Toro Workman 4000 Series Manuals

Manuals and User Guides for Toro Workman 4000 Series. We have 2 Toro Workman 4000 Series manuals available for free PDF download: Service Manual

Toro Workman 4000 Series Service Manual (438 pages)

Brand: Toro | Category: Utility Vehicle | Size: 10.25 MB

Chapter 5 - Kohler Command Series

3
- Table of Contents
  3
Before Operating

7
- Chapter 1 - Safety
  
  7
  - Safety Instructions
    7
    
    Before Operating
    7
    
    While Operating
    8
  - Maintenance and Service
    9
  - Jacking the Vehicle
    10
  - Using Bed Safety Support
    11
- Chapter 2 - Product Records and Maintenance
  
  13
  - Product Records
    13
  - Equivalents and Conversions
    14
  - Torque Specifications
    15
  - Lubrication
    19
  - Operation and Service History Report
    23
Table of Contents

39
- Chapter 3 - Liquid Cooled Mitsubishi Gas Engine
  
  40
  - General Information
    40
  - Specifications
    41
  - General
    41
  - Engine
    42
  - Lubrication System
    46
  - Fuel System
    46
  - Cooling System
    46
  - Electrical System
    47
  - Special Tools
    50
  - Inspection and Adjustments
    55
  - Valve Clearance
    55
  - Timing Belt Tension
    57
  - Idle Speed
    58
  - Ignition Timing
    58
  - CO Concentration (Mixture Adjustment)
    59
  - Governor / Accelerator Pedal
    60
  - Carburetor Acceleration Pump
    62
  - Choke Valve
    63
  - Full-Auto-Choke
    63
  - Choke Breaker Opening
    64
  - Fast Idle
    65
  - Troubleshooting
    66
  - Testing
    68
  - Compression Pressure
    71
  - Intake Manifold Vacuum
    71
  - Centrifugal Timing Control Device
    72
  - Vacuum Timing Control Device
    73
  - Crankcase Emission Control System
    74
  - Exhaust Emission Control System
    75
  - Thermo Valve
    77
  - Ignition Coil
    78
  - Starter Pinion Gap
    79
  - Starter No-Load Test
    80
  - Magnetic Switch Pull-In Test
    81
  - Magnetic Switch Hold-In Test
    81
  - Magnetic Switch Return Test
    81
  - Alternator Regulated Voltage
    82
  - Preparation for Engine Repair
    84
  - Cylinder and Cylinder Block Overhaul
    84
  - External Engine Component Repairs
    85
  - External Engine Component Repair
    85
    
