Toro Workman HD Series Service Manual
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Toro Workman HD Series Service Manual

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Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing,
and repair of major systems and components on the
Workman HD, HDX and HDX- D vehicles.
REFER TO THE OPERATOR'S MANUAL FOR OPER-
ATING,
MAINTENANCE
INSTRUCTIONS. For reference, insert a copy of the
Operator's Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator's Manual and Parts Catalog are avail-
able on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
HDX/HDX- D Models with Kubota Gasoline & Diesel Engines
AND
ADJUSTMENT
EThe Toro Company - 2014
Workman
R
HD Model 07369 S/N 314000001 & Up,
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing, or re-
pair of the machine.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
Part No. 14208SL
Service Manual
HD Series

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  • Page 1 The Toro Company reserves the right to change product specifications or this publication without notice. IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine.
  • Page 2 This page is intentionally blank. Workman HD Series...

  • Page 3: Table Of Contents

    ..... . . 9 - 37 KOHLER COMMAND ENGINE SERVICE MANUAL SAUER/DANFOSS STEERING UNIT TYPE OSPM SERVICE MANUAL Workman HD Series...
  • Page 4 This page is intentionally blank. Workman HD Series...
  • Page 5 ..... . 11 - 3 Wire Harness Drawings ....11 - 6 Workman HD Series...
  • Page 6 This page is intentionally blank. Workman HD Series...

  • Page 7: Safety Instructions

    ....SAFETY AND INSTRUCTION DECALS ..Workman HD Series Safety Page 1 − 1...

  • Page 8: Safety Instructions

    Safety Instructions The Workman HD series vehicles are designed and tested to offer safe service when operated and main- WARNING tained properly. Although hazard control and accident prevention are partially dependent upon the design and To reduce the potential for injury or death, configuration of the vehicle, these factors are also de- comply with the following safety instructions.

  • Page 9: While Operating

    6. Do not park on slopes unless wheels are chocked or E. Turn ignition key to START. blocked. 3. Do not run engine in a confined area without ade- quate ventilation. Exhaust fumes are hazardous and could possibly be deadly. Workman HD Series Safety Page 1 − 3...

  • Page 10: Maintenance And Service

    Hydraulic 16.To ensure optimum performance and continued fluid escaping under pressure can penetrate skin and safety of the vehicle, use genuine Toro replacement cause injury. Fluid accidentally injected into the skin parts and accessories. Replacement parts and acces-...

  • Page 11: Jacking Vehicle

    (or similar material) between jack and vehicle frame support. 4. The jacking point at the rear of the vehicle is under the axle tube (Fig. 2). Figure 2 1. Rear jacking point Workman HD Series Safety Page 1 − 5...

  • Page 12: Using Bed Safety Support

    Numerous safety and instruction decals are affixed to the Workman HD vehicle. If any decal becomes illegible or damaged, install a new decal. Decal descriptions and part numbers are listed in the vehicle Operator’s Manual and Parts Catalog. Safety Workman HD Series Page 1 − 6...

  • Page 13: Product Records

    ......Product Records Insert Operator’s Manual and Parts Catalog for your Workman HD series vehicle at the end of this chapter. Refer to Operator’s Manual for recommended mainte- nance intervals. Additionally, insert Installation Instruc- tions, Operator’s Manuals, Parts Catalogs and Service...

  • Page 14: Equivalents And Conversions

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

  • Page 15: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 16 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Product Records and Maintenance Page 2 − 4 Workman HD Series...
  • Page 17 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Workman HD Series Page 2 − 5 Product Records and Maintenance...

  • Page 18: Specifications

    All torque values are based on non−lubri- cated fasteners. Conversion Factors in−lb X 11.2985 = N−cm N−cm X 0.08851 = in−lb ft−lb X 1.3558 = N−m N−m X 0.7376 = ft−lb Product Records and Maintenance Page 2 − 6 Workman HD Series...

  • Page 19: General Information

    Chapter 3 Kubota EFI Gasoline Engine Table of Contents SPECIFICATIONS ......Fuel System .
  • Page 20 This page is intentionally left blank. Kubota EFI Gasoline Engine Page 3 − 2 Workman HDX...

  • Page 21: Specifications

    Specifications Item Description Make / Designation Kubota, Vertical, 4−Cycle, 3 Cylinder, Liquid Cooled, Gasoline Engine Bore 2.93 in (74.5 mm) Stroke 2.90 in. (73.6 mm) Total Displacement 58.68 cu. In. (962 cc) Compression Ratio 9.2:1 Ignition Timing 31_ BTDC @ 3600 rpm Ignition System Full Transistor Battery Ignition Type Firing Order...

  • Page 22: Introduction

    Service and repair parts for Kubota gasoline engines maintenance, troubleshooting, testing, and repair of the are supplied through your local Toro Distributor. If a Kubota EFI gasoline engine used in the Workman HDX. parts list is not available, be sure to provide your distribu- tor with the Toro model and serial number.

  • Page 23: Kubota Gasoline Engine Electronic Control Unit (Ecu)

    Connect the Kubota Gasoline Service Tool (KGST) to the diagnostic connector above the engine ECU (Fig. 3). Contact your Toro distributor for assist- ance in Kubota engine troubleshooting. Figure 2 1.

  • Page 24: Air Cleaner System

    Service and Repairs Air Cleaner System VACUATOR DIRECTION RIGHT FRONT Figure 4 1. Air cleaner assembly 4. Hose clamp 7. Flange nut (2) 2. Hose clamp 5. Air intake hose 8. Mounting bracket 3. Air inlet hood 6. Hose clamp 9.
  • Page 25 Check Air Filter, Dust Cup, & Burp Valve The air cleaner body, air filter, dust cup, and burp valve should be checked daily, prior to operation. IMPORTANT: Any leaks in the air cleaner system will cause serious engine damage. Make sure that all air cleaner components are in good condition and are properly secured during operation.

  • Page 26: Exhaust System

    Exhaust System RIGHT FRONT 22 to 26 ft−lb (30 to 35 N−m) 22 to 26 ft−lb 28 to 36 ft−lb (30 to 35 N−m) (38 to 49 N−m) 22 to 26 ft−lb (30 to 35 N−m) Figure 7 1. Oxygen sensor 11.
  • Page 27 Removal Installation 1. Park vehicle on a level surface and engage parking 1. Replace any removed gaskets. brake. Stop the engine and remove key from ignition 2. Fit all exhaust components to vehicle before tighten- switch. Allow engine to cool. ing any fasteners (Fig.

  • Page 28: Fuel System

    Fuel System 175 to 200 in−lb (20 to 22 N−m) ENGINE PURGE PORT RIGHT FRONT Figure 8 1. Fuel hose (to engine) 9. Flange nut (2) 16. Washer head screw (2) 2. Hose clamp 10. Fuel tank 17. Rollover valve 3.

  • Page 29: Fuel Tank

    Fuel Tank Removal (Fig. 8) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 3.
  • Page 30 Fuel Pump Removal (Fig. 8) 1. Park vehicle on a level surface, raise bed and en- gage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Install bed support on bed lift cylinder to prevent bed from lowering.

  • Page 31: Carbon Canister

    Carbon Canister The function of the fuel evaporative control system is to collect and store evaporative emissions from the fuel tank and engine. A carbon canister that is mounted to the left side of the frame is used to collect these evapora- tive emissions.

  • Page 32: Radiator

    Radiator RIGHT FRONT Thread Sealant Thread Sealant Figure 12 1. Radiator guard (industrial) 10. Clip (2) 21. Tee fitting 2. Radiator screen 11. Radiator mount 22. Lower radiator hose 3. Swell latch (4) 12. Hose (lower hose to reservoir) 23. Flange nut (2) 4.
  • Page 33 Removal (Fig. 12) Installation (Fig. 12) 1. Park vehicle on a level surface, stop engine, engage 1. If radiator assembly was disassembled, install com- parking brake and remove key from the ignition switch. ponents to radiator using (Fig. 13) as a guide. Make sure Allow engine and radiator to cool.

  • Page 34: Engine

    Engine RIGHT FRONT 15 to 20 ft−lb (20 to 27 N−m) LOCTITE #242 15 to 20 ft−lb (20 to 27 N−m) ANTI−SEIZE LUBRICANT Figure 14 1. Gear pump 11. Square key 21. Hex flange nut (2) 2. O−ring 12. Pump/engine mount 22.
  • Page 35 Engine Removal (Fig. 14) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s) to gain access to engine. If bed is raised, place safety sup- port on lift cylinder.
  • Page 36 17.Use engine lifting lugs provided and a hoist or lift to CAUTION remove engine from chassis. One person should oper- ate hoist or lift and a second person should help guide engine out of chassis. Move engine forward before lift- Do not open radiator cap or drain coolant if the ing to disengage transaxle input shaft from clutch.
  • Page 37 Engine Installation (Fig. 14) 14.Fill radiator with coolant (see vehicle Operator’s Manual). 1. Install pressure plate and clutch disc if removed (see Installing Clutch Disc and Cover in Chapter 6 − Drive 15.Connect wire harness connectors to engine compo- Train). nents.
  • Page 38 This page is intentionally blank. Kubota EFI Gasoline Engine Page 3 − 20 Workman HDX...
  • Page 39 Chapter 4 Kubota Diesel Engine Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Operator’s Manual .

  • Page 40: Specifications

    Specifications Item Description Make / Designation Kubota water−cooled, Diesel, Model D902−E3B Number of Cylinders Bore x Stroke 2.83” x 2.9” (72mm x 73.6mm) Total Displacement 54.8 in (898 cc) Compression Ratio 24.0:1 Firing Order 1 (front) − 2 − 3 Direction of Rotation Counterclockwise (viewed from flywheel) Fuel...

  • Page 41: General Information

    Service and repair parts for Kubota engines are sup- shooting, testing and repair of the diesel engine used in plied through your local local Toro distributor. If no parts the Workman HDX−D is included in this chapter and the list is available, be sure to provide your distributor with Kubota Workshop Manual, Diesel Engine, SM−E3B Se-...

  • Page 42: Adjust Accelerator Cable

    Adjustments Adjust Accelerator Cable 1. Position the machine on a level surface, stop the en- gine, and engage the parking brake. 2. Check position of the engine speed control lever on fuel injection pump. The speed control lever should be contacting the high speed stop screw when the acceler- ator pedal arm is .200”...
  • Page 43 This page is intentionally blank. Workman HDX−D Kubota Diesel Engine Page 4 − 5...

  • Page 44: Service And Repairs

    Service and Repairs Air Cleaner System STANDARD MODELS RIGHT FRONT VACUATOR DIRECTION INDUSTRIAL MODELS Figure 4 1. Air cleaner assembly 6. Kubota diesel engine 11. Hose intake 2. Hose clamp 7. Mounting bracket 12. Tube assembly 3. Air inlet hood 8.
  • Page 45 Air Cleaner Removal 7. Carefully slide the primary filter over the safety filter. Ensure that it is fully seated by pushing on the outer rim 1. Park vehicle on a level surface and engage parking of the filter while installing it. brake.

