Toro HD 07369 User Manual
Part No. 14208SL
Service Manual
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 OPERATING, MAINTENANCE AND ADJUSTMENT
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 available on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
Workman
HD Model 07369 S/N 314000001 & Up,
HDX/HDX- D Models with Kubota Gasoline & Diesel Engines
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. 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 repair of the machine.
IMPORTANT: The IMPORTANT noti ce will give important instructions which must be followed to prevent damage to systems or components on the
machine.
HD Series
R
EThe Toro Company - 2014
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Workman HD Series
Table Of Contents
Chapter 1 - Safety
Safety Instructions 1 - 2..........................
Safety and Instruction Decals 1 - 6................
Chapter 2 - Product Records and Maintenance
Product Records 2 - 1...........................
Maintenance 2 - 1...............................
Equivalents and Conversions 2 - 2................
Torque Specifications 2 - 3.......................
Chapter 3 - Kubota EFI Gasoline Engine
Specifications 3 - 3..............................
General Information 3 - 4........................
Service and Repairs 3 - 6........................
KUBOTA WORKSHOP MANUAL, GASOLINE EN-
GINE, WG972- G- E3F SERIES
KUBOTA DIAGNOSTIC MANUAL, GASOLINE EN-
GINE, WG972- G- E3F SERIES
Chapter 4 - Kubota Diesel Engine
Specifications 4 - 2..............................
General Information 4 - 3........................
Adjustments 4 - 4...............................
Service and Repairs 4 - 6........................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
SM- E3B SERIES
Chapter 5 - Kohler Air Cooled Gasoline Engine
Specifications 5 - 2..............................
General Information 5 - 3........................
Service and Repairs 5 - 5........................
KOHLER COMMAND ENGINE SERVICE MANUAL
Chapter 6 - Drive Train
Specifications 6 - 2..............................
General Information 6 - 3........................
Special Tools 6 - 4..............................
Adjustments 6 - 5...............................
Troubleshooting 6 - 6............................
Service and Repairs 6 - 10.......................
Chapter 7 - Chassis
Specifications 7 - 2..............................
General Information 7 - 3........................
Special Tools 7 - 4..............................
Troubleshooting 7 - 5............................
Service and Repairs 7 - 8........................
Chapter 8 - Electrical System
Electrical Schematics 8 - 2.......................
Special Tools 8 - 2..............................
Troubleshooting 8 - 4............................
Electrical System Quick Checks 8 - 6..............
Component Testing 8 - 8.........................
Service and Repairs 8 - 33.......................
Chapter 9 - Hydraulic System
Specifications 9 - 3..............................
General Information 9 - 4........................
Special Tools 9 - 8..............................
Hydraulic Schematics 9 - 10......................
Hydraulic Circuit Operation 9 - 12.................
Troubleshooting 9 - 15...........................
Tes t ing 9 - 1 8...................................
Service and Repairs 9 - 37.......................
SAUER/DANFOSS STEERING UNIT TYPE OSPM
SERVICE MANUAL
SafetyProduct Records
Kubota EFI
Kubota
Kohler Air Cooled
Drive TrainChassis
and Maintenance
Gasoline Engine
Diesel Engine
Gasoline Engine
Workman HD Series
System
Electrical
System
Hydraulic
This page is intentionally blank.
Workman HD Series
Table Of Contents
Chapter 10 - Front Wheel Drive (4WD)
Specifications 10 - 2.............................
General Information 10 - 3.......................
Service and Repairs 10 - 4.......................
HILLIARD FRONT DRIVE DIFFERENTIAL PARTS and
SERVICE MANUAL
Chapter 11 - Electrical Drawings
Electrical Drawing Designations 11 - 2.............
Electrical Schematics 1 1 - 3......................
Wire Harness Drawings 11 - 6....................
Front Wheel
Electrical
Drive (4WD)
Drawings
Workman HD Series
This page is intentionally blank.
Workman HD Series
Table of Contents
SAFETY INSTRUCTIONS 2......................
Before Operating 2............................
While Operating 3............................
Maintenance and Service 4....................
Jacking Vehicle 5.............................
Using Bed Safety Support 6....................
SAFETY AND INSTRUCTION DECALS 6..........