    Belt Replacement and Adjustment
    85
    
    Timing Belt Replacement
    86
    
    Water Pump, Hose, Pipe and Thermostat Removal and Installation
    93
    
    Governor Removal and Installation
    95
    
    Electrical System Repairs
    96
    
    Spark Plug Replacement
    96
    
    Alternator Removal and Installation
    97
    
    Alternator Service
    98
    
    Starter Removal and Installation
    102
    
    Starter Service
    103
    
    Distributor Removal and Installation
    107
    
    Distributor Service
    108
    
    Carburetor Removal and Installation
    110
    
    Fuel System Repairs
    110
    
    Carburetor Service
    111
    
    Removing and Installing the Engine
    117
    
    Removing the Engine
    117
    
    Installing the Engine
    118
    
    Cylinder Head Overhaul
    119
    
    Intake and Exhaust Manifolds
    119
    
    Rocker Arm, Rocker Shaft and Camshaft
    120
    
    Rocker Arm and Rocker Shaft
    123
    
    Cylinder Head and Valves
    124
    
    Cylinder Block Overhaul
    129
    
    Front Case, Counterbalance Shaft and Oil Pan
    129
    
    Piston and Connecting Rod
    134
    
    Oil Pump
    139
    
    Crankshaft and Flywheel
    142
    
    Cylinder Block
    147
    
    Lubrication System Repair
    149
    
    Oil Screen, Dipstick and Oil Filter
    149
Liquid Cooled Diesel Engine

151
- Chapter 4 - Mitsubishi Diesel Engine
  
  152
  - General Information
    152
  - Specifications
    153
  - General
    154
  - Engine
    155
  - Lubrication System
    157
  - Cooling System
    158
  - Fuel System
    158
  - Electrical System
    159
  - Tightening Torque
    160
  - Special Tools
    161
  - Adjustments
    163
  - Valve Clearance
    163
  - Engine Speed Adjustments
    164
  - Accelerator Pedal Adjustment
    165
  - Troubleshooting
    165
  - Glow Plug Test
    168
  - Testing
    168
  - Compression Test
    169
  - Nozzle Tests
    170
  - Injection Pump Test
    172
  - Injection Timing Test
    173
  - Fuel Pump Test
    174
  - Thermostat Test
    174
  - Fuel Stop (ETR) Solenoid
    175
  - Engine Oil Pressure Switch
    176
  - Temperature Gauge Sender
    177
  - Checking Starter Pinion Gap
    178
  - Starter No-Load Test
    178
  - Magnetic Switch (Solenoid) Attraction Test
    179
  - Magnetic Switch (Solenoid) Holding Test
    179
  - Magnetic Switch (Solenoid) Return Test
    179
  - Alternator Output Test
    180
  - Alternator Regulated Voltage Test
    180
  - Cylinder and Cylinder Block Overhaul
    181
  - Preparation for Engine Repair
    181
  - Belt Replacement and Adjustment
    182
  - External Engine Component Repair
    182
  - Thermostat Removal and Installation
    183
  - Water Pump Service
    183
  - Alternator Removal and Installation
    184
  - Electrical System Repairs
    184
  - Starter Removal and Installation
    184
  - Glow Plug Replacement
    186
  - Oil Pressure Switch Replacement
    186
  - Starter Service
    187
  - Alternator Service
    191
  - Governor Operation
    195
  - Governor System Repairs
    195
  - Governor Inspection
    196
  - Governor Service
    197
  - Installation of Torque Spring Set
    198
  - Assembly of Torque Spring Set
    199
  - Bleeding the Fuel System
    200
  - Fuel System Repairs
    200
  - Bleeding Air from the Injectors
    201
  - Fuel Pump Service
    201
  - Injection Pump Service
    202
  - Nozzle Service
    205
  - Removing and Installing the Engine
    207
  - Removing the Engine
    207
  - Installing the Engine
    208
  - Cylinder Head Overhaul
    209
  - Cylinder Head Removal
    209
  - Cylinder Head Service
    210
  - Valve Guides
    211
  - Valve Seats
    212
  - Valves
    212
  - Rocker Arm and Rocker Shaft
    213
  - Valve Springs
    213
  - Cylinder Head Reassembly and Installation
    214
  - Cylinder Block Overhaul
    216
  - Gear Case and Oil Pump
    216
  - Timing Gears and Camshafts
    219
  - Piston and Connecting Rod
    222
  - Crankshaft
    226
  - Cylinder Block
    229
Air Cooled Gas Engine

231
- Chapter 5 - Kohler Command Series
  
  231
  - Kohler Engine Service Manual
    231
  - Specifications
    232
  - General Information
    233
    
    Removing Debris from the Engine
    233
    
    Spark Plug Replacement
    233
  - Adjustments
    234
    
    Belt Adjustment
    234
  - Carburetor Adjustment
    234
  - Accelerator Adjustment
    235
  - Engine Removal and Installation
    236
  - Repairs
    236
- Chapter 6 - Drive Train
  
  237
Chapter 6 Drive Train

239
- General Information
  240
- Specifications
  241
- Special Tools
  242
- Adjustments
  244
  - Clutch Pedal
    244
  - High-Low Cable
    245
  - Differential Lock Cable
    246
  - PTO Cable
    246
- Troubleshooting
  247
- Repairs
  250
  - Stub Axle and Drive Shaft Service
    251
  - Drive Shaft Universal Joint Service
    253
  - P.T.O. Removal and Installation
    254
  - Transaxle Removal and Installation
    255
  - Clutch Service
    258
  - Transaxle Service
    260
Chapter 7 Steering, Brakes and Suspension

303
- Specifications
  304
- Special Tools
  305
- Adjustments
  306
  - Brake Pedal Adjustment
    306
  - Parking Brake Adjustment
    307
  - Front Wheel Toe-In
    307
- Troubleshooting
  308
- Repairs
  312
  - Wheel Installation
    312
  - Front Wheel Bearing Service
    313
  - Rear Wheel Bearing Service
    313
  - Brake Service
    314
- Bleeding the Brakes
  317
- Master Brake Cylinder Service
  318
- Parking Brake Cable Replacement
  319
- Steering Linkage Service
  320
- Steering Wheel Installation
  320
- Rear Shock Absorber Replacement
  322
- Rear Leaf Spring Replacement
  326
- Steering Gear Service
  328
Electrical System

335
- Chapter 8 - Electrical System
  
  336
  - Wiring Schematics
    336
    
    Workman 3100 (Model 07210 and 07214)
    336
    
    Workman 3200/4200
    337
    
    Workman 3200/4200
    338
    
    Workman 3300-D/4300-D (Models 07205, 07206, 07215, 07205TC, 07206TC, 07215TC)
    339
    
