Toro HD 07369 S?N 3140000001 & up manual

Part No. 14208SL Service Manual Wo r k m a n R HD Series HD Model 07369 S /N 314000001 & U p, HDX/HDX - D Models with Kubota Gasoline & Diesel Engines Preface The purpose of this publica tion is to provide the ser vice technician with information for trou bleshooting, testing, and repair of major systems and components on the Workman HD, HD[...]

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Wor km an H D Se ri es T able Of Contents Chapter 1 - Safety Safety Instr uctions 1 - 2 .......................... Safety and Instruction De cals 1 - 6 ................ Chapter 2 - Product Records and Maintenanc e Product Records 2 - 1 ........................... Maintenance 2 - 1 ............................. .. Equivalents and Conversions 2 - 2 .[...]

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Wor km an H D Se ri es T able Of Contents Chapter 10 - Front Wheel Drive (4WD) Specifications 10 - 2 ............................ . General Information 10 - 3 ....................... Service and Repairs 10 - 4 .. ..................... HILLIARD FRONT DRIVE DIFFERENTIAL P ARTS and SERVICE MANUAL Chapter 1 1 - Electrical Drawings Electrical Drawing De[...]

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Workman HD Series Page 1 − 1 Safety Chapter 1 Safety T able of Contents SAFETY INSTRUCTIONS 2 ...................... Before Operating 2 ............................ While Operating 3 ............................ Maintenance and Service 4 .................... Jacking V ehicle 5 ............................. Using Bed Safety Support 6 .............[...]

Workman HD Series Page 1 − 2 Safety Safety Instructions The Workman HD series vehicles are designed and tested to offer safe service when operated and main- tained properly . Although hazard control and accident prevention are partially dependent upon the design and configuration of the vehicle, these factors are also de- pendent upon the awarene[...]

Workman HD Series Page 1 − 3 Safety While Operating 1. S it on the operator seat when starting and operating the vehicle. 2. When starting the engine: A. Sit on operator ’ s seat and engage the parking brake. B. Disengage PT O (if so equipped) and return hand throttle lever to OFF position (if so equipped). C. Make sure that hydraulic lift leve[...]

Workman HD Series Page 1 − 4 Safety Maintenance and Service 1. Before servicing or making adjustments, turn all ac- cessories off, put traction pedal in neutral, stop engine, engage parking brake and remove key from the ignition switch. 2. Make sure vehicle is in safe operating condition by keeping all nuts, bolts and screws tight. 3. Never store[...]

Workman HD Series Page 1 − 5 Safety Jacking V ehicle When cha nging attachments, tires or perform- in g other service, use correct jacks, hoists and jack stands. Always chock or block the wheels and use jack stands to support the vehicle. If the vehicle is not properly supported by jack stands, the vehicle may move or fall resulting in personal i[...]

Workman HD Series Page 1 − 6 Safety Using Bed Safety Support Many of the procedures shown in this manual re- quire raising and lowering the bed. The following precautions must be taken or serious injury or death could result. Before servicing or making adjustments to the vehicle, stop engine, engage parking brake and remove key from ignition swit[...]

Workman HD Series Page 2 − 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 .............................. EQUIV ALENTS AND CONVERSIONS 2 ........... Decimal and Millimeter Equivalents 2 ............ U.S. to Metric Conversions 2 ...............[...]

0.09375 Workman HD Series Page 2 − 2 Product Records and Maintenance Equivalents and Conversions[...]

Workman HD Series Page 2 − 3 Product Records and Maintenance T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Service Manual. Thes[...]

Workman HD Series Page 2 − 4 Product Records and Maintenance Standard T orque 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) SAE Grade 5 Bolts, Screws, Studs & Sems wi[...]

Workman HD Series Page 2 − 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Fasteners) 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 + 6 in−lb[...]

Workman HD Series Page 2 − 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque 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[...]

Workman HDX Page 3 − 1 Kubota EFI Gasoline Engine Chapter 3 Kubota EFI Gasoline Engine T able of Contents SPECIFICA TIONS 3 ............................ GENERAL INFORMA TION 4 ..................... Introduction 4 ................................ Operator ’s Manual 4 .......................... Kubota Workshop and Diagnostics Manuals 3 .... Kubot[...]

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Workman HDX Page 3 − 3 Kubota EFI Gasoline Engine Specifications Item Description Make / Designation Kubota, V ertical, 4−Cycle, 3 Cylinder , Liquid Cooled, Gasoline Engine Bore 2.93 in (74.5 mm) Stroke 2.90 in. (73.6 mm) T otal Displacement 58.68 cu. In. (962 cc) Compression Ratio 9.2:1 Ignition T iming 31_ BTDC @ 3600 rpm Ignition System Full[...]

Workman HDX Page 3 − 4 Kubota EFI Gasoline Engine Introduction This Chapter gives information about specifications, maintenance, troubleshooting, testing, and repair of the Kubota EFI gasoline engine used in the W orkman HDX . Most repairs and adjustments require tools which are commonly available in many service shops. The use of some specialize[...]

Workman HDX Page 3 − 5 Kubota EFI Gasoline Engine Kubota Gasoline Engine Electronic Control Unit (ECU) Th e Kubota gasoline engine that powers your W orkman HDX uses an electronic control unit (ECU) for engine management. All wire harness electrical connectors should be plugged into the ECU before the machine igni- tion switch is moved from the O[...]

Workman HDX Page 3 − 6 Kubota EFI Gasoline Engine Service and Repairs Air Cleaner System Figure 4 1. Air cleaner assembly 2. Hose clamp 3. Air inlet hood 4. Hose clamp 5. Air intake hose 6. Hose clamp 7. Flange nut (2) 8. Mounting bracket 9. Flange head screw (2) V ACUA TOR DIRECTION FRONT RIGHT 1 2 3 4 5 6 7 8 9[...]

Workman HDX Page 3 − 7 Kubota EFI Gasoline Engine Check Air Filter , Dust Cup, & Burp V alve The air cleaner body , air filter , dust cup, and burp valve should be checked daily , prior to operation. IMPORT ANT : Any leaks in the air cleaner system will cause serious engine damage. Make sure that all air cleaner components are in good conditi[...]

Workman HDX Page 3 − 8 Kubota EFI Gasoline Engine Exhaust System Figure 7 FRONT RIGHT 1. Oxygen sensor 2. Lock washer (4) 3. Hex nut (4) 4. Exhaust tube 5. Stud (4) 6. Exhaust gasket (3) 7. Catalytic converter 8. Flange head screw 9. Heat shield mount 10. Flange nut (8) 1 1. Retainer nut (3) 12. Heat shield 13. Heat shield mount 14. Flange head s[...]

Workman HDX Page 3 − 9 Kubota EFI Gasoline Engine Removal 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder . 3. Note position of exhaust system heat shiel[...]

Workman HDX Page 3 − 10 Kubota EFI Gasoline Engine Fuel System Figure 8 1. Fuel hose (to engine) 2. Hose clamp 3. Fuel hose (to vacuum valve) 4. V acuum check valve 5. Fuel hose (to engine) 6. Filter hose 7. Canister filter 8. Fuel hose (tank to canister) 9. Flange nut (2) 10. Fuel tank 1 1. Fuel cap 12. Fuel pump/sender assembly 13. Carbon canni[...]

Workman HDX Page 3 − 1 1 Kubota EFI Gasoline Engine Fuel T ank Removal (Fig. 8) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder . 3. Disconnect wire harn[...]

Workman HDX Page 3 − 12 Kubota EFI Gasoline Engine Fuel Pump Removal (Fig. 8) 1. Park vehicle on a level surface, raise bed and en- gage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Install bed support on bed lift cylinder to prevent bed from lowering. 3. Disconnect vehicle wire harness connectors f[...]

Workman HDX Page 3 − 13 Kubota EFI Gasoline Engine Carbon Canister The function of the fuel evaporative control system is to collect and store evaporative emissions from the fuel tank and engine. A carbon canister that is mounted to th e left side of the frame is used to collect these evapora- tive emissions. Fuel vapors from the engine and fuel [...]

Workman HDX Page 3 − 14 Kubota EFI Gasoline Engine Radiator Figure 12 1. Radiator guard (industrial) 2. Radiator screen 3. Swell latch (4) 4. Flange head screw (4 − industrial) 5. Flange head screw (4) 6. Flat W asher 7. Hose clamp 8. Hose (radiator to reservoir) 9. Flange head screw (2 − industrial) 10. Clip (2) 1 1. Radiator mount 12. Hose [...]

Workman HDX Page 3 − 15 Kubota EFI Gasoline Engine Removal (Fig. 12) 1. Park vehicle on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Allow engine and radiator to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder . 3. Unlatch and remove ra[...]

Workman HDX Page 3 − 16 Kubota EFI Gasoline Engine Engine Figure 14 FRONT RIGHT 1. Gear pump 2. O−ring 3. Hydraulic fitting 4. Hose clamp 5. Suction hose (from transaxle) 6. O−ring 7. Hose (to lift valve) 8. O−ring 9. Hydraulic fitting 10. Flange nut (4) 1 1. Square key 12. Pump/engine mount 13. Flange head screw (4) 14. Flange head screw ([...]

Workman HDX Page 3 − 17 Kubota EFI Gasoline Engine Engine Removal (Fig. 14) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s) to gain ac c e s s t o e ngine. If bed is raised, place saf ety sup- port on lift cyli[...]

Workman HDX Page 3 − 18 Kubota EFI Gasoline Engine CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot cool- ant can escape and cause burns. Ethylene−glycol antifreeze is poisonous. Dis- pose of coolant properly or store it in a properly labeled container away from children and pets. 9. Remove th[...]

Workman HDX Page 3 − 19 Kubota EFI Gasoline Engine Engine Installation (Fig. 14) 1. Install pressure plate and clutch disc if removed (see Installing Clutch Disc and Cover in Chapter 6 − Drive T rain). 2. If coupler assembly was removed, assemble coupler to engine pulley . Apply Loctite #242 (or equivalent) to threads of flange head screws that[...]

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Workman HDX−D Page 4 − 1 Kubota Diesel Engine Chapter 4 Kubota Diesel Engine T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... ADJUSTMENTS 4 .............................. Adjust Accelerator Cable 4 ..................... SERVICE AND RE[...]

Workman HDX−D Page 4 − 2 Kubota Diesel Engine Specifications Item Description Make / Designation Kubota water−cooled, Diesel, Model D902−E3B Number of Cylinders 3 Bore x Stroke 2.83” x 2.9” (72mm x 73.6mm) T otal Displacement 54.8 in 3 (898 cc) Compression Ratio 24.0:1 Firing Order 1 (front) − 2 − 3 Direction of Rotation Countercloc[...]

Workman HDX−D Page 4 − 3 Kubota Diesel Engine General Information Information about specifications, maintenance, trouble- shooting, testing and repair of the diesel engine used in th e W orkman HDX−D is included in this chapter and the Kubota W orkshop Manual, Diesel Engine, SM−E3B Se- ries. Most engine repairs and adjustments require tools[...]

Workman HDX−D Page 4 − 4 Kubota Diesel Engine Adjustments Adjust Accelerator Cable 1. Position the machine on a level surface, stop the en- gine, and engage the parking brake. 2. Check position of the engine speed control lever on fuel injection pump. The speed control lever should be contacting the high speed stop screw when the acceler- ator [...]

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Workman HDX−D Page 4 − 6 Kubota Diesel Engine Service and Repairs Air Cleaner System Figure 4 1. Air cleaner assembly 2. Hose clamp 3. Air inlet hood 4. Air intake hose 5. Hose clamp 6. Kubota diesel engine 7. Mounting bracket 8. Flange nut (2) 9. Hose clamp 10. Flange head screw (2) 1 1. Hose intake 12. T ube assembly 13. Flange head screw 14.[...]

Workman HDX−D Page 4 − 7 Kubota Diesel Engine Air Cleaner Removal 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s) if n e - cessary . If bed is raised, place safety support on lift cylin- der . 3. Remove air c[...]

Workman HDX−D Page 4 − 8 Kubota Diesel Engine Exhaust System Figure 6 1. Engine 2. Muffler 3. Exhaust gasket 4. Hex nut 5. Exhaust tube 6. Flange head screw 7. T ransaxle 8. Flange nut 9. Flange head screw 10. Mount plate 1 1. Flange head screw 12. Shift cable mount bracket 13. Carriage bolt 14. Flange head screw FRONT RIGHT 8 7 9 11 14 1 5 13 [...]

Workman HDX−D Page 4 − 9 Kubota Diesel Engine Removal (Fig. 6) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder . 3. Remove exhaust system components as[...]

Workman HDX−D Page 4 − 10 Kubota Diesel Engine Fuel System Figure 7 1. Fuel tank cap 2. Grommet 3. Rollover valve 4. Fuel hose (vent) 5. Fuel sender 6. Fuel sender nut 7. Gasket 8. Hose clamp 9. Fuel hose (return from engine) 10. Hose clamp 1 1. Fuel hose (tank to pump) 12. Fuel tank 13. W asher head screw 14. W asher head screw 15. Retainer pl[...]

