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1. P3 TO ENGINE HARNESS LIFT KIT PIA OPTION P8 FUSE BLOCK OPTIONAL FUSE BLOCK BOX LIFT SW Workman 1100 1110 2100 and 2110 Serial Number Above 240000000 Main Electrical Harness Wiring Diagram HEAD LIGHT HEAD LIGHT A RATOR LS RS REVERSE SW JII 0 PI JI J2 J3 J4 P4 P5 t io NO NC Log 102 3 4 5 2 3 4 lt lt c o YELLOW WHITE BLUE VIOLET GRAY BLACK BLACK A ENGINE GROUND 5 d MAGNETO K WHITE BLUE c OIL PRESSURE 2 D DF 3 ORANGE BROWNWHITE 4 SP4 x F 5 5 E B 1 RED ley 8 2 TAIL LIGHT A GRAY 3 LEFT TURN a Sp BLACK lt 3 4 RIGHT TURN BLACK 1 ey SP BLUE BLACK D P WHITE F3 BLACK ul x 8 2 i 5 x 3 m z a T u gt ul A ia PII 5 RED
2. POWER POINT HEAD LIGHT HEAD LIGHT ACCELERATOR REVERSE SWITCH P1 P4 P5 J1 J2 J3 J4 NO NC NO NC 112 1 2 3 11213 x Y Im 2 1 T e n VIOLET 2 YELLOW SPA 3 ORANGE 4 5 6 1 8 5 A ENGINE GROUND BROWN B MAGNETO D gt ENGINE HARNESS 5 WHITE BLUE OIL PRESSURE 3 Va ens x x 4 2 z GREEN D DF 5 5 5 a m BROWN WHITE E BLACK SP3 BLACK BLACK SP2 5 4 E BLUE o EE 2 E RED 5 1 VIOLET 2 TAIL LIGHT KEKIT L BLACK GRAY 3 LEFT TURN P14 OPTION lu WHITE BLACK amp RIGHT TURN E 5 d VIOLET 2 F1 PINK 3 B 1 PINK YELLOW 4 d lie DR rust BLOCK BLACK F3 A 3 WHITE 6 VIOLET M 4 BROWN RED 7 S 5 BLUE 718 F a c EN D OPTIONAL FUSE BLOCK 1A BLUE 1B WHITE BLUE 2A RED BLACK k BLACK 2 GROUND YELLOW 3 x 4 Y p BOX LIFT SWITCH BLUE 5 12 V RED BLACK 6 Y BLACK 7 BLUE 5 i 8 1 8 T
3. B HEAD LIGHT HEAD LIGHT Be LEFT SIDE RIGHT SIDE rna Oo m J2 J3 JA NO NC NO NC 1 2 1 2 3 4 1 2 3 4 x z o E o o 2 lt 3 9832 c am c a gt e VIOLET 2 YELLOW NO 54 3 ORANGE 4 LIGHT SWITCH P2 5 6 7 8 BLACK uM 1 ENGINE GROUND x x 9 2 BROWN MAGNETO P3 ENGINE HARNESS 3 a WHITE RED 3 OIL PRESSURE a BLACK GREEN 4 DF BLACK SS BLACK 53 BLACK u 5 5 am 2 2 RED 1 12V a VIOLET 2 TAILLIGHT BLUE BLUE 81 pi4 9 BLUE ui GRAY 8 LEFT TURN OPTION HOUHMEIER a WHITE BLACK 4 RIGHT TURN J45 BLACK 1 F1 Jo 1 PINK PINK 1 2 3 YELLOW ES J11 2 VIOLET a z P8 FUSE BLOCK KEY SWITCH 6 17 BLACK J2 Me RED 7 BLACK F4 BLUE 8 J3 M BROWN 1 P11 OPTIONAL FUSE BLOCK 1 BLUE LOWOILLEVEL pg 1B WHITE RED WARNING LIGHT x 2 YELLOW 1 x 2B BLACK 2 GROUND RED BLACK 3 x L _ RED BLACK 4 Y P7 BOX LIFT SWITCH BLUE 5
4. POWER POINT HEAD LIGHT HEAD LIGHT ACCELERATOR REVERSE SW 15 RS P1 P4 P5 C 02 J1 J2 J3 J4 NO NC NO NC 2 MEE 2 3 BLUE VIOLET 5 GRAY lt lt BLACK c c 2 o e 3 ORANGE WHITE BLUE 4 SPA GREEN 5 4 BROWN WHITE j 6 5 d 1 5 8 Q RED eb gt VIOLET SP BLACK GRAY BLACK WHITE BLACK 3 BLUE BLACK WHITE BLACK E LJ x 2 a 5 ao uj RED o gt 2 3 VIOLET 4 BROWN 5 BLACK RED BLACK BLACK 5 YELLOW j a RED BLUE iA RED BLACK IB 2 x 2B 5 BLACK 1 te BLUE YELLOW 2 A B 72 c 4 C 0 2 m Jg P12 FS P6 P19 START RUN BOX LIFT ACTUATOR BACKUP DIODE SOLENOID REGULATOR ENGINE GROUND MAGNETO OIL PRESSURE P3 TO ENGINE HARNESS pre 12 V TAIL LIGHT LIFT KIT LEFT TURN P14 RIGHT TURN ibl dil F2 P8 FUSE BLOCK E F3 F4 P11 OPTIONAL FUSE BLOCK GROUND Y P7 BOX LIFT SW 12
5. J J4 REVERSE SWITCH PS 1 NO NC 2 3 p 7 aae pL 5 ua un di 102 LIFT KIT SW 10 OPTION sits L2 P7 POINT i 1 ra 7585 3 1 n 3 Li j E mim BACKUP O ACCELERATOR ALARM oS 4922 FEO Ph 5 aL 8 6 amp 2 66098 EL 3 FUSES t 219 4 3 a PB OPTIONAL LIGHT p 5 ENGINE pe Be OPTIONAL P3 P14 P2 KIT P13 _U 2 1 START OPTIONAL FUSE BLOCK TT RUN SOLENOID COIL J7 Q P11 P19 DIODE P10 VOLTAGE REGULATOR LABEL P12 LIFT KIT OPTION 4 J2 HEADLIGHT 1 OPTIONS J18 J17 P9 LOW OIL P18 IGNITION SWITCH Workman 1100 and 2100 Serial Number From 220000001 To 220999999 Main Electrical Harness Drawing Page 8 12 Rev B LIGHT SWITCH 2 HOUR METER OPTIONS IGNITION SWITCH P18 LOW OIL PRESSURE WARNING LIGHT P9
6. 16 Installation 0 eee 17 Transaxle Service 18 Disassembly and Inspection 19 ASSertibly c cb lig bik ee ak 33 Drive Train Specifications Item Description Transaxle Transaxle Fluid Capacity Transaxle Fluid Mechanically governed differential 1 5 quarts 1 4 liters 10W 30 Motor Oil Clutch System Drive Clutch Driven Clutch Continuously variable transmission type torque convertor Speed sensing with mechanical fly weights Torque sensing with spring loaded cam Note Workman 2100 and 2110 vehicles with serial numbers above 240000000 use an engine governor for speed control rather than a transaxle governor Drive Train 5 2 Rev A Workman 1100 2100 2110 Special Tools OTC Owatonna Tool Company supplies special tools for servicing Toro Commercial Products The TORO SPECIAL TOOLS AND APPLICATIONS GUIDE shows service tool applications Clutch Removal Tool TOR4094 This tool is required to remove the drive clutch from the tapered drive shaft of the engine It is placed in the threaded hole of the fixed clutch sheave after the clutch holding cap screw is removed Some tools may have been supplied with your vehicle or available as TORO parts Some tools may also be available from a local supplier Figure 1 Spider Removal Tool Kit Drive Clutch TOR4098 This kit is require
7. 13 Inspect Tires and Wheels 13 Upper Steering 14 Steering Gearbox 16 Lower Steering and Front Wheels Workman 1100 and 2100 18 Lower Steering and Front Wheels Workman 1110 and 2110 20 Chapter 7 Chassis Wheels and Brakes A arm and Frame Pivot Yoke 22 Rear Wheels and Brakes Workman 1100 and 2100 26 Rear Brake Service Workman 1100 and 2100 28 Parking Brake Workman 1110 and 2110 30 Rear Wheels and Brakes Workman 1110 and 2110 s cele 32 Rear Brake Service Workman 1110 and 2110 34 Front Brake Calipers Workman 1110 and 2110 36 Front Brake Caliper Service Workman 1110 and 2110 Serial Number Below 240000000 38 Front Brake Caliper Service Workman 1110 and 2110 Serial Number Above 240000000 39 Brake Master Cylinder Workman 1110 and 2110 40 Brake Master Cylinder Service Workman 1110 2110 eka RTS 41 Hydraulic Brake System Workman 1110 and 2110 erect 42 Bleed Brake System Workman 1110 and 2110 43 Front Hood ca rk tae eese 44 Cargo Bed and Tailgate 45 Workman 1100 1110 2100 2110 7 1 Rev C Chassis Wheels and Brakes a 9 S s LO 25 aoc Specifications
8. Item Description Workman 1100 front tire 20 x 10 8 4 ply pressure 6 to 12 PSI 0 41 to 0 83 bar Workman 1100 rear tire 22 5 x 10 8 4 ply pressure 8 to 22 PSI 0 55 to 1 52 bar Workman 2100 front tire 22 5 x 10 8 4 ply pressure 8 to 22 PSI 0 55 to 1 52 bar Workman 2100 rear tire 25 x 12 9 4 ply pressure 8 to 22 PSI 0 55 to 1 52 bar Workman 1110 and 2110 front tire 22 x 9 5 10 4 ply pressure 8 to 22 PSI 0 55 to 1 52 bar Workman 1110 and 2110 rear tire 24 x 12 10 4 ply pressure 8 to 22 PSI 0 55 to 1 52 bar Front wheel bolt torque WM1100 and WM2100 135 to 165 ft lb 183 to 224 Wheel lug nut torque 45 to 65 ft lb 61 to 88 Chassis Wheels and Brakes Rev B Page 7 2 Workman 1100 1110 2100 2110 Troubleshooting Suspension and Steering Problem Possible Cause Front end is noisy Front wheel bearings are loose or worn Front wheel lug nuts are loose Front end components are loose or worn Steering gear is loose Control arm bushings are worn Rear end is noisy Clutch or transaxle problem see Chapter 5 Drive Train Rear wheel lug nuts are loose Excessive steering play Front wheel bearings are loose or worn Front wheel lug nuts are loose Steering linkage is loose or worn Tie rod ends are worn Steering gear is incorrectly adjusted Front end shimmies Front wheel bearings are loose or worn Front wheel lug nuts are loose Steering linkage
9. 15 SPEGIAL TOOLS win otis et ee eee atti 3 Headlights i i suid dae ee elie La wd hae es 15 TROUBLESHOOTING 4 Starter Generator 16 Starting Problems 4 Hemoval es te ie 16 General Run Problems 5 Installation 17 ELECTRICAL SYSTEM QUICK CHECKS 6 Starter Generator Service 18 Battery Test 2 o e eben i 6 Brush and Brush Spring Service 19 COMPONENT TESTING 7 Armature and Field Coil Service 20 Ignition Switch 7 Rework Starter Generator 22 Hour Meter aX ead 8 Battery Service 23 Audio Alarm 8 sees eres eee bes RI PERS 23 Headlight Switch 8 Inspection Maintenance and Testing 23 Starter Solenoid 9 Installation 25 Fuse Block ERR ene 9 Charging 25 Starter Generator amp Voltage Regulator 10 Battery Storage 26 Starter Generator 11 Accelerator Switch 12 Diode Assembly 1
10. Ll o D D o o Engine CON OA PONS Hose clamp Air intake hose Cable bracket Cable clamp Cap screw Threaded insert Washer Cap screw Nut Torque arm Flat washer 2 used Lock washer 2 used Cap screw 2 used Starter V belt Cap screw 4 used Briggs amp Stratton Gasoline Engine Figure 19 Lock washer 4 used Engine pulley Starter spacer Drive belt Drive clutch Washer Cap screw Cap screw 4 used Flange lock nut 4 used Screw Engine mount Starter generator pulley Starter generator pivot Starter generator Flanged lock nut Page 3 16 Negative battery cable Positive battery cable Cotter pin Starter rod Fuel hose Fuel filter Fuel line clamp Fuel line conduit Briggs amp Stratton engine Intake bracket Screw 4 used Hose clamp Cable bracket Transaxle with driven clutch Workman 2100 2110 Engine Removal Fig 19 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Remove cargo bed to gain access to the engine 3 Disconnect negative black cable from the battery Then disconnect positive red cable from the battery IMPORTANT Make sure all hoses and engine open ings are plugged after disconnecting Prevent con taminants from entering the e
11. 2 Secure cable bracket to the actuator lever with clevis pin and cotter pin Fig 19 IMPORTANT Do not get antiseize lubricant onto brake shoes 3 Apply light coat of antiseize lubricantto the transaxle shaft splines 4 Secure wheel hub to the shaft with spacer lock washer and castle nut Workman 1100 1110 2100 2110 Page 7 27 5 Torque castle nut to the shaft between 120 to 200 ft Ib 163 to 271 N m while aligning nut to hole in shaft Install cotter pin 6 Slide brake drum onto wheel hub 7 Position wheel assembly to the machine with valve stem facing out and secure with five lug nuts Torque lug nuts in a criss cross pattern from 45 to 65 ft lb 61 to 88 N m 8 Lower machine to ground After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 9 Check and adjust brakes see Brake Adjustment Burnish Brake Shoes Sintered metal linings may not provide maximum brake stopping distance after brake shoes are replaced It is necessary to burnish new brake shoe linings IMPORTANT Do not drive machine with the brakes applied The brake shoe linings will overheat IMPORTANT Do not allow the brakes to lock up Al low brakes to cool between applications 1 Drive machine while making 6 to 7 normal stops at about 200 ft 60 m intervals while traveling at 10 to 15 mph 16 to 24 KPH 2 Make several normal stops with the
12. 25 aoc Steering Gearbox Gasket Hex washer head screw Seal Sector gear Flat washer Ball bearing Output shaft spacer Dg OU EOM Chassis Wheels and Brakes Rev B 27 to 33 ft lb 37 to 44 N m 90 to 110 in Ib 10 2 to 12 4 N m Figure 11 Stepped washer Flange head screw with patch lock Ball bearing Input shaft spacer Flat washer Cap screw Page 7 16 175 to 225 in Ib 20 to 25 N m Lube fitting Steering housing cover Steering housing Pinion gear Oil seal Pitman arm Workman 1100 1110 2100 2110 Disassembly IMPORTANT Do not reuse flange head screw with patch lock after it has been removed 1 Remove flange head screw with patch lock and stepped washer from Pitman arm Discard flange head screw 2 Remove cap screw and flat washer from pinion gear shaft 3 Remove hex washer head screws securing the housing cover and gasket to the steering housing Re move cover and gasket from the housing Replace gas ket if damaged 4 Inspect gears Sector and pinion gear teeth must be free of damage that prevents them of free movement 5 Remove pinion gear from the housing IMPORTANT Matchmark pitman arm shaft and sec tor gear Their position is critical during reassembly 6 Separate Pitman arm from the sector gear an
13. Starter Generator 10 5 VDC 100 Amps 14 VDC and 23 Amps Workman 2100 2110 Page3 3 Rev B Briggs amp Stratton Gasoline Engine L4 5 22 N D o gt o e General Information Fill Fuel Tank and Fuel Safety Precautions The Toro Company strongly recommends the use of fresh clean UNLEADED regular grade gasoline in Toro gasoline powered products Unleaded gasoline burns cleaner extends engine life and promotes good starting by reducing the build up of combustion chamber depos its Minimum Octane rating of 85 IMPORTANT Never use gasoline containing METH ANOL gasoline containing more than 10 ethanol gasoline additives or white gas Damage could re sult to the engine fuel system 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Clean area around fuel tank cap 3 Remove fuel tank cap 4 Fill tank to about one inch below the top of tank bot tom of filler neck This space in the tank allows gasoline to expand Do not overfill 5 Install fuel tank cap securely Wipe up any fuel that may have spilled Figure 1 1 Fuel tank cap 2 Fuel gauge Briggs amp Stratton Gasoline Engine Page 3 4 POTENTIAL HAZARD e Gasoline is extremely flammable and highly explosive under certain conditions WHAT CAN HAPPEN e A fire or explosion from gasoline can
14. 1 Position pivot yoke to the front frame so the diamond pattern faces up Secure yoke to front frame with four flange head screws and flanged lock nuts Tighten lower two fasteners first then tighten upper two fasteners 2 Secure pivot yoke to the front frame tab with cap screw and hardened washer Torque cap screw from 240 to 290 ft lb 325 to 393 Chassis Wheels and Brakes Rev B Page 7 24 3 Secure pivot yoke to the rear frame with four cap screws and flat washers 4 Install seat base to the front frame see Seat Base Installation in Engine Chapter 5 Install cargo bed to the rear frame see Cargo Bed and Tailgate Installation Figure 17 1 Cap screw amp flat washer 2 Pivot yoke 3 Rear frame 4 Flange lock nut 5 Front frame 6 Diamond pattern Workman 1100 1110 2100 2110 This page is intentionally blank a 33 x r 25 ac Workman 1100 1110 2100 2110 7 25 Chassis Wheels and Brakes Rev Rear Wheels and Brakes Workman 1100 and 2100 20 ft lb 120 to 200 ft lb 4 163 to 271 N m 45 to 65 ft lb 61 to 88 N m Antiseize Lubricant Figure 18 1 Lugnut 7 Lock washer 12 Cotter pin 2 Wheel assembly 8 Spacer 13 Flange lock nut 3 Wheel hub 9 Cap screw 14 Transaxle shaft 4 Brake drum 10 Brake cable 15 Brake assembly LH shown 5 Cotter pin 11 Clevis pin 16 Wheel stud 6 Castle nut Chassis Wheels and Brake
15. 4 Secure engine mount to the rear frame as follows Fig 23 and 25 A Attach both isolation mounts to the engine mount B Align engine mount to rear frame Insert cap screw through rear frame channel isolation mounts and engine mount C Secure cap screw with flat washer and flange lock nut 5 Position select lever assembly and shift cables to the transaxle Secure select lever assembly to the selector shaft with lock nut Secure both shift cables to the cable bracket with jam nuts Fig 22 6 Secure governor and cable brackets to the transaxle as follows Fig 21 A Position governor and cable brackets with cables as a complete unit to the transaxle case and gover nor shaft B Secure cable bracket to the transaxle case with both lock nuts C Align scribe marks on the governor bracket and shaft Secure bracket to the shaft with both set screws Workman 1100 2100 2110 Page 5 17 7 Secure both battery cables to the passenger side axle tube with tie wraps 8 Install drive belt to the driven clutch see Service Drive Belt in Engine Chapter 9 Install both brake assemblies and wheels to the transaxle see Rear Wheel and Brake Installation in Chapter 7 Chassis Wheels and Brakes 10 Install cargo box to the frame see Cargo Box Instal lation in Chapter 7 Chassis Wheels and Brakes 11 Verify proper ground speed see Adjust Ground Speed 12 Check brakes for proper adjustme
16. Product Records and Maintenance A warnine Use caution when working with fuel system com ponents see Fill Fuel Tank and Fuel Safety Pre cautions 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Raise bed and support with prop rod 3 Place a clean container under fuel filter Fig 10 4 Remove clamps securing fuel filter to fuel lines 5 Remove fuel lines from fuel filter IMPORTANT Mount filter so the arrow points in the di rection of fuel flow to the carburetor 6 Install new fuel filter to fuel lines with clamps pre viously removed Workman 1100 1110 Page 4 9 Figure 9 1 Drive clutch 3 Drive belt 2 Driven clutch N e 2 Figure 10 1 Fuel filter 3 Vacuum line 2 Fuelline Kohler Gasoline Engine Spark Plug Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance Type Champion RC 14YC or equivalent Air Gap 0 030 inch 0 76 mm Note spark plug usually lasts a long time however the plug should be removed and checked whenever the engine malfunctions 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Raise bed and support with prop rod 3 Clean area around spark plug so foreign matter can not fall int
17. 10 5 VDC 100 Amps 14 VDC and 23 Amps Workman 1100 1110 Page 4 3 Kohler Gasoline Engine o a e x General Information Fill Fuel Tank and Fuel Safety Precautions The Toro Company strongly recommends the use of fresh clean UNLEADED regular grade gasoline in Toro gasoline powered products Unleaded gasoline burns cleaner extends engine life and promotes good starting by reducing the build up of combustion chamber depos its Minimum Octane rating of 87 IMPORTANT Never use gasoline containing METH ANOL gasoline containing more than 10 ethanol gasoline additives or white gas Damage could re sult to the engine fuel system 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Clean area around fuel tank cap 3 Remove fuel tank cap 4 Fill tank to about one inch below the top of tank bot tom of filler neck This space in the tank allows gasoline to expand Do not overfill 5 Install fuel tank cap securely Wipe up any fuel that may have spilled Figure 1 1 Fuel tank cap 2 Fuel gauge Kohler Gasoline Engine Page 4 4 POTENTIAL HAZARD e Gasoline is extremely flammable and highly explosive under certain conditions WHAT CAN HAPPEN e A fire or explosion from gasoline can burn you others and cause property damage HOW TO AVOID THE HAZARD Use a funnel and fill the fuel tank outdo
18. 9 Remove starter bracket from the engine and frame 10 Disconnect engine electrical harness connector from the main harness 11 Remove four flange lock nuts and flange head Screws securing the engine to the engine mount Note location of ground cable for proper reassembly Workman 1100 1110 Page 4 15 M CAUTION One person should operate the chain fall or hoist while the other person guides the engine out of the frame 12 Remove engine from the engine mount A Attach a short section of chain between fuel pump bracket lift hole and exhaust manifold Fig 18 B Connect hoist or chain fall to center of chain IMPORTANT Make sure not to damage the engine fuel hoses electrical harness or other parts while removing the engine C Slowly remove engine and attachments from the machine 13 Remove engine parts and attachments as neces sary to repair the engine A Figure 18 4 Drive belt 5 Starter generator belt 1 Fuel pump bracket 2 Exhaust manifold 3 Fuel line Kohler Gasoline Engine Kohler Gasoline Engine Installation Fig 17 1 If removed install engine parts and attachments to the engine One person should operate the chain fall or hoist while the other person guides the engine into the frame 2 Install engine to the frame A Attach a short section of chain between fuel pump bracket lift hole and exhaust manifold Fig 18 B Connect a hoist or chain fa
19. 5 Gently slide filter out of the air cleaner body to reduce the amount of dust dislodged Avoid knocking filter against the air cleaner body IMPORTANT Do not wash or reuse a damaged filter 6 Inspect filter Discard filter if damaged 7 Clean filter element using either the washing method or compressed air method Washing Method A Prepare a solution of filter cleaner and water Soak filter element for about 15 minutes Refer to directions on the filter cleaner carton for complete in formation IMPORTANT Maximum water pressure must not exceed 40 psi to prevent damage to the filter ele ment B After soaking the filter for 15 minutes rinse it with clear water Rinse filter from the clean side to the dirty side IMPORTANT Do not use a light bulb to dry the filter element because damage could result C Dry filter element using warm flowing air that does not to exceed 160 F 71 C or allow element to air dry Briggs amp Stratton Gasoline Engine Page 3 8 Compressed Air Method Ad caution Use eye protection such as goggles when using compressed air IMPORTANT Maximum air pressure must not ex ceed 100 psi to prevent damage to the element A Blow compressed air from the inside to the out side of the dry filter element B Keep air hose nozzle at least 2 inches 5 cm from the filter Move nozzle up and down while rotating the filter element Inspect for holes and tears by looking through