    Workman 3300-D/4300-D (Models 07213, 07217, 07213TC, and 07217TC)
    340
    
    Workman 3210
    341
    
    Workman 3310-D
    342
    
    Workman 3120 (Industrial Model 07232)
    343
    
    Workman 3220 (Industrial Model 07231)
    344
    
    Workman 3320-D (Industrial Model 07230)
    345
    
    Workman 3420-LP (Industrial Model 07233)
    346
  - Special Tools
    347
  - Troubleshooting
    348
    
    Verify Interlock System Operation
    350
  - Testing
    351
    
    Ignition Key Switch
    351
    
    Brake Switch
    352
    
    Clutch Switch
    352
  - Rear PTO Switch
    352
    
    2-3 and High-Low Lockout Switches
    353
  - 3Rd-High Lockout Key Switch
    353
    
    Relays
    353
    
    Battery
    354
    
    Indicator Lights and Gauges
    354
    
    Fuel Gauge Sender
    355
  - Service and Repairs
    356
    
    Battery Service
    356
    
    Fuses
    359
    
    Headlamp Replacement
    359
    
    Tail Lamp Replacement
    360
Chapter 9 Hydraulic System

361
- Specifications
  362
- General Information
  363
  - Hydraulic Hoses
    363
  - Hydraulic Fitting Installation
    363
- Hydraulic Schematics
  365
  - Base Vehicle
    365
  - Vehicle with Optional Remote Hydraulic Kit
    366
- Special Tools
  368
  - Hydraulic Pressure Test Kit
    368
  - Hydraulic Tester (Pressure and Flow)
    368
- Troubleshooting
  370
- Testing
  372
  - Test No. 1: Pump Flow and Relief Pressure
    373
- Test No. 2: Remote Hydraulics Relief Pressure
  374
- Test No. 3: Power Steering Relief Pressure
  375
- Removing Hydraulic System Components
  377
  - Pump Drive Shaft Service
    378
  - Pump Removal and Installation
    380
- Service and Repairs
  377
- Pump Repair
  381
- Lift Valve Repair
  384
- Lift Cylinder Repair
  385
Front Wheel Drive - 4Wd

387
- Specifications
  388
- General
  389
  - Check Front Differential Oil
    389
- Repairs
  390
  - Front Wheel Assembly
    390
  - Front Wheel Bearing
    391
  - Front Brake
    394
- Chapter 10 Constant Velocity (CV) Joint
  
  398
  - Change Front Differential Oil
    401
  - Front Suspension Control Arm Assembly
    402
  - Front Differential
    403
  - Ring to Pinion Gear Engagement
    416
  - Differential Drive Shaft
    419
  - Bidirectional Clutch
    420
  - Lubrication
    424
Liquid Propane Gas Conversion Kit

425
- Specifications
  426
- General Information
  427
  - Gas Fuel Systems
    427
  - Refueling
    428
  - Starting Engine
    428
- Special Tools
  429
- Functional Operation
  430
- Chapter 11 Testing LP Gas Fuel System
  
  433
  - Adjustments
    434
    
    Adjust LP Fuel System
    434
  - Service and Repairs
    435
    
    Check Spark Plug Gap
    435
    
    Fuel Tank Assembly
    436
    
    Conversion Kit Assembly
    437

Toro Workman 4000 Series Service Manual (306 pages)

Brand: Toro | Category: Utility Vehicle | Size: 14.57 MB

Table of Contents

3
Chapter 1 Safety

7
- Before Operating
  8
- Safety Instructions
  8
- While Operating
  9
- Maintenance and Service
  10
- Jacking Vehicle
  11
- Using Bed Safety Support
  12
Product Records

13
Briggs & Stratton/Daihatsu Repair Manual/For 3-Cylinder, Liquid-Cooled, Gasoline

21
- Chapter 1 -- Safety
  
  21
  - Briggs & Stratton/Daihatsu Repair Manual
    21
- Chapter 2 -- Product Records and Maintenance
  
  21
- Chapter 3 -- Briggs/Daihatsu Gasoline Engine
  
  21
  - Engines
    21
    
    Specifications
    22
    
    Adding Oil to Engine
    23
    
    General Information
    23
    
    Adjustments
    24
    
    Engine Speed Adjustment
    24
    
    Radiator
    26
    
    Service and Repairs
    26
    
    Pump Driveshaft Service
    28
    
    Fuel Tank
    30
    
    Air Cleaner System
    32
    
    Exhaust System
    34
    
    Engine
    36
    
    Engine Throttle Bracket
    40
Briggs & Stratton/Daihatsu Repair Manual/For 3-Cylinder, Liquid-Cooled, Diesel en