Workman HDX−D Page 4 − 1 1 Kubota Diesel Engine Fuel T ank Removal (Fig. 7) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder . 3. Disconnect wire harnes[...]

Workman HDX−D Page 4 − 12 Kubota Diesel Engine Radiator Figure 9 1. Radiator guard (industrial) 2. Radiator screen 3. Swell latch (4) 4. Flange head screw (4 − industrial) 5. Flange head screw (4) 6. Flat W asher 7. Hose clamp 8. Hose (radiator to reservoir) 9. Flange head screw (2 − industrial) 10. Clip (2) 1 1. Radiator mount 12. Hose (lo[...]

Workman HDX−D Page 4 − 13 Kubota Diesel Engine Removal (Fig. 9) 1. Park vehicle on a level surface, stop engine, engage parking brake and remove key from the ignition switch. Allow engine and radiator to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder . 3. Unlatch and remove radia[...]

Workman HDX−D Page 4 − 14 Kubota Diesel Engine Engine Figure 1 1 FRONT RIGHT 1. Gear pump 2. O−ring 3. Hydraulic fitting 4. Hose clamp 5. Suction hose (from transaxle) 6. O−ring 7. Hose (to lift valve) 8. O−ring 9. Hydraulic fitting 10. Flange nut (4) 1 1. Square key 12. Pump/engine mount 13. Flange head screw (4) 14. Flange head screw (8[...]

Workman HDX−D Page 4 − 15 Kubota Diesel Engine Engine Removal (Fig. 1 1) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s) to gain ac c e s s t o e ngine. If bed is raised, place saf ety sup- port on lift cylin[...]

Workman HDX−D Page 4 − 16 Kubota Diesel Engine CAUTION Do not open radiator cap or drain coolant if the radiator or engine is hot. Pressurized, hot cool- ant can escape and cause burns. Ethylene−glycol antifreeze is poisonous. Dis- pose of coolant properly or store it in a properly labeled container away from children and pets. 9. Remove the [...]

Workman HDX−D Page 4 − 17 Kubota Diesel Engine 2. If coupler assembly was removed, assemble coupler to engine pulley . Apply Loctite #242 (or equivalent) to threads of flange head screws that secure coupler to en- gine pulley . T orque fasteners to 15 to 20 ft−lb (20 to 27 N−m) . 3. If engine mount was removed, secure mount to en- gine with[...]

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Workman HD Page 5 − 1 Kohler Air Cooled Gasoline Engine Chapter 5 Kohler Air Cooled Gasoline Engine T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... SERVICE AND REP AIRS 5 ...................... Cooling System 5 ........................[...]

Workman HD Page 5 − 2 Kohler Air Cooled Gasoline Engine Specifications Item Description Make / Designation Kohler , CH680−3025, 4−stroke, V−T win Air Cooled, OHV Number of Cylinders 2 Bore x Stroke 3.15 in x 2.64 in (80 mm x 67 mm) T otal Displacement 41.1 in 3 (674 cc) Compression Ratio 8.5:1 Governor Mechanical Idle Speed (no load) 1200 +[...]

Workman HD Page 5 − 3 Kohler Air Cooled Gasoline Engine General Information This Chapter gives information about specifications and repair of the Kohler engine used in the Workman HD. General engine maintenance procedures are described in your Operator ’s Manual. Information on engine trou- bleshooting, testing, disassembly and assembly is iden[...]

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Workman HD Page 5 − 5 Kohler Air Cooled Gasoline Engine Service and Repairs Cooling System T o ensure proper engine cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. NOTE: Perform this maintenance procedure at the in- terval specified in the Operator ’s Manual. IMPORT ANT : [...]

Workman HD Page 5 − 6 Kohler Air Cooled Gasoline Engine Exhaust System Figure 2 1. Flange head screw (4) 2. Exhaust manifold 3. Hex nut (4) 4. Exhaust gasket (2) 5. Flange nut (9) 6. Flange head screw (3) 7. Flange head screw 8. Bracket 9. Muffler gasket 10. Muffler 1 1. Flange head screw 12. Shift cable mount bracket 13. Carriage bolt (2) 14. Mu[...]

Workman HD Page 5 − 7 Kohler Air Cooled Gasoline Engine Removal (Fig. 2) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder . 3. Remove exhaust system compo[...]

Workman HD Page 5 − 8 Kohler Air Cooled Gasoline Engine Fuel System Figure 3 1. Fuel hose (to filter) 2. Hose clamp 3. Fuel hose 4. V acuum check valve 5. Fuel hose (engine purge) 6. Filter hose 7. Canister filter 8. Fuel hose (tank vent) 9. Flange nut (2) 10. Fuel tank 1 1. Fuel tank cap 12. Grommet 13. Rollover valve 14. Fuel sender cap 15. Fue[...]

Workman HD Page 5 − 9 Kohler Air Cooled Gasoline Engine Fuel T ank Removal (Fig. 3) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder . 3. Disconnect wire [...]

Workman HD Page 5 − 10 Kohler Air Cooled Gasoline Engine Carbon Canister The function of the fuel evaporative control system is to collect and store evaporative emissions from the fuel tank and engine. A carbon canister that is mounted to th e left side of the frame is used to collect these evapora- tive emissions. Fuel vapors from the engine and[...]

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Workman HD Page 5 − 12 Kohler Air Cooled Gasoline Engine Engine Figure 6 1. Lock nut 2. Flat washer 3. Pulley 4. Woodruff key 5. Flange nut 6. Cap screw (low idle stop) 7. Cap screw (high idle stop) 8. Throttle bracket 9. Throttle lever 10. Return spring 1 1. Shoulder bolt 12. Socket head screw 13. Shoulder screw 14. Jam nut (2) 15. Choke lever 1[...]

Workman HD Page 5 − 13 Kohler Air Cooled Gasoline Engine Engine Removal (Fig. 6) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder . 3. Disconnect negative[...]

Workman HD Page 5 − 14 Kohler Air Cooled Gasoline Engine Flywheel and Pilot Bearing Inspection 1. Inspect flywheel surface for stepped wear , streaking or seizure and replace if necessary . Check flywheel run- out and replace if runout exceeds 0.005 in. (0.13 mm). 2. Check pilot bearing for smooth rolling and noise. Check (sealed) bearing for gre[...]

Workman HD Series Page 6 − 1 Drive T rain Chapter 6 Drive T rain T able of Contents SPECIFICA TIONS 2 ............................. GENERAL INFORMA TION 3 ...................... Drive T rain Operation 3 ......................... Operator ’s Manual 3 ........................... SPECIAL TOOLS 4 .............................. Clutch Alignment T oo[...]

Workman HD Series Page 6 − 2 Drive T rain Specifications Item Specification T ransaxle Oil Dexron III A TF T ransaxle Oil Capacity 7.5 U.S. quart (7.1 liter) system capacity[...]

Workman HD Series Page 6 − 3 Drive T rain General Information Drive T rain Operation Workman HD series vehicles are equipped with a T oro designed transaxle with 3 forward speeds, 1 reverse speed and a dif ferential lock. Hi−Lo range gives an effec - tive 6 forward and 2 reverse speeds. The transaxle is a constant mesh, collar shift transmis- s[...]

Workman HD Series Page 6 − 4 Drive T rain Special T ools Order special tools from your T oro Distributor . Clutch Alignment T ool Use clutch alignment tool to align clutch friction disk to engine flywheel before tightening pressure plate cap screws. T oro Part Number: TOR6002 Figure 2[...]

Workman HD Series Page 6 − 5 Drive T rain Adjustments Power−T ake−Off (PTO) Cable Adjustment (If Equipped) 1. Remove clevis pin that secures PT O cable to PTO le- ver arm. 2. Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in PTO lever arm. 3. T ighten jam nut making sure that holes in clevis and lever arm still align.[...]

Workman HD Series Page 6 − 6 Drive T rain T roubleshooting Clutch Problem Possible Causes Clutch slips. Clutch pedal out of adjustment. Excessive wear of clutch disc facing. Hardening of clutch disc facing, or adhesion of oil. Weak or broken clutch diaphragm spring. Damaged pressure plate or flywheel. Clutch operation erratic or rough. Improper i[...]

Workman HD Series Page 6 − 7 Drive T rain 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 chatte[...]

Workman HD Series Page 6 − 8 Drive T rain T ransaxle 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 dri[...]

Workman HD Series Page 6 − 9 Drive T rain T ransaxle (Continued) Problem Possible Causes T ransaxle 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 [...]

Workman HD Series Page 6 − 10 Drive T rain Service and Repairs Shift Cable Replacement 1. Shift knob 2. Jam nut 3. Boot seal 4. Shift cable 5. Shift pin 6. Jam nut 7. Hair pin 8. Clevis pin 9. Shift lever 10. Shift link 1 1. Cable clevis 12. Cap screw 13. Lower shift boot 14. Lock nut 15. Lever support 16. Hex nut (2) 17. Shift stop bolt (2) 18. [...]

Workman HD Series Page 6 − 1 1 Drive T rain 6. Remove shift cable from transaxle shift lever (Fig. 6): A. Remove hair pin and clevis pin that secure shift cable to shift lever on transaxle. B. Loosen jam nuts on bulkhead fitting of cable. C. Disconnect cable from shift lever . 7. Note routing of shift cable and location of cable ties used to secu[...]

Workman HD Series Page 6 − 12 Drive T rain Driveshaft 1. Rear axle 2. Wheel hub assembly (2) 3. Brake rotor (2) 4. Brake caliper (LH shown) 5. Flange nut (2) 6. Parking brake caliper (LH shown) 7. Splined shaft (2) 8. Parking brake bracket (LH shown) 9. Spindle nut (2) 10. Rear wheel assembly 1 1. Lug nut (5 per wheel) 12. Driveshaft assembly (2)[...]

Wor km an H D Se ri es Page 6 - 1 3 Drive T rain Removal (Fig. 7) 1. Park vehicle on a leve l surface, shut engine off and remove key from ignition switch. 2. For driveshaft to be servi ced, remove wheel, b rake caliper , brake rotor and wheel hub (see Wheel Hub Re- moval in Chapt er 7 - Chassis in th is manual). 3. Loosen and remove flange nu ts, [...]

Workman HD Series Page 6 − 14 Drive T rain Driveshaft Cross and Bearing Service 1. Remove driveshaft from vehicle (see Driveshaft Re- moval in this section). IMPORT ANT : When placing yoke in vise, clamp lightly on the solid part of the yoke to prevent yoke damage. Also, the use of a vise with soft jaws is rec- ommended. 2. Lightly clamp yoke in [...]

Workman HD Series Page 6 − 15 Drive T rain Power−T ake−Off (PTO) Removal & Installation (If Equipped) PTO Removal 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Remove clevis pin to disconnect PTO control cable clevis from leve[...]

Workman HD Series Page 6 − 16 Drive T rain T ransaxle 1. T ransaxle assembly 2. Snubbing washer (4) 3. Isolation mount assembly (2) 4. T ransaxle mount (2) 5. Flange nut (4) 6. Cap screw (2) 7. Flange head screw (4) 8. Shift arm 9. Lock nut (3) 10. Shift cable mount bracket 1 1. Shift lever (2) 12. Differential lock lever 13. Strainer 14. Shift a[...]

Workman HD Series Page 6 − 17 Drive T rain T ransaxle Removal (Fig. 12) 1. Park vehicle on a level surface. Stop the engine and remove key from ignition switch. Remove the bed or oth- er attachment(s). Allow transaxle and engine to cool. 2. Disconnect negative (−) battery cable from battery first. Then disconnect positive (+) battery cable from[...]

Workman HD Series Page 6 − 18 Drive T rain 16 . Pu t blocking under engine for support. Support trans- axle with a floor jack or suspend transaxle from vehicle frame rails. 17. Remove isolation mount assemblies and transaxle mounts (Fig. 16). 18. Remove driveshaft clamp bolts, then slide transaxle side−to−side to disconnect each driveshaft fr[...]

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Workman HD Series Page 6 − 20 Drive T rain Clutch Service 1. Spring pin 2. Throw out bearing 3. Release guide 4. Clutch release fork 5. Clutch release shaft 6. Bushing 7. Spring pin (2) 8. Bell housing 9. Oil seal 10. Cap screw (6) 1 1. Lock washer (6) 12. Pressure plate 13. Clutch disc 14. Extension spring Figure 19 FRONT RIGHT 5 9 6 1 4 3 2 9 6[...]

Workman HD Series Page 6 − 21 Drive T rain Clutch Disassembly and Inspection (Fig. 19) 1. Insert clutch alignment tool (see Special T ools in this chapter) in engine flywheel pilot bearing hole to keep clutch disk from falling off (Fig. 20). 2. Loosen pressure plate cap screws in a diagonal se- quence. 3. Remove cap screws, lock washers and press[...]

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Workman HD Series Page 6 − 23 Drive T rain T ransaxle Service T ransaxle Disassembly NOTE: Item numbers in figures are shown in order of disassembly; for example, remove item 1 first, then item 2, etc. assemble transaxle in reverse order; for example, install item 1 last. 1. Remove extension spring. 2. Loosen and remove flange head screws and rem[...]

