
3
10
9
4
6
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
7
8
5. Remove mount plate with pump from vehicle.
LOCTITE #242
130 to 160 in–lb
(14.7 to 18.1 N–m)
6. Remove gear pump from mount plate using Figure
20 as a guide.
Figure 20
Installation (Fig. 20)
1. Install parts as shown in Figure 20 and using the following instructions:
A. Apply antiseize lubricant to gear pump shaft before installing pulley.
1.
2.
3.
4.
5.
6.
7.
Gear pump
Pressure hose
Suction hose
Lock nut (4 used)
Cap screw (4 used)
Pump pulley
Flat washer
B. After installing key and pulley on pump shaft,
tighten lock nut (Item 8) to a torque from 130 to 160
in–lb (14.7 to 18.1 N–m).
8.
9.
10.
11.
12.
13.
Lock nut
Cap screw (4 used)
Lock washer (4 used)
Fan
Mount plate
Set screw
1
2
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 N–m).
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 Operator’s Manual).
Hydraulic System
3
Figure 21
1. Gear pump
2. Pressure hose
Page 9 – 26
3. Suction hose
Workman 3000/4000 Series
Gear Pump (Vehicles with Air Cooled Engine)
Removal (Fig. 22)
3. Check oil level in transaxle (see Operator’s Manual).
Add Dexron III ATF if necessary.
1. Park vehicle on a level surface, raise and support bed
(if installed), shut engine off and engage the parking
brake.
4. Start the engine and operate at idle speed until air is
out of hydraulic system.
2. Loosen pump drive belt and remove belt from pump
pulley (see Operator’s Manual).
5. Stop the engine and check oil level in transaxle (see
Operator’s Manual). Add Dexron III ATF if necessary.
3. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
8
9
10
11
7
CAUTION
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
12
6
1
ANTISIEZE
LUBRICANT
5
3
4
2
130 to 160 in–lb
(14.7 to 18.1 N–m)
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.
Figure 22
5. Remove gear pump from mount using Figure 22 as
a guide.
Installation (Fig. 22)
1. Install gear pump to mount using Figure 22 as a guide
and using the following instructions:
1.
2.
3.
4.
5.
6.
Drive belt
Lock nut
Flat washer
Pump pulley
Cap screw
Carriage screw
7.
8.
9.
10.
11.
12.
Mount
Suction hose
Square key
Gear pump
Lock nut (2 used)
Pressure hose
A. Apply antiseize lubricant to gear pump shaft before installing pulley.
B. After installing key and pulley on pump shaft,
tighten lock nut (Item 8) to a torque from 130 to 160
in–lb (14.7 to 18.1 N–m).
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.
Hydraulic
System
2. After installing the pump and connecting hydraulic
hoses, install belt and adjust belt tension (see Operator’s Manual).
Workman 3000/4000 Series
Page 9 – 27
Hydraulic System
Gear Pump Service (Barnes Gear Pump)
9.5 to 12.5 ft--lb
(13 to 17 N--m)
18
17
20
23
12
13
14
15
16
11
19
10
9
8
6
1
2
3
4
4
7
5
4
12
16
11
21
12
22
1.
2.
3.
4.
5.
6.
7.
8.
Retaining ring
Shaft seal
Spacer
Crescent ring
Square key
Drive shaft
Shear pin
Stator
9.
10.
11.
12.
13.
14.
15.
16.
Figure 23
Seal plate
Wear plate
Gear
Bearing
Pressure plate
Back--up seal
Pressure plate seal
Dowel pin
Before disassembling gear pump, plug ports, wash exterior of pump with cleaning solvent and dry pump thoroughly.
Shaft Seal Replacement (Fig. 23)
Gear end housing
Socket head cap screw
Plug
Idler shaft
Wear plate seal
Bearing
Ball key
4. Clean any foreign material from seal bore and drive
shaft of pump.
5. Install spacer (Item 3) on driveshaft.
6. Put a seal protector tool on driveshaft or apply thin
plastic or tape on shaft to protect new seal from damage.
1. Remove retaining ring (Item 1).
2. Punch two (2) holes in face of seal, 180o 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
17.
18.
19.
20.
21.
22.
23.
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).
Page 9 -- 28 Rev. D
Workman 3000/4000 Series
Disassembly (Fig. 23)
Assembly (Fig. 23)
1. Remove shaft seal (see Shaft Seal Replacement).
IMPORTANT: Use caution when using a vise to
avoid distorting any pump components.
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 assembly into stator (Item 8).
2. Secure flange end of pump in a vise with drive shaft
(Item 6) facing down.
2. Apply Dexron III ATF to wear plate (Item 10) and
install on stator.
3. Remove four (4) socket head cap screws (Item 18).
3. Install one crescent ring (Item 4) to idler shaft, then
install ball key (Item 23), gear (Item 11) and other crescent ring. Make sure to maintain the original gear location. Apply Dexron III ATF to gear and idler shaft
assembly, then install into stator.
4. Put your hand on gear end housing (Item 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
4. Install shear pin (Item 7), then apply Dexron III ATF
to remaining gear and install to drive shaft (Item 6) maintaining the original timing and locations.
5. Apply Dexron III ATF to pressure plate seal (Item 15),
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 N–m).
1. Wash all parts in cleaning solvent.
8. Install shaft seal (see Shaft Seal Replacement).
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. Replace bearing if loose on shaft or noisy when rotated.
Hydraulic
System
5. Inspect square key (Item 5), shear pin (Item 7), ball
key (Item 23) and keyways in shafts for wear or damage.
Replace parts as necessary.
Workman 3000/4000 Series
Page 9 – 29
Hydraulic System
Gear Pump Service (Casappa Gear Pump)
4
13
9
3
1
6
14
7
2
16
5
10
12
5
4
17
15
11
220 in--lb
(25 N--m)
8
Figure 23.1
1.
2.
3.
4.
5.
6.
Retaining ring
Shaft seal
Front cover
Dowel pin
O--ring (2 used)
Back--up seal
7.
8.
9.
10.
11.
12.
Pressure seal
Front thrust plate
Drive shaft
Idler shaft
Body
Rear thrust plate
13.
14.
15.
16.
17.
Pressure seal
Back--up seal
Rear flange
Lock washer (4 used)
Screw (4 used)
Disassembly (Fig. 23.1)
1. Plug pump ports and clean the outside of the pump
thoroughly. After cleaning, remove plugs and drain any
oil out of the pump.
MARKER LINE
2. Use a marker to make a diagonal line across the
front thrust plate, body and rear flange for assembly purposes (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 remove. Make sure the rear thrust plate remains on the
drive and idler gear shafts. Locate and retrieve dowel
pins.
Hydraulic System
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.
Page 9 -- 29.1 Rev. D
Workman 3000/4000 Series
IMPORTANT: Make sure to not damage the seal
bores when removing the seal from the front cover
and rear flange.
3
10.Carefully remove retaining ring and shaft seal from
front cover. Discard seal.
2
Inspection
1. Remove any nicks and burrs from all parts with
emery cloth.
1
CAUTION
4
Use eye protection such as goggles when using
compressed air.
Figure 23.3
1.
2.
Gear shaft spline
Gear shaft
3.
4.
Gear teeth
Gear face edge
2. Clean all parts with solvent. Dry all parts with compressed air.
2. Press new shaft seal into front cover until it reaches
the bottom of the bore and secure with retaining ring.
3. Inspect drive and idler shafts for the following (Fig.
23.3):
3. Install the lubricated pressure and backup seals into
the grooves in the front and rear thrust plates. Install lubricated O--rings to the body.
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 indicates need for replacement.
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.
B. Gear teeth should be free of excessive scoring
and wear. Any broken or nicked gear teeth must be
replaced.
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.
C. Inspect gear face edge for sharpness. Sharp
edges of gears will mill into wear plates and, thus,
must be replaced.
IMPORTANT: When installing drive shaft into front
cover, make sure that shaft seal (item 2) is not damaged.
6. Carefully install shaft with front thrust plate into front
cover taking care to not damage shaft seal.
A. Bearing areas should not have excessive wear or
scoring.
B. Face of thrust 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 jelly. Lubricate all other internal parts freely with clean Dexron III ATF.
Workman 3000/4000 Series
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 rear thrust plate with pressure seal side up and
open side of the seals pointing to the inlet side of the
pump.
9. Install two (2) dowel pins into front cover. Align marker line on the body and front cover.
IMPORTANT: Do not dislodge seals during installation.
10.Gently slide the body onto the assembly. Firm hand
pressure should be sufficient to engage the dowel pins.
11. Align marker line on the body and rear flange.
Page 9 -- 29.2 Rev. D
Hydraulic System
Hydraulic
System
4. Inspect thrust plates for the following:
12.Carefully install rear flange onto pump assembly.
15.Remove pump from vise.
13.Install the four (4) screws (item 17) with lock washers
and hand tighten.
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.
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 in--lb (25
N--m).
Hydraulic System
Page 9 -- 29.3 Rev. D
Workman 3000/4000 Series
Hydraulic
System
This page is intentionally blank.
Workman 3000/4000 Series
Page 9 -- 29.4 Rev. D
Hydraulic System
Lift Valve
20
17
18 17
5
16
RIGHT
21
19
FRONT
5
12 10
2
15
1
10 11
8
9
14
2
5
3
13
6
4
5
7
Figure 24
1.
2.
3.
4.
5.
6.
7.
Lift valve
O–ring
Tee fitting
Hyd. hose (steering circuit return)
O–ring
Hyd. hose (return to hydraulic filter)
Flange nut
Hydraulic System
8.
9.
10.
11.
12.
13.
14.
Lift lever
Clevis pin
Hairpin
Jam nut
Link rod
Clevis
Hyd. hose (to male quick fitting)
Page 9 – 30
15.
16.
17.
18.
19.
20.
21.
Hyd. hose (to female quick fitting)
90o hydraulic fitting
O–ring
Hydraulic adapter
Cap screw
Hyd. hose (pressure supply)
90o 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 Removal in the Service and Repairs section of Chapter 7
– Chassis).
1
2
3
4
3. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
CAUTION
Figure 25
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
1. Lift lever
2. Clevis
3. Link rod
4. Lift valve spool
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 location of clevis on link rod if needed (Fig. 25).
2. Replace o–rings on hydraulic hoses and fittings. Remove caps and plugs from hoses and fittings. Connect
hydraulic hoses to lift valve.
3. Install seat base to vehicle (see Seat Base Installation 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.
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 interlock switch.
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.
8
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.
9
7
2
3
4
5
6
1
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
spool retaining ring (Item 13). Carefully push and twist
spool to remove spool from valve body.
9
10
11
12
10
13
14
5. Use a hooked scribe or thin screwdriver to remove o–
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)
Figure 26
1.
2.
3.
4.
5.
6.
7.
Hex cap 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
8.
9.
10.
11.
12.
13.
14.
Spool
O–ring
Spring retainer
Spring
Spacer
Spool retaining ring
Retaining ring
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 components in reverse order of disassembly. Install spool into
valve body before inserting cam pins, balls, springs and
hex cap plugs.
Hydraulic System
Page 9 – 32
Workman 3000/4000 Series
Hydraulic
System
This page is intentionally blank.
Workman 3000/4000 Series
Page 9 – 33
Hydraulic System
Steering Control Valve
1
RIGHT
20 to 26 ft--lb
(28 to 35 N--m)
2
10
3
FRONT
12
11
CONTROL VALVE PORTS
Anti--seize
Lubricant
13
4
9
FRONT OF VEHICLE
8
5
6
7
20
19
14
15
1.
2.
3.
4.
5.
6.
7.
