Page 1 For Vehicles with Liquid Cooled Engines S/N 220000001 – 239999999 Use this book along with the Toro Operator’s Manual and Parts Catalog for the specific model and serial number of the machine, and the Briggs–Daihatsu 3LC Gas or Diesel Engine Repair Preface Manual: Toro Part No.
Page 2 Workman 3000/4000 Series...
Page 3: Table Of Contents
Table Of Contents Chapter 1 – Safety Chapter 5 – Kohler Command Series Air Cooled Gas Engine Safety Instructions ......1 – 1 Specifications .
Page 4 Workman 3000/4000 Series...
Page 5 Table Of Contents Chapter 10 – Front Wheel Drive Section (4WD) Specifications ......10 – 2 General .
Page 6 Workman 3000/4000 Series...
Page 7: Safety Instructions
While Operating ......2 Safety Instructions The WORKMAN 3000 Series vehicles are designed and Not all of the attachments that adapt to the Workman ve ...
Page 8: While Operating
Never overfill attachments or exceed the vehicle maximum GVW. B. Watch for holes or other hidden hazards. Safety Workman 3000 Series Page 1 – 2...
Page 9: Maintenance And Service
27. To make sure entire machine is in good condition, Use paper or cardboard, not hands, to search for leaks. keep all nuts, bolts and screws properly tightened. Workman 3000 Series Safety Page 1 – 3 Rev. C...
Page 10: Jacking The Vehicle
Keep everyone away. ty of The Toro Company. 30. Do not over–speed engine by changing governor 33. This vehicle should not be modified without the Toro settings. Maximum engine speed is 3650 RPM. To as Company’s authorization. Direct any inquiries to: sure safety and accuracy, have an Authorized Toro Dis ...
Page 11: Using Bed Safety Support
5. Always install or remove bed support from outside of bed. 6. Do not try to lower bed with bed safety support on cyl inder. Figure 4 1. Bed support 2. Cylinder barrel 3. Bed Workman 3000 Series Safety Page 1 – 5...
Page 12 Safety Workman 3000 Series Page 1 – 6...
Page 13: Product Records
Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......1 TORQUE SPECIFICATIONS ....3 EQUIVALENTS AND CONVERSIONS .
Page 14: Equivalents And Conversions
Equivalents and Conversions Product Records and Maintenance Page 2 – 2 Workman 3000/4000 Series...
Page 15: Torque Specifications
25% for lubricated fasteners to achieve following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe ...
Page 16 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Inch Series) Grade 1, 5, & SAE Grade 1 Bolts, Screws, Studs, & SAE Grade 5 Bolts, Screws, Studs, & SAE Grade 8 Bolts, Screws, Studs, & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
Page 17 Standard Torque for Dry, Zinc Plated, and Steel Fasteners (Metric Fasteners) Class 8.8 Bolts, Screws, and Studs with Class 10.9 Bolts, Screws, and Studs with Thread Size Thread Size Reg lar Height N ts Regular Height Nuts Reg lar Height N ts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts)
Page 18 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 – 20 UNF 65 + 10 ft–lb 88 + 14 N–m Grade 5 1/4 –...
Page 19: Lubrication
Lubrication WARNING Before servicing or making adjustments to the machine, stop engine, set parking brake, and remove key from the ignition switch. Any load material must be removed from the bed or other attachment before working un der it. Always place the safety support on an extended lift cylinder to hold up the bed.
Page 20 Figure 6 Figure 4 Figure 7 Figure 5 Figure 8 IMPORTANT Heavy Duty Operation If vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently. � Desert operation � Cold climate operation (below 32_F) � Trailer or 5 wheel towing �...
Page 21 SAE 10W–30 SG, SH or SJ SAE 10W–30 SG, SH or SJ DEXTRON III ATF 93–2195 NOTE: Two wheel drive chart shown. Page 2 – 9 Rev. D Workman 3000/4000 Series Product Records and Maintenance...
Page 22 See Note Below NOTE: Four wheel drive chart shown. Use SAE 10W–30 CD, CE, CF, or CF–4 engine oil. Product Records and Maintenance Page 2 – 10 Rev. D Workman 3000/4000 Series...
Page 23: Operation And Service History Report
_________________________ _________________________ _________________________ Contacts: Parts _________________________ Phone___________________ Service _________________________ Phone___________________ Sales _________________________ Phone___________________ See your TORO Distributor for other Publications, Manuals, and Videos from the TORO company. Workman 3000/4000 Series Page 2 – 11 Rev. D Product Records and Maintenance...
Page 24 WORKMAN� 3100 and 3120 Maintenance Schedule Minimum Recommended Maintenance Intervals: Maintenance Procedure Maintenance Interval & Service Every Every Every Every 800hrs 400hrs Check Battery Fluid Level Every 200hrs 100hrs 50hrs Check Battery Cable Connections Lubricate Engine Prefilter A Level � Change Engine Oil and Filter Service Lubricate All Grease Fittings Remove Engine Shrouds and Clean Fins...
Page 25 WORKMAN� 3100 and 3120 Daily Maintenance Check List Unit Designation:_____________ Daily Maintenance: (duplicate this page for routine use) TORO ID#________–_________ Daily Maintenance Check For Week Of _________________ Maintenance TUES THURS Check Item � ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs.
Page 26 Product Records and Maintenance Page 2 – 14 Rev. D Workman 3000/4000 Series...
Page 27 _________________________ _________________________ _________________________ Contacts: Parts _________________________ Phone___________________ Service _________________________ Phone___________________ Sales _________________________ Phone___________________ See your TORO Distributor for other Publications, Manuals, and Videos from the TORO company. Workman 3000/4000 Series Page 2 – 15 Rev. D Product Records and Maintenance...
Page 28 WORKMAN� 3200, 3210, 3220, and 4200 Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Every Every Every Every 800hrs Check Battery Fluid Level Every 400hrs 200hrs 100hrs 50hrs Check Battery Cable Connections A Level Check Dust Cup and Baffle Service Lubricate All Grease Fittings Inspect Condition and Wear of Tires...
Page 29 WORKMAN� 3200, 3210, 3220, and 4200 Daily Maintenance Checklist Unit Designation:_____________ Daily Maintenance: (duplicate this page for routine use) TORO ID#________–_________ Daily Maintenance Check For Week Of _________________ Maintenance TUES THURS Check Item � ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs.
Page 30 Product Records and Maintenance Page 2 – 18 Workman 3000/4000 Series Rev. D...
Page 31 _________________________ _________________________ _________________________ Contacts: Parts _________________________ Phone___________________ Service _________________________ Phone___________________ Sales _________________________ Phone___________________ See your TORO Distributor for other Publications, Manuals, and Videos from the TORO company. Workman 3000/4000 Series Page 2 – 19 Rev. D Product Records and Maintenance...
Page 32 WORKMAN� 3300–D, 3310–D, 3320–D, and 4300–D Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Every Every Every 800hrs Every 400hrs Check Battery Fluid Level Every 200hrs 100hrs 50hrs Check Battery Cable Connections A Level Check Dust Cup and Baffle Service Lubricate All Grease Fittings Inspect Condition and Wear of Tires...
Page 33 WORKMAN� 3300–D, 3310–D, 3320–D, and 4300–D Daily Maintenance Checklist Unit Designation:_____________ Daily Maintenance: (duplicate this page for routine use) TORO ID#________–_________ Daily Maintenance Check For Week Of _________________ Maintenance TUES THURS Check Item � ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs.
Page 34 Product Records and Maintenance Page 2 – 22 Workman 3000/4000 Series Rev. D...
Page 35 _________________________ _________________________ _________________________ Contacts: Parts _________________________ Phone___________________ Service _________________________ Phone___________________ Sales _________________________ Phone___________________ See your TORO Distributor for other Publications, Manuals, and Videos from the TORO company. Page 2 – 23 Rev. D Workman 3000/4000 Series Product Records and Maintenance...
Page 36 WORKMAN� 3420–LP Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Every Every Every Every 800hrs Check Battery Fluid Level Every 400hrs 200hrs 100hrs 50hrs Check Battery Cable Connections A Level Check Dust Cup and Baffle Service Lubricate All Grease Fittings Inspect Condition and Wear of Tires �...
Page 37 WORKMAN� 3420–LP Daily Maintenance Checklist Unit Designation:_____________ Daily Maintenance: (duplicate this page for routine use) TORO ID#________–_________ Daily Maintenance Check For Week Of _________________ Maintenance TUES THURS Check Item � ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. ____Hrs. � Safety Interlock Operation �...
Page 38 Product Records and Maintenance Page 2 – 26 Rev. D Workman 3000/4000 Series...
Page 39 Chapter 3 Mitsubishi Engine (Workman S/N Below 220000001) Liquid Cooled Gas Engine Table of Contents GENERAL INFORMATION ..... 2 Magnetic Switch Hold–In Test ....43 SPECIFICATIONS .
Page 40: General Information
AA9999 done at a engine repair facility. If no parts list is available AB0001 AY9999 be sure to provide your Distributor with the TORO Model BA0001 YY9999 Number and Serial Number. The engine used in the Workman 3200 is manufactured by Mitsubishi Motors.
Page 41: Specifications
Specifications General Item Specification Make/Designation Mitsubishi 3G83–051TV, In–line slant (60�), over head camshaft Number of Cylinders Cylinder Bore 65 mm (2.559 in.) Piston Stroke 66 mm (2.598 in.) Total Displacement 657 cc (40.09 cu. in.) Compression Ratio 9.8:1 Firing Order 1 –...
Page 42: Engine
Engine Item Standard Specification Limit Compression kPa (psi) Minimum 960 (137) Compression pressure difference between cylinders kPa (psi) Maximum 100 (14) Cylinder Head Overall height mm (in.) 108.9 – 109.1 (4.287 – 4.295) 0.2 ( .008) see NOTE * Flatness of gasket surface mm (in.) Less than 0.05 (.0019) 0.2 (.008) Oversize rework...
Page 43 Engine (cont.) Item Standard Specification Limit Valves Valve length mm (in.) Intake 100.6 (3.960) Exhaust 100.8 (3.968) Stem O.D. mm (in.) Intake 6.565 – 6.580 (.2585 – .2591) Exhaust 6.530 – 6.550 (.2571 – .2579) Face angle 45� – 45.5� Thickness of valve head (margin) mm (in.) Intake 1.0 (.039)
Page 44 Engine (cont.) Item Standard Specification Limit Piston O.D. mm (in.) 64.97 – 65.00 (2.5579 – 2.5591) Clearance (piston to cylinder) mm (in.) 0.02 – 0.04 (.0008 – .0016) Ring groove width mm (in.) No. 1 1.22 – 1.24 (.0480 – .0488) No.
Page 45 Engine (cont.) Item Standard Specification Limit Crankshaft End play mm (in.) 0.05 – 0.25 (.0020 – .0098) Journal O.D. mm (in.) 39.98 – 40.00 (1.5740 – 1.5748) Pin. O.D. mm (in.) 35.98 – 36.00 (1.4165 – 1.4173) Cylindricity of journal and pin mm (in.) Less than 0.005 (.0002) Concentricity of journal and pin mm (in.) Less than 0.015 (.0006)
Page 46: Lubrication System
Lubrication System Item Standard Specification Limit Engine oil Capacity 3.2 liter (3.4 U.S. qt.) including oil filter API Service Class SJ or SJ/CF Viscosity 10� C to 40� C (14� F to 104� F) SAE 10W–30 Above 68� F (20� C) SAE 30 or 10W–30 Oil Pump Type...
Page 47: Electrical System
Electrical System Item Standard Specification Limit Alternator Nominal Output 12V – 40A Slip ring O.D. mm (in.) 14.4 (.567) 14.0 (.551) Rotor coil resistance ohms 2.8 – 3.0 Brush length mm (in.) 10.5 (.413) 4.5 (.177) Regulated voltage volts at 25� C (77� F) 14.2 –...
Page 48 Tightening Torques The Mitsubishi 3G83 engine has many bolts and caps- gine. The torque specifications in American Standard crews of special materials and sizes. It is very important and Metric as listed below MUST be followed in order to that special care be used to replace all bolts and caps- have the assembled engine conform to the original crews in their proper location during assembly of the en- specifications.
Page 49 Tightening Torques (cont.) Item (ft–lb) Cooling system Water pump pulley bolt 8 – 12 (7 – 9) Water outlet fitting bolt 10 – 13 (7 – 9) Engine coolant temperature gauge sender 10 – 12 (7 – 9) Thermo valve 20 –...
Page 50: Special Tools
Special Tools Order special tools from TORO SPECIAL TOOLS AND Some tools may be listed in the Workman 3200 Parts APPLICATIONS GUIDE (Commercial Products). Catalog. Tools may also be available from a local supplier. Filter Cleaner Filter cleaner. Mix with water and use solution to wash the Donaldson air cleaner element.
Page 51 Flywheel Stopper Stopper for locking crankshaft pulley, sprocket and fly wheel during removal. Mitsubishi Motors Part No. MD998608 Figure 4 Valve Spring Compressor Use for compression of valve spring during removal and installation. Mitsubishi Motors Part No. MD999597 Figure 5 Valve Stem Seal Installer Use for installation of valve stem seals.
Page 52 Oil Pan Gasket Cutter User for Removing oil pan to break oil pan seal. Mitsubishi Motors Part No. MD998727 Figure 7 Balancer Shaft Bearing Remover Use to pull out counterbalance shaft front and rear bearing. Mitsubishi Motors Part No. MD999593 Figure 8 Balancer Shaft Front Bearing Installer Use for press fitting counterbalance shaft front bearing.
Page 53 Balancer Shaft Rear Bearing Installer Use for press fitting counterbalance shaft rear bearing. Mitsubishi Motors Part No. MD999592 Figure 10 Crankshaft Front Oil Seal Installer Use for installing crankshaft front oil seal. Mitsubishi Motors Part No. MD999570 Figure 11 Camshaft Oil Seal Installer Use for installation of camshaft oil seal.
Page 54 Crankshaft Rear Oil Seal Installer Use for installation of crankshaft rear oil seal. Mitsubishi Motors Part No. MD998376 Figure 13 Piston Pin Setting Base Use with Push Rod and Guide Pin Set (Fig. 14) to pull out and press in piston pin. Mitsubishi Motors Part No.
Page 55: Inspection And Adjustments
Inspection and Adjustments Valve Clearance IMPORTANT: After adjusting timing belt tension, ad Tiiming belt just valve clearance. cover A 1. Warm up the engine until coolant is at 80� to 95� C (176� to 203� F). 2. Remove rocker cover. 3.
Page 56 6. If valve clearance is not at standard value, loosen rocker arm locknut and use a feeler gauge to adjust clearance while turning adjusting screw. 7. Hold screwdriver so adjusting screw will not turn and tighten locknut to specified torque. Adjusting screw torque 8 –...
Page 57: Timing Belt Tension
Timing Belt Tension 1. Remove alternator drive belt. Timing belt cover A 2. Remove timing belt cover. 3. Remove access cover. Access cover 4. Turn crankshaft clockwise (right turn) to check that timing belt is okay over it’s entire length. IMPORTANT: Turn crankshaft only in clockwise direction.
Page 58: Idle Speed
Idle Speed 1. Make sure engine is warm (coolant temperature 80 – 95�C (176 – 203�F), all lights and accessories are OFF and transmission is in NEUTRAL. 2. If vehicle is not equipped with a tachometer, connect CONNECTOR an electronic tachometer: END VIEW A.
Page 59: Co Concentration (Mixture Adjustment)
Protection Agency (EPA) and California Air Re sources Board (CARB) certified and must be adjusted by the manufacturer or your Mitsubishi/Toro Distributor. 4. On carburetors with identification mark TMB: A. If concentrations are outside the standard value, use the mixture adjusting screw (MAS) to adjust the CO concentration.
Page 60: Governor / Accelerator Pedal
Governor / Accelerator Pedal 1. Put vehicle on a level surface, stop engine and en- gage the parking brake. 0.200” (5 mm) 2. Rotate governor input lever clockwise to put a light tension load on the governor spring. Hold carburetor throttle against wide open throttle stop and adjust ball joint on throttle rod to allow ball joint socket to travel past carburetor throttle stud by 0.200+0.031 in.