Workman HD Series Page 6 − 24 Drive T rain 7. Loosen and remove fifteen (15) flange head screws and separate center plate from transaxle case. Note dowel pins in transaxle case. Remove seal cap, shims and snap ring from center plate. 1 3 2 4 1. Seal cap 2. Shims 3. Shim 4. Snap ring Figure 27 8. 4 WD UNITS ONL Y: remove front drive shaft and 41T [...]

Workman HD Series Page 6 − 25 Drive T rain 10. Remove main shaft assembly together with fork shaft assembly from transaxle case. 1 2 1. Main shaft assembly 2. Fork shaft assembly Figure 30 1 1. Remove, all at the same time, reduction shaft as- sembly , 2nd−3rd shift assembly , countershaft assembly and High−Low shift assembly . 1 2 4 3 1. Red[...]

Workman HD Series Page 6 − 26 Drive T rain 13. Remove roll pin from differential lock lever . Remove lever from shaft. Loosen and remove five (5) flange head screws. Remove L.H. side cover from transaxle case. 14. Inspect side cover for cracks or damage and replace if necessary . 1 2 3 1. Lever 2. Flange head screw (5) 3. L.H. Side cover Figure 3[...]

Workman HD Series Page 6 − 27 Drive T rain 17. Remove washer from inside of transaxle case. NOTE: W asher may stick to fork shaft when removed in step 16. 1 1. W asher Figure 36 18. T o remove shift arms: A. Loosen and remove nut. Remove 2nd−3rd shift arm together with shift arm plate, spring, lock nut, washer and cap screw . B. Loosen and remo[...]

Workman HD Series Page 6 − 28 Drive T rain 19 . I f PTO cover is on transaxle, remove cap screws and nut with washer . Separate PTO cover from transaxle case. Inspect PTO cover for cracks or damage and re- place if necessary . 1 2 3 1. Cap screw (5) 2. Nut 3. PTO cover Figure 39 20. Remove oil cap and O−ring from transaxle case if necessary . 2[...]

Workman HD Series Page 6 − 29 Drive T rain 23. Disassemble main shaft assembly: A. U se a bearing puller to remove bearing from main shaft. B. Remove snap ring and washer . Measure thick- ness of washer . Replace washer if it is less than 0.0709 in. (1.8 mm) thick. C. Remove needle bearings and gear (item 4). In- spect needle bearings and replace[...]

Workman HD Series Page 6 − 30 Drive T rain 24. Disassemble reduction shaft assembly: A. Use a bearing puller to remove bearing from re- duction shaft. B. Remove gear , helical gear , collar and gear . C. Use a bearing puller to remove bearing. D. Remove washer , needle bearing and gear . E. Remove spacer . F . Remove snap ring. G. Remove shifter [...]

Workman HD Series Page 6 − 31 Drive T rain 25. Disassemble reverse shaft assembly: A. Use a bearing puller to remove bearing from re- verse shaft. B. Remove gear . C. Use a bearing puller to remove bearing from re- verse shaft. 1. Bearing 2. Gear 3. Bearing 4. Reverse shaft Figure 46 1 2 34 26. Disassemble countershaft assembly: A. Use a bearing [...]

Workman HD Series Page 6 − 32 Drive T rain 27. Disassemble fork shaft assemblies: A. Remove lock pin from 2nd−3rd fork shaft assem- bly . B. Note or mark mating shafts and forks for as- sembly . C. Remove shift fork from fork shaft. D. Remove lock pin from 1st−R fork shaft assembly . E. Remove shift fork from fork shaft. 1. Lock pin 2. Shift [...]

Workman HD Series Page 6 − 33 Drive T rain 29. Disassemble differential gear assembly: A. Use a bearing puller to remove bearing (item 1) from differential case. B. Remove snap ring. C. Use a bearing puller to remove bearing and slider . D. Loosen screws from ring gear . E. Remove ring gear from differential case and re- move dowel pins. F . Driv[...]

Workman HD Series Page 6 − 34 Drive T rain 30. Disassemble differential fork shaft assembly: A. Remove O−ring from fork shaft. B. Remove snap ring, washer and spring. C. Remove fork. D. Remove lock pin if necessary . 1. O−ring 2. Snap ring 3. W asher 4. Spring 5. Fork 6. Lock pin 7. Fork shaft Figure 53 6 54 3 2 1 7 ARM LOCK PIN 31. Disassemb[...]

Workman HD Series Page 6 − 35 Drive T rain T ransaxle 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 synch[...]

Workman HD Series Page 6 − 36 Drive T rain 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 th[...]

Workman HD Series Page 6 − 37 Drive T rain 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. UNDAMAGED GROOVE Figure 60 DAMAGED GROOVE EDGES Figure 61 10. Inspect reduction shaft for wear or damage. If O.D. of outer needle bea[...]

Workman HD Series Page 6 − 38 Drive T rain 12. Inspect differential: A. Inspect pinion shaft for excessive wear or dam- age. If O.D. is less than 0.707 in. (17.95 mm), replace the pinion shaft. B. Measure thickness of pinion liners. If thickness is less than 0.035 in. (0.9 mm), replace the pinion lin- ers. C. Measure thickness of side gear liners[...]

Workman HD Series Page 6 − 39 Drive T rain T ransaxle Assembly 1. Clean gasket material from all mating surfaces be- fore reassembling. Make sure all parts are clean and free of dirt and dust. IMPORT ANT : Be careful not to damage mating sur- faces when removing gasket material. 2. Assemble L.H. axle shaft: A. Install new oil seal into differenti[...]

Workman HD Series Page 6 − 40 Drive T rain 5. Assemble differential gears: A. Apply moly disulfide grease on pinion liners, holes of pinion gears, side gear liners and hubs of side gears. B. Install side gear liners, side gears, pinion liners and pinion gears. C. Rotate side gears until holes of pinion gears and liners align with holes of differe[...]

Workman HD Series Page 6 − 41 Drive T rain 6. Assemble Hi−Lo fork shaft: A. Install E−ring onto fork shaft. B. Insert spring and steel ball into fork. C. Insert fork shaft into fork. Put moly disulfide grease onto the shaft before installing. 1 5 4 2 3 1. Shift fork 2. Steel ball 3. Spring 4. E−ring 5. Hi−Lo fork shaft Figure 70 7. Assemb[...]

Workman HD Series Page 6 − 42 Drive T rain 8. Assemble countershaft: A. U se a press to install new bearings (item 15) onto countershaft. B. Install collar and snap ring. C. Install washer and gear . Apply moly disulfide grease into bushing of countershaft gear before installing. Oil groove on washer must face the gear . D. Install collar−splin[...]

Workman HD Series Page 6 − 43 Drive T rain 9. Assemble synchro hub: A. Install keys into grooves of hub. 1 2 1. Key (3) 2. Hub Figure 74 B. Install shifter onto hub. 1 2 1. Shifter 2. Hub Figure 75 C. Insert springs into hub. Pay attention to direction of spring. 1. Key (3) 2. Hub 3. Spring (2) Figure 76 Figure 77[...]

Workman HD Series Page 6 − 44 Drive T rain 10. Assemble reduction shaft: A. Install thrust washer (item 17), needle bearings and gear onto reduction shaft. Apply moly disulfide grease to washer and needle bearings before instal- ling. Oil groove on washer must face the gear . B. Install synchro ring onto gear . Apply clean Dex- ron III transmissi[...]

Workman HD Series Page 6 − 45 Drive T rain 1 1. Assemble reverse shaft: A. Install gear onto reverse shaft. B. Use a press to install bearings. 1. Bearing 2. Gear 3. Bearing 4. Reverse shaft Figure 80 1 2 34 12. Assemble main shaft: A. Install gears and snap ring. B. Install gear . C. Use a press to install bearing. D. Install washer and needle b[...]

Workman HD Series Page 6 − 46 Drive T rain 13. Assemble shift arms: A. Install new oil seals into transaxle case. Apply multi−purpose grease on lips of oil seals before installing. B. Install keeper plates and tighten flange head screws to a torque from 1 1 to 13 ft−lb (15 to 17 N−m) . C. Apply Loctite #680 (or equivalent) to threads and ta[...]

Workman HD Series Page 6 − 47 Drive T rain 16. Assemble reduction shaft and countershaft together with R−1 fork shaft and Hi−Lo fork shaft. Figure 86 17. Insert reduction shaft and countershaft assembly into transaxle case. Insert heads of shift arms into grooves of forks when installing them. Figure 87 18. Assemble main shaft together with 2[...]

Workman HD Series Page 6 − 48 Drive T rain 20. Install reverse shaft into transaxle case. Rotate main shaft and reverse shaft gears to mesh gears when installing. 1 2 1. Reverse shaft 2. Bearing (gear case) Figure 90 21.4WD UNITS ONL Y : Install bearing to gear case and center plate. Install front drive shaft and 41T gear to the gear case. 1 1. F[...]

Workman HD Series Page 6 − 49 Drive T rain NOTE: The thickest shim of the shim set should be positioned against the snap ring. 23. Insert tabbed shim against the bearing. Insert shim set against the tabbed shim. Use thickest shims in set possible, that will permit installation of the snap ring. 1 3 2 1. Seal cap 2. Shims 3. Snap ring 4. Shim Figu[...]

Workman HD Series Page 6 − 50 Drive T rain 25. Measure countershaft end play . Rotate one of the axle shafts back and forth to take up all back lash. Rotat- ing the shaft in one direction will pull the shaft and bear- ing away from the snap ring. Rotate axle shaft in this direction, then measure space between the snap ring an d shim (set) with a [...]

Workman HD Series Page 6 − 51 Drive T rain B. Insert steel balls and springs into the grooves. 1 2 3 1. Spindle 2. Spring (2) 3. Ball (2) Figure 99 C. Apply silicone sealant to mating surface of fork shaft case. D. Install fork shaft case. Install and tighten flange head screws to a torque from 18.5 to 22 ft−lb (24.5 to 29.5 N−m) . E. Check o[...]

Workman HD Series Page 6 − 52 Drive T rain 29. Install dif ferential gear assembly together with fork shaft onto transaxle case. Figure 102 1 2 1. Differential gear assy . 2. Fork shaft Figure 103 30. Install side cover: A. Insert dowel pins onto transaxle case. B. Apply silicone sealant onto mating surface of side cover . C. Install side cover a[...]

Workman HD Series Page 6 − 53 Drive T rain 31. Install R.H. axle shaft assembly: A. Apply silicone sealant onto mating surface of seal cover . B. Install axle shaft assembly and secure with four (4) flange head screws. T orque screws from 18.5 to 22 ft−lb (24.5 to 29.5 N−m) . 1 2 1. Flange head screw (4) 2. Axle shaft assembly Figure 105 18.5[...]

Workman HD Series Page 6 − 54 Drive T rain 33. 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 0.0031 to 0.0071 in. (0.08 to 0.18 mm) and must not vary more than 0.0019 in. (0.05 mm) at the points checked. If backlash is not in thi[...]

Workman HD Series Page 6 − 55 Drive T rain 36. Apply multi−purpose grease to O−ring and insert O− ring into groove of transaxle case. Install cover and se- cure with nut, lockwasher and cap screws. T orque fasteners from 1 1 to 13 ft−lb (15 to 17 N−m) . NOTE: If equipped with optional PTO, install PT O as- sembly after the transaxle has[...]

Workman HD Series Page 6 − 56 Drive T rain Power T ake−Off (PTO) Service (If Equipped) 1. PTO cover 2. Cap screw (4) 3. Lock washer (7) 4. Cap screw (3) 5. O−ring 6. Shift arm 7. Shifter block 8. Spring 9. Ball 10. Retaining ring 1 1. Bearing 12. Input shaft 13. Shift collar 14. Gear (29T) 15. Bushing 16. Thrust washer 17. Bearing 18. Retaini[...]

Workman HD Series Page 6 − 57 Drive T rain 6. Remove P T O output shaft assembly from PTO hous- ing. Remove oil seal from PTO cover . 1 1. Output shaft assembly Figure 1 14 7. Remove intermediate shaft assembly from PTO housing. Remove intermediate gear . Remove bearing from housing if necessary . 1 2 1. Intermediate shaft assy . 2. Intermediate [...]

Workman HD Series Page 6 − 58 Drive T rain 8. Remove PTO input shaft from PT O housing: A. Shift PTO to ”ON” position. B. Remove retaining rings from PTO housing. C. Slide input shaft assembly toward PTO shaft. D. Remove bearing (item 4). E. Slide input shaft away from PTO shaft. F . Remove bearing. G. Remove thrust washer and gear by sliding[...]

Workman HD Series Page 6 − 59 Drive T rain 10. Disassemble PTO intermediate shaft: A. Use a bearing puller to remove bearing if neces- sary . 1 1. Bearing Figure 120 1 1. Disassemble PTO output shaft: A. Use a bearing puller to remove bearing. B. Remove gear and retaining ring. C. Remove retaining ring and thrust washer . D. Use a bearing puller [...]