20. Percent of Fully Charged Capacity inte 80 or less 3 8hrs 7 5hrs 11 3 hrs 15 hrs 3 amps 3amps 3amps 3 amps 81 125 5 3hrs 10 5 hrs 15 8 hrs 21 hrs 4amps 4amps 4amps 4amps 126 to 5 5 hrs 11 hrs 16 5 hrs 22 hrs 170 5 amps 5amps 5amps 5 amps 171 to 5 8hrs 11 5 hrs 17 3 hrs 23 hrs 250 6 amps Gamps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge battery a well ventilated place to dissi pate gases produced from charging These gases are explosive Keep open flame and electrical spark away from the battery Do not smoke Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts Nausea may result if the gases are inhaled 3 Follow the manufacturer s instructions Connect charger cables to the battery Make sure a good connec tion is made Electrical System 2 5 i System 4 Charge the battery following the manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 6 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temp
21. Plastic threads thread tool only enough to remove the clutch 6 Use clutch removal tool see Special Tools to re move drive clutch from the engine tapered shaft 7 necessary the engine starter pulley can be re moved from the drive clutch Remove four cap screws and lock washers securing the pulley and starter spacer to the clutch Installation 1 Install engine pulley to the drive clutch as follows A Insert four cap screws through lock washers pulley and spacer B Apply Loctite Blue 242 or equivalent to the threads of the cap screws C Secure pulley and starter spacer to the clutch with cap screws 2 Slide drive clutch onto the tapered engine shaft A Apply Loctite Blue 242 or equivalent to the threads of the cap screw B Secure clutch to shaft with cap screw and washer Torque cap screw from 25 to 30 ft lb 34 to 41 3 Install plastic cap carefully to the drive clutch 4 Install starter generator V belt to the engine and starter pulley and adjust see Install Starter Generator Belt and Adjust Starter Generator Belt in Engine Chap ter 5 Install drive belt to the drive clutch see Service Drive Belt in Engine Chapter Workman 1100 2100 2110 Page 5 9 Drive Train 100 ft Ib 136 7 5 75100 8 5 to 11 3 N m Figure 10 1 Fixed sheave 5 Cap screw 9 Roller kit 2 Spring 6 Plastic cap 10 Cam weight 3 Washer 7 Cover 11 Nut 4 Spider assemb
22. Figure 6 1 Ride height adj bolt 2 A arm Figure 7 1 Front A arm LH shown Workman 1100 1110 2100 2110 Adjust Front Wheel Note Adjust front wheel ride height before checking or adjusting front wheel toe in 1 Adjust tire pressures to 12 psi before checking front wheel toe in 2 With a 175 to 225 Ib 79 to 102 kg operator in the driver s seat drive vehicle back and forth a few times on a level surface to relax suspension 3 Stop vehicle With operator still in driver s seat and wheels pointed straight ahead measure the front wheel toe in 4 Measure distance between the front tires at axle height at both the front and rear of the tires To obtain an accurate measurement at axle height a universal align ment gauge or equivalent should be used Fig 8 Front wheel toe in should be 1 8 to 5 8 inch 3 to 16 mm NOTE If the vehicle will be run with medium to heavy loads most of the time adjust the toe in toward the max imum specification Conversely if light loads are carried adjust toe in toward the minimum specification 5 If the front wheel toe in is incorrect adjust as follows A Loosen jam nuts at both ends of tie rods Fig 9 B Rotate both tie rods to move front of tire inward or outward C Tighten tie rod jam nuts when toe in adjustment is correct 6 Ensure that there is full steering travel in both direc tions Figure 8 1 Tire center line back 4 Ali
23. IMPORTANT Flange head screw with patch lock should be replaced whenever it is removed 8 Secure flange head screw with patch lock and step washer to the Pitman arm Make sure to position step washer as in Figure 11 Torque screw from 27 to 33 ft lb 37 to 44 9 Secure cap screw and flat washer to the pinion gear shaft Torque screw from 175 to 225 in Ib 20 to 25 Chassis Wheels and Brakes Rev a 33 x Ss 25 ac Lower Steering and Front Wheels Workman 1100 and 2100 9 J gt na 20 to 25 ft Ib 27 to 34 Antiseize lubricant 135 to 165 ft Ib 183 to 224 N m 1 20 to 25 ft lb M uid UN LO a 11 75 to 100 ft Ib Thread locking P dii 3 102 to 136 compound 2 Figure 12 1 10 Lock nut 19 Ball joint LH thread 2 Front wheel 11 Thrust washer 20 Pitman arm 3 Plastic dust cap 12 Cap screw king pin 21 A arm LH 4 Cap screw 13 Jam nuts 22 A arm RH 5 Large flat washer 14 Tie rod assembly 23 Kingpin sleeve 6 Flat washer 15 Ball joint RH thread 24 Bushing 7 Bearing 16 Jam nut RH thread 25 Spindle RH 8 Spacer 17 Tie rod 26 Grease fitting 9 Spindle LH 18 Jam nut LH thread NOTE Both front wheels 2 have two bearings 7 and 3 Remove tire and front wheel as follows one spacer 8 A Remove plastic dust cap carefully from the wheel NOTE Both tie rod assemblies 14
24. Clevis 11 Primary piston assy 6 Jamnut 12 Cylinder housing cylinder bore Assembly Fig 27 1 Apply a film of clean brake fluid to cylinder bore and piston assemblies 2 Install secondary piston assembly and primary pis ton assembly into cylinder 3 Install retainer washer 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 a 33 x Ss 25 ac Workman 1100 1110 2100 2110 Page 7 41 Chassis Wheels and Brakes Rev B Hydraulic Brake System Workman 1110 and 2110 Thread locking Compound Figure 28 1 Brake caliper LH 12 Clip 23 Rear brake tube 2 Brake caliper RH 13 Tee fitting 24 Rear brake hose 3 Brake rotor 14 Rear brake tube RH 25 Hose bracket 4 Front brake tube 15 Rear brake tube LH 26 Tube clamp 5 Front brake hose 16 Insulated clip 27 Clamp 6 Carriage screw 17 Cap screw 28 Cap screw 2 per caliper used 7 Rear brake tube 18 Flange head screw 29 Lock washer 2 per caliper used 8 Carriage screw 19 Clevis pin 30 Socket head screw 4 per rotor used 9 Rear brake hose bracket 20 Cotter pin 31 Cap screw 10 Cap screw 21 Master cylinder 32 Lock nut 11 Thread forming screw 22 Union fitting When performing service work on the Workman 1110 and 2110 hydraulic brake syste
25. Ibs 10 8 to 11 8 N m K Slide brushes into holders Secure brushes by positioning brush springs into the notch at the end of the brushes Fig 25 L Install brush covers to the commutator end cover M Position spacer and woodruff key onto the shaft Place pulley onto the shaft N Secure pulley to the shaft with spring washer and nut Torque nut from 15 to 25 ft lb 20 to 34 9 ft lIb x 5 12 43 to 52 in Ib 4 9 to 5 9 Figure 27 5 Setscrew 6 Pole piece 7 Yoke Field coils Nut and washers Threaded terminal Insulator Electrical System n o m System Rework Starter Generator Fig 22 NOTE Rework to the starter generator must be per motors and generators It may be more economically formed by a properly trained technician using the correct feasible to replace the starter generator than have it re tools and equipment for testing and reworking electrical worked ar a a Minimum commutator diameter 1 575 inches 40mm Commutator concentricity to the shaft 0 0003 inch 0 008 mm Commutator machining limit per cut 0 005 inch 0 127 mm Insulator depth between commutator bars 0 020 inch 0 5 mm Armature insulation resistance 0 2 Mohm at 500 VDC Dielectric insulation strength 500 VDC for one minute with no insulation break down Starter field coil resistance 2 38 to 2 44 ohms at 20 C 68 F Generator field coil resistance 0 041 o
26. screwdriver through loop in pins 3 Slide brake pads from caliper For assembly pur poses note orientation of inner and outer pads as the pads are not the same 4 Replacethe brake pads ifthe friction material is worn to less than 1 32 0 8 mm Assembly Fig 26 1 If brake pads are being replaced it will be necessary to push caliper pistons back into the caliper bore before installing new pads 2 Slide brake pads into caliper Make sure that lining material on pads is toward brake rotor position 3 Secure pads into caliper with two 2 pins Make sure that pins snap into caliper slots 4 If caliper is equipped with anti rattle clip install clip to caliper pins and brake pads Workman 1100 1110 2100 2110 Figure 26 3 Clip if equipped 1 Brake pad 2 Pin 2 used Page 7 39 Rev C Chassis Wheels and Brakes a 9 z bm nas aoc Brake Master Cylinder Workman 1110 and 2110 Figure 26 1 Master cylinder 4 Clevis pin 6 Flange head nut 2 Cap screw 5 Cotter pin 7 Pedal frame 3 Brake pedal Removal Installation 1 Remove front hood from machine 2 Remove cotter pin from the clevis pin that connects master cylinder to brake pedal 3 Clean hydraulic brake line area of master cylinder to prevent contamination Remove both brake lines from master cylinder Cap ends of brake lines and position them away from master cylinder 4 Remove flange he
27. 2 Product Records and Maintenance 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch 2 Remove drain plug from the right side of the trans axle case Fig 19 Let fluid flow into a drain pan 3 When fluid stops draining reinstall and tighten drain plug Fig 19 Torque plug from 15 to 18 ft Ib 21 to 25 N m 4 Use 10W 30 motor oil to fill the transaxle case A Fill case with about 1 5 quarts 1 4 liters of motor oil Fig 20 B Or fill case until oil level is at the bottom level of the indicator hole with the plug removed Fig 19 5 Reinstall level indicating plug and fill cap Tighten plugs that were removed Fig 19 and 20 6 Start engine and operate vehicle to allow the trans axle to fill Recheck oil level Replenish oil if required Drive Train Page 5 14 LS Figure 18 1 Moveable sheave 3 Button 2 Drive belt 4 Ramp fixed sheave 15 to 18 ft lb 21 to 25 N m Figure 19 1 Drain plug 2 Level indicating plug 11 7 Figure 20 1 Fill cap 2 Driven clutch Workman 1100 2100 2110 This page is intentionally blank Workman 1100 2100 2110 Page 5 15 Drive Train Transaxle Removal 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch 2 Remove cargo box from the frame see Cargo Box Removal in Chapter 7 Chassis Wheels and Brake
28. A Slide pin clutch onto the centershaft Install gears fide grease to the inside of gears 47 and 55 47 and 55 onto shaft noting correct orientation of gears Slide collars small gear and spacer onto the center shaft Figure 56 1 Ball bearing 2 Ball bearing B Press ball bearings onto the center shaft using a bearing press Workman 1100 2100 2110 Page 5 35 Drive Train C Make sure distance from one ball bearing outer edge to the other ball bearing outer edge is 136 8 to 137 1 mm Fig 55 Figure 57 D The center shaft should appear as above when assembled 3 Assemble differential assembly 123 3 to 124 0 mm Figure 58 1 Pinion gear greased surface 6 Bolt 2 Pinion shaft 7 Spring pin 3 Side gear greased surface 8 Ball bearing 4 Differential case 9 Ball bearing 5 Gear 62 Drive Train Page 5 36 Workman 1100 2100 2110 A Apply molybdenum disulfide grease to the inside side of both side gears where they contact the differ of both pinion gears where they contact the pinion ential case and gear 62 shaft Apply molybdenum disulfide grease to the out Figure 59 1 Side gear 3 Pinion shaft 2 Pinion gear 4 Differential case B Install side gear both pinion gears and pinion shaft into the differential case Figure 60 1 Spring pin 2 Differential case C Align pinion shaft hole and install new spring pin through the differential case and pinion shaft Workman 1100 2100 211
29. Adjustments 2 Briggs and Stratton Repair Manual for 4 V Twin Service and Repairs Cylinder OHV Head Engines 2 Chapter 8 Electrical Diagrams Chapter 4 Kohler Gasoline Engine 5 Electrical Schematics 5 2 2 2 4 2 Circuit 08 Specifications 4 3 Electrical Harness Drawings Wiring General Information 4 4 EROR Adjustments ine cic 4 6 Service and Repairs 4 7 Kohler Service Manual for COMMAND PRO CS Series Engines SE 2 rri Chassis Wheels and Brakes Electrical Diagrams Workman 1100 1110 2100 2110 Rev A This page is intentionally blank Workman 1100 1110 2100 2110 Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS 2 JACKING AND OTHER INSTRUCTIONS 6 Supervisor s Responsibilities 2 Jack Vehicle 6 Before 2 Transport Vehicle 6 While Operating 3 Tow Vehicle 7 Maintenance and Service 5 Transaxle Neutral Position 7 SAFE
30. Brake cable is binding Workman 1100 and 2100 Brake linings are saturated Brake drums are bent or out of round Brake pedal is hard to push Incorrect brake lining material Brake pedal linkage is binding Brake cable is binding Workman 1100 and 2100 Wheels lock up when braking Brake linings are contaminated Brake linings are loose or damaged Wheel or transaxle bearings are damaged Shoe to shoe springs are weak Brake drums are grooved in the contact face with brake shoes Brakes fade Brake drums are overheated Brake linings are saturated Vehicle surges at slow speeds and Brake drums are bent or out of round chatters at fast speeds Brakes do not self adjust Adjuster bolt is seized Workman 1100 and 2100 Adjuster lever does not engage star wheel Workman 1100 and 2100 Chassis Wheels and Brakes Rev B Page 7 6 Workman 1100 1110 2100 2110 Adjustments Adjust Brakes Workman 1100 and 2100 Serial Number Below 230000000 Before and after adjusting the brakes always check the brakes in a wide open area that is flat and free of other persons and obstructions 1 While driving the machine depress brake pedal Both wheels should lock equally 2 Park machine on a level surface Make sure engine is off Remove key from ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety Figure 1 1 Cable adjusting screw 2 Brake e
31. Flange nut Cap screw Cap screw Carriage bolt Thrust washer Cap screw Hose clamp Clamp Flat washer Rebound washer Static debris screen Screw Washer Workman 1100 1110 Engine Removal Fig 17 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Remove cargo bed to gain access to the engine see Cargo Bed and Tailgate Removal Chapter 7 3 Disconnect ground black cable from the battery Then disconnect positive red cable from the battery IMPORTANT Make sure all hoses and engine open ings are plugged after disconnecting Prevent con taminants from entering the engine and fuel system and damaging the engine 4 Disconnect the following components A Choke and throttle cables from the carburetor and cable bracket B Air intake hose from the carburetor C Breather hose from the engine valve cover Read safety precautions for handling gasoline before working on the fuel system see Fill Fuel Tank and Fuel Safety Precautions 5 Disconnect fuel hose from the fuel pump Fig 18 Remove cable tie securing the choke and throttle cables to the fuel pump bracket 6 Remove muffler and exhaust coupler see Muffler Removal 7 Remove drive belt see Service Drive Belt 8 Remove V belt from the engine and starter genera tor by loosening the tension on the belt see Adjust Start er Generator Belt
32. Generator Testing of starter generator field and armature windings is difficult with the starter generator still mounted in the Workman Follow the procedures for Starter Generator S amp Voltage Regulator Component Testing prior to remov Q ing the starter generator for further testing and repairs Starter generator resistance tests are as follows NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from the measured value of the component you are testing 1 Measure resistance Ohms between starter gener Figure 12 ator terminals DF and F1 field The meter reading 1 Starter Generator end cover view should be 5 5 to 5 9 Ohms 2 Measure resistance Ohms between starter gener ator terminals A1 and A2 armature The meter reading should be under 1 Ohm 3 Measure resistance between each terminal Fig 12 and ground The meter reading should be infinite 4 Starter generator disassembly and repair will be needed if readings are incorrect n o K System Workman 1100 1110 2100 2110 Page 6 11 Electrical System Accelerator Switch The accelerator switch is a four terminal two circuit switch When the accelerator pedal is pushed the switch allows current flow to
33. Install dust cap to hub 7 Install brake caliper to spindle see Front Brake Cali per 8 Install wheel assembly with valve stem facing out Torque lug nuts from 45 to 65 ft lb 61 to 88 9 Lower machine to ground 10 Align steering and toe in see Adjust Front Wheel Toe in 11 Lubricate tie rod ball joints and king pin see Lubrica tion in Chapter 2 Product Records and Maintenance Chassis Wheels and Brakes Rev B C 5 77 5 N x Eg 59 i and Frame Pivot Yoke Flange lock nut Light duty hitch Flange head screw Decal Decal Rear frame Retaining ring Decal 10 Flange head screw 11 Flange nut 12 Flat washer CON ho N 240 to 290 ft lb 325 to 393 N m Chassis Wheels and Brakes Rev B Figure 14 Cap screw Rubber bumper Flange head screw Pedal cover Decal Flange nut Ride height adjustment bolt A arm LH Grease fitting Lock nut Cap screw Lock washer Page 7 22 25 26 27 28 29 Front frame 31 32 33 Hardened washer 35 Travel limiting bolt A arm RH Bushing Decal Cable tie Pivot yoke Flange head screw Front frame tab Brake cable Workman 1100 1110 2100 2110 Removal Fig 14 and 15 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition swi
34. PEREAT axa i MES eee eer uu S OPTIONAL FUSES OR GN BK HEAD LIGHTS VOLTAGE REGULATOR P3 4 o 4 i Y armature XE To I I P3 2 A MAG SPARK PLUG SPARK PLUG IGNITION ba ad O MODULES ENGINE FRAME GROUND RPM SHUTDOWN O BK lt rT gt Current Direction Page 8 6 Rev B 1 2 VIO o o REVERSE SW IN FORWARD BU STOP RUN BoA IGNITION SW ITCH START B A S e OFF RUN START o 4 3 ree lt m OPTIONS BN M ME BU 1 1 gt BK BN W ACCELERATOR PEDAL PUSHED H LOW OIL Y PRESSURE W BK ka amp POWER POINT LIGHT SWITCH 9 i a 6 OPTIONAL FUSES BN lt 2 OR Eu BACKUP ALARM GN R BK HEAD LIGHTS VOLTAGE REGULATOR P3 3 P3 4 MAG SPARK PLUG SPARK PLUG IGNITION a um 1 ENGINE OIL MODULES z ENGINE FRAME GROUND PRESSURE RPM SHUTDOWN Run Circuits Workman 2100 Schematic Shown Power Current Control Current gt gt Indication Current gt Current Direction Page 8 7
35. SWITCH END VIEW TERMINAL M TERMINAL B 3 POSITION SWITCH END VIEW TERMINAL M TERMINAL S TERMINAL A TERMINAL M Figure 4 Electrical System Electrical System Hour Meter IMPORTANT Make sure to observe polarity on the hour meter terminals when testing Damage to the meter may result from an improper connection 1 Isolate hour meter from the circuit 2 Connect positive terminal of a 12 VDC source to the positive terminal of the hour meter 3 Connect negative terminal of the voltage source to the other terminal of the hour meter 4 The hour meter should move 1 10 of an hour in six minutes 5 Disconnect voltage source from the hour meter Re connect hour meter to the circuit Audio Alarm Reverse IMPORTANT Make sure to observe polarity on the alarm terminals when testing Damage to the alarm may result from an improper connection 1 Isolate alarm from the circuit Correctly connect 12VDC source to the terminals Fig 6 2 Alarm should sound Remove voltage source from the alarm Reconnect alarm to the circuit or replace as needed Headlight Switch The headlight switch is located on the control panel Fig 7 This rocker switch allows the headlights to be turned on and off The switch terminals are marked as shown in Figure 7 The circuitry of the headlight switch is shown in the chart below With the use of a multimeter ohms setting
36. South ADDRESS f Minneapolis Minnesota 55420 1196 American National Standards Institute Inc 1430 Broadway The safety alert symbol means New York New York 10018 U S A A CAUTION WARNING or DANGER OR personal safety instruction Read Underwriters Laboratories and understand the instruction because it has to 333 Pfingsten Road do with safety Failure to comply with the instruc Northbrook Illinois 60062 U S A tion may result in personal injury The Toro Company The Workman is an off highway vehicle only It is not designed equipped or manufactured for use on public streets roads or highways To reduce the potential for injury or death comply with the following safety instructions Supervisors operators and service persons should be familiar with the following standards and publications The material may be obtained from the addresses shown Supervisor s Responsibilities 1 Make sure operators are thoroughly trained and fa 2 Be sure to establish your own special procedures miliar with the Operator s Manual and all labels on the and work rules for unusual operating conditions e g vehicle slopes too steep for vehicle operation Before Operating 1 Operate machine only after reading and understand Only trained and authorized persons should operate this ing the contents of this manual vehicle Make sure all operators are physically and men tally capable of operating the vehicle Anyone who