Chapter 1
Safety
Safety
Workman HD Series
Page 1 − 1
Safety
Safety Instructions
The Workman HD series vehicles are designed and
tested to offer safe service when operated and maintained properly. Although hazard control and accident
prevention are partially dependent upon the design and
configuration of the vehicle, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport,
maintenance and storage of the vehicle. Improper use
or maintenance of the vehicle can result in injury or
death. To reduce the potential for injury or death, comply
with the following safety instructions.
Before Operating
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
1. Review and understand the contents of the Operator’s Manual and Operator’s DVD before starting and
operating the vehicle. Become familiar with the controls
and know how to stop the vehicle and engine quickly.
Additional copies of the Operator’s Manual are available
on the internet at www.Toro.com.
2. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible or
damaged, repair or replace it before operating the vehicle. Also tighten any loose nuts, bolts or screws to ensure vehicle is in safe operating condition.
3. Assure interlock switches are adjusted correctly so
engine cannot be started unless clutch pedal is depressed and hydraulic lever is in the neutral position. On
vehicles equipped with the optional PTO kit, engine
should start only when PTO is disengaged.
4. Since fuel used in Workman vehicles is highly flammable, handle it carefully:
A. Store fuel in containers specifically designed for
this purpose.
B. Do not remove vehicle fuel tank cap while engine
is hot or running.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill
the fuel tank.
E. Wipe up any spilled fuel.
Safety
Page 1 − 2
Workman HD Series
While Operating
1. Sit on the operator seat when starting and operating
the vehicle.
2. When starting the engine:
A. Sit on operator’s seat and engage the parking
brake.
B. Disengage PTO (if so equipped) and return hand
throttle lever to OFF position (if so equipped).
C. Make sure that hydraulic lift lever is in the neutral
position.
D. Move shift lever to NEUTRAL and depress clutch
pedal. Keep foot off accelerator pedal.
E. Turn ignition key to START.
3. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
4. Do not touch engine, exhaust system components,
transaxle or radiator (if equipped), while engine is running or soon after it is stopped. These areas could be hot
enough to cause burns.
5. Before getting off the seat:
A. Stop movement of the vehicle.
B. Lower bed.
C. Shut engine off and wait for all movement to stop.
D. Engage parking brake and remove key from igni-
tion switch.
6. Do not park on slopes unless wheels are chocked or
blocked.
Safety
Workman HD Series
Page 1 − 3
Safety
Maintenance and Service
1. Before servicing or making adjustments, turn all accessories off, put traction pedal in neutral, stop engine,
engage parking brake and remove key from the ignition
switch.
2. Make sure vehicle is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Never store the vehicle or fuel container inside
where there is an open flame, such as near a water heater or furnace.
4. Never work under a raised bed without placing the
bed safety support on the fully extended lift cylinder rod.
5. Make sure all hydraulic line connectors are tight and
that all hydraulic hoses and lines are in good condition,
before applying pressure to the system.
6. Keep body and hands away from pin hole leaks in hydraulic lines t h a t e j e c t h i g h p ressure hydraulic fluid. Use
cardboard or paper to find hydraulic leaks. Hydraulic
fluid escaping under pressure can penetrate skin and
cause injury. Fluid accidentally injected into the skin
must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
11.Do not overspeed the engine by changing governor
setting. To ensure safety and accuracy, check maximum
engine speed.
12.Shut engine off before checking or adding oil to the
engine crankcase.
13.Disconnect battery before servicing the vehicle. Disconnect negative (−) battery cable first and positive (+)
cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery.
Connect positive (+) cable first and negative (−) cable
last.
14.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
15.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
16.To ensure optimum performance and continued
safety of the vehicle, use genuine Toro replacement
parts and accessories. Replacement parts and accessories made by other manufacturers may result in nonconformance with safety standards and the warranty
may be voided.
7. Before disconnecting or performing any work on the
hydraulic system, all pressure in hydraulic system must
be relieved. To relieve system pressure, push hydraulic
lever forward and backward and rotate steering wheel
in both directions after the ignition switch has been
turned off.
8. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
9. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt.
10.If engine must be running to perform maintenance or
an adjustment, keep clothing, hands, feet and other
parts of the body away from moving parts. Keep bystanders away.