Workman HD Series Page 6 − 60 Drive T rain 12. Disassemble shift arm: A. Remove lock pins from shift arm. B. Remove O−rings. 1 1. O−ring (2) Figure 123[...]

Workman HD Series Page 6 − 61 Drive T rain Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. 3. Measure clearance between groove on shift collar and shifter block. Replace shifter block if clearance ex- ceeds 0.039 in. (1.0 mm). CLEARANCE Figure 124 4. Measure I.D. of input shaft bushin[...]

Workman HD Series Page 6 − 62 Drive T rain 1. PTO cover 2. Cap screw (4) 3. Lock washer (7) 4. Cap screw (3) 5. O−ring 6. Shift arm 7. Shifter block 8. Spring 9. Ball 10. Retaining ring 1 1. Bearing 12. Input shaft 13. Shift collar 14. Gear (29T) 15. Bushing 16. Thrust washer 17. Bearing 18. Retaining ring 19. Shift lever 20. Spring pin 21. Spr[...]

Workman HD Series Page 6 − 63 Drive T rain 3. Assemble shift arm: A. Apply moly disulfide grease to new O−rings and install onto shift arm. 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 spring pins into shift lever and shift arm. Pay attention to direc[...]

Workman HD Series Page 6 − 64 Drive T rain 4. Assemble PTO output shaft: A. If bearing was removed, use a press to install bearing onto output shaft. B. Install washer and retaining ring. C. Install retaining ring and gear . D. Use a press to install bearing. 1 2 3 7 6 4 5 1. Bearing 2. Gear 3. Retaining ring 4. Retaining ring 5. Thrust washer 6.[...]

Workman HD Series Page 6 − 65 Drive T rain 6. Assemble PTO input shaft: A. Insert spring and steel balls into hole. B. Insert shift collar onto input shaft. C. Move shift collar to ”ON” position. 1 2 2 3 1. Shift collar 2. Steel ball (2) 3. Spring Figure 135 Drive T rain[...]

Workman HD Series Page 6 − 66 Drive T rain 7. Install PTO input shaft sub−assembly: A. Insert shifter block 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 on the shifter block. C. Install gear with bushing and thrust washer onto input shaft aft[...]

Workman HD Series Page 6 − 67 Drive T rain 8. Install PTO intermediate shaft sub−assembly: A. If removed during disassembly , insert bearing into PTO housing. B. Put gear on mating gear . C. Move gear until bores of gear and bearing line up. D. Insert intermediate shaft sub−assembly . Apply grease to intermediate shaft to aid assembly . 3 3. [...]

Workman HD Series Page 6 − 68 Drive T rain 10. Install PTO cover: A. Insert new oil seal into PTO cover . Apply multi− purpose grease to lip of oil seal. B. Insert alignment pins into PTO housing. C. Apply silicone sealant onto mating surface of PTO cover . D. Install PT O cover . Secure cover with cap screws, nut and lock washers. T orque fast[...]

Workman HD Series Page 7 − 1 Chassis Chapter 7 Chassis T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... T ire Pressure 3 ............................... SPECIAL TOOLS 4 ............................. TROUBLESHOOTING 5 ...................[...]

Workman HD Series Page 7 − 2 Chassis Specifications Item Specification Front tire 20” x 9” − 12, 6 ply Maximum front tire pressure* 32 PSI (220 kPa) Front wheel alignment 0 + 0.120 in. (0 + 3 mm) Rear tire 24” x 12” − 12, 6 ply Model 07383 = 24” x 13” − 12, 6 ply Model 07379 (Industrial) = 23” x 10.5” − 12, 4 ply Maximum r[...]

Workman HD Series Page 7 − 3 Chassis General Information Operator ’s Manual The vehicle Operator ’s Manual provides information re- garding the operation, general maintenance and main- tenance intervals for your W orkman vehicle. Refer to the Operator ’s Manual for additional information when ser- vicing the vehicle. Tire Pressure 1. T ire [...]

Workman HD Series Page 7 − 4 Chassis Special T ools Compression Spring T ool Use to remove and install the front suspension com- pression springs. Quantity Item 2 1/2” x 20” threaded steel rods 4 1/2” nuts 4 1/2” flat washers 20” 5” 5” Figure 1[...]

Workman HD Series Page 7 − 5 Chassis T roubleshooting 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. T ire pressure low (4WD vehicles). Worn tires[...]

Workman HD Series Page 7 − 6 Chassis Suspension and Steering (Continued) Problem Possible Causes Hard steering. Loose, worn or glazed hydraulic pump drive belt (Workman HD vehicles). Binding or damaged steering linkage. Low or uneven tire pressure. Low hydraulic pressure (see Chapter 9 − Hydraulic System). Damaged or binding steering cylinder .[...]

Workman HD Series Page 7 − 7 Chassis Brakes (Continued) Problem Possible Causes Brakes pulling. Incorrect tire pressure. Contaminated brake pads. Front end is out of alignment. Bent or damaged brake rotors. Damaged brake hoses. Parking brake caliper or cable is sticking or damaged. Unmatched tires on same axle. Dragging brakes. Parking brake is e[...]

Workman HD Series Page 7 − 8 Chassis Service and Repairs Wheel Assembly 5 6 7 3 8 9 11 12 10 2 4 80 to 90 ft−lb (109 to 122 N−m) 35 to 40 ft−lb (48 to 55 N−m) 5 4 6 1 2 3 80 to 90 ft−lb (109 to 122 N−m) 35 to 40 ft−lb (48 to 55 N−m) 6 1. Front wheel assembly 2. Brake rotor 3. Wheel hub assembly 4. Lug nut (5 per wheel) 5. Brake ca[...]

Workman HD Series Page 7 − 9 Chassis Removal (Fig. 2) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Partially loosen wheel lug nuts that secure wheel to be removed, then jack up and support vehicle (see Jack- ing V ehicle in Chapter 1 − Safety in this manual). 3. Remove lug nu[...]

Workman HD Series Page 7 − 10 Chassis Brake System 5 6 7 3 8 9 11 12 10 2 4 80 to 90 ft−lb (109 to 122 N−m) 35 to 40 ft−lb (48 to 55 N−m) 5 4 6 1 2 3 80 to 90 ft−lb (109 to 122 N−m) 35 to 40 ft−lb (48 to 55 N−m) 6 1. Front wheel assembly 2. Brake rotor 3. Wheel hub assembly 4. Lug nut (5 per wheel) 5. Brake caliper 6. Flange head [...]

Workman HD Series Page 7 − 1 1 Chassis Disassembly (Fig. 4) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. W ARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety . 2. Chock wheels not being jacked up. For brake that is to be serviced, [...]

Workman HD Series Page 7 − 12 Chassis Brake Caliper Service 1. Bolt (2) 2. Caliper body 3. O−ring (4) 4. Caliper bracket 5. Square seal (2) 6. Dust seal (2) 7. Piston (2) 8. Brake pad (2) 9. Caliper anvil Figure 6 2 3 6 8 1 5 7 4 (37 to 44 N−m) 27 to 33 ft−lb BAF−12 Assembly Lube White Lithium Grease 9[...]

Workman HD Series Page 7 − 13 Chassis Disassembly (Fig. 6) 1. Remove two (2) bolts that secure brake caliper as- sembly . 2. Remove caliper anvil and then slide brake pads from pins on caliper bracket. 3. Slide caliper body assembly from caliper bracket. 4. If necessary , remove remaining components from caliper body: A. Carefully remove pistons [...]

Workman HD Series Page 7 − 14 Chassis Bleed Brake System 1. Remove hood to access brake master cylinder (see Hood in this section). Make sure that brake fluid level is correct. 2. Connect a suitable transparent hose to bleeder valve on left rear wheel caliper and submerge other end of hose in a clean glass container partially filled with clean br[...]

Workman HD Series Page 7 − 15 Chassis Parking Brake Caliper Service Disassembly (Fig. 8) 1. Remove carrier side brake pad and pad support from caliper . 2. Remove cam side brake pad and pad support from caliper . 3. Replace the brake pads if the friction material is worn to less than 0.135” (3.4 mm). 4. I f necessary , remove lever retainer spr[...]

Workman HD Series Page 7 − 16 Chassis Brake Master Cylinder 1. Brake master cylinder 2. Flange head screw (2) 3. Clevis pin 4. Grease fitting 5. Brake pedal 6. Flange bushing 7. Flange nut 8. Flange nut (2) 9. Cotter pin 10. Shoulder screw 1 1. Brake shaft 12. Brake switch (2WD models) 13. Brake switch (4WD models) Figure 9 1 FRONT RIGHT 2 3 4 5 [...]

Workman HD Series Page 7 − 17 Chassis Removal (Fig. 9) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Remove hood to access brake master cylinder (see Hood Removal in this section). 3. Remove cotter pin from the clevis pin that connects master cylinder to brake pedal. 4. Clean hy[...]

Workman HD Series Page 7 − 18 Chassis Brake Master Cylinder Service Disassembly (Fig. 1 1) 1. Thoroughly clean outside of master cylinder before disassembly . 2. Remove reservoir and flange seal. Push in on the push rod (item 8) so the stop pin (item 3) can be re- moved. 3. Disconnect lower end of the dust cover from the housing. 4. Push in on th[...]

Workman HD Series Page 7 − 19 Chassis This page is intentionally blank. Chassis[...]

Workman HD Series Page 7 − 20 Chassis Parking Brake Cable 1. Parking brake lever handle 2. Parking brake lever 3. Spacer 4. Curved washer 5. Clevis pin 6. Lock nut 7. Bellcrank 8. Cap screw 9. Hair pin 10. Flat washer 1 1. Cable equalizer bracket 12. Clevis pin 13. Socket head screw (3) 14. Cable clamp 15. Parking brake cable 16. Retaining ring ([...]

Workman HD Series Page 7 − 21 Chassis 7. Remove retaining ring that secures brake cable to le- ver support assembly . 8. Disconnect brake cable from cable equalizer bracket (Fig. 14). 9. Note routing of parking brake cable and location of cable ties to secure brake cable to vehicle frame. Re- move brake cable from vehicle. Installation (Fig. 12) [...]

Wor km an H D Se r ie s Page 7 - 22 Chassis Wheel Hub 1. Front wheel assembly 2. Brake rotor 3. Wheel hub assembly 4. Lug nut (5 per wheel) 5. Brake caliper 6. Flange head screw 7. Parking brake caliper (LH shown) 8. Parking brake bracket (LH shown) 9. Parking brake return spri ng 10. C levis pin 1 1. Rear wheel assembly 12. Rear axle 13. Parking b[...]

Wor km an H D Se ri es Page 7 - 23 Chassis Removal (Fig. 15) 1. Park vehicle on a level surface, shut engine off and remove key from ignition switch. 2. Jack up and suppo rt rear of vehi cle (see Jacking V e- hicle in Chapter 1 - Safety in this manual). Make sure that vehicle is suppo rted with jack stands. 3. For wheel hub to be serviced , remove [...]

Workman HD Series Page 7 − 24 Chassis Steering Assembly 18 19 15 17 16 20 13 12 14 11 10 3 6 8 9 5 1 4 2 7 12 2 1 3 12 14 14 11 21 28 29 31 24 27 22 23 23 30 26 25 35 to 40 ft−lb (48 to 55 N−m) 35 to 40 ft−lb (48 to 55 N−m) 170 to 180 ft−lb (231 to 244 N−m) 80 to 90 ft−lb (109 to 122 N−m) 80 to 90 ft−lb (109 to 122 N−m) 40 to [...]

Wor km an H D Se ri es Page 7 - 25 Chassis Disassembly (Fig. 16) 1. Park vehicle on a level surface, shut engine of f, re- move key from ignition switch and apply parking brake. 2. T o remove tie rod from vehicle (Fig. 17) : A. Remove cotter pin and slotted hex nut that secure outer tie rod ball joint stud to knuckle. B. Use puller to separate ball[...]

Workman HD Series Page 7 − 26 Chassis Assembly (Fig. 16) 1. If steering linkage and center link is disassembled (Fig. 17 and 18). A. If flange bushings (Fig. 18) were removed from pivot mount, make sure that new bushings are pressed fully into the pivot mount. B. Fill pivot mount cavities with grease. C. T orque new spindle nut to 85 ft−lb (1 1[...]

Workman HD Series Page 7 − 27 Chassis This page is intentionally blank. Chassis[...]

Workman HD Series Page 7 − 28 Chassis Front Control Arms 1. LH upper control arm 2. LH lower control arm 3. RH upper control arm 4. RH lower control arm 5. Cap screw (4) 6. Flange nut (4) 7. Flange head screw (6) 8. Lock nut (8) 9. Cap screw (2) 10. Flange bushing (2 per arm) 1 1. Ball joint 12. Grease fitting 13. Ball joint seal 14. Knuckle (LH [...]

Workman HD Series Page 7 − 29 Chassis Removal (Fig. 19) W ARNING FRONT SUSPENSION IS SPRING LOADED! T o prevent possible personal injury , use special tool to remove compression springs before dis- assembling the front suspension. 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. If[...]