16
17
18
Hex nut
Lock washer
Steering wheel
Steering control valve
Hyd hose (to control valve P port)
Hyd hose (to control valve E port)
Hyd hose (to control valve T port)
8.
9.
10.
11.
12.
13.
14.
Figure 27
Hyd hose (to control valve R port)
Hyd hose (to control valve L port)
Cap screw (4 used)
Dust cover
Steering hose cover
Cable tie
Bulkhead fitting (to valve L port)
Removal (Fig. 27)
1. Park vehicle on a level surface, shut engine off and
engage the parking brake.
2. Remove steering wheel (see Steering Wheel Removal in the Service and Repairs section of Chapter 7
-- Chassis).
Hydraulic System
15.
16.
17.
18.
19.
20.
Bulkhead fitting (to valve R port)
Bulkhead fitting (to valve T port)
Bulkhead fitting (to valve P port)
Bulkhead fitting (to valve E port)
Hyd hose (to steer cyl shaft end)
Hyd hose (to steer cyl barrel end)
3. Remove cable ties that secure steering hose cover
to hydraulic hoses. Remove cover from hoses.
4. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
Page 9 -- 34
Rev. C
Workman 3000/4000 Series
7. Start the engine, operate at idle speed and rotate the
steering wheel in both directions until air is out of hydraulic system.
CAUTION
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
8. Stop the engine and check oil level in transaxle (see
Operator’s Manual). Add Dexron III ATF if necessary.
7
8
6
5
5. Raise dash to gain access to steering control (Fig.
28):
4
2
A. Remove seven (7) screws (item 2) that secure
hood and dash to frame.
3
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 removal.
6. Remove steering control valve from vehicle frame by
removing four (4) cap screws.
1
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.
Figure 28
1.
2.
3.
4.
Hood
Screw (7 used)
Well nut (7 used)
Flat washer (2 used)
5.
6.
7.
8.
Cap screw (2 used)
Knob
Cover
Dash
Installation (Fig. 27)
1. Replace o–rings on hydraulic hoses and fittings. Remove 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.
5
1
2. Secure steering control valve to vehicle with four (4)
cap screws.
3. Install hydraulic hose cover over hoses and secure
with cable ties.
2
3
4
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 Installation in the Service and Repairs section of Chapter 7 –
Chassis).
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
Workman 3000/4000 Series
Page 9 – 35
Hydraulic
System
6. Check oil level in transaxle (see Operator’s Manual).
Add Dexron III ATF if necessary.
Hydraulic System
Steering Control Valve Service
8
9
7
6
10
5
4
3
2
11
1
12
22
13
14
15
21
13
16
20
13
17
18
20 to 24 ft–lb
(27 to 33 N–m)
19
Figure 30
1.
2.
3.
4.
5.
6.
7.
8.
Sleeve
Cross pin
Ring
Spool
Bearing assembly
Shaft seal
Ball stop
Ball
9.
10.
11.
12.
13.
14.
15.
Dust seal ring
Housing
Cardan shaft
Spacer
O–ring
Distribution plate
Inner gearwheel
16.
17.
18.
19.
20.
21.
22.
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
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
Workman 3000/4000 Series
Hydraulic
System
This page is intentionally blank.
Workman 3000/4000 Series
Page 9 – 37
Hydraulic System
Steering Cylinder
14
12
15
1
2
3
3
13
4
7
12
11
8
5
6
10
9
RIGHT
FRONT
Figure 31
1.
2.
3.
4.
5.
Steering cylinder
Retaining ring
Grease fitting
90o hydraulic fitting
Hyd. hose (from steering valve R)
Hydraulic System
6.
7.
8.
9.
10.
Hyd. hose (from steering valve L)
45o hydraulic fitting
Jam nut
Pitman arm
Slotted hex nut
Page 9 – 38
11.
12.
13.
14.
15.
Dust seal
Cotter pin
Ball joint
Slotted hex nut
Ball joint
Workman 3000/4000 Series
Removal (Fig. 31)
50 ft--lb
(68 N--m)
1. Park vehicle on a level surface, shut engine off and
engage the parking brake.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
7
8
4
CAUTION
1
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
3. Label and disconnect hydraulic hoses from steering
cylinder. Install caps or plugs in hoses to prevent contamination and leakage of hydraulic oil. Install plugs in
cylinder ports.
4. Remove steering cylinder from vehicle using Figures
31 and 32 as guides.
5
2
6
3
Figure 32
1.
2.
3.
4.
O--ring
45o hydraulic fitting
O--ring
O--ring
5.
6.
7.
8.
90o hydraulic fitting
O--ring
Ball joint
Jam nut
CYLINDER LENGTH WHEN FULLY RETRACTED
Installation (Fig. 31)
1. If ball joint was removed from cylinder shaft, fully retract cylinder shaft and thread ball joint onto shaft. Adjust
center to center length to dimension shown in Figure 33
before tightening jam nut. Torque jam nut 50 ft--lb (68
N--m).
14.520” (36.88 cm) for 2WD
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. Remove 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 III ATF if necessary.
5. Start the engine, operate at idle speed and rotate the
steering wheel in both directions until air is out of hydraulic system.
6. Stop the engine and check oil level in transaxle (see
Operator’s Manual). Add Dexron III ATF if necessary.
Hydraulic
System
7. Check front wheel alignment and adjust as needed
(see Front Wheel Alignment in the Service and Repair
section of Chapter 7 -- Chassis).
Workman 3000/4000 Series
Page 9 -- 39 Rev. A
Hydraulic System
Steering Cylinder Service
10
9
8
7
11
30 to 36 ft–lb
(41 to 49 N–m)
6
2
3
4
5
1
12
13
14
Figure 34
1.
2.
3.
4.
5.
Lock nut
Wear ring
Seal
O–ring
Piston
6.
7.
8.
9.
10.
11.
12.
13.
14.
Head
O–ring
Back–up ring
Retaining ring
Seal
Wiper
Barrel
Shaft
O–ring
Disassembly (Fig. 34)
1. Pump oil out of cylinder into a drain pan by slowly
moving piston back and forth.
Spanner wrench
2. Before disassembling cylinder, plug ports, wash exterior with cleaning solvent and dry thoroughly.
IMPORTANT: Use caution when using a vise to avoid
scratching or distorting any parts.
Retaining ring
3. Put cylinder in a vise so shaft end is facing up.
4. Use a spanner wrench to rotate head (Item 6) and remove retaining ring (Item 9). Grasp end of shaft and use
a twisting and pulling motion to carefully extract the piston, shaft and head assembly from the barrel.
Figure 35
Removing retaining ring
5. Remove cylinder from vise.
6. Remove lock nut (Item 1) from shaft, then remove piston (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
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.
Spanner wrench
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
III ATF to all seal kit components before installing.
Retaining ring
(Offset end against left
side of barrel groove
after 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).
Figure 36
Installing retaining ring
3. Coat all cylinder parts with clean Dexron III ATF. Slide
shaft assembly and head into barrel, being careful not to
damage seals.
Hydraulic
System
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.
Workman 3000/4000 Series
Page 9 – 41
Hydraulic System
Lift Cylinder
12
1
11
RIGHT
FRONT
10
2
4
8
3
3
2
4
9
7
6
5
Figure 37
1.
2.
3.
4.
Box frame
O–ring
Hydraulic fitting
O–ring
Hydraulic System
5.
6.
7.
8.
Hydraulic hose
Lift cylinder (LH shown)
Hydraulic hose
Cotter pin
Page 9 – 42
9.
10.
11.
12.
Engine support
Frame rail (LH shown)
Clevis pin
Lynch pin
Workman 3000/4000 Series
Removal (Fig. 37)
Installation (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.
1. Make sure that lift cylinder is fully retracted.
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
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.
CAUTION
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
5. Stop the engine and check oil level in transaxle (see
Operator’s Manual). Add Dexron III ATF if necessary.
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 cylinder to bed.
5. Remove cotter pin that secures lift cylinder to engine
support.
Hydraulic
System
6. Remove lift cylinder from vehicle.
Workman 3000/4000 Series
Page 9 – 43
Hydraulic System
Lift Cylinder Service
60 to 75 ft–lb
(81 to 102 N–m)
8
9
7
11
10
6
3
4
2
5
1
12
13
14
Figure 38
1.
2.
3.
4.
5.
Lock nut
Wear ring
Seal
O–ring
Piston
6.
7.
8.
9.
10.
11.
12.
13.
14.
Head
O–ring
Back–up seal
Retaining ring
Seal
Wiper
Barrel
Shaft
O–ring
Disassembly (Fig. 38)
1. Pump oil out of cylinder into a drain pan by slowly
moving piston back and forth.
Spanner wrench
2. Before disassembling cylinder, plug ports, wash exterior with cleaning solvent and dry thoroughly.
IMPORTANT: Use caution when using a vise to avoid
scratching or distorting any parts.
Retaining ring
3. Put cylinder in a vise so shaft end is facing up.
4. Use a spanner wrench to rotate head (Item 6) and remove retaining ring (Item 9). Grasp end of shaft and use
a twisting and pulling motion to carefully extract the piston, shaft and head assembly from the barrel.
Figure 39
Removing retaining ring
5. Remove cylinder from vise.
6. Remove lock nut (Item 1) from shaft, then remove piston (Item 5), and head (Item 6). Remove and discard
seals, o–rings, wear ring and wiper from piston and
head.
Hydraulic System
Page 9 – 44
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.
Spanner wrench
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
III ATF to all seal kit components before installing.
Retaining ring
(Offset end against left
side of barrel groove
after 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 60 to 75 ft–lb (81 to 102
N–m).
Figure 40
Installing retaining ring
3. Coat all cylinder parts with clean Dexron III ATF. Slide
shaft assembly and head into barrel, being careful not to
damage seals.
Hydraulic
System
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.
Workman 3000/4000 Series
Page 9 – 45
Hydraulic System
Hydraulic Manifold (Optional High Flow Hydraulic Kit)
Removal (Fig. 41)
1. Park vehicle on a level surface, raise bed, shut engine off and engage the parking brake.
RIGHT
FRONT
2. Read the General Precautions for Removing and
Installing Hydraulic System Components at the beginning of the Service and Repairs section of this chapter.
2
6
1
7
3
4
CAUTION
5
4
3
Before performing any service or repair on hydraulic system components, relieve system
pressure to avoid injury from pressurized hydraulic oil. Stop the engine, remove key from the
ignition switch, rotate the steering wheel in both
directions, lower or support the bed and operate
other hydraulic accessories.
3. Label and disconnect hydraulic hoses from hydraulic
manifold. Install caps or plugs in hoses to prevent contamination and leakage of hydraulic oil. Install plugs in
manifold ports.
2
Figure 41
1.
2.
3.
4.
Hydraulic manifold
O–ring
Hydraulic fitting
O–ring
4. Remove manifold from vehicle using Figure 41 as a
guide.
1
50 to 55 in–lb
(5.6 to 6.2 N–m)
Installation (Fig. 41)
5. Cap screw
6. Lock nut (2 used)
7. Engine mount bracket
2
3
2
1. Install manifold to vehicle using Figure 41 as a guide.
4
2. Replace o–rings on hydraulic hoses and fittings. Remove caps and plugs from hoses and fittings. Connect
hydraulic hoses to manifold.
5
3. Check oil level in reservoir (see High Flow Hydraulic
Kit Installation Instructions). Add correct oil if necessary.
6
30 to 35 ft–lb
(41 to 47 N–m)
30 to 35 ft–lb
(41 to 47 N–m)
Valve Cartridge Service (Fig. 42)
7
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
off the valve. Locate and retrieve seals from top and bottom of coil.
IMPORTANT: Use care when handling the valve cartridge. Slight bending or distortion of the stem tube
can cause binding and malfunction.