17.When raising the vehicle to change tires or to perform other service, use correct blocks, hoists and jacks.
Make sure vehicle is parked on a solid level surface such
as a concrete floor. Prior to raising the vehicle, remove
any attachments that may interfere with the safe and
proper raising of the vehicle. Always chock or block
wheels. Use appropriate jack stands to support the
raised vehicle. If the vehicle is not properly supported by
jack stands, the vehicle may move or fall, which may result in personal injury (see Jacking Vehicle in this section).
Safety
Page 1 − 4
Workman HD Series
Jacking Vehicle
WARNING
When changing attachments, tires or performing other service, use correct jacks, hoists and
jack stands. Always chock or block the wheels
and use jack stands to support the vehicle. If
the vehicle is not properly supported by jack
stands, the vehicle may move or fall resulting
in personal injury.
1. Do not start engine while vehicle is on jack, because
engine vibration or wheel movement could cause vehicle to slip off jack.
2. Do not work under vehicle without jack stands supporting it. The vehicle could slip off jack, injuring any one
beneath it.
3. The jacking point at the front of the vehicle is under
the front center frame support (Fig. 1). When jacking up
front of vehicle, always place a wood block (or similar
material) between jack and vehicle frame support.
Safety
1
Figure 1
1. Front jacking point
4. The jacking point at the rear of the vehicle is under
the axle tube (Fig. 2).
1
Figure 2
1. Rear jacking point
Workman HD Series
Page 1 − 5
Safety
Using Bed Safety Support
Many of the procedures shown in this manual require raising and lowering the bed. The following
precautions must be taken or serious injury or
death could result.
WARNING
Before servicing or making adjustments to the
vehicle, stop engine, engage parking brake and
remove key from ignition switch. Any load material must be removed from bed or other attachment before working under raised bed. Never
work under a raised bed without positioning bed
safety support on a fully extended cylinder rod.
After work is completed, remove bed safety support, insert safety support into storage brackets on
back of ROPS panel and lower bed.
1. Raise bed until lift cylinders are fully extended.
2. Remove bed safety support from storage brackets
on back of ROPS panel.
3. Push bed safety support onto cylinder rod, making
sure support end tabs rest on end of cylinder barrel and
on cylinder rod end (Fig. 3).
4. To store bed safety support, remove support from lift
cylinder and insert into storage brackets on back of
ROPS panel.
1
2
1. Bed safety support
2. Cylinder barrel
3
Figure 3
3. Bed
5. Always install or remove bed safety support from
outside of bed.
6. Do not try to lower bed with bed safety support on lift
cylinder: cylinder and bed damage may occur.
Safety and Instruction Decals
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
Page 1 − 6
Workman HD Series
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS 1.........................
MAINTENANCE 1..............................
EQUIVALENTS AND CONVERSIONS 2...........
Decimal and Millimeter Equivalents 2............
U.S. to Metric Conversions 2...................
TORQUE SPECIFICATIONS 3...................
Fastener Identification 3.......................
Using a Torque Wrench with an Offset Wrench 3..
Standard Torque for Dry, Zinc Plated and Steel
Fasteners (Inch Series Fasteners) 4...........
Standard Torque for Dry, Zinc Plated and Steel
Fasteners (Metric Fasteners) 5...............
Other Torque Specifications 6..................
Conversion Factors 6.........................
Chapter 2
Product Records
and Maintenance
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 maintenance intervals. Additionally, insert Installation Instructions, Operator’s Manuals, Parts Catalogs and Service
Manuals for any accessories that have been installed on
your Workman at the end of this section.
Maintenance
Maintenance procedures and recommended service intervals for the Workman HD series vehicles are covered
in the Operator’s Manual. Refer to that publication when
performing regular equipment maintenance. Several
maintenance procedures have break−in intervals identified in the Operator’s Manual. Refer to the Engine Operator’s Manual for additional engine specific
maintenance procedures.
Workman HD Series Page 2 − 1 Product Records and Maintenance
Equivalents and Conversions
0.09375
Workman HD SeriesPage 2 − 2Product Records and Maintenance
Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and specified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Service Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature
(e.g. Nylock nut), hardness of the surface underneath
the fastener’s head or similar condition which affects the
installation.
Fastener Identification
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread engagement, etc.
