(Serial No. 240000001 and Above)

PART NO. 03126SL (Rev.D)

Service Manual

WorkmanR 3000/4000 Series

Preface

The purpose of this publication is to provide the servicetechnician with information for troubleshooting, testing,and repair of major systems and components on theWorkman 3000/4000 Series vehicles.

REFER TO THE OPERATORS MANUAL FOR OPER-ATING, MAINTENANCE AND ADJUSTMENTINSTRUCTIONS. Space is provided in Chapter 2 of thisbook to insert the Operators Manuals and Parts Cata-logs for your vehicle. Replacement Operators Manualsare available on the internet at www.toro.com.

TheToroCompany reserves the right to change productspecifications or this publication without notice.

This safety symbol means DANGER, WARNING,or CAUTION, PERSONAL SAFETY INSTRUC-TION. When you see this symbol, carefully readthe instructions that follow. Failure to obey theinstructions may result in personal injury.

NOTE: ANOTEwill give general information about thecorrect operation, maintenance, service, testing, or re-pair of the machine.

IMPORTANT: The IMPORTANT notice will give im-portant instructions whichmust be followed to pre-vent damage to systems or components on themachine.

E The Toro Company -- 2003, 2004, 2006, 2007, 2011

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Workman 3000/4000 Series

Table Of Contents

Chapter 1 -- Safety

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2

Chapter 2 -- Product Records and Maintenance

Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1

Equivalents and Conversions . . . . . . . . . . . . . . . . 2 -- 2

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -- 3

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 7

Chapter 3 -- Briggs/Daihatsu Gasoline Engine

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 1

BRIGGS & STRATTON/DAIHATSU REPAIR MANUAL

FOR 3--CYLINDER, LIQUID--COOLED, GASOLINE

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2

General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 4

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 6

ENGINES

Chapter 4 -- Briggs/Daihatsu Diesel Engine

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 1

BRIGGS & STRATTON/DAIHATSU REPAIR MANUAL

FOR 3--CYLINDER, LIQUID--COOLED, DIESEL EN-

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 2

General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 3

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 4

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 6

GINES

Chapter 5 -- Kohler Gasoline Engine

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3

KOHLER ENGINE SERVICE MANUAL

Workman 3000/4000 Series

Chapter 6 -- Drive Train

General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 5

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 6

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 6 -- 10

Chapter 7 -- Chassis

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 2

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 3

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 4

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 8

Chapter 8 -- Electrical System

Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . 8 -- 2

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 2

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 3

Electrical System Quick Checks . . . . . . . . . . . . . . 8 -- 5

Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 8 -- 7

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 8 -- 17

Chapter 9 -- Hydraulic System

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 3

General Information . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 4

Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . 9 -- 6

Hydraulic Circuit Operation . . . . . . . . . . . . . . . . . . 9 -- 8

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 12

Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 -- 15

Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 9 -- 25

SAUER/DANFOSS STEERING UNIT TYPE OSPM

SERVICE MANUAL

Safety

Product

Records

and

Maintenan

ce

Briggs/Daihatsu

Gasolin

e Engine

Briggs/Daihatsu

Diesel E

ngine

Kohler

Gasolin

e Engine

Drive

Train

Chassis

Electrical

System

Hyd

raulic

System

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Workman 3000/4000 Series

Rev. CWorkman 3000/4000 Series

Table Of Contents

Chapter 10 -- Front Wheel Drive (4WD)

Specifications 10 -- 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . .General Information 10 -- 3. . . . . . . . . . . . . . . . . . . . . . .Service and Repairs 10 -- 4. . . . . . . . . . . . . . . . . . . . . . .

Chapter 11 -- Electrical Schematics

Vehicle Electrical Schematics 11 -- 3. . . . . . . . . . . . . . .Wire Harness Drawings 11 -- 10. . . . . . . . . . . . . . . . . . .

Fro

nt

Wh

eel

Dri

ve(4

WD

)E

lect

rica

lS

chem

atic

s

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Workman 3000/4000 Series

Chapter 1

Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2

Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Maintenance and Service . . . . . . . . . . . . . . . . . . . . 4 Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Using Bed Safety Support . . . . . . . . . . . . . . . . . . . . 6

Safe

ty

Workman 3000/4000 Series Page 1 1 Safety

Rev. D Workman 3000/4000 SeriesPage 1 -- 2Safety

Safety InstructionsThe Workman 3000/4000 series vehicles are designedand tested to offer safe service when operated andmaintained properly. Although hazard control and acci-dent prevention are partially dependent upon the designand configuration of the vehicle, these factors are alsodependent upon the awareness, concern, and propertrainingof thepersonnel involved in theoperation, trans-port, maintenance, and storage of the vehicle. Improperuse or maintenance of the vehicle can result in injury or

death. To reduce the potential for injury or death, complywith the following safety instructions.

WARNINGTo reduce the potential for injury or death, com-ply with the following safety instructions.

Before Operating

1. Read and understand the contents of the OperatorsManual and Operators Video before starting and oper-ating the vehicle. Become familiar with the controls andknow how to stop the vehicle and engine quickly. A re-placement Operators Manual is available on the Inter-net at www.Toro.com.

2. Keep all shields, safety devices, and decals in place.If a shield, safety device, or decal is defective, illegibleor damaged, repair or replace it before operating the ve-hicle. Also tighten any loose nuts, bolts or screws to en-sure vehicle is in safe operating condition.

3. Assure interlock switches are adjusted correctly soengine cannot be started unless clutch pedal is de-pressed. On TC models, engine should start only whenhydraulic lever is in the neutral position. On vehiclesequipped with the optional PTO kit, engine should startonly when PTO is disengaged.

4. Since fuel used in Workman vehicles is highly flam-mable, handle it carefully:

A. Store fuel in containers specifically designed forthis purpose.

B. Do not remove vehicle fuel tank cap while engineis hot or running.

C. Do not smoke while handling fuel.

D. Fill fuel tank outdoors and only towithin an inch ofthe top of the tank, not the filler neck. Do not overfillthe fuel tank.

E. Wipe up any spilled fuel.

While Operating

1. Sit on the seat when starting and operating the ve-hicle.

2. Before starting the engine:

A. Sit on operators seat and engage the parking brake.

B. Disengage PTO (if so equipped) and return hand throttle lever to OFF position (if so equipped). C. On TC models, make sure that hydraulic lever is in the neutral position.

D. Move shift lever to NEUTRAL and depress clutch pedal. Keep foot off accelerator pedal.

E. Turn ignit