Workman HD Series Page 7 − 30 Chassis Front Compression Spring Service 1. Spring cradle (2) 2. Compression spring (2) 3. Flange nut 4. Cap screw 5. Stabilizer link 6. Lock nut 7. Cap screw 8. LH control arm tower 9. Spring pivot sleeve 10. RH control arm tower Figure 20 2 3 4 7 6 1 5 9 8 10 11 12 4 FRONT RIGHT[...]

Workman HD Series Page 7 − 31 Chassis Disassembly (Fig. 20) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Remove seat base to gain access to front suspen- sion assembly (see Seat Base Removal in this section). 3. Jack up front of vehicle and secure with jack stands (see Jacking [...]

Workman HD Series Page 7 − 32 Chassis Front Shock Absorber Removal (Figs. 23 and 24) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Remove lower and upper lock nuts, then remove shock absorber and washers. Note that washers on up- per end of shock absorber are different. W ashers[...]

Workman HD Series Page 7 − 33 Chassis Rear Shock Absorber Removal (Fig. 26) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. NOTE: The three (3) flat washers used to retain shock absorber to vehicle are different. Note location of each washer during removal. 2. Remove lock nut and fla[...]

Workman HD Series Page 7 − 34 Chassis Rear Leaf Spring 13 12 14 11 10 3 6 8 9 5 1 4 2 7 12 10 12 12 5 5 12 See tightening procedure in text 1. Washer (4 per plate) 2. Spring mount (LH shown) 3. Rear frame 4. Flange head screw 5. Flange nut 6. Rear axle 7. Axle bumper (2) 8. Lock nut 9. Bolt (4 per plate) 10. Spring shackle (2 per spring) 1 1. Spr[...]

Workman HD Series Page 7 − 35 Chassis 8. Remove flange nut that secures spring mount to leaf spring and remove mount from spring. 9. Remove rubber bushings from leaf spring and frame side rails. Installation (Fig. 27) 1. Make sure that four (4) rubber bushings are posi- tioned in leaf spring and two (2) rubber bushings are fitted in frame side ra[...]

Workman HD Series Page 7 − 36 Chassis Front Wheel Alignment 1. Rotate steering wheel to center the pitman arm with th e vehicle to ensure correct front wheel alignment mea- surement. 2. With the pitman arm centered, measure center to center distance (at axle height) between the front wheels a t both front and rear of the wheels (Fig. 28 ). T he f[...]

Workman HD Series Page 7 − 37 Chassis Steering Wheel Removal (Fig. 29) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Carefully remove steering wheel cover from steering wheel. 3. Remove hex nut and flat washer that secure steering wheel to steering control valve. 4. Pull steerin[...]

Workman HD Series Page 7 − 38 Chassis Seat Base 18 19 15 17 16 20 13 12 14 11 10 4 6 8 9 5 1 2 7 3 22 21 13 9 1. LH (operator) seat 2. RH (passenger) seat 3. Socket head screw (8) 4. Washer head screw (12) 5. Shift boot 6. Carriage bolt (8) 7. Seat bracket (4) 8. Seat base 9. Flange nut (9) 10. U−clip nut (8) 1 1. Rubber bumper (2) 12. Mudflap [...]

Workman HD Series Page 7 − 39 Chassis Removal (Fig. 30) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and apply the parking brake. Remove key from ignition switch. 2. Remove six (6) carriage screws and flange nuts that secure ROPS cover to ROPS frame. Remove cover from vehicle (Fig. 31). 3. Remove knobs[...]

Workman HD Series Page 7 − 40 Chassis Hood 1. Hood 2. Clip (3 per headlight) 3. Headlight (2) 4. Bumper 5. Bumper bracket 6. Cover 7. Operator frame 8. Hood attachment tab Figure 32 FRONT RIGHT 3 6 5 1 4 2 7 8 8 8 8 Removal (Fig. 32) 1. Park vehicle on a level surface, shut engine off and apply the parking brake. Remove key from ignition switch. [...]

Workman HD Series Page 8 − 1 Electrical System Chapter 8 Electrical System T able of Contents ELECTRICAL SCHEMA TICS 2 .................... SPECIAL TOOLS 2 .............................. TROUBLESHOOTING 4 .......................... ELECTRICAL SYSTEM QUICK CHECKS 6 ......... Battery T est (Open Circuit T est) 6 ................ Charging System T e[...]

Wor km an H D Se r ie s Page 8 - 2 Electrical System Electrical Schematics The electrical schematics and other electrical drawings for Workman HD se ries vehicles are locate d in Chapter 1 1 - Electrical Drawings. Special T ools Order special to ols from your T o ro Distributor . Some tools may also be available from a local supplier . Digital Mul [...]

Wor km an H D Se ri es Page 8 - 3 Ele ctrical Syst em Battery T erminal Protector Aerosol spray that shoul d be used on battery terminals, ring terminals, and fork terminals to reduce corrosio n problems. Apply battery termin al protector to the con- nection after the battery cable, ring ter minal, or fork ter- minal has been secured. T oro Part Nu[...]

Workman HD Series Page 8 − 4 Electrical System T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage. Fo r e f fective troubleshooting and repairs, you must have a good understanding of the electri[...]

Workman HD Series Page 8 − 5 Electrical System Condition Possible Cause Starter cranks, but should not, with hydraulic lift lever out of the neutral position. Lift lever interlock switch out of adjustment. Lift lever interlock switch faulty . Starter cranks, but should not, with rear PTO (if equipped) engaged. Rear PTO switch faulty . Starter cra[...]

Workman HD Series Page 8 − 6 Electrical System Electrical System Quick Checks Battery T est (Open Circuit T est) Use a multimeter to measure the voltage between the battery terminals. Set the multimeter to the DC volts setting. The battery should be a t a temperature of 60F to 100F (16C to 38C). Th e ignition key should be in the OFF position and[...]

Workman HD Series Page 8 − 7 Electrical System V erify Interlock System Operation Th e purpose of the interlock system is to prevent the en- gine from cranking or starting unless the clutch pedal is depressed (all models), the hydraulic lift lever is in the neutral position (all models) and rear PTO (if equipped) is disengaged. CAUTION Do not dis[...]

Workman HD Series Page 8 − 8 Electrical System Component T esting This section will define electrical component operation and supply test procedures that can be performed on those components. For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the clutch switch conne[...]

Workman HD Series Page 8 − 9 Electrical System Gauge Cluster Hourmeter Th e hourmeter should move 1/10 of an hour for every six minutes that the ignition switch is in the ON position. Fuel Level Gauge The fuel level gauge displays the approximate amount of fuel remaining in the fuel tank. Additionally , a red LED will illuminate when the fuel tan[...]

Workman HD Series Page 8 − 10 Electrical System Fuses Th e fuse blocks are located below the center of the dash panel. Identification and Function (Fig. 9) T op Row LH: Protects ignition power supply . T op Row RH: Protects power supply for light system (headlights, running lights and brake lights). Second Row LH: Protects main (switched) power s[...]

Workman HD Series Page 8 − 1 1 Electrical System Headlight Switch This headlight switch allows the headlights to be turned on and off and is located on the dash (Fig. 10). T esting The headlight switch terminals are marked as shown (Fig. 1 1). The circuitry of the headlight switch is shown in the chart below . With the use of a multimeter (ohms s[...]

Workman HD Series Page 8 − 12 Electrical System Clutch Switch(s) A proximity switch is attached to the frame under the dash o f all units (Fig. 1 2). The switch is in its normal open position as long as the clutch pedal is released (clutch engaged). When the clutch pedal is depressed (clutch disengaged), the pedal is positioned close to the clutc[...]

Workman HD Series Page 8 − 13 Electrical System Brake Switch(s) The brake switch is is attached to the frame under the dash (Fig. 13). A switch with one set of normally closed terminals is used on 2WD units. A switch with one set of normally closed terminals and one set of normally open terminals is used on 4WD units (Fig. 14). When the brakes ar[...]

Workman HD Series Page 8 − 14 Electrical System Hydraulic Lift Lever Interlock Switch Th e lift lever interlock switch is a normally open proximity switch that is attached to the control lever support (Fig. 15). The interlock switch is in its normal open position whenever the hydraulic lift lever is moved away from the neutral position. When the [...]

Workman HD Series Page 8 − 15 Electrical System 3rd − High Lockout Key Switch The 3rd − High lockout key switch has two positions: SLOW (turtle) and F AST (rabbit). This switch is located on the dash (Fig. 17). T esting The switch terminals are identified (Fig. 18). The circuit wiring of the switch is shown in the chart below . With the use o[...]

Workman HD Series Page 8 − 16 Electrical System T ransaxle Switches 3 rd Gear Lockout Switch The transaxle 2−3 Lockout switch is located on the top of the transaxle (Fig. 19) . The switch is closed in 1 st and 2nd gear and open in 3rd gear . T o test the switch, disconnect the wire harness connec- tor from the switch. Use a multimeter (ohms set[...]

Workman HD Series Page 8 − 17 Electrical System Power Relay (Four T erminals) Th e main power relay is used to provide electrical power to the majority of the Workman circuits. When the igni- tion key is in either the ON or ST ART position, the main power relay is energized. The main power relay is at- tached to the relay bracket under the right [...]

Workman HD Series Page 8 − 18 Electrical System Relay (Five T erminals) Workman H D series vehicles use a number of relays that have five (5) terminals: The start enable relay on Workman HD, HDX and HDX−D vehicles ensures that the clutch pedal is de- pressed before the engine starter can be engaged. The start relay on W orkman HD, HDX and HDX?[...]

Workman HD Series Page 8 − 19 Electrical System 4. Connect multimeter (ohms setting) leads to relay ter- minals 3 0 and 87 (Fig. 2 3 ). 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. 5. Disconnect voltage from terminal [...]

Workman HD Series Page 8 − 20 Electrical System Diodes A diode is used for starting circuit protection from voltage spikes that occur when the starter solenoid is de−ener- gized. If a vehicle is equipped with the optional High Flow Hy- draulics Kit, an additional diode is used for circuit protec- tion from voltage spikes that occur when the Kit[...]

Workman HD Series Page 8 − 21 Electrical System Fuel Run/Stop Solenoid (Workman HDX−D) The fuel run/stop solenoid used on the Workman HDX− D (Kubota Diesel engine) must be energized for the die- sel engine to run. The solenoid is mounted to the injection pump on the engine (Fig. 28). The fuel run/stop solenoid includes two coils for opera- ti[...]

Workman HD Series Page 8 − 22 Electrical System Fuel Gauge Sender (Workman HD & HDX−D) The fuel gauge sender is located in the fuel tank (Fig. 30). The fuel gauge sender on W orkman HDX vehicles (Kubota EFI gasoline engine) is included with the fuel pump and fuel filter assembly that fits into the fuel tank. Use the following procedure to t[...]

Workman HD Series Page 8 − 23 Electrical System Fuel Pump/Sender (Workman HDX) The electric fuel pump/sender used on Workman HDX vehicles (Kubota EFI gasoline engine) is a combination positive displacement pump that provides pressurized fuel to the engine fuel rail in a return−less system, and a fuel level sending unit. The fuel pump assembly i[...]

Workman HD Series Page 8 − 24 Electrical System Fuel Pump (Workman HDX−D) The fuel pump is attached to the left frame rail near the engine. Operational T est 1. Park machine on a level surface, lower cutting decks, stop engine, and engage parking brake. Unlatch and raise hood. 2. Disconnect electrical connector from the fuel stop/ run solenoid [...]

Workman HD Series Page 8 − 25 Electrical System T emperature Sender (Workman HDX and HDX−D) Liquid cooled vehicles have a temperature sender threaded into the water pump housing on the engine (Fig. 35). The resistance of the temperature sender re- duces as the engine coolant temperature increases. This re s i s t a nc e c hange is used by the i[...]

Workman HD Series Page 8 − 26 Electrical System Electric Fan Thermal Switch (Workman HDX−D) The thermal fan switch is threaded into the thermostat housing on the engine (Fig. 37 ). The fan switch is a nor- mally open switch that closes when the engine coolant temperature reaches 190F to 210F (88C to 99C). There is a green wire attached to the s[...]

Workman HD Series Page 8 − 27 Electrical System Speed Sensor NOTE: The speed sensor and speedometer are stand- ard equipment on the Workman HDX and HDX−D, and optional equipment on the Workman HD. The speed sensor is attached to the upper transaxle cover (Fig. 39). It uses a magnetically based, Hall Ef fect integrated circuit to provide a signa[...]

Workman HD Series Page 8 − 28 Electrical System Glow Controller (Workman HDX−D) The controller is located under the instrument panel. NOTE: Refer t o Electrical Diagrams − Chapter 1 1 in this manual when troubleshooting the glow controller . Controller Operation 1. When the ignition switch is placed in the RUN posi- tion, the controller energ[...]