The standard method of verifying torque shall be performed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Product Records
and Maintenance
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 1
Using a Torque Wrench with an Offset Wrench
Use of an o f fset wrench (e.g. crowfoot wrench) will affect
torque wrench calibration due to the effective change of
torque wrench length. When using a torque wrench with
an offset wrench, multiply the listed torque recommendation by the calculated torque conversion factor (Fig.
3) to determine proper tightening torque. Tightening
torque when using a torque wrench with an offset
wrench will be lower than the listed torque recommendation.
Example: The measured effective length of the torque
wrench (distance from the center of the handle to the
center of the square drive) is 18”.
The measured effective length of the torque wrench with
the offset wrench installed (distance from the center of
the handle to the center of the offset wrench) is 19”.
Class 8.8 Class 10.9
Metric Bolts and Screws
Figure 2
If the listed torque recommendation for a fastener is
from 76 to 94 ft−lb, the proper torque when using this
torque wrench with an offset wrench would be from 72
to 89 ft−lb.
(effective length of
torque wrench)
A
B
(effective length of torque
wrench + offset wrench)
TORQUE CONVERSION FACTOR = A / B
Torque wrenchOffset wrench
The calculated torque conversion factor for this torque
wrench with this offset wrench would be 18 / 19 = 0.947.
Workman HD Series Page 2 − 3 Product Records and Maintenance
Figure 3
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series Fasteners)
Thread Size
# 6 − 32 UNC
# 6 − 40 UNF 17 + 2 192 + 23 25 + 3 282 + 34
# 8 − 32 UNC
# 8 − 36 UNF 31 + 4 350 + 45 43 + 5 486 + 56
# 10 − 24 UNC
# 10 − 32 UNF 48 + 5 542 + 56 68 + 7 768 + 79
1/4 − 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 113 140 + 15 1582 + 169
1/4 − 28 UNF 53 + 7 65 + 10 734 + 113 115 + 12 1299 + 136 160 + 17 1808 + 192
5/16 − 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339
5/16 − 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373
3/8 − 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7
Grade 1, 5 &
8 with Thin
Height Nuts
in−lb in−lb N−cm in−lb N−cm in−lb N−cm
10 + 2 13 + 2 147 + 23
13 + 2 25 + 5 282 + 30
18 + 2 30 + 5 339 + 56
ft−lb ft−lb N−m ft−lb N−m ft−lb N−m
SAE Grade 1 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 5 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
15 + 2 169 + 23 23 + 3 262 + 34
29 + 3 328 + 34 41 + 5 463 + 56
42 + 5 475 + 56 60 + 6 678 + 68
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
3/8 − 24 UNF 17 + 2 18 + 2 24 + 3 35 + 4 47 + 5 50 + 6 68 + 8
7/16 − 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 − 20 UNF 29 + 3 29 + 3 39 + 4 55 + 6 75 + 8 77 + 8 104 + 11
1/2 − 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15
1/2 − 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16
5/8 − 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28
5/8 − 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33
3/4 − 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52
3/4 − 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58
7/8 − 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 − 14 UNF 155 + 25 260 + 30 353 + 41 475 + 48 644 + 65 667 + 66 904 + 89
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the minimum proof load specified in SAE J429. The tolerance is
approximately +
10% of the nominal torque value. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
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 SeriesPage 2 − 4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws and Studs with
Thread Size
M5 X 0.8 57 + 6 in−lb 644 + 68 N−cm 78 + 8 in−lb 881 + 90 N−cm
M6 X 1.0 96 + 10 in−lb 1085 + 113 N−cm 133 + 14 in−lb 1503 + 158 N−cm
M8 X 1.25 19 + 2 ft−lb 26 + 3 N−m 28 + 3 ft−lb 38 + 4 N−m
M10 X 1.5 38 + 4 ft−lb 52 + 5 N−m 54 + 6 ft−lb 73 + 8 N−m
M12 X 1.75 66 + 7 ft−lb 90 + 10 N−m 93 + 10 ft−lb 126 + 14 N−m
M16 X 2.0 166 + 17 ft−lb 225 + 23 N−m 229 + 23 ft−lb 310 + 31 N−m
M20 X 2.5 325 + 33 ft−lb 440 + 45 N−m 450 + 46 ft−lb 610 + 62 N−m
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Regular Height Nuts
(Class 8 or Stronger Nuts)
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately +
nominal torque value.