  • Page 46: Exhaust System

    Exhaust System RIGHT FRONT Figure 6 1. Engine 6. Flange head screw 11. Flange head screw 2. Muffler 7. Transaxle 12. Shift cable mount bracket 3. Exhaust gasket 8. Flange nut 13. Carriage bolt 4. Hex nut 9. Flange head screw 14.
  • Page 47 Removal (Fig. 6) Installation (Fig. 6) 1. Park vehicle on a level surface and engage parking 1. Replace any removed gaskets. brake. Stop the engine and remove key from ignition 2.Fit all exhaust components to vehicle before tighten- switch. Allow engine to cool. ing any fasteners.

  • Page 48: Fuel System

    Fuel System 175 to 200 in−lb (20 to 22 N−m) RIGHT Thread Sealant FRONT Thread Sealant Figure 7 1. Fuel tank cap 10. Hose clamp 18. Fuel hose (filter/separator to engine) 2. Grommet 11. Fuel hose (tank to pump) 19. Fitting 3.

  • Page 49: Fuel Tank

    Fuel Tank Removal (Fig. 7) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 3.

  • Page 50: Radiator

    Radiator RIGHT FRONT Thread Sealant 31 32 Thread Sealant Thread Sealant Figure 9 1. Radiator guard (industrial) 11. Radiator mount 23. Flange nut (2) 2. Radiator screen 12. Hose (lower hose to reservoir) 24. Reservoir cap 3. Swell latch (4) 13.
  • Page 51 Removal (Fig. 9) Installation (Fig. 9) 1. Park vehicle on a level surface, stop engine, engage 1. If radiator assembly was disassembled, install com- parking brake and remove key from the ignition switch. ponents to radiator using (Fig. 10) as a guide. Make sure Allow engine and radiator to cool.

  • Page 52: Engine

    Engine RIGHT FRONT 15 to 20 ft−lb (20 to 27 N−m) LOCTITE #242 15 to 20 ft−lb (20 to 27 N−m) ANTI−SEIZE LUBRICANT Figure 11 1. Gear pump 11. Square key 21. Hex flange nut (2) 2. O−ring 12. Pump/engine mount 22.
  • Page 53 Engine Removal (Fig. 11) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s) to gain access to engine. If bed is raised, place safety sup- port on lift cylinder.
  • Page 54 17.Use engine lifting lugs provided and a hoist or lift to CAUTION remove engine from chassis. One person should oper- ate hoist or lift and a second person should help guide engine out of chassis. Move engine forward before lift- Do not open radiator cap or drain coolant if the ing to disengage transaxle input shaft from clutch.
  • Page 55 2. If coupler assembly was removed, assemble coupler 14.Fill radiator with coolant (see vehicle Operator’s to engine pulley. Apply Loctite #242 (or equivalent) to Manual). threads of flange head screws that secure coupler to en- 15.Connect wire harness connectors to engine compo- gine pulley.
  • Page 56 This page is intentionally left blank. Kubota Diesel Engine Workman HDX−D Page 4 − 18...
  • Page 57 Chapter 5 Kohler Air Cooled Gasoline Engine Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .
  • Page 58 Specifications Item Description Make / Designation Kohler, CH680−3025, 4−stroke, V−Twin Air Cooled, OHV Number of Cylinders Bore x Stroke 3.15 in x 2.64 in (80 mm x 67 mm) Total Displacement 41.1 in (674 cc) Compression Ratio 8.5:1 Governor Mechanical Idle Speed (no load) 1200 + 100 RPM High Idle (no load)

  • Page 59: General Information

    General Information This Chapter gives information about specifications and Most repairs and adjustments require tools which are repair of the Kohler engine used in the Workman HD. commonly available in many service shops. Special tools are described in the Kohler Command Engine Ser- General engine maintenance procedures are described vice Manual.
  • Page 60 This page is intentionally blank. Kohler Air Cooled Gasoline Engine Workman HD Page 5 − 4...

  • Page 61: Service And Repairs

    Service and Repairs Cooling System To ensure proper engine cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. NOTE: Perform this maintenance procedure at the in- terval specified in the Operator’s Manual. IMPORTANT: The engine that powers the Workman HD vehicle is air−cooled.

  • Page 62: Exhaust System

    Exhaust System RIGHT FRONT Figure 2 1. Flange head screw (4) 6. Flange head screw (3) 11. Flange head screw 2. Exhaust manifold 7. Flange head screw 12. Shift cable mount bracket 3. Hex nut (4) 8. Bracket 13. Carriage bolt (2) 4.
  • Page 63 Removal (Fig. 2) Installation (Fig. 2) 1. Park vehicle on a level surface and engage parking 1. Replace any removed gaskets. brake. Stop the engine and remove key from ignition 2. Fit all exhaust components to vehicle before tighten- switch. Allow engine to cool. ing any fasteners (Fig.

  • Page 64: Fuel System

    Fuel System 175 to 200 in−lb (20 to 22 N−m) FILTER FROM TANK PURGE PORT ENGINE RIGHT FRONT Figure 3 1. Fuel hose (to filter) 11. Fuel tank cap 21. Washer head screw (2) 2. Hose clamp 12. Grommet 22. Support tube 3.

  • Page 65: Fuel Tank

    Fuel Tank Removal (Fig. 3) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 3.

  • Page 66: Carbon Canister

    Carbon Canister The function of the fuel evaporative control system is to collect and store evaporative emissions from the fuel tank and engine. A carbon canister that is mounted to the left side of the frame is used to collect these evapora- tive emissions.
  • Page 67 This page is intentionally blank. Workman HD Kohler Air Cooled Gasoline Engine Page 5 − 11...

  • Page 68: Engine

    Engine Antiseize Lubricant 35 to 40 ft−lb (48 to 55 N−m) Antiseize Lubricant RIGHT FRONT Figure 6 1. Lock nut 17. Flange nut 33. Choke cable 2. Flat washer 18. Clutch adapter 34. Flange nut (4) 3. Pulley 19. Cap screw (6) 35.
  • Page 69 Engine Removal (Fig. 6) 1. Park vehicle on a level surface and engage parking brake. Stop the engine and remove key from ignition switch. Allow engine to cool. 2. Raise or remove the bed or other attachment(s). If bed is raised, place safety support on lift cylinder. 3.

  • Page 70: Flywheel And Pilot Bearing Inspection

    Flywheel and Pilot Bearing Inspection 7. Secure engine to engine mount with four (4) flange nuts and flange head screws. 1. Inspect flywheel surface for stepped wear, streaking or seizure and replace if necessary. Check flywheel run- 8. Connect choke cable to choke lever on engine (Fig. out and replace if runout exceeds 0.005 in.

  • Page 71: Troubleshooting

    ....... . . Workman HD Series Page 6 − 1...
  • Page 72 Specifications Item Specification Transaxle Oil Dexron III ATF Transaxle Oil Capacity 7.5 U.S. quart (7.1 liter) system capacity Drive Train Page 6 − 2 Workman HD Series...

  • Page 73: Drive Train Operation

    General Information Drive Train Operation Workman HD series vehicles are equipped with a Toro designed transaxle with 3 forward speeds, 1 reverse Optional PTO speed and a differential lock. Hi−Lo range gives an effec- tive 6 forward and 2 reverse speeds.

  • Page 74: Clutch Alignment Tool

    Special Tools Order special tools from your Toro Distributor. Clutch Alignment Tool Use clutch alignment tool to align clutch friction disk to engine flywheel before tightening pressure plate cap screws. Toro Part Number: TOR6002 Figure 2 Drive Train Page 6 − 4...

  • Page 75: Power−Take−Off (Pto) Cable Adjustment (If Equipped)

    4. Secure PTO cable clevis to PTO lever arm with clevis pin. Figure 3 1. PTO lever arm 3. Clevis pin 2. PTO cable 4. Clevis jam nut Workman HD Series Page 6 − 5 Drive Train...

  • Page 76: Clutch

    Damaged release bearing. Clutch noisy. Improper installation of clutch cover assembly. Excessive wear of clutch disc facing. Worn clutch disc spline. Weak or broken clutch torsion spring. Damaged pilot bushing. Damaged release bearing. Drive Train Page 6 − 6 Workman HD Series...
  • Page 77 Oil adhered to clutch disc facing. Uneven height of diaphragm spring. Weak or damaged clutch torsion spring. Damaged pressure plate or flywheel. Damaged clutch release bearing. Loose or worn front wheel bearings. Workman HD Series Page 6 − 7 Drive Train...

  • Page 78: Transaxle

    Excessive wear of driveshaft(s). Transaxle sticks in gear. Clutch not releasing. Shift fork detent ball stuck. Shift linkage damaged, loose or out of adjustment. Sliding gears tight on shaft splines. Synchronizer shift keys damaged. Drive Train Page 6 − 8 Workman HD Series...
  • Page 79 Excessive end play in gears. Lack of spring pressure on shift fork detent ball. Badly worn bearings. Overheating of transaxle. Oil level too high. Excessive hydraulic load. See Chapter 9 − Hydraulic System. Workman HD Series Page 6 − 9 Drive Train...

  • Page 80: Service And Repairs

    2. Remove knobs from control levers, then remove cen- 5. Loosen jam nut that retains clevis to shift cable and ter console shift boot and control plate (Fig. 5). remove clevis from cable. Drive Train Page 6 − 10 Workman HD Series...
  • Page 81 Hold lever in stopped position and adjust stop bolt so that head just contacts lever. Tighten hex nut on stop bolt. 9. Install shift boot, control plate and control lever knobs. Workman HD Series Page 6 − 11 Drive Train...
  • Page 82 5. Flange nut (2) 12. Driveshaft assembly (2) 18. Clevis pin (2) 6. Parking brake caliper (LH shown) 13. Flange nut (2 per shaft) 19. Flange head screw (20) 7. Splined shaft (2) Drive Train Page 6 − 12 Workman HD Series...

  • Page 83: Driveshaft

    Repairs section of Chapter 7 - Chassis). Make sure that wheel lug nuts are properly torqued from 80 to 90 ft- lb (109 to 122 N- m). 4. Lubricate driveshaft grease fittings. Workman HD Series Page 6 - 13 Drive Train...

  • Page 84: Driveshaft Cross And Bearing Service

    E. Carefully place second bearing into yoke bore and onto cross shaft. Press bearing into yoke. F. Install snap rings to bearings to secure bearings in place. G. Repeat procedure for remaining yoke. Drive Train Page 6 − 14 Workman HD Series...
  • Page 85 4. Connect wire harness electrical connector to PTO switch. Figure 11 5. Adjust PTO control cable (see PTO Cable Adjust- ment in the Adjustments section of this chapter). 1. PTO assembly 2. Alignment pin Workman HD Series Page 6 − 15 Drive Train...

  • Page 86: Transaxle

    11. Shift lever (2) 17. 90 elbow fitting 5. Flange nut (4) 12. Differential lock lever 18. Drain plug 6. Cap screw (2) 13. Strainer 19. O−ring 7. Flange head screw (4) Drive Train Page 6 − 16 Workman HD Series...