Workman HD Series Page 8 − 29 Electrical System High Flow Hydraulics Kit Switch (High Flow Hydraulics Kit) On vehicles equipped with the high flow hydraulics kit, the switch to engage the high flow hydraulic circuit is mounted on the dash (Fig. 42). When the high flow hy- draulics kit switch is ON, the solenoid coil on the control manifold is ene[...]

Workman HD Series Page 8 − 30 Electrical System Hydraulic Solenoid V alve Coil (High Flow Hydraulics Kit) V ehicles equipped with the High Flow Hydraulics Kit use a hydraulic solenoid valve coil for system control (Fig. 44 ). When the solenoid coil is energized, hydraulic valve shift occurs to provide hydraulic flow for the attachment. T esting o[...]

Workman HD Series Page 8 − 31 Electrical System Rear PT O Switch (Optional Kit) On vehicles equipped with the optional rear PTO kit, the rear PTO switch is located in the rear PT O housing mounted on the top of the transaxle. The Rear PTO switch i s normally closed and opens when the PTO is e n- gaged. T esting 1. Park machine on a level surface,[...]

Workman HD Series Page 8 − 32 Electrical System Interlock Switch (1/3 Area Lift Platform Kit) A proximity switch is attached to the frame under the dash of units with a 1/3 area lift platform installed. The switch is in its closed position as long as the parking brake is released. When the parking brake is engaged, th e brake lever moves away fro[...]

Workman HD Series Page 8 − 33 Electrical System Service and Repairs NOTE: Refer to the appropriate engine Service Manual for engine electrical component repair information. Battery Storage If the machine will be stored for more than 30 days: 1. Remove the battery from the machine and charge it fully (see Battery Service). 2. Either store battery [...]

Workman HD Series Page 8 − 34 Electrical System Battery Service Th e battery is the heart of the electrical system. With reg- ular and proper service, battery life can be extended. Ad- ditionally , battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid splashing or spilling e[...]

Workman HD Series Page 8 − 35 Electrical System Battery T esting 1. If battery filler caps are removable, conduct a hydrometer test of the battery electrolyte. IMPORT ANT : Make sure the area around the cells is clean before opening the battery caps. A. Measure the specific gravity of each cell with a hydrometer . Draw electrolyte in and out of t[...]

Workman HD Series Page 8 − 36 Electrical System Battery Charging T o minimize possible damage to the battery and to allow th e battery to be fully charged, the slow charging method is presented here. This charging method can be accom- plished with a constant current battery charger which is available in most shops. CAUTION Follow the battery char[...]

Workman HD Series Page 8 − 37 Electrical System Headlights CAUTION Th e W orkman headlights use a halogen bulb that becomes extremely hot when in operation. Han- dling a hot headlight bulb can cause severe burns and personal injury . Allow enough time f o r bulb to cool before handling. CAUTION Any surface contamination can damage the headlight b[...]

Workman HD Series Page 8 − 38 Electrical System T ail Lamps Disassemble and assemble tail lamp as necessary Fig. 51). 1. Screw (2) 2. Lens 3. Bulb 4. Base Figure 51 1 2 4 3[...]

Workman HD Series Page 9 − 1 Hydraulic System Chapter 9 Hydraulic System T able of Contents SPECIFICA TIONS 3 ............................. GENERAL INFORMA TION 4 ...................... Operator ’s Manual 4 ........................... Hydraulic Hoses 4 ............................. Hydraulic Hose and T ube Installation 5 ........... Hydraulic F[...]

Workman HD Series Page 9 − 2 Hydraulic System This page is intentionally left blank.[...]

Workman HD Series Page 9 − 3 Hydraulic System Specifications NOTE: V ehicles that are equipped with the High Flow Hydraulics Kit have two (2) independent hydraulic sys- tems. Each of these hydraulic systems include a hydrau- lic gear pump, reservoir , oil filter and controls. Maintenance, troubleshooting and repair of each hy- draulic system need[...]

Workman HD Series Page 9 − 4 Hydraulic System General Information Operator ’s Manual The Operator ’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Opera- tor ’s Manual for additional information when servicing the vehicle. Hydraulic Hoses Hydraulic h[...]

Workman HD Series Page 9 − 5 Hydraulic System Hydraulic Hose and T ube Installation (O−Ring Face Seal Fitting) 1. Make sure threads and sealing surfaces of the hose/ tube and the fitting are free of burrs, nicks, scratches or any foreign material. 2. A s a preventative measure against leakage, it is rec- ommended that the face seal O−ring be [...]

Workman HD Series Page 9 − 6 Hydraulic System Hydraulic Fitting Installation (SAE Straight Thread O−Ring Fitting into Component Port) Non−Adjustable Fitting (Fig. 4) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. A s a preventative measure against lea[...]

Workman HD Series Page 9 − 7 Hydraulic System Adjustable Fitting (Fig. 6) 1. Make sure all threads and sealing surfaces of fitting and component port are free of burrs, nicks, scratches or any foreign material. 2. A s a preventative measure against leakage, it is rec- ommended that the O−ring be replaced any time the connection is opened. 3. Li[...]

Workman HD Series Page 9 − 8 Hydraulic System Special T ools Order these special tools from your T oro Distributor . Hydraulic Pressure T est Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided fo[...]

Workman HD Series Page 9 − 9 Hydraulic System Hydraulic T est Fitting Kit This kit includes a variety of O−ring Face Seal fittings to enable you to connect test gauges into the system. Th e kit includes: tee’s, unions, reducers, plugs, caps and male test fittings. T oro Part Number: TOR4079 Figure 10 TORO TEST FITTING KIT O−ring Kit Th e ki[...]

Workman HD Series Page 9 − 10 Hydraulic System Hydraulic Schematics Primary Hydraulic System Schematic STEERING CONTROL VA LV E STEERING CYLINDER LIFT CYLINDERS 1800 to 1900 PSI[...]

Workman HD Series Page 9 − 1 1 Hydraulic System High Flow Hydraulic System Schematic HYDRAULIC MANIFOLD Hydraulic System[...]

Workman HD Series Page 9 − 12 Hydraulic System Hydraulic Circuit Operation Steering Circuit The hydraulic gear pump supplies flow for the steering circuit and for raising and lowering the bed. Pump output flows to the steering control valve before reaching the lift valve so the steering circuit has priority . Circuit pressure is limited by a reli[...]

Workman HD Series Page 9 − 13 Hydraulic System 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 limite[...]

Workman HD Series Page 9 − 14 Hydraulic System High Flow Hydraulic Circuit On Workman HDX and HDX−D vehicles that are equipped with the high flow hydraulics kit, a second gear pump is directly coupled to the standard gear pump. This second gear pump provides hydraulic system flow for the high flow circuit that is designed to power hydraulic att[...]

Workman HD Series Page 9 − 15 Hydraulic System T roubleshooting Th e cause of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equip- ment and a thorough understanding of the complete hy- draulic system. A hydraulic system with an excessive increase in heat or noise is a potential failure. Should either [...]

Workman HD Series Page 9 − 16 Hydraulic System Problem Possible Cause Bed does not lift or lifts very slowly . Excessive load in bed. Oil level in transaxle is low . Engine RPM is low . Incorrect oil in system (see oil recommendations in Operator ’s Manual). Lift cylinder pivots or bed pivots are binding or damaged. Hydraulic pump drive belt is[...]

Workman HD Series Page 9 − 17 Hydraulic System Problem Possible Cause Difficulty in connecting or discon- necting quick couplers. Hydraulic pressure is not relieved (coupler under pressure − engine running). Hydraulic lift valve is not in neutral (centered) position. Hydraulic attachment does not func- tion. Quick couplers are not fully engaged[...]

Workman HD Series Page 9 − 18 Hydraulic System T esting 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 T ools section in this Chapter). CAUTION Failure to use gauge with recommended [...]

Workman HD Series Page 9 − 19 Hydraulic System 7. T o minimize the possibility of damaging components when using tester with pressure and flow capabilities, completely open load valve in hydraulic tester before starting engine. 8. Install fittings finger tight, far enough to insure that they are not cross−threaded, before tightening the fit- ti[...]

Workman HD Series Page 9 − 20 Hydraulic System Primary Hydraulic System Gear Pump Flow T est (Workman HDX and HDX−D) TESTER STEERING CONTROL VA LV E LIFT CYLINDERS 1800 to 1900 PSI Figure 16 NOTE: This test procedure is for the primary hydraulic system gear pump used on W orkman HDX and HDX−D vehicles. If vehicle is equipped with the High Flo[...]

Workman HD Series Page 9 − 21 Hydraulic System Procedure for Primary Hydraulic System Gear Pump Flow (Workman HDX and HDX−D) The primary hydraulic system gear pump is designed to satisfy both steering cylinder and lift cylinder needs sim- ultaneously (at full speed throttle). If unit steering is slug- gish or otherwise performs poorly , see Ste[...]

Workman HD Series Page 9 − 22 Hydraulic System 9. T h e under load test flow reading (step 7 . B) should n o t drop more than 15% when compared to the no load test flow reading (step 6.A). A difference in flow of more than 15%, or the inability to achieve specified pressure may indicate: A. A restriction in the pump intake line B. The primary hyd[...]

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Workman HD Series Page 9 − 24 Hydraulic System Primary Hydraulic System Gear Pump Flow T est (W orkman HD) TESTER STEERING CONTROL VA LV E LIFT CYLINDERS 1800 to 1900 PSI Figure 18 NOTE: This test procedure is for the belt driven primary hydraulic system gear pump used on Workman HD ve- hicles. 1. Gear pump 2. Pressure hose 3. Suction hose Figure[...]

Workman HD Series Page 9 − 25 Hydraulic System Procedure for Primary Hydraulic System Gear Pump Flow T est (Workman HD) The primary hydraulic system gear pump is designed to satisfy both steering cylinder and lift cylinder needs sim- ultaneously (at full speed throttle). If unit steering is slug- gish or otherwise performs poorly , see Steering C[...]

Workman HD Series Page 9 − 26 Hydraulic System 10 . T h e under load test flow reading (step 7 . B) should n o t drop more than 15% when compared to the no load test flow reading (step 6.A). A difference in flow of more than 15%, or the inability to achieve specified pressure may indicate: A. A restriction in the pump intake line B. A slipping pu[...]

Workman HD Series Page 9 − 27 Hydraulic System This page is intentionally blank. Hydraulic System[...]

Workman HD Series Page 9 − 28 Hydraulic System Primary Hydraulic System Relief V alve Pressure T est STEERING CONTROL VA LV E LIFT CYLINDERS 1800 to 1900 PSI TEST GAUGE Figure 20 1. Gear pump 2. Pressure hose 3. Suction hose Figure 21 1 2 3 FRONT WORKMAN HDX and HDX−D PRIMAR Y HYDRAULIC SYSTEM GEAR PUMP 1. Gear pump 2. Pressure hose 3. Suction [...]

Workman HD Series Page 9 − 29 Hydraulic System Primary Hydraulic System Relief V alve Pressure T est: The relief valve for the steering and lift circuits is integ- rated into the steering control valve. If both steering and lift operations perform poorly , perform the relief valve pressure test and primary hydraulic system gear pump flow test (se[...]

Workman HD Series Page 9 − 30 Hydraulic System Steering Control V alve and Steering Cylinder T est PLUG STEERING CYLINDER (ROT A TED FOR RIGHT TURN) STEERING CONTROL VA LV E LIFT CYLINDERS 1800 to 1900 PSI Figure 23[...]

Workman HD Series Page 9 − 31 Hydraulic System Procedure for Steering Control V alve and Steering Cylinder T est This steering test procedure will be af fected 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 [...]

Workman HD Series Page 9 − 32 Hydraulic System Lift Cylinder Internal Leakage T est STEERING CYLINDER PLUG (IN LOWER POSITION) LIFT CYLINDERS STEERING CONTROL VA LV E 1800 to 1900 PSI Figure 24[...]

Workman HD Series Page 9 − 33 Hydraulic System Procedure for Lift Cylinder Internal Leakage T est 1. Shut off engine and engage parking brake. CAUTION Prevent personal injury and/or damage to equip- ment. Read all W ARNINGS, CAUTIONS and Pre- cautions for Hydraulic T esting at the beginning of this section. 2. Remove all pressure from cylinder by[...]

Workman HD Series Page 9 − 34 Hydraulic System High Flow Hydraulic System Gear Pump Flow and Relief Pressure T ests TESTER HYDRAULIC MANIFOLD (SOLENOID ENERGIZED) Figure 26 NOTE: This test procedure is for the high flow hydraulic system gear pump and high flow hydraulic system relief valve on Workman HDX and HDX−D vehicles that are equipped wit[...]

Workman HD Series Page 9 − 35 Hydraulic System Procedure for High Flow Hydraulics System Gear Pump Flow and Relief Pressure T ests If both steering and lift operations perform poorly , per- form the primary hydraulic system gear pump flow test and relief valve pressure test. This test compares fluid flow a t No Load with fluid flow Under Load. A [...]