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
10% of the
Product Records
and Maintenance
Workman HD Series Page 2 − 5 Product Records and Maintenance
Other Torque Specifications
SAE Grade 8 Steel Set Screws
Recommended Torque
Thread Size
Square Head Hex Socket
1/4 − 20 UNC 140 + 20 in−lb 73 + 12 in−lb
5/16 − 18 UNC 215 + 35 in−lb 145 + 20 in−lb
3/8 − 16 UNC 35 + 10 ft−lb 18 + 3 ft−lb
1/2 − 13 UNC 75 + 15 ft−lb 50 + 10 ft−lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 − 32 UNC 20 + 5 in−lb
Wheel Bolts and Lug Nuts
Thread Size
7/16 − 20 UNF
Grade 5
1/2 − 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non−lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 + 5 in−lb
Threads per Inch
Type A Type B
Recommended Torque**
65 + 10 ft−lb 88 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
80 + 10 ft−lb 108 + 14 N−m
Baseline Torque*
No. 8 − 32 UNC 30 + 5 in−lb
No. 10 − 24 UNC 38 + 7 in−lb
1/4 − 20 UNC 85 + 15 in−lb
5/16 − 18 UNC 110 + 20 in−lb
3/8 − 16 UNC 200 + 100 in−lb
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
No. 8 15 18 30 + 5 in−lb
No. 10 12 16 38 + 7 in−lb
No. 12 11 14 85 + 15 in−lb
* Hole size, material strength, material thickness and finish must be considered when determining specific
torque values. All torque values are based on non−lubricated fasteners.
Workman HD SeriesPage 2 − 6Product Records and Maintenance
Table of Contents
Chapter 3
Kubota EFI Gasoline Engine
SPECIFICATIONS 3............................
GENERAL INFORMATION 4.....................
Introduction 4................................
Operator’s Manual 4..........................
Kubota Workshop and Diagnostics Manuals 3....
Kubota Gasoline Engine 3.....................
Kubota Gasoline Engine
Electronic Control Unit (ECU) 5...............
SERVICE AND REPAIRS 6......................
Air Cleaner System 6..........................
Exhaust System 8............................
Fuel System 10...............................
Fuel Tank 11.................................
Fuel pump 12...............................
Carbon canister 13..........................
Radiator 14..................................
Engine 16....................................
KUBOTA WORKSHOP MANUAL, GASOLINE EN-
GINE, WG972−G−E3F
KUBOTA DIAGNOSTICS MANUAL, GASOLINE EN-
GINE, WG972−G−E3F
Kubuta EFI
Gasoline Engine
Workman HDX Page 3 − 1 Kubota EFI Gasoline Engine
This page is intentionally left blank.
Workman HDXPage 3 − 2Kubota EFI Gasoline Engine
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 1−2−3
Spark Plug Type/Gap NGK BKR6E 0.028 to 0.031 in. (0.7 to 0.8 mm)
Intake & Exhaust Valve Clearance (check when engine is cold) 0.0065 + 0.0001 in. (0.165 + 0.02 mm)
Fuel Unleaded Gasoline (up to 10% ethanol)
Fuel Capacity 6.5 Gal (24.6 Ltr)
Governor Electronic
Kubuta EFI
Gasoline Engine
Low Idle (no load) 1100 + 50 RPM
High Idle (no load) 3600 + 50 RPM
Direction of Rotation Counterclockwise (Viewed from Flywheel)
Engine Oil API classification SL or higher
Oil Pump Trochoid Type
Crankcase Oil Capacity 3.5 qt. (3.3 ltr.) with Filter
Starter 12 VDC, 1.2 KW
Alternator/Regulator 12 VDC, 480W
Dry Weight U.S. 163 lbs. (74 Kg)
Coolant Capacity U.S. 3.7 qt. (3.5 ltr.) with 1.0 qt. (0.9 ltr.) Reservoir
(see Vehicle Operator’s Manual for viscosity recommendations)
Workman HDX Page 3 − 3 Kubota EFI Gasoline Engine
Introduction
This Chapter gives information about specifications,
maintenance, troubleshooting, testing, and repair of the
Kubota EFI gasoline engine used in the Workman HDX.