37. Wheels and Brakes Rev B Page 7 30 Workman 1100 1110 2100 2110 Disassembly Fig 21 1 Park machine on a level surface stop engine and re move key from the ignition switch Chock wheels to pre vent the machine from moving 2 Disconnect both brake cables from rear of machine A Remove cotter pin and clevis pin that secures each brake cable end to brake lever B Remove retaining ring that secures each brake cable to frame C Remove screw and flange nut that secure each R clamp to rear frame 3 Note routing of brake cables for assembly purposes 4 Remove parking brake cover from seat base 5 Remove four 4 flange head screws that secure parking brake support to seat base 6 Carefully remove parking brake support and brake cables from machine Take care to not damage brake cables while removing them from seat base opening 7 Remove brake cables from parking brake support and cable equalizer bracket using Figure 21 as a guide Workman 1100 1110 2100 2110 Page 7 31 Assembly Fig 21 1 Secure brake cables to parking brake support and cable equalizer bracket using Figure 21 as a guide 2 Route brake cables through seat base opening tak ing care to not damage cables Position parking brake support to seat base 3 Secure parking brake support to seat base with four 4 flange head screws 4 Position brake cables to rear brake assemblies using cable routing noted during disassembly 5
38. air cleaner cover to the air cleaner body Separate cover from the body Clean inside of air cleaner cover 5 Gently slide filter out of the air cleaner body to reduce the amount of dust dislodged Avoid knocking filter against the air cleaner body IMPORTANT Do not wash or reuse a damaged filter 6 Inspect filter Discard filter if damaged 7 Clean filter element using either of the following two methods Washing Method A Prepare a solution of filter cleaner and water Soak filter element for about 15 minutes Refer to directions on the filter cleaner carton for complete in formation IMPORTANT Maximum water pressure must not exceed 40 psi to prevent damage to the filter ele ment B After soaking the filter for 15 minutes rinse it with clear water Rinse filter from the clean side to the dirty side IMPORTANT Do not use a light bulb to dry the filter element because damage could result C Dry filter element using warm flowing air that does not to exceed 160 F 71 C or allow element to air dry Kohler Gasoline Engine Page 4 8 Compressed Air Method Ad caution Use eye protection such as goggles when using compressed air IMPORTANT Maximum air pressure must not ex ceed 100 psi to prevent damage to the element A Blow compressed air from the inside to the out side of the dry filter element B Keep air hose nozzle at least 2 inches 5 cm from the filter Move nozzle up and down whil
39. and let it run for a few minutes to warm the oil 2 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 3 Raise bed and secure it with the prop rod 4 Disconnect spark plug wire 5 Remove drain plug and let the oil flow into a drain pan When the oil stops reinstall the drain plug Fig 6 and torque it to 13 ft lb 17 6 Note Dispose of the used oil at a certified recycling center Note See Check Engine Oil for the proper type and viscosity of oil to add to the engine 6 Pour oil into filler tube until the oil level is up to the FULL mark on the dipstick Add oil slowly and check level often during this process Do not overfill Fig 7 7 Install dipstick firmly in place Fig 7 8 Connect spark plug wire Figure 6 1 Drain plug o N oS 2 Figure 7 1 Dipstick 2 Filler tube Workman 1100 1110 Page 4 7 Kohler Gasoline Engine Service Air Cleaner Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Raise bed and secure with prop 3 Check air cleaner body and hoses for damage which could possibly cause an air leak Replace air cleaner body if damaged 4 Release latches securing the
40. at mid span between the pul leys with 10 Ib 44 5 of force adjust jam nut on the starter rod until the belt flexes 1 4 inch 6 mm 4 Tighten starter generator pivot bolt Adjust Throttle Cable Note Workman 2100 and 2110 machines with Serial Numbers above 240000000 are equipped with an en gine governor rather than a transaxle governor Refer to the Briggs amp Stratton Repair Manual at the end of this chapter for governor information on these machines Releasing the accelerator pedal should allow the throttle cable to close the carburetor throttle control lever so that the lever touches the adjustment screw The adjustment Screw keeps the throttle valve inside the carburetor open slightly to prevent the valve from binding 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Lift cargo bed and prop with rod to gain access to the engine 3 Rotate governor arm on transaxle fully clockwise Fig 5 4 Make sure of the following A The engine throttle control lever should be to the fully open position Fig 6 B Adjust throttle cable at the cable bracket as nec essary so there is no compression of the throttle cable Fig 5 This will allow the throttle control lever to fully close when the accelerator pedal is released Figure 4 1 Generator pivot bolt 3 Starter rod 2 Jamnut 4 Torque arm Figure 5 1 Governor arm 3 Ca
41. below the top of tank bottom of filler neck Do not overfill E Wipe up any spilled gasoline A Use extreme caution reduce speed and main tain a safe distance around sand traps ditches creeks ramps unfamiliar areas or any areas that have abrupt changes in ground conditions or eleva tion Operating the vehicle on a hill may cause tipping or rolling of the vehicle or the engine may stall and you could lose headway on a hill This could result in personal injury Do not exceed slopes greater than 12 degrees If the engine stalls or you lose headway on a hill never attempt to turn the vehicle around Never drive across a steep hill always drive straight up or down or go around the hill Avoid turning on a hill Do not accelerate quickly or slam on the brakes Reduce your load and the speed of the vehicle Avoid stopping on hills especially with a load B Use caution when operating vehicle on a slope Normally travel straight up and down slopes Reduce speed when making sharp turns or when turning on hillsides Avoid turning on hillsides whenever pos sible If the engine stalls or you begin to lose head way while climbing a hill gradually apply the brakes and slowly back straight down the hill Safety C Watch for holes or other hidden hazards D Use extra caution when operating the vehicle on wet surfaces at higher speeds or with a full load Stopping distance will increase with a full load Slow d
42. burn you others and cause property damage HOW TO AVOID THE HAZARD e Use a funnel and fill the fuel tank outdoors in an open area when the engine is cold Wipe up any gasoline that spills Do not fill the fuel tank completely full Add gasoline to the fuel tank until the level is no higher than 1 inch 25 mm below the bottom of the filler neck This empty space in the tank allows gasoline to expand Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by a spark Store gasoline in an approved container and keep it out of the reach of children Never buy more than a 30 day supply of gasoline Always place gasoline containers on the ground away from your vehicle before filling Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Workman 2100 2110 Check Engine Oil Procedure Fig 2 The engine i
43. caution when working with fuel system com ponents see Fill Fuel Tank and Fuel Safety Pre cautions 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Raise bed and support with prop rod see Operator s Manual 3 Place a clean container under fuel filter 4 Remove clamps securing fuel filter to fuel lines 5 Remove fuel lines from fuel filter IMPORTANT Mount filter so the arrow points in the di rection of fuel flow to the fuel pump 6 Install new fuel filter to fuel lines with clamps pre viously removed Figure 10 1 Drive belt 3 Driven clutch 2 Drive clutch Figure 11 1 Fuel filter 3 Fuel pump 2 Rear cylinder head Workman 2100 2110 Page 3 9 Briggs amp Stratton Gasoline Engine 52 Au So 23 oO Spark Plugs Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance Type Champion RC 12YC or equivalent Air Gap 0 030 inch 0 76 mm Note spark plug usually lasts a long time however the plug should be removed and checked whenever the engine malfunctions 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch Figure 12 2 Raise cargo bed to allow access to engine 3 Clean area around spark plugs so foreign matter cannot fall into cylinder w
44. clutch 6 Button Two Clutch System Fig 4 Power is transferred from the engine to the transaxle by a variable clutch system that consists of two clutches connected by a drive belt The drive clutch responds to engine speed and is mounted to the engine drive shaft The driven clutch responds to changes in load to the rear axle and is mounted to the transaxle input shaft 9 Fixed sheave driven clutch Both clutches work together as a matched unit The units automatically up shift and back shift with changes in load and speed This shifting changes the turning ratio between the drive and driven clutches and allows the engine to operate at optimum efficiency Workman 1100 2100 2110 Page 5 7 Drive Train Drive Clutch Figure 8 1 Fixed sheave 4 Cover 7 Spring 2 Moveable sheave 5 Washer 8 Cam weight 3 Spider assembly 6 Plastic cap 9 Roller Principles of Operation Fig 8 The operation of the drive clutch is affected by engine shaft speed With the engine not turning the drive belt rests low within the clutch sheaves as the pressure of the spring holds the sheaves apart As the engine in creases in speed the cams attached to the moveable sheave move outward as they spin about the engine drive shaft The outward movement of the cams presses against the rollers and over
45. cylinder Workman 1110 and 2110 Brake master cylinder faulty Workman 1110 and 2110 Brake pedal is spongy Brake drums are excessively worn or cracked Workman 1100 and 2100 Brake shoes are not burnished Brake cable is loose or broken Workman 1100 and 2100 Brakes are incorrectly adjusted Workman 1100 and 2100 Air in brake lines Workman 1110 and 2110 Ground speed is too fast see Chapter 5 Drive Train Engine has excessive run on when accelerator pedal is released due to carburetor not fully closing see Engine Chapter Brakes pull to either side Tire pressure is incorrect or uneven between tires Brake linings are contaminated Front wheel alignment toe in is incorrect Brake cable is loose or broken Workman 1100 and 2100 Brake cable is binding Workman 1100 and 2100 Brake shoes are distorted Tires on same axle are unmatched a Sg x r ee 25 ac Workman 1100 1110 2100 2110 7 5 Chassis Wheels and Brakes Rev Brakes continued Problem Possible Cause Brakes squeal Brake lining is glazed or saturated Shoe to shoe spring s is are weak or broken Brake shoes are distorted Anchor plate is bent Brake drums and shoes are dusty Brake drums are scored or out of round Brakes drag Parking brake is set Brakes are incorrectly adjusted Workman 1100 and 2100 Shoe to shoe spring s is are weak or broken Brake pedal is binding
46. damage and be dangerous Altering this vehicle in any manner may affect its opera tion performance and or durability Alterations may re sult in injury or death Such use could void the product warranty of The Toro Company Sound Pressure Level This unit has an equivalent continuous A weighted sound pressure at the operator s ear of 80 dB A which is based on measurements of identical machines per SAE J1174 MAR 85 procedures Vibration Level This unit does not exceed a vibration level of 2 5 m s at the hands which is based on measurements of identical machines per ISO 5349 procedures This unit does not exceed a vibration level of 0 5 m s at the posterior which is based on measurements of iden tical machines per ISO 2631 procedures Safety Jacking and Other Instructions Jack Vehicle POTENTIAL HAZARD A vehicle that is not properly supported may become unstable WHAT CAN HAPPEN The vehicle may move or fall Personal injury or damage to the machine may result HOW TO AVOID THE HAZARD Make sure vehicle is parked on a solid level surface such as a concrete floor Make sure engine is off and key is removed from the ignition switch before getting off the vehicle Before raising the vehicle remove any attachments that may interfere with the safe and proper raising of the vehicle Always chock or block wheels to prevent the vehicle from rolling Do not start vehicle while it is on jack stand
47. drums B Replace drums that are cracked deeply grooved tapered significantly out of round scored heat spotted or excessively rusted C Minor scoring can be removed with sandpaper 2 Inspect brake shoe linings IMPORTANT Replace brake shoes as a set all four shoes to maintain equal braking forces A Replace brake shoes if damaged or if lining is worn to 1 16 1 6 mm Replace if lining is contami nated by oil grease or other fluids NOTE Overheated springs lose their tension and can cause brake linings to wear out prematurely B Inspect brake shoe webbing upper and lower springs and shoe hold down springs for overheat ing Overheating is indicated by a slight blue color In spect brake shoe webbing for deformation Replace parts as necessary C Inspect hold down pins on adjuster levers for bends rust and corrosion Replace as necessary 3 Inspect backing plate surfaces which contact with the brake shoes for grooves that may restrict shoe movement Replace plate if grooves can not be re moved by light sanding with emery cloth or other suit able abrasive Replace plate if cracked warped or excessively rusted 4 Inspect adjuster levers for deformation Replace lev ers if deformation or excessive rust is found 5 Replace parking brake cables if frayed stretched or kinked Workman 1100 1110 2100 2110 Page 7 35 Assembly Fig 23 IMPORTANT Brake shoe lining surfaces must be free o
48. gear teeth are not accept able D Replace center shaft if worn or damaged Splines that are cracked broken chipped or missing are not acceptable 7 8 9 Page 5 28 Pin clutch Center shaft Collar Spacer E Replace pin clutch if cracked or bent Ball bearing roller balls must be free of deforma tion and scoring Ball bearings must spin freely and have minimum axial play Replace ball bearings as necessary G Replace collars or spacer if excessively worn or damaged Replace both collars as a set Workman 1100 2100 2110 6 Disassemble differential case assembly Figure 45 1 Bolt 3 Differential case 2 Gear 62 A Remove bolts securing gear 62 to the differential case Figure 46 1 Spring pin 3 Pinion shaft 2 Differential case 4 Pinion gear Note The spring pin can be punched out from the hole C Remove pinion shaft and gears from the case on the opposite side of gear 62 Separate gears from shaft B Remove spring pin from the differential case Dis card pin and replace it with new spring pin Workman 1100 2100 2110 Page 5 29 Drive Train Drive Train Figure 47 Side gear Pinion gear Gear 34 Ball bearing BON D Replace gears if worn or damaged Cracked bro ken missing or chipped gear teeth are not accept able E Ball bearing roller balls must be free of deforma tion and scoring Ball bearing must spin freely and have minimum axial play Replace bal
49. machine going in the reverse direction This will self adjust the clear ance between the brake shoe and drum Figure 19 1 Cotter pin 3 Brake cable bracket 2 Clevis pin 4 Actuator lever Chassis Wheels and Brakes Rev B a 33 x Ss 25 ac Rear Brake Service Workman 1100 and 2100 i AS ROTATION TO EXPAND BRAKE SHOES Figure 20 1 Backing plate 8 Actuator lever 14 Pivot pin 2 Hold down pin 9 Adjusting screw 15 Wave washer 3 shoe to shoe spring 10 PTFE coated washer 16 Washer 4 Bottom shoe to shoe spring 11 Push rod 17 Adjusting lever 5 Auto adjust spring 12 Shim washer 18 Retaining clip 6 Shoe cup spring loaded 13 Protective boot 19 Anchor abutment 7 Brake shoe Chassis Wheels and Brakes Rev B Page 7 28 Rev D Workman 1100 1110 2100 2110 Disassembly Fig 20 1 Remove auto adjust spring and shoe to shoe springs from brake shoes 2 Remove hold down pins and shoe cups securing the brake shoes to the backing plate 3 Remove brake shoes from backing plate Inspection Fig 18 and 20 1 Inspect brake drums IMPORTANT Brake drum machining is not recom mended Replace brake drums as a set to maintain equal braking forces A Clean drums with denatured alcohol Chec
50. oil filter Fig 7 Apply light coat of clean oil to the new filter gasket 3 Screw filter on until gasket contacts mounting plate then tighten filter an additional 1 2 to 3 4 turn further Do not overtighten Workman 2100 2110 Page 3 7 Figure 7 1 Drain plug 2 Oil filter Figure 8 2 Filler cap 1 Dipstick Note See Check Engine Oil for the proper type and viscosity of oil to add to the engine 4 Pour oil into fill opening until the oil level is up to the FULL mark on the dipstick Add oil slowly and check level often during this process Do not overfill Fig 8 5 Start and run engine to check for leaks 6 Stop engine and recheck the oil level Add oil if nec essary Briggs amp Stratton Gasoline Engine 05 N D o gt Service Air Cleaner Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Raise bed and support with prop rod see Operator s Manual 3 Check air cleaner body and hoses for damage which could possibly cause an air leak Replace air cleaner body if damaged 4 Release latches securing the air cleaner cover to the air cleaner body Separate cover from the body Clean inside of air cleaner cover
51. or testing Disconnect the battery cables unless the test requires battery voltage Starting Problems Starter solenoid clicks but starter will not crank Nothing happens when start attempt is made Engine cranks but does not start Electrical System Page For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and components used on this vehicle see Wiring Schemat ics in Chapter 8 If the vehicle has any interlock switches by passed they must be reconnected for proper troubleshooting and safety Possible Causes Battery charge is low Battery cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter is faulty and causing an incomplete circuit for the solenoid Battery is dead Wiring to the start circuit see Wiring Schematics components is loose corroded or damaged Battery cables are loose or corroded Battery ground to frame is loose or corroded Fuse block is faulty 10 ampere fuse to the ignition switch is loose or blown The ignition switch is faulty Switch at accelerator pedal is faulty or needs adjustment Starter solenoid is faulty Shutdown module is faulty Workman 2100 and 2110 Wiring to start circuits see Wiring Schematics is loose corroded or damaged Shutdown module is faulty Workman 2100 and 2110 Engine or fuel system is malfunct
52. parked on an incline chock wheels after getting off of the vehicle Workman 1100 2100 2110 Maintenance and Service 1 Only qualified and authorized personnel should maintain repair adjust or inspect the vehicle 2 Before servicing or making adjustments to the ma chine stop engine set parking brake and remove key from the ignition switch to prevent someone from acci dentally starting the engine 3 Make sure entire machine is in good condition Keep all nuts bolts and screws properly tightened 4 Reduce potential fire hazards Keep engine area free of excessive grease grass leaves and accumula tion of dirt 5 Never use an open flame to check level or leakage of fuel or battery electrolyte 6 If the engine must be running to perform a mainte nance adjustment keep hands feet clothing and any parts of the body away from the engine and any moving parts Keep everyone away 7 Do not use open pans of fuel or flammable cleaning fluids for cleaning parts 8 Do not adjust ground speed governor To assure safety and accuracy have an Authorized Toro Distribu tor check the ground speed Workman 1100 2100 2110 Page 1 5 9 If major repairs are needed or assistance is required contact an Authorized Toro Distributor 10 Make sure of optimum performance and safety Al ways use genuine Toro replacement parts and accesso ries Replacement parts and accessories made by other manufacturers could cause