  • Page 87: Transaxle Removal

    15.Block front wheels. Jack−up rear of vehicle and install jack stands so transaxle can be removed by slid- ing out from under rear axle (see Jacking Vehicle in Chapter 1 − Safety in this manual). Workman HD Series Page 6 − 17 Drive Train...

  • Page 88: Transaxle Installation

    3. Adjust clutch pedal, shift cables, high−low cable and differential lock cable (see vehicle Operator’s Manual). 4. If equipped with PTO, adjust PTO cable (see PTO Cable Adjustment in the Adjustments section of this chapter). Figure 18 Drive Train Page 6 − 18 Workman HD Series...
  • Page 89 This page is intentionally blank. Workman HD Series Page 6 − 19 Drive Train...

  • Page 90: Clutch Service

    3. Inspect clutch release fork, release shaft and bush- ings for wear or damage. Inspect extension spring. Re- place worn or damaged parts. Replace oil seals. Drive Train Page 6 − 20 Workman HD Series...
  • Page 91 Wipe off any excess grease. 2. Use clutch alignment tool (see Special Tools in this chapter) to position clutch disk to engine flywheel. Figure 23 Workman HD Series Page 6 − 21 Drive Train...
  • Page 92 This page is intentionally blank. Drive Train Page 6 − 22 Workman HD Series...

  • Page 93: Transaxle Service

    6. Inspect fork shaft case for cracks or damage and re- place if necessary. Figure 26 1. Spindle 3. Ball (2) 2. Spring (2) Workman HD Series Page 6 − 23 Drive Train...
  • Page 94 1. Front drive shaft 3. Bearing (gear case) 2. 41T gear 4. Bearing (center plate) 9. Remove reverse shaft from transaxle case. Figure 29 1. Reverse shaft 2. Bearing (gear case) Drive Train Page 6 − 24 Workman HD Series...
  • Page 95 L.H. side cover still at- tached to transaxle. Figure 32 1. Flange head screw (5) 3. Shims 2. L.H. axle shaft assembly 4. L.H. Side cover Workman HD Series Page 6 − 25 Drive Train...
  • Page 96 Figure 34 1. Flange head screw (4) 2. R.H. Axle shaft assy. 16.Remove differential gear assembly together with fork shaft assembly. Figure 35 1. Differential gear assy. 2. Fork shaft assy. Drive Train Page 6 − 26 Workman HD Series...
  • Page 97 7. Cap screw 3. Shift arm plate 8. Lock nut 4. Spring 9. 1st−Rev shift arm 5. Lock nut Figure 38 10. Cap screw 12. Oil seal 11. Keeper plate Workman HD Series Page 6 − 27 Drive Train...
  • Page 98 21.Remove air breather if necessary. Figure 40 1. Oil cap 2. Air breather 22.Loosen flange head screws and remove upper cover from transaxle case. Figure 41 1. Flange head screw (4) 2. Upper cover Drive Train Page 6 − 28 Workman HD Series...
  • Page 99 14. Bearing 5. Needle bearing (2) 15. Gear 6. Synchro ring 16. Snap ring 7. Snap ring 17. Gear 8. Shifter 18. Gear 9. Key 19. Main shaft 10. Snap ring Workman HD Series Page 6 − 29 Drive Train...
  • Page 100 12. Shifter 4. Collar 13. Key 5. Gear 14. Synchro ring 6. Bearing 15. Gear 7. Washer 16. Needle bearing 8. Gear 17. Thrust washer 9. Needle bearing 18. Reduction shaft Drive Train Page 6 − 30 Workman HD Series...
  • Page 101 3. Snap ring 11. Gear 4. Thrust washer 12. Washer 5. Gear 13. Snap ring 6. Inner race 14. Collar 7. Thrust washer 15. Bearing (2) 8. Snap ring (2) 16. Countershaft Workman HD Series Page 6 − 31 Drive Train...
  • Page 102 A. Remove shift fork, steel ball and spring from Hi− Lo shift fork assembly. B. Remove E−ring. Figure 50 1. Shift fork 4. E−ring 2. Steel ball 5. Hi−Lo fork shaft 3. Spring Drive Train Page 6 − 32 Workman HD Series...
  • Page 103 9. Pinion shaft 3. Bearing 10. Pinion (2) 4. Slider 11. Liner (2) 5. Screws 12. L.H. side gear 6. Ring gear 13. R.H. Side gear 7. Dowel pin (2) 14. Liner (2) Workman HD Series Page 6 − 33 Drive Train...
  • Page 104 10. Snap ring 3. L.H. axle shaft assembly 11. Washer 4. Snap ring 12. Bearing 5. Washer 13. Oil seal 6. Bearing 14. Washer 7. Oil seal 15. Seal cover 8. Differential carrier Drive Train Page 6 − 34 Workman HD Series...

  • Page 105: Transaxle Inspection

    C. Inspect I.D. of gear for excessive wear or scoring. Gear should fit snuggly on shaft. Figure 56 1. Front drive shaft 3. Bearing (gear case) 2. 41T gear 4. Bearing (center plate) Workman HD Series Page 6 − 35 Drive Train...
  • Page 106 4. Spline for clutch disc 8. Inspect snap ring and shim(s) for damage. Replace all parts if any part is cracked or broken. Figure 59 1. Seal cap 3. Snap ring 2. Shims 4. Shim Drive Train Page 6 − 36 Workman HD Series...
  • Page 107 1.100 in. (27.95 mm) or 71T gear portion is less than 1.179 in. (29.95 mm), replace the countershaft. Figure 63 1. Countershaft 3. Gear portion 2. Inner portion Workman HD Series Page 6 − 37 Drive Train...
  • Page 108 5. Side gear (2) and pinion shaft mating area. Replace the case if ma- 3. Side gear liner (2) chined surfaces are scored or if the pinion shaft fits loosely in the bore. Drive Train Page 6 − 38 Workman HD Series...

  • Page 109: Transaxle Assembly

    C. Install new O−ring. Apply multi−purpose grease on O−ring before installing. Figure 66 1. O−ring 5. Fork 2. Snap ring 6. Lock pin 3. Washer 7. Fork shaft 4. Spring Workman HD Series Page 6 − 39 Drive Train...
  • Page 110 14. Liner (2) O. Install slider. Put moly disulfide grease onto slid- ing area of differential case before installing. P. Use a press to install bearing. Q. Install snap ring. Figure 69 Drive Train Page 6 − 40 Workman HD Series...
  • Page 111 C. Insert 2−3 fork shaft into 2−3 fork. D. Drive lock pin into fork and fork shaft. Pay atten- tion to direction of slit in lock pin. Figure 71 1. Lock pin 3. Fork shaft 2. Shift fork Workman HD Series Page 6 − 41 Drive Train...
  • Page 112 3. Snap ring 11. Gear 4. Thrust washer 12. Washer 5. Gear 13. Snap ring 6. Inner race 14. Collar 7. Thrust washer 15. Bearing (2) 8. Snap ring (2) 16. Countershaft Drive Train Page 6 − 42 Workman HD Series...
  • Page 113 B. Install shifter onto hub. Figure 75 1. Shifter 2. Hub C. Insert springs into hub. Pay attention to direction of spring. Figure 76 1. Key (3) 3. Spring (2) 2. Hub Figure 77 Workman HD Series Page 6 − 43 Drive Train...
  • Page 114 12. Shifter 4. Collar 13. Key 5. Gear 14. Synchro ring 6. Bearing 15. Gear 7. Washer 16. Needle bearing 8. Gear 17. Thrust washer 9. Needle bearing 18. Reduction shaft Drive Train Page 6 − 44 Workman HD Series...
  • Page 115 14. Bearing 5. Needle bearing (2) 15. Gear 6. Synchro ring 16. Snap ring 7. Snap ring 17. Gear 8. Shifter 18. Gear 9. Key 19. Main shaft 10. Snap ring Workman HD Series Page 6 − 45 Drive Train...
  • Page 116 14.Install oil cap with O−ring. Apply multi−purpose grease to O−ring. 15.If removed, install air breather. Use sealing tape on threads of air breather. Figure 85 1. Oil cap 2. Air breather Drive Train Page 6 − 46 Workman HD Series...
  • Page 117 18.Assemble main shaft together with 2−3 fork shaft. Figure 88 19.Insert main shaft and 2−3 fork shaft assembly into transaxle case. Insert head of shift arm into groove of fork while installing. Figure 89 Workman HD Series Page 6 − 47 Drive Train...
  • Page 118 E. Apply multi−purpose grease onto lips of oil seal, then insert oil seal flush with face of housing. Figure 92 F. Apply moly disulfide grease to spline of main shaft for clutch disk hub. Drive Train Page 6 − 48 Workman HD Series...
  • Page 119 4. Shim 24.Install snap ring into the groove of the bearing hous- ing. Figure 94 1. Countershaft 4. Snap ring 2. Bearing 5. Center plate 3. Shims 6. Sealing cap Figure 95 Workman HD Series Page 6 − 49 Drive Train...
  • Page 120 Pay attention to direction of sealing cap. Figure 97 1. Sealing cap 27.Install fork shaft case: A. Insert spindle between fork shafts. Figure 98 1. Spindle Drive Train Page 6 − 50 Workman HD Series...
  • Page 121 1. Flange head screw (1) 3. Fork shaft case 2. Flange head screw (3) 28.Insert a washer into housing of transaxle case. Apply moly disulfide grease to washer before installing. Figure 101 1. Washer Workman HD Series Page 6 − 51 Drive Train...
  • Page 122 B. Apply silicone sealant onto mating surface of side cover. C. Install side cover and secure with ten (10) flange head screws. Torque screws from 18.5 to 22 ft−lb (24.5 to 29.5 N−m). Figure 104 Drive Train Page 6 − 52 Workman HD Series...
  • Page 123 C. Install axle shaft assembly and secure with flange head screws. Torque screws from 18.5 to 22 ft−lb 18.5 to 22 ft−lb (24.5 to 29.5 N−m) (24.5 to 29.5 N−m). Figure 107 1. Flange head screw (5) Workman HD Series Page 6 − 53 Drive Train...
  • Page 124 Torque screws from 18.5 to 22 ft−lb (24.5 to 29.5 N−m). 18.5 to 22 ft−lb (24.5 to 29.5 N−m) Figure 110 1. Flange head screw (4) 2. Upper cover Drive Train Page 6 − 54 Workman HD Series...
  • Page 125 Torque screws from 18.5 to 22 ft−lb (24.5 to 29.5 N−m). 38.Install extension spring. 18.5 to 22 ft−lb (24.5 to 29.5 N−m) Figure 112 1. Extension 2. Flange hd screw (9) Workman HD Series Page 6 − 55 Drive Train...