Most repairs and adjustments require tools which are
commonly available in many service shops. The use of
some specialized test equipment is explained in the engine service manual included at the end of this chapter.
However, the cost of the test equipment and the specialized nature of some repairs may dictate that the work be
done at an engine repair facility.
Traction Unit Operator’s Manuals
The V ehicle Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman HDX. Refer to this
publication for additional information when servicing the
machine.
Kubota Workshop and Diagnostics Manuals
Service and repair parts for Kubota gasoline engines
are supplied through your local Toro Distributor. If a
parts list is not available, be sure to provide your distributor with the Toro model and serial number.
The engine that powers your Workman HDX is a Kubota
model WG972−G−E3F . Both the Kubota Workshop
Manual and Kubota Diagnostics Manual are available
for this engine. Make sure that the correct engine manuals are used when servicing the engine.
Kubota Gasoline Engine
The engine used in your Workman HDX is a Kubota
WG972 Series gasoline engine. Engine features include an electronic control unit (ECU) that controls a
common rail fuel injection system with direct injection,
electronic throttle valve (ETV), an electronic governor
and a catalytic muffler exhaust system with an oxygen
sensor. The ECU receives information from numerous
engine sensors. The information provided allows the engine ECU to monitor and control engine operation for
optimum engine performance.
Figure 1
Workman HDXPage 3 − 4Kubota EFI Gasoline Engine
Kubota Gasoline Engine Electronic Control Unit (ECU)
The Kubota gasoline engine that powers your Workman
HDX uses an electronic control unit (ECU) for engine
management. All wire harness electrical connectors
should be plugged into the ECU before the machine ignition switch is moved from the OFF position to either the
ON or START position.
The engine electrical components (e.g. ECU, O2
sensor, throttle control, power relay , ETV relay) are identified and matched in the engine ECU program. If engine
electrical components are replaced on the engine, the
Kubota electronic tool must be used to update the ECU
program which will ensure correct engine operation.
If the engine ECU identifies that an engine problem exists, the check engine light on the Operator’s Control
Panel will illuminate. The engine speed may be reduced
or the engine might stop. The Kubota Gasoline Service
Tool (KGST) and software, and the Kubota Diagnostic
Manual should be used to provide assistance in identifying the cause of the problem and any repairs that are necessary. Connect the Kubota Gasoline Service Tool
(KGST) to the diagnostic connector above the engine
ECU (Fig. 3). Contact your Toro distributor for assistance in Kubota engine troubleshooting.
IMPORTANT: Two (2) communication connectors
are located near the engine ECU. The connector
along side of the ECU (near the middle of the engine)
is not used for service diagnostics.
1
2
Kubuta EFI
Gasoline Engine
Figure 2
1. Engine (Model 30809)
2. Engine ECU
Do not plug or unplug the engine ECU for a period
of thirty (30) seconds after the machine key switch
is turned OFF. The ECU may remain energized even
though the ignition switch is OFF.
If the engine ECU is to be disconnected for any reason,
make sure that the ignition switch is in the OFF position
with the key removed before disconnecting the engine
ECU. Also, to prevent possible ECU damage when
welding on the machine, disconnect and remove the engine ECU from the machine before welding.
Figure 3
Diagnostic connector
Workman HDX Page 3 − 5 Kubota EFI Gasoline Engine
Service and Repairs
Air Cleaner System
3
2
5
6
4
VACUATOR
DIRECTION
9
RIGHT
FRONT
1. Air cleaner assembly
2. Hose clamp
3. Air inlet hood
1
7
8
Figure 4
4. Hose clamp
5. Air intake hose
6. Hose clamp
7. Flange nut (2)
8. Mounting bracket
9. Flange head screw (2)
Workman HDXPage 3 − 6Kubota EFI Gasoline Engine
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.
1
2
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.
1. Park machine on a level surface, lower cutting units,
stop engine, engage parking brake, and remove key
from the ignition switch. Unlatch and raise hood.
2. Check air cleaner body for damage that could cause
possible air leaks. Make sure cover seals completely to
the air cleaner body (Fig. 5).