53. should remain seated whenever the vehicle is in motion Operator should keep both hands on the steering wheel Whenever possible the passenger should use the hand holds provided Keep arms and legs within the vehicle body at all times Never carry passengers in the box or on any attach ments Remember your passenger may not be expect ing you to brake or turn 2 Never overload your vehicle The name plate lo cated under the dash and on the center column shows load limits for the vehicle The load rating is for level sur faces only Never overload attachments or exceed the vehicle maximum gross vehicle weight GVW 3 Operating the vehicle demands attention Failure to operate the vehicle safely may result in an accident tip over of vehicle and or serious injury or death Drive carefully To prevent tipping or loss of control Workman 1100 2100 2110 Page 1 3 9 Keep everyone especially children and pets away from the areas of operation 10 Before operating the vehicle always check vehicle and any attachments for damage If something is wrong stop using the vehicle Make sure problem is cor rected before the vehicle or attachment is operated again 11 Since gasoline is highly flammable handle it careful ly A Use an approved gasoline container B Do not remove cap from the fuel tank when the engine is hot or running C Do not smoke while handling gasoline D Fill fuel tank outdoors to about one inch
54. shown 25 Self tapping screw 4 Ignition switch 15 Self tapping screw 26 Hood 5 Ignition key 16 Flange lock nut 27 Manuals tube 6 Hole plug 17 Decal 28 Hex flange head screw 7 Oil light 18 Reflector 29 R clamp 8 Light switch 19 Lock washer 30 Dash 9 Hourmeter 20 Cap screw 31 Flat washer 10 Decal 21 Plastic bumper 32 Cap screw 11 Hex flange head screw 22 Headlight Removal Installation 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition 2 Remove screws attaching the wire harness to each head light 3 Remove both self tapping screws 15 securing the center lower hood to the front frame support 4 Remove flange lock nut 12 both flat washers 31 and cap screw 32 securing the hood to each fender front 5 Remove both flange lock nuts 12 and hex flange head screws 11 securing the hood to the top of each fender 6 Remove both hex flange head screws 11 securing the hood to the dash Remove hood from the vehicle Chassis Wheels and Brakes Rev B Page 7 44 NOTE Do not tighten fasteners securing the hood until all fasteners are in place 1 Position hood to the machine Secure hood to the dash with both hex flange head screws 11 2 Secure hood to the top of each fender with two hex flange head screws 11 and flange lock nuts 12 3 Secure hood to each fender front with cap screw 32 two flat washers 31 and flange lock n
55. speeds could cause the vehicle to lose control WHAT CAN HAPPEN e Loss of control could result in personnel injury and or damage to the vehicle HOW TO AVOID THE HAZARD e Never tow vehicle more than 5 mph 8 KPH Transaxle Neutral Position When performing routine maintenance and or engine testing the transaxle must be shifted into the neutral position 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch 2 On vehicles equipped with a neutral position on the shift lever Fig 3 A Move shift lever to the neutral position B Make sure transaxle is locked in neutral by rotat ing the driven clutch Fig 4 The tires should not ro tate If tire rotation does occur see Adjust Shift Cables Chapter 5 Drive Train 3 On vehicles without a neutral position on the shift le ver Fig 3 A Lock transaxle into neutral by rotating the locking pin 180 relative to the shift block Fig 4 B Shift gear selector into REVERSE and then into FORWARD Leave gear shift selector in the FOR WARD position C Make sure transaxle is locked in neutral by rotat ing the driven clutch Fig 4 The tires should not ro tate If tire rotation does occur repeat steps A amp B until the tires no longer rotate Workman 1100 2100 2110 Page 1 7 Towing the vehicle is a two person job If the vehicle must be moved a considerable distance transport it on a truck or
56. tab as necessary If the button is loose apply Loctite 242 blue or equivalent on its mounting tab 8 Install new button to ramp Push button in straight with a screw driver by prying against the ramp 9 Remove and install remaining buttons 10 Carefully remove block of wood that was placed to keep the clutch ramps apart 11 Install drive belt to the driven clutch see Service Drive Belt in Service and Repairs section of Engine Chapter Drive Train Check Driven Clutch Spring Torsion 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch 2 Place transaxle in gear to prevent the fixed sheave from moving 3 Remove drive belt from the driven clutch see Ser vice Drive Belt in Engine Chapter IMPORTANT Use protective strips of soft metal when clamping the moveable sheave with locking pliers to prevent damage to the sheave 4 Clamp moveable sheave with locking pliers 5 Measure spring torsion A Pull scale tangentially to the outer diameter of the moveable sheave B When the button on the ramp of the moveable sheave is 0 125 inch 3 18 mm from the ramp of the fixed sheave read the scale The reading should be 16 to 20 Ibf 71 to 89 6 If the above specification is not met replace the driv en clutch Change Transaxle Fluid Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter
57. the start run solenoid hour meter and engine oil indicator and provides an open cir cuit to the engine ignition system With the accelerator pedal released the switch provides a grounding circuit i END VIEW for the engine ignition system and prevents current flow to the start run solenoid hour meter and engine oil indi cator Testing 1 Place machine in the NEUTRAL position Turn igni tion switch off remove key from ignition switch and en 5 gage parking brake SIDE VIEW 2 If equipped remove floor mat from around pedal area of machine 3 Remove two screws that secure pedal cover to floor Figure 13 of machine Remove pedal cover to gain access to ac 1 Terminal 1 4 Terminal 4 celerator switch 2 Terminal 2 5 Switch plunger 3 Terminal 3 6 Mounting tab 4 Unplug wiring harness connector from switch 5 With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the switch terminals for both switch positions Verify continuity between switch termi nals using the following table PLUNGER NO POSITION CONTINUITY CONTINUITY Adjustment 1 Release the parking brake Figure 14 2 With the accelerator pedal released adjust the dis 1 Switch bolt 5 Accelerator awith tance between the head of the accelerator switch bolt and the body of the swit
58. to 120 in Ib 12 4 to 13 6 N m Figure 23 1 Brake backing plate 6 Parking brake lever LH shown 10 Flat washer 2 Washer head screw 7 Belleville washer 11 Bolt 3 Brake shoe 8 Adjuster lever 12 Shoe hold down cup and spring 4 Lower spring 9 Dust cover 13 Upper spring 5 Wheel cylinder Disassembly Fig 23 4 If required slide parking brake lever from slot and dust cover in backing plate 5 If necessary remove two washer head screws that secure wheel cylinder to backing plate Remove wheel cylinder from backing plate Be careful when removing springs from brake shoes The springs are under heavy load and 6 If necessary remove bolts and washers to allow ad may cause personal injury juster levers to be separated from backing plate Locate gt and remove belleville washers from between adjuster 1 Remove upper and lower springs from brake shoes levers and backing plate 2 Remove shoe hold down cups and springs that se cure the brake shoes to the backing plate 3 Remove brake shoes from backing plate Chassis Wheels and Brakes Rev B Page 7 34 Workman 1100 1110 2100 2110 Inspection Fig 23 1 Inspect brake drums IMPORTANT Brake drum machining is not recom mended Replace brake drums as a set to maintain equal braking forces A Clean drums with denatured alcohol Check braking surface diameter in at least three places If the diameter exceeds 6 320 inches 16 05 cm re place both brake
59. use or yearly cleaning and lubrication of the drive clutch is recommended 1 Park machine alevel surface stop engine and re move key from the ignition switch Raise and latch cargo bed 2 Remove the three 3 cap screws that secure the cover to the drive clutch Fig 6 Remove the cover from the clutch When using compressed air for cleaning the clutch the dust in the clutch will become airborne and could damage your eyes or you could inhale it causing breathing difficulties Wear safety goggles and a dust mask or other eye and respiratory protection when performing this procedure 3 Using compressed air thoroughly clean the inside of the clutch cover and the clutch components 4 Lubricate the clutch components as shown in Figure 7 using Toro Dry Lubricant Spray see Special Tools in Chapter 5 Drive Train 5 Install cover to clutch and secure with three 3 cap screws Torque cap screws from 75 to 100 in Ib 8 5 to 11 3 N m Maintenance Maintenance procedures and recommended service in tervals for your Workman are covered in the Operator s Manual Refer to that publication when performing regu lar equipment maintenance Product Records and Maintenance Page2 8 Rev A Figure 6 1 Clutch cover 2 Cap screw Figure 7 Workman 1100 2100 2110 Chapter 3 TORO Briggs amp Stratton Gasoline Engine Table of Contents SP
60. 0 Page 4 11 Kohler Gasoline Engine Seat Base and Fuel Tank Figure 14 1 Seat 9 Gas cap 16 Shift bracket 2 Seat bracket 10 Fuel tank 17 Shifter plate 3 Cap screw 11 Web strapping 48 inch 18 Long cap screw 4 used 4 Seat base 12 Hex head flange screw 19 Knob 5 Fuel hose to filter 13 Flat washer 20 Short cap screw 4 used 6 Clamp 14 Fuel gauge 21 Choke cable 7 Stand pipe 15 Grommet 22 Shift cable 2 used 8 Bushing Seat Base Removal Fig 14 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Flip both seats forward and remove them from the seat base Kohler Gasoline Engine 4 12 Rev B 3 On Workman 1110 machines remove parking brake assembly from seat base see Parking Brake Disas sembly in the Service and Repairs section of Chapter 7 Chassis Wheels and Brakes 4 Unscrew knob from the shift lever Remove four short cap screws securing the shift plate to the shift bracket Fig 15 Workman 1100 1110 5 Remove four long cap screws securing the shift plate to the seat base Fig 15 Separate shift bracket from the choke cable and seat base 6 Remove four hex head flange screws and flat wash ers securing the front of the seat base to the frame Re move four hex head flange screws securing the back of the seat base to the frame IMPORTANT Make sure shift bracket shift cables choke cable and fue
61. 0 Page 5 37 Drive Train Figure 61 1 Side gear 3 Gear 62 2 Pinion gear 4 Differential case D Install remaining side gear to the pinion gears E Secure gear 62 to the differential case with bolts Torque bolts from 40 to 45 ft lb 54 to 61 ina criss cross pattern 40 to 45 ft lb 54 to 61 5 t MY Figure 62 IMPORTANT The length from the outer most side of G The differential assembly should appear as each ball bearing must be from 123 3 to 124 0 mm above when assembled Fig 58 F If ball bearings were removed press new ball bearings onto differential case and gear 62 Drive Train Page 5 38 Workman 1100 2100 2110 4 Assemble governor fork Figure 63 1 Ball bearing 2 Case bore A Install ball bearing into the bore of the case RH Figure 64 1 Governor shaft 2 Boss IMPORTANT Make sure not to damage the oil seal B Lubricate governor shaft with molybdenum disul when installing the governor shaft into the governor fide grease before installing boss C Install governor shaft into the boss Workman 1100 2100 2110 Page 5 39 Drive Train Figure 65 1 Screw 3 Governor fork 2 Stopper 4 Case RH IMPORTANT To prevent the screws that secure the D Secure stopper and governor fork to the governor governor fork and stopper to the governor shaft shaft with both screws from loosening apply Loctite Blue No 242 or equiv alent t
62. 00 ft lb 102 to 136 D Insert tie rod ball joints down through the spindle and up through the Pitman arm Secure with jam nuts E Torque first jam nut from 20 to 25 ft lb 27 to 34 to secure ball joint to spindle and Pitman arm Then torque second jam nut to the same value 2 Install tire and front wheel as follows A Place antiseize lubricant on spindle shaft B Slide tire and wheel assembly onto the shaft with the valve stem facing out NOTE Apply thread locking compound to the threads of the cap screw 3 4 C Place large washer and then small washer onto the cap screw Thread cap screw with washers into the spindle shaft D Torque cap screw from 135 to 165 ft lb 183 to 224 Lower machine to ground Align steering and toe in see Adjust Front Wheel Toe in 5 Lubricate tie rod ball joints and king pin see Lubrica tion in Chapter 2 Product Records and Maintenance Page 7 19 Chassis Wheels and Brakes Rev B a 33 x Ss 25 ac Lower Steering and Front Wheels Workman 1110 and 2110 24 20 to 25 ft lb 27 to 34 N m Thread locking Compound 20 to 25 ft lb 27 to 34 N m d 45 to 65 ft lb 61 to 88 75 to 100 ft Ib 102 to 136 Nm Figure 13 1 Wheel assembly 15 Brake rotor 28 Jam nut RH thread 2 Lugnut 16 Socket head screw 29 Tie rod tube 3 Dust 17 Lock nut
63. 1 Nut 7 Washer 12 Steering column 2 Lock washer 8 Steering shaft 13 Dust cover 3 Steering wheel 9 Cap screw 14 Steering wheel cover 4 Flanged lock nut 10 Upper steering bushing 15 Decal 5 Steering gearbox 11 Carriage screw 16 Pitman arm 6 Cap screw Removal 3 Remove steering wheel cover carefully from the steering wheel Remove nut and lock washer securing 1 Park machine on a level surface stop engine set the steering wheel to the steering shaft Pull wheel from parking brake and remove key from the ignition switch the shaft 2 Remove front hood to gain access to the steering 4 Remove cap screw and lock washer securing the mechanism see Front Hood Removal lower steering shaft knuckle to the steering gearbox shaft Pull knuckle from the gearbox shaft Chassis Wheels and Brakes 7 14 Rev C Workman 1100 1110 2100 2110 5 Remove four flange lock nuts and carriage screws securing the steering column to the mounting plate on the frame 6 Remove dust cover from the steering shaft Replace cover if damaged Slide steering shaft out of the steering column 7 Disconnect both tie rods from the Pitman arm on the steering gearbox see Lower Steering and Front Wheel Removal 8 Remove flange lock nuts and cap screws securing the steering gearbox to the tower plate on the front frame Remove gearbox from the tower plate Installation 1 Position steering gearbox to the tower plate of the front frame with
64. 12V 6 Y YELLOW 7 2 8 Q a z e E 5 n uc gt 4 5 m lt a amp c m 3 a gt 210r o am m 1 2 1 2 1 112134 Workman 1100 90 J7 J8 J9 P10 P13 es a 27 Serial Number Under 220000000 BOX LIFT VOLTAGE OPTION i i BACKUP ACTUATOR REGULATOR Main Electrical Harness ALARM START RUN Man b SOLENOID iring Diagram Page 8 9 Rev B START RUN SOLENOID HEADLIGHT RH 4 28 J3 J4 bd 9 yoo 3 REVERSE SWITCH 5 zh 8 E 4257 1 r 592 6 wine 3 1 2 SWITCH 3 2 OPTIONAL se Ur 2910 755 39554 4 3 P1 E Ed BACKUP 6 JB 12 12 Jb ACCELERATOR qz hi 1 2 P4 5 232 6 8 6 4 2 1 Ni FUSE BLOCK 4 3 NA P8 TO ENGINE OPTIONAL LIGHT 3 HARNESS KIT SWITCH OPTIONAL 14 2 P13 IO P11 FUSE BLOCK
65. 2 3 VIOLET 4 BROWN 5 BLACK RED BLACK m X YELLOW BLACK 2 GROUND 2 YELLOW 3 x 3 3 a 4 Y PT a 4 5 BLUE 5 42 V RED BLACK 6 Y 1B 8 2A YELLOW ao x oO 5 e i 12 A ss 22 4 o 0 C t T PA PIg J8 J PIO J5 FIELD START RUN VOLTAGE LIGHT KIT KEY START KIT BACKUP DIODE SOLENOID BOX LIFT ACTUATOR REGULATOR ALARM Page 8 17 Rev 1 MAIN HARNESS 3 PI 4 J1 J4 J3 J2 MAIN HARNESS J2 Q DF BLACK BROWN WHITE BLUE GREEN 7 7 J1 ENGINE GROUND eo NaS ENGINE GROUND MAGNETO OIL LEVEL J3 OIL LEVEL J4 MAGNETO Workman 1100 Serial Number Under 220000000 Engine Electrical Harness Drawing and Wiring Diagram Page 8 18 Rev A BLACK ENGINE GROUND B BROWN jl MAGNETO MAIN HARNESS D t BROWN WHITE BLUE J 3 OIL PRESSURE F GREEN J JZ e MAIN HARNESS F C 4 O O J3 SLT 1 7 15 OIL PRESS 5 J1 REUNIR Workman 1100 Serial Number From 220000001 To 230
66. 3 RPM Shutdown Module Workman 2100 2110 13 Oil Pressure Switch Workman 2100 2110 14 Workman 1100 1110 2100 2110 Page 6 1 Electrical System o K System Electrical Schematics The electrical schematics and other electrical drawings for the Workman 1100 1110 2100 and 2110 are located in Chapter 8 Electrical Diagrams Electrical System 6 2 Rev B Workman 1100 1110 2100 2110 Special Tools Order special tools from the TORO SPECIAL TOOLS AND APPLICATIONS GUIDE COMMERCIAL PROD UCTS Some tools may also be available from a local supplier Multimeter The meter can test electrical components and circuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease Toro Part No 505 47 which forms a light protective skin which helps water proof electrical switches and contacts Figure 2 n o wi System Workman 1100 1110 2100 2110 6 Electrical System Troubleshooting Remove all jewelry especially rings and watches before doing any electrical trouble shooting
67. 30 Pitman arm 4 Cotter pin 18 LH spindle 31 Ball joint LH thread 5 Nutretainer 19 Cap screw 32 Grease fitting 6 Jamnut 20 Tie rod assembly 33 Jam nut LH thread 7 Tab washer 21 Bushing 34 A arm RH 8 Bearing cone 22 Thrust washer 35 A arm LH 9 Bearing cup 23 RH spindle 36 Grease fitting 10 Wheel hub 24 Castle nut 37 Brake caliper LH shown 11 Wheel stud 25 Cotter pin 38 Lock washer 12 Bearing cup 26 Kingpin sleeve 39 Cap screw 13 Bearing cone 27 Ball joint RH thread 40 Brake hose bracket 14 Seal NOTE Both tie rod assemblies 20 consist of the fol lowing parts ball joints 27 and 31 jam nuts 28 and 33 tie rod tube 29 and grease fittings 32 and 36 Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety Removal 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition 2 Chock wheels not being jacked up Jack front wheel off the ground and place blocks beneath the frame Chassis Wheels and Brakes Rev B Page 7 20 Workman 1100 1110 2100 2110 3 Remove lug nuts and pull wheel assembly from ma chine 4 Remove brake caliper from spindle see Front Brake Caliper Position caliper away from wheel hub and spindle 5 Carefully pry dust cap from wheel hub 6 Remove cotter pin and nut retainer from spindle 7 Remove jam nut that secures wheel hub to spindle Slide wheel hub with bearing
68. 34 113 115 10 1300 100 160 15 1800 170 105 17 1186 169 200 25 2250 280 300 30 3390 340 128 17 1446 192 225 25 2540 280 325 30 3670 340 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 48 7 1 4 28 UNF 5 16 18 UNC 115 15 5 16 24 UNF 138 17 10 2 13 2 e es 1672 1 2 20 UNF 32 3 115 11 120 10 163 14 5 8 11 UNC 65 10 88 12 119 16 150 15 203 20 210 20 285 27 5 8 18 UNF 75 10 95 15 129 20 170 15 230 20 240 20 325 27 3 4 10 UNC 93 12 140 20 190 27 265 25 359 34 375 35 508 47 3 4 16 UNF 115 15 165 25 224 34 300 25 407 34 420 35 569 47 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 45 644 61 660 60 895 81 Note Reduce torque values listed in the table above on the fastener size the aluminum or base material by 25 for lubricated fasteners Lubricated fasteners strength length of thread engagement etc are defined as threads coated with a lubricant such as oil graphite 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 mini Note Torque values may have to be reduced when mum proof load specified in SAE J429 Th
69. 6 Workman 1100 1110 2100 2110 Page 7 21 D Insert tie rod ball joints down through the spindle and up through the Pitman arm Secure with castle nuts E Torque castle nuts from 20 to 25 ft lb 27 to 34 N m to secure ball joint while aligning castle nut slot with hole in ball joint stud If necessary to align holes castle nut torque may be slightly more than specifi cation Install cotter pin 2 Assemble wheel hub A If bearing cups were removed from the wheel hub press inner and outer cups into the hub until they seat against the hub shoulder B Pack both bearings with grease Install inner bearing into the cup on inboard side of the wheel hub IMPORTANT The lip seal must be pressed in so it is flush with the end of the hub The lip of the seal must be toward the bearing C Lubricate the inside of the new lip seal and press it into the wheel hub D If brake rotor was removed apply thread locking compound to socket head screws and install rotor to hub 3 Slide wheel hub assembly onto spindle Install outer bearing tab washer and jam nut onto spindle 4 Rotate the wheel by hand and tighten the jam nut from 75 to 100 in Ib 8 5 to 11 3 N m to set the bearings Then loosen the nut until the hub has end play 5 Rotate the wheel by hand and re tighten the jam nut from 15 to 20 in Ib 1 7 to 2 3 6 Position nut retainer over jam nut and install cotter pin through spindle shaft hole