  • Page 126: Power Take−Off (Pto) Service (If Equipped)

    1. Put vehicle on a level surface. Stop the engine and cap screws. remove key from ignition switch. Remove the bed or oth- 5. Separate PTO cover from PTO housing. er attachment(s). Allow transaxle and engine to cool. Drive Train Page 6 − 56 Workman HD Series...
  • Page 127 1. Output shaft assembly 7. Remove intermediate shaft assembly from PTO housing. Remove intermediate gear. Remove bearing from housing if necessary. Figure 115 1. Intermediate shaft assy. 2. Intermediate gear Figure 116 3. Bearing Workman HD Series Page 6 − 57 Drive Train...
  • Page 128 6. Thrust washer 8. Shift arm 9. Disassemble PTO input shaft: A. Remove shift collar. B. Remove steel balls and spring. Figure 119 1. Shift collar 3. Spring 2. Steel ball (2) Drive Train Page 6 − 58 Workman HD Series...
  • Page 129 6. Bearing 3. Retaining ring 7. Output shaft 4. Retaining ring Figure 122 1. Bearing 5. Thrust washer 2. Gear 6. Bearing 3. Retaining ring 7. Output shaft 4. Retaining ring Workman HD Series Page 6 − 59 Drive Train...
  • Page 130 12.Disassemble shift arm: A. Remove lock pins from shift arm. B. Remove O−rings. Figure 123 1. O−ring (2) Drive Train Page 6 − 60 Workman HD Series...

  • Page 131: Inspection

    BUSHING AREA Figure 126 6. Inspect surface of oil seal area on output shaft for wear or damage. OIL SEAL AREA Figure 127 Workman HD Series Page 6 − 61 Drive Train...

  • Page 132: Assembly

    1. Clean gasket material from mating surfaces of hous- ing and cover. IMPORTANT: Be careful not to damage mating sur- faces when removing gasket material. 2. Make sure all parts are free of dirt and dust. Drive Train Page 6 − 62 Workman HD Series...
  • Page 133 E. Drive spring pins into shift lever and shift arm. Pay attention to direction of slit in spring pins. Figure 129 1. O−ring (2) 3. Shift arm 2. Spring pin (2) Figure 130 Figure 131 Workman HD Series Page 6 − 63 Drive Train...
  • Page 134 1. Bearing 5. Thrust washer 2. Gear 6. Bearing 3. Retaining ring 7. Output shaft 4. Retaining ring 5. Use a press to install bearing onto intermediate shaft. Figure 134 1. Bearing Drive Train Page 6 − 64 Workman HD Series...
  • Page 135 A. Insert spring and steel balls into hole. B. Insert shift collar onto input shaft. C. Move shift collar to ”ON” position. Figure 135 1. Shift collar 3. Spring 2. Steel ball (2) Workman HD Series Page 6 − 65 Drive Train...
  • Page 136 9. Shifter block 5. Bearing Figure 137 3. Input shaft assembly 6. Thrust washer 4. Bearing 7. Gear 5. Bearing Figure 138 3. Input shaft assembly Figure 139 6. Thrust washer 7. Gear Drive Train Page 6 − 66 Workman HD Series...
  • Page 137 Figure 140 3. Bearing Figure 141 1. Intermediate shaft 2. Gear sub−assembly 9. Insert PTO shaft assembly into bearing housing of PTO housing. Figure 142 1. PTO shaft assembly Workman HD Series Page 6 − 67 Drive Train...
  • Page 138 Torque fasteners from 18 to 22 ft−lb (24.5 to 29.5 N−m). 18.5 to 22 ft−lb (24.5 to 29.5 N−m) 11. Install PTO to transaxle (see PTO Removal and Figure 143 Installation in this chapter). Drive Train Page 6 − 68 Workman HD Series...
  • Page 139 ........Workman HD Series Page 7 −...
  • Page 140 Minimum thickness = 0.154” (3.9 mm) Service Brake pads Minimum thickness = 1/16” (1.6 mm) Parking Brake pads Minimum thickness = 0.135” (3.4 mm) *For proper 4WD operation, keep tires at maximum pressure. Chassis Page 7 − 2 Workman HD Series...

  • Page 141: General Information

    4. Higher tire pressure should be used for heavier pay- loads at higher speeds. Do not exceed maximum tire pressure (see Specifications). 5. See vehicle Operator’s Manual for additional tire, pressure, loading, and towing information. Workman HD Series Page 7 − 3 Chassis...
  • Page 142 Compression Spring Tool Use to remove and install the front suspension com- pression springs. 5” Quantity Item 1/2” x 20” threaded steel rods 1/2” nuts 5” 1/2” flat washers 20” Figure 1 Chassis Page 7 − 4 Workman HD Series...

  • Page 143: Troubleshooting

    Low or uneven tire pressure. Worn or loose wheel bearings. Worn steering linkage bushings. Broken or loose rear leaf spring. Worn shock absorber(s). Incorrect front wheel alignment (toe−in). Worn or loose ball joints. Workman HD Series Page 7 − 5 Chassis...

  • Page 144: Brakes

    Broken or worn brake pedal pivot bushing. Squealing brakes. Glazed, saturated or worn brake pads. Contaminants on brake pads and/or rotors. Missing anti−rattle clip in brake caliper. Scored or bent brake rotors. Chassis Page 7 − 6 Workman HD Series...
  • Page 145 Sticking brake master cylinder. Wheel bearing is seized. Brakes fade. Overheated brake rotors. Saturated brake pads. Brakes surge at slow speeds and chatter at fast Warped or unevenly worn brake rotors. speeds. Workman HD Series Page 7 − 7 Chassis...

  • Page 146: Wheel Assembly

    6. Flange head screw 10. Clevis pin (2) 3. Wheel hub assembly 7. Parking brake caliper (LH) 11. Rear wheel assembly 4. Lug nut (5 per wheel) 8. Parking brake bracket (LH) 12. Rear axle Chassis Page 7 − 8 Workman HD Series...
  • Page 147 (Fig. 3) and in two (2) steps. First, tighten all lug nuts to 40 ft−lb (55 N−m) and then torque all lug nuts to a final torque from 80 to 90 ft−lb (109 to 122 N−m). Workman HD Series Page 7 − 9 Chassis...

  • Page 148: Brake System

    3. Wheel hub assembly 8. Parking brake bracket (LH shown) 12. Rear axle 4. Lug nut (5 per wheel) 9. Parking brake return spring 13. Parking brake cable (2) 5. Brake caliper Chassis Page 7 − 10 Workman HD Series...
  • Page 149 B. Place banjo washer on each side of brake line fit- ting. C. Install banjo bolt through brake line fitting and banjo washers and then thread into caliper. Torque banjo bolt from 108 to 132 in−lb (12.3 to 14.9 N−m). Workman HD Series Page 7 − 11 Chassis...

  • Page 150: Brake Caliper Service

    Figure 6 1. Bolt (2) 4. Caliper bracket 7. Piston (2) 2. Caliper body 5. Square seal (2) 8. Brake pad (2) 3. O−ring (4) 6. Dust seal (2) 9. Caliper anvil Chassis Page 7 − 12 Workman HD Series...
  • Page 151 (37 to 44 N−m). 3. Check that pins on caliper bracket are not worn or damaged. Wear on the pins will prevent smooth brake operation. Workman HD Series Page 7 − 13 Chassis...

  • Page 152: Bleed Brake System

    9. After bleeding of brakes is completed, test vehicle to make sure brakes are operating correctly and brake pedal is solid. Chassis Page 7 − 14 Workman HD Series...

  • Page 153: Parking Brake Caliper Service

    8. Pivot pin 2. Install cam side pad support (notch facing cam lever) and brake pad into caliper body. 3. Slide carrier side pad support and brake pad into cali- per body. Workman HD Series Page 7 − 15 Chassis...

  • Page 154: Brake Master Cylinder

    7. Flange nut 11. Brake shaft 3. Clevis pin 8. Flange nut (2) 12. Brake switch (2WD models) 4. Grease fitting 9. Cotter pin 13. Brake switch (4WD models) 5. Brake pedal Chassis Page 7 − 16 Workman HD Series...
  • Page 155 5. Install hood (see Hood Installation in this section). CAUTION After servicing the brakes, always check the brakes in a wide open, level area that is free of other persons and obstructions. 6. Check brake operation. Workman HD Series Page 7 − 17 Chassis...

  • Page 156: Brake Master Cylinder Service

    4. Install push rod and secure in place with circlip. Install lower end of dust cover to housing. 5. Push in on push rod so stop pin can be installed to retain secondary piston assembly, then install flange seal and reservoir. Chassis Page 7 − 18 Workman HD Series...
  • Page 157 This page is intentionally blank. Workman HD Series Page 7 − 19 Chassis...

  • Page 158: Parking Brake Cable

    4. For parking brake cable that is to be serviced, re- brake cables in console. move rear wheel from vehicle (see Wheel Assembly Re- moval in this section). Chassis Page 7 − 20 Workman HD Series...
  • Page 159 Torque screws a maximum of 12 in−lb (1.3 N−m). 6. Install control lever knobs. 7. Adjust parking brake lever (see vehicle Operator’s Manual) and check operation of brakes before returning the vehicle to service. Workman HD Series Page 7 − 21 Chassis...

  • Page 160: Wheel Hub

    8. Parking brake bracket (LH shown) NOTE: If vehicle is equipped with 4WD, see CV Axle Assembly in Chapter 10 - Front Wheel Drive (4WD) in this manual for front wheel hub removal and installation procedure. Chassis Page 7 - 22 Workman HD Series...
  • Page 161 7. If front wheel hub replacement is necessary, remove cap screw, washers and lock nut from wheel hub assem- bly so that these components can be installed on re- placement hub. Workman HD Series Page 7 - 23 Chassis...

  • Page 162: Steering Assembly

    9. Grease fitting (2) 20. Center link 31. Snap ring (2) 10. Lock nut (2) 21. Flat washer (2) 32. Cap screw (2) 11. Tie rod assembly 22. Cap screw (2) 33. Lock nut (2) Chassis Page 7 − 24 Workman HD Series...

  • Page 163: Steering Assembly

    FRONT Figure 18 1. Pivot mount 5. Thrust washer (2) 2. Flange bushing (2) 6. Pitman arm 3. Flange bushing (2) 7. Idler arm 4. Wave washer (2) 8. Spindle nut (2) Workman HD Series Page 7 - 25 Chassis...
  • Page 164 Install cotter pin. C. Install tie rods to center link (see below). D. Install seat base to vehicle (see Seat Base Instal- lation in this section). Chassis Page 7 − 26 Workman HD Series...
  • Page 165 This page is intentionally blank. Workman HD Series Page 7 − 27 Chassis...

  • Page 166: Front Control Arms

    8. Lock nut (8) 13. Ball joint seal 4. RH lower control arm 9. Cap screw (2) 14. Knuckle (LH shown) 5. Cap screw (4) 10. Flange bushing (2 per arm) 15. Retaining ring Chassis Page 7 − 28 Workman HD Series...
  • Page 167 4. Remove control arm from vehicle frame. 5. Disassemble control arm as needed. A. Remove retaining ring and press ball joint out of control arm. B. Press flange bushings from control arm. Workman HD Series Page 7 − 29 Chassis...