Page 61 6. Release and advance accelerator to find if high idle speed is erratic (surges). If engine surges more than twice, turn surge screw clockwise until high idle speed increases 10 to 50 RPM. Release and advance acceler ator to find if engine is still surging. If engine is still surg ing, turn screw clockwise to increase high idle an additional 10 to 50 RPM.
Page 62: Carburetor Acceleration Pump
Carburetor Acceleration Pump Throttle valve Pump nozzle Pump leak jet Outlet check valve Check valve Inlet check valve Diaphragm Lever From float chamber Figure 33 1. Remove air intake hose. 3. Clean the fuel path if fuel is not injected. 2.
Page 63: Choke Valve
Full – Auto – Choke Choke adjusting screw Fast idle cam Choke pinion Choke lever Cam follower Fast idle adjusting screw Thermo–wax element Figure 35 1. Remove air intake hose. Choke valve 2. Make sure engine coolant temperature is below 10�C (50�F).
Page 64: Choke Breaker Opening
Choke Breaker Opening 1. Inspect after doing Full–Auto–Choke inspection. Choke valve 2. Run engine at idle. Move choke valve in closing direc tion with light finger force until valve resists being moved. Measure clearance between choke valve and Clearance choke bore at this point.
Page 65: Fast Idle
Fast Idle Choke adjusting screw Fast idle cam Choke pinion Choke lever Cam follower Fast idle adjusting screw Thermo–wax element Figure 39 1. Make sure engine coolant temperature is below 10�C (50�F). Fast idle adjusting screw 2. Start the engine. Make sure idle speed during the warm up period changes smoothly as coolant tempera ...
Page 66: Troubleshooting
Troubleshooting Giving Immediate attention to any indication of a prob- Never make more that one adjustment at a time, then lo lem can prevent major failures, and increase the life of cate the trouble by a process of elimination. Remember the engine.
Page 67 Symptom Possible Causes Engine will not start or starts too hard (cranks OK). Ignition system problems. Compression too low. No fuel supply to carburetor. Carburetor problems. Vacuum leaks: – Purge control valve hose. – Vacuum hoses. – Intake manifold. – Carburetor. Engine will not crank.
Page 68: Testing
Testing Temperature Gauge Sender 1. Lower the coolant level in the engine and remove the temperature gauge sender (see Water Pump, Water Hose, Pipe and Thermostat Removal and Installation). 2. Put the switch in a container of oil with a thermometer and heat the oil.
Page 69 Engine Oil Pressure Switch The switch is normally closed (NC) and opens with pres If oil pressure light is ON with engine running: sure. The switch opens at approximately 8 psi (55 kPa). 1. Shut off engine immediately. (See Oil Screen, Dipstick and Oil Filter Removal and Installation for location).
Page 70 Fuel Cut–Off (ETR) Solenoid NOTE: The fuel cut–off solenoid is an energize–to–run (ETR) solenoid. 1. Check that valve makes an operating sound when ignition switch is turned ON. Slow fuel cut solenoid valve Figure 44 2. Start the engine. Let engine run at idle. Make sure en gine stalls when slow fuel cut–off solenoid valve electri...
Page 71: Compression Pressure
Compression Pressure 1. Make sure engine is warm (coolant temperature 80 – 95�C (176 – 203�F), all lights and accessories are OFF and transmission is in NEUTRAL. 2. Remove spark plug caps (3). 3. Remove spark plugs (3). 4. Install a compression gauge in a spark plug hole. 5.
Page 72: Centrifugal Timing Control Device
Centrifugal Timing Control Device 1. Start engine and run at idle. 2. Remove vacuum hose from vacuum controller. Plug disconnected vacuum hose. Plug disconnected vacuum hose. 3. Increase engine speed gradually and check advance. It is normal if advancing smoothly according to increas ing speed.
Page 73: Vacuum Timing Control Device
Vacuum Timing Control Device 1. Start engine and run at idle. 2. Remove vacuum hose from vacuum controller. Plug disconnected vacuum hose. Connect vacuum pump to nipple. 3. Add vacuum on vacuum pump gradually and check advance. Timing should advance smoothly with in creased vacuum.
Page 74: Crankcase Emission Control System
Crankcase Emission Control System Breather hose Positive crankcase ventilation (PCV) valve Ventilation hose Induction chamber Blowby gas (high load region) Blowby gas and fresh air (low load region) Figure 52 System Inspection 1. Remove ventilation hose from rocker cover where positive crankcase ventilation (PCV) valve is attached.
Page 75: Exhaust Emission Control System
Exhaust Emission Control System EGR valve Carburetor Thermo valve Figure 55 1. Remove vacuum hose (green stripe) from carburetor Vacuum hose and connect a hand pump to the vacuum hose. (Green stripe) 2. Plug nipple that vacuum hose was removed from. 3.
Page 76 When engine is hot Coolant temperature 80�C (176�F) or higher: Hand vacuum Normal condition p mp pump Engine Vacuum 4 kPa (30 mm Hg, No change Vacuum is 1.2 in. Hg) of maintained vacuum applied 20 kPa (150 mm Idling becomes Hg, 6 in.
Page 77: Thermo Valve
Thermo Valve 1. Disconnect vacuum hose from thermo valve and con nect a hand vacuum pump to thermo valve. 2. Apply a vacuum and check for passage of air through thermo valve. Engine coolant temperature Normal condition 40�C (104�F) or less Vacuum leaks 80�C (176�F) or more Vacuum is maintained...
Page 78: Ignition Coil
Ignition Coil Primary Coil Secondary terminal Measure resistance of (+) and (–) terminal of ignition – coil. Primary coil resistance 1.08 – 1.32 Ohm Secondary Coil Measure resistance between (+) terminal and high volt age terminal of ignition coil. Figure 59 Secondary coil resistance 22.1 –...
Page 79: Starter Pinion Gap
Starter Pinion Gap 1. Disconnect lead wire from terminal ”M” of magnetic switch. 2. Connect 12 volt battery between terminal ”50” and starter body (connect positive terminal of battery to ter minal ”50”. IMPORTANT: To prevent switch coil from overheat ing, never apply battery voltage for longer than 10 seconds.
Page 80: Starter No-Load Test
Starter No–Load Test 1. Connect a 12 volt battery, ammeter and voltmeter to the starter as shown. Variable resistor Ammeter 2. Starter motor should turn smooth and steady when battery is connected with a maximum resistance value. Battery Adjust variable resistance so voltmeter indicates stan Starter motor dard value.
Page 81: Magnetic Switch Pull-In Test
Magnetic Switch Pull–In Test 1. Disconnect the wire from terminal ”M”. 2. Connect a 12 volt battery to the magnetic switch ter- minals ”50” and ”M”. The pinion must protrude. IMPORTANT: Lead wire must be disconnected from terminal ”M” for this test. To prevent switch coil from overheating, never ap...
Page 82: Alternator Regulated Voltage
Alternator Regulated Voltage 1. Disconnect battery ground (–) cable. 2. Install an ammeter between the positive (+) terminal Ignition of the battery and terminal ”B” of the alternator. Switch Alternator 3. Connect a voltmeter between alternator ”L” and ground. 4. Connect the battery ground (–) cable. 5.
Page 83 Alternator Current Output 1. Disconnect the battery ground (–) cable. Load 2. Install an ammeter between the positive (+) terminal of the battery and terminal ”B” of the alternator. Ignition 3. Ground alternator terminal ”B” through a voltmeter. Switch Battery 4.
Page 84: Preparation For Engine Repair
Preparation for Engine Repair 1. Before cleaning and disassembly, carefully check for 4. Disassemble the engine in proper order, arranging problems that cannot be found after the engine has the parts the disassembled parts neatly. Apply clean been cleaned or disassembled (e.g. oil leaks from engine oil to disassembled parts, as necessary to cracked components, gaskets or loose fittings, prevent rust.
Page 85: External Engine Component Repairs
External Engine Component Repair Belt Replacement and Adjustment Governor and Alternator Belt Replacement 1. Loosen idler pulley mounting nut and move pulley to remove governor belt tension. 2. If removing alternator belt, loosen the two (2) alterna tor mounting bolts and pivot alternator to remove belt tension.
Page 86: Timing Belt Replacement
Timing Belt Replacement 10 – 12 Nm (7 – 9 ft–lb) 10 – 12 Nm (7 – 9 ft–lb) 80 – 100 Nm (58 – 72 ft–lb) 22 – 30 Nm (16 – 22 ft–lb) 15 – 18 Nm (11 – 13 ft–lb) 50 –...
Page 87 Timing Belt Removal Timing mark 1. Turn crankshaft clockwise to align timing mark on camshaft sprocket and timing belt rear cover. IMPORTANT: Always turn crankshaft clockwise (right turn). Figure 71 2. Remove plug on left side of cylinder block and insert a 8 mm (.31 in.) diameter rod to lock counterbalance shaft.
Page 88 Camshaft Sprocket Removal 1. Prevent camshaft from turning and remove camshaft sprocket bolt. End yoke holder tool MB990767 Figure 75 Oil Pump Sprocket Removal Oil pump sprocket 1. Remove plug on left side of cylinder block and insert a 8 mm (.31 in.) diameter rod to lock counterbalance shaft.
Page 89 Timing Belt Inspection Inspect all sections of timing belt closely. Replace the belt if any of the following conditions are found: 1. Hardening of rubber on rear surface (rear surface is glossy, no mark is left when scratched and has no elas ticity).
Page 90 Flange Installation Crankshaft sprocket 1. Install flange as shown in the illustration before instal ling crankshaft sprocket. Flange Adaptor Figure 82 Crankshaft Sprocket Installation Flywheel 1. Install crankshaft sprocket. 2. Install special tool to prevent flywheel from turning. Tighten the crankshaft bolt to a torque of 135 – 145 Nm (98 –...
Page 91 Timing Belt Tensioner Installation Timing belt tensioner 1. Install tensioner spring and timing belt tensioner. 2. Hook tensioner spring onto bent section of timing belt tensioner bracket and onto cylinder block stopper pin. 3. Put timing belt tensioner as close as possible to water pump and tighten tensioner nut to temporarily secure in position.
Page 92 5. Install timing belt first onto crankshaft sprocket, then oil pump sprocket and camshaft sprocket in that order. IMPORTANT: Install belt so there is no looseness on tension side of timing belt. The rod should not be re moved until timing belt is completely installed. 6.
Page 93: Water Pump, Hose, Pipe And Thermostat Removal And Installation
Water Pump, Hose, Pipe and Thermostat Removal and Installation 10 – 12 Nm 10 – 13 Nm (7 – 9 ft–lb) (7 – 9 ft–lb) 20 – 30 Nm (14 – 22 ft–lb) Before disassembling: 1. Remove timing belt. 10 – 13 Nm 2.
Page 94 Water Pump Installation Thread diameter x length mm (in.) Bolts used to secure water pump are different sizes. Make sure different size bolts are installed in the correct 6 x 35 locations. Tighten bolts evenly to a torque of 8 – 10 Nm (.24 x 1.38) 6 x 18 (.24 x .71)
Page 95: Governor Removal And Installation
Governor Removal and Installation 20 21 Figure 96 1. Accelerator cable 11. Linkage rod 21. Locknut 2. Jam nut 12. Capscrew 22. Throttle lever 3. Flange nut 13. Lockwasher 23. Extension spring 4. High idle stop bracket 14. Governor bracket 24.
Page 96: Electrical System Repairs
Electrical System Repairs Spark Plug Replacement Spark plug type Champion RN 16Y NGK BPR 4ES Spark plug air gap 1 mm (.040 in.) 1. Clean area around spark plugs to prevent foreign ma terial from falling into cylinder when spark plug is re moved.
Page 97: Alternator Removal And Installation
Alternator Removal and Installation 20 – 25 Nm (15 – 18 ft–lb) 50 – 70 Nm (36 – 51 ft–lb) Figure 99 1. Drive belt 2. Alternator Remove and install alternator as shown in illustration. Workman 3000/4000 Series Liquid Cooled Gas Engine Page 3 –...
Page 98: Alternator Service
Alternator Service Figure 100 1. Alternator pulley 6. Seal ring 11. Rear bearing 2. Space collar 7. IC regulator 12. Rotor assembly 3. ”B” terminal 8. Rectifier 13. Drive end frame and stator assembly 4. Rear end cover 9. Rear end frame 14.
Page 99 2. Use a puller to remove rear end frame as shown. Figure 102 Hold lightly in a soft face Puller 3. Use a puller to remove the bearing. vice to prevent damage Press at the center Figure 103 4. Put drive end frame on a pair of blocks as shown and Press use a press to remove rotor assembly.
Page 100 Alternator Inspection 1. Check for continuity of rotor coil. Check for continuity between slip rings. Measure resistance of rotor. If resis tance is low, it indicates a short circuit. If there is no conti nuity or a short circuit, replace the rotor assembly. Resistance standard value 2.8 –...
Page 101 5. Check the rectifier for continuity. If there is continuity in only one direction of the diode, it is good. Figure 109 6. Measure the brush length from end of brush holder. P1 P2 P3 If it is more than the limit value, replace the brush holder. Standard value Limit Brush length...
Page 102: Starter Removal And Installation
Starter Removal and Installation 8 – 10 Nm (6 – 7 ft–lb) 43 – 55 Nm (31 – 40 ft–lb) Figure 113 1. Connector 2. Battery (+) cable connection 3. Starter motor Remove and install starter as shown in illustration. Liquid Cooled Gas Engine Workman 3000/4000 Series Page 3 –...
Page 103: Starter Service
Starter Service Figure 114 1. Magnetic switch 6. Brush holder 11. Pinion stop nut 2. Boot 7. Yoke assembly 12. Snap ring 3. Rear bracket assembly 8. Front bracket assembly 13. Pinion stop nut 4. Insulator 9. Plate washer 14. Overrunning clutch 5.
Page 104 Snap ring 3. To remove overrunning clutch, expand pinion stop nut as shown and remove front side. Remove snap ring, then remove rear side of pinion stop nut and overrun ning clutch. Starter Motor Parts Cleaning 1. Do not immerse parts in solvent for cleaning. Immer Pinion stop nut sion of yoke, field coil assembly or armature in solvent causes damage to the insulation.
Page 105 3. Check depth of undercuts between segments. Segment Undercut Mica Figure 121 4. Check for continuity between brush and yoke as shown. Replace the field coil if there is no continuity. Figure 122 5. Make sure pinion on overrunning clutch locks when it is turned counterclockwise and moves smoothly when it is turned clockwise.
Page 106 Growler 7. Put the armature on a growler. While applying a thin iron piece in parallel with armature, turn armature slowly. Armature is okay if iron piece is not attracted or does not vibrate. NOTE: Clean armature surface thoroughly be fore doing growler test.
Page 107: Distributor Removal And Installation
Distributor Removal and Installation 10 – 13 Nm (7 – 9 ft–lb) Figure 129 1. Vacuum hose connection 3. Spark plug cable connection 5. Distributor 2. Harness connector 4. High tension cable connection Remove and install distributor as shown in illustration. Workman 3000/4000 Series Liquid Cooled Gas Engine Page 3 –...
Page 108: Distributor Service
Distributor Service Figure 130 1. Distributor cap 5. Signal rotor 9. Vacuum control 2. Packing 6. Lead cable 10. Breaker plate 3. Rotor 7. Pick–up assembly 11. O–ring 4. Cover 8. Lead cable 12. Housing assembly Disassemble and assemble parts as shown in illustra tion above.
Page 109 Distributor Installation Tiiming belt cover A 1. Remove timing belt cover A. Figure 133 Rotation 2. Turn crankshaft clockwise and align mating marks on Rear timing camshaft sprocket and rear timing belt cover to bring belt cover No. 1 cylinder to top dead center on compression stroke. Camshaft sprocket Mating...
Page 110: Fuel System Repairs
Fuel System Repairs Carburetor Removal and Installation 15 – 20 Nm (11 – 14 ft–lb) 3G80031 Figure 137 1. Bolt 3. Gasket 5. Gasket 2. Carburetor assembly 4. Insulator Remove and install carburetor as shown in illustration. Liquid Cooled Gas Engine Workman 3000/4000 Series Page 3 –...