8
Figure 42
1.
2.
3.
4.
Retaining nut
Solenoid seal
Solenoid coil
Solenoid cartridge valve
5.
6.
7.
8.
Seal kit
Manifold body
Seal kit
Relief valve cartridge
3. Remove cartridge valve with a deep socket wrench.
Note correct 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 contamination.
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 damaged, the hydraulic system may be overheating or
there may be water in the system.
7. Reinstall the cartridge valve:
A. Lubricate new seal kit components with clean hydraulic 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 sealing.
IMPORTANT: Use care when handling the valve cartridge. 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 N–m).
CAUTION
Use eye protection such as goggles when using
compressed air.
8. If problems still exist, remove valve and clean again
or replace valve.
Hydraulic
System
6. Clean cartridge valve using clean mineral spirits.
Submerge valve in clean mineral spirits to flush out contamination. Particles as fine as talcum powder can affect
the operation of high pressure hydraulic valves. If cartridge 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 cartridge. Use compressed air for cleaning.
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 N–m). Over–tightening
may damage the solenoid or cause the valve to malfunction.
Workman 3000/4000 Series
Page 9 – 47
Hydraulic System
This page is intentionally blank.
Hydraulic System
Page 9 – 48
Workman 3000/4000 Series
Front Wheel Drive (4WD)
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
SERVICE and REPAIRS . . . . . . . . . . . . . . . . . . . . . . . 4
Front Wheel and Axle Housing Assembly . . . . . . 4
Front Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front Brake Service . . . . . . . . . . . . . . . . . . . . . . . . 10
Inspect Constant Velocity (CV) Joint Boot and
Test CV Joint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Workman 4000 Series
Constant Velocity (CV) Joint . . . . . . . . . . . . . . . . .
Front Differential . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Differential Service . . . . . . . . . . . . . . . . . . . .
Ring to Pinion Gear Engagement . . . . . . . . . . . .
Differential Drive Shaft . . . . . . . . . . . . . . . . . . . . . .
Drive Shaft Cross and Bearing Service . . . . . . . .
Bidirectional Clutch . . . . . . . . . . . . . . . . . . . . . . . . .
Page 10 – 1
12
14
16
28
30
31
32
Front Wheel Drive (4WD)
Front Wheel
Drive (4WD)
Chapter 10
Specifications
Item
Description
Front Differential
5.0 to 1 ratio, single reduction
Front Brakes
Hydraulically operated, self adjusting, 8–inch diameter drum
Bidirectional Clutch
Front Wheel Drive (4WD)
Overrunning type
Page 10 – 2
Workman 4000 Series
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
have enough traction to move the vehicle without slipping. Once this occurs, the system stops delivering power to the front wheels and the handling characteristics
become similar to that of a two wheel drive vehicle. The
four wheel drive system functions in both forward and
reverse. When front wheels are turned, the rear wheels
will slip slightly more before power is delivered to the
front wheels.
Page 10 – 3
Front Wheel Drive (4WD)
Front Wheel
Drive (4WD)
General Information
Service and Repairs
Front Wheel and Axle Housing Assembly
1
45 to 65 ft–lb
(61 to 88 N–m)
40 to 60 ft–lb
(54 to 81 N–m)
2
LOCTITE #680
3
4
22
SMALL SPACER
5
21
6
7
8
9
170 to 200 ft–lb
(230 to 271 N–m)
10
11
12
13
16
CUP
20
ACCESS HOLE
19
CONE
18
15
23
RIGHT
17
24
16
LOCTITE #271
25
FRONT
14
26
27
24
28
APPLY GREASE
TO SPLINES
Figure 1
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Wheel nut (5 used per wheel)
Wheel and tire assembly
Brake drum
Stub axle
Lock washer
Hex bolt (5 used per wheel)
Brake cable clip
Cap screw (4 used per brake)
Lock washer (4 used per brake)
Cap screw
11.
12.
13.
14.
15.
16.
17.
18.
19.
Flat washer
Brake hose retainer clip
Brake hose bracket
Constant velocity (CV) joint assembly
Differential
Bearing assembly
Axle housing (RH shown)
Brake plate plug
Front brake assembly (RH shown)
20.
21.
22.
23.
24.
25.
26.
27.
28.
Wheel bearing spacer
Hardened washer
Hex flange nut
Tie rod end (RH thread)
Cotter pin
Jam nut (RH thread)
Tie rod
Jam nut (LH thread)
Tie rod end (LH thread)
Disassembly (Fig. 1)
3. Remove brake drum from the stub axle.
1. Park vehicle on a level surface. Make sure engine is
off. Engage parking brake and block rear wheels.
4. Remove hex flange nut (22) and hardened washer
(21) from the threaded shaft of the CV joint (14). Discard
nut.
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.
5. Pull stub axle (4) and outer bearing cone from the
axle housing.
6. Remove cap screw and flat washer securing the
NOTE: If the brake drum sticks to the brake shoes durbrake hose bracket (13) to the axle housing.
ing removal, loosen brake shoes from the drum by turning bolt adjuster through access hole in brake drum.
Front Wheel Drive (4WD)
Page 10 – 4 Rev. B
Workman 4000 Series
4
8. Remove cotter pin and slotted hex nut from the tie
rod end assembly. Separate tie rod end from the axle
housing.
9
80 to 90 ft–lb
(108 to 122 N–m)
1
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.
3
5
2
B. Remove cap screw (6) and lock nut (5) from axle
housing.
8
6
9
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.
7
D. Remove remaining inner bearing cone.
10
Figure 2
Inspection (Fig. 1)
IMPORTANT: If any part of a bearing assembly (16)
needs replacement, replace bearings as a matched
set.
1. If any foreign material is in the bearing, clean bearing
and determine source of the material. Replace bearings
(16) if any of the following conditions occur (Fig. 3):
1.
2.
3.
4.
5.
Axle housing
Cotter pin
Slotted hex nut
Upper ball joint
Lock nut
6.
7.
8.
9.
10.
CUP
SEAL
A. Spalling or pitting on roller or cone contact surfaces. Corrosion that can not be cleaned up with light
polishing.
ROLLER
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 rollers. Scalloping, high spots, brinelling or burrs in the
cups.
CONE
CAGE
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 damaged.
Cap screw
Lower ball joint
CV joint
Ball joint seal
Inner bearing cone
Figure 3
Assembly (Fig. 1)
1. If hex bolts and lock washers were removed from the
stub axle:
A. Thoroughly clean threads of hex bolt and stub
axle. Apply Loctite #680 (or equivalent) to threads of
hex bolt closest to bolt head.
B. Install hex bolt with lock washer into stub axle.
Torque bolt from 40 to 60 ft–lb (54 to 81 N–m).
Workman 4000 Series
Page 10 – 5 Rev. B
Front Wheel Drive (4WD)
Front Wheel
Drive (4WD)
7. Remove four cap screws and lock washers securing
the brake assembly (19) to the axle housing. Position
brake assembly away from the housing.
IMPORTANT: Bearing cones and bearing cups are
part of a matched bearing set; these parts are not interchangeable. Use one matched bearing set per
axle housing.
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 N–m). If necessary to install cotter pin, tighten nut further and secure assembly with cotter pin..
2. If a bearing cup was removed from the axle housing,
press new bearing cup(s) into each end of the axle
housing.
IMPORTANT:Hex flange nut (22) should be replaced
whenever it is removed.
3. Pack both bearing cones with Mobile high temperature grease or equivalent. If the outer bearing cone was
removed from the stub axle, slide wide end of new bearing cone onto the shaft of the stub axle and press cone
onto the shaft (Fig. 4).
4. Position front brake assembly (19) to the axle housing. Secure brake assembly to the axle housing with four
cap screws (8) and lock washers (9).
5. Insert shaft of the stub axle into the axle housing.
Slide small spacer onto the shaft, then slide wheel bearing spacer onto the shaft.
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 N–m).
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:
6. Slide inner bearing cone, with its narrow end first,
onto the shaft of the stub axle.
A. Align access hole in brake drum with adjuster bolt
on adjuster assembly.
7. Apply No. 2 general purpose grease to the splines of
the CV joint.
B. Rotate adjusting bolt to increase adjuster length
until brake shoes contact brake drum.
8. Position stub axle/axle housing assembly to the CV
joint. Insert splined end of the CV joint into the stub axle.
C. Back off adjuster until drum rotates freely.
9. Install axle housing as follows (Fig. 2):
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 N–m).
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 N–m). If necessary to install cotter pin,
tighten nut further and secure assembly with cotter
pin.
PRESS BEARING
CONE TO HERE.
B. Install cap screw into axle housing and secure
with lock nut.
STUB AXLE
C. Connect upper ball joint to the axle housing.
Install slotted hex nut and torque from 80 to 90 ft–lb
(108 to 122 N–m). If necessary to install cotter pin,
tighten nut further and secure assembly with cotter
pin.
Front Wheel Drive (4WD)
Page 10 – 6
Figure 4
Rev. B
Workman 4000 Series
Front Wheel
Drive (4WD)
This page is intentionally blank.
Workman 4000 Series
Page 10 – 7
Front Wheel Drive (4WD)
Front Brake
1
45 to 65 ft–lb
(61 to 88 N–m)
40 to 60 ft–lb
(54 to 81 N–m)
2
LOCTITE #680
3
4
23
SMALL SPACER
5
22
6
8
7
9
11
10
170 to 200 ft–lb
(230 to 271 N–m)
12
14
13
15
17
21
20
ACCESS HOLE
16
19
18
17
RIGHT
LOCTITE #271
FRONT
APPLY GREASE
TO SPLINES
Figure 5
1.
2.
3.
4.
5.
6.
7.
8.
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)
9.
10.
11.
12.
13.
14.
15.
16.
Lock washer (4 used per brake)
Brake tube
Cap screw
Flat washer
Brake hose retainer clip
Brake hose
Brake hose bracket
Constant velocity (CV) joint assembly
Removal (Fig. 5)
1. Park vehicle on a level surface. Make sure engine is
off. Engage parking brake and block rear wheels.
2. Partially loosen front wheel lug nuts. Jack up and secure front wheel off the ground (see Jacking Instructions
in Operator’s Manual). Remove wheel nuts and wheel
from the brake drum.
NOTE: If the brake drum sticks to the brake shoes during removal, loosen brake shoes from the drum by turning bolt adjuster through access hole in brake drum.
3. Remove brake drum from hub.
4. Remove hex flange nut (23) and hardened washer
(22) from the threaded shaft of the CV joint. Discard nut.
Front Wheel Drive (4WD)
17.
18.
19.
20.
21.
22.
23.
Bearing assembly
Axle housing (RH shown)
Brake plate plug
Front brake assembly (RH shown)
Wheel bearing spacer
Hardened washer
Hex flange nut
5. Pull stub axle and outer bearing cone from the axle
housing and the splined end of the CV joint. Make sure
wheel bearing spacer and small spacer come out with
the stub axle.
NOTE: It may be necessary to remove the brake assembly from the axle housing for servicing some components such as the brake cylinder assembly.
6. If necessary, remove brake assembly as follows:
A. Disconnect brake tube (10) from the brake assembly. Plug brake tube to prevent contaminants
from entering brake system.
B. Remove brake assembly from the axle housing
by removing the four cap screws (8) and lock washers (9) from the housing.
Page 10 – 8
Rev. B
Workman 4000 Series
1. If the brake assembly was removed from the axle
housing, install brake assembly as follows:
IMPORTANT:Hex flange nut (23) should be replaced
whenever it is removed.
A. Secure brake assembly to the axle housing with
four cap screws and lock washers.
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).
IMPORTANT: Make sure brake hose connections
are clean and free of dirt.