  • Page 168: Front Compression Spring Service

    5. Stabilizer link 8. LH control arm tower 2. Compression spring (2) 6. Lock nut 9. Spring pivot sleeve 3. Flange nut 7. Cap screw 10. RH control arm tower 4. Cap screw Chassis Page 7 − 30 Workman HD Series...
  • Page 169 8. Carefully loosen compression spring tool rods to al- low disassembly of compression springs, spring cradles and stabilizer links. Assembly (Fig. 20) 1. Reverse the disassembly procedure to install com- pression springs. Workman HD Series Page 7 − 31 Chassis...

  • Page 170: Front Shock Absorber

    Install second washer 5. Outer washer (0.563” ID) 11. Frame stud onto cap screw and secure with lock nut. 6. Lock nut Figure 24 1. Shock absorber 3. Control arm tower 2. Frame stud Chassis Page 7 − 32 Workman HD Series...

  • Page 171: Rear Shock Absorber

    1. Rubber bushing 6. Spacer 2. Flat washer (0.563” ID) 7. Flat washer (0.445” ID) 3. Shock absorber 8. Cap screw 4. Flat washer (0.656” ID) 9. Flange nut 5. Lock nut Workman HD Series Page 7 − 33 Chassis...

  • Page 172: Rear Leaf Spring

    7. Remove two (2) lock nuts and flange head screws (See Jacking Vehicle in Chapter 1 − Safety). securing spring mount to frame rail, then remove leaf spring assembly. 3. Remove rear wheels (see Wheel Assembly Remov- al in this section). Chassis Page 7 − 34 Workman HD Series...
  • Page 173 80 to 90 ft−lb (109 to 122 tighten finger tight. N−m). NOTE: During leaf spring installation, make sure axle and spring plate are centered on leaf spring knob. Workman HD Series Page 7 − 35 Chassis...

  • Page 174: Front Wheel Alignment

    If necessary, adjust tie rods equally to center steering components and then re− check front wheel alignment. 5. Make sure that all jam nuts are properly torqued. Chassis Page 7 − 36 Workman HD Series...

  • Page 175: Steering Wheel

    Torque hex nut from 20 to 25 ft−lb (28 to 33 N−m). Figure 29 4. Install steering wheel cover. 1. Steering wheel 4. Steering control valve 2. Flat washer 5. Frame 3. Hex nut Workman HD Series Page 7 − 37 Chassis...

  • Page 176: Seat Base

    13. Flat washer (8) 20. Spring washer 6. Carriage bolt (8) 14. Flange head screw (4) 21. Flat washer 7. Seat bracket (4) 15. Flange nut (4) 22. Detent lever 8. Seat base Chassis Page 7 − 38 Workman HD Series...
  • Page 177 3. Secure engine coolant overflow tank into slots in rear of seat base. 4. Secure center console control plate to seat base with removed screws. Install knobs on control levers. 5. Install ROPS cover to vehicle (Fig. 31). Workman HD Series Page 7 − 39 Chassis...

  • Page 178: Hood

    3. Secure hood to frame by pressing hood attachment hood away from operator frame. tabs to dash and bumper. 3. Unplug the wire harness connector from the two (2) headlights. 4. Remove hood from vehicle. Chassis Page 7 − 40 Workman HD Series...
  • Page 179 ....... . . Electronic Throttle Control (Workman HDX) ..Workman HD Series Page 8 − 1 Electrical System...

  • Page 180: Electrical Schematics

    Electrical Schematics The electrical schematics and other electrical drawings for Workman HD series vehicles are located in Chapter 11 - Electrical Drawings. Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier.
  • Page 181 Apply battery terminal protector to the con- nection after the battery cable, ring terminal, or fork ter- minal has been secured. Toro Part Number: 107- 0392 Figure 4 Workman HD Series Page 8 - 3...

  • Page 182: Troubleshooting

    Start relay faulty. Start relay wiring loose, corroded or damaged. Starter solenoid wiring loose, corroded or damaged. Starter solenoid faulty. Starter cranks, but should not, with clutch pedal Clutch proximity switch faulty. released. Electrical System Page 8 − 4 Workman HD Series...
  • Page 183 Damaged or disconnected wiring for 2−3 lockout switch or High−Low switch on transaxle. Battery does not charge. Alternator drive belt loose or damaged. Loose or broken wire(s). Fusible link faulty. Battery faulty. Alternator faulty. Workman HD Series Page 8 − 5 Electrical System...

  • Page 184: Electrical System Quick Checks

    (27 amps total). If low current reading is observed, one (refer to manufacturers’ instructions) and set the multi- (or more) of the glow plugs is faulty. meter to the correct scale. With the ignition switch in the Electrical System Page 8 − 6 Workman HD Series...

  • Page 185: Verify Interlock System Operation

    3. If engine cranks or starts, there is a malfunction in the interlock system that must be repaired before operating 4. If engine cranks or starts, there is a malfunction in the vehicle. interlock system that must be repaired before operating vehicle. Workman HD Series Page 8 − 7 Electrical System...

  • Page 186: Component Testing

    B + C + F, D + E START A + B + C START After testing is completed, connect wire harness con- nector to ignition switch. REAR VIEW FRONT VIEW Figure 7 Electrical System Page 8 − 8 Workman HD Series...

  • Page 187: Gauge Cluster

    ON position with the engine not Kubota Gasoline Service Tool (KGST) to the diagnostic running or if the charging circuit is not operating properly connector above the engine ECU. Contact your Toro dis- during engine operation. tributor for assistance in Kubota engine troubleshooting.

  • Page 188: Fuses

    1. Make sure that ignition switch is OFF and key is re- moved from switch. 2. Remove fuse from fuse block for testing. 3. Fuse should have continuity across the terminals. Electrical System Page 8 − 10 Workman HD Series...

  • Page 189: Headlight Switch

    CIRCUITS CIRCUITS 2 + 3 5 + 6 1 + 2 4 + 5 After testing is completed, connect wire harness con- nector to headlight switch. BACK OF SWITCH Figure 11 Workman HD Series Page 8 − 11 Electrical System...

  • Page 190: Clutch Switch(S)

    (zero ohms) when the clutch pedal is released. 4. After switch testing is completed, connect the wire harness connector(s) to the switch(s). 5. Install hood (see Hood Installation in Chapter 7 − Chassis). Electrical System Page 8 − 12 Workman HD Series...

  • Page 191: Brake Switch(S)

    (infinite ohms) when the brake pedal is depressed and there should be continuity (zero ohms) when the brake pedal is released. 4. After switch testing is completed, connect the wire harness connector to the brake switch. Workman HD Series Page 8 − 13 Electrical System...

  • Page 192: Hydraulic Lift Lever Interlock Switch

    7. Secure center console control plate to seat base with removed screws. Install knobs on control levers. Figure 16 1. Seat base 3. Screw (6) 2. Control plate Electrical System Page 8 − 14 Workman HD Series...

  • Page 193: 3Rd − High Lockout Key Switch

    B + C FAST B + C, A + D SLOW FAST After testing is completed, connect wire harness con- nector to the 3rd − High lockout key switch. Figure 18 Workman HD Series Page 8 − 15 Electrical System...

  • Page 194: Transaxle Switches

    With the engine off and the shift lever in LOW range, there should be continuity (zero ohms). Move shift lever to HIGH range and there should not be continuity (infi- nite ohms). After testing, connect wire harness connec- tor to switch. Electrical System Page 8 − 16 Workman HD Series...

  • Page 195: Power Relay (Four Terminals)

    6. Replace relay if testing determines that relay is faulty. 7. After testing is complete, install relay to relay bracket and connect wire harness connector to relay. 8. Remove bed support from lift cylinder and lower bed. Workman HD Series Page 8 − 17 Electrical System...

  • Page 196: Relay (Five Terminals)

    Relay (Five Terminals) Workman HD series vehicles use a number of relays that have five (5) terminals: The start enable relay on Workman HD, HDX and HDX−D vehicles ensures that the clutch pedal is de- pressed before the engine starter can be engaged.

  • Page 197: Fusible Link

    30 and 87A as +12 VDC is applied and removed from terminal 85. Fusible Link A Workman HD series vehicle uses three (3) fusible links for circuit protection. These fusible links are located in a harness that connects the starter B+ terminal to the ve- hicle wire harness (Fig.

  • Page 198: Diodes

    Use the Kubota Gasoline Service Tool (KGST) and software, and the Kubota Diagnostic Manual for WG972 engines to test the electronic throttle control. Contact your Toro distrib- utor for assistance in Kubota engine troubleshooting. Figure 27 1.

  • Page 199: Fuel Run/Stop Solenoid (Workman Hdx−D)

    (ground) (Fig. 29). The resistance of the hold coil should be approximately 15.5 ohms. 4. Reconnect solenoid to the wiring harness. Workman HD Series Page 8 − 21 Electrical System...

  • Page 200: Fuel Gauge Sender (Workman Hd & Hdx−D)

    B. Resistance with the float in the empty position 9. Remove bed support from bed lift cylinder and lower (completely down) should be from 89 to 95 ohms. bed. Electrical System Page 8 − 22 Workman HD Series...
  • Page 201 Fuel 1. Fuel supply hose 3. Fuel inlet fitting 2. Hose clamp 4. Fuel return hose pump pressure should be approximately 40 PSI (276 kPa). Workman HD Series Page 8 − 23 Electrical System...

  • Page 202: Fuel Pump (Workman Hdx−D)

    21 to 37 fl oz (0.62 to 1.1 Ltr) after thirty (30) seconds. 7. Replace fuel pump as necessary. Reconnect fuel hose to the fuel filter/separator. 8. Reconnect electrical connector to the fuel run/stop solenoid. 9. Bleed fuel system. Electrical System Page 8 − 24 Workman HD Series...

  • Page 203: (Workman Hdx And Hdx−D)

    405 to 495 ohms 160F (71C) 120 to 140 ohms 8. Fill engine cooling system. 220F (105C) 44 to 48 ohms 9. Remove bed support from lift cylinder and lower bed. Workman HD Series Page 8 − 25 Electrical System...
  • Page 204 190F to 210F (88C to 99C). As the switch cools, it should open at approximate- ly the same temperature. 6. Replace thermal fan switch if necessary. Figure 38 Electrical System Page 8 − 26 Workman HD Series...

  • Page 205: Speed Sensor (Workman Hdx And Hdx−D)

    Figure 40 ness. 1. Speed sensor 4. Red striped wire 2. Sensor tip 5. Green wire 12.Remove bed support from lift cylinder and lower bed. 3. Sensor connector 6. Black wire Workman HD Series Page 8 − 27 Electrical System...

  • Page 206: Glow Controller (Workman Hdx−D)

    NOTE: If there is no power to terminal 1 of the glow con- troller, verify continuity of the circuitry from the ignition switch to the controller and perform Step 4 again (see Electrical Diagrams − Chapter 11 in this manual). Electrical System Page 8 − 28 Workman HD Series...

  • Page 207: High Flow Hydraulics Kit)

    CIRCUITS CIRCUITS BACK OF SWITCH 2 + 3 5 + 6 Figure 43 2 + 1 5 + 4 4. After testing, connect wire harness electrical connec- tor to the switch. Workman HD Series Page 8 − 29 Electrical System...
  • Page 208 (6.8 N−m) 2. Carefully slide coil from valve. 3. When installing coil on cartridge valve, torque nut to 5 ft−lb (6.8 N−m). Figure 45 1. Nut 3. Manifold body 2. Solenoid coil Electrical System Page 8 − 30 Workman HD Series...