3. Check burp valve and dust cup for damage.
4. Make sure air hoses connecting the air cleaner to the
engine and radiator are secured tightly and free of possible air leaks.
Air Cleaner Removal
1. Park vehicle on a level surface and engage parking
brake. Stop the engine and remove key from ignition
switch. Allow engine to cool.
7
1. Plug
2. Body
3. Primary filter element
4. Safety filter element
(if equipped)
3
Figure 6
5. Cover
6. Vacuator valve
7. Gasket (if equipped)
5
6
Kubuta EFI
Gasoline Engine
2. Raise or remove the bed or other attachment(s) if ne cessary . I f bed is raised, place safety support on lift cylinder.
3. Remove air cleaner components as needed.
Air Cleaner Installation
1. Assemble air cleaner system (Fig. 4). Air cleaner inlet hood should be positioned straight upward. The vacuator valve on the air cleaner assembly should be
positioned downward.
2. Lower or install bed or attachment(s).
Workman HDX Page 3 − 7 Kubota EFI Gasoline Engine
Exhaust System
28
RIGHT
FRONT
28 to 36 ft−lb
(38 to 49 N−m)
1
22 to 26 ft−lb
(30 to 35 N−m)
22 to 26 ft−lb
(30 to 35 N−m)
29
27
26
2520
23
6
13
24
20 21
2
3
17
4
5
16
19
18
10
22 to 26 ft−lb
(30 to 35 N−m)
22
23
15
6
7
8
9
6
14
10
11
11
12
13
1. Oxygen sensor
2. Lock washer (4)
3. Hex nut (4)
4. Exhaust tube
5. Stud (4)
6. Exhaust gasket (3)
7. Catalytic converter
8. Flange head screw
9. Heat shield mount
10. Flange nut (8)
Figure 7
11. Retainer nut (3)
12. Heat shield
13. Heat shield mount
14. Flange head screw (4)
15. Flange head screw (4)
16. Heat shield
17. Retainer nut
18. Flange head screw
19. Heat shield
20. Flange nut (4)
8
21. Flange head screw (2)
22. Flange head screw
23. Flange head screw (4)
24. Heat shield
25. Muffler
26. Carriage bolt (2)
27. Mount plate
28. Flange head screw (2)
29. Transaxle
Workman HDXPage 3 − 8Kubota EFI Gasoline Engine
Removal
Installation
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. Note position of exhaust system heat shields and
mounting brackets before removal. Remove exhaust
system components as needed (Fig. 7).
4. Discard gaskets and thoroughly clean flange surfaces of exhaust tube, catalytic converter and muffler.
1. Replace any removed gaskets.
2. Fit all exhaust components to vehicle before tightening any fasteners (Fig. 7). When securing exhaust, tighten fasteners in the following order:
A. Hex nuts that secure exhaust tube to engine.
Torque from 22−26 ft−lbs (30 to 35 N−m).
B. Hex nuts that secure catalytic converter to exhaust tube. Torque from 22−26 ft−lbs (30 to 35
N−m).
C. Flange head screws and flange nuts that secure
muffler to catalytic converter. Torque from 22−26 ft−
lbs (30 to 35 N−m).
D. Flange head screw that secures muffler to transaxle.
E. Flange head screws and flange nuts that secure
muffler to shift cable mount bracket.
F. Carriage bolts and flange nuts that secure muffler
to mount plate.
Kubuta EFI
Gasoline Engine
3. Install all exhaust system heat shields.
NOTE: If oxygen sensor was removed, torque sensor
from 28 to 36 ft−lb (38 to 49 N−m).
4. Lower or install bed or attachment(s).
Workman HDX Page 3 − 9 Kubota EFI Gasoline Engine
Fuel System
l
RIGHT
175 to 200 in−lb
(20 to 22 N−m)
11
17
18
10
20
12
8
21
22
2
1
TO
ENGINE
3
19
15
16
9
5
4
TO
PURGE
PORT
13
6
8
7
FRONT
14
1. Fuel hose (to engine)
2. Hose clamp
3. Fuel hose (to vacuum valve)
4. Vacuum check valve
5. Fuel hose (to engine)
6. Filter hose
7. Canister filter
8. Fuel hose (tank to canister)
9. Flange nut (2)
10. Fuel tank
11. Fuel cap
12. Fuel pump/sender assembly
13. Carbon cannister
14. Support tube
15. Retainer plate
DANGER
Because gasoline is highly flammable, use caution when storing or handling it. Do not smoke
while filling or servicing the fuel tank. Do not fill
or service fuel tank while engine is running, hot
or when vehicle is in an enclosed area. Always fil
fuel tank outside and wipe up any spilled fuel before starting the engine. Store fuel in a clean,
safety−approved container and keep cap in
place. Use fuel for the engine only; not for any
other purpose.