NOTE: Make sure access hole on both the brake drum
and stub axle align when installed.
B. Remove plug from front brake hose. Connect
brake tube to brake assembly.
2. 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 N–m).
3. Insert small spacer and then wheel bearing spacer
onto the stub axle. Make sure bearing cones are sufficiently greased.
4. Apply No. 2 general purpose grease to the splines of
the CV joint.
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 N–m).
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
Page 10 – 9 Rev. B
Front Wheel Drive (4WD)
Front Wheel
Drive (4WD)
Installation (Fig. 5)
Front Brake Service
2
49 to 97 in–lb
(5.5 to 11 N–m)
8
1
7
13
26
25
5
4
3
11
6
9
12
10
10
24
12
11
14
16
17
18
21
13
15
27
19
20
23
22
Figure 6
1.
2.
3.
4.
5.
6.
7.
8.
9.
Cap screw and lock washer (2 used)
Back plate
Plug
Bleed screw
Bleed screw cap
Brake cylinder body
Parking brake lever
Pin
Spring
10.
11.
12.
13.
14.
15.
16.
17.
18.
L–type seal
Piston
Dust cover
Brake shoe
Upper shoe spring
Lower shoe spring
Female push rod
Bolt adjuster
Adjuster sleeve
19.
20.
21.
22.
23.
24.
25.
26.
27.
Pawl
Adjuster spring
Pawl pin
Hold down washer (2 used)
Hold down spring (2 used)
Pipe guide
Inspection plug
Hold down pin (2 used)
Adjuster assembly
For brake service procedures, refer to Brake Service in
the Service and Repairs section of Chapter 7 – Chassis.
Front Wheel Drive (4WD)
Page 10 – 10
Workman 4000 Series
Front Wheel
Drive (4WD)
Inspect Constant Velocity (CV) Joint Boot and Test CV Joint
Inspect CV Joint Boot
Inspect CV joint boot after every 200 hours of operation.
A torn boot is the most common cause of CV joint failures.
NOTE: A worn and noisy CV joint with the boot in good
condition and filled with grease is not uncommon. Potholes, curb contact, or collision damage can chip bearing components and initiate worn conditions.
1. Look for grease on the suspension, inner tire sidewall, 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.
1
2
3
Figure 7
2. If the boot is cracked or torn, or has any holes or
loose clamps, remove CV joint (see Constant Velocity
Joint in this section) and replace boot.
1. Inboard boot
2. Outboard boot
3. Differential
Test CV Joint
1. Test drive vehicle on a smooth surface to verify CV
joint problem.
2. Accelerate or 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. Vibration or shudder indicates a worn or sticking inboard CV
joint.
4. Accelerate vehicle at an angle over a ramp or up a
hill. A clunking noise indicates a worn inboard CV joint.
5. If any CV joint components are worn or damaged, the
CV joint assembly must be replaced.
Workman 4000 Series
Page 10 – 11
Front Wheel Drive (4WD)
Constant Velocity (CV) Joint
1
45 to 65 ft–lb
(61 to 88 N–m)
2
3
4
22
5
21
6
7
8
9
10
11
170 to 200 ft–lb
(230 to 271 N–m)
12
13
16
CUP
20
CONE
19
14
18
15
23
RIGHT
17
24
LOCTITE #271
25
FRONT
16
26
27
APPLY GREASE
TO SPLINES
24
28
Figure 8
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
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)
Lock washer (4 used per brake)
Cap screw
Front Wheel Drive (4WD)
11.
12.
13.
14.
15.
16.
17.
18.
19.
Flat washer
Brake hose retainer clip
Brake hose bracket
Constant velocity (CV) joint assembly
Differential
Bearing assembly
Axle housing (RH shown)
Brake plate plug
Front brake assembly (RH shown)
Page 10 – 12
20.
21.
22.
23.
24.
25.
26.
27.
28.
Wheel bearing spacer
Hardened washer
Hex flange nut
Tie rod end (RH thread)
Cotter pin
Jam nut (RH thread)
Tie rod
Jam nut (LH thread)
Tie rod end (LH thread)
Workman 4000 Series
LEVERAGE
POINT
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).
2
IMPORTANT: Make sure not to damage the oil seal
on the front differential with the pry bars when removing the CV joints.
1
2. Use two small pry bars (180o apart) to leverage the
CV joint out of the front differential. Use even pressure
on both pry bars (Fig. 9).
LEVERAGE
POINT
Figure 9
IMPORTANT: With damaged CV joints, there is the
possibility that the wheel bearings may be damaged
as well. It is recommended that the wheel bearings
be inspected when CV joints are replaced.
1. CV joint
2. Front differential
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 purpose lithium base grease.
3. Insert end of CV joint into the front differential until a
snap is heard. Pull outward 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 (4WD)
Front Wheel
Drive (4WD)
Removal (Fig. 8)
Front Differential
1
RIGHT
2
4
FRONT
3
15
25
24
7
22
19
4
38
7
9
8
35
16
16
6
14
2
17
18
6
28
4
4
18
18
29
13
1
19
17
34 15
11
10 12
32
26
17
37
5
33
18
36
6
21
23
27
30
20
31
Figure 10
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Grease fitting
Retaining ring
Upper control arm
Flange bushing
Slotted hex nut
Lock nut
Ball joint seal
Lower ball joint
Brake hose retainer
Cap screw
Brake hose bracket
Lock nut
R–clamp
Front Wheel Drive (4WD)
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
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)
Cap screw (4 used)
Front differential
Differential rear mount
Lock washer (4 used)
Cap screw (4 used)
Differential drive shaft
Upper ball joint
Socket hex head screw (6 used)
Page 10 – 14
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
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
1. Park vehicle on a level surface. Make sure engine is
off. Set parking brake and block rear wheels.
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 Assembly Removal).
4. Remove differential drive shaft from the front differential flange (see Differential Drive Shaft Removal).
5. Remove front brake lines and clamps that might interfere with the removal of the front differential. Tie any
cables out of the way that might interfere with removal.
CAUTION
Support front differential during installation to
prevent personal injury from falling and damage
to the differential.
1. Secure front differential to the differential front bracket with three cap screws (28) and lock washers (29).
2. Secure differential rear mount (21) to frame with cap
screws (19), snubbing washers (18), mount assemblies
(17), and lock nuts (6).
3. Secure front differential to differential rear mount
with four cap screws (23) and lock washers (22).
4. Reconnect front brake lines and clamps. Reposition
cables.
CAUTION
Support front differential during removal to prevent personal injury from falling and damage to
the differential.
6. Remove four cap screws (23) and lock washers (22)
securing the front differential to the differential rear
mount (21).
7. Remove differential rear mount (21) from frame by
removing both lock nuts (6) and cap screws (19). Locate
and remove mount assemblies (17) and snubbing
washers (18).
5. Reinstall differential drive shaft to the front differential flange (see Differential Drive Shaft Installation).
6. Reinstall both CV joints to the front differential (see
Constant Velocity (CV) Joint Assembly Installation).
7. Make sure front differential drain plug is installed
properly. Fill front differential with oil (see Operator’s
Manual).
8. Bleed front brakes (see Bleeding the Brakes in Service and Repairs section of Chapter 7 – Chassis).
8. Remove three cap screws (28) and lock washers
(29) from the differential front bracket (27) and front differential.
9. Pull front differential from the vehicle.
Workman 4000 Series
Page 10 – 15
Front Wheel Drive (4WD)
Front Wheel
Drive (4WD)
Installation (Fig. 10)
Removal (Fig. 10)
Front Differential Service
75 to 90 ft–lb
(102 to 122 N–m)
15 to 20 ft–lb
(20 to 27 N–m)
20 to 25 ft–lb
(27 to 33 N–m)
16
14
30 to 45 ft–lb
(41 to 61 N–m)
12
15
19
13
20
22
23
21
24
BEARING CAP
11
1
2
3
7
6
4 5
18
17
10
9
BEARING CRADLE
8
29 30
BEARING CAP
25
28
6
7
26
58 to 65 ft–lb
(79 to 88 N–m)
32
34
27
33
31
Figure 11
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Vent
Front housing
Alignment pin (2 used)
Thrust washer
Side bevel gear
Pinion gear
Thrust washer
Pinion gear
Bearing cone
Bearing cup
Cap screw (4 used)
Plug (2 used)
Front Wheel Drive (4WD)
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
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
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
Bearing spacer
Pinion shaft
Cap screw (5 used)
Differential case
Roll pin
Bearing cone (2 used)
Bearing cup (2 used)
Shim
Ring gear
Oil seal (2 used)
Needle bearing (2 used)
Workman 4000 Series
Front Wheel
Drive (4WD)
Disassembly (Fig. 11)
1. Remove flange (19) from the pinion shaft (8) by removing lock nut (18) and washer (17) from the threaded
end of the shaft. Use a bearing puller if necessary to remove the coupler flange (Fig. 12).
2. Secure carrier assembly (15) so that pinion gear
shaft (8) is facing up. Remove eight cap screws (16) securing 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 reassembly. Place caps in a safe place to avoid damaging their machined surface. Place caps back in the
same position during reassembly.
4. Remove four cap screws (11) and both bearing caps
from the bearing cradles (Fig. 14).
IMPORTANT: Keep mating bearing bearing cups
(30) with matching bearing cups (30) and bearing
caps.
5. Remove differential gears from the carrier assembly
by using two wooden handles under the differential case
(27) to pry up the case and gears (Fig. 15).
Figure 13
Figure 14
Figure 15
Workman 4000 Series
Page 10 – 17
Front Wheel Drive (4WD)
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).
PUNCH
8. Remove both sets of pinion gear shafts (5 and 6) and
thrust washers (4 and 7) by rotating the gears 90o
through the opening in the differential case (27) (Fig.
18).
Figure 16
IMPORTANT: Avoid damaging gear teeth when removing the gear ring (32) from the differential case
(27).
9. Remove five cap screws (26) from the differential
case (27) and gear ring (32). Drive ring gear off the differential case using a hard wood block and a hammer
(Fig. 19).
Figure 17
Figure 18
Figure 19
Front Wheel Drive (4WD)
Page 10 – 18
Workman 4000 Series
Front Wheel
Drive (4WD)
NOTE: Remove bearing cones (29) from the differential case only if they need replacing (see Inspection).
Retain shims (31) for reassembly of new bearing cones.
10.Remove bearing cone (29) from the differential case
(27) with a puller. Make sure puller is inserted into the
indentations on the differential case (Fig. 20).
IMPORTANT: Make sure shims (21) are kept after
they are removed from the carrier assembly (15).
11. Pull pinion gear shaft (8) and bearing cone (9) from
the carrier assembly (15). If necessary, press pinion
gear shaft out of the carrier housing. Remove oil seal
(20) and discard it. Remove bearing cone (22), shims
(21), and spacer (24) from the carrier housing(15) (Fig.
21).
Figure 20
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 housing (15) only if it needs replacing (see Inspection).
13.Press bearing cup (23) from the carrier assembly
(15) (Fig. 23).
Figure 21
Figure 22
Figure 23
Workman 4000 Series
Page 10 – 19
Front Wheel Drive (4WD)
IMPORTANT: Make sure shims (14) are kept after
they are removed from the carrier assembly (15).
NOTE: Remove bearing cup (10) from the carrier housing (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).
Figure 24
Inspection (Fig. 11)
1. Inspect front housing (2) and carrier assembly (15)
for cracks and damage. Replace either part if its condition could affect the operation of the front differential assembly. 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 freely, 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).
Figure 25
Figure 26
Figure 27
Front Wheel Drive (4WD)
Page 10 – 20
Workman 4000 Series
Front Wheel
Drive (4WD)
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 pinion shaft (25) fits loosely in its bore (Fig. 28).