70. 7 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 32 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 028125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 16 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 mm 0 03937 in 0 001 in 0 0254 mm U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimet
71. 8 cap screw torque cap screw from 25 to 30 ft lb 34 to 41 B For machines that have a 3 8 16 cap screw torque cap screw from 39 to 47 ft lb 53 to 64 N m 5 Install drive belt to the driven clutch see Service Drive Belt in Service and Repairs section of Engine Chapter 6 Install muffler to the engine and engine mount see Muffler Removal in Service and Repairs section of En gine Chapter Ramp Button Replacement Fig 17 1 Park vehicle on a level surface stop engine set parking brake and remove key from the ignition switch 2 Remove drive belt from the driven clutch see Ser vice Drive Belt in Service and Repairs section of Engine Chapter 3 Turn fixed and moveable sheaves in opposite direc tions so button is separated sufficiently enough from the ramp to allow removal 4 Place small block of wood between the outer ramps to keep the ramps apart Workman 1100 2100 2110 5 13 Rev A A CAUTION To prevent burns hold allen wrench with locking pliers when heating allen wrench 5 Clamp long end of a 2 mm allen wrench with locking pliers Heat short end of the allen wrench until it is red hot 6 Insert hot end of the allen wrench into the button so it melts around the end of the wrench Hold wrench in place until the button hardens 7 Pull and twist on the allen wrench to remove the but ton from the ramp Note If the new button is difficult to install sand its mounting
72. 999999 Engine Electrical Harness Drawing and Wiring Diagram Page 8 19 Rev MAIN HARNESS 2 AIN E 7 O B BROWN WHITE 16 ACCELERATOR SWITCH A BLACK B C BROWN D E al WHITE BLUE GREEN BROWN 15 IGNITION SWITCH NS KR 5 9 is ENGINE GROUND j MAGNETO 13 OIL PRESSURE 2 J DF 27 inne GROUND Mee OIL PRESS Workman 1100 and 1110 Serial Number Over 240000000 Engine Electrical Harness Drawing and Wiring Diagram Page 8 20 Rev B FRAME GROUNDJ5 1 MAIN WIRE HARNESS BLACK 1 BLACK 2 BROWN 3 4 WHITE BLUE GREEN J2 DF TERMINAL STARTER GENERATOR Ji MAGNETO _ MA T UNT EN EET 1 E E P1 J3 TO MAIN OIL WIRE HARNESS PRESSURE SWITCH J5 O FRAME J4 GROUND ENGINE GROUND J4 J1 J3 J2 ENGINE GROUND MAGNETO OIL PRESSURE DF TERMINAL STARTER GENERATOR Workman 2100 Serial Number Under 220000000 Engine Electrical Harness Drawing and Wiring Diagram Pag
73. ACCELERATOR SWITCH i i PEDAL NOT PUSHED IN VIO as ted os d see E LOW OIL PRESSURI BK OR F4 F2 F1 F3 W BK p A VB P16 10A 10A 10A Lo o GY gt J16 LIGHT POWER POINT 5 SWITCH OPTIONAL FUSES R BN R BACKUP E ALARM By oD i BNW GN i i W BU 4 BU f 1 e cx e p oo 6 6 SOLENOID STSP BK HOUR BK BK HEAD LIGHTS METER HR VOLTAGE REGULATOR BK P3 3 P3 4 P3 1 STARTER GENERATOR PET re m F1 DF fields E emo rnm Bd o o A2 9 RAAN BK 1 armature BK P3 2 MAG SPARK PLUG SPARK PLUG io IGNITION 5 ENGINE OIL MODULES RPM ENGINE FRAME GROUND PRESSURE SHUTDOWN o O Workman 2100 Serial Number Under 220000000 BK Electrical Schematic Solenoid is shown de energized Page 8 4 Rev B 1 2 vio oe GY REVERSE SW UN FORW ARD BU p Bea IGNITION SW ITCH START 8 55 boli OFF START B A 4 3 PK J VIO d BU OPTIONS M BN BK M Hg o 1 2 d Y BK o BN W ACCELERATOR PEDAL NOT PUSHED IN LOW OIL PRESSURE FL F2
74. Bi T i d B am 12 1 112 o Workman 1100 and 2100 P19 P6 27 18 J3 p12 P10 P13 Serial Number From 220000001 To 220999999 FIELD i i DIODE BACKUP SAIN rent saree TGT KIT Main Electrical Harness ALARM SOLENOID ACTUATOR REGULATOR Wiring Diagram Page 8 13 Rev B START RUN SOLENOID n ILI 4 M P8 FUSES 1 PH 1 OPTIONAL FUSE BLOCK 2 P13 OPTIONAL KIT aul REVERSE SWITCH HEAD J3 LIGHT 5 174 OPTION 1 P9 LOW OIL PRESSURE P1 WARNING LIGHT POWER POINT nl P2 P7 LIFT KIT L LIGHT SWITCH a 7 4 P19 DIODE P6 BACKUP ALARM mt 8 P12 LIFT KIT OPTION P10 VOLTAGE REGULATOR 27 OPTION J18 OPTION P18 IGNITION SWITCH AN S 5 M M P14 OPTIONAL KIT 1 da 3 AUN Ph ACCELERATOR J2 HEAD LIGHT 15 4 a zu Workman 1100 and 2100 Serial Number From 230000001 To 230999999 Workman 2110 Serial Number From 220000001 To 230999999 Main Electrical Harness Drawing METER J14 J5 Page 8 14 Rev LIGHT SW P2 J14 HOUR METER J15 J18 OPTIONS J17 IGNITION SW P18 LOW OIL PRESSURE WARNING LIGHT P8
75. Damage to the brushes may result 1 Remove brush covers from the commutator end cov er Lift brush springs from the notch at the end of the brushes while pulling the brushes out Allow springs to hold brushes out from the center Fig 23 2 Remove both through bolts and flat washers secur ing the commutator end cover to the yoke Separate end cover from the commutator and yoke IMPORTANT Use clean dry lint free rags when cleaning the starter generator When using com pressed air air should be filtered and not exceed 15 PSI 1 Bar 3 Remove brushes from their holders Clean carbon dust from the commutator end cover and brushes IMPORTANT Label armature leads connected to brush leads prior to disconnecting any brush leads 4 Inspect brushes for damage A Replace any brush that is cracked or severely chipped B If the length from the end of the brush to the wear line is less than 1 16 inch 1 6 mm replace all four brushes Fig 24 5 Inspect brush springs for heat discoloration Replace all four brushes if any brush is straw or bluish colored 6 Check brush springs for correct tension A Secure all four brushes into their holders with the brush springs B Using a spring scale check tension on all four brushes in the direction of the spring Fig 25 C Replace all four springs if any spring s tension is less than 24 ounces 1 6 N 7 Secure brush and armature leads with set screws and lock was
76. ECIFICATIONS GENERAL INFORMATION Fill Fuel Tank and Fuel Safety Precautions Check Engine Oil ADJUSTMENTS Adjust Starter Generator Belt Adjust Throttle Cable SERVICE AND REPAIRS Change Engine Oil Change Engine Oil Filter Workman 2100 2110 2 Service Air 8 3 Service Drive Belt 9 4 Replace Fuel Filter 9 4 Spark Plugs cce pene te 10 5 Clean Debris from Engine 11 6 MufflGt 255 EE oe Seas 12 6 Seat Base and Fuel Tank 14 6 EDOMO oy aore knees en oe eds 16 7 BRIGGS amp STRATTON REPAIR MANUAL FOR 7 4 CYCLE V TWIN CYLINDER OHV HEAD EN 7 GINES Page 3 1 Briggs amp Stratton Gasoline Engine gc os Se 6 aco Introduction This Chapter gives information about specifications maintenance troubleshooting testing and repair of the V twin cylinder gasoline engine used in the Workman 2100 and 2110 Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Briggs amp Stratton Repair Manual for 4 V Twin Cylinder OHV Head En gines The use of some specialized test equipment is ex Briggs amp St
77. F1 F3 W BK 10 A 10 A 10 A GY POWER POINT an LIGHT SWITCH 22 x i OPTIONAL FUSES R BN R N y Q BACKUP ALARM GN 3 i 0 A ea ai 01 SOLENOID STSP R HEAD LIGHTS Bk BK VOLTAGE METER HR REGULATOR P3 3 P3 4 3 1 STARTER GENERATOR E 2 rem mm oF fields GN YYYY YN 2 M YYYY 1 armature Ss BK BK P3 2 MAG SPARK PLUG SPARK PLUG P3 5 5 IGNITION ad MODULES ENGINE FRAME GROUND ENGINE OIL PRESSURE SHUTDOWN o Workman 2100 and 2110 Serial Number Over 220000000 Electrical Schematic BK Solenoid is shown de energized 8 5 Rev VIO LOW OIL PRESSURE W BU P3 3 ENGINE OIL PRESSURE 1 2 GY REVERSE SW IN FORW ARD BACKUP ALARM Start Circuits Workman 2100 Schematic Shown Power Current Control Current Indication Current BU STOP RUN IGNITION SW ITCH START 5 OFF RUN START 4 pak er e deg ae ao EE OPTIONS ote M BN T M o Mp BK BN W ACCELERATOR PEDAL PUSHED Y FL W BK peer LIGHT SWITCH
78. LJ OPTIONAL 7 E e pm H VOLTAGE REGULATOR 1 15 P10 2 oc 4 i 5 rie 1 3 P12 P17 LIFT KIT OPTIONAL P9 LOW OIL PRESSURE WARNING LIGHT 2B 1 M 5 J10 2 M J13 J11 J12 IGNITION SWITCH O J2 HEADLIGHT LH Workman 2100 Serial Number Under 220000000 Main Electrical Harness Drawing Page 8 10 Rev B LIGHT SWITCH NO P2 J14 HOURMETER J15 J10 J11 IGNITION SWITCH J12 J13 LOW OIL PRESSURE WARNING LIGHT P17 ACCELERATOR HEAD LIGHT HEAD LIGHT REVERSE SWITCH POWER POINT LEFT SIDE RIGHT SIDE P4 5 P1 J1 J2 J3 J4 NO NC NO NC P16 J16 O 112 0 1 2 4 1 2 3 4 I
79. RI F amp VIO ono BU OPTIONS Ip stp aM BN BK E v o o BU 1 2 y BK BN W ACCELERATOR PEDAL NOT PUSHED IN D LOw OIL PRESSURE FL F2 Fi F3 Ww BK 10 10 A 10 A GY POWER POINT LIGHT SWITCH R Ja OPTIONAL FUSES R BN R N PA r 7073 BU E OR d BACKUP ALARM W BU f i 3 1 Tete teal Li 2 01 SOLENOID STSP BK HOUR BK HEAD LIGHTS METER HR VOLTAGE G Q REGULATOR BK P3 3 3 4 P3 1 STARTER GENERATOR DERE to c a fYYYY f YYYY 1 m fields GN YYYA n BK armature BK P3 2 MAG SPARK PLUG P3 5 IGNITION BN W T 95 MODULE FRAME GROUND ENGINE OIL PRESSURE o Ci BK ENGINE GROUND Workman 1100 and 1110 BK Electrical Schematic Solenoid is shown de energized Page 8 3 Rev B 1 o2 VIO GY REVERSE SWITCH IN FORWARD BU 4 3 PK d 2 vio BU Bk V o 1_o M BN KEY SWITCH OFF RELAY i BK 2 BN W 30 aen
80. Rev B HEADLIGHT RS J3 J4 NEUTRAL SWITCH c P5 1 NO NC 23 2 1 7758 1 2091 5 alum 2 653 dl 1 Tice LIFT KIT SW 3 OPTION POWER Ep 16 5 P1 20 5 3 1 4 3 1 el BACKUP JL 10 T ACCELERATOR A 1 ALARM 21 5 5 3 FUSES E OPTIONAL 21 4 3 ENGINE KIT 2 OPTIONAL 14 ct m OPTIONAL peal FUSE BLOCK E SOLENOID COIL _ BI P11 Hu E ia TP ii AER _ 17 9L P 1 P10 VOLTAGE REGULATOR rin P12 LIFT KIT OPTION J10 J12 J13 M9 IGNITION SWITCH J1 2 o HEADLIGHT LS Workman 1100 Serial Number Under 220000000 Main Electrical Harness Drawing J14 HOUR METER J15 Page 8 8 Rev B POWER POINT ACCELERATOR REVERSE SWITCH
81. Screws E Replace governor shaft if cracked bent or ex cessively worn F Replace governor fork or stopper if bent or de formed Workman 1100 2100 2110 Assembly 1 Assemble input shaft assembly 12 to 16 in Ib 1 4 to 1 8 N m Figure 51 1 Governor plate 3 Screw 2 Governor base 4 Governor sleeve IMPORTANT To prevent the screws that secure the A Secure governor plate unit to the governor base governor plate to the governor from loosening ap with screws Torque screws from 12 to 16 1 4 ply Loctite Blue No 242 or equivalent to the screw to 1 8 threads Figure 52 1 Ball bearing 2 Input shaft IMPORTANT Make sure to press ball bearing at the B Press ball bearing onto the input shaft inner race to prevent damaging the ball bearing Workman 1100 2100 2110 Page 5 33 Drive Train Figure 53 1 Governor sleeve 2 Input shaft C Apply molybdenum disulfide grease to the inside of the governor sleeve Slide sleeve onto the input shaft Figure 54 1 Pivot point 2 Governor plate D Make sure to apply molybdenum disulfide grease to the pivot points of the weights on the governor plate unit Drive Train Page 5 34 Workman 1100 2100 2110 2 Assemble the center shaft assembly 136 8 to 137 1 mm Figure 55 1 Pin clutch 6 Gear small 2 Center shaft 7 Bearing 3 Gear 47 8 Bearing 4 Gear 55 9 Spacer 5 Collar Note Before assembling apply molybdenum disul
82. Secure brake cables to rear of machine A Secure each R clamp to rear frame with screw and flange nut B Secure each brake cable to frame with retaining ring C Secure each brake cable end to brake lever with clevis pin and cotter pin 6 Check parking brake operation and adjust if neces sary see Adjust Parking Brake Workman 1110 and 2110 in the Adjustments section Chassis Wheels and Brakes Rev B a 33 x Ss 25 ac Rear Wheels and Brakes Workman 1110 and 2110 Wheel assembly Lug nut Castle nut Brake drum Socket head screw Brake assembly LH shown Clevis pin Chassis Wheels and Brakes Rev B Antiseize Lubricant 45 to 65 ft lb Figure 22 Cotter pin Cotter pin Flange lock nut Transaxle Parking brake cable Wheel hub Washer Page 7 32 120 to 200 ft lb 163 to 271 1 Spring washer Wheel stud Flange nut Retaining ring R clamp Cap screw Workman 1100 1110 2100 2110 Removal Fig 22 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being jacked up Lift rear wheel off the ground using a jack and place blocks beneath the frame under the axle tube 3 Remove five lug nuts wheel assembly and brake drum from the
83. Side gear Pinion gear Pinion shaft Spring pin Ball bearing Needle bearing Gear 62 Bolt Axle shaft LH Axle shaft RH Figure 27 2 Case LH Page 5 19 Ball bearing Axle case LH Axle case RH Snap ring Castle nut Snap ring Shift shaft Pipe knock Steel ball Spring Gasket Bolt Gasket Flange bolt Flange bolt Flange bolt Bolt Collar Flange bolt Axle bracket Lock nut Spring washer Washer Wheel hub complete Select lever 15 to 18 ft lb 21 to 25 N m A Remove drain plug Drain oil completely from transaxle Replace drain plug gasket if damaged B Reinstall drain plug to transaxle case Torque plug from 15 to 18 ft lb 21 to 25 Drive Train Figure 28 1 Bolt steel ball spring amp gasket 2 Selector shaft C Remove bolt near the selector shaft Remove spring and steel ball Replace gasket if damaged Figure 29 1 Input shaft 2 Oil seal D Wrap vinyl tape around the splined portion of the input shaft This should protect the oil seal from being damaged Drive Train Page 5 20 Workman 1100 2100 2110 Figure 30 1 Flange bolts 3 Axle case 2 Axle bracket E Remove three flange bolts securing the axle bracket and axle case to each case Separate brack et from each axle case Figure 31 1 Flange bolt 2 Flange nut F With the input shaft sid
84. T x gt E Ini lt x E 2 2 S 2 x ru y T 919 z dE 5248 a 4 1 o a VIOLET VIOLET 5 ra 2 YELLOW 54 Es 3 ORANGE BROWN WHITE 1 30 BLACK 2 85 RELAY NOT USED 1 aea PS NOT USED 6 4 87 ORANGE 5 86 8 z 5 ra m 1 ENGINE GROUND 2 MAGNET 5 5 BROWN P3 NETS ENGINE HARNESS 9 9 lt WHITE RED 4 3 OIL PRESSURE t a a BLACK 3 GREEN 4 DF BLACK BLACK S2 ul x x 3 9 5 5 5 5 RED 1 12V em a VIOLET 2 TAIL LIGHT BLUE BLUE BLUE P14 LIFT KIT m GRAY 3 LEFT TURN OPTION BLUE S1 i WHITE BLACK 4 RIGHT TURN m Q BLACK 1 F1 1 PINK PINK 2 3 F2 2 VIOLET P8 FUSE BLOCK WHITE 6 BLACK RED 7 BLACK F4 BLUE 4 8 M BROWN 1 P11 OPTIONAL FUSE BLOCK 1A VWHITE RED 1B BLUE YELLOW 1 2A BLACK 2 GROUND RED BLACK 2B 3 L zi RED BLACK a P7 BOX LIFT SWITCH BLUE 5 12V BLUE 6 1 BLUE YELLOW 7 2 BLACK 8 BLACK x 5 x E m gt 65 5 d j d E q Q e IE 3 3 5 8 gt nl gt 5 O m m am ra Workman 2100 1 2 o B mm 1 1 2 3 4 Serial Number Under 220000000 7 J8 9 P12 P10 P13 Main Electrical Harness P6 BOX LIFT VOLTAGE LIGHT KIT me BACKUP SIART RUN ACTUATOR REGULATOR OPTION Wiring Diagram SOLENOID GREEN LEAD Page 8 11 Rev B HEADLIGHT RS
85. TORO 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 1100 1110 2100 and 2110 REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT STRUCTIONS Space is provided in Chapter 2 of this book to insert the Operator s Manuals and Parts Cata logs for your machine Replacement Operator s Manu als are available on the Internet at www toro com or by sending complete Model and Serial Number to The Toro Company Attn Technical Publications 8111 Lyndale Avenue South Bloomington MN 55420 1196 The Toro Company reserves the right to change product specifications or this publication without notice Part No 02110SL Rev D Service Manual Workman 1100 1110 2100 2110 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 The Toro Company 2002 2004 2005 2006 2007 This page is intentionally blank Workm
86. TY AND INSTRUCTION DECALS 8 Workman 1100 2100 2110 Page 1 1 Safety Safety Instructions The Workman 1100 2100 2110 was tested and certified e Flammable and Combustible Liquids Code by TORO for compliance with the B71 4 1984 specifica ANSI NFPA 30 tions of the American National Standards Institute Al though hazard control and accident prevention partially National Fire Protection Association are dependent upon the design and configuration of the ANSI NFPA 505 Powered Industrial Trucks machine these factors are also dependent upon the ADDRESS awareness concern and proper training of the person nel involved in the operation transport maintenance and storage of the machine Improper use or mainte nance of the machine can result in injury or death National Fire Prevention Association Barrymarch Park Quincy Massachusetts 02269 U S A Read and understand the contents of the Operator s e B56 8 Personal Burden Carriers Manual before starting and operating the machine Be ADDRESS come familiar with all controls and know how to stop it American National Standards Institute Inc quickly A replacement manual is available on the Inter 1430 Broadway net at www toro com or by sending complete Model and New York New York 10018 U S A Serial Number to ANSI UL 558 Internal Combustion Engine P Industrial Truck Attn Technical Publications Owared 8111 Lyndale Avenue
87. Tighten bolt and wing nut 5 Secure battery to the base with rubber strap 6 Connect a digital multimeter set to amps between the negative battery post and the negative cable black connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the unit s electrical sys tem should be tested and repaired 7 Connect negative cable black connector to the negative battery post Tighten bolt and wing nut 8 Apply a light coat of grease on battery posts and cable connectors to reduce corrosion after connections are made Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops Ad CAUTION Follow the manufacturer s instructions when us ing a battery charger NOTE Using specific gravity of the battery cells is the most accurate method of determining battery condition 1 Determine the battery charge level from either its open specific gravity or circuit voltage Workman 1100 1110 2100 2110 Page 6 25 Battery Charge Level 100 1 265 75 1 225 50 1 190 25 1 155 0 1 120 Specific Gravity 2 Determine the charging time and rate using the manufacturer s battery charger instructions or the following table Open Circuit Voltage Battery Battery Charge Level Reserve
88. V Workman 1100 and 2100 Serial Number From 230000001 To 230999999 Workman 2110 Serial Number From 220000001 To 230999999 Main Electrical Harness Wiring Diagram Page 8 15 Rev Jn HORN SW HORN SW K gt p2 LIGHT um A E PAL OPTIONAL KIT Ce L 1 d HEAD LIGHT 15 J2 i J15 HOUR METER Ju P9 LOW OIL PRESSURE WARNING LIGHT 57 P1 POWER POINT P7 GNITION SWITCH LIFT KIT OPTION 5 Jte KEY START 55 Jm OPTIONS M p5 sw 3 EX D3 P15 NEUTRAL SW pF Pit OPTIONAL FUSE BLOCK P3 ENGINE 13 d os oe P13 a eT OPTIONAL KIT HEAD LIGHT 2059 182 1 d T i n1 ce a a Ae eio o 11 L ACCELERATOR START RU A 1 T SOLENOID P10 VOLTAGE REGULATOR P 2 2 P19 P12 DIODE LIFT KIT OPTION P6 BACKUP ALARM Workman 1100 1110 2100 and 2110 Serial Number Above 240000000 Main Electrical Harness Drawing Page 8 16 Rev B HORN JI3 NO LIGHT SW P2 JI4 HOUR METER JIS JI8 OPTIONS JIT B IGNITION SW PI8 M 5 NEUTRAL SW PIS LOW OIL PRESSURE Pg WARNING LIGHT HORN SWITCH POWER POINT
89. ad nuts from cap screws that se cure master cylinder to pedal frame 5 Pull master cylinder from machine Chassis Wheels and Brakes Rev B Page 7 40 1 Position master cylinder to pedal frame and secure with cap screws and flange nuts 2 Remove plugs from brake lines Install brake lines to master cylinder 3 Connect master cylinder to brake pedal with clevis pin and cotter pin 4 Install front hood to machine 5 Bleed brakes see Bleed Brake System Check brake operation Workman 1100 1110 2100 2110 Brake Master Cylinder Service Workman 1110 and 2110 Disassembly Fig 27 1 Remove reservoir and flange seal Push in on the push rod so the stop pin can be removed 2 Disconnect lower end of the dust cover from the housing 3 Push in on the push rod and remove circlip then re move push rod with dust cover and clevis Remove re tainer washer 4 Remove primary piston assembly and secondary piston assembly from cylinder housing Inspection 1 Clean all metal parts with isopropyl alcohol then clean out and dry grooves and passageways with com pressed air Make sure cylinder bore and component 3 Figure 27 pieces are thoroughly clean gure 1 Reservoir 7 Dust cover 2 Check cylinder bore pistons and springs for dam Seo EN age or excessive wear Replace brake cylinder assem 4 Secondary piston assy 10 Retainer washer bly if signs of pitting scoring or cracks are evident in 5
90. age the oil seal G Lift up differential assembly center shaft assem when removing the input shaft bly and input shaft assembly at the same time First remove input shaft assembly Then remove center shaft assembly with the shift shaft and differential as sembly Note If any of the assemblies can not be pulled out by hand hold the assembly while gently tapping the case with a plastic hammer Make sure to tap equally around the case 3 Remove axle case from case RH and LH 1 Flange bolt 3 Case 2 Axle case Figure 37 A Remove flange bolts securing each axle case to the case Remove axle case from the case Drive Train Page 5 24 Workman 1100 2100 2110 Figure 38 1 Snap ring 3 2 Axle case 4 IMPORTANT Do not reuse snap ring Discard and replace ring with new one B Remove snap ring from the axle case Remove axle shaft from case IMPORTANT When replacing ball bearings both ball bearings must be replaced as a set 4 Disassemble input shaft assembly Figure 39 1 Input shaft A Remove governor sleeve from the input shaft Workman 1100 2100 2110 Page 5 25 Axle shaft Ball bearing C Ball bearing roller balls must be free of deforma tion and scoring Ball bearing must spin freely and have minimum axial play Replace ball bearing as necessary 2 Governor sleeve Drive Train Figure 40 1 Ball bearing 2 Input shaft IMPORTANT Do not reuse ball bearings th