  • Page 209: Rear Pto Switch (Optional Kit)

    (infinite ohms). 5. If necessary, replace switch. 6. When switch testing is complete, connect wire har- ness connector to switch. 7. Remove bed support from lift cylinder and lower bed. Workman HD Series Page 8 − 31 Electrical System...
  • Page 210 5. Secure shifter boot and boot retainer to seat base with removed screws. Install knob on gear shift lever. Figure 48 1. Screw 3. Boot plate 2. Control plate 4. Shifter boot Electrical System Page 8 − 32 Workman HD Series...

  • Page 211: Service And Repairs

    A. Clean battery by washing entire case with a solu- tion of baking soda and water. Rinse with clear water. B. Coat battery posts and cable connectors with Bat- tery Terminal Protector (Toro Part No. 107−0392) or petroleum jelly to prevent corrosion. Workman HD Series Page 8 −...

  • Page 212: Battery Service

    6. Coat battery posts and cable connectors with Battery Terminal Protector (Toro Part No. 107−0392) or petro- leum jelly to prevent corrosion. 7. Make sure that battery retainer secures battery in place.
  • Page 213 12.4 VDC, charge the battery. B. If the battery has been charged, apply a 150 amp load for 15 seconds to remove the surface charge. Use a battery load tester following the manufactur- er’s instructions. Workman HD Series Page 8 − 35 Electrical System...
  • Page 214 0.003 change in specific gravity for three consecutive read- ings. 8. If battery filler caps are removable, check the electro- lyte level in each cell. Adjust electrolyte level if needed. Electrical System Page 8 − 36 Workman HD Series...

  • Page 215: Headlights

    2. If bulb was removed from headlight, align tabs on bulb with notches in headlight opening. Insert bulb into back of headlight without touching the clear bulb sur- face. Secure bulb to headlight by rotating it 1/4 turn clockwise. Workman HD Series Page 8 − 37 Electrical System...

  • Page 216: Tail Lamps

    Tail Lamps Disassemble and assemble tail lamp as necessary Fig. 51). Figure 51 1. Screw (2) 3. Bulb 2. Lens 4. Base Electrical System Page 8 − 38 Workman HD Series...
  • Page 217 Lift Cylinder Internal Leakage Test ... . . High Flow Hydraulics System Gear Pump Flow and Relief Pressure Tests . . . Workman HD Series Page 9 − 1 Hydraulic System...
  • Page 218 This page is intentionally left blank. Hydraulic System Page 9 − 2 Workman HD Series...

  • Page 219: Specifications

    Automotive, 10 micron spin−on cartridge type 25 PSI by−pass valve 100 mesh strainer in transaxle High Flow Hydraulic System Filter Automotive, 10 micron spin−on cartridge type 25 PSI by−pass valve 100 mesh strainer in reservoir Workman HD Series Page 9 − 3 Hydraulic System...

  • Page 220: General Information

    Installation in this section). If the hose has an elbow at one end, tighten the swivel nut on that end before tight- ening the nut on the straight end of the hose. For additional hydraulic hose information, refer to Toro Service Training Book, Hydraulic Hose Servicing (Part Number 94813SL).

  • Page 221: Hydraulic Hose And Tube Installation

    85 to 105 ft−lb (116 to 142 N−m) 1 7/16 − 12 110 to 136 ft−lb (150 to 184 N−m) 1 11/16 − 12 140 to 172 ft−lb (190 to 233 N−m) Figure 3 Workman HD Series Page 9 − 5 Hydraulic System...

  • Page 222: Hydraulic Fitting Installation

    202 to 248 ft−lb (274 to 336 N−m) 121 to 149 ft−lb (165 to 202 N−m) 1 5/8 − 12 247 to 303 ft−lb (335 to 410 N−m) 149 to 183 ft−lb (202 to 248 N−m) Figure 5 Hydraulic System Page 9 − 6 Workman HD Series...
  • Page 223 1.00 + 0.25 6 (3/8 in.) 1.50 + 0.25 8 (1/2 in.) 1.50 + 0.25 10 (5/8 in.) 1.50 + 0.25 12 (3/4 in.) 1.50 + 0.25 16 (1 in.) 1.50 + 0.25 Workman HD Series Page 9 − 7 Hydraulic System...

  • Page 224: Special Tools

    Special Tools Order these special tools from your Toro Distributor. Hydraulic Pressure Test Kit Use to take various pressure readings for diagnostic tests. Quick disconnect fittings provided attach directly to mating fittings on machine test ports without tools. A high pressure hose is provided for remote readings.
  • Page 225 Hydraulic Test Fitting Kit This kit includes a variety of O−ring Face Seal fittings to TORO TEST FITTING KIT enable you to connect test gauges into the system. The kit includes: tee’s, unions, reducers, plugs, caps and male test fittings.

  • Page 226: Hydraulic Schematics

    Hydraulic Schematics Primary Hydraulic System Schematic Hydraulic System Page 9 − 10 Workman HD Series...

  • Page 227: High Flow Hydraulic System Schematic

    High Flow Hydraulic System Schematic Workman HD Series Page 9 − 11 Hydraulic System...

  • Page 228: Hydraulic Circuit Operation

    PISTON MOVEMENT NO PISTON MOVEMENT 1800 to 1900 1800 to 1900 1800 to 1900 STEERING STEERING STEERING CONTROL CONTROL CONTROL VALVE VALVE VALVE NEUTRAL POSITION LEFT TURN RIGHT TURN Figure 13 Hydraulic System Page 9 − 12 Workman HD Series...

  • Page 229: Raise And Lower Bed

    (transaxle). LIFT CYLINDERS (2) LIFT CYLINDERS (2) PISTON MOVEMENT PISTON MOVEMENT LIFT VALVE LIFT VALVE (IN RAISE POSITION) (IN LOWER POSITION) RAISE BED LOWER BED Figure 14 Workman HD Series Page 9 − 13 Hydraulic System...

  • Page 230: High Flow Hydraulic Circuit

    Flow from the gear pump is routed through the manifold, the oil cooler, the oil filter and then returns to the reservoir. ROCKER SWITCH IN ON POSITION ENERGIZED ACCESSORY HYDRAULIC MOTOR HYDRAULIC MANIFOLD Figure 15 Hydraulic System Page 9 − 14 Workman HD Series...

  • Page 231: Troubleshooting

    Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Workman HD Series Page 9 − 15...
  • Page 232 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Hydraulic System Page 9 − 16 Workman HD Series...
  • Page 233 Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Workman HD Series Page 9 − 17...

  • Page 234: Testing

    One person should be in the seat to oper- ate the machine and the other should read and not reversed. record test results. Hydraulic System Page 9 − 18 Workman HD Series...
  • Page 235 9. Position the tester hoses so that rotating vehicle parts will not make contact with them and result in hose or tester damage. Workman HD Series Page 9 − 19 Hydraulic System...

  • Page 236: Primary Hydraulic System Gear Pump Flow Test (Workman Hdx And Hdx−D)

    Gear Pump Flow and Relief Pressure Test for test- ing of the high flow hydraulic system pump section. FRONT Figure 17 1. Gear pump 3. Suction hose 2. Pressure hose Hydraulic System Page 9 − 20 Workman HD Series...
  • Page 237 Make sure the tester flow control valve is fully open. 3. Make sure the hydraulic reservoir (transaxle) is full after connecting the tester. Workman HD Series Page 9 − 21 Hydraulic System...
  • Page 238 A. A restriction in the pump intake line this test (see Primary Hydraulic System Relief Valve B. The primary hydraulic system gear pump is worn Pressure Test in this chapter). and should be repaired or replaced Hydraulic System Page 9 − 22 Workman HD Series...
  • Page 239 This page is intentionally blank. Workman HD Series Page 9 − 23 Hydraulic System...

  • Page 240: Workman Hd

    NOTE: This test procedure is for the belt driven primary WORKMAN HD hydraulic system gear pump used on Workman HD ve- FRONT PRIMARY HYDRAULIC SYSTEM hicles. GEAR PUMP Figure 19 1. Gear pump 3. Suction hose 2. Pressure hose Hydraulic System Page 9 − 24 Workman HD Series...
  • Page 241 Make sure the tester flow control valve is open. 4. Make sure the hydraulic reservoir (transaxle) is full after connecting the tester. Workman HD Series Page 9 − 25 Hydraulic System...
  • Page 242 C. The primary hydraulic system gear pump is worn can be conducted with tester in the same location as for and should be repaired or replaced this test (see Primary Hydraulic System Relief Valve Pressure Test in this chapter). Hydraulic System Page 9 − 26 Workman HD Series...
  • Page 243 This page is intentionally blank. Workman HD Series Page 9 − 27 Hydraulic System...
  • Page 244 PRIMARY HYDRAULIC SYSTEM FRONT GEAR PUMP GEAR PUMP FRONT Figure 21 Figure 22 1. Gear pump 3. Suction hose 1. Gear pump 3. Suction hose 2. Pressure hose 2. Pressure hose Hydraulic System Page 9 − 28 Workman HD Series...

  • Page 245: Primary Hydraulic System Relief Valve Pressure Test

    6. Make sure steering wheel is positioned so the front 14.Make sure the hydraulic reservoir (transaxle) is full wheel points directly ahead. before returning the vehicle to service. Workman HD Series Page 9 − 29 Hydraulic System...

  • Page 246: Steering Control Valve And Steering Cylinder Test

    Steering Control Valve and Steering Cylinder Test (ROTATED FOR RIGHT TURN) PLUG 1800 to 1900 PSI STEERING CYLINDER STEERING CONTROL VALVE LIFT CYLINDERS Figure 23 Hydraulic System Page 9 − 30 Workman HD Series...
  • Page 247 D. Read Precautions for Hydraulic Testing. E. Clean and remove hydraulic hose from the fitting on the rod end of the steering cylinder. Plug the end of the disconnected hose (Fig. 23). Workman HD Series Page 9 − 31 Hydraulic System...

  • Page 248: Lift Cylinder Internal Leakage Test

    Lift Cylinder Internal Leakage Test 1800 to 1900 PSI STEERING CYLINDER STEERING CONTROL VALVE (IN LOWER POSITION) LIFT CYLINDERS PLUG Figure 24 Hydraulic System Page 9 − 32 Workman HD Series...
  • Page 249 (move hydraulic lift lever to LOWER position). 5. If any oil comes out of open cylinder port, cylinder has an internal leak. Repair or replace cylinder. 6. Reconnect hose after testing is complete. Workman HD Series Page 9 − 33 Hydraulic System...

