Toro Workman Service Manual

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Transcript of Toro Workman Service Manual

  • (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

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    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