Page 111: Carburetor Service
Carburetor Service 3.5 Nm (2.5 ft–lb) SEE NOTE BELOW 2.0 Nm (1.6 ft–lb) 2 Nm 0.8 Nm (1.6 ft–lb) (0.6 ft–lb) 3.5 Nm 12 13 (2.5 ft–lb) 0.8 Nm (0.6 ft–lb) 6 Nm (4 ft–lb) 2 Nm (1.6 ft–lb) 3G80029 3.5 Nm (2.5 ft–lb) 3G80030...
Page 112 1. After removing retainer (Item 2), remove FCSV from mixing body by pulling out with a pliers as shown. DO NOT pull on lead wire of FCSV. Be careful not to loose the O–ring (Item 4). 2. After removing float chamber body, remove retainer (Item 27), weight (Item 28) and ball (Item 29).
Page 113 5. Check float operation. Check float and lever for de formation and damage. 6. Check operation of throttle valve, choke valve and linkage. If they do not operate with light force, wash well and apply engine oil sparingly to the shaft(s). 7.
Page 114 2. Adjust float level. A. Lightly push up float until it stops, then measure clearance between needle valve and float lever. Needle valve to float lever clearance 1.45 mm (.057 in.) Figure 145 B. If clearance is out of specification, adjust by bending float lever as shown.
Page 115 Carburetor Inspection and Adjustment After Reassembly 1. After installing mixture adjusting screw (MAS) set ini tially by turning clockwise until seated – DO NOT over tighten – then back out 2 full turns counterclockwise. Figure 149 2. Make sure alignment mark (engraved) on cam lever is lined up with center of cam follower.
Page 116 5. Use light pressure with a finger to fully close choke valve. Measure clearance between choke valve and choke bore when throttle valve is fully opened. Choke valve to choke bore clearance 1.45 mm (0.57 mm) Figure 153 If clearance is out of specification, adjust by moving choke shaft end.
Page 117: Removing And Installing The Engine
Removing and Installing the Engine Removing the Engine Figure 156 1. Put machine on a level surface and engage parking brake. Stop the engine and remove key from ignition CAUTION switch. Remove the bed or other attachment(s). Allow engine and radiator to cool. DO NOT open radiator cap or drain coolant if 2.
Page 118: Installing The Engine
9. Disconnect and label electrical leads that attach to crews securing lower sheet metal clutch cover to engine engine and engine accessories. and bell housing. 10. Remove hydraulic pump drive shaft (connected to 16. Remove two (2) capscrews and locknuts securing engine crankshaft pulley).
Page 119: Cylinder Head Overhaul
Cylinder Head Overhaul Intake and Exhaust Manifold Before Removing 1. Remove oil level dipstick and guide tube. 2. Remove alternator. Removal and Installation 7 – 11 Nm (5 – 8 ft–lb) 9 – 14 Nm (7 – 10 ft–lb) 8 – 12 Nm (6 –...
Page 120: Rocker Arm, Rocker Shaft And Camshaft
Rocker Arm, Rocker Shaft and Camshaft 5 – 7 Nm (4 – 5 ft–lb) 29 – 35 Nm (21 – 25 ft–lb) 29 – 35 Nm (21 – 25 ft–lb) 10 – 12 Nm (7 – 9 ft–lb) Figure 158 1.
Page 121 Camshaft Inspection 1. Check camshaft journal surfaces for damage or sei- zure. If journal is seized, check cylinder head for pos sible damage. Also check for clogged oil holes in cylinder head. Journal Figure 159 2. Check camshaft surface for irregular wear or dam age.
Page 122 3. Apply engine oil to lip of camshaft oil seal. Use seal installer tool to drive seal into cylinder head. Figure 163 4. Install rocker shaft so illustrated portion is located to Chamfer Bolt hole ward the front (there is a chamfer and the oil hole is clos- er to the shaft end than the bolt hole).
Page 123: Rocker Arm And Rocker Shaft
Rocker Arms and Rocker Shaft 8 – 10 Nm (6 – 7 ft–lb) Figure 165 1. Rocker arm (intake) 5. Wave washer 9. Rocker arm (exhaust) 2. Wave washer 6. Rocker arm (exhaust) 10. Rocker shaft 3. Rocker arm (exhaust) 7.
Page 124: Cylinder Head And Valves
Cylinder Head and Valves Cold engine 60 – 70 Nm (43 – 51 ft–lb) Figure 168 1. Cylinder head bolt 8. Valve stem seal 15. Valve spring seat 2. Cylinder head assembly 9. Valve spring seat 16. Intake valve guide 3.
Page 125 Cylinder Head Removal and Disassembly 1. Loosen bolts in order as shown and remove cylinder head assembly. Figure 169 2. Use a valve spring compressor tool to compress valve spring. Remove retainer lock. Remove valve spring retainer, valve spring, valve spring seat and valve.
Page 126 3. Check valve seat for proper contact with valve. If it is not concentric, recondition valve seat. Check valve mar gin. Replace if margin is at limit. Contact with valve seat (to be at center of valve face) Margin Figure 173 2 �...
Page 127 Cylinder Head Reassembly and Installation 1. Install valve spring seat. Use stem seal installer tool to install new stem seal to valve guide. DO NOT reuse valve stem seals. Valve spring Valve stem seat seal Figure 177 Enamel Spring retainer 2.
Page 128 4. Make sure cylinder head and cylinder block gasket surface is clean. Put new cylinder head gasket on top of cylinder block with identification mark ”66N” facing up. Indentification mark Figure 180 5. Tighten cylinder head bolts firmly in three steps. Intake side Tighten bolts in order as shown.
Page 129: Cylinder Block Overhaul
Cylinder Block Overhaul Front Case, Counterbalance Shaft and Oil Pan 10 – 12 Nm (7 – 9 ft–lb) 8 – 10 Nm (6 – 7 ft–lb) 8 – 10 Nm 34 – 40 Nm (6 – 7 ft–lb) (25 – 29 ft–lb) 35 –...
Page 130 2. Remove plug on left side of cylinder block and insert a 8 mm (.32 in.) rod to lock counterbalance shaft. Re move flange bolt securing oil pump drive gear. Remove oil pump drive gear. Figure 184 3. Remove rear cover. Use special tool to drive out counterbalance shaft front bearing from cylinder block.
Page 131 2. Check counterbalance shaft to bearing oil clearance. Replace bearing and/or counterbalance shaft if worn or damaged. Front 0.035 – 0.068 mm (.0014 – .0026 in.) Rear 0.035 – 0.071 mm (.0014 – .0028 in.) 3. Check front case oil holes for clogging and clean if necessary.
Page 132 3. Install crankshaft front oil seal: A. Apply engine oil to crankshaft front oil seal lip in ner circumference. B. Use special tool to install oil seal into front case. Figure 191 À À 4. Install front case assembly with a new gasket. Make Á...
Page 133 7. Align timing marks on oil pump drive gears, then install drive gears in cylinder block. Timing mark Figure 195 Oil pump cover 8. Insert a new oil pump cover gasket into groove of oil pump cover. Gasket should be inserted so flat side is to ward oil pump cover.
Page 134: Piston And Connecting Rod
Piston and Connecting Rod 20 – 23 Nm (14 – 17 ft–lb) Figure 199 1. Nut 5. Connecting rod bearing 9. Oil ring 2. Connecting rod cap 6. Bolt 10. Piston pin 3. Connecting rod assembly 7. No. 1 piston ring 11.
Page 135 2. Disassemble piston pin, piston and connecting rod: A. Insert special tool. Push rod and Guide B, into piston pin. Set piston and connecting rod assembly Push rod on base. Make sure front mark (arrow) stamped on Front mark piston top surface faces up. Guide B Base Figure 201...
Page 136 8. Visually check surface of connecting rod bearing. Re place bearing if uneven, streaked, damaged or seized. When streaks or seizure are excessive, check the crankshaft. If crankshaft is damaged, replace crank shaft or machine to next undersize. 9. Measure inner diameter of connecting rod bearing and outer diameter of crankshaft pin.
Page 137 3. Use a ring expander to Install No. 2 and No. 1 piston rings. Pay attention to difference in shape between No. 1 and No. 2 rings. Install rings with marks facing up (to wards top of piston). Figure 209 Piston ring No.
Page 138 6. Use a ring compressor tool to compress the piston rings and carefully insert piston and connecting rod as sembly into cylinder. Figure 213 7. Install connecting rod bearing cap, aligning it with mark made during disassembly. If connecting rod is new and has no alignment mark, install it so notches for lock ...
Page 139: Oil Pump
Oil Pump 34 – 40 Nm (24 – 29 ft–lb) 8 – 10 Nm (6 – 7 ft–lb) 8 – 10 Nm (6 – 7 ft–lb) Figure 216 1. Oil pump cover 3. Oil pump cover gasket 5. Flange bolt 2.
Page 140 Oil Pump Inspection 1. Fit oil pump gear into cylinder block, then use a feeler gauge to check clearance with body at points shown. Driven gear 0.410 – 0.675 mm (.0161 – .0266 in.) 0.130 – 0.175 mm (.0051 – .0069 in.) Drive gear 0.440 –...
Page 141 3. Align timing marks, then install oil pump drive gear. Timing mark Figure 222 Oil pump cover 4. Install a new oil pump cover gasket into groove of oil pump cover. Install gasket with flat side toward oil pump cover. Coil pump cover gasket Figure 223 5.
Page 142: Crankshaft And Flywheel
Crankshaft and Flywheel 8 – 12 Nm 70 – 80 Nm (6 – 9 ft–lb) (51 – 58 ft–lb) 35 – 55 Nm (25 – 40 ft–lb) 10 – 12 Nm (7 – 9 ft–lb) 8 – 12 Nm (6 – 9 ft–lb) 50 –...
Page 143 Crankshaft Inspection 1. Inspect crankshaft journal and pin areas for streaking or seizure. Measure outside diameter of journal and in side diameter of main bearing. If clearance exceeds the limit replace main bearing. If installing new bearing does not reduce clearance to within service limit, crankshaft must be reground and undersize bearings installed.
Page 144 NOTE: Crankshaft oil clearance can be measured by Plastic gauge using a plastic gauge as follows: A. Remove oil, grease and any other foreign materi al from crankshaft journal and bearing inner sur face. B. Install the crankshaft. Figure 230 C.
Page 145 Flywheel and Ring Gear Inspection Ring gear 1. Check ring gear teeth for wear or damage and re place ring gear if necessary. If ring gear teeth are dam aged or broken, check starter motor pinion. To replace ring gear, strike ring gear at several points on out circum ference.
Page 146 Arrow mark 3. When installing bearing cap, note cap No. and arrow indicating front of mark. Tighten capscrews to the specified torque. Make engine Cap No. sure crankshaft turns freely. Front Figure 236 4. Push crankshaft rearward, then insert a feeler gauge in gap between crankshaft journal side surface and thrust bearing end surface to measure end play.
Page 147: Cylinder Block
Cylinder Block 8 – 12 Nm (6 – 9 ft–lb) 35 – 45 Nm (25 – 33 ft–lb) 35 – 45 Nm (25 – 33 ft–lb) 15 – 22 Nm 11 – 16 ft–lb) Figure 240 1. Taper plug 6. Stud 11.
Page 148 3. Use a cylinder gauge to measure inside diameter of cylinder in six (6) locations as shown. Calculate differ ence between maximum and minimum values (cylin dricity). If there is excessive wear or damage, rebore or replace cylinder block. 12 mm (.47 in.) Standard value Cylindricity 0.01 mm (.0004 in.) or less...
Page 149: Lubrication System Repair
Lubrication System Repair Oil Screen, Dipstick and Oil Filter 19 – 28 Nm (14 – 20 ft–lb) 15 – 22 Nm (11 – 16 ft–lb) 9 – 14 Nm (7 – 10 ft–lb) 10 – 12 Nm (7 – 9 ft–lb) 15 –...
Page 150 Liquid Cooled Gas Engine Workman 3000/4000 Series Page 3 – 112...
Page 151 Chapter 4 Mitsubishi Engine (Workman S/N Below 220000001) Liquid Cooled Diesel Engine Table of Contents GENERAL INFORMATION ....2 ELECTRICAL SYSTEM REPAIRS ... . . 34 SPECIFICATIONS .
Page 152: General Information
Limited. Service and repair parts for Mitsubishi engines are supplied through TORO Distributors. Re pair parts may be ordered by TORO Part Number. If no parts list is available be sure to provide your dealer or distributor with the TORO Model Number and Serial Number.
Page 153: Specifications
Specifications The illustrations (Figs. 2a and 2b) will give information Refer to the specifications listed in this section when about the general construction of the engine. performing tests on the engine or examining parts for wear. Some specifications are included in the service procedures later in this chapter.
Page 154: General
General Item Specification __________________________________________________________________________________________ Make/Designation Mitsubishi L3Ca-62TG or L3Ea-62TG, overhead valve, vertical in-line, 4 cycle diesel ________________________________________________________________________________________________________________________________________________________ Combustion Chamber Swirl chamber type ________________________________________________________________________________________________________________________________________________________ Number of Cylinders ________________________________________________________________________________________________________________________________________________________ Bore x Stroke L3Ca-62TG 70 x 70 mm (2.76 x 2.76 in.) L3Ea-62TG 76 x 70 mm (2.99 x 2.76 in.) ________________________________________________________________________________________________________________________________________________________ Total Displacement...
Page 155: Engine
Engine Item Standard Specification Repair Limit Service Limit ____________________________ ______________________________ ________________ ________________ Governor Mechanical/Centrifugal _______________________________________________ _________________________________________________ _______________________________________________________ ± 50 rpm High Idle (no load) 3600 rpm _______________________________________________ _________________________________________________ _______________________________________________________ Idle Speed (no load) ± 50 rpm L3Ca-62TG 1500 rpm ± 50 rpm L3Ea-62TG 1600 rpm _______________________________________________...
Page 156 Engine (cont.) Item Standard Specification Repair Limit Service Limit ____________________________ ____________________________ __________________________________ Piston Type Solid Material Aluminum alloy Piston Outside Diameter (skirt end) L3Ca-62TG 70 mm (2.756 in.) L3Ea-62TG 76 mm (2.992 in.) Piston to Cylinder Wall Clearance 0.2 mm (0.008 in.) Oversize 0.25, 0.50 mm (0.01, 0.02 in.)
Page 157: Lubrication System
Engine (cont.) Item Standard Specification Repair Limit Service Limit _____________________________ ______________________________________________________________ Camshafts Drive System Gear Front Journal Ball bearing Journal to Cylinder Block Hole Clearance 0.15 mm (0.006 in.) Cam Lobe Major Diameter 27.37 mm (1.078 in.) – 1.0 mm (– 0.0433 in.) (both intake and exhaust) Cam Lobe Major Diameter (pump cam) 30 mm (1.224 in.)
Page 158: Fuel System
Fuel System Item Standard Specification Repair Limit Service Limit ___________________________ _____________________________ _________________________________ Fuel Pump Delivery Rate 225 cc (13.73 in ) or more (15 sec., 12V) _______________________________________________ __________________________________________________ _______________________________________________________ Fuel Injection Pump Model ND-PFR-NC ± 1.52 ± 2 Injection Timing (B.T.D.C.) (at SS) _______________________________________________ __________________________________________________...
Page 159: Electrical System
Electrical System Item Standard Specification Repair Limit Service Limit ____________________________ ______________________________ _________________________________ Starter Type Solenoid shift type Nominal Output 1.6 kW - 12V Direction of Rotation Clockwise as viewed from pinion side No-load Characteristics (Cold) Terminal Voltage 11.5V Current 100A or less Speed 3000 rpm or more Load Characteristics...
Page 160: Tightening Torque
Tightening Torque The Mitsubishi diesel engine has many bolts and cap- the engine. The torque specifications in American screws of special materials and sizes. It is very impor- Standard and Metric as listed below MUST be followed tant that special care be used to replace all bolts and in order to have the assembled engine conform to the capscrews in their proper location during assembly of original specifications.
Page 161: Special Tools