IMPORTANT: The ring gear (32) and pinion gear (8)
must be replaced as a matched set.
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).
Figure 28
IMPORTANT: If any part of a bearing needs replacement, both bearing cone and cup must be replaced.
5. Replace bearing cones (9, 22, or 29) and corresponding bearing cups (10, 23, or 30) if any of the following conditions occur (Fig. 30 and 31):
A. Spalling or pitting on roller or cone contact sur
faces. Corrosion 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
BEARING
CUP
Figure 31
Workman 4000 Series
Page 10 – 21
Front Wheel Drive (4WD)
Assembly (Fig. 11)
RING GEAR (32)
PINION
SHAFT (25)
PINION
GEAR (6)
CAP SCREW (26)
THRUST
WASHER (7)
DIFFERENTIAL
CASE (27)
THRUST
WASHER (4)
SIDE BEVEL
GEAR (5)
SHIM (31)
CAP SCREW (11)
BEARING
CAP
BEARING
CRADLE
BEARING
CONE (29)
BEARING
CUP (30)
3.750 INCH
ROLL PIN (28)
CARRIER
ASSEMBLY (15)
BEARING
CONE (9)
BEARING
CUP (10)
SHIMS (14)
BEARING
SPACER (24)
SHIMS (21)
BEARING
CONE (22)
BEARING
CUP (23)
COUPLER
FLANGE (19)
OIL SEAL (20)
WASHER (17)
PERMATEX
LOCK NUT (18)
Figure 32
NOTE: In Figure 32, numbers in parentheses ( ) correspond to the reference numbers in Figure 11.
Front Wheel Drive (4WD)
Page 10 – 22
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 differential (Fig. 33).
Front Wheel
Drive (4WD)
SHIMMING
DIMENSION
MATCHING
NUMBERS
The distance from the center line of the ring gear to the
bottom of the pinion gear teeth is 3.750 inches (5.525
cm). This distance represents the best running position
for the gear set (Fig. 32).
On the end of each pinion gear, there is an etched number indicated by plus (+), minus (–), or zero (0). This
number indicates a shimming dimension for the best
running position of the gear set. This dimension is controlled by shimming between the the bearing cup (10)
and the carrier assembly (15) (Fig. 33).
For example: If a pinion gear shaft is etched +4, this pinion would require 0.004 inch less shims than a pinion
etched ”0”. By removing shims, the running position is
increased to 3.754 inches. The +4 represents a 0.004
inch increase in the running position. On the other hand:
If a pinion gear shaft is etched –4, this pinion would require 0.004 inch more shims than a pinion etched ”0”. By
adding shims, the running position is decreased to
3.746 inches. The –4 represents a 0.004 inch decrease
in the running position.
Figure 33
When reusing an old ring gear and pinion gear shaft set,
measure the old shim pack thickness and build a new
shim pack to the same thickness. Measure each shim
separately with a micrometer. Add each shim thickness
to get the total shim pack thickness.
If a new gear set is being used, note the (+) or (–) etching
on both the old and new pinion gear shaft. Change the
thickness of the new shim pack to compensate for the
difference between these two dimensions.
For example: If the old pinion gear shaft reads + 2 and
the new gear is –2, add 0.004 inch of shims to the old
shim pack (see Table 1).
NOTE: All shims (14, 21, and 31) are available in thicknesses of 0.003, 0.005, 0.010, and 0.030 inch.
Old Pinion
Marking
New Pinion Marking
–4
–3
–2
–1
0
+1
+2
+3
+4
+4
+0.008
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
+3
+0.007
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
–0.001
+2
+0.006
+0.005
+0.004
+0.003
+0.002
+0.001
0
–0.001
–0.002
+1
+0.005
+0.004
+0.003
+0.002
+0.001
0
–0.001
–0.002
–0.003
0
+0.004
+0.003
+0.002
+0.001
0
–0.001
–0.002
–0.003
–0.004
–1
+0.003
+0.002
+0.001
0
–0.001
–0.002
–0.003
–0.004
–0.005
–2
+0.002
+0.001
0
–0.001
–0.002
–0.003
–0.004
–0.005
–0.006
–3
+0.001
0
–0.001
–0.002
–0.003
–0.004
–0.005
–0.006
–0.007
–4
0
–0.001
–0.002
–0.003
–0.004
–0.005
–0.006
–0.007
–0.008
Table 1
1. If the bearing cone (9) was removed, press new
bearing cone onto the shaft of the pinion gear (8) (Fig.
34).
Figure 34
Workman 4000 Series
Page 10 – 23
Front Wheel Drive (4WD)
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 a new carrier assembly (15) is being installed, proceed as follows:
A. Press bearing cup (10) into the assembly with out
any shims (14).
Figure 35
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 using a depth micrometer (Fig. 32 and 37).
D. Note shimming dimension on the pinion gear
(Fig. 33). If the dimension is (+) positive, add the dimension to 3.750 inch. If the dimension is (–) negative, 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.
Figure 36
E. Now determine the difference between the measurement taken in a step C and the value calculated
in step D. This difference is the new shim thickness.
F. Remove bearing cup from the carrier assembly.
G. Install required shim thickness and bearing cup
into the carrier assembly.
IMPORTANT: The pinion gear (8) and ring gear (32)
are supplied only as a matched set. Matching numbers on both gears are etched for verification. When
using a new gear set, make sure the matching numbers are verified before using (Fig. 33).
Figure 37
5. Install pinion gear (8) and bearing cone (9) into the
carrier assembly (15). Place bearing spacer (24), shims
(21), and bearing cone (22) on to the shaft of the pinion
gear (Fig. 38).
Figure 38
Front Wheel Drive (4WD)
Page 10 – 24
Workman 4000 Series
Front Wheel
Drive (4WD)
6. Verify bearing preload and pinion gear shaft (8) rotation as follows:
A. Install coupler flange (19), washer (17), and lock
nut (18) to the shaft of the pinion gear. Torque lock
nut from 75 to 90 ft–lb (102 to 122 N–m).
B. The torque required to rotate the shaft of the pinion 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 pinion gear is more than specified in step B, remove lock
nut, washer, coupler flange, bearing cone (22), and
shim (21) from the shaft of the pinion gear. Increase
shim thickness to decrease bearing preload.
Figure 39
D. If the torque required to rotate the pinion gear
shaft is less than specified in step B, remove lock nut,
washer, coupler flange, bearing cone (22), and shim
(21) from the pinion gear shaft. Decrease shim thickness to increase bearing preload.
E. Install shim, bearing cone, coupler flange, washer, and lock nut to the pinion gear shaft. Torque lock
nut from 75 to 90 ft–lb (102 to 122 N–m).
F. The torque required to rotate the pinion gear shaft
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 necessary.
Figure 40
SPLINES
G. If the torque required to rotate the shaft of the pinion gear shaft is as specified in step B or F, remove
lock nut, washer, coupler flange, bearing cone (22)
from the shaft of the pinion gear. Press new oil seal
(20) into the carrier assembly (15) (Fig. 40).
H. Apply No. 2 Permatex sealant or equivalent to the
splines of the pinion gear. Make sure not to get
sealant on the oil seal (20) (Fig. 41).
I. Install flange coupler, washer, and lock nut back
onto the pinion gear. Torque lock nut from 75 to 90
ft–lb (102 to 122 N–m).
Figure 41
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 differential case, thrust washers, and pinion gear shafts.
C. Install pinion shaft into the differential case and
pinion gear shafts. Secure shaft with roll pin (28).
Figure 42
Workman 4000 Series
Page 10 – 25
Front Wheel Drive (4WD)
IMPORTANT: When bearing cones (29) are removed
removed from the differential case (27) they should
replaced with new ones. When installing new bearing 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
N–m) (Fig. 44).
Figure 43
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).
Figure 44
IMPORTANT: The bearing caps are marked for identification. Place caps back in the same position during reassembly (Fig. 46).
11. Secure bearing caps to their original positions on the
bearing cradles with four cap screws (11). Torque cap
screws from 30 to 45 ft–lb (41 to 61 N–m) (Fig. 46).
Figure 45
MARKING
MARKING
Figure 46
Front Wheel Drive (4WD)
Page 10 – 26
Workman 4000 Series
Front Wheel
Drive (4WD)
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).
Figure 47
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 housing 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 N–m) using a criss–cross pattern (Fig. 50).
Figure 48
FLANGE
SURFACE
FLANGE
SURFACE
Figure 49
Figure 50
Workman 4000 Series
Page 10 – 27
Front Wheel Drive (4WD)
17.Make sure both plugs (12) and O–rings (13) are
installed. Verify that plugs are torqued between 20 to 25
ft–lb (27 to 33 N–m).
FILL PLUG
DRAIN PLUG
Figure 51
Ring to Pinion Gear Engagement
When replacing the ring and pinion gear set, final position 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 pinion gear may differ slightly from gear pattern shown.
PROFILE
TOP LAND
TOE
GEAR TOOTH DEFINITIONS (Fig. 52):
LENGTHWISE
BEARING
ARC
Toe - the portion of the tooth surface at the end towards the center.
HEEL
Heel - the portion of the gear tooth at the outer end.
Top Land - top surface of tooth.
ROOT
1. Paint the teeth of the ring gear, both drive and coast
side, with a gear marking compound, such as DyKemR
Steel Blue.
2. While applying a light load to the ring gear, rotate the
pinion gear until the ring gear has made one complete
revolution. Both the drive side pattern and the coast side
pattern on the ring gear should be at the toe portion of
the tooth (Fig. 53).
Figure 52
RING GEAR
DRIVE SIDE
RING GEAR
COAST SIDE
Heel
Heel
Toe
Toe
Study the patterns in the following illustrations and correct engagement as necessary.
NOTE: When making changes, note that two variables
are involved. Example: If you have the backlash set correctly to specifications and you change the pinion position shim, you may have to readjust backlash to the
correct specification before re–checking the pattern.
Figure 53
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 position changes, shims should be changed in the range of
.002” to .004” until a correct pattern has been obtained.
Front Wheel Drive (4WD)
Page 10 – 28
Workman 4000 Series
Heel
Heel
Toe
High backlash is corrected by moving the ring gear closer to the pinion. Low backlash is corrected by moving the
ring gear away from the pinion. These corrections are
made by switching shims from one side of the differential
case to the other.
Example 1: Backlash correct. Thicker pinion position
shims required (Fig. 54).
RING GEAR
COAST SIDE
RING GEAR
DRIVE SIDE
Toe
Figure 54
Heel
Toe
Example 2: Backlash correct. Thinner pinion position
shims required (Fig. 55).
RING GEAR
COAST SIDE
RING GEAR
DRIVE SIDE
Heel
Toe
Example 3: Backlash incorrect. Thinner pinion position
shim required. Adjust backlash to match (Fig. 56).
GEAR PATTERN MOVEMENT SUMMARY:
Figure 55
1. Decreasing backlash moves the ring gear closer to
the pinion.
A. Drive pattern (convex side of gear) moves lower
and toward the toe.
RING GEAR
COAST SIDE
RING GEAR
DRIVE SIDE
Heel
Heel
Toe
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.
Figure 56
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.
Workman 4000 Series
Page 10 – 29
Front Wheel Drive (4WD)
Front Wheel
Drive (4WD)
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.
Differential Drive Shaft
7
4
2
5
2
3
1
6
SNAP RING
SNAP RING
3
Figure 57
1. Flange yoke
2. Cross and bearing kit
3. Tube yoke
4. Slip yoke
5. Grease fitting
6. Seal
7. Socket head screw (6 used)
Removal
1. Park vehicle on a level surface. Make sure engine is
off. Engage parking brake and block rear wheels.