91. agement etc Note The nominal torque values listed above are based on 75 of the minimum proof load specified in SAE J1199 The tolerance is approximately 10 of the nominal torque value Product Records and Maintenance Product Records o o 2 c Other Torque Specifications SAE Grade 8 Steel Set Screws Recommended Torque Thread Size Square Head 1 4 20 UNC 140 20 in lb 73 12 in lb 5 16 18 UNC 215 35 in lIb 145 20 in Ib 3 8 16 UNC 35 10 ft 18 3 ft lb 1 2 13 UNC Ib b 75 15 ft lb 50 10 ft Thread Cutting Screws Zinc Plated Steel No 10 24 UNC 38 7 in lb 1 4 20 UNC 85 15 in lb 5 16 18 UNC 110 20 3 8 16 UNC 200 100 in lb Conversion Factors in lb X 11 2985 ft lb X 1 3558 N m Product Records and Maintenance Page 2 6 Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF 65 10 ft lb Grade 5 1 2 20 UNF 80 10 ft lb 108 14 Grade 5 M12 X 1 25 80 10 ft lb f 108 14 Class 8 8 M12 X 1 5 80 10 ft lb f 108 14 Class 8 8 For steel wheels and non lubricated fasteners 88 14 Thread Cutting Screws Zinc Plated Steel Thread Threads per Inch Size Baseline Torque Type A Type B 85 15 in lb Hole size material strength material thickness amp finish must be considered when determining specific torque
92. al Diagrams Main Electrical Harness Wiring Diagram Workman 1100 and 2100 Serial No From 230000001 To 230999999 Workman 2110 Serial No From 220000001 To 230999999 Main Electrical Harness Drawing Workman 1100 1110 2100 and 2110 Serial No Above 240000000 Main Electrical Harness Wiring Diagram Workman 1100 1110 2100 and 2110 Serial No Above 240000000 Engine Electrical Harness Drawing and Wiring Diagram Workman 1100 Serial No Under 220000000 Engine Electrical Harness Drawing and Wiring Diagram Workman 1100 Serial No From 220000001 To 230999999 Engine Electrical Harness Drawing and Wiring Diagram Workman 1100 and 1110 Serial No Over 240000000 Engine Electrical Harness Drawing and Wiring Diagram Workman 2100 Serial No Under 220000000 Engine Electrical Harness Drawing and Wiring Diagram Workman 2100 and 2110 Serial No Over 220000000 Rev B 15 16 17 18 19 Electrical Diagrams Electrical o S This page is intentionally blank Electrical Diagrams Page 8 2 Workman 1100 1110 2100 2110 Ae INE VIO GY REVERSE SW CIN FORW BU STOP CMM RUN B A IGNITION SW ITCH START BrAsS JENITIONSS WE ETUR OFF RUN START 3 PK e
93. an 1100 1110 2100 2110 Table Of Contents Chapter 1 Safety Chapter 5 Drive Train Safety 1 2 Specifications Jacking and Other Instructions 1 6 Special Tools Safety and Instruction Decals 1 8 Adjustments Service and Repairs Chapter 2 Product Records and Maintenance 22 Chapter 6 Electrical System oS Product Records 2 1 8 5 Equivalents and Conversions 2 2 Electrical Schematics ss Torque Specifications 2 3 Special THOS e nere Oi 32 L brication EE ems 2 7 Troubleshooting Maintenance 2 8 Electrical System Quick Checks Component Testing EN Chapter 3 Briggs amp Stratton Gasoline Engine Service and Repairs 2 3 2 Chapter T Chassis Wheels and Brakes je r Specifications 3 3 as General Information 3 4 Specifications D8 Adjustments 3 6 Troubleshooting mo Service and Repairs 3 7
94. are made with rubber and have different spring rates Because of the different spring rates the A arms come adjusted from the factory based on that spring rate Generally the ride height adjustment bolts will be installed in hole number 2 3 or 4 Fig 7 and it may be different from the left side driver side to the right side passenger side If the A arms look like they are sagging then they should be ad justed to the next higher number Fig 7 Each hole equals about 3 4 inch 19 mm of adjustment at the wheel Ride height should be adjusted to the next higher position when adding heavy attachments or carrying heavy loads often 6 Rotate A arm to the desired position and replace ride height adjustment bolt 7 Tighten and torque ride height adjustment bolt from 135 to 165 ft lb 183 to 224 N m NOTE To reinstall the travel limiting bolt it may be nec essary to lower the machine to the ground 8 Replace travel limiting bolt Fig 5 and 6 9 Tighten and torque centering bolts from 240 to 290 ft lb 325 to 393 10 Repeat procedure on opposite side of the vehicle 11 Recheck front ride height 12 After front ride height is adjusted check and adjust front wheel toe in see Adjust Front Wheel Chassis Wheels and Brakes Rev B Page 7 10 Figure 5 3 A arm 4 Ride height adj bolt 1 Travel limiting bolt 2 Centering bolt b 4 135 to 165 f 183 to 224 N m
95. arings if commutator bars are loose Raised bars may be reworked see Rework Starter Generator 7 Measure diameter of the commutator using a mi crometer A Measure diameter at two points along the axis of the commutator and shaft Measurements must also be 90 apart along the circumference of the commu tator B If diameter is less than 1 575 inches 40 mm re place armature and bearings 8 Clean armature completely with clean cloth and or air Do not use solvent Make sure slots between com mutator bars are free of dust and metal particles 9 Inspect field coils Fig 27 A Replace field coils if insulation is blackened charred flaking or cracked B Make sure poles are tight Figure 26 3 Armature shaft 1 Armature 2 Commutator Workman 1100 1110 2100 2110 IMPORTANT Do not remove field coils unless they are to be replaced 10 To remove field coils Fig 27 A Remove nuts from threaded terminal and slide insulator and terminal out of yoke B Remove four pole piece screws and pole sets from the yoke Remove field coils from the yoke 11 Assemble starter generator as follows A Position field coil into yoke Make sure both insu lators that look similar go into the slots marked F1 and F2 The different looking insulator goes into the slot marked DF Seat insulators into slots Fig 27 IMPORTANT Make sure field coil terminal wire will not make contact with the armature B Instal
96. at have B Remove ball bearing from the input shaft with a been removed bearing puller Figure 41 1 Governor plate assembly 2 Governor base IMPORTANT Make sure not to damage the screw C Remove screws securing the governor plate as heads when removing screws Each screw is se sembly to the governor base cured with an adhesive Drive Train Page 5 26 Workman 1100 2100 2110 Figure 42 1 Input shaft 4 Governor sleeve 2 Ball bearing 5 Lock pin 3 Governor plate weight 6 Screw D Replace input shaft if worn or damaged Gear F Replace governor plate if cracked bent or any teeth that are cracked broken chipped or missing weight is missing Weights must swing freely are not acceptable G Replace governor sleeve if cracked or worn E Ball bearing roller balls must be free of deforma tion and scoring Ball bearing must spin freely and have minimum axial play Replace ball bearing as necessary 5 Disassemble center shaft assembly Figure 43 1 Ball bearing 2 Ball bearing IMPORTANT Do not reuse ball bearings that have A Remove ball bearings from the center shaft as been removed sembly Workman 1100 2100 2110 Page 5 27 Drive Train Drive Train Figure 44 6 Gear 55 Gear 47 Gear small Ball bearing Ball bearing CP ONS B Remove gears pin clutch collars and spacer from the input shaft C Replace gears if worn or damaged Cracked bro ken missing or chipped
97. b 61 to 88 N m 5 Lower machine to ground 6 Bleed brakes see Bleed Brake System After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 7 Check brake operation Chassis Wheels and Brakes Rev B a 33 x Ss 25 ac Front Brake Caliper Service Workman 1110 and 2110 Serial Number Below 240000000 72 to 94 in Ib ig4 amp 8 1 to 10 8 N m Figure 25 Caliper bracket Caliper housing Rubber spring O ring Inner brake pad Outer brake pad 7 Piston plug 8 Oval piston 10 Square seal 11 Gasket PARON Disassembly Fig 25 1 Slide caliper from bracket rails being careful not to damage rubber springs 2 Remove inner and outer brake pads from housing 3 Remove four cover screws and separate cover from caliper housing Remove gasket from between cover and housing 4 Remove oval piston and o ring from housing Re move round piston and square seal from cover IMPORTANT The seat insert is pressed into the cali per cover and should not be removed 5 If necessary remove rubber springs from housing and piston plugs from oval piston Chassis Wheels and Brakes 9 Round piston Page 7 38 Rev C 12 Cover LH shown 13 Bleeder screw 14 Seat insert 15 Cover screw 4 used 16 Cap Inspection 1 Clean all metal parts with isopropyl alcohol then clean out and dry
98. ble bracket 2 Throttle cable Figure 6 1 Carburetor 3 Adjustment screw 2 Throttle cable 4 Throttle control lever Briggs amp Stratton Gasoline Engine Page3 6 Rev Workman 2100 2110 Service and Repairs Change Engine Oil Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance 1 Start vehicle and let it run for a few minutes to warm the oil 2 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 3 Raise bed and support with prop rod see Operator s Manual 4 Disconnect spark plug wires 5 Remove drain plug and let the oil flow into a drain pan When the oil stops reinstall the drain plug Fig 7 Note center Dispose of the used oil at a certified recycling Note See Check Engine Oil for the proper type and viscosity of oil to add to the engine 6 Pour oil into fill opening until the oil level is up to the FULL mark on the dipstick Add oil slowly and check level often during this process Do not overfill Fig 8 7 Install filler cap and dipstick firmly in place Fig 8 8 Connect spark plug wires Change Engine Oil Filter Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance 1 Drain oil from the engine see Change Engine Oil 2 Remove existing
99. ch to 5 8 inch 1 6 cm Fig 14 3 After switch adjustment make sure that the engine starter does not engage when the parking brake is en gaged If starter does engage when parking brake is set accelerator switch should be readjusted by reducing the distance between the head of the accelerator switch bolt and the body of the switch slightly 4 After final switch adjustment make sure that switch plunger is not bottomed out when accelerator pedal is released Electrical System Page 6 12 Workman 1100 1110 2100 2110 Diode Assembly The diode D1 Fig 15 is used to protect the ignition switch from voltage spikes that can occur when the start er solenoid is de energized The diode plugs into the wiring harness Testing The diode can be tested using a digital multimeter diode test or ohms setting and the table to the right Figure 15 1 Diode 3 Female terminal 2 Male terminal Multimeter Multimeter Red Lead Black Lead Continuity on Terminal on Terminal Female RPM Shutdown Module Workman 2100 2110 The RPM shutdown module allows the engine to contin ue running briefly after the accelerator pedal is released and the vehicle is decelerating The module monitors engine speed at the engine stop switch terminal Through the RPM shutdown module the engine ignition system is not grounded until the engine speed has slowed to approximately 1300 RPM By allowing the en gine to continue running br
100. ck for cracks caused by overly tight or loose hold down clamp Replace battery if cracked and leaking B Check battery terminal posts for corrosion Use a terminal brush or steel wool to clean corrosion from the battery terminal posts Electrical System n o System IMPORTANT Before cleaning the battery tape or block the vent holes to the filler caps and make sure the caps are on tightly C Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or over filling Also check the battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with clean water D Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking E Check the electrolyte level in each cell If the level is below the tops of the plates in any cell fill all cells with distilled water to the bottom of the cap tubes or fill line Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte 2 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time ta
101. comes spring pressure through the spider assembly which forces the move able sheave closer to the fixed sheave This inward movement of the sheave engages the drive belt Drive Train 5 8 With increasing engine speed the moveable sheave continues to move inward which forces the drive belt to ride towards the outer diameter of the clutch sheaves When engine speed is decreased the cams exert less force on the rollers and thus the spring The spring pres sure overcomes the force of the cams and shifts the moveable sheave away from the fixed sheave The drive belt disengages from the clutch sheaves at a point where the force of the spring is greater than that of the weights Workman 1100 2100 2110 Removal 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch 2 Remove drive belt from the drive clutch see Service Drive Belt in Engine Chapter 3 Remove starter generator V belt from the engine pulley see Replace Starter Generator Belt in Engine Chapter 4 Remove plastic cap carefully from the drive clutch 251030ft Ib 7 2 5 Remove cap screw and washer securing the drive 34 to 41 N m clutch to the engine tapered shaft 1 screw 5 Lock washer IMPORTANT Grease end of clutch removal tool 2 Washer 6 Engine starter pulley i 3 Drive clutch 7 Starter spacer lightly to prevent wear Prevent damage to clutch 4 Can
102. component being tested from the circuit e g unplug the ignition switch connector before doing a continuity check on the switch NOTE See the Briggs and Stratton Repair Manual for 4 Cycle V Twin Cylinder OHV Head Engines or the Kohler Service Manual for Command Pro CS Se ries Engines for additional component testing informa tion Ignition Switch Two types of ignition key switches have been used on the Workman 1100 1110 2100 and 2110 Early production switches had four switch terminals and two key positions OFF and RUN The switch terminals are marked as shown in Figure 3 Later production switches had five switch terminals and three key switch positions but only two or those posi tions are used OFF and RUN The switch terminals are marked as shown in Figure 4 Testing The circuitry of the ignition switch is shown in the charts below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each key position Verify continuity between switch terminals 1 For 2 position switch Fig 3 POSITION CIRCUIT MAKE AMPS 2 For 3 position switch Fig 4 POSITION CIRCUIT MAKE AMPS Workman 1100 1110 2100 2110 Page 6 7 Rev B When testing electrical components for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected TERMINAL 1 2 POSITION
103. consist of the fol to prevent damage to the cap lowing parts ball joints 15 and 19 jam nuts 16 and 18 and tie rod 17 B Remove cap screw and washers securing the wheel to the spindle Slide tire and wheel assembly Removal from the spindle shaft 1 Park machine on a level surface stop engine set 4 Remove spindle as follows parking brake and remove key from the ignition A Remove jam nuts securing tie rod ball joint to the spindle Separate ball joint from the spindle Remove tie rod from Pitman arm if necessary B Remove lock nut and cap screw king pin secur Before jacking up the machine review and follow ing the spindle to the A arm Separate spindle from Jacking Instructions in Chapter 1 Safety the A arm 2 Chock wheels not being jacked up Jack front wheel off the ground and place blocks beneath the frame Chassis Wheels and Brakes Rev B Page 7 18 Workman 1100 1110 2100 2110 Installation 1 Install spindle as follows A Position king pin sleeve into the pivot hub of the A arm Spacer must extend through the bottom of the hub B Place thrust washer onto the bottom of the king pin sleeve Then position spindle over the hub king pin sleeve and thrust washer NOTE Make sure cap screw king pin is inserted down through the spindle and A arm hub Workman 1100 1110 2100 2110 C Secure spindle to A arm hub with cap screw king pin and lock nut Torque fasteners from 75 to 1
104. d 5 Replace adjuster screw and shim washers if rusted corroded bent or fatigued 6 Replace brake cables if frayed stretched or kinked Assembly Fig 20 IMPORTANT Brake shoe lining surfaces must be free of grease oil and other foreign matter 1 Apply a light film of lubricant to the following A Surfaces of the shoe web that contact the back ing plate push rod and adjusting screw B Six ledges on which the brake shoes rest Entire surfaces of PTFE coated washers C D Entire surface of pivot pin E Slot in push rod that contacts actuator lever Surfaces of adjusting lever that contact wave washer washer and pivot pin G Surfaces of the actuator bracket that contact the star wheel of the adjusting screw 2 Position brake shoes to backing plate Secure shoes to plate with shoe cups and hold down pins 3 Secure brake shoes with shoe to shoe springs and auto adjust spring Chassis Wheels and Brakes Rev B a 33 x Ss 25 ac Parking Brake Workman 1110 and 2110 Figure 21 1 Parking brake cover 7 Lock nut 13 Cotter pin 2 Operator seat 8 Flat washer 14 Clevis pin 3 Seat base 9 Flange head screw 4 used 15 Parking brake cable 2 used 4 Cable equalizer bracket 10 Flat washer 2 used 16 Parking brake support 5 Parking brake lever 11 Screw 2 used 17 Cable retaining ring 2 used 6 Curved washer 12 Cap screw Chassis
105. d steer ing housing and remove from the housing 7 Inspect bearings Bearings must spin smoothly and be free of damage Press bearings and spacer out of housing if necessary 8 Inspect seals Seals must be free of rips and tears Replace seals if necessary Assembly IMPORTANT Always replace ball bearings as a set 1 If ball bearings were removed A Press new bearing into housing from the inside first B Turn housing over Insert spacer and press new bearing into housing Workman 1100 1110 2100 2110 Page 7 17 2 If seals were removed press new seals into housing Seal lips should be facing up 3 Place flat washer onto shaft of the Pitman arm Insert shaft into steering housing IMPORTANT The position of the Pitman arm and sector gear is critical during reassembly If either or both of these parts is replaced make sure their alignment matches the matchmark position of the original gear and arm 4 Position sector gear onto the spline of the Pitman arm shaft IMPORTANT Make sure sector gear is centered to the pinion gear 5 Insert pinion gear into the small bearing in the steer ing housing 6 Fill steering housing with number 2 general purpose grease Make sure all gear teeth on the sector and pin ion gears are covered 7 Place gasket and steering housing cover onto the housing Secure cover to housing with four hex washer head screws Torque screws from 90 to 110 in Ib 10 2 to 12 4
106. d to remove the drive clutch spider from the post of the fixed sheave Kit includes spanner and clutch holding bar Clutch Dry Lubricant Toro Part 104 7011 This lubricant should be used to properly lubricate drive clutch components Workman 1100 2100 2110 Page5 3 Rev A Figure 2 1 Holding bar 2 Spanner Figure 3 Drive Train Adjustments Adjust Ground Speed Vehicles With Transaxle Governor Note All Workman 1100 and 1110 models are equipped with a transaxle governor Workman 2100 and 2110 models with serial numbers below 240000000 are also equipped with a transaxle governor Vehicles operating at ground speeds greater than the recommended speed will require further distances to fully stop Do not adjust ground speed greater than specified 1 Park machine on a level surface stop engine and re move key from the ignition switch Raise and latch cargo bed Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Jack up rear of vehicle so both rear wheels are at least 1 inch 25mm off the ground with the rear axle tubes supported on jack stands 3 Chock front and rear of both front tires to prevent the vehicle from moving 4 Lock transaxle into neutral see Transaxle Neutral Position in Chapter 1 Safety 5 Verify ground speed as follows A Start engine and hold accelerator pedal to the floor B Verify driven clutch RPM with a tac