Special Tools Order special tools from TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (Commercial Products) . Some tools may be available from a local supplier. Filter Cleaner Filter cleaner (Fig. 3). Mix with water and use solution to wash the Donaldson air cleaner element.
Page 162 Nozzle Tester Nozzle tester (Fig. 7). Tests condition and opening pressure of fuel injector nozzles. Figure 7 Nozzle Tester Adapter Nozzle tester adapter (Fig.8) is required to test the fuel injection nozzles. Figure 8 Liquid Cooled Diesel Engine Page 4 - 12 Workman 3300-D/4300-D...
Page 163: Adjustments
Adjustments Valve Clearance Check the valve clearance after the first 50 hours of operation and every 600 hours of operation after that. 1. The engine must be cold when the valve clearance is checked. 2. Remove the air breather hose from the rocker cover. 3.
Page 164: Engine Speed Adjustments
Engine Speed Adjustments Adjustments to the engine speed settings are not nor mally necessary unless the throttle linkage, injection pump, or governor mechanism have been repaired, rebuilt, replaced or are not operating correctly. If your machine is not equipped with the optional ta chometer, use a vibration-type tachometer to set engine speed.
Page 165: Troubleshooting
Accelerator Pedal Adjustment If engine throttle lever does not contact high idle stop when accelerator pedal is fully depressed, an adjust ment to the accelerator cable is required. 1. Put vehicle into position on a level surface, stop engine and engage parking brake. NOTE: Engine must NOT be running and return spring must be attached.
Page 166 Liquid Cooled Diesel Engine Page 4 - 16 Workman 3300-D/4300-D...
Page 167 Workman 3300-D/4300-D Page 4 - 17 Liquid Cooled Diesel Engine...
Page 168: Testing
Testing Glow Plug Test CAUTION Be careful while handling or testing glow plugs. Glow plugs become extremely hot. Ac cidental contact with the heated plug tip could cause personal injury. 1. Disconnect the wire lead(s) to the glow plug. 2. Remove the glow plug. 3.
Page 169: Compression Test
Compression Test Normal cylinder compression is 28 kg/cm (398 psi) at 280 rpm (normal cranking speed). The engine should be warm - coolant temperature of 50 C (120 IMPORTANT: DO NOT put oil into the combustion chamber before performing a compression test. Damage may result because of “hydraulic”...
Page 170: Nozzle Tests
Nozzle Tests There are several tests to examine the condition of the 3. Allow pressure to dissipate before performing the test. injection nozzles. These tests require the use of a nozzle tester and nozzle tester adapter. (See the Spe 4.
Page 171 amount of fuel may be present due to a previous chat tering test - this would be normal. If the fuel accumulates and drips down during the test (about ten seconds) the nozzle assembly is defective and must be replaced. Spray Test For proper combustion, the nozzle must effectively at ...
Page 172: Injection Pump Test
Injection Pump Test Calibration of fuel delivery volumes, pressure and dis D. Push accelerator pedlal to the floor. Turn the tribution between pump barrels should be performed by ignition key to the START position to crank the a professional diesel engine service shop. Special test engine.
Page 173: Injection Timing Test
Injection Timing Test Injection timing can be adjusted by installing shims pipe. If the slowest flow rate exceeds 1 drop in 5 under the pump body. The timing is important because seconds, repair of the pump should be considered. it determines when the fuel enters the combustion chamber.
Page 174: Fuel Pump Test
Fuel Pump Test 1. Turn the ignition switch to the ON position. Test for pump operation by listening for the pump oscillating sound, or by feeling for vibration which indicates the pump is operating. 2. If no pumping action occurs when the ignition switch is turned on, connect a 12 volt DC battery directly to the pump (Fig.
Page 175: Fuel Stop (Etr) Solenoid
Fuel Stop (ETR) Solenoid The Workman 3300-D/4300-D has an energize-to-run (ETR) fuel stop solenoid. The solenoid will stop injector pump fuel delivery with any electrical failure in the RUN circuit. 1. Disconnect the wire connector and remove the fuel stop solenoid from the engine. 2.
Page 176: Engine Oil Pressure Switch
Engine Oil Pressure Switch The switch is normally closed (NC) and opens with pressure. The switch opens at approximately 8 psi. 1. Turn ignition key switch ON. Oil pressure lamp should be on. If bulb is not on: 1. Disconnect wire from switch and touch wire to a good ground.
Page 177: Temperature Gauge Sender
Temperature Gauge Sender 1. Lower the coolant level in the engine and remove the temperature gauge sender. 2. Put the switch in a container of oil with a thermometer and heat the oil. 3. With an Ohm meter connected as shown, the follow ing resistance readings should be indicated.
Page 178: Checking Starter Pinion Gap
Checking Starter Pinion Gap 1. Install 12 volt battery between the “S” terminal and the starter body. The pinion should protrude and stop. IMPORTANT: Never apply battery voltage to the starter for longer than 10 seconds. 2. Lightly push the pinion back and measure the return stroke (called pinion gap).
Page 179: Magnetic Switch (Solenoid) Attraction Test
Magnetic Switch (Solenoid) Attraction Test 1. Disconnect the wire from terminal “M” (Fig. 31). 2. Connect a 12 volt battery to the magnetic switch terminals “S” and “M”. The pinion must protrude. IMPORTANT: Never apply battery voltage to the starter for longer than 10 seconds. Figure 31 Magnetic Switch (Solenoid) Holding Test 1.
Page 180: Alternator Regulated Voltage Test
Alternator Regulated Voltage Test 1. Install an ammeter between the positive (+) terminal of the battery and terminal “B” of the alternator. 2. Ground alternator terminal “L” through a voltmeter. 3. Note that the voltmeter shows 0 volts when the ignition key switch is in the OFF position.
Page 181: Preparation For Engine Repair
Preparation for Engine Repair 1. Before cleaning and disassembly, carefully check for engine oil to disassembled parts, as necessary to pre problems that cannot be found after the engine has vent rust. been cleaned or disassembled (e.g. oil leaks from cracked components, gaskets or loose fittings, dam...
Page 182: External Engine Component Repair
External Engine Component Repair Belt Replacement and Adjustment Alternator Belt 1. Loosen bolt securing alternator brace to engine and bolt securing alternator to brace (Fig. 36). 2. Remove two capscrews securing drive shaft coupler to engine crankshaft pulley. 3. Move drive shaft out of the way so belt can be removed and new one installed.
Page 183: Thermostat Removal And Installation
Thermostat Removal and Installation 1. Lower the coolant level to below the thermostat. 7. Fill the cooling system to the proper level with a 50/50 solution of clean, soft water and ethylene glycol anti 2. Loosen the hose clamp and disconnect the hose from freeze (See Checking the Cooling System and Chang...
Page 184: Electrical System Repairs
Electrical System Repairs Alternator Removal and Installation 1. Disconnect the negative (–) cable from the battery. 2. Disconnect the wire from terminal “B” on the back of the alternator. 3. Disconnect the alternator wiring harness connector. 4. Loosen alternator brace bolt and alternator support bolt (Fig.
Page 185 Replacing and/or Adjusting Engine Stop Solenoid An improperly adjusted stop solenoid can result in fail 7. Hold the solenoid body to prevent it from turning and ure of the engine to stop when the key switch is turned tighten the nut against the engine to secure the adjust off or could cause injection pump damage or malfunc...
Page 186: Glow Plug Replacement
Glow Plug Replacement Replace the glow plug(s) if they do not operate correctly. 3. Remove the glow plug. (See Glow Plug Test in the Testing section of this chapter.) 4. Install a new glow plug. Tighten the glow plug to a torque of 11-14.5 ft-lb (1.5-2 KgM).
Page 187: Starter Service
Starter Service Disassembly and Inspection 7. Unscrew the bolts and remove the center bracket. As the bracket is removed, washers for pinion shaft end 1. Remove the starter from the engine (see Starter play adjustment will come off. Removal and Installation). 8.
Page 188 Break and short circuit Wear and ch pping One-way mechan sm Bearing: P ay, no se, and rough rotation Insu at on Break and short c rcu Bearing: Play, noise, and rough rotation Figure 47 10. Check the magnetic switch for continuity between terminals “S”...
Page 189 11. Put the armature on a growler tester to check for a shorted armature. A burned commutator bar is an indi cation of a shorted armature. With the growler turned on, put a thin strip of steel or a hacksaw blade on the armature as it is slowly rotated.
Page 190 Assembly and Adjustment of Starter Gear Adjusting 1. Reverse steps 1 - 10 under Disassembly and Inspec Washer tion and also following the following instructions: Washer Snap 2. Set the pinion shaft end play (thrust gap) to 0.5 mm (0.02 in.) or less by inserting an adjusting washer be tween the center bracket and reduction gear.
Page 191: Alternator Service
Alternator Service Disassembly and Inspection 4. Put the rotor in a vise. Remove pulley nut and pull off the pulley and spacer. 1. Remove the alternator from the engine (see Alterna tor Removal and Installation). 5. Pull the rotor assembly from the front bracket. 2.
Page 192 Deformation Break and and damage short circuit Wear and roughness Wear Crack and damage Break and short circu Wear to limit line Figure 54 9. Check each diode in the rectifier for conduction. Connect an ohm meter across the lead wire and diode case.
Page 193 11. Check for continuity between a slip ring and shaft (core). Replace the field coil if there is continuity. Figure 57 12. Check for continuity between lead wires of the stator coil. Replace the stator coil if there is no continuity. Figure 58 13.
Page 194 Assembly of Alternator 1. Reverse steps 1 - 8 under Disassembly and Inspec tion and also following the following instructions: 2. The rear bearing has an eccentric groove. Install the snap ring so its projection fits in the deepest part of the groove.
Page 195: Governor System Repairs
Governor System Repairs Governor Operation The governor keeps the engine operating at a constant governor weights, thus maintaining constant engine speed by balancing the centrifugal force acting on the speed. governor weights and the governor spring tension. As the engine picks up speed, the governor weights open When the speed control lever is pulled toward high to move the sliding shaft forward.
Page 196: Governor Inspection
Governor Inspection A governor failure can cause engine starting failure, loss 3. Push the tie rod forward only with only enough force of engine speed control, or engine surging (hunting). to overcome the spring pressure and operate the speed Before removal and disassembly of the engine the control lever (or throttle lever).
Page 197: Governor Service
Governor Service 1. Remove the tie rod cover (Fig. 33). 2. Remove the tie rod clip and disconnect the tie rod from the injection pump control rack. 3. Disconnect the governor spring from the tension lever. 4. Remove the cover assembly. 5.
Page 198: Installation Of Torque Spring Set
Installation of Torque Spring Set IMPORTANT: Torque spring set adjustment has been done and sealed at the factory. Do not remove, disassemble or adjust this device unless necessary. The torque spring set adjustment is very sensitive. Improper adjustment can vary fuel delivery to under power or over fuel the engine.
Page 199: Assembly Of Torque Spring Set
Assembly of Torque Spring Set If the torque spring set has been disassembled or parts replaced, reassemble and adjust the torque spring set using the following procedure. IMPORTANT: The torque spring set has been ad justed and sealed at the factory. Do not remove, disassemble or adjust this device unless necessary.
Page 200: Fuel System Repairs
Fuel System Repairs When cleaning the engine, DO NOT spray water onto a tolerance parts of the fuel system can be easily dam hot injection pump. This could cause the fuel pump to aged by dirt. seize and be damaged. Wash fuel system parts in clean fresh diesel fuel.
Page 201: Bleeding Air From The Injectors
Bleeding Air From the Injectors This procedure should only be used if the fuel system has been purged of air. (See Bleeding the Fuel System in this section of the book.) 1. Loosen the pipe connection at the number one nozzle and holder assembly on the cylinder head (Fig.
Page 202: Injection Pump Service
5. Carefully remove the spring retainer from the end of the plunger tube (Fig. 43). Remove the washer, o-ring, valve, plunger spring and plunger. IMPORTANT: Be careful not to bend or deform the plunger tube while disassembling the fuel pump. If the plunger tube is bent, the fuel pump plunger will bind and the pump will need to be replaced.
Page 203 Injection Pump Disassembly 3. Remove the tappet roller and stopper pin. Remove the tappet and adjusting shim. IMPORTANT: Do not mix the delivery valves, deliv ery valve seats, plungers or plunger barrels from 4. Remove the lower seat from the plunger. Remove the one cylinder to another.
Page 204 Injection Pump Inspection Inspect the injection pump parts for proper operation, wear, corrosion, seizure, etc. (Fig. 47). Replace worn or damaged parts. Injection Pump Assembly 1. Insert the plunger barrel into the housing. 2. Install the delivery valve seat, gasket, delivery valve and valve spring.
Page 205: Nozzle Service
Nozzle Service IMPORTANT: When servicing the injection nozzles make sure that the engine and fuel delivery pipes are clean to prevent dirt from entering cylinder or nozzle. Do not mix components of one nozzle with the other. Nozzle Removal and Disassembly 1.
Page 206 Nozzle Inspection and Cleaning 1. Clean the inside and outside of the retaining nut in clean diesel fuel or kerosene to remove carbon or fuel deposits. Inspect the lower seating surface for rust or damage. The sealing area may be restored with emery cloth.
Page 207: Removing And Installing The Engine
Removing and Installing the Engine Removing the Engine Figure 52 1. Put machine on a level surface and engage parking 4. Disconnect coolant and radiator hoses from engine. brake. Stop the engine and remove key from ignition switch. Remove the bed or other attachment(s). Allow 5.
Page 208: Installing The Engine
12. Remove clamps and wire ties where wiring harness, 16. Remove capscrews securing clutch bell housing to hydraulic hoses or cables are attached to the engine. engine. 13. Put blocking under transaxle for support. 17. Use a hoist or block and tackle to remove engine from chassis.
Page 209: Cylinder Head Overhaul
Cylinder Head Overhaul Cylinder Head Removal 1. If the engine will not be removed from the vehicle, lower the coolant level in the engine. Loosen the hose clamp and remove the upper radiator hose from the thermostat housing. Disconnect the coolant bypass hose from the thermostat housing.
Page 210: Cylinder Head Service
Cylinder Head Service 1. Use a valve lifter tool to compress the valve spring (Fig. 61). To remove each valve retainer, depress the retainer against the valve spring and remove the re tainer lock (Fig. 62). Remove the valve retainer, spring and valve.
Page 211: Valve Guides
8. Use a straight edge and feeler gauge to check the flatness of the cylinder head lower surface (Fig. 63). Be sure to check the surface variation crosswise, length wise, and diagonally. If the variation in surface flatness exceeds (0.05 mm) 0.002 in. , the cylinder head or cylinder block must be replaced or resurfaced.