2. Jack up and secure front wheels off the ground (see
Jacking Instructions in Operator’s Manual).
2
WARNING
1
Prevent flange yoke from dropping and causing
personal injury when removing.
3. Remove six socket head screws securing the differential drive shaft flange yoke to the coupler flange on the
front differential (Fig. 58).
3
Figure 58
1. Flange yoke
2. Socket head screw
3. Front differential
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
2. Position flange yoke to the coupler flange on the front
differential. Secure yoke to the flange with six socket
head screws (Fig. 58).
1
3. Grease differential drive shaft assembly (see Operators Manual).
3
Figure 59
1. Slip yoke
2. Clutch shaft
Front Wheel Drive (4WD)
Page 10 – 30
3. Bidirectional clutch
Workman 4000 Series
Front Wheel
Drive (4WD)
Drive Shaft Cross and Bearing Service
1. Remove drive shaft from vehicle (see Differential
Drive Shaft Removal).
3
2. Remove snap rings that secure bearings.
2
IMPORTANT: Yokes must be supported when removing and installing bearings to prevent damage.
1
3. Use a press to remove cross and bearings from
yokes. Thoroughly clean drive shaft yokes.
4
4. To install new cross and bearings:
A. Apply a coating of grease to all bearing bores.
3
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.
Figure 60
1. Flange yoke
2. Cross and bearing kit
3. Snap ring (4 used)
4. Tube yoke
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
Front Wheel Drive (4WD)
Bidirectional Clutch
14
13
CAGE AND ROLLER ASSEMBLY
10
11
12
9
8
7
4
6
19
5
2
3
15
4
1
18
16
17
Figure 61
1.
2.
3.
4.
5.
6.
7.
Clutch shaft
Seal plug
Retaining ring
Ball bearing
Housing and race
Garter gear
Roller (6 used)
8.
9.
10.
11.
12.
13.
Cam
Thrust bearing
Thrust washer
Spring
Cage
Oil seal
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 wheels off the ground (see
Jacking Instructions in Operator’s Manual).
14.
15.
16.
17.
18.
19.
Adapter plate
Screw (4 used)
Lock washer (6 used)
Hex socket head screw (6 used)
Differential drive shaft
Front drive shaft (transaxle)
IMPORTANT: When removing the bidirectional
clutch from the front drive shaft (19), hold the bearing end of the housing and race (5) down as it is removed 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 transaxle front drive shaft (19) and adaptor plate (14).
Disassembly (Fig. 61)
4. Remove differential drive shaft (18) from clutch shaft
(1) and the front differential (see Differential Drive Shaft
Removal).
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).
5. Remove six hex socket head screws (17) and lock
washers (16) securing the clutch shaft (1) to the housing
and race (5).
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 and 63). Be careful
not to drop parts or damage oil seal.
6. Remove seal plug (2) from the housing and race (5).
Discard seal plug.
7. Remove retaining ring (3) from the transaxle front
drive shaft (19) using a snap ring pliers. Discard snap
ring if it is cracked, distorted, or bent.
Front Wheel Drive (4WD)
2. Pull ball bearings (4) and/or oil seal (13) if they require replacement (see Inspection).
Page 10 – 32
Workman 4000 Series
Front Wheel
Drive (4WD)
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.
Figure 62
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).
Figure 63
7. Replace ball bearings (4) if any of the following
conditions occur:
1
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.
2
8. Replace oil seal (13) if its metal ring is distorted or
bent. Distortion, cracks, or tears of the rubber seal is not
acceptable.
Figure 64
1. Thrust bearing
2. Cam
9. Replace adapter plate (14) if the contact surface with
the oil seal is nicked, cracked, or distorted (Fig. 65).
CONTACT SURFACE
Figure 65
Workman 4000 Series
Page 10 – 33
Front Wheel Drive (4WD)
Assembly (Fig. 61)
1. Clean all parts thoroughly of all dirt and debris to prevent 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).
1
2
4. Insert cam with thrust bearing, thrust washer, and
spring into the cage (Fig. 68).
NOTE: Rollers must be replaced as a complete set.
Figure 66
1. Garter spring
5. Insert rollers into the slots of the cage. Make sure
garter spring fits snuggly into the groove of all rollers
(Fig. 68).
2. Cage
3
2
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).
1
4
7. If the oil seal (13) was removed, press new seal into
the housing and race (5). Make sure the metal side of the
seal faces out from the housing.
Figure 67
Installation (Fig. 61)
1. Thrust bearing
2. Thrust washer
1. Clean adapter plate (14) thoroughly of all dirt and debris to prevent damage to the bidirectional clutch and
transaxle.
3. Spring
4. Cam
1
2. If the adapter plate (14) was removed from the transaxle, install as follows:
4
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.
2
3
Figure 68
1. Cam
2. Cage
3. Roller
4. Garter spring
3. Coat front drive shaft (19) and adapter plate (14)
lightly with Dexron III ATF. Slide cage and roller assembly 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 roller assembly. Make sure assembly parts are positioned
properly by pushing the clutch towards the transaxle
and feeling for spring (11) compression.
Front Wheel Drive (4WD)
Page 10 – 34
Workman 4000 Series
7. Secure clutch shaft to housing and race (5) with lock
washers (16) and hex socket head screws (17).
5. Secure clutch to front drive shaft (19) with retaining
ring (3).
9. Make sure drain plug is installed properly to the
transaxle. Fill transaxle with Dexron III ATF (see Operators Manual).
IMPORTANT: Make sure rubber side of the seal plug
(2) faces towards the clutch when installing.
6. Insert seal plug (2) into the housing and race (5) using a driver.
Workman 4000 Series
8. Lower front wheels to ground.
10.Install differential drive shaft (18) to clutch shaft (1)
and the front differential (see Differential Drive Shaft
Installation).
Page 10 – 35
Front Wheel Drive (4WD)
Front Wheel
Drive (4WD)
IMPORTANT: Make sure retaining ring (3) is properly seated in the drive shaft (19) groove. Pull clutch
out from the transaxle to make sure that it holds in
place. Replace ring if bent or damaged.
This page is intentionally blank.
Front Wheel Drive (4WD)
Page 10 – 36
Workman 4000 Series
Chapter 11
Electrical
Schematics
Electrical Schematics
Table of Contents
VEHICLE ELECTRICAL SCHEMATICS
Workman 3100
Serial Number Below 260000000 . . . . . . . . . . . . . 3
Serial Number Above 260000000 . . . . . . . . . . . . . 4
Workman 3200 and 4200
Serial Number Below 260000000 . . . . . . . . . . . . . 5
Serial Number Above 260000000 . . . . . . . . . . . . . 6
Workman 3300 and 4300
Serial Number Below 260000000 . . . . . . . . . . . . . 7
Serial Number Above 260000000 . . . . . . . . . . . . . 8
WIRE HARNESS DRAWINGS
Front Wire Harness Drawing: Workman 3000/4000
Serial Number Below 270999999 . . . . . . . . . . . . 10
Serial Number Above 280000000 . . . . . . . . . . . . 12
Rear Wire Harness Drawing: Workman 3100
Serial Number Below 260000000 . . . . . . . . . . . . 14
Serial Number From 260000001 to 260000400 15
Serial Number Above 260000400 . . . . . . . . . . . . 16
Rear Wire Harness Drawing: Workman 3200/4200
Serial Number Below 260000000 . . . . . . . . . . . . 18
Serial Number Above 260000000 . . . . . . . . . . . . 20
Rear Wire Harness Diagram: Workman 3300/4300
Serial Number Below 260000000 . . . . . . . . . . . . 22
Serial Number From 260000000 to 270999999 24
Serial Number Above 280000000 . . . . . . . . . . . . 26
Workman 3000/4000
Page 11 -- 1 Rev. C
Electrical Schematics
This page is intentionally blank.
Electrical Schematics
Page 11 -- 2
Workman 3000/4000
VIA MATING CONN
FACTORY SHUNT
REAR HARNESS
PK
PK
10 A
F1
FRONT HARNESS
OFF
ENGINE
B
R
I
RUN
86
FACTORY SHUNT VIA MATING CONN
R/BK
PK
10 A
F2
RUN
X
OR
Y
15 A
D
GY
GY
OR
PK/BU
STARTER
P101--C
C
GY
PROTECTION DIODE (D2)
GY
GY
3
4
5
OR
F
BK
1
2
GY
E
OR
IGNITION SWITCH
F3
BK
B+
Start
START ENABLE
HIGH FLOW HYDRAULICS KIT (OFF)
A
R
85
GY+BK
PK/BU
PK/BU
BK
START
S
87
PTO KIT (OFF)
CLUTCH SWITCH
(ENGAGED)
B+ TO POSITIVE BATTERY CABLE
87a
30
PK
8
P101--E
B
6
Y
Y
NOT CONNECTED
7
BRAKE SWITCH
LIGHTS, HORN, BRAKE
W
P101--H
W
BN
BN
BN
HORN
F4
HORN SWITCH
POWER POINT
15 A
LIGHT SWITCH
W/BK
W/BK
BK
BK
AUX FUSE BLOCK
R
R/BK
BK
AUX LIGHT KIT
BK
BK
P101--G
P102--D
OR
OR
I
R/BK
FUSIBLE LINK INSIDE HARNESS
OR
OR
R/W
VIO/R
BK
OR
TEMP
POSITIVE BATTERY CABLE
B+
TIE POINT
ON STARTER
HIGH
OTHER 3RD
P101--B
GN/BK
G
BK
Y
BU
BK
BATTERY LAMP
P20 (NOT USED)
BN/W
VIO
P102--B
P102--C
P101--K
FRONT HARNESS
VIO/R
R/W
GN/BK
BU/W
P101--F
NOT CONNECTED
P21
P101--A
P102--A
VIA MATING CONN
FACTORY SHUNT
(--)
BN/W
NOT CONNECTED
BK
BK
R/W
ENGINE
GROUND
GLOW PLUG LAMP
P19 (NOT USED)
G
BU/W
OVER TEMP LAMP
P21 (NOT USED)
REAR HARNESS
NEGATIVE BATTERY CABLE
BK
GLOW PLUG SWITCH
P29 (NOT USED)
FUEL
BK
LOW
L
S
HR
(--)
G
OIL
PRES
OR
I
L
S
TACH
KIT
TACH
PK
OR
I
(+)
L
S
TRANSMISSION
SWITCHES
BATTERY
LIGHTS
TAIL/BRAKE
HEADLIGHTS
OR
P100--A
(+)
BN
BK
P100--B
R
W/BK
BN
SUPERVISOR
SWITCH
(OFF)
AT FUSE BLOCK
GROUND TIE POINT
R
W/BK
ELEC BRAKE KIT
W
AUX FUSE BLOCK
R
P101--J
GN
PK
FRAME
GROUNDS
C
TACH SENSOR
(TACH KIT)
FUEL
SENDER
ENGINE
BK
OIL PRESSURE
SWITCH
(LOW PRESSURE)
TEMPERATURE
SENDER
ENGINE
BK
BK
GROUND CONNECTION TO FRONT HARNESS
IS VIA THE REAR HARNESS (SEE P100--A)
ENGINE HARNESS
BK
BK
BK
R
MAGNETO
ENGINE HARNESS
R/W
BK
R
R
A
ENGINE
VOLTAGE REGULATOR
Y
POWER
ENGINE KILL
KEY TO WIRE COLORS
R = RED
Y = YELLOW
W = WHITE
T = TAN
BK = BLACK
BN = BROWN
BU = BLUE
GN = GREEN
GY = GRAY
OR = ORANGE
PK = PINK
VIO = VIOLET
BK
30
87a
W
B
SPARK MODULE
BN
W
KILL
87
Y
SPARK MODULE
R/W
86
85
BK
FUEL SOLENOID
BN
ENGINE
Workman 3100
Kohler Gasoline Engine
Vehicle Electrical Schematic
Serial Number Below 260000000
All relays and solenoids
are shown as de-- energized.