Figure 8
16. Washer head screw (2)
17. Rollover valve
18. Grommet
19. Washer head screw (2)
20. Cap
21. Gasket
22. Fuel filter
Check Fuel Lines and Connections
Check fuel lines and connections periodically as recommended in the O p e r a t o r’s Manual. Check lines for deterioration, damage, leaks or loose connections. Replace
hoses, clamps and connections as necessary.
Workman HDXPage 3 − 10Kubota EFI Gasoline Engine
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. Disconnect wire harness connectors from fuel pump
and sender on fuel tank.
CAUTION
The fuel supply hose will contain pressurized
fuel. Be careful when disconnecting supply
hose. Wipe up any spilled fuel before starting the
engine.
4. Note routing of fuel hoses for installation purposes
(Fig. 9). Disconnect fuel supply hose from fuel pump/
sender and tank vent hose from rollover valve. Plug fuel
hoses to prevent leakage or system contamination.
3
1. Retainer plate
2. Fuel supply hose
2
Figure 9
1
Kubuta EFI
Gasoline Engine
3. Tank vent hose
5. Remove washer head screws and retainer plate that
secure fuel tank.
6. Remove fuel tank from vehicle.
Fuel Tank Installation (Fig. 8)
1. Position fuel tank to support tube on vehicle.
2. Remove plugs placed in fuel hoses during fuel tank
removal. Connect fuel supply hose to fuel pump/sender
and tank vent hose to rollover valve (Fig. 9). Secure fuel
hoses with hose clamps.
3. Connect wire harness connectors to fuel pump and
sender.
4. Position retainer plate to tank and frame. Make sure
that fuel hoses are correctly placed under plate (Fig. 9).
While pressing down on retainer plate to best retain
tank, install and tighten washer head screws to secure
fuel tank.
5. Lower or install the bed or other attachment(s).
6. Fill fuel tank. Check for fuel leakage and correct if
found.
Workman HDX Page 3 − 11 Kubota EFI Gasoline Engine
Fuel Pump Removal (Fig. 8)
1. Park vehicle on a level surface, raise bed and engage 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.
3. Disconnect vehicle wire harness connectors from
fuel pump/sender assembly on fuel tank.
CAUTION
The fuel supply hose will contain pressurized
fuel. Be careful when disconnecting fuel supply
hose. Wipe up any spilled fuel before starting the
engine.
4. Disconnect fuel supply hose from fuel pump/sender.
Plug fuel hose to prevent leakage or system contamination.
1
1. Fuel pump/sender
2. Wire harness
2
3
Figure 10
3. Fuel supply hose
5. Note orientation of fuel fitting on fuel pump for assembly purposes.
6. Remove cap that secures fuel pump/sender assembly in fuel tank.
NOTE: Do not allow fuel pump/sender assembly to rotate during removal or damage to the sender float arm
may result.
7. Carefully remove fuel pump/sender and gasket from
tank.
Fuel Pump Installation (Fig. 8)
1. Make sure that fuel tank and fuel pump/sender gasket surfaces are thoroughly clean.
2. Position gasket to sealing surface of fuel pump/
sender.
3. Carefully insert fuel pump/sender and gasket into
tank. Orientate fuel fitting so that it is pointing toward the
vehicle frame.
4. Secure fuel pump/sender to fuel tank with cap.
Torque cap from 175 to 200 in−lb (20 to 22 N−m).
5. Remove plug placed in fuel supply hose and connect
supply hose to fuel pump/sender. Secure fuel hose with
hose clamp.
6. Connect vehicle wire harness connectors to fuel
pump/sender assembly on fuel tank.
7. Remove bed support from lift cylinder and lower bed.
Workman HDXPage 3 − 12Kubota EFI Gasoline Engine
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