Page 212: Valves
Valves 1. Carefully clean each valve with a wire wheel to remove all carbon deposits. 2. Check the valve face and valve stem for excessive wear, damage, cracks or deformation. If any of these conditions exist, the valve must be replaced. It is possi ble to reface the valve if the valve head thickness (margin width) is not less than the service limit (Fig.65).
Page 213: Valve Springs
Valve Springs 1. Check the valve springs for rust, pitting, cracks or other damage. 2. Check the squareness of the valve spring by putting it upright on a level surface. Any spring that is 3 or more out of square must be replaced. 3.
Page 214: Cylinder Head Reassembly And Installation
Cylinder Head Assembly and Installation 1. Install the thermostat housing. Use a new gasket. valve springs and valve retainers. Compress the spring with a valve lifter, then install the retainer lock. 2. Install the intake and exhaust manifolds. Use new gaskets.
Page 215 8. Make sure that the cylinder head and cylinder block surfaces are clean. Put a new gasket on the cylinder head. Insert dowel pins into two cylinder head bolt holes to assist in mounting the head onto the block. Carefully put the cylinder head into position on the cylinder block.
Page 216: Cylinder Block Overhaul
Cylinder Block Overhaul NOTE: The engine must be removed from the vehicle chassis and put in an engine stand. (See Removing and Installing The Engine.) Gear Case and Oil Pump 1. Remove the crankshaft pulley. 4. Remove the water pump. (See Water Pump Service in the External Engine Component Repair section of this 2.
Page 217 7. Check removed parts for wear or damage (Fig. 73). Replace parts as necessary. Figure 73 Workman 3300-D/4300-D Page 4 - 67 Liquid Cooled Diesel Engine...
Page 218 8. Check the governor parts for wear or damage (Fig 74). Replace parts as necessary. A. Remove the expansion plug (Fig 75). Be careful to not scratch the gear case. B. Pull out the grooved pin. C. Remove the shaft, spring and levers. D.
Page 219: Timing Gears And Camshafts
Timing Gears and Camshafts 1. Remove the cylinder head (see Cylinder Head Re moval in the Cylinder Head Overhaul section of this chapter). 2. Remove the gear case (see Gear Case and Oil Pump in this section). 3. Remove the snap ring and remove the idle gear (Fig.
Page 220 6. Check the gears for incorrect tooth contact, wear and 7. Inspect the camshaft parts (Fig. 80). Replace any damage. Replace any gears that are badly worn or parts that are worn or damaged. damaged. Major diameter of cam: Injection pump cam: 29.3 - 30 mm (1.154 - 1.181 in.) Maximum idle gear bushing to shaft clearance: Valve cam: 26.37 - 27.37 mm (1.038 - 1.078 in.) 0.2 mm (0.008 in.)
Page 221 8. Before installing the camshafts and timing gears, turn the crankshaft to set the No. 1 cylinder to top dead center (TDC) of the compression stroke. Reverse steps 1 - 5 to install the camshafts and timing gears (Fig. 81). Figure 81 9.
Page 222: Piston And Connecting Rod
Piston and Connecting Rod 1. Remove the cylinder head (see Cylinder Head Re moval in the Cylinder Head Overhaul section of this chapter). 2. Remove the oil pan and gasket. 3. Remove the oil screen NOTE: Before removing the pistons, mark the number of the cylinder onto the top of each piston and on the side face of each connecting rod (on the large end).
Page 223 8. Measure the piston outside diameter (Fig. 84). (See Cylinder Block in this section). Maximum piston to cylinder wall clearance: 0.3 mm (0.012 in.) Figure 84 9. Use a thickness gauge to check the piston ring side clearance (Fig. 85). If the piston ring side clearance exceeds the service limit, the ring must be replaced.
Page 224 11. To remove the piston from the connecting rod press the piston pin from each piston. Use the piston setting tool (Fig. 87). IMPORTANT: Do not attempt to remove the piston pins by driving then out with a hammer. A stuck piston pin, requiring excessive pressure to remove, should be replaced.
Page 225 15.Install the piston rings. Each piston ring has different wooden block. Make sure the arrow mark on top of the shape. Make sure they are installed in the proper posi piston is facing toward the front of the engine. tion and with the ring gaps in the directions as illustrated (Fig.
Page 226: Crankshaft
Crankshaft 1. Perform steps 1 - 5 under Piston and Connecting Rod in this section. 2. Remove the flywheel. 3. Remove the rear oil seal case. 4. Remove the main bearing caps (Fig. 91). Keep each set of bearings together with its bearing cap. 5.
Page 227 6. Measure the crankshaft for “run-out” (bend). Mount the crankshaft in a pair of V-blocks (or live centers) and use a dial indicator to measure the run-out in the crank shaft (Fig. 103). The maximum allowable crankshaft run-out is 0.05 mm (0.002 in.). 7.
Page 228 10. Reverse steps 1 - 5 to install the crankshaft (Fig. 97). When installing the No. 1 and No. 4 bearing caps, apply sealant (Permatex No. 2 or equivalent) to the upper surface that meets with the cylinder block. 11. Use a dial indicator to measure the crankshaft end play.
Page 229: Cylinder Block
Cylinder Block Before cleaning check the cylinder block for coolant leaks, oil leaks or damage. Clean all parts to remove dirt, oil, carbon deposits and water scale. Check the cylinder block for cracks or other damage. Check the water jacket for water scale and rust. Replace the cylinder block if necessary.
Page 230 Liquid Cooled Diesel Engine Page 4 - 80 Workman 3300-D/4300-D...
Page 231: Kohler Engine Service Manual
Chapter 5 Air Cooled Gas Engine Table of Contents SPECIFICATIONS ......2 Carburetor Adjustment ..... . . 4 GENERAL INFORMATION .
Page 232: Specifications
Specifications Item Specification Make / Designation Kohler Air Cooled, Gasoline Engine Serial Number Below 220000000 CH 22S Spec. No. 66513 Serial Number Above 220000000 CH 23S Spec. No. 76548 Bore/Stroke Serial Number Below 220000000 3.03 in. / 2.64 in. (77 mm / 67 mm) Serial Number Above 220000000 3.15 in.
Page 233: General Information
General Information Removing Debris From Engine To ensure proper cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. To clean, remove the blower housing and other cooling shrouds and clean the cooling fins and external surfaces as necessary.
Page 234: Adjustments
Adjustments Belt Adjustment 1. Park machine on a level surface, stop engine and en- gage parking brake. 2. Check tension by depressing belt at mid span of crankshaft and pump pulleys with 22 lbs. (10 Kg) of force. A new belt should deflect .48 – .58 in. (12 – 15 mm).
Page 235: Accelerator Adjustment
Choke Adjustment 1. Park machine on a level surface, stop engine and en- gage parking brake. 2. Loosen cable clamp screw securing choke cable to engine. 3. Push choke control knob down to OFF position. 4. Push choke cable firmly toward operator’s side of ve- hicle and tighten cable clamp screw.
Page 236: Repairs
Repairs Engine Removal and Installation 35 – 41 ft–lb (47 – 56 Nm) Never–seez Figure 7 1. Battery Positive (+) cable 8. Locknut 15. Flywheel 2. Hydraulic pump drive belt 9. Flat washer 16. Woodruff key 3. Locknut 10. Pulley 17.
Page 237: Chapter 6 - Drive Train
11. Attach hoist or block and tackle to engine for sup- port. Pilot bearing 12. Remove four (4) locknuts (Item 3), flat washers (Item 4), capscrews (Item 5) and lockwashers (Item 6) 35 – 41 ft–lb securing engine to frame. (47 –...
Page 238 Air Cooled Gas Engine (Rev. G) Workman 3100 Page 5 – 8...
Page 239 Chapter 6 Drive Train Table of Contents GENERAL INFORMATION ..... . 2 TROUBLESHOOTING ......SPECIFICATIONS .
Page 240: General Information
General Information Workman 3000/4000 Series vehicles are equipped with a Toro designed transaxle with 3 forward speeds, 1 re- verse and a differential lock. Hi–Lo range gives an effec- tive 6 forward and 2 reverse speeds. The transaxle is a constant mesh, collar shift transmis- sion with synchronizers for gears 1, 2 and 3.
Page 241: Specifications
Specifications General Specifications Item Specification Clutch pedal free play 19 mm (.75 in.) min. Transaxle countershaft end play 0.00 – 0.10 mm (.000 – .0039 in.) Transaxle ring gear backlash 0.08 – 0.18 mm (.0031 – .0071 in.) with max. variation of 0.05 mm (.0019 in.) at three different points checked Liquid gasket (transaxle case gasket) Three–Bond 1216 or Loctite 599...
Page 242: Special Tools
Special Tools Drive Shaft Yoke Flange Nut Wrench A modified 1–1/8� box end wrench is required to remove and install flange nut securing drive shaft yoke to stub axle on early production machines. NOTE: If your ma chine has a half yoke on the stub axle, this modified tool is not necessary.
Page 243 Stub Axle Use an extra stub axle (Toro P/N 87–8740) with washer (Toro P/N 87–3060) and flange lock nut (Toro P/N 32128–53) as a tool to install stub axle. Attach this tool to the wheel studs on the stub axle. Secure tool with wheel nuts.
Page 244: Adjustments
Adjustments Clutch Pedal Adjustment 1. Loosen jam nuts securing clutch cable to bracket on bell housing. NOTE: Ball joint may be removed and rotated, if addi tional adjustment is required. 2. Disconnect return spring from clutch lever. 3. Adjust jam nuts/or ball joint until bottom rear edge of clutch pedal is “A”...
Page 245: High-Low Cable
Shift Cable Adjustment 1st–Rev. / 2nd–3rd Cable Adjustments 1. Move shift lever to neutral. 2. Remove clevis pins securing shift cables 1st–Rev. and 2nd–3rd cables to transaxle shift arms. 3. Loosen clevis jam nuts and adjust each clevis so cable free play is equal forward and backward relative to hole in transaxle shift arm (with transaxle lever free play taken up in same direction).
Page 246: Differential Lock Cable
Differential Lock Cable Adjustment Note: On units without a Differential Lock lever, do not perform this adjustment. 1. Move differential lock lever to OFF position. 2. Loosen jam nuts securing differential lock cable to bracket on transaxle. 3. Adjust jam nuts to obtain 0.9 + 0.6 mm (.035� + .025�) gap between spring hook and O.D.
Page 247: Troubleshooting
Troubleshooting Clutch Symptom Possible Causes Clutch slips. Excessive wear of clutch disc facing. Clutch pedal out of adjustment. Hardening of clutch disc facing, or adhesion of oil. Weak or broken clutch diaphragm spring. Damaged pressure plate or flywheel. Clutch operation erratic or rough. Improper installation of clutch cover assembly.
Page 248 Clutch (continued) Symptom Possible Causes Clutch chatters. Worn or damaged clutch disc facing. Oil adhered to clutch disc facing. Uneven height of diaphragm spring. Weak or damaged clutch torsion spring. Damaged pressure plate or flywheel. Damaged release bearing. Transaxle Symptom Possible Causes Noisy operation.
Page 249 Transaxle (continued) Symptom Possible Causes Gears make clashing noise when shifting. Shifting too fast. Excessive wear of synchro rings. Excessive wear of differential side gear liners and pinion liners. Damaged synchro springs and/or keys. Main gear needle bearings worn or damaged. Excessive wear of drive shaft(s).
Page 250: Repairs
Repairs Shifter Cable Replacement 20 – 24 Nm (15 – 18 ft–lb) 2nd–3rd High–Low First–Rev Figure 17 NOTE: Before removing cable(s), note routing and loca- tion of cable ties. 9.5 mm (.375 in.) 1. Before installing cables adjust clevis (Item 1) on 1st– Rev and 2nd–3rd cables as shown Figure 18.
Page 251: Stub Axle And Drive Shaft Service
Stub Axle and Drive Shaft Service 300 – 340 Nm (220 – 250 ft–lb) 47 – 57 Nm (35 – 42 ft–lb) Loctite 271 Drive Shaft with Half Yoke Half yoke 60 – 75 Nm (45 – 55 ft–lb) Figure 19 1.
Page 252 6. Install stub axle removal tool onto wheel studs. 7. Loosen flange lock (Item 4) nut by turning counter clockwise. 8. Remove stub axle (Item 6). 9. To remove driveshaft, loosen locknuts (Item 9) , then remove bolts securing driveshaft at splined axle shaft of transaxle.
Page 253: Drive Shaft Universal Joint Service
Drive Shaft Universal Joint Service 1. Remove drive shaft from machine (see Stub Axle and Drive Shaft Service). 2. Remove snap rings (Item 1). IMPORTANT: Yokes must be supported when re moving and installing bearings to prevent bending. 3. Use a press to remove cross and bearings (Item 2). 4.
Page 254: P.t.o. Removal And Installation
P.T.O. Removal and Installation PTO Removal 1. Remove clevis pin to disconnect PTO control cable clevis from shift arm on PTO. Do not loosen jam nuts to remove cable from support bracket. 2. Disconnect and label electrical lead that attaches to PTO switch.
Page 255: Transaxle Removal And Installation
Transaxle Removal and Installation Transaxle Removal 1. Put machine on a level surface. Stop the engine and remove key from ignition switch. Remove the bed or oth er attachment(s). Allow engine and radiator to cool. 2. Disconnect positive (+) and negative (–) battery cables from battery.
Page 256 Figure 29 (Workman 3200 shown) 1. PTO 3. Control cable support bracket 5. Mount bracket 2. Drive shaft coupler 4. Drive shaft assembly 5. Remove muffler. 11. Disconnect shifter control cables from levers on transaxle and PTO (see Shift Cable Adjustment). Do not 6.
Page 257 16. Block front wheels. Jack–up rear of machine under rear axle and install jack stands so transaxle can be re moved by sliding out under rear axle. 17. Put blocking under engine for support. Support transaxle with a floor jack or suspend transaxle from vehicle frame rails.
Page 258: Clutch Service
Clutch Service Silicone sealant (Workman 3100 only) 7 – 9 Nm (5 – 7 ft–lb) Never–Seez (if bearing has metal inside diameter) Figure 31 Clutch Release Mechanism 1. Remove transaxle. 2. Inspect main shaft of transaxle for wear or damaged splines.
Page 259 Clutch Disassembly and Inspection Special tool 1. Insert special tool (or transaxle main shaft) in flywheel (or transaxle main shaft pilot bearing hole to keep disk from falling off. 2. Loosen clutch cover capscrews (Item 10) in a diago- nal sequence. 3.
Page 260: Transaxle Service
Transaxle Service Transaxle Disassembly NOTE: Item numbers in figures are shown in order of disassembly; for example, remove Item 1 first, then Item 2, etc. Reassemble in reverse order; for example, install Item 1 last. 1. Remove extension spring (Item 1). 2.
Page 261 IMPORTANT:Make sure to note the type of shim set removed from the center plate. Early versions of the centerplate have either four shims (Item 2) without tabs or one thick shim (Item 4) with a tab (Fig. 40). Newer versions of the center plate have one tabbed shim (Item 4) with three tabless shims (Item 2) (Fig.
Page 262 10. Remove main shaft assembly (Item 1) together with fork shaft assembly (Item 2) from transaxle case. Figure 44 11. Remove, all at the same time, reduction shaft as sembly (Item 1), 2nd–3rd shift assembly (Item 2), coun tershaft assembly (Item 3) and High–Low shift assembly (Item 4).
Page 263 15. Loosen capscrews and remove R.H. axle shaft as- sembly from transaxle case. Figure 48 16. Remove differential gear assembly (Item 1) together with fork shaft assembly (Item 2). Figure 49 17. Remove washer (Item 1) from inside of transaxle case.
Page 264 18. To remove shift arms (Transaxle Model KT40): A. Loosen shift arm clamp bolt (Item 1) with a 3/16� Allen wrench. B. Loosen nut (Item 2), then remove 2nd–3rd shift arm (Item 3) together with shift arm plate (Item 4), spring (Item 5), locknut (Item 6), washer (Item 7) and capscrew (Item 8).
Page 265 20. Loosen capscrews (Item 1) and remove nut (Item 2) with washer. Separate P.T.O. cover (Item 3) or P.T.O. and O–ring from transaxle case. Inspect P.T.O. cover for cracks or damage and replace if necessary. Figure 54 21. Remove oil cap (Item 1) and O–ring from transaxle case if necessary.