SPEED ADVANCE
MODULE
Page 11 -- 3
Rev. C
Workman 3100
Kohler Gasoline Engine
Vehicle Electrical Schematic
Serial Number Above 260000000
All relays and solenoids
are shown as de-- energized.
Page 11 -- 4
Rev. C
VIA MATING CONN
FACTORY SHUNT
REAR HARNESS
PK
F1
FRONT HARNESS
OFF
10 A
ENGINE
B
R
I
RUN
CLUTCH SWITCH
(ENGAGED)
86
R/BK
START
S
PK
F2
10 A
RUN
X
OR
Y
GY
GY
OR
OR
D
E
C
GY
4
6
8
LIGHTS, HORN, BRAKE
1
2
HYD. LIFT INTERLOCK
(CE VEHICLES ONLY)
GY
GY+BK
R
B+
Start
STARTER
BK
BK
1
GY
PROTECTION DIODE (D2)
2
GY
PARKING BRAKE SWITCH
(LIFT KIT)
HIGH FLOW HYDRAULICS KIT
P101--E
Y
B
Y
Y
Y
7
BK
W
W
85
VIA MATING CONN
FACTORY SHUNT
BRAKE SWITCH
15 A
F3
VIA MATING CONN
FACTORY SHUNT
P101--C
GY
3
5
OR
F
BK
1
2
GY
R
START ENABLE
HIGH FLOW HYDRAULICS KIT (OFF)
A
R
87
PTO KIT (OFF)
FACTORY SHUNT VIA MATING CONN
B+ TO POSITIVE BATTERY CABLE
87a
30
PK
W
PROTECTION DIODE (D1)
P101--H
BN
BN
BN
HORN
F4
HORN SWITCH
POWER POINT
15 A
PK
LIGHT SWITCH
W/BK
R
BK
AUX FUSE BLOCK
W/BK
W/BK
BK
R
P101--J
GN
R/BK
BN
LIGHTS
TAIL/BRAKE
HEADLIGHTS
ELEC BRAKE KIT
W
W/BK
BN
AUX FUSE BLOCK
SUPERVISOR
SWITCH
(OFF)
BK
BK
OR
OR
AT FUSE BLOCK
GROUND TIE POINT
P100--B
P100--A
P101--G
P101--D
OR
FL3
C
R
LOW
POSITIVE BATTERY CABLE
HIGH
TACH
KIT
TACH
R/W
OTHER 3RD
OR
VIO/R
P101--B
TEMP
(--)
GN/BK
G
GLOW PLUG LAMP
P19 (NOT USED)
FUEL
BU/W
BATT.
OIL
PRES
GLOW PLUG SWITCH
P29 (NOT USED)
BU
BK
Y
G
P102--C
P101--K
FRONT HARNESS
L
S
HR
G
OVER
TEMP
OR
I
L
S
TRANSMISSION
SWITCHES
R/BK
OR
I
L
S
FL2
B
PK
(+)
R/BK
FL1
A
OR
OR
OR
I
FUSIBLE LINK HARNESS
R
BK
AUX LIGHT KIT
BK
P102--B
VIO
P101--F
P102--A
BN/W
P101--A
REAR HARNESS
B+
TIE POINT
ON STARTER
R/W
VIO/R
GN/BK
BU/W
BU
NOT CONNECTED
P21
VIO
BN/W
NEGATIVE BATTERY CABLE
BK
BK
R
BK
FUEL
SENDER
R/W
(+)
(--)
ENGINE
GROUND
BATTERY
FRAME
GROUNDS
OIL PRESSURE
SWITCH
(LOW PRESSURE)
ENGINE OVER TEMP.
SWITCH
TEMPERATURE
SENDER
ENGINE
ENGINE
ENGINE
FRAME GROUND TO FRONT HARNESS
IS VIA THE REAR HARNESS (SEE P100--A)
BK
BK
B
R
R
R/BK
L
VIO
ALTERNATOR
CHOKE HEATER
VIO/R
KEY TO WIRE COLORS
R = RED
Y = YELLOW
W = WHITE
T = TAN
BK = BLACK
BN = BROWN
BU = BLUE
GN = GREEN
GY = GRAY
OR = ORANGE
PK = PINK
VIO = VIOLET
R/W
POWER
3
BK
BK
GROUND
2
BK
BK
N.C.
1
THIS WIRE (DASHED LINE)
INCLUDED ONLY IN
SERIAL NUMBERS FROM
250000001 TO 250999999
CRANK
POSITION
BU/W
PULSAR COIL
5
GN/W
PULSAR COIL
6
TACH
ENGINE
2
W
3
GN
4
OR
R/W
-- IGN COIL 1 +
-- IGN COIL 2 +
W
R/W
R/W
30
R/W
R/W
85
87a
87
86
-- IGN COIL 3 +
FUEL PUMP
4
P31
P32
1
IGNITION CONTROL
MODULE
BU
FUEL PUMP
W
BU
ENGINE
FUEL SOLENOID
FUEL PUMP
BK
Workman 3200 and 4200
Briggs/Daihatsu Gasoline Engine
Vehicle Electrical Schematic
Serial Number Below 260000000
All relays and solenoids
are shown as de-- energized.
BK
Page 11 -- 5
Rev. C
Workman 3200 and 4200
Briggs/Daihatsu Gasoline Engine
Vehicle Electrical Schematic
Serial Number Above 260000000
All relays and solenoids
are shown as de-- energized.
Page 11 -- 6
Rev. C
VIA MATING CONN
FACTORY SHUNT
B+ TO POSITIVE BATTERY CABLE
REAR HARNESS
W
PK
10 A
F1
ENGINE
B
R
I
RUN
START
R
10 A
F2
PK
RUN
X
OR
Y
GY
GY
OR
15 A
F4
GY
E
OR
IGNITION SWITCH
F3
D
BK
OR
F
1
2
VIA MATING CONN
FACTORY SHUNT
P101--C
C
GY
1
GY
4
6
8
W
1
GY
2
GY
BED LIFT & REMOTE HYD
(CE VEHICLES ONLY)
HIGH FLOW HYDRAULICS KIT
Y
BK
BN
LIGHT SWITCH
W/BK
BK
W/BK
BK
AUX LIGHT KIT
BK
BK
OR
P101--G
P100--A
P101--D
OR
OR
OR
I
FUSIBLE LINK HARNESS
PK
OR
(+)
TACH
R/BK
R
BK
FL3
LOW
VIO/R
TACH
KIT
HR
G
GN/BK
GLOW PLUG
SWITCH
L
BK
S
TEMP
(--)
OIL
PRES
BATT.
G
FUEL
BU/W
BU
BK
Y
G
VIO
BN/W
GLOW PLUG LAMP
BK
OTHER 3RD
P101--B
P101--K
FRONT HARNESS
P101--F
P102--B
P102--C
P102--A
P101--A
REAR HARNESS
B+
TIE POINT
ON STARTER
POSITIVE BATTERY CABLE
HIGH
I
L
S
S
OVER
TEMP
OR OR
OR
I
L
TRANSMISSION
SWITCHES
FL2
C
R
R/BK
FL1
B
LIGHTS
TAIL/BRAKE
HEADLIGHTS
BK
A
W/BK
BN
SUPERVISOR
SWITCH
(OFF)
AT FUSE BLOCK
GROUND TIE POINT
R
BN
BN
ELEC BRAKE KIT
W
PROTECTION DIODE (D1)
P101--J
W/BK
R/BK
P100--B
BK
P101--H
BN
BK
R
BK
Y
HORN
HORN SWITCH
AUX FUSE BLOCK
STARTER
BK
P101--E
B
Y
GN
AUX FUSE BLOCK
B+
Start
7
PK
R
2
W
POWER POINT
15 A
R
PROTECTION DIODE (D2)
BRAKE SWITCH
LIGHTS, HORN, BRAKE
85
VIA MATING CONN
FACTORY SHUNT
1/3 VERTICAL LIFT KIT
3
5
R
START ENABLE
HIGH FLOW HYDRAULICS KIT (OFF)
A
GY+BK
87
86
FACTORY SHUNT VIA MATING CONN
R/BK
S
30
PK
PTO KIT (OFF)
CLUTCH SWITCH
(ENGAGED)
FRONT HARNESS
OFF
87a
VIO/R
R
GN/BK
BU/W
BU
Y
VIO
BN/W
BK
R
(+)
BK
BK
(--)
ENGINE
GROUND
BATTERY
VIA MATING CONN
FACTORY SHUNT
NEGATIVE BATTERY CABLE
FRAME
GROUNDS
FUEL
SOLENOID
FUEL
SENDER
TACH SENSOR
(TACH KIT)
TEMPERATURE
SENDER
SWITCH
ENGINE
ENGINE
ENGINE
ENGINE OVER TEMP.
OIL PRESSURE
SWITCH
(LOW PRESSURE)
ENGINE
BK
FRAME GROUND TO FRONT HARNESS
IS VIA THE REAR HARNESS (SEE P100--A)
BK
B
R
R
R/BK
L
VIO
ALTERNATOR
GLOW RELAY
BK
PK
87
KEY TO WIRE COLORS
R = RED
Y = YELLOW
W = WHITE
T = TAN
BK = BLACK
BN = BROWN
BU = BLUE
GN = GREEN
GY = GRAY
85
OR = ORANGE
PK = PINK
VIO = VIOLET
86
30
Y
R
GLOW PLUGS (3)
Workman 3300 and 4300
Briggs/Daihatsu Diesel Engine
Vehicle Electrical Schematic
Serial Number Below 260000000
All relays and solenoids
are shown as de-- energized.
Page 11 -- 7
Rev. C
Workman 3300 and 4300
Briggs/Daihatsu Diesel Engine
Vehicle Electrical Schematic
Serial Number Above 260000000
All relays and solenoids
are shown as de-- energized.
Page 11 -- 8
Rev. C
This Page Is Intentionally Blank.