43
- Chapter 4 -- Briggs/Daihatsu Diesel Engine
  
  43
  - For 3-Cylinder, Liquid-Cooled, Gasoline
    21
  - Briggs & Stratton/Daihatsu Repair Manual
    43
  - For 3-Cylinder, Liquid-Cooled, Diesel en
    43
  - Gines
    43
  - Introduction
    43
    
    Specifications
    44
    
    Adding Oil to Engine
    45
    
    General Information
    45
    
    Adjust Engine Speed
    46
    
    Adjustments
    46
    
    Radiator
    48
    
    Service and Repairs
    48
    
    Pump Driveshaft Service
    50
    
    Fuel Tank
    52
    
    Air Cleaner System
    54
    
    Exhaust System
    56
    
    Engine
    58
    
    Engine Throttle Bracket
    62
Kohler Engine Service Manual

63
- Specifications
  64
- Service and Repairs
  65
  - Cooling System
    65
  - Fuel Tank
    66
  - Exhaust System
    68
  - Engine
    70
Chapter 6 Drive Train

73
- General Information
  74
- Specifications
  75
- Clutch Alignment Tool
  76
- Special Tools
  76
- Adjustments
  77
- PTO Cable Adjustment
  77
- Troubleshooting
  78
  - Clutch
    78
  - Transaxle
    80
  - Service and Repairs
    82
  - Shift Cable Replacement
    82
  - Stub Axle and Drive Shaft Service
    84
- Chapter 7 - Chassis)
  
  85
  - Drive Shaft Universal Joint Service
    86
  - Removal and Installation (if Equipped)
    87
    
    Transaxle
    88
    
    Removal
    89
    
    Installation
    90
    
    Clutch Service
    92
    
    Disassembly
    94
    
    Transaxle Service
    94
    
    Inspection
    105
    
    Assembly
    109
    
    Disassembly
    126
    
    Power Take-Off (PTO) Service
    126
    
    Inspection
    130
    
    Assembly
    131
Chassis

137
- Specifications
  138
- Special Tools
  139
- Troubleshooting
  140
  - Suspension and Steering
    140
  - Brakes
    142
- Service and Repairs
  144
  - Wheel Installation
    144
  - Front Wheel Assembly (2 Wheel Drive)
    146
  - Rear Wheel Assembly
    148
  - Brake Service
    150
  - Wheel Brake Cylinder Service
    153
  - Bleeding the Brakes
    154
  - Brake Master Cylinder
    156
  - Brake Master Cylinder Service
    157
- Parking Brake Cable Replacement
  158
- Steering Wheel
  159
  - Control Arm Ball Joint Replacement
    160
- Tie Rod End Replacement
  161
  - Front Wheel Alignment
    162
- Front Compression Spring Service
  163
- Front Shock Absorber Replacement
  164
  - Rear Shock Absorber Replacement
    165
- Rear Leaf Spring Replacement
  166
  - Seat Base
    168
Chapter 8 Electrical System

171
- Electrical Schematics
  172
- Special Tools
  172
- Troubleshooting
  173
- Battery Test (Open Circuit Test)
  175
- Charging System Test
  175
- Electrical System Quick Checks
  175
- Verify Interlock System Operation
  176
- Component Testing
  177
- Ignition Key Switch
  177
- Brake Switch
  178
- Clutch Switch
  178
- 3Rd-High Lockout Key Switch
  179
- Transaxle Lockout Switches
  179
- Engine) Relay
  180
- Start (Briggs/Daihatsu Gas and Diesel Engine) and Fuel Pump (Briggs/Daihatsu Gas
  180
- Glow Relay (Briggs/Daihatsu Diesel Engine)
  181
- Start Relay (Kohler Engine)
  181
- Battery
  182
- Indicator Lights and Gauges
  182
- High Temperature Shutdown Switch (Briggs/Daihatsu Gas and Diesel Engine)
  183
- Fuel Gauge Sender
  184
- Headlight Switch
  184
- Diode Assembly (Kohler Engine)
  186
- Rear PTO Switch (Optional)
  186
- Battery Service
  187
- Service and Repairs
  187
- Tail Lamp Replacement
  190
Chapter 9 Hydraulic System