Page 266 24. Disassemble main shaft assembly: A. Use a bearing puller to remove bearing (Item 1) from main shaft. B. Remove snap ring (Item 2) and washer (Item 3). Measure thickness of washer. Replace washer if it is less than 1.8 mm (.0709 in.) thick. C.
Page 267 25. Disassemble reduction shaft assembly: 14 13 10 A. Use a bearing puller to remove bearing (Item 1) from reduction shaft. B. Remove gear (Item 2), helical gear (Item 3), col lar (Item 4) and gear (Item 5). C. Use a bearing puller to remove bearing (Item 6). D.
Page 268 26. Disassemble reverse shaft assembly: A. Use a bearing puller to remove bearing (Item 1) from reverse shaft. B. Remove gear (Item 2). C. Use a bearing puller to remove bearing (Item 3) from reverse shaft. Figure 61 27. Disassemble countershaft assembly: A.
Page 269 28. Disassemble fork shaft assemblies: A. Remove lock pin (Item 1) from 2nd–3rd fork shaft assembly. B. Remove shift fork (Item 2) from fork shaft. C. Remove lock pin (Item 1) from 1st–R fork shaft assembly. D. Remove fork (Item 2) from fork shaft. Figure 64 29.
Page 270 31. Disassemble differential fork shaft assembly: A. Remove O–ring (Item 1) from fork shaft. B. Remove snap ring (Item 2), washer (Item 3) and spring (Item 4). C. Remove fork (Item 5). D. Remove lock pin (Item 6) if necessary. Figure 68 32.
Page 271 Transaxle Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. 3. Inspect synchronizer ring: A. Inspect the chamfer for excessive wear or dam- age. B. Inspect inner tapered area for excessive wear or damage.
Page 272 6. Inspect hub, shifter, synchro key and synchro spring: A. Inspect hub for worn or damaged spline. B. Inspect shifter for chipping or damaged chamfer. C. Inspect synchro keys for wear or damage. D. Inspect synchro springs for wear or damage. E.
Page 273 10. Inspect center plate for cracks and damage. Re place center plate if the snap ring groove has more than 15% of its edges damaged due to nicks, rounding, cracks, or dents (Fig. 76 and 77). UNDAMAGED GROOVE Figure 76 DAMAGED GROOVE EDGES Figure 77...
Page 274 11. Inspect reduction shaft: A. Inspect reduction shaft for wear or damage. If O.D. of needle bearing area is less than 21.95 mm (.864 in.) or 24.95 mm (.982 in.), replace the reduc tion shaft. Figure 78 12. Inspect countershaft: A.
Page 275 Transaxle Reassembly NOTE: Item numbers in figures are shown in reverse or der of assembly; for example, when reassembling, install Item 1 last. 1. Clean gasket material from all mating surfaces before reassembling. Make sure all parts are clean and free of dirt and dust.
Page 276 5. Assemble differential gears: A. Apply moly disulfide grease on pinion liners (Item 11), holes of pinion gears (Item 10), side gear liners (Item 14) and hubs of side gears (Item 13, 12). B. Install side gear liners (Item 14), side gears (Item 13, 12), pinion liners (Item 11) and pinion gears (Item 10).
Page 277 6. Assemble Hi–Lo fork shaft: A. Install E–ring (Item 4) onto fork shaft (Item 5). B. Insert spring (Item 3) and steel ball (Item 2) into fork (Item 1). C. Insert fork shaft into fork. Put moly disulfide grease onto the shaft before installing. 7.
Page 278 8. Assemble countershaft: A. Use a press to install 2 new bearings (Item 15) onto countershaft. B. Install collar (Item 14) and snap ring (Item 13). C. Install washer (Item 12) and gear (Item 11). Apply moly disulfide grease into bushing of countershaft gear before installing.
Page 279 9. Assemble synchro hub: A. Install 3 keys (Item 1) into grooves of hub (Item Figure 91 B. Install shifter (Item 1) onto hub (Item 2). Figure 92 C. Insert 2 springs (Item 3) into hub. Pay attention to direction of spring. Figure 93 Figure 94 Workman 3000/4000 Series...
Page 280 10. Assemble reduction shaft: 14 13 10 A. Install washer(s) (Item 17), 2 needle bearings (Item 16) and gear (Item 15) onto reduction shaft (Item 18). Apply moly disulfide grease to washer and needle bearings before installing. Oil groove on washer must face the gear.
Page 281 11. Assemble reverse shaft: A. Install gear (Item 2) onto reverse shaft. B. Use a press to install bearings (Item 3, 1 ). Figure 97 12. Assemble main shaft: A. Install gear (Item 18), gear (Item 17) and snap ring (Item 16). B.
Page 282 13. Assemble shift arms (Transaxle Model KT40): A. Install 3 new oil seals (Item 14) onto transaxle case. Apply multi–purpose grease on lips of oil seals before installing. B. Install 3 keeper plates (Item 13) and tighten 3 capscrews (Item 12) to a torque of 15 – 17 Nm (11 –...
Page 283 15. Install oil cap (Item 1) with O–ring. Apply multi–pur- pose grease to O–ring. 16. Install air breather (Item 2). Use sealing tape on threads of air breather. Figure 103 Workman 3000/4000 Series Page 6 – 45 Drive Train...
Page 284 17. Install reduction shaft and countershaft together with R–1 fork shaft and Hi–Lo fork shaft. Insert heads of shift arms into grooves of forks when installing them. Figure 104 Figure 105 18. Install main shaft together with 2–3 fork shaft. Insert head of shift arm into groove of fork while installing.
Page 285 19. Install reverse shaft (Item 1). Rotate main shaft and reverse shaft gears to mesh gears when installing. Figure 108 20. On 4WD units, install bearing to gear case and cen FRONT DRIVE SHAFT ter plate. Install front drive shaft and 41T gear to the gear case (see Item 2 of Fig.
Page 286 IMPORTANT:On early versions of the center plate, use one thick, tabbed shim (Item 2) (Fig. 111). 22. Insert shim (Item 2) against the bearing. Use thick- est shim possible that will permit installation of the snap ring. (Fig. 111 and 113). Figure 111 IMPORTANT:On newer versions of the center plate, use one tabbed shim (Item 4) with three tabless...
Page 287 25. Measure countershaft end play. Rotate one of the axle shafts back and forth to take up all back lash. Rotat ing the shaft in one direction will pull the shaft and bear ing away from the snap ring. Rotate axle shaft in this direction, then measure space between the snap ring and shim (set) with a feeler gauge.
Page 288 27. Install fork shaft case: A. Apply silicone sealant to mating surface of fork shaft case. B. Insert spindle (Item 1) between fork shafts. Figure 117 C. Insert 2 steel balls (Item 2) and 2 springs (Item 1) into the grooves. Figure 118 D.
Page 289 29. Install differential gear assembly (Item 1) together with fork shaft (Item 2) onto transaxle case. Figure 121 Figure 122 30. Install side cover: A. Insert 2 dowel pins onto transaxle case. B. Apply silicone sealant onto mating surface of side cover.
Page 290 32. Install L.H. axle shaft assembly: A. Thoroughly clean mating surface of differential carrier and side cover (Item 1). B. Insert selected shims (Item 2) into housing of side cover. NOTE: The thickest shim should be in serted against the bearing. Figure 125 C.
Page 291 34. Install differential lock arm (Item 1) onto fork shaft. Insert lock pin into fork shaft and arm. Pay attention to direction of slit in lock pin. Figure 128 35. Apply silicone sealant to mating surface of upper cover (Item 2). Pay attention to direction of cover and install.
Page 292 36. Apply multi–purpose grease to O–ring and insert O– ring into groove of transaxle case. If installing P.T.O., in sert 2 dowel pins in transaxle case. Install P.T.O. or cover. Tighten capscrews and nut with lockwasher to a torque of 15 – 17 Nm (11 – 13 ft–lb). Figure 130 37.
Page 293 P.T.O. Service Figure 132 Power Take–Off (PTO) Disassembly NOTE: Item numbers in figures are shown in order of dis assembly; for example, remove Item 1 first, then Item 2, etc. Reassemble in reverse order; for example, install Item 1 last. 1.
Page 294 3. Remove PTO shaft assembly (Item 1) from PTO case. Remove oil seal from PTO cover. Figure 134 4. Remove idle shaft assembly (Item 1) from PTO case. Remove idle gear (Item 2). Remove bearing (Item 3) if necessary. Figure 135 Figure 136 Drive Train Workman 3000/4000 Series...
Page 295 5. Remove PTO drive shaft: C. Shift PTO to ”ON” position. D. Remove 2 snap rings (Item 1, 2) from PTO case. E. Slide drive shaft assembly (Item 3) toward PTO shaft side. F. Remove bearing (Item 4). G. Slide drive shaft toward other side. H.
Page 296 7. Disassemble PTO idle shaft: A. Use a bearing puller to remove bearing (Item 1) if necessary. Figure 140 8. Disassemble PTO shaft: A. Use a bearing puller to remove bearing (Item 1). B. Remove gear (Item 2) and snap ring (Item 3). C.
Page 297 Power Take–Off (PTO) Inspection 1. Thoroughly clean and dry all parts. 2. Use emery cloth to remove nicks and burrs from all parts. 3. Measure clearance between shifter groove and shift- er block. Replace shifter block if clearance exceeds 1.0 mm (.039 in.).
Page 298 Power Take–Off (PTO) Reassembly NOTE: Item numbers in figures are shown in reverse or der of assembly; for example, when reassembling, install Item 1 last. 1. Clean gasket material from mating surfaces of case and cover. IMPORTANT: Be careful not to damage mating sur faces when removing gasket material.
Page 299 4. Assemble PTO shaft: A. Use a press to install bearing (Item 6) onto PTO shaft. B. Install washer (Item 5) and snap ring (Item 4). C. Install snap ring (Item 3) and gear (Item 2). D. Use a press to install bearing (Item 1). Figure 151 Figure 152 5.
Page 300 7. Install PTO drive shaft sub–assembly: A. Insert block (Item 9) into pin of shift arm. Apply moly disulfide grease onto both sides of block before installing. B. Put shifter of PTO drive shaft sub–assembly (Item 3) on the block. C.
Page 301 8. Install PTO idle shaft sub–assembly: A. Insert bearing (Item 3) into PTO case. Figure 159 B. Put gear (Item 2) on mating gear. C. Move gear until holes of gearing and bearing line D. Insert idle shaft sub–assembly (Item 1). Apply grease to idle shaft to aid assembly.
Page 302 10. Install PTO cover: A. Insert new oil seal into PTO cover. Apply multi– purpose grease to lip of oil seal. B. Insert 2 dowel pins onto PTO case. C. Apply silicone sealant onto mating surface of PTO cover. D. Install PTO cover. Tighten capscrews and nut with lockwasher to a torque of 24.5 –...
Page 303 Steering Gear Service ..... . . 26 Wheel Cylinder Service ..... Workman 3000 Series Page 7 – 1 Steering, Brakes and Supension...
Page 304: Specifications
Wheel nut torque 45 to 55 ft–lb (61 – 75 Nm) Brake fluid (Fig. 1) DOT 3 IMPORTANT:On 4WD vehicles, used only Toro ap proved tires (see Operator’s Manual) to prevent the clutch from locking up. Tire Pressure 1. Air pressure needed is determined by the payload carried.
Page 305: Special Tools
Use to remove and install the two (2) front suspension compression springs. 5� Qty. Item 1/2� x 20� threaded steel rods 1/2� nuts 5� 1/2� flat washers 20 � Figure 1 Workman 3000 Series Page 7 – 3 Steering, Brakes and Supension...
Page 306: Adjustments
1 brakes must be adjusted or repaired. Figure 2 1. Link rod ball joint Figure 3 1. Brake pedal 2. Clutch pedal 3. Clutch pedal up stop Steering, Brakes and Suspension Page 7 – 4 Rev. D Workman 3000 Series...
Page 307: Parking Brake Adjustment
3. Rotate tie rod to move front of tires inward or outward. 4. Tighten tie rod jam nuts after making adjustment. Center–to–center Distance Figure 5 Figure 6 1. Tie rod Workman 3000 Series Page 7 – 5 Rev. D Steering, Brakes and Supension...
Page 308: Troubleshooting
Low or uneven tire pressure. Loose wheel bearings. Loose steering shaft bearings. Broken or loose rear leaf spring. Bad shock absorber. Improper steering gear adjustment. Incorrect front wheel alignment (toe–in). Steering, Brakes and Suspension Page 7 – 6 Workman 3000 Series...
Page 309 Loose or broken brake lines. Leaking or worn master cylinder. Excessively worn brake shoes. Spongy brake pedal. Air in brake system. Excessively worn or cracked brake drums. Broken or worn pedal pivot bushing. Workman 3000 Series Page 7 – 7 Steering, Brakes and Supension...
Page 310 Improper brake or parking brake adjustment. Parking brake engaged. Weak or broken brake shoe return spring. Binding brake pedal. Sticking master cylinder. Saturated brake linings. Bent or out of round brake drums. Steering, Brakes and Suspension Page 7 – 8 Workman 3000 Series...
Page 311 Machining grooves in contact face of brake drums. Weak hold down springs. Brakes do not self adjust. Adjuster bolt seized in thread. Adjuster lever does not engage star wheel. Workman 3000 Series Page 7 – 9 Steering, Brakes and Supension...
Page 312: Repairs
45 – 55 ft–lb (61 – 75 Nm) after 1 – 4 hours of operation and again after 10 hours of operation and every 200 hours thereafter. Figure 7 1. Wheel 2. Wheel nut Steering, Brakes and Suspension Page 7 – 10 Workman 3000 Series...
Page 313: Front Wheel Bearing Service
45 – 55 ft–lb (61 – 75 Nm). Rear Wheel Bearing Service See Stub Axle and Drive Shaft Service in Repairs sec tion of Chapter 6 – Drive Train. Workman 3000 Series Page 7 – 11 Steering, Brakes and Supension...
Page 314: Brake Service
3. If servicing front brakes, remove wheel hub (see Front Wheel Bearing Service). If servicing rear brakes, remove stub axle (See Chapter 6 – Drive Train). Steering, Brakes and Suspension Page 7 – 12 Workman 3000 Series...
Page 315 1. Remove upper spring (Item 1), then the adjuster ment). spring (Item 2) and lower spring (Item 3). Remove hold– down washers (Item 4) and hold–down springs (Item 5), Workman 3000 Series Page 7 – 13 Steering, Brakes and Supension...
Page 316 4. Install brake cylinder assembly to backing plate with two (2) capscrews and lockwashers. 5. Connect brake line to brake cylinder. 6. Reassemble brakes as described in Brake Service. 7. Bleed brakes. Steering, Brakes and Suspension Page 7 – 14 Workman 3000 Series...
Page 317: Bleeding The Brakes
5. Do steps 1 – 4 for left rear, right front and left front Figure 11 brakes. 6. After bleeding of brakes is completed, road test ve- hicle to make sure brakes are operating correctly and pedal is solid. Workman 3000 Series Page 7 – 15 Steering, Brakes and Supension...
Page 318: Master Brake Cylinder Service
2. Flange seal 3. Stop pin 9. Retainer washer 4. Clevis 10. Primary piston assy. 5. Nut 11. Secondary piston assy. 6. Dust cover 12. Cap assembly Steering, Brakes and Suspension Page 7 – 16 Rev. D Workman 3000 Series...
Page 319: Parking Brake Cable Replacement
11. Adjust parking brake control lever and check opera- Figure 16 tion of brakes before using the machine. Workman 3000 Series Page 7 – 17 Steering, Brakes and Supension...
Page 320: Steering Wheel Installation
1. Disassemble and reassemble as shown in illustra- parts are not replaceable. tion. Note: The pitman arm has a splined and tapered joint. Use a puller when removing. Steering, Brakes and Suspension Page 7 – 18 Rev. D Workman 3000 Series...
Page 321 Install washer (Item 8) onto capscrew and slide shock absorber onto capscrew. Install second washer (Item 9) onto capscrew and secure with locknut (Item 10). Figure 19 Shock absorber Figure 20 Workman 3000 Series Page 7 – 19 Steering, Brakes and Supension...
Page 322: Rear Shock Absorber Replacement
(Item 4) and locknut (Item 5). Figure 21 1. Rubber bushing 4. Large washer 2. Large washer 5. Locknut 3. Shock absorber Shock absorber Figure 22 Steering, Brakes and Suspension Page 7 – 20 Workman 3000 Series...
Page 323 Nm) and secure with cotter pin (Item 1). 6) out of spindle. 5. Install front compression springs. 3. Remove control arm (Item 3 or 4). 6. Grease ball joint. Workman 3000 Series Page 7 – 21 Steering, Brakes and Supension...