Page 11 -- 9
Rev. C
SN 280000001
AND UP
Workman 3000/4000
Front Wire Harness Drawing
Serial Number Below 270999999
Page 11 -- 10
Rev. C
GRAY
RED/BLACK
RED/WHITE
RED/BLACK
RED/WHITE
WHITE
WHITE
BROWN
WHITE
WHITE/BLACK
BROWN
WHITE
YELLOW
GRAY
GRAY
ORANGE
BLACK
BROWN
WHITE/BLACK
ORANGE
YELLOW
RED
RED
RED
WHITE
RED
ORANGE
SN 280000001
AND UP
BLACK
VIOLET/RED
BLACK
ORANGE
ORANGE
BROWN/WHITE
GRAY
YELLOW
BLUE
RED/BLACK
BROWN
WHITE/BLACK
GREEN/BLACK
ORANGE
ORANGE
RED
GRAY
RED/BLACK
VIOLET
YELLOW
RED/WHITE
ORANGE
BLUE/WHITE
BLACK
ORANGE
ORANGE
BLACK
ORANGE
ORANGE
BLACK
BLACK
WHITE/BLACK
BLACK
WHITE/BLACK
BLACK
BLACK
GREEN
BLACK
ORANGE
YELLOW
BLACK
ORANGE
ORANGE
BLACK
Workman 3000/4000
Front Wire Harness Diagram
Serial Number Below 270999999
Page 11 -- 11
Rev. C
Workman 3000/4000
Front Wire Harness Drawing
Serial Number Above 280000000
Page 11 -- 12
Rev. C
GRAY
RED/BLACK
RED/WHITE
WHITE
WHITE
BROWN
WHITE
WHITE/BLACK
BROWN
WHITE
YELLOW
GRAY
GRAY
ORANGE
BLACK
BROWN
WHITE/BLACK
BLACK
ORANGE
GRAY
YELLOW
RED
RED
RED
WHITE
RED
ORANGE
BLACK
VIOLET/RED
BLACK
ORANGE
ORANGE
BROWN/WHITE
GRAY
YELLOW
BLUE
RED/BLACK
BROWN
WHITE/BLACK
GREEN/BLACK
ORANGE
ORANGE
RED
GRAY
RED/BLACK
VIOLET
YELLOW
RED/WHITE
ORANGE
BLUE/WHITE
BLACK
ORANGE
ORANGE
BLACK
ORANGE
ORANGE
BLACK
WHITE/BLACK
BLACK
WHITE/BLACK
BLACK
BLACK
GREEN
BLACK
ORANGE
YELLOW
ORANGE
ORANGE
ORANGE
BLACK
BLACK
Workman 3000/4000
Front Wire Harness Diagram
Serial Number Above 280000000
Page 11 -- 13
Rev. C
21A
19B
FUEL
SENDER
23A
22A
24A
2B
TAIL
LIGHT
17B
CBA
SPLICE ”E”
BLACK
16A 17A 18A
19A 34A
30
85
KILL
RELAY
SPEED
PICKUP
PLUG
20A
5B
B A
87A
86
18B
12A
P101
INTERCONNECT
FRONT HARNESS
START
RELAY
33A
86
26A
33B
25A
30
85 87
34B
14B
27A
28A
GROUND
5A
6A
BA
STARTER
4B
32A
13B
32B
14A
P102
INTERCONNECT
FRONT HARNESS
B A
4A
BA
7A
1A
SPLICE ”C”
RED/WHITE
1B 10B 30B
8B 20B
SPLICE ”B”
BLACK
7B 16B 24B
25B 27B
FUSIBLE LINK
SPLICE ”A”
6B 15B 29B
SPLICE ”D”
RED/BLACK
9B 11B 31B
CBA
2A
ENGINE
HARNESS
SPEED
PICKUP
PTO
SWITCH
3A
A
B
A
WIRE LIST
B
8A
CLUTCH
SWITCH
9A
SUPERVISOR
SWITCH-TRANSAXLE
Page 11 -- 14
Rev. C
ITEM
13A
15A
10A
11A
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
WIRE
COLOR
RED/WHT
BLACK
BRN/WHT
PNK/BLU
PNK/BLU
GRAY
BLACK
RED/WHT
RED/BLK
RED/WHT
RED/BLK
GRAY
PINK
PINK
PINK
BLACK
BLACK
BLACK
BLACK
RED/WHT
BLU/WHT
BROWN
WHT/BLK
BLACK
BLACK
BLACK
BLACK
BLUE
RED
RED/WHT
RED/BLK
PINK
BLACK
TERMINAL A
CONNECTOR
DESTINATION
TERMINAL B
CONNECTOR
DESTINATION
ENGINE HARNESS
ENGINE HARNESS
ENGINE HARNESS
STARTER
STARTER
STARTER
DIODE
SUPR SWITCH TRANS
SUPR SWITCH TRANS
SUPR SWITCH TRANS
SUPR SWITCH TRANS
START RELAY
CLUTCH SWITCH
PTO SWITCH
CLUTCH SWITCH
SPLICE ”E”
SPLICE ”E”
SPLICE ”E”
SPLICE ”E”
KILL RELAY
FUEL SENDER
TAIL LIGHT
TAIL LIGHT
TAIL LIGHT
GROUND
GROUND
SPEED PICKUP
SPEED PICKUP
FRONT HARNESS (P100) PIN B
FRONT HARNESS (P102) PIN D
FRONT HARNESS (P101) PIN G
PTO SWITCH PLUG
SPEED PICKUP PLUG
SPLICE ”E”
SPICE ”C”
KILL RELAY
FRONT HARNESS (P101) PIN A
DIODE
START RELAY
SPLICE ”A”
SPLICE ”B”
SPLICE ”C”
SPLICE ”D”
SPLICE ”C”
SPLICE ”D”
FRONT HARNESS (P101) PIN C
PTO SWITCH
START RELAY
SPLICE ”A”
SPLICE ”B”
START RELAY
START RELAY
FUEL SENDER
SPLICE ”C”
FRONT HARNESS (P102) PIN C
FRONT HARNESS (P101) PIN H
FRONT HARNESS (P101) PIN J
SPLICE ”B”
SPLICE ”B”
FRONT HARNESS (P100) PIN A
SPLICE ”B”
FRONT HARNESS (P101) PIN B
SPLICE ”A”
SPLICE ”C”
SPLICE ”D”
PTO SWITCH PLUG
SPEED PICKUP PLUG
START RELAY
Workman 3100
Kohler Gasoline Engine
Rear Wire Harness
Serial Number Below 260000000
P100
INTERCONNECT
FRONT HARNESS
WIRE LIST
Workman 3100
Kohler Gasoline Engine
Rear Wire Harness
Serial Number From 260000001 To 260000400
Page 11 -- 15
Rev. C
Workman 3100
Kohler Gasoline Engine
Rear Wire Harness Drawing
Serial Number Above 260000400
Page 11 -- 16
Rev. C
RED/BLACK
RED/WHITE
RED/BLACK
RED/WHITE
GRAY
GRAY
GRAY
GRAY
GRAY
GRAY
RED
BLACK
RED
PINK
GRAY
GRAY
BLACK
PINK
RED/BLACK
BLACK
FUSIBLE LINK
BLUE/WHITE
RED/WHITE
RED/WHITE
WHITE
BROWN/WHITE
BLACK
BLACK
BROWN
WHITE/BLACK
BLACK
BLACK
BLUE
PINK
BLACK
RED/WHITE
BLACK
BLACK
Workman 3100
Kohler Gasoline Engine
Rear Wire Harness Diagram
Serial Number Above 260000400
Page 11 -- 17
Rev. C
Workman 3200 and 4200
Briggs/Daihatsu Gasoline Engine
Rear Wire Harness Drawing
Serial Number Below 260000000
Page 11 -- 18
Rev. C
BLUE
BLACK
YELLOW
GRAY
GRAY
GRAY
GRAY
WHITE
BROWN/WHITE
PINK
BLACK
RED/BLACK
RED
YELLOW
GRAY
RED
WHITE
GREEN/BLACK
WHITE
BLACK
RED
BLUE/WHITE
PINK
BLACK
PINK
BLACK
BLACK
BLACK
RED/WHITE
RED/BLACK
BLACK
WHITE/BLACK
BROWN
RED/WHITE
RED/BLACK
RED/BLACK
RED/WHITE
RED/WHITE
BLACK
RED/WHITE
RED/WHITE
WHITE
RED/WHITE
RED/WHITE
WHITE
VIOLET/RED
BLACK
RED
GREEN
BLUE/WHITE
BLACK
BLACK
RED/
WHITE
RED/
WHITE
RED/WHITE
BLUE
GREEN/WHITE
VIOLET
ORANGE
THIS WIRE (DASHED LINE) INCLUDED
ONLY IN SERIAL NUMBERS FROM
250000001 TO 250999999
Workman 3200 and 4200
Briggs/Daihatsu Gasoline Engine
Rear Wire Harness Diagram
Serial Number Below 260000000
Page 11 -- 19
Rev. C
Workman 3200 and 4200
Briggs/Daihatsu Gasoline Engine
Rear Wire Harness Drawing
Serial Number Above 260000000
Page 11 -- 20
Rev. C
BLUE
BLACK
YELLOW
YELLOW
BROWN/WHITE
GRAY
GRAY
GRAY
WHITE
WHITE
BLACK
RED/BLACK
RED
RED
PINK
RED
BLACK
RED
GRAY
GRAY
GREEN/BLACK
BLACK
BLUE/WHITE
GRAY
GRAY
BLACK
BLACK
PINK
RED/WHITE
RED/BLACK
BLACK
WHITE/BLACK
BROWN
RED/WHITE
RED/BLACK
RED/WHITE
RED/WHITE
RED/WHITE
WHITE
RED/WHITE
BLACK
RED/BLACK
VIOLET/RED
RED/WHITE
VIOLET
BLACK
GREEN/WHITE
BLUE/WHITE
BLACK
BLACK
RED/WHITE
WHITE
GREEN
ORANGE
BLUE
RED/WHITE
RED/WHITE
RED/WHITE
BLACK
Workman 3200 and 4200
Briggs/Daihatsu Gasoline Engine
Rear Wire Harness Diagram
Serial Number Above 260000000
Page 11 -- 21
Rev. C
Workman 3300 and 4300
Briggs/Daihatsu Diesel Engine
Rear Wire Harness Drawing
Serial Number Below 260000000
Page 11 -- 22
Rev. C
BLUE
PINK
GRAY
GRAY
RED
PINK
YELLOW
RED/BLACK
RED
WHITE
BLACK
GRAY
BLACK
YELLOW
PINK
RED
BLUE/WHITE
PINK
BLACK
PINK
BLACK
GREEN/BLACK
BLACK
BLACK
RED
RED/BLACK
BLACK
WHITE/BLACK
BROWN
RED
RED/BLACK
RED/BLACK
RED
BROWN/WHITE
VIOLET
BLACK
GRAY
RED
BLACK
GRAY
BLACK
VIOLET/RED
BLACK
RED
ORANGE
YELLOW
Workman 3300 and 4300
Briggs/Daihatsu Diesel Engine
Rear Wire Harness Diagram
Serial Number Below 260000000
Page 11 -- 23
Rev. C
Workman 3300 and 4300
Briggs/Daihatsu Diesel Engine
Rear Wire Harness Drawing
Serial Number From 260000001 To 270999999
Page 11 -- 24
Rev. C
GRAY
BLUE
BLACK
GRAY
GRAY
BROWN/WHITE
GRAY
GRAY
RED
RED/BLACK
PINK
RED
BLACK
RED
GRAY
BLACK
GRAY
BLUE/WHITE
PINK
BLACK
GREEN/BLACK
BLACK
BLACK
RED
RED/BLACK
PINK
BLACK
WHITE/BLACK
BROWN
RED
RED/BLACK
BLACK
RED
BLACK
RED
BLACK
RED/BLACK
VIOLET/RED
GRAY
RED
VIOLET
GRAY
PINK
BLACK
YELLOW
ORANGE
Workman 3300 and 4300
Briggs/Daihatsu Diesel Engine
Rear Wire Harness Diagram
Serial Number From 260000001 To 270999999
Page 11 -- 25
Rev. C
Workman 3300 and 4300
Briggs/Daihatsu Diesel Engine
Rear Wire Harness Drawing
Serial Number Above 280000000
Page 11 -- 26
Rev. C
GREEN/BLACK
BLUE
BLACK
YELLOW
YELLOW
BROWN/WHITE
GRAY
GRAY
GRAY
RED
RED/BLACK
PINK
RED
BLACK
RED
GRAY
BLACK
GRAY
BLUE/WHITE
PINK
BLACK
BLACK
RED
RED/BLACK
BLACK
WHITE/BLACK
BROWN
RED
RED/BLACK
RED
BLACK
RED
BLACK
RED/BLACK
VIOLET/RED
GRAY
RED
VIOLET
GRAY
PINK
BLACK
BLACK
YELLOW
RED/BLACK
PINK
ORANGE
Workman 3300 and 4300
Briggs/Daihatsu Diesel Engine
Rear Wire Harness Diagram
Serial Number Above 280000000
Page 11 -- 27
Rev. C
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