  • Page 250: Gear Pump Flow And Relief Pressure Tests

    Primary Hydraulic System Gear Pump Flow Test (Workman HDX and HDX−D) or Primary Hydraulic Sys- tem Relief Pressure tests. LEFT FRONT Figure 27 1. Pressure coupler 2. Return coupler Hydraulic System Page 9 − 34 Workman HD Series...
  • Page 251 To guard against possible personal injury, engage parking brake and keep clothing, hands, opens. feet, face and other parts of the body away from moving vehicle parts while testing. Workman HD Series Page 9 − 35 Hydraulic System...
  • Page 252 Repairs section of this chapter). tor pedal to allow engine to return to low idle, turn High Flow Kit switch OFF and stop engine. Record 12.Remove tester from vehicle. test results. Hydraulic System Page 9 − 36 Workman HD Series...

  • Page 253: Service And Repairs

    If fluid is in- jected into the skin, it must be surgically re- moved within a few hours by a doctor familiar with this type of injury. Gangrene may result from such an injury. Workman HD Series Page 9 − 37 Hydraulic System...

  • Page 254: Primary Hydraulic System Gear Pump (Workman Hdx And Hdx−D)

    Workman HDX and HDX−D vehicles is a single gear pump. If the High Flow Hydraulics Kit is installed, a sec- ond pump section is added to the primary system gear pump. Both gear pump assemblies are shown (Fig. 28). Hydraulic System Page 9 − 38 Workman HD Series...
  • Page 255 Add correct oil if necessary. 8. If hydraulic fittings are to be removed from gear pump, mark fitting orientation to allow correct assembly. Remove fittings from pump and discard O−rings. Workman HD Series Page 9 − 39 Hydraulic System...

  • Page 256: Primary Hydraulic System Gear Pump (Workman Hd)

    C. Install pump pressure hose to fitting on pump (see Figure 30 Hydraulic Hose and Tube Installation in the General 1. Gear pump 3. Engine pulley Information section of this chapter). 2. Pump pulley Hydraulic System Page 9 − 40 Workman HD Series...
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  • Page 258: Primary Hydraulic System Gear Pump Service

    23. Socket head screw (2) 8. Front thrust plate 16. Lock washer (4) NOTE: If vehicle is equipped with High Flow Hydraulics Kit, refer to High Flow Hydraulics System Gear Pump Service in this section. Hydraulic System Page 9 − 42 Workman HD Series...
  • Page 259 (HDX and HDX−D). should be free of wear, roughness or scoring. Discard seals. C. Thickness of thrust plates should be equal. 5. Inspect front cover and rear flange for damage or wear. Workman HD Series Page 9 − 43 Hydraulic System...
  • Page 260 IMPORTANT: Do not dislodge seals during installa- the pump and check for assembly problems. tion. 10.Gently slide the body onto the assembly. Firm hand pressure should be sufficient to engage the dowel pins. Hydraulic System Page 9 − 44 Workman HD Series...
  • Page 261 This page is intentionally blank. Workman HD Series Page 9 − 45 Hydraulic System...

  • Page 262: High Flow Hydraulic System Gear Pump Service

    8. Thrust plate 19. Retaining ring 29. Rear pump section body 9. Drive shaft 20. O−ring 30. Thrust plate 10. Idler shaft 21. Rear cover 31. Front flange 11. Front pump section body Hydraulic System Page 9 − 46 Workman HD Series...
  • Page 263 Figure 35 clean Dexron III ATF and rear section components with clean hydraulic oil. 1. Gear pump 2. Suction hose from transaxle (Dexron III ATF) 3. Suction hose from reservoir (hydraulic oil) Workman HD Series Page 9 − 47 Hydraulic System...

  • Page 264: Lift Valve

    19. Flange head screw (2) 6. Hyd. tube (return to hydraulic filter) 13. 90 hydraulic fitting 20. Hyd. tube (pressure supply) 7. Flange nut (2) 14. Hyd. tube (to male quick fitting) Hydraulic System Page 9 − 48 Workman HD Series...
  • Page 265 Tighten fittings (see Hy- draulic Fitting Installation in the General Information 8. On TC models, verify correct operation of lift lever in- section of this chapter). terlock switch. 2. Install lift valve to vehicle. Workman HD Series Page 9 − 49 Hydraulic System...

  • Page 266: Lift Valve Service

    2. Coat all O−rings and spool with clean Dexron III ATF before installation into valve body. Assemble compo- nents in reverse order of disassembly. Install spool into valve body before inserting cam pins, balls, springs and hex cap plugs. Hydraulic System Page 9 − 50 Workman HD Series...
  • Page 267 This page is intentionally blank. Workman HD Series Page 9 − 51 Hydraulic System...

  • Page 268: Steering Control Valve

    4. Read the General Precautions for Removing and switch. Installing Hydraulic System Components at the begin- ning of this chapter section. 2. Remove steering wheel (see Steering Wheel Re- moval in Chapter 7 − Chassis in this manual). Hydraulic System Page 9 − 52 Workman HD Series...
  • Page 269 7. Start the engine, operate at idle speed and rotate the steering wheel in both directions until air is out of hydrau- lic system. 8. Stop the engine and check oil level in transaxle. Add Dexron III ATF if necessary. Workman HD Series Page 9 − 53 Hydraulic System...

  • Page 270: Steering Control Valve Service

    15. Inner gearwheel 22. Spring set 8. Ball NOTE: For service of the steering control valve, see the Sauer/Danfoss Steering Unit Type OSPM Service Manual at the end of this chapter. Hydraulic System Page 9 − 54 Workman HD Series...
  • Page 271 This page is intentionally blank. Workman HD Series Page 9 − 55 Hydraulic System...

  • Page 272: Steering Cylinder

    20. Center link 31. Snap ring (2) 10. Lock nut (2) 21. Flat washer (2) 32. Cap screw (2) 11. Tie rod assembly 22. Cap screw (2) 33. Lock nut (2) Hydraulic System Page 9 − 56 Workman HD Series...
  • Page 273 5. Hydraulic hose tings (see Hydraulic Fitting Installation in this chapter). 2. O−ring 6. 90 hydraulic fitting 3. Hydraulic fitting 7. Hydraulic hose 4. O−ring 2. Install steering cylinder to vehicle. Workman HD Series Page 9 − 57 Hydraulic System...

  • Page 274: Steering Cylinder Service

    9. Remove and discard seals, O−rings and wear ring from piston and heads. B. Insert a screwdriver under the beveled edge of the retaining ring to start the retaining ring through the opening. Hydraulic System Page 9 − 58 Workman HD Series...
  • Page 275 3. Install piston with new seals and back−ups onto rear shaft. C. Apply silicone sealer to tube access slot. IMPORTANT: When installing roll pin into front and rear shafts, make sure that shaft surfaces are not damaged. Workman HD Series Page 9 − 59 Hydraulic System...

  • Page 276: Lift Cylinder

    9. Engine support 2. O−ring 6. Lift cylinder (LH shown) 10. Frame rail (LH shown) 3. 90 hydraulic fitting 7. Hydraulic hose 11. Clevis pin 4. O−ring 8. Cotter pin 12. Lynch pin Hydraulic System Page 9 − 60 Workman HD Series...
  • Page 277 6. Remove lift cylinder from vehicle. 7. If hydraulic fittings are to be removed from lift cylin- der, mark fitting orientation to allow correct assembly. Remove fittings from cylinder and discard O−rings. Workman HD Series Page 9 − 61 Hydraulic System...

  • Page 278: Lift Cylinder Service

    C. Rotate the head counter−clockwise to remove re- scoring, pitting or wear. taining ring from barrel and head. 4. Replace lift cylinder if internal components are found to be worn or damaged. Hydraulic System Page 9 − 62 Workman HD Series...
  • Page 279 C. Apply silicone sealer to tube access slot. B. Slide head and piston onto the shaft. C. Secure piston to shaft with lock nut. Torque lock nut from 60 to 75 ft−lb (81 to 102 N−m). Workman HD Series Page 9 − 63 Hydraulic System...

  • Page 280: Hydraulic Manifold (High Flow Hydraulics Kit)

    4. Visually inspect the port in the manifold for damage to the sealing surfaces, damaged threads or contamina- tion. Figure 49 1. Nut 3. Solenoid cartridge valve 2. Solenoid coil 4. Manifold body Hydraulic System Page 9 − 64 Workman HD Series...
  • Page 281 5 ft−lb (6.8 N−m). Over−tightening may damage the solenoid or cause the valve to mal- function. 8. If problems still exist, remove valve and clean again or replace valve. Workman HD Series Page 9 − 65 Hydraulic System...
  • Page 282 This page is intentionally blank. Hydraulic System Page 9 − 66 Workman HD Series...
  • Page 283 Chapter 10 Front Wheel Drive (4WD) Table of Contents SPECIFICATIONS ......GENERAL INFORMATION .

  • Page 284: Specifications

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

  • Page 285: General Information

    General Information The “Automatic on Demand” four wheel drive feature on continues to deliver power to the front wheels until the 4WD Workman vehicles does not require operator ac- rear wheels have enough traction to move the vehicle tivation. The front differential on 4WD Workman ve- without slipping.

  • Page 286: Service And Repairs

    Service and Repairs Constant Velocity (CV) Axle Assembly ANTISEIZE LUBRICANT ANTISEIZE 170 to 180 ft−lb LUBRICANT (231 to 244 N−m) STAKED 35 to 40 ft−lb (48 to 55 N−m) 20 to 26 ft−lb (27 to 35 N−m) RIGHT 35 to 40 ft−lb FRONT (48 to 55 N−m) Figure 1...
  • Page 287 4. Using wheel hub hole to access flange head screws, remove screws that secure wheel hub to knuckle. Slide wheel hub assembly from CV axle. LEVERAGE 5. Remove axle spacer from CV axle. POINT IMPORTANT: Make sure to not damage the oil seal on the differential with the pry bars when removing the CV axle.
  • Page 288 Inspect CV Axle Boot and Test CV Axle Inspect CV Axle Boot A torn CV axle boot is the most common cause of CV axle failures. NOTE: A worn and noisy CV axle joint with the boot in good condition and filled with grease is not uncommon. Potholes, curb contact or collision damage can damage bearing components and initiate worn conditions.
  • Page 289 This page is intentionally blank. Workman HDX/HDX−D Page 10 − 7 Front Wheel Drive (4WD)

  • Page 290: Differential Driveshaft

    Differential Driveshaft RIGHT FRONT ANTISEIZE LUBRICANT ANTISEIZE LUBRICANT 20 to 26 ft−lb (27 to 35 N−m) Figure 4 1. Transaxle 4. Driveshaft 6. CV axle assembly 2. Cap screw 5. Differential assembly 7. Flange head screw (4) 3. Flat washer Front Wheel Drive (4WD) Page 10 −...
  • Page 291 Removal (Fig. 4) 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 2. Remove cap screw and flat washer that secure the driveshaft yokes to differential input shaft and transaxle output shaft.