Page 324 45 – 55 ft–lb 6. Grease tie rod end. (61 – 75 Nm) Figure 25 1. Jam nut 4. Rod end 2. Cotter pin 5. Tie rod 3. Slotted nut Steering, Brakes and Suspension Page 7 – 22 Workman 3000 Series...
Page 325 (Item 2). NOTE: Extended portion of each compression spring tool must be on op posite ends so capscrews (Item 7) can be removed. Figure 27 Workman 3000 Series Page 7 – 23 Steering, Brakes and Supension...
Page 326: Rear Leaf Spring Replacement
(Item 9) securing spring mount (Item 10) to frame rail, then remove leaf spring assembly. 2. Support frame side rails (Item 13) so rear axle (Item 4) can be removed. Steering, Brakes and Suspension Page 7 – 24 Workman 3000 Series...
Page 327 B. Tighten nuts to 50 – 60 ft–lb (68 – 81 Nm) in a crossing pattern. C. Retighten nuts to 50 – 60 ft–lb (68 – 81 Nm). Workman 3000 Series Page 7 – 25 Steering, Brakes and Supension...
Page 328: Steering Gear Service
The control valve in the steering gear directs the power which turns the wheels through the steering linkage. steering fluid to either side of the rack piston. The rack Steering, Brakes and Suspension Page 7 – 26 Workman 3000 Series...
Page 329 8. Remove adjuster nut (Fig. 29, Item 25) (Fig. 32). Figure 33 9. Remove adjuster plug (Fig. 29, Item 26) using a span ner wrench (Fig. 33). Spanner wrench Adjuster plug Stub shaft Figure 34 Workman 3000 Series Page 7 – 27 Steering, Brakes and Supension...
Page 330 (Item 19, 33, 34). Figure 37 13. Remove screws (Fig. 29, Item 9), clamp (Item 8) and ball guide (Item 7) from rack piston, then remove balls (Item 10). Steering, Brakes and Suspension Page 7 – 28 Workman 3000 Series...
Page 331 8. Install worm shaft and valve assembly into gear hous ing. 9. Install adjuster plug into gear housing using a span ner wrench (Fig. 40). Spanner wrench Adjuster plug Figure 41 Page 7 – 29 Rev. D Workman 3000 Series Steering, Brakes and Supension...
Page 332 ). If not, ad juster plug may not be tightened properly or may have turned during adjuster plug nut installation. Thrust bear ings and races may also be damaged. Figure 45 Steering, Brakes and Suspension Page 7 – 30 Workman 3000 Series...
Page 333 Do not exceed a total steering gear preload of 14 in–lb (16 kgcm 8. Install and tighten adjuster screw jam nut. Workman 3000 Series Page 7 – 31 Rev. D Steering, Brakes and Supension...
Page 334 Steering, Brakes and Suspension Page 7 – 32 Workman 3000 Series...
Page 335 Chapter 8 Electrical System Table of Contents WIRING SCHEMATICS ......2 TROUBLESHOOTING ......14 Workman 3100 (Model 07210 and 07214) .
Page 336: Chapter 8 - Electrical System
Wiring Schematics Workman 3100 (Model 07210 and 07214) WHITE BROWN PINK/BLUE VIOLET BROWN BLACK BLACK YELLOW Electrical System (Rev. G) Page 8 – 2 Workman 3000/4000 Series...
Page 337: Workman 3200/4200
Workman 3200/4200 (Models 07200, 07202, 07216, and 07200TC) WHITE Workman 3000/4000 Series Page 8 – 3 Electrical System (Rev. G)
Page 338: Workman 3200/4200
Workman 3200/4200 (Models 07211, 07212, 07218, and 07211TC) Electrical System (Rev. G) Page 8 – 4 Workman 3000/4000 Series...
Page 339: Workman 3300-D/4300-D (Models 07205, 07206, 07215, 07205Tc, 07206Tc, 07215Tc)
Workman 3300–D/4300–D (Models 07205, 07206, 07215, 07205TC, 07206TC, 07215TC) WHITE IGNITION Workman 3000/4000 Series Page 8 – 5 Electrical System (Rev. G)
Page 340: Workman 3300-D/4300-D (Models 07213, 07217, 07213Tc, And 07217Tc)
Workman 3300–D/4300–D (Models 07213, 07217, 07213TC, and 07217TC) Electrical System (Rev. G) Page 8 – 6 Workman 3000/4000 Series...
Page 341: Workman 3210
Workman 3210 (Heavy Industrial Model 07220) Workman 3000/4000 Series Page 8 – 7 Electrical System (Rev. G)
Page 342: Workman 3310-D
Workman 3310–D (Heavy Industrial Model 07222) TEMP SENDER Electrical System (Rev. G) Page 8 – 8 Workman 3000/4000 Series...
Page 343: Workman 3120 (Industrial Model 07232)
Workman 3120 (Industrial Model 07232) WHITE GREEN BROWN FUEL SENDER PINK/BLUE VIOLET BROWN BLACK BLACK YELLOW Workman 3000/4000 Series Page 8 – 9 Electrical System (Rev. G)
Page 344: Workman 3220 (Industrial Model 07231)
Workman 3220 (Industrial Model 07231) WHITE WHITE Electrical System (Rev. G) Page 8 – 10 Workman 3000/4000 Series...
Page 345: Workman 3320-D (Industrial Model 07230)
Workman 3320–D (Industrial Model 07230) WHITE Workman 3000/4000 Series Page 8 – 11 Electrical System (Rev. G)
Page 346: Workman 3420-Lp (Industrial Model 07233)
Workman 3420–LP (Industrial Model 07233) Electrical System (Rev. G) Page 8 – 12 Workman 3000/4000 Series...
Page 347: Special Tools
Multimeter The meter can test electrical components and circuits for current, resistance, or voltage. NOTE: Toro recommends the use of a DIGITAL Volt– Ohm–Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
Page 348: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and com- CAUTION ponents used on this machine (see Wiring Schematics section of this chapter). Remove all jewelry, especially rings and If the machine has any interlock switches by–passed, watches, before doing...
Page 349 Condition Possible Cause Nothing happens when start attempt is made. Clutch pedal not depressed – instruct operator. PTO engaged – instruct operator. Low battery charge. Loose or corroded battery cables. Loose or corroded ground. ”RUN” fuse open. Fusible link open. Clutch cable out of adjustment.
Page 350: Verify Interlock System Operation
Verify Interlock System Operation The purpose of the interlock system is to prevent the en- To verify PTO interlock switch operation: gine from cranking or starting unless the clutch pedal is 1. Sit on operator’s seat and engage parking brake. depressed or PTO (if so equipped) is disengaged.
Page 351: Testing
Testing This section will define given components, and the tests Note: Electrical troubleshooting of any 12 Volt power that can be performed on those components, when connection can also be performed through voltage drop those parts are disconnected from the electrical system. tests without disconnection of the component.
Page 352: Clutch Switch
Clutch Switch The clutch switch is normally open and closes when the clutch pedal is depressed. Test the switch by disconnecting the wiring connector and connecting a continuity tester across the two termi- nals. With the engine off, depress the clutch pedal com- pletely –...
Page 353: 2-3 And High-Low Lockout Switches
2–3 and High–Low Lockout Switches 2–3 Lockout Switch The 2–3 Lockout switch is closed in 2nd gear and open in 3rd gear. Test the switch by disconnecting the wiring connector and connecting a continuity tester across the two termi- nals. With the engine off, move transmission shifter to 2nd gear –...
Page 354: Battery
Battery Use a volt–ohm meter to measure the voltage between the battery terminals. If the voltage is less than 12.3 Volts D.C., the battery should be charged. NOTE: Regulated voltage will increase to approximately 13.5 Volts when the engine is running. Figure 12 1.
Page 355: Fuel Gauge Sender
Fuel Gauge Sender Disconnect wire and remove the fuel gauge sender from the fuel tank. Install an ohm meter between the terminal and base. With arm completely down (empty position), resistance should be 240–260 ohms. With arm completely up (full position), resistance should be 29–34 ohms.
Page 356: Service And Repairs
Service and Repairs Battery Service The battery is the heart of the electrical system. With reg- ular and proper service, battery life can be extend. Addi- tionally, battery and electrical component failure can be prevented. CAUTION When working with batteries, use extreme cau- tion to avoid slashing or spilling electrolyte.
Page 357 2. Conduct a hydrometer test of the battery electrolyte. D. Measure the temperature of the center cell. IMPORTANT: Make sure the area around the cells is E. Connect a battery load tester to the battery termi- clean before opening the battery caps. nals following the manufacturer’s instructions.
Page 358 6. Apply a light coat of grease on all battery posts and Battery Battery Charge Level cable connectors to reduce corrosion after connections Reserve (Percent of Fully Charged) are made. Capacity Capacity (Minutes) 7. Connect a digital multimeter (set to amps) between 80 or less 3.8 hrs 7.5 hrs...
Page 359: Fuses
Fuses The fuse block is located under the right side of the dash panel. NOTE: It is not always possible to see if a fuse is faulty. It is recommended that you check for faulty fuses with a continuity tester, not visually. FUSES OPEN ––...
Page 360: Tail Lamp Replacement
Tail Lamp Replacement Assemble and disassemble tail lamp as shown in il- lustration. The tail lamp uses a standard #1157 12volt bulb. Figure 19 1. Screw 3. Bulb #1157 2. Lens 4. Gasket Electrical System (Rev. G) Page 8 – 26 Workman 3000/4000 Series...
Page 361 Chapter 9 Hydraulic System Table of Contents SPECIFICATIONS ......2 TROUBLESHOOTING ......10 GENERAL INFORMATION .
Page 362: Specifications
Specifications Item Description Pump Pump Capacity 3.5 GPM (13.4 liter/min.) at 1,500 PSI (10,342 kPa) and 2,250 RPM Pump Relief Pressure (Vehicles with Hydraulic Lift Capabilities) Full bypass at 2,500 PSI (17,238 kPa) Pump Relief Pressure (Vehicles without Hydraulic Lift Capabilities) Full bypass at 1,000 PSI (6,895 kPa) Lift Control Valve (Vehicles with Hydraulic Lift Capabilities) Three position control valve Spring return to neutral Ball checks to...
Page 363: General Information
General Information Hydraulic Hoses Hydraulic hoses are subject to extreme conditions such WARNING as, pressure differentials during operation and exposure to weather, sun, chemicals, very warm storage condi Before disconnecting or performing any work tions or mishandling during operation or maintenance. on hydraulic system, all pressure in system These conditions can cause damage or premature dete...
Page 364 SAE Straight Thread O–Ring Port – Non–adjustable (Fig. 4) 1. Make sure both threads and sealing surfaces are free of burrs, nicks, scratches, or any foreign material. 2. Always replace the O–ring seal when this type of fit ting shows signs of leakage. O–Ring 3.
Page 365: Hydraulic Schematics
Hydraulic Schematics Base Vehicle Workman 3000/4000 Series Page 9 – 5 Hydraulic System...
Page 366: Vehicle With Optional Remote Hydraulic Kit
Vehicle with Optional Remote Hydraulic Kit Hydraulic System Page 9 – 6 Workman 3000/4000 Series...
Page 367 Industrial Models without Hydraulic Lift Capabilities Industrial Workman Models: 07220, 07222, 07230, 07231, 07232, 07233 DISPLACEMENT HYDRAULIC PUMP .388 IN /REV INTERNAL 1000 PSI RELIEF VALVE OPERATING SPEED 0.625 OF ENGINE SPEED PITMAN OUTPUT POWER ASSISTED SHAFT STEERING GEAR WORM SCREW IN TANK SUCTION...
Page 368: Special Tools
Special Tools Order these tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE (COMMERCIAL PRODUCTS). Hydraulic Pressure Test Kit – TOR47009 Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
Page 369 Hydraulic Test Fitting Kit – TOR4079 This kit includes a variety of O–ring Face seal fittings to enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps, and male test fittings. Figure 9 Workman 3000/4000 Series Page 9 –...
Page 370: Troubleshooting
Troubleshooting The cause of an improperly functioning hydraulic system ued use of an improperly functioning hydraulic system is best diagnosed with the use of proper testing equip could lead to extensive internal component damage. ment and a thorough understanding of the complete hy The charts that follow contain information to assist in draulic system.
Page 371 Problem Possible Causes Difficulty in connecting or disconnecting quick Pressure not relieved (coupler under pressure – en couplers. gine running). Remote hydraulic valve not in float position. Attachment does not function. Quick couplers not fully engaged. Quick couplers are interchanged. Pump drive belt loose.
Page 372: Testing
Testing The most effective method for isolating problems in the 1. Thoroughly clean the machine before disconnecting hydraulic system is by using hydraulic test equipment or disassembling any hydraulic components. Always such as pressure gauges and flow meters in the circuits keep in mind the need for cleanliness when working on during various operational checks.
Page 373: Test No. 1: Pump Flow And Relief Pressure
TEST NO. 1: Pump Flow and Relief Pressure 1. Make sure hydraulic oil is at normal operating temper ature before performing tests. 2. Raise and support dump box if installed, then engage parking brake and stop the engine. 3. Install tester in series between pump outlet (pressure hose) and dump valve or steering valve on units without dump cylinders.
Page 374: Test No. 2: Remote Hydraulics Relief Pressure
TEST NO. 2: Remote Hydraulics Relief Pressure Install tester in series between pump outlet and dump valve Tester Figure 11 1. Make sure hydraulic oil is at normal operating temper- Remote hydraulics 1,900 + 100 PSI relief pressure (13,100 + 690 kPa) ature before performing tests.
Page 375: Test No. 3: Power Steering Relief Pressure
TEST NO. 3: Power Steering Relief Pressure(Units with Lift Capabilities Only) Install tester in series between pump outlet and dump valve Tester Figure 13 IMPORTANT:This test can be performed on units Steering relief pressure 1,000 + 100 PSI with dump cylinders installed. Units without dump (6,895 + 690 kPa) cylinders installed do not have a separate relief valve installed for the steering valve.
Page 376 TEST NO. 4: Lift Cylinder Internal Leakage Test. 1. Remove all pressure from cylinder by fully retracting Disconnect and it (e.g. put hydraulic dump lever in LOWER position). plug this hose ANY oil flow or droplets from this fitting indicates internal leak 2.
Page 377: Service And Repairs
Service and Repairs Removing Hydraulic System Components 1. Thoroughly clean the machine before disconnecting, 2. After repairs, check control linkage for proper adjust- removing or disassembling any hydraulic components. ment, binding or broken parts. Always keep in mind the need for cleanliness when 3.
Page 378: Pump Drive Shaft Service
Pump Drive Shaft Service (Workman 3200/3300–D) 100 to 130 in–lb (11.3 to 14.7 N–m) Never–seez Figure 16 1. Driveshaft assembly 5. Pulley 8. Bearing 2. Belt 6. Woodruff key 9. Spacer 3. Locknut 7. Driveshaft 10. Support bracket 4. Washer 1.
Page 379 Pump Removal and Installation (Excluding Models with Air Cooled Engines) Removal 1. Loosen fan belt and remove from drive pulley. 2. Disconnect hydraulic lines from pump (Item 11). Install caps or plugs in hydraulic lines to prevent contam- 130 – 160 in–lb (150 –...
Page 380: Pump Removal And Installation
Pump Removal and Installation (Models with Air Cooled Engines Only) Removal 130 – 160 in–lb 1. Disconnect hydraulic lines from pump (Item 9). Install (150 – 184 kgcm) caps or plugs in hydraulic lines to prevent contamination and leakage of hydraulic oil. Install plugs in pump ports. 2.
Page 381: Pump Repair
Pump Repair 9.5 – 12.5 ft–lb (13 – 17 Nm) 12 – 15 ft–lb (16 – 10 Nm) Figure 19 1. Retaining ring 11. Gear 20. Ball 2. Oil seal 12. Bearing 21. Spring 3. Spacer 13. Pressure plate 22. Adjusting screw 4.
Page 382 9.5 – 12.5 ft–lb (13 – 17 Nm) 12 – 15 ft–lb (16 – 10 Nm) Figure 20 1. Retaining ring 11. Gear 20. Ball 2. Oil seal 12. Bearing 21. Spring 3. Spacer 13. Pressure plate 22. Adjusting screw 4.
Page 383 Disassembly 4. Check bearing (Item 27) for smooth operation. Re place bearing if loose on shaft or noisy when rotated. 1. Remove shaft seal (see Shaft Seal Replacement). 5. Inspect square key (Item 5), shear pin (Item 7), ball 2. Remove relief valve (see Relief Valve Service). key (Item 28) and keyways for wear or damage and re...
Page 384: Lift Valve Repair