Workman HD Series Page 9 − 36 Hydraulic System D. System pressure should be approximately 2000 PSI (138 bar) as the relief valve lifts. E. Open tester flow control valve, release accelera- tor pedal to allow engine to return to low idle, turn High Flow Kit switch OFF and stop engine. Record test results. 1 1 . I f relief pressure is incorrect, in[...]

Workman HD Series Page 9 − 37 Hydraulic System Service and Repairs General Precautions for Removing and Installing Hydraulic System Components Before Repair or Replacement of Components 1. Before removing any parts from the hydraulic sys- tem, park vehicle on a level surface, engage parking brake and stop engine. Remove key from the ignition swit[...]

Workman HD Series Page 9 − 38 Hydraulic System Primary Hydraulic System Gear Pump (Workman HDX and HDX−D) Figure 28 FRONT RIGHT 1. Gear pump 2. O−ring 3. Hydraulic fitting 4. Hose clamp 5. Suction hose (from transaxle) 6. O−ring 7. Hose (to lift valve) 8. O−ring 9. Hydraulic fitting 10. Flange nut (4) 1 1. Square key 12. Pump/engine mount[...]

Workman HD Series Page 9 − 39 Hydraulic System Removal (Fig. 28) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage parking brake. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this section. CAUTIO[...]

Workman HD Series Page 9 − 40 Hydraulic System Primary Hydraulic System Gear Pump (Workman HD) Removal (Fig. 29) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Loosen pump drive belt and remove belt from pump pulley . 3. Read the Gener[...]

Workman HD Series Page 9 − 41 Hydraulic System This page is intentionally blank. Hydraulic System[...]

Workman HD Series Page 9 − 42 Hydraulic System Primary Hydraulic System Gear Pump Service 1. Retaining ring 2. Shaft seal 3. Front cover 4. Dowel pin 5. O−ring (2) 6. Back−up seal 7. Pressure seal 8. Front thrust plate 9. Drive shaft 10. Idler shaft 1 1. Body 12. Rear thrust plate 13. Pressure seal 14. Back−up seal 15. Rear flange 16. Lock [...]

Workman HD Series Page 9 − 43 Hydraulic System NOTE: The Workman HDX and HDX−D gear pump in- cludes a rear flange that will allow the installation of a second pump section for the High Flow Hydraulics Kit. The W orkman HD gear pump does not have this type of rear flange. Disassembly (Fig. 31) 1. Plug pump ports and clean the outside of the pump[...]

Workman HD Series Page 9 − 44 Hydraulic System Assembly (Fig. 31) NOTE: When assembling the pump, check the marker line on each part to make sure the pump components are properly aligned during assembly (Fig. 32). 1. Lubricate O−rings, pressure seals, back−up seals an d thrust plate grooves with a thin coat of petroleum jel- ly . Lubricate al[...]

Workman HD Series Page 9 − 45 Hydraulic System This page is intentionally blank. Hydraulic System[...]

Workman HD Series Page 9 − 46 Hydraulic System High Flow Hydraulic System Gear Pump Service 1. Retaining ring 2. Shaft seal 3. Front cover 4. Dowel pin (6) 5. O−ring (4) 6. Back−up seal 7. Pressure seal 8. Thrust plate 9. Drive shaft 10. Idler shaft 1 1. Front pump section body 12. Thrust plate 13. Pressure seal 14. Back−up seal 15. Rear fl[...]

Workman HD Series Page 9 − 47 Hydraulic System Th e two section gear pump assembly used on W orkman HDX and HDX−D vehicle equipped with the High Flow Hydraulics Kit is shown (Fig. 34). The first section of the pump (drive end) is identical in form and function to the Primary Hydraulic System Gear Pump. When servicing this gear pump, follow the [...]

Workman HD Series Page 9 − 48 Hydraulic System Lift V alve 1. Lift valve 2. O−ring 3. T ee fitting 4. Hyd. tube (steering circuit return) 5. O−ring 6. Hyd. tube (return to hydraulic filter) 7. Flange nut (2) 8. Lift lever 9. Clevis pin 10. Hairpin 1 1. Retainer pin 12. Link 13. 90 hydraulic fitting 14. Hyd. tube (to male quick fitting) 15. Hy[...]

Workman HD Series Page 9 − 49 Hydraulic System Removal (Fig. 36) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Remove seat base from vehicle (see Seat Base Re- moval in Chapter 7 − Chassis in this manual). 3. Read the General Precau[...]

Workman HD Series Page 9 − 50 Hydraulic System Lift V alve Service Disassembly (Fig. 38) 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 should be facing up. 3. Remove two (2) hex cap plugs [...]

Workman HD Series Page 9 − 51 Hydraulic System This page is intentionally blank. Hydraulic System[...]

Workman HD Series Page 9 − 52 Hydraulic System Steering Control V alve 1. Lock nut 2. Flat washer 3. Steering wheel 4. Steering control valve 5. Hyd hose (to control valve E port) 6. Hyd hose (to control valve T port) 7. Hyd hose (to control valve P port) 8. Hyd hose (to control valve L port) 9. Hyd hose (to control valve R port) 10. Cap screw (4[...]

Workman HD Series Page 9 − 53 Hydraulic System CAUTION Before performing any service or repair on hy- draulic system components, relieve system pressure to avoid injury from pressurized hy- draulic oil. Stop the engine, remove key from the ignition switch, rotate the steering wheel in both directions, lower or support the bed and operate other hy[...]

Workman HD Series Page 9 − 54 Hydraulic System Steering Control V alve Service 1. Sleeve 2. Cross pin 3. Ring 4. Spool 5. Bearing assembly 6. Shaft seal 7. Ball stop 8. Ball 9. Dust seal ring 10. Housing 1 1. Cardan shaft 12. Spacer 13. O−ring 14. Distribution plate 15. Inner gearwheel 16. Outer gearwheel 17. End cover 18. O−ring (5) 19. Scre[...]

Workman HD Series Page 9 − 55 Hydraulic System This page is intentionally blank. Hydraulic System[...]

Workman HD Series Page 9 − 56 Hydraulic System Steering Cylinder 18 19 15 17 16 20 13 12 14 11 10 3 6 8 9 5 1 4 2 7 12 2 1 3 12 14 14 11 21 28 29 31 24 27 22 23 23 30 26 25 35 to 40 ft−lb (48 to 55 N−m) 35 to 40 ft−lb (48 to 55 N−m) 170 to 180 ft−lb (231 to 244 N−m) 80 to 90 ft−lb (109 to 122 N−m) 80 to 90 ft−lb (109 to 122 N−[...]

Workman HD Series Page 9 − 57 Hydraulic System Removal (Fig. 43) 1. Park vehicle on a level surface, shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Components at the begin- ning of this chapter section. CAUTION Before performing any se[...]

Workman HD Series Page 9 − 58 Hydraulic System Steering Cylinder Service 1. Rear shaft 2. Wear ring 3. Seal 4. O−ring 5. Piston 6. Rear head 7. O−ring 8. Back−up ring 9. Retaining ring 10. Seal 1 1. Dust seal 12. Barrel 13. Front shaft 14. Roll pin 15. Front head Figure 45 12 71 5 8 2 14 11 91 0 5 4 3 1 13 3 4 68 9 11 Disassembly (Fig. 45) [...]

Workman HD Series Page 9 − 59 Hydraulic System Inspection 1. W ash all cylinder parts in clean solvent. Dry parts with compressed air . Do not wipe parts dry with paper towels or cloth. Lint in the hydraulic system will cause da- mage. 2. Carefully inspect internal surface of barrel for dam- age (deep scratches, out−of−round, etc.). 3. Inspec[...]

Workman HD Series Page 9 − 60 Hydraulic System Lift Cylinder 1. Bed frame 2. O−ring 3. 90 o hydraulic fitting 4. O−ring 5. Hydraulic hose 6. Lift cylinder (LH shown) 7. Hydraulic hose 8. Cotter pin 9. Engine support 10. Frame rail (LH shown) 1 1. Clevis pin 12. L ynch pin Figure 46 1 2 3 4 5 6 7 8 9 2 3 4 10 11 12 FRONT RIGHT[...]

Workman HD Series Page 9 − 61 Hydraulic System Removal (Fig. 46) 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 of f and engage the parking brake. Re- move key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic Sy[...]

Workman HD Series Page 9 − 62 Hydraulic System Lift Cylinder Service 1. Lock nut 2. Wear ring 3. Seal 4. O−ring 5. Piston 6. Head 7. O−ring 8. Back−up seal 9. Retaining ring 10. Seal 1 1. W iper 12. Barrel 13. Shaft 14. O−ring Figure 47 1 2 3 4 5 13 14 6 7 8 9 10 11 12 60 to 75 ft−lb (81 to 102 N−m) Disassembly (Fig. 47) 1. Pump oil o[...]

Workman HD Series Page 9 − 63 Hydraulic System Assembly (Fig. 47) 1. Make sure all parts are clean before assembly . 2. Coat new O−rings, piston seal, wear ring, shaft seal, back−up ring and dust seal with clean Dexron III A TF . A. Install piston seal, O−rings and wear ring to the piston. B. Install O−ring, back−up seal, seal and wiper[...]

Workman HD Series Page 9 − 64 Hydraulic System Hydraulic Manifold (High Flow Hydraulics Kit) Removal (Fig. 48) 1. Park vehicle on a level surface, raise and support bed (if installed), shut engine off and engage the parking brake. Remove key from the ignition switch. 2. Read the General Precautions for Removing and Installing Hydraulic System Com[...]

Workman HD Series Page 9 − 65 Hydraulic System 5. Visually inspect cartridge valve for damaged sealing surfaces and contamination. A. Contamination may cause valves to stick or hang up . Contamination can become lodged in small valve orifices or seal areas causing malfunction. B. If valve sealing surfaces appear pitted or dam- aged, the hydraulic[...]

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Workman HDX/HDX−D Page 10 − 1 Front Wheel Drive (4WD) Chapter 10 Front Wheel Drive (4WD) T able of Contents SPECIFICA TIONS 2 ............................ GENERAL INFORMA TION 3 ..................... Operator ’s Manual 3 .......................... SER VICE and REP AIRS 4 ....................... Constant V elocity (CV) Axle Assembly 4 ........[...]

Workman HDX/HDX−D Page 10 − 2 Front Wheel Drive (4WD) Specifications Item Description Differential Oil Capacity 8.5 fl oz (250 ml) Differential Oil T ype Mobil 424 Hydraulic Oil[...]

Workman HDX/HDX−D Page 10 − 3 Front Wheel Drive (4WD) General Information The “Automatic on Demand” four wheel drive feature o n 4WD Workman vehicles does not require operator ac- tivation. The front differential on 4WD W orkman ve- hicles is an electro−mechanically activated bi−directional overrunning clutch system. The front dif- fere[...]

Workman HDX/HDX−D Page 10 − 4 Front Wheel Drive (4WD) Service and Repairs Constant V elocity (CV) Axle Assembly 1. Spindle nut 2. CV axle assembly 3. Differential assembly 4. Flange head screw (4) 5. Driveshaft 6. Cap screw 7. Flat washer 8. Wheel hub assembly 9. Tie rod assembly 10. Axle spacer 1 1. Flange head screw 12. Brake caliper (LH show[...]

Workman HDX/HDX−D Page 10 − 5 Front Wheel Drive (4WD) 4. Using wheel hub hole to access flange head screws, remove screws that secure wheel hub to knuckle. Slide wheel hub assembly from CV axle. 5. Remove axle spacer from CV axle. IMPORT ANT : Make sure to not damage the oil seal on the differential with the pry bars when removing the CV axle. [...]

Workman HDX/HDX−D Page 10 − 6 Front Wheel Drive (4WD) Inspect CV Axle Boot and T est CV Axle Inspect CV Axle Boot A torn CV axle boot is the most common cause of CV axle failures. NOTE: A worn and noisy CV axle joint with the boot in good condition and filled with grease is not uncommon. Potholes, curb contact or collision damage can damage bea[...]

Workman HDX/HDX−D Page 10 − 7 Front Wheel Drive (4WD) This page is intentionally blank. Front Wheel Drive (4WD)[...]

Workman HDX/HDX−D Page 10 − 8 Front Wheel Drive (4WD) Differential Driveshaft 1. T ransaxle 2. Cap screw 3. Flat washer 4. Driveshaft 5. Differential assembly 6. CV axle assembly 7. Flange head screw (4) Figure 4 FRONT RIGHT 1 2 3 4 5 ANTISEIZE LUBRICANT ANTISEIZE LUBRICANT 2 3 6 6 7 20 to 26 ft−lb (27 to 35 N−m)[...]

Workman HDX/HDX−D Page 10 − 9 Front Wheel Drive (4WD) Removal (Fig. 4) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Remove cap screw and flat washer that secure the driveshaft yokes to dif ferential input shaft and transaxle output shaft. W ARNING Support driveshaft to preven[...]

Workman HDX/HDX−D Page 10 − 10 Front Wheel Drive (4WD) Driveshaft Cross and Bearing Service 1. Y oke 2. Cross and bearing kit 3. Y oke and shaft 4. Y oke and tube 5. Snap ring Figure 7 2 3 1 4 1 2 5 5 5 5 Disassembly (Fig. 7) 1. Remove driveshaft from vehicle (see Dif ferential Dri- veshaft Removal in this section). IMPORT ANT : When placing yo[...]