107. der 2 RH brake caliper 7 Socket head screw 4 per rotor used 11 Wheel assembly 3 Lock washer 2 per caliper used 8 Spindle LH shown 12 Lug nut 4 Cap screw 2 per caliper used 9 A arm LH shown 13 Brake hose 5 Wheel hub assembly Chassis Wheels and Brakes Rev B Page 7 36 Workman 1100 1110 2100 2110 Removal 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being jacked up Jack front wheel off the ground and place blocks beneath the frame 3 Remove front wheel from machine see Lower Steering and Front Wheel Removal 4 Clean hydraulic brake line area of brake caliper to prevent contamination Loosen and disconnect brake line from caliper Plug brake line and position it away from caliper 5 Remove two cap screws and lock washers that se cure the brake caliper to the spindle 6 Slide brake caliper from brake rotor and remove cali per from machine Workman 1100 1110 2100 2110 Page 7 37 Installation 1 Slide brake caliper onto brake rotor Make sure that rotor is between brake pads 2 Align caliper mounting holes with spindle Secure caliper with cap screws and lock washers Torque screws 18 ft lb 24 3 Install brake hose to caliper 4 Install front wheel assembly Torque lug nuts from 45 to 65 ft l
108. e 8 21 Rev B FRAME GROUND 5 BLACK BLACK BROWN MAIN HARNESS D 1 m ENGINE GROUND d MAGNETO WHITE BLUE GREEN BROWN WHITE J2 DE 46 MAGNETO RPM SHUTDOWN F 60 P1 E B MAIN olo HARNESS J5 FRAME GROUND OIL PRESSURE DE RPM SHUT DOWN gx PO UJ J3 J4 ENG INE GROUND te OIL d PRESSURE Workman 2100 and 2110 Serial Number Over 220000000 Engine Electrical Harness Drawing and Wiring Diagram Page 8 22 Rev
109. e down loosen and re move flange bolts and nuts securing the case RH and case LH together Workman 1100 2100 2110 Page 5 21 Drive Train Figure 32 1 Case RH 2 Governor boss IMPORTANT Make sure not to hit the governor G Hold the case RH and lift up while lightly tapping boss too hard when separating the cases the boss the governor boss with a plastic hammer may get damaged Do not pry open the two cases with a screw driver damage may result to the seal ing surfaces 2 Remove input shaft center shaft and differential assemblies Figure 33 1 Gasket 2 Pipe knock A Remove gasket and pipe knocks Drive Train Page 5 22 Workman 1100 2100 2110 Figure 34 1 Counter shaft 2 Spacer B Pull out counter shaft Remove spacer needle bearing gear 34 and spacer 3 Needle bearing 4 Gear 34 Figure 35 1 Counter shaft 2 Spacer C Replace counter shaft if it has abnormal wear cracks or damage D Replace spacer if either one is cracked or bent Workman 1100 2100 2110 Page 5 23 3 Needle bearing 4 Gear 34 E Replace needle bearing if needles are bent do not rotate freely or do not remain in the bearing cage F Replace gear 34 if worn or damaged Cracked broken missing or chipped gear teeth are not ac ceptable Drive Train 1 Differential assembly 3 Center shaft assembly 2 Input shaft assembly 4 Shift shaft IMPORTANT Make sure not to dam
110. e nut on the adjusting carriage bolt 5 Pivot the starter in the slot until the belt flexes 1 4 inch 6 mm with 10 Ib 4 5 Kg of force 6 Tighten the carriage bolt nut Tighten starter genera tor pivot bolt Adjust Throttle Cable Releasing the accelerator pedal should allow the throttle cable to close the carburetor throttle control lever so that the lever touches the adjustment screw The adjustment screw keeps the throttle valve inside the carburetor open slightly to prevent the valve from binding 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Lift cargo bed and prop with rod to gain access to the engine 3 Rotate governor arm fully clockwise Fig 5 4 Make sure of the following A The throttle control lever should be to the fully open position B Adjust throttle cable at the cable bracket as nec essary so there is no compression of the throttle cable Fig 5 This will allow the throttle control lever to fully close when the accelerator pedal is released Figure 4 1 Starter Gen pivot bolt 2 Carriage bolt Figure 5 1 Governor arm 3 Cable bracket 2 Throttle cable Kohler Gasoline Engine Page 4 6 Workman 1100 1110 Service and Repairs Change Engine Oil Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance 1 Start vehicle
111. e rotating the filter element Inspect for holes and tears by looking through the filter toward a bright light 8 If filter element is being replaced inspect new filter for shipping damage Check sealing end of the filter Do not install a damaged filter 9 Insert new or cleaned filter correctly into the air cleaner body Make sure filter is sealed properly by ap plying pressure to the outer rim of the filter when instal ling Do not press on the flexible center of the filter 10 Reinstall cover and secure latches Figure 8 3 Filter element 1 Air cleaner latches 2 Cover Workman 1100 1110 Service Drive Belt Inspection Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Raise bed and secure with prop rod 3 Put vehicle transmission in neutral see Set Neutral Lock Assembly in Chapter 1 Safety 4 Rotate and inspect belt for excessive wear or dam age Replace as necessary Replacement 1 Rotate and route belt over the driven clutch 2 Remove belt from the drive clutch 3 Place new belt around drive clutch 4 Rotate driven clutch while routing the belt on Replace Fuel Filter Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2
112. e sure gasket sealing surfaces of both cases B Install both pipe knocks to the case LH are clean Install gasket to case Drive Train Page 5 44 Workman 1100 2100 2110 15 to 18 ft lb 21 to 25 Figure 75 1 Governor shaft 2 Bolt Note When installing case RH to the case LH hold C Install case RH so each shaft fits properly into governor shaft so the ball bearing will not drop off Keep the case the gasket sealing surfaces of the cases as horizontal to each other as possible If the sealing surfaces do not join D Secure case RH to case LH with bolts Torque to each other tap the case lightly with a plastic hammer bolts from 15 to 18 ft lb 21 to 25 N m Figure 76 1 Axle bracket 2 Flange bolt E Position axle bracket to each axle case Secure axle bracket to each axle case with flange bolts Torque bolts from 25 to 31 ft lb 34 to 42 N m Workman 1100 2100 2110 Page 5 45 Drive Train 12 to 15 ft lb 16 to 20 Figure 77 1 Cable bracket 2 Bolt steel ball spring amp gasket F Install cable bracket to the transaxle H Fill transaxle with 1 5 quarts 1 4 liters of new 10W 30 motor oil G Install steel ball spring gasket and bolt Torque bolt from 12 to 15 ft lb 16 to 20 N m Drive Train Page 5 46 Workman 1100 2100 2110 TORO Table of Contents Chapter 6 Electrical System ELECTRICAL SCHEMATICS 2 SERVICE AND REPAIRS
113. e tolerance is installing fasteners into threaded aluminum or brass approximately 10 of the nominal torque value Thin The specific torque value should be determined based height nuts include jam nuts Product Records and Maintenance Page 2 4 Workman 1100 2100 2110 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Thread Size Regular Height Nuts M5 X 0 8 57 5 in lb M6 X 1 0 96 9 in Ib 1018 100 N cm 26 3 N m M8 X 1 25 19 2 ft Class 8 or Stronger Nuts Class 8 8 Bolts Screws and Studs with 640 60 Class 10 9 Bolts Screws and Studs with Regular Height Nuts Class 10 or Stronger Nuts 78 7 in lb 885 80 N cm 133 13 in lb 1500 150 N cm 27 2 ft lb 36 3 N m M12 X 1 75 66 7 ft 90 10 N m 92 9 ft lb 125 12 N m M16 X 2 0 166 15 ft lb 225 20 N m 229 22 ft lb 310 30 M20 X 2 5 325 33 ft lb 440 45 450 37 ft lb 610 50 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 oil graphite 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 Workman 1100 2100 2110 Page 2 5 Ib Ib the fastener size the aluminum or base material strength length of thread eng
114. ener Identification 3 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 Product Records Insert Operator s Manual and Parts Catalog for your Workman at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installation Instructions Op erator s Manuals and Parts Catalogs for those options at the end of this chapter Workman 1100 2100 2110 Page 2 1 Rev Product Records and Maintenance Decimal and Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 9375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 1
115. ers 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance 2 2 Workman 1100 2100 2110 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 spe cified 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 Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant Loctite degree of lubrication on the fastener presence of a prevailing torque feature hard ness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Iden
116. ers to fully return Overtightening of the brake rod will not allow self adjusting of the brakes and will cause premature brake wear 6 Thread the brake rod in or out of the brake equalizer as needed to remove the gap identified in Step 2 7 Reinstall the spring into the hole in the brake rod NOTE Use a pry bar placed between the accelerator pivot shaft and the brake equalizer to aid in installation of the clevis pin that secures the brake rod clevis to the brake lever 8 Connect the brake rod clevis to the brake lever using the clevis pin and cotter pin removed previously 9 Verify that brake pedal travel is from 1 to 1 1 2 25 4 to 38 1 mm with a 75 to 100 pound 34 to 45 4 kg input force to the brake pedal Chassis Wheels and Brakes Rev 7 8 Clevis pin cotter Brake lever Brake rod clevis Brake rod Figure 2 5 Brake equalizer 6 Spring 7 Brake cable 8 Accelerator pedal shaft Workman 1100 1110 2100 2110 Adjust Parking Brake Workman 1110 and 2110 1 Pry the rubber cover off of the parking brake 2 Loosen the set screw securing the knob to the park ing brake lever Fig 3 3 Rotate the knob until a force of 30 35 lb 133 156 is required to actuate the lever 4 Tighten the set screw and install the rubber cover Figure 3 1 Parking brake lever 3 Set screw 2 Brake knob Check Front Ride Height 1 Adjust tire pressures to 12 ps
117. ey from the shaft B Remove woodruff key and spacer from the shaft Electrical System 6 16 Rev B Figure 19 1 Pivot bolt 5 V belt 2 nut 6 Pulley 3 Starter rod 7 Starter Generator 4 Torque arm WORKMAN 1100 1110 Figure 20 1 Starter Gen pivot bolt 2 Carriage bolt Workman 1100 1110 2100 2110 Installation 1 5 6 Install pulley to the starter generator shaft Fig 21 A Position spacer and woodruff key onto the shaft Place pulley onto the shaft B Secure pulley to the shaft with spring washer and nut Torque nut from 15 to 25 20 to 34 Position starter generator to the engine mount A Insert pivot bolt through the engine mount start er generator front bracket pivot and starter genera tor rear bracket B Install flanged lock nut onto the pivot bolt C Tighten lock nut enough so starter generator piv ots with slight resistance On the Workman 2100 and 2110 Fig 19 A Insert end of starter rod with jam nuts through the torque arm B Secure starter rod to the starter generator with the cotter pin On the Workman 1100 and 1110 Fig 20 A Install carriage bolt through starter flange and starter bracket B Thread flange nut onto carriage bolt Correctly connect all wires to the starter generator Install V belt to the pulley Adjust V belt see Adjust Starter Generator Belt in Engine Chapter Work
118. f grease oil and other foreign matter 1 Apply a light film of lubricant to the following A Ledges on which the brake shoes rest B Pin surfaces on adjuster levers C Anchor block surface that contacts shoe webs D Both surfaces of belleville washers that are posi tioned between adjuster levers and backing plate 2 If removed position lubricated belleville washer be tween lever adjuster and backing plate Secure adjuster to backing plate with washer and bolt Torque bolt from 110 to 120 inb 12 4 to 13 6 3 If removed secure wheel cylinder to backing plate with two washer head screws Torque screws from 110 to 120 inb 12 4 to 13 6 4 If removed from backing plate slide parking brake le ver into slot and dust cover in backing plate 5 Position brake shoes to backing plate Make sure that each shoe is properly positioned at anchor block parking brake lever wheel cylinder and pin on adjuster lever Secure shoes to backing plate with shoe hold down cups and springs Be careful when installing springs to brake shoes The springs are under heavy load and may cause personal injury 6 Secure brake shoes with upper and lower springs Chassis Wheels and Brakes Rev B a 33 x Ss 25 ac Front Brake Calipers Workman 1110 and 2110 Thread locking Compound 45 to 65 ft Ib 61 to 88 Figure 24 1 LH brake caliper 6 Brake rotor 10 Brake master cylin
119. found replace all rollers as a set Fig 15 4 Clean pilot bolts and roller pins with 800 1000 grit Figure 14 abrasive paper Ifthe chrome plated surface of the bolts 1 ee Cam weight 2 Worn contact surface or pins is scaled off replace the damaged components 5 Check the contact surface of the movable sheave for wear and or fraying If surface is worn frayed replace component 6 Inspect the clutch spring and replace if damaged or fatigued Assembly Fig 12 1 If removed install rollers washers and roller pins to spider Roller pins should be lubricated with Toro part 3104 7011 or equivalent 2 Lubricate cam weights with Toro part 4104 7011 or Figure 15 equivalent Make sure lubricant penetrates to pilot bolts 1 Roller 3 Roller uneven wear 2 Weight contact surface by rotating and sliding the weights side to side or re move weights if needed to lubricate properly Assemble cam weights to moveable sheave as follows A Make sure the threads of the pilot bolts are clean and dry Apply Loctite 2271 or equivalent to the threads of each bolt IMPORTANT To maintain the balance of the clutch all pilot bolts must be installed with their threads pointing in a clockwise direction Fig 16 B Immediately install new self locking nuts on the pilot bolts Tighten nuts until they just touch the sheave casting Never reuse self locking nuts 3 Apply Loctite 271 or equivalent
120. ge 3 18 4 Connect the following electrical components A Connect ground cable from the engine at starter generator terminal A1 Fig 22 B Connect engine harness connector to the main harness connector 5 Install torque arm to the engine and transaxle 6 Secure starter rod to the torque arm Install V belt to the engine and starter generator Tension and adjust the V belt see Adjust Starter Generator Belt 7 Install drive belt see Service Drive Belt 8 Install muffler and exhaust pipe to the cylinder heads see Muffler Removal 9 Connect fuel hose to the fuel pump Fig 21 10 Connect the following components IMPORTANT Make sure all hoses and engine open ing plugs are removed A Choke and throttle cables to the carburetor and cable bracket Fig 20 B Air intake hose to the carburetor Fig 21 C Breather hose to the crankcase Fig 21 11 Secure choke throttle and shift cables to the brack et on the front cylinder head with cable tie Fig 21 12 Connect positive red cable to the battery Then connect negative black cable to the battery 13 Install cargo bed to the frame 14 Make sure engine oil level is correct see Check En gine Oil 15 When starting a new or repaired engine observe the following A After starting a cold engine let it warm up for about 15 seconds before applying any load to it B Check engine oil level regularly Be alert for con ditions
121. gnment gauge 2 Tire center line front 5 Axle center line height 3 Axle center line 6 Ruler Workman 1100 1110 2100 2110 Page 7 11 Figure 9 2 Tie rod Chassis Wheels and Brakes Rev B a 33 x r 25 ac This page is intentionally blank Chassis Wheels and Brakes Rev B Page 7 12 Workman 1100 1110 2100 2110 Service and Repairs Check Tire Pressure See Specifications for tire pressure range for front and rear tires The air pressure needed is determined by the payload carried The lower the air pressure the less the com Inspect Tires and Wheels Operating accidents such as hitting curbs can damage a tire or rim and also disrupt wheel alignment so inspect tire condition after an accident Workman 1100 1110 2100 2110 Page 7 13 paction and tire marks are minimized Lower pressure should not be used for heavy payloads at high speeds Higher pressures should be used for heavier payloads at higher speeds Do not exceed the maximum tire pres sure Check wheels to ensure they are mounted securely Torque wheel lug nuts to 45 to 65 ft lb 61 to 88 The front wheel bolts on Workman 1100 and 2100 should be torqued from 135 to 165 ft Ib 183 to 224 N m Chassis Wheels and Brakes Rev B a 33 x r 25 ac Upper Steering Antiseize lubricant 13 to 17 ft lb 18 to 23 N m Antiseize lubricant Figure 10
122. grooves and passageways with com pressed air Make sure components are thoroughly clean 2 Check piston bore and pistons for damage or exces sive wear Replace caliper parts as required 3 Replace pads when pad thickness is less than 250 in 6 35 mm Workman 1100 1110 2100 2110 Assembly Fig 25 1 Coat round piston with a small amount of silicone grease and coat square seal with clean brake fluid 2 Install square seal and round piston into cover 3 Insert o ring into bore of caliper housing 4 Coat housing bore with a small amount of silicone grease Insert oval piston into housing with logo on pis ton face orientated to the rubber spring side of the hous ing 5 Rotate round piston so the piston slot will mate with oval piston boss 6 Position gasket and cover to housing Secure cover to housing with four cover screws Torque screws from 72 to 94 in Ib 8 1 to 10 8 N m 7 If removed press piston plugs into oval piston and place rubber springs to housing 8 Apply light coat of grease to rubber springs 9 Place outer and inner brake pads to caliper assem bly 10 Push caliper on to bracket rails being careful not to damage rubber springs Front Brake Caliper Service Workman 1110 and 2110 Serial Number Above 240000000 Disassembly Fig 26 1 Ifcaliperis equipped with anti rattle clip remove clip from caliper pins and brake pads 2 Remove pins from caliper by prying with a flat blade
123. hen spark plug is removed 4 Pull spark plug wires off spark plugs and remove plugs from cylinder head IMPORTANT Replace cracked fouled dirty or mal functioning spark plugs Do not clean plugs Grit from the plug may damage the engine 5 Check condition of side electrode center electrode and center electrode insulator for damage 6 Set air gap between center and side electrodes at 0 030 0 76 mm Install correctly gapped spark plug and tighten plug to 180 in Ib 20 7 Install spark plug wires Briggs amp Stratton Gasoline Engine Page 3 10 Workman 2100 2110 Clean Debris from Engine Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance IMPORTANT This engine is air cooled Operating the engine with dirty or plugged cooling fins a blocked rotating screen or plugged or dirty blower housing will result in overheating and engine dam age 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Raise bed and support with prop rod see Operator s Manual IMPORTANT Never clean engine with pressurized Figure 13 2 water Water could enter and contaminate the fuel 1 Cylinder head cooling fins 55 system S 3 Clean cooling fins on both cylinder heads Fig 13 4 Clean rotating screen and blower housing of dirt and debr
124. hers 8 Lift brush springs from the notch at the end of the brushes while pulling the brushes out Allow springs to hold brushes out from the center Fig 23 9 Position commutator end cover to the commutator and yoke Secure commutator end cover to the yoke with both through bolts and flat washers Torque bolts from 95 5 to 104 10 8 to 11 8 Workman 1100 1110 2100 2110 Page 6 19 10 Slide brushes into holders Secure brushes by posi tioning brush springs into the notch at the end of the brushes Fig 25 11 Install brush covers to the commutator end cover Figure 23 1 Brush 3 Brush holder 2 Spring Figure 24 3 Wear line 4 Setscrew 1 Brush 2 Brush holder Figure 25 3 Brush holder 1 Brush spring 2 Brush Electrical System Electrical System Armature and Field Coil Service Fig 22 IMPORTANT When removing the commutator end cover make sure brushes do not contact the com mutator Damage to the brushes may result 1 Remove brush covers from the commutator end cov er Lift brush springs from the notch at the end of the brushes while pulling the brushes out Allow springs to hold brushes out from the center Fig 23 2 Remove both through bolts and flat washers secur ing the commutator end cover to the yoke Separate end cover from the commutator and yoke 3 Separate front end cover from the armature shaft A Remove hex nut spring washer pulley