Lift Valve Repair 1. After removing control valve, wash valve in solvent and dry thoroughly. 2. Carefully mount control valve in a vise so that control valve mounting pads are against jaws of vise. Control valve spool snap ring (Item 15) should be facing up. 3.
Page 385: Lift Cylinder Repair
Lift Cylinder Repair Figure 22 1. Barrel 6. Head 10. O–ring seal 2. Shaft 7. Retaining ring 11. Piston 3. Dust seal 8. Backup ring 12. Nut 4. Backup ring 9. O–ring seal 13. Warning decal 5. O–ring seal Disassembly 1.
Page 386 Figure 24 1. Barrel 6. Head 10. O–ring seal 2. Shaft 7. Retaining ring 11. Piston 3. Dust seal 8. Backup ring 12. Nut 4. Backup ring 9. O–ring seal 13. Warning decal 5. O–ring seal Inspection 4. Install retaining ring (Item 7) to secure assembly in barrel.
Page 387 Chapter 10 Front Wheel Drive – 4WD Table of Contents SPECIFICATIONS ......2 Constant Velocity (CV) Joint .
Page 388: Specifications
Specifications Item Description Front Differential 5.0 to 1 ratio, single reduction Front Brakes Hydraulically operated, self adjusting, 8–inch diameter drum Bidirectional Clutch Overrunning type Rev. B Front Wheell Drive Section (4WD) Page 10 – 2 Workman 4000 Series...
Page 389: General
General The “Automatic on Demand” four wheel drive feature, on have enough traction to move the vehicle without slip this vehicle, does not require operator activation. The ping. Once this occurs, the system stops delivering pow front wheel drive is not engaged (no power delivered to er to the front wheels and the handling characteristics front wheels) until the rear wheels begin to lose traction.
Page 390: Repairs
Repairs Front Wheel Assembly SMALL SPACER WHEEL ACCESS HOLE CONE Figure 2 1. Lug nut 13. Front brake hose 25. Jam nut 2. Lock washer 14. Bearing (matched set) 26. Grease fitting 3. Cap screw 15. Constant velocity (CV) joint 27.
Page 391: Front Wheel Bearing
Front Wheel Bearing Disassembly (Fig. 2) 1. Park machine on a level surface. Make sure engine is off. Set parking brake and block rear wheels. 2. Partially loosen lug nuts (1). Jack up and secure front wheel off the ground (see Jacking Vehicle in Chap ter 1 –...
Page 392 2. If ball joint seals are torn or cracked, replace seals IMPORTANT:If the cotter pin does not align, tighten and lubricate ball joints (Fig. 3). slotted hex nut until the key hole is aligned. Make sure cotter pin has a 0.002 inch (0.005 cm) clearance 3.
Page 393 Rev. B Workman 4000 Series Page 10 – 7 Front Wheel Drive Section (4WD)
Page 394: Front Brake
Front Brake Figure 6 1. Cap screw and lock washer 10. L–type seal 19. Pawl 2. Back plate 11. Piston 20. Adjuster spring 3. Plug 12. Dust cover 21. Pawl pin 4. Bleed screw 13. Brake shoe 22. Hold down washer 5.
Page 395 Disassembly (Fig. 6 and 7) Note: The front brake assembly may be disas sembled as necessary for inspection and repairs. 1. Remove upper shoe spring (14), adjuster spring (20), and then lower shoe spring (15). Note: The adjuster assembly (27) consists of the fe male push rod (16), bolt adjuster (17), and adjuster sleeve (18).
Page 396 6. Inspect female push rod (16), bolt adjuster (17), and 6. Install adjuster assembly (27) in the slots on the adjuster sleeve (18) for rust, corrosion, bending, and fa brake shoes (13). Install pawl (19) into brake shoe and tigue.
Page 397 Inspect Constant Velocity (CV) Joint Boot and Test CV Joint Inspecting Boot Inspect CV joint boot after every 200 hours of operation. A torn boot is the most common cause of CV joint fail ures. Note: A worn and noisy CV joint with the boot in good condition and filled with grease is not uncommon.
Page 398: Constant Velocity (Cv) Joint
Constant Velocity (CV) Joint BOOT CLAMPS RETAINING RING BALL INNER RACE BOOT CAGE SNAP RING OUTER RACE Figure 9 5. Outboard joint and shaft 1. Outboard boot kit 3. Circular clip 4. Inboard joint assembly 2. Inboard boot kit Removal (Fig. 2) LEVERAGE 1.
Page 399 Disassembly (Fig. 9) RETAINING RING Note: The inboard and outboard joints are similar in OUTER RACE construction. The principle difference is the inboard joint’s outer race has internal ball tracks that are longer, which allow the shaft of the outboard joint to plunge into the inboard joint.
Page 400 Inspection 1. Clean all parts thoroughly of dirt, grease, and de bris. Note: If any single part of either the outboard or in board joint is defective, the complete inboard or out board joint must be replaced 2. Inspect cage for worn windows; balls should be able to snap in.
Page 401: Change Front Differential Oil
Change Front Differential Oil Change front differential oil every 800 hours. 1. Position vehicle on a level surface. stop engine and engage parking brake. Remove key from ignition switch. 2. Clean area around drain plug on the side of the dif ferential.
Page 402: Front Suspension Control Arm Assembly
Front Suspension Control Arm Assembly 22 23 17 18 8 9 10 11 12 13 14 Figure 20 1. Grease fitting 13. R–clamp 25. Not used 2. Retaining ring 14. Front brake hose 26. Socket hex head screw 3. Upper control arm 15.
Page 403: Front Differential
Front Differential Removal (Fig. 20) Installation (Fig. 20) 1. Park machine on a level surface. Make sure engine is off. Set parking brake and block rear wheels. CAUTION 2. Drain front differential (20) oil into a suitable contain Support front differential during installation er by removing the drain plug from its bottom.
Page 404 17 18 BEARING CAP BEARING CRADLE 29 30 BEARING CAP Figure 21 1. Vent 13. O–ring seal 24. Bearing spacer 2. Front housing 14. Shim 25. Pinion shaft 3. Alignment pin 15. Carrier assembly 26. Cap screw 4. Thrust washer 16.
Page 405 Disassembly (Fig. 21) 1. Remove flange (19) from the pinion shaft (8) by re moving lock nut (18) and washer (17) from the threaded end of the shaft. Use a bearing puller if necessary to re move the coupler flange (Fig. 22). 2.
Page 406 IMPORTANT:When using a hammer and punch to remove the roll pin (28) and pinion shaft (25), be careful not to damage any gear teeth. 6. Drive roll pin (28) from the pinion shaft (25) using a long thin drift punch (Fig. 26). PUNCH Figure 26 7.
Page 407 Note: Remove bearing cones (29) from the differen tial case only if they need replacing (see Inspection). Retain shims (31) for reassembly of new bearing cones. 10. Remove bearing cone (29) from the differential case (27) with a puller. Make sure puller is inserted into the indentations on the differential case (Fig.
Page 408 IMPORTANT:Make sure shims (14) are kept after they are removed from the carrier assembly (15). Note: Remove bearing cup (10) from the carrier hous ing (15) only if it needs replacing (see Inspection). 14. Pull bearing cup (10) and shims (14) from the carrier assembly (15) (Fig.
Page 409 3. Inspect differential case (27) in the area where the bevel side gears (5) and pinion gear shafts (6) mesh. Replace case if machined areas are scored or if the pin ion shaft (25) fits loosely in its bore (Fig. 38). Figure 38 IMPORTANT:The ring gear (32) and pinion gear (8) must be replaced as a matched set.
Page 410 Assembly (Fig. 21) PINION SHAFT (25) RING GEAR (32) PINION GEAR (6) CAP SCREW (26) THRUST WASHER (7) DIFFERENTIAL THRUST CASE (27) WASHER (4) SIDE BEVEL SHIM (31) GEAR (5) CAP SCREW (11) BEARING BEARING CRADLE BEARING CONE (29) BEARING CUP (30) 3.750 INCH ROLL PIN (28)
Page 411 The ring gear (32) and pinon gear (8) are supplied as a SHIMMING matched set. Both gears are etched for verification with DIMENSION matching numbers. If a new gear set is being used, verify that the matching numbers are the same on both the ring and pinion gear before assembling the front dif...
Page 412 2. If the bearing cup (23) was removed, press new bearing cup into the carrier assembly (15) (Fig. 45). Figure 45 3. If the bearing cup (10) was removed, place shims (14) into the carrier assembly (15). Press new bearing cup into the assembly (Fig.
Page 413 6. Verify bearing preload and pinion gear shaft (8) rota tion as follows: A. Install coupler flange (19), washer (17), and lock nut (18) to the shaft of the pinion gear. Torque lock nut from 75 to 90 ft–lb (10.3 to 12.4 kg–m). B.
Page 414 IMPORTANT:When bearing cones (29) are removed removed from the differential case (27) they should replaced with new ones. When installing new bear ing cones to the differential case, use original shims (31) or new shims of the same thickness. 8. Press bearing cone (29) onto the differential case (27) (Fig.
Page 415 12. Check backlash of ring gear (32) with a dial indicator at three equally spaced positions (Fig. 57). A. Backlash should be from 0.002 to 0.006 inch (0.051 to 0.152 mm) and should not vary more than 0.002 inch (0.051 mm). B.
Page 416: Ring To Pinion Gear Engagement
17. Make sure both plugs (12) and O–rings (13) are installed. Verify that plugs are torqued between 20 to 25 ft–lb (2.8 to 3.5 kg–m). FILL PLUG DRAIN PLUG Figure 61 Ring to Pinion Gear Engagement When replacing the ring and pinion gear set, final posi- PROFILE tion of pinion is verified by using the gear contact pattern TOP LAND...
Page 417 When a change in backlash is required, backlash shims RING GEAR RING GEAR should be changed in the range of 1-1/2 times the COAST SIDE DRIVE SIDE amount of backlash required to bring the gears into Heel Heel specification. For example, if the backlash needed to be changed by .004”, the shim pack should be changed by .006”...
Page 418 Front Wheel Drive Section – 4WD (Rev. F) Page 10 – 32 Workman 4000 Series...
Page 419: Differential Drive Shaft
Differential Drive Shaft SNAP RING SNAP RING Figure 67 1. Flange yoke 4. Slip yoke 6. Seal 7. Socket head screw 2. Cross and bearing kit 5. Grease fitting 3. Tube yoke Removal 1. Park machine on a level surface. Make sure engine is off.
Page 420: Bidirectional Clutch
Bidirectional Clutch CAGE AND ROLLER ASSEMBLY Figure 70 1. Clutch shaft 8. Cam 14. Adapter plate 2. Seal plug 9. Thrust bearing 15. Screw 3. Retaining ring 10. Thrust washer 16. Lock washer 4. Ball bearing 11. Spring 17. Hex socket head screw 5.
Page 421 Inspection (Fig. 70) 1. Replace cage (12) if it is bent, cracked, or broken. Corrosion that can not be cleaned up with light polishing is not acceptable. 2. Replace spring (11) if flattened or distorted. 3. Replace thrust washer (10) if flat surfaces are pitted, gouged, or distorted.
Page 422 Assembly (Fig. 70) 1. Clean all parts thoroughly of all dirt and debris to prevent damage to the bidirectional clutch and trans- axle. 2. Place garter spring around the cage and into the groove (Fig. 75). 3. Place thrust bearing, thrust washer, and spring onto the cam (Fig.
Page 423 IMPORTANT:Make sure rubber side of the seal plug 9. Make sure drain plug is installed properly to the (2) faces towards the clutch when installing. transaxle. Fill transaxle with Dexron III ATF (see Chang- ing Transaxle/Hydraulic Fluid in the Service and Repairs 6.
Page 424: Lubrication
Lubrication WARNING Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition switch. Any load material must be re- moved from bed or other attachment before working under raised bed. Always Figure 78 place the safety support on extended lift cylinder to hold box up.
Page 425 Chapter 11 (For Mitsubishi Engine only) Liquid Propane Gas Conversion Kit Table of Contents SPECIFICATIONS ......2 TROUBLESHOOTING AND TESTING .
Page 426: Specifications
Specifications Item Description Engine Mitsubishi 3G83 liquid cooled gasoline (Modified) Ignition Timing (low idle) 11� BTDC + 2� @ 1200 + 100 RPM Ignition Timing (high speed) 22� BTDC + 2� @ 3000 + 100 RPM Spark Plug Gap 0.030 inch (0.762 mm) Fuel Liquid propane gas Fuel Tank...
Page 427: General Information
General Information Precautions for Working on Liquid Propane (LP) Gas Fuel Systems CAUTION CAUTION LP gas must be treated with care. This fuel is nat Before starting work on any liquid propane sys urally odorless and invisible. An identifying odor tem, disconnect the negative cable (black) from has been added to LP gas so the presence of the the battery.
Page 428: Refueling
Refueling LPG gas is stored in a 20 lb fork lift style tank. Acceptable LP Gas mixtures should meet the specifications for Pro pane HD–5 of Gas Producers Association Standard 2140, or the specifications documented in California title 13 CCR 2292.6 or a mixture with a minimum of 90% pro pane by volume that can pass the ASTM D2713 test for moisture content.
Page 429: Special Tools
Special Tools Pressure Test Pressure Gauge Kit Use this kit to take various pressure readings for diag nostic tests of the liquid propane (LP) gas fuel system. The kit contains one each of the following: 0 to 160 PSI test gauge, 0 to 5 PSI test gauge, and 0 to 10 inches O) vacuum gauge, vacuum hose, and assorted fit...
Page 430: Functional Operation
Functional Operation Liquid Propane Conversion Kit Page 11 – 6 Rev. D Workman 3000/4000 Series...
Page 431 Application LP Gas (Liquid) Liquid Propane (LP) Fuel Tank The Liquid Propane (LP) Gas Conversion Kit is installed to replace the gasoline fuel system on the Mitsubishi LP Gas (Vapor) Mixing 3G83 liquid cooled engine. With the kit installed, only LP Cleaner Adapter LP Gas...
Page 432 Troubleshooting With the exception of the fuel system, a gasoline engine 2. Make sure there are no air leaks in the fuel system. converted to run on LP gas operates as a gasoline one. The LP gas fuel system operates using negative pres When looking for the source of a engine malfunction, it sures.
Page 433: Testing Lp Gas Fuel System
Testing LP Gas Fuel System (Fig. 5) Preliminary 1. Park machine on a level surface, stop engine, en gage parking brake, and remove key from the ignition switch. 2. Read carefully Precautions for Working on Liquid Propane Gas Systems before proceeding to any of the tests.
Page 434: Adjustments
Adjustments Adjust LP Fuel System 1. Park machine on a level surface, stop engine, en gage parking brake, and remove key from the ignition switch. 2. Read carefully Precautions for Working on Liquid Propane Gas (LP) Fuel Systems before proceeding fur ther.
Page 435: Service And Repairs
Service and Repairs Check Spark Plug Gap 1. Park machine on a level surface, stop engine, en IMPORTANT:A cracked, fouled, dirty or otherwise gage parking brake, and remove key from the ignition malfunctioning spark plug must be replaced. Do not switch.
Page 436: Fuel Tank Assembly
Fuel Tank Assembly Figure 9 6. LP gas fuel decal 10. Flange head screw 1. 20 lb. LP gas fuel tank 11. Lock nut 7. LP gas dash decal 2. Flange head screw 8. Flange nut 12. Hose assembly 3. Clip 4.
Page 437: Conversion Kit Assembly
Conversion Kit Assembly 9 10 Figure 10 1. Hose clamp 15. 1/2–inch heater hose 29. Not used 2. Hose adapter 16. 1/2–inch heater hose 30. 1/8–inch NPT to 1/4–inch fitting 3. 2–inch rubber elbow 17. 1/4–inch NPT 31. Vacuum fuelock–Filter 4.

This manual is also suitable for:

Workman 4000 series Workman 3100 Workman 4300-d 3200

Toro Workman 3000 Series Service Manual

Chapter 5 - Kohler Command Series

Before Operating

Chapter 1 - Safety

Chapter 2 - Product Records and Maintenance

Table of Contents

Chapter 3 - Liquid Cooled Mitsubishi Gas Engine

Liquid Cooled Diesel Engine

Chapter 4 - Mitsubishi Diesel Engine

Air Cooled Gas Engine

Chapter 5 - Kohler Command Series

Chapter 6 - Drive Train

Chapter 6 Drive Train

Chapter 7 Steering, Brakes and Suspension

Electrical System

Chapter 8 - Electrical System

Chapter 9 Hydraulic System

Front Wheel Drive - 4Wd

Chapter 10 Constant Velocity (CV) Joint

Liquid Propane Gas Conversion Kit

Chapter 11 Testing LP Gas Fuel System

Quick Links

Chapters

Troubleshooting

Related Manuals for Toro Workman 3000 Series

Summary of Contents for Toro Workman 3000 Series