Workman HDX/HDX−D Page 10 − 1 1 Front Wheel Drive (4WD) This page is intentionally blank. Front Wheel Drive (4WD)[...]

Workman HDX/HDX−D Page 10 − 12 Front Wheel Drive (4WD) Front Differential 1. Spindle nut 2. CV axle assembly 3. Differential assembly 4. Flange head screw (4) 5. Driveshaft 6. Cap screw 7. Flat washer 8. Wheel hub assembly 9. Tie rod assembly 10. Axle spacer 1 1. Flange head screw 12. Brake caliper (LH shown) 13. Brake rotor 14. Slotted hex nut[...]

Workman HDX/HDX−D Page 10 − 13 Front Wheel Drive (4WD) Removal (Fig. 8) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. Block rear wheels to prevent the vehicle from moving unexpectedly . 2. Drain differential oil into a suitable container by re- moving the drain plug. Install drai[...]

Workman HDX/HDX−D Page 10 − 14 Front Wheel Drive (4WD) Front Differential Service 1. O−ring 2. Set screw 3. O−ring 4. O−ring 5. Bearing (2) 6. Armature plate 7. Bearing 8. Bushing 9. Roller cage assembly 10. V ent 1 1. Plug clip 12. Coil 13. T orsion spring 14. Cover plate 15. End ring (2) 16. Flange head screw (9) 17. Bearing 18. Gear ca[...]

Workman HDX/HDX−D Page 10 − 15 Front Wheel Drive (4WD) Front Differential Disassembly 1. Make sure that the oil is drained from the dif ferential assembly . 2. Remove the four (4) flange head screws from the in- put cover . Remove the cover . 1. Input cover 2. Pinion shaft Figure 1 1 2 1 3. Remove the pinion shaft from housing by pulling it out[...]

Workman HDX/HDX−D Page 10 − 16 Front Wheel Drive (4WD) 5. Place the differential assembly on workbench with the cover plate facing up. 6. Remove the five (5) flange head screws that secure cover plate to gear case. Note location of plug clip for a s - sembly purposes. Carefully remove the cover plate from the gear case by lifting straight up. 1[...]

Workman HDX/HDX−D Page 10 − 17 Front Wheel Drive (4WD) 9. Carefully lift the ring gear out of the gear case. In- spect ring gear teeth for any damage or abnormal wear . 1. Ring gear 2. Gear case Figure 17 2 1 10. Remove the gear spacer from between the gear case and the ring gear . 1. Gear spacer 2. Gear case Figure 18 2 1 Front Wheel Drive (4W[...]

Workman HDX/HDX−D Page 10 − 18 Front Wheel Drive (4WD) IMPORT ANT : When removing female output hub from gear case, be careful to not damage the seal in the gear case. The seal cannot be serviced sepa- rately . 1 1 . T urn the gear case over . Using a hammer and a suit- able drift, carefully remove the female output hub and bearing by driving i[...]

Workman HDX/HDX−D Page 10 − 19 Front Wheel Drive (4WD) 14. Remove the gear spacer from the cover plate. 1. Male output hub 2. Gear spacer Figure 21 2 1 15. Remove the armature plate from the cover plate. IMPORT ANT : When removing male output hub from cover plate, be careful to not damage the seal in the cover plate. The seal cannot be serviced[...]

Workman HDX/HDX−D Page 10 − 20 Front Wheel Drive (4WD) Front Differential Assembly 1. Be sure that all parts are clean and free of any dirt or debris. Make sure that all residual oil has been removed from differential components. 2. Check the condition of the square sectioned O−ring located on the cover plate. Make sure that it is clean and f[...]

Workman HDX/HDX−D Page 10 − 21 Front Wheel Drive (4WD) IMPORT ANT : When installing female output hub as- sembly into gear case, be careful to not damage the seal in the gear case. The seal cannot be serviced separately . 6. Press the new female output hub/bearing assembly into the gear case from the inside. The bearing has a slight interferenc[...]

Workman HDX/HDX−D Page 10 − 22 Front Wheel Drive (4WD) 9. Align torsion spring on roller cage with the slot in the ring gear and then carefully lower the cage assembly into the ring gear bore. The torsion spring must align and fit into the notch cut into the ring gear . 10. Install remaining nine (9) rollers into the top row of the roller cage [...]

Workman HDX/HDX−D Page 10 − 23 Front Wheel Drive (4WD) 14. Install the pinion shaft and then the input cover . Se- cure cover with four (4) flange head screws. T orque screws from 14 to 17 ft−lbs (19 to 27 N−m) . 1. Input cover 2. Pinion shaft Figure 30 2 1 15. Remove the oil fill plug and fill the unit with 8.45 oz. (250 ml.) of Mobil 424 [...]

Workman HDX/HDX−D Page 10 − 24 Front Wheel Drive (4WD) This page is intentionally blank.[...]

Wor km an H D Se ri es Electrical Drawi ngs Page 1 1 - 1 Chapter 1 1 Electrical Drawings T able of Contents ELECTRICAL DRA WING DESIGNA TIONS 2 ....... ELECTRICAL SCHEMA TICS Wor km an H D 3 ................................ Workman HDX 4 .............................. Workman HDX - D 5 ... ......................... WIRE HARNESS DRA WINGS Front Wire[...]

Wor km an H D Se r ie s Electrical Drawings Page 1 1 - 2 Electrical Drawing Designations The following a bbreviations are u sed for wir e harness colors on the electrical schematics and wire harn ess drawings in this chapter . ABBREVIA TION COLOR BK BLACK BR or BN BROWN BU BLUE GN GREEN GY GRA Y OR ORANGE PK PINK Ro rR D R E D TT A N VIO VIOL ET Wo[...]

Page 1 1 − 3 V ehicle Electrical Schemat ic Kohler Gasoline Engin e All relays and solenoids are shown as de−energized. W orkman H D HAZARD FLASHER SIGNAL FLASHER TURN MPH/KPH SHUNT (OPTIONAL KIT) (OPTIONAL KIT) (OPTIONAL KIT) (IF EQUIPPED) (IF EQUIPPED) 3rd − HIGH LOCKOUT SWITCH (SLOW) LIFT LEVER INTERLOCK SWITCH (OPTIONAL KIT) (OPTIONAL KIT[...]

Page 1 1 − 4 V ehicle Electrical Schemat ic Kubota EFI Gasoline Engin e All relays and solenoids are shown as de−energized. W orkman HD X 3RD − HIGH LOCKOUT (OFF)[...]

Page 1 1 − 5 V ehicle Electrical Schemati c All relays and solenoids are shown as de−energized. W orkman HDX− D Kubota Diesel Engin e FUEL PUMP? Y T 1 2 1 2 T BK T PK T (+) (−) T GN Y R R Y BK VIO W/B K BK W/B K GY GN BN R T GY R BK R PK W BK BK GY BK GN Y Y BK BK BN OR W/B K BU GN T OR BU Y GY Y BK BN GN R R GN T DIODE BK FAN BU PK GY Y PK[...]

Page 1 1 − 6 Front Wire Harness Drawin g W orkman HD Kohler Gasoline Engin e 3RD−HIGH LOCKOUT SWITCH 3RD−HIGH LOCKOUT SWITCH[...]

Page 1 1 − 7 Front Wire Harness Diagra m W orkman H D Kohler Gasoline Engin e 3RD−HIGH LOCKOUT SWITCH RED RED ORANGE PINK RED/BLACK YELLOW TA N RED GREEN BLUE YELLOW GRA Y BLACK BLACK PINK GREEN WHITE/BLACK YELLOW ORANGE RED GREEN BLACK TA N GREEN BROWN GREEN ORANGE VIOLET BLUE PINK BLACK BLACK BROWN WHITE/BLACK BLACK GREEN WHITE/BLACK RED GREE[...]

Page 1 1 − 8 Rear Wire Harness Drawin g Kohler Gasoline Engin e W orkman H D LIFT LEVER INTERLOCK SWITCH[...]

Page 1 1 − 9 Rear Wire Harness Diagra m Kohler Gasoline Engin e W orkman H D BLUE RED BROWN ORANGE WHITE ORANGE TA N YELLOW PINK BLACK GRA Y GRA Y GRA Y PINK YELLOW WHITE GREEN ORANGE BLUE ORANGE WHITE/BLACK ORANGE BLACK RED BLACK BLACK RED/BLACK GRA Y WHITE/BLACK ORANGE GREEN RED BLACK BLACK BLACK BLACK ORANGE WHITE/BLACK BLACK BLACK ORANGE BLAC[...]

Page 1 1 − 10 Front Wire Harness Drawin g W orkman HD X Kubota EFI Gasoline Engin e[...]

Page 1 1 − 1 1 Front Wire Harness Diagra m W orkman HD X Kubota EFI Gasoline Engin e 3RD−HIGH LOCKOUT SWITCH BLACK GREEN GREEN BLUE RED ORANGE YELLOW PINK GRA Y BROWN RED/BLACK BLACK PINK BLACK BLACK GRA Y YELLOW ORANGE TA N ORANGE GREEN RED RED PINK RED/BLACK YELLOW BLACK BLACK TA N TA N GREEN WHITE/BLACK ORANGE GRA Y TA N YELLOW GREEN VIOLET [...]

Page 1 1 − 12 Rear Wire Harness Drawin g Kubota EFI Gasoline Engin e W orkman HD X[...]

Page 1 1 − 13 Rear Wire Harness Diagra m Kubota EFI Gasoline Engin e W orkman HD X PINK GRA Y GRA Y GRA Y GRA Y PINK BLACK RED BLACK RED BLUE BLUE BLACK BLUE BLACK BLUE BLACK BLACK PINK BLACK BLACK WHITE WHITE ORANGE PINK GRA Y RED RED YELLOW GREEN GRA Y TA N VIOLET BLUE YELLOW TA N BLUE GREEN BROWN VIOLET GRA Y BROWN PINK YELLOW ORANGE BLUE GREE[...]

Page 1 1 − 14 Front Wire Harness Drawin g W orkman HDX−D Kubota Diesel Engin e 3RD−HIGH LOCKOUT SWITCH 3RD−HIGH LOCKOUT SWITCH[...]

Page 1 1 − 15 Front Wire Harness Diagra m W orkman HDX− D Kubota Diesel Engin e 3RD−HIGH LOCKOUT SWITCH RED RED ORANGE PINK RED/BLACK YELLOW TA N RED GREEN BLUE YELLOW GRA Y BLACK BLACK PINK GREEN WHITE/BLACK YELLOW ORANGE RED GREEN BLACK TA N GREEN BROWN GREEN ORANGE VIOLET BLUE PINK BLACK BLACK BROWN WHITE/BLACK BLACK GREEN WHITE/BLACK RED [...]

Page 1 1 − 16 Rear Wire Harness Drawin g Kubota Diesel Engin e W orkman HDX− D[...]

Page 1 1 − 17 Rear Wire Harness Diagra m Kubota Diesel Engin e W orkman HDX− D VIOLET BLUE PINK ORANGE BLACK GRA Y PINK VIOLET BLACK WHITE PINK ORANGE ORANGE BLACK BLACK RED/BLACK ORANGE RED/BLACK BLUE RED/BLACK ORANGE BLUE BLUE YELLOW BLACK BLACK RED BLUE RED BLACK BLACK YELLOW GRA Y PINK GRA Y GRA Y GRA Y PINK ORANGE WHITE BLUE TA N VIOLET GR[...]

Page 1 1 − 18 Front Wire Harness Drawin g W orkman HDX−D (Industria l) Kubota Diesel Engin e[...]

Page 1 1 − 19 Front Wire Harness Diagra m W orkman HDX−D (Industria l) Kubota Diesel Engin e 3RD−HIGH LOCKOUT SWITCH ORANGE WHITE BLUE TA N VIOLET GREEN YELLOW ORANGE BLUE PINK YELLOW GRA Y RED/BLACK TA N BROWN GREEN ORANGE BLUE YELLOW BLACK RED BLACK GREEN ORANGE BLACK GREEN VIOLET VIOLET BLACK PINK ORANGE ORANGE WHITE VIOLET BLACK BLACK BLU[...]

Page 1 1 − 20 Rear Wire Harness Drawin g W orkman HDX−D (Industria l) Kubota Diesel Engin e[...]

Page 1 1 − 21 Rear Wire Harness Diagra m W orkman HDX−D (Industria l) Kubota Diesel Engin e YELLOW RED WHITE TA N VIOLET ORANGE BLUE PINK RED/BLACK YELLOW GRA Y TA N BROWN GREEN ORANGE BLUE GRA Y PINK VIOLET BLACK YELLOW BLACK RED YELLOW PINK PINK BLACK ORANGE VIOLET BLACK ORANGE RED BLACK ORANGE BLACK BLUE ORANGE BLACK BLUE BLACK YELLOW BLACK [...]

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