191
- Specifications
  193
- General Information
  194
  - Hydraulic Fitting Installation
    194
  - Hydraulic Hoses
    194
- Hydraulic Schematics
  196
  - Vehicle Hydraulic Schematic
    196
  - High Flow Hydraulic Kit (Optional) Schematic
    197
- Hydraulic Circuit Operation
  198
  - Steering Circuit
    198
  - Raise and Lower Bed
    199
- Special Tools
  200
  - Hydraulic Pressure Test Kit
    200
  - Hydraulic Tester (Pressure and Flow)
    200
  - Hydraulic Test Fitting Kit
    201
  - Male Coupler
    201
- Troubleshooting
  202
- Testing
  205
- Check Hydraulic Lines and Hoses
  215
- General Precautions for Removing and Installing Hydraulic System Components
  215
- Service and Repairs
  215
- Gear Pump (Vehicles with Liquid Cooled Engine)
  216
- Gear Pump (Vehicles with Air Cooled Engine)
  217
- Gear Pump Service Barnes Gear Pump)
  218
- Gear Pump Service (Casappa Gear Pump)
  220
- Lift Valve
  224
- Lift Valve Service
  226
- Steering Control Valve
  228
- Chapter 5 -- Kohler Gasoline Engine
  
  230
- Chapter 8 -- Electrical System
  
  230
- Sauer/Danfoss Steering Unit Type Ospm Service Manual
  230
  - Steering Control Valve Service
    230
  - Steering Cylinder
    232
  - Steering Cylinder Service
    234
  - Lift Cylinder
    236
  - Lift Cylinder Service
    238
  - Hydraulic Manifold (Optional High Flow Hydraulic Kit)
    240
Front Wheel Drive (4Wd)

243
- Specifications
  244
- General Information
  245
- SERVICE and REPAIRS
  246
- Chapter 10 Constant Velocity (CV) Joint
  
  254
  - Front Differential
    256
  - Front Differential Service
    258
  - Ring to Pinion Gear Engagement
    270
  - Differential Drive Shaft
    272
  - Drive Shaft Cross and Bearing Service
    273
  - Bidirectional Clutch
    274
Chapter 11 Electrical Schematics

279
- Serial Number below 260000000
  281
- Workman 3100
  281
- Serial Number above 260000000
  282
- Workman 3200 and 4200
  284
  - Serial Number below 260000000
    285
- Workman 3300 and 4300
  285
  - Serial Number above 260000000
    286
  - Serial Number below 270999999
    288
  - Serial Number above 280000000
    290
  - Serial Number below 260000000
    292
  - Serial Number from 260000001 to 260000400
    293
  - Serial Number above 260000400
    294
  - Serial Number above 260000000
    295
  - Serial Number below 260000000
    296
  - Serial Number from 260000000 to 270999999
    302
  - Serial Number above 280000000
    304

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Toro Workman 4000 Series Manuals

Toro Workman 4000 Series Service Manual (438 pages)

Table of Contents

Chapter 5 - Kohler Command Series

Before Operating

Chapter 1 - Safety

Chapter 2 - Product Records and Maintenance

Table of Contents

Chapter 3 - Liquid Cooled Mitsubishi Gas Engine

Liquid Cooled Diesel Engine

Chapter 4 - Mitsubishi Diesel Engine

Air Cooled Gas Engine

Chapter 5 - Kohler Command Series

Chapter 6 - Drive Train

Chapter 6 Drive Train

Chapter 7 Steering, Brakes and Suspension

Electrical System

Chapter 8 - Electrical System

Chapter 9 Hydraulic System

Front Wheel Drive - 4Wd

Chapter 10 Constant Velocity (CV) Joint

Liquid Propane Gas Conversion Kit

Chapter 11 Testing LP Gas Fuel System

Toro Workman 4000 Series Service Manual (306 pages)

Table of Contents

Table of Contents

Chapter 1 Safety

Product Records

Briggs & Stratton/Daihatsu Repair Manual/For 3-Cylinder, Liquid-Cooled, Gasoline

Chapter 1 -- Safety

Chapter 2 -- Product Records and Maintenance

Chapter 3 -- Briggs/Daihatsu Gasoline Engine

Briggs & Stratton/Daihatsu Repair Manual/For 3-Cylinder, Liquid-Cooled, Diesel en

Chapter 4 -- Briggs/Daihatsu Diesel Engine

Kohler Engine Service Manual

Chapter 6 Drive Train

Chapter 7 - Chassis)

Chassis

Chapter 8 Electrical System

Chapter 9 Hydraulic System

Chapter 5 -- Kohler Gasoline Engine

Chapter 8 -- Electrical System

Front Wheel Drive (4Wd)

Chapter 10 Constant Velocity (CV) Joint

Chapter 11 Electrical Schematics

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