  • Page 292: Driveshaft Cross And Bearing Service

    Driveshaft Cross and Bearing Service Figure 7 1. Yoke 3. Yoke and shaft 5. Snap ring 2. Cross and bearing kit 4. Yoke and tube Disassembly (Fig. 7) Assembly (Fig. 7) 1. Remove driveshaft from vehicle (see Differential Dri- 1. To install new cross and bearings: veshaft Removal in this section).
  • Page 293 This page is intentionally blank. Workman HDX/HDX−D Page 10 − 11 Front Wheel Drive (4WD)

  • Page 294: Front Differential

    Front Differential ANTISEIZE LUBRICANT ANTISEIZE 170 to 180 ft−lb LUBRICANT (231 to 244 N−m) STAKED 35 to 40 ft−lb (48 to 55 N−m) 20 to 26 ft−lb (27 to 35 N−m) RIGHT 35 to 40 ft−lb FRONT (48 to 55 N−m) Figure 8 1.
  • Page 295 Removal (Fig. 8) 2. Secure differential to the frame with four (4) flange head screws. 1. Park vehicle on a level surface, shut engine off, re- move key from ignition switch and apply parking brake. 3. Install and tighten inner two (2) flange head screws Block rear wheels to prevent the vehicle from moving and flange nuts that secure control arm tower to upper unexpectedly.

  • Page 296: Front Differential Service

    Front Differential Service 15 ft−lb (20 N−m) 14 to 20 ft−lb (19 to 27 N−m) 27 28 14 to 20 ft−lb (19 to 27 N−m) 15 ft−lb (20 N−m) Figure 10 1. O−ring 14. Cover plate 26. Male output hub 2.

  • Page 297: Front Wheel Drive (4Wd)

    Front Differential Disassembly 1. Make sure that the oil is drained from the differential assembly. 2. Remove the four (4) flange head screws from the in- put cover. Remove the cover. Figure 11 1. Input cover 2. Pinion shaft 3. Remove the pinion shaft from housing by pulling it out of the gear case by hand.
  • Page 298 5. Place the differential assembly on workbench with the cover plate facing up. 6. Remove the five (5) flange head screws that secure cover plate to gear case. Note location of plug clip for as- sembly purposes. Carefully remove the cover plate from the gear case by lifting straight up.
  • Page 299 9. Carefully lift the ring gear out of the gear case. In- spect ring gear teeth for any damage or abnormal wear. Figure 17 1. Ring gear 2. Gear case 10.Remove the gear spacer from between the gear case and the ring gear. Figure 18 1.
  • Page 300 IMPORTANT: When removing female output hub from gear case, be careful to not damage the seal in the gear case. The seal cannot be serviced sepa- rately. 11. Turn the gear case over. Using a hammer and a suit- able drift, carefully remove the female output hub and bearing by driving it in toward the center of the gear case.
  • Page 301 14.Remove the gear spacer from the cover plate. Figure 21 1. Male output hub 2. Gear spacer 15.Remove the armature plate from the cover plate. IMPORTANT: When removing male output hub from cover plate, be careful to not damage the seal in the cover plate.
  • Page 302 Front Differential Assembly 1. Be sure that all parts are clean and free of any dirt or debris. Make sure that all residual oil has been removed from differential components. 2. Check the condition of the square sectioned O−ring located on the cover plate. Make sure that it is clean and free of any cuts or nicks.
  • Page 303 IMPORTANT: When installing female output hub as- sembly into gear case, be careful to not damage the seal in the gear case. The seal cannot be serviced separately. 6. Press the new female output hub/bearing assembly into the gear case from the inside. The bearing has a slight interference fit to the bore, so it should not take much force to press in.
  • Page 304 9. Align torsion spring on roller cage with the slot in the ring gear and then carefully lower the cage assembly into the ring gear bore. The torsion spring must align and fit into the notch cut into the ring gear. 10.Install remaining nine (9) rollers into the top row of the roller cage assembly.
  • Page 305 14.Install the pinion shaft and then the input cover. Se- cure cover with four (4) flange head screws. Torque screws from 14 to 17 ft−lbs (19 to 27 N−m). Figure 30 1. Input cover 2. Pinion shaft 15.Remove the oil fill plug and fill the unit with 8.45 oz. (250 ml.) of Mobil 424 hydraulic oil (or equivalent).
  • Page 306 This page is intentionally blank. Front Wheel Drive (4WD) Page 10 − 24 Workman HDX/HDX−D...
  • Page 307 ....Rear Wire Harness: Workman HDX- D (Industrial) ....Workman HD Series Page 11 - 1 Electrical Drawings...

  • Page 308: Electrical Drawing Designations

    NOTE: A splice used in a wire harness will be identified on the wire harness diagram by SP. The manufacturing number of the splice is also identified on the wire har- ness diagram (e.g. SP01 is splice number 1). Electrical Drawings Page 11 - 2 Workman HD Series...

  • Page 309: Workman Hd

    3rd − HIGH LOCKOUT SWITCH (SLOW) (OPTIONAL KIT) LIFT LEVER (OPTIONAL KIT) (OPTIONAL KIT) INTERLOCK SWITCH MPH/KPH SHUNT (IF EQUIPPED) (IF EQUIPPED) LEFT FRONT ELECTRIC TURN/RUNNING BRAKE KIT LIGHT (OPTIONAL KIT) (OPTIONAL KIT) RIGHT FRONT TURN/RUNNING LIGHT (OPTIONAL KIT) TURN SIGNAL FLASHER (OPTIONAL KIT)

  • Page 310: Workman Hdx

    3RD − HIGH LOCKOUT (OFF) Workman HDX Kubota EFI Gasoline Engine Vehicle Electrical Schematic All relays and solenoids are shown as de−energized. Page 11 − 4...

  • Page 311: Workman Hdx- D

    (−) ALTERNATOR Start FUSIBLE LINK KUBOTA STARTER 98−9705 R/BK R/BK RELAY R/BK FUEL PUMP FUEL PUMP? RELAY RELAY (MOMENTARY) R/BK R/BK FUEL TEMP RELAY BATTERY SPEED TACH E/G LOW GROUND SPEED POWER STOP −−−− NONE RUN −−−− B+C+F; D+E R/BK START −−−...
  • Page 312 3RD−HIGH LOCKOUT SWITCH 3RD−HIGH LOCKOUT SWITCH Workman HD Kohler Gasoline Engine Front Wire Harness Drawing Page 11 − 6...
  • Page 313 3RD−HIGH LOCKOUT SWITCH ORANGE PINK RED/BLACK YELLOW ORANGE WHITE BLUE GREEN VIOLET GREEN BLUE YELLOW ORANGE YELLOW BLUE PINK GRAY BLACK BLACK YELLOW GRAY RED/BLACK BROWN GREEN ORANGE WHITE/BLACK BLACK PINK YELLOW BLACK GREEN WHITE/BLACK PINK BLACK GREEN ORANGE YELLOW ORANGE BLACK GREEN...
  • Page 314 LIFT LEVER INTERLOCK SWITCH Workman HD Kohler Gasoline Engine Rear Wire Harness Drawing Page 11 − 8...
  • Page 315 LIFT LEVER INTERLOCK SWITCH 3RD−HIGH LOCKOUT ORANGE WHITE GREEN ORANGE BLUE GRAY RED/BLACK BROWN GREEN BLACK ORANGE WHITE/BLACK BLACK BLACK YELLOW BLACK BLACK ORANGE WHITE BLACK ORANGE BLACK Workman HD Kohler Gasoline Engine Rear Wire Harness Diagram Page 11 − 9...
  • Page 316 Workman HDX Kubota EFI Gasoline Engine Front Wire Harness Drawing Page 11 − 10...
  • Page 317 3RD−HIGH LOCKOUT SWITCH GRAY YELLOW GREEN VIOLET ORANGE BLUE PINK RED/BLACK YELLOW BLUE WHITE BLUE ORANGE GREEN VIOLET GREEN YELLOW ORANGE BLUE PINK YELLOW GRAY BLACK BLACK YELLOW GRAY RED/BLACK YELLOW BROWN GREEN ORANGE WHITE/BLACK BLACK PINK GRAY BROWN RED/BLACK BLACK YELLOW PINK...
  • Page 318 Workman HDX Kubota EFI Gasoline Engine Rear Wire Harness Drawing Page 11 − 12...
  • Page 319 BLUE WHITE BLUE GREEN YELLOW BLUE PINK BLACK BLACK BLACK WHITE BLACK YELLOW WHITE GRAY ORANGE PINK RED/BLACK GRAY BROWN GREEN YELLOW ORANGE GREEN WHITE/BLACK GRAY VIOLET BLACK BLUE YELLOW BLACK BLUE GREEN YELLOW BROWN BLACK VIOLET GRAY BROWN PINK YELLOW BLACK YELLOW...
  • Page 320 3RD−HIGH LOCKOUT SWITCH 3RD−HIGH LOCKOUT SWITCH Workman HDX−D Kubota Diesel Engine Front Wire Harness Drawing Page 11 − 14...
  • Page 321 3RD−HIGH LOCKOUT SWITCH ORANGE PINK RED/BLACK YELLOW ORANGE WHITE BLUE GREEN VIOLET GREEN BLUE YELLOW ORANGE YELLOW BLUE PINK GRAY BLACK BLACK YELLOW GRAY RED/BLACK BROWN GREEN ORANGE WHITE/BLACK BLACK PINK YELLOW BLACK GREEN WHITE/BLACK PINK BLACK GREEN ORANGE YELLOW ORANGE BLACK GREEN...
  • Page 322 Workman HDX−D Kubota Diesel Engine Rear Wire Harness Drawing Page 11 − 16...
  • Page 323 ORANGE WHITE BLUE VIOLET GREEN YELLOW ORANGE BLUE PINK BLACK YELLOW GRAY RED /BLACK BROWN GREEN ORANGE WHITE/BLACK BLACK BLACK YELLOW BLACK GRAY PINK VIOLET BLACK ORANGE BLACK YELLOW BLUE BLUE PINK ORANGE YELLOW VIOLET BLUE ORANGE GREEN Workman HDX−D Kubota Diesel Engine Rear Wire Harness Diagram Page 11 −...

  • Page 324: Workman Hdx- D (Industrial)

    Workman HDX−D (Industrial) Kubota Diesel Engine Front Wire Harness Drawing Page 11 − 18...

  • Page 325: Workman Hdx- D (Industrial)

    3RD−HIGH LOCKOUT SWITCH ORANGE PINK RED/BLACK YELLOW ORANGE WHITE BLUE GREEN VIOLET GREEN BLUE YELLOW YELLOW ORANGE BLUE PINK GRAY BLACK BLACK YELLOW GRAY RED/BLACK BROWN GREEN ORANGE BLUE BLACK PINK YELLOW BLACK BLACK YELLOW BLACK ORANGE GREEN ORANGE BLUE GREEN BLACK BLACK...
  • Page 326 Workman HDX−D (Industrial) Kubota Diesel Engine Rear Wire Harness Drawing Page 11 − 20...
  • Page 327 BLACK WHITE VIOLET ORANGE BLUE PINK YELLOW ORANGE BLACK YELLOW BLUE YELLOW GRAY RED/BLACK YELLOW BROWN BLUE GREEN ORANGE BLUE GREEN GRAY PINK VIOLET BLACK YELLOW BLACK BLACK YELLOW PINK ORANGE VIOLET Workman HDX−D (Industrial) Kubota Diesel Engine Rear Wire Harness Diagram Page 11 −...
  • Page 328 This page is intentionally blank. Page 11 − 22...

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