125. hm for F1 and 0 043 ohm for F2 at 20 C 68 F Electrical System Page 6 22 Workman 1100 1110 2100 2110 Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally battery and electrical component failure can be prevented POTENTIAL HAZARD Either the battery terminals or metal tools could short against metal vehicle components WHAT CAN HAPPEN Sparks can cause the battery gasses to explode Damaged cables could short against metal ve hicle components and cause sparks HOW TO AVOID THE HAZARD When removing or installing the battery do not allow the battery terminals to touch any metal parts of the vehicle Always DISCONNECT the negative black bat tery cable before disconnecting the positive red cable Always RECONNECT the positive red battery cable before black cable Do not allow metal tools to short between the battery terminals and metal parts of the ve hicle Always keep the battery strap in place to protect and secure the battery reconnecting the negative Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 7 C Discharged less than 1 240 Battery Specifications BCI Group Size UI 300 Amp Cranking Performance at 0 F 17 89C Reserve Capacity at 25 Amps and 80 F 26 7 C is 34 Minutes Removal Fig 28 IMPORTANT Be careful not to damage terminal posts or cable connectors when
126. hometer With the accelerator pedal to the floor the driven clutch speed should be as follows MODEL DRIVEN CLUTCH RPM 1100 2900 3000 RPM 2100 3250 3350 RPM 2110 2950 3050 RPM Drive Train 5 4 C If unable to identify the driven clutch RPM an al ternate method to verify ground speed would be to determine the distance that the vehicle will travel in three 3 seconds with the accelerator pedal to the floor Use the following chart to determine if vehicle ground speed is correct GROUND DISTANCE IN MODEL 3 SECONDS SPEED 14 mph 23 kph 16 mph 26 kph 1100 62 ft 18 9 m 2100 2110 70ft 21 3 m 6 If ground speed adjustment is necessary drill out an odized rivet and retain anti tamper bracket for rein stallation Fig 4 7 Adjust throttle cable accelerator pedal to transaxle at the cable bracket until the correct driven clutch RPM is obtained with the accelerator pedal fully to the floor Fig 4 8 Reinstall antittamper bracket to the cable bracket with a new anodized rivet Toro P N 99 7122 Fig 4 9 Lower machine to ground Lower cargo bed d Figure 1 Anodized rivet 3 Throttle cable 2 Anti tamper bracket 4 Cable bracket Rev A Workman 1100 1110 2100 2110 Adjust Ground Speed Vehicles Without Transaxle Governor Note Workman 2100 and 2110 models with serial numbers above 240000001 are not equipped with a transaxle governor These models use an e
127. i before checking front ride height 2 With a 175 to 225 Ib 79 to 102 kg operator in the driver s seat drive vehicle back and forth a few times on a level surface to relax suspension 3 Stop vehicle With operator still in driver s seat and wheels pointed straight ahead measure the front ride height The front ride height is the distance from the bot tom of the front towing tongue to the ground Front ride height should be as follows A For the Workman 1100 front ride height should be from 7 1 2 to 8 1 4 inches 19 1 to 21 cm B For the Workman 1110 2100 and 2110 front ride Figure 4 height should be from 8 3 4 to 9 1 2 inches 22 2 to 1 Fronttowing tongue 24 1 cm 4 Ifthe ride height is incorrect adjustment needs to be made see Adjust Front Ride Height a 33 x r 25 ac Workman 1100 1110 2100 2110 Page 7 9 Chassis Wheels and Brakes Rev B Adjust Front Ride Height 1 If front ride height adjustment is needed park ma chine on a level surface stop engine set parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Jack front end of the vehicle off the ground 3 Remove travel limiting bolt Fig 5 4 Loosen centering bolts front and rear in the Fig 5 5 Remove ride height adjustment bolt Fig 6 NOTE The A arms suspension inserts
128. iefly during vehicle decelera tion better vehicle performance can be achieved Testing 1 Make sure that accelerator switch is working correct ly and is adjusted properly see Accelerator Switch n 5 System 2 Place drive system in the NEUTRAL position see Operator s Manual 3 Connect an ignition spark tester in series between Figure 16 spark plug and spark plug wire 1 RPM shutdown module 2 Stop switch terminal 4 Start engine and monitor engine speed with a tachometer Press the accelerator pedal to raise engine speed briefly and then release pedal while watching tachometer and spark tester When engine speed de creases to approximately 1300 RPM spark tester should register no spark and the engine should stop Workman 1100 1110 2100 2110 Page 6 13 Electrical System Oil Pressure Switch Workman 2100 2110 The oil pressure switch is located on the mounting adapter for the oil filter It is a normally closed switch and opens with pressure Oil pressure switch testing 1 Turn the ignition switch to ON The oil indicator light should be on 2 If the light is not on disconnect the wire from the oil pressure switch and ground the wire to the engine block 3 Ifthe light comes on the oil pressure switch is bad 4 Ifthe light does not come on after step 2 check the indicating circuit see Electrical Schematic Figure 17 If the lamp comes on with the engine running 1 Oi
129. ioning see Engine Chapter Engine and fuel may be too cold 6 4 Workman 1100 1110 2100 2110 General Run Problems Battery does not charge Wiring to the charging circuit see Wiring Schematics components is loose corroded or damaged Voltage regulator and or starter generator is faulty Battery is dead Engine kills during operation Wiring to the run circuit see Wiring Schematics components became broken or disconnected RPM shutdown module is faulty Workman 2100 and 2110 Engine or fuel system is malfunctioning see Engine Chapter n o K System Workman 1100 1110 2100 2110 Page 6 5 Electrical System Electrical System Quick Checks Battery Test battery terminals 7 12 68 V or higher Fully charged 100 Set the multimeter to the DC volts setting The battery 12 45 V 75 charged should be at a temperature of 60 to 100 F The ignition 5 key should be off and all accessories turned off Connect deque Se charged the positive meter lead to the positive battery post 12 06 V 25 charged and the negative meter lead the the negative battery 11 89 V 0 charged post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Electrical System Page 6 6 Workman 1100 1110 2100 2110 Component Testing For accurate resistance and or continuity checks elec trically disconnect the
130. is Remove screen and housing if necessary Fig 14 IMPORTANT Never operate engine without the blower housing installed Overheating and engine damage will result 5 Make sure rotating screen and blower housing are reinstalled to the engine if removed Figure 14 1 Rotating screen 2 Blower housing Workman 2100 2110 Page 3 11 Briggs amp Stratton Gasoline Engine Muffler Removal 1 Park machine on a level surface stop the engine en gage parking brake and remove the key from the igni tion switch 2 Raise bed and support with prop rod The muffler and exhaust pipe may be hot To avoid possible burns allow engine and exhaust Figure 15 system to cool before working on the muffler Exhaust manifold 6 Socket head screw Exhaust coupler 7 Lock washer 8 Engine 5 Muffler RONTE 3 Remove two coupler springs securing the exhaust Coupler spring 4 used coupler to the muffler Flange head screw 4 Remove two flange screws securing the muffler to the frame 5 Separate muffler carefully from the frame and ex haust coupler Remove muffler from machine 6 If manifold needs to be removed from engine re move socket head screws and lock washers securing the exhaust manifold to the engine 7 Remove exhaust manifold with coupler and exhaust gaskets from engine Installation 1 Make sure engine is off Note Mount all fasteners before securing tightly to ensure a proper fit of exha
131. is loose or worn Tie rod ends are worn Front wheel alignment toe in is incorrect Rubber shock insert A arm is worn Vehicle is unstable or wanders Tire pressure is low or uneven between tires Front wheel bearings are loose Wheel lug nuts are loose Steering column bushings are worn a 33 x Ss 25 ac Rubber shock insert A arm is worn Steering gear is incorrectly adjusted Front wheel alignment toe in is incorrect Workman 1100 1110 2100 2110 Page 7 Chassis Wheels and Brakes Rev B Suspension and Steering continued Problem Possible Cause Steering is hard Steering linkage is binding or damaged Tire pressure is low or uneven between tires Steering gear is damaged or worn Front wheel alignment toe in is incorrect Vehicle pulls to one side when not Tire pressure is low or uneven between tires braking Front wheel alignment toe in is incorrect Steering or suspension component may be bent Chassis Wheels and Brakes Rev B Page 7 4 Workman 1100 1110 2100 2110 Brakes Problem Possible Cause Brake pedal goes to the floor Brakes are incorrectly adjusted Workman 1100 and 2100 Brake cable is loose or broken Workman 1100 and 2100 Rear brake shoes are excessively worn Front brake pads are excessively worn Workman 1110 and 2110 Brake fluid level low Workman 1110 and 2110 Brake fluid leak at hose caliper or wheel
132. k braking surface diameter in at least three places If the diameter exceeds 6 320 inches 16 05 cm re place both brake drums B Replace drums that are cracked deeply grooved tapered significantly out of round scored exces sively rusted or heat spotted C Minor scoring can be removed with sandpaper 2 Inspect brake shoe linings IMPORTANT Replace brake shoes as a set all four shoes to maintain equal braking forces A Replace brake shoes if damaged or if lining is worn to 1 16 1 6 mm Replace if lining is contami nated by oil grease or other fluids NOTE Overheated springs lose their tension and can cause brake linings to wear out prematurely B Inspect brake shoe webbing shoe to shoe springs and auto adjust spring for overheating Overheating is indicated by a slight blue color In spect brake shoe webbing for deformation Replace parts as necessary C Inspect hold down pins and shoe cups for bends rust and corrosion Replace as necessary Workman 1100 1110 2100 2110 Page 7 29 Rev D 3 Inspect backing plate surfaces which contact with the brake shoes for grooves that may restrict shoe movement Replace plate if grooves can not be re moved by light sanding with emery cloth or other suit able abrasive Replace plate if cracked warped or excessively rusted 4 Inspect anchor abutment and rivets for deformation Replace entire brake assembly if deformation or exces sive rust is foun
133. ke the tem perature of the cell B Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 7 C add 0 004 to the specific gravity reading For each 10 F 5 5 C below 80 F 26 7 C subtract 0 004 from the specific grav ity reading Example Cell Temperature 100 F Cell Gravity 1 245 ADD 20 above 80 F 0 008 Correction to 80 F 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv en in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 3 Perform a high discharge test with an adjustable load tester This is one of the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test CAUTION Follow the manufacturer s instructions when us ing a battery tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 0 VDC recharge 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 instruc
134. l bearing as necessary 5 6 7 8 Page 5 30 Differential case Pinion shaft Spring pin Bolt F Replace case if machined areas where the side and pinion gears mesh are scored or if the pinion shaft fits loosely in its bore G Replace pinion shaft if cracked or bent H Replace oil seal if cracked nicked or distorted such that it would not hold a proper seal Workman 1100 2100 2110 7 Disassemble governor fork and shaft 1 Screw Figure 48 3 2 Stopper Governor fork 4 Case RH IMPORTANT Make sure not to damage the screw A Remove both screws and washers securing the heads when removing screws Each screw is se stopper and governor fork to the case RH Remove cured with an adhesive stopper and fork from the case t Figure 49 1 Governor shaft 3 Oil seal 2 Boss IMPORTANT Make sure not to damage the oil seal B Pull governor shaft from the boss when removing the governor shaft from the gover nor boss C Replace oil seal if if cracked nicked or distorted such that it would not hold a proper seal Workman 1100 2100 2110 Page 5 31 Drive Train 1 Ball bearing 2 Case RH 3 Governor shaft Figure 50 4 5 6 D Remove ball bearing from the case Ball bearing roller balls must be free of deformation and scoring Ball bearing must spin freely and have minimum ax ial play Replace ball bearing as necessary Drive Train Page 5 32 Governor fork Stopper
135. l pressure switch 2 Oil filter 1 Shut off the engine immediately 2 Disconnect the wire from the oil pressure switch 3 Turn the ignition switch to ON The oil pressure lamp should go out 4 If the light is still on check for short circuiting in the indicating circuit see Electrical Schematic 5 Refer to the Briggs and Stratton Repair Manual for 4 Cycle V Twin Cylinder OHV Head Engines for addi tional testing information Electrical System Page 6 14 Workman 1100 1110 2100 2110 Service and Repairs NOTE For more component testing information see the Briggs and Stratton Vanguard Service and Re pair Manual for 4 V Twin Cylinder OHV En gines or the Kohler Service Manual for Command Pro CS Series Engines Headlights Specification GE Headlight H7610 1 Set parking brake turn ignition off and remove key 2 Reach beneath dash and push headlight out of the hood 3 Remove screws attaching the wire harness to the headlight 4 Remove rubber seal from around the headlight Dis card headlight 5 Align notch on the inside of the seal with the notch on the new headlight Slide seal onto the headlight until the seal is firmly in place 6 Attach headlight to the wire harness using the pre Figure 18 i 1 Rubber seal 3 Outside notch VigueIMreMaved SELON 2 Inside notch 4 Headlight NOTE Applying soapy water to the outside of the seal may aid in sliding the seal into the hood 7 A
136. l tank do not catch on the seat base during removal 7 Lift seat base carefully from the machine Seat Base Installation Fig 14 IMPORTANT Make sure shift bracket shift cables choke cable and fuel tank do not catch on the seat base during installation 1 Position seat base carefully to the frame Note Do not tighten fasteners securing the seat base to the frame until all of them are installed 2 Install four hex head flange screws and flat washers through the frame and to the front of the seat base Install four hex head flange screws through the frame and into the back of the seat base Tighten all fasteners 3 Place shift bracket shift cables and choke cable through the opening at the front of the seat base 4 Position choke cable and shift plate to shift bracket making sure to capture cable flange Secure shift plate to shift bracket with four short cap screws Screw knob onto the shift lever Fig 15 5 Position shift plate with shift bracket to the seat base Secure shift plate to seat base with 4 long cap screws Fig 15 6 On Workman 1110 machines install parking brake assembly to seat base see Parking Brake Assembly in the Service and Repairs section of Chapter 7 Chassis Wheels and Brakes Fuel Tank Removal Fig 16 Use caution when working with fuel system com ponents see Fill Fuel Tank and Fuel Safety Pre cautions 1 Remove seat base from the frame see Seat Base Removal Wo
137. l terminals through wire connectors and in sulators Secure flat washer lock washer and nut onto each terminal Torque nuts from 43 to 52 in lb 4 9 to 5 9 Fig 27 C Position all four pole pieces into the yoke Secure pole pieces with set screws Torque screws to 9 ft lb 12 N m Fig 27 D Position bearing retainer onto the output shaft of the armature Press new ball bearing onto the shaft being careful not to damage the retainer E Press new ball bearing onto the commutator end of the armature shaft F Position front end cover onto the output shaft Se cure bearing retainer to the end cover with flat wash ers lock washers and screws Torque screws from 35 to 43 in lb 4 0 to 4 9 G Position armature carefully into the yoke Make sure not to damage field coils Align front end cover to the yoke with the locating pin IMPORTANT When installing the commutator end cover make sure brushes do not contact the com mutator Damage to the brushes may result H Lift brush springs from the notch at the end of the brushes while pulling the brushes out Allow springs to hold brushes out from the center Fig 23 Workman 1100 1110 2100 2110 PONS gt Page 6 21 Position commutator end cover carefully to the commutator and yoke Align end cover to the yoke with the locating pin J Secure both end covers to the yoke with both through bolts and flat washers Torque bolts from 95 5 to 104 in
138. lange lock nuts and cap screws secur 1 Starter Generator ground cable to engine ing the engine to the engine mount 2 Starter Generator terminal A1 Workman 2100 2110 Page 3 17 Briggs amp Stratton Gasoline Engine Ad CAUTION One person should operate the chain fall or hoist while the other person guides the engine out of the frame 12 Remove engine from the engine mount A Attach a short section of chain between both en gine lift tabs B Connect hoist or chain fall to center of chain IMPORTANT Make sure not to damage the engine fuel hoses electrical harness or other parts while removing the engine C Slowly remove engine and mounts from the ma chine 13 Remove engine parts and attachments as neces sary to repair the engine Engine Installation Fig 19 1 If removed install engine parts and attachments to the engine One person should operate the chain fall or hoist while the other person guides the engine into the frame 2 Install engine to the frame A Attach a short section of chain between both en gine lift tabs B Connect a hoist or chain fall at the center of the short section of chain IMPORTANT Make sure not to damage engine fuel lines electrical harness or other parts while instal ling the engine C Carefully lower engine onto the engine mount 3 Secure engine to the engine mount with flange lock nuts and cap screws Briggs amp Stratton Gasoline Engine Pa
139. lign notch on the outside of the seal with the notch in the hood Push headlight and seal into the hood until it is firmly in place o K System Workman 1100 1110 2100 2110 Page 6 15 Electrical System Starter Generator Removal 1 Park vehicle on a level surface stop engine set parking brake and remove key from the ignition switch 2 Raise bed and secure with prop rod to gain access to the starter generator NOTE Place all fasteners back onto starter generator terminals after disconnecting wires to prevent loss of fasteners 3 Label all wires on the starter generator Disconnect all wires from the starter generator 4 Loosen starter generator pivot bolt and flanged lock nut 5 On the Workman 2100 and 2110 Fig 19 A Loosen jam nuts on the starter rod enough to al low the V belt to be removed from the pulley Re move V belt from the pulley B Remove cotter pin from the starter rod Separate starter rod from the starter generator 6 On the Workman 1100 and 1110 Fig 20 A Loosen flange nut on starter bracket carriage bolt Rotate starter to allow the V belt to be removed from the pulley B Remove flange nut and carriage bolt from starter bracket 7 Remove pivot bolt and flanged lock nut Remove starter generator from the vehicle 8 Remove pulley from the starter generator shaft Fig 21 A Remove nut and spring washer from the shaft Use puller to remove pull
140. ll at the center of the short section of chain IMPORTANT Make sure not to damage engine fuel lines electrical harness or other parts while instal ling the engine C Lower engine into the engine mount 3 Route ground cables to proper mounting point Se cure engine to the engine mount with four flange lock nuts and flange head screws 4 Connect engine harness connector to the main har ness connector 5 Install starter bracket to the engine and frame 6 Install V belt to the engine and starter generator Tension and adjust the V belt see Adjust Starter Gen erator Belt Kohler Gasoline Engine Page 4 16 7 Install drive belt see Service Drive Belt 8 Install muffler and coupler to the exhaust manifold see Muffler Removal 9 Connect fuel hose to the fuel pump Fig 18 10 Connect the following components IMPORTANT Make sure all hoses and engine open ing plugs are removed A Choke and throttle cables to the carburetor and cable bracket B Air intake hose to the carburetor C Breather hose to the engine valve cover 11 Secure choke and throttle cables to the fuel pump bracket with cable tie 12 Connect positive red cable to the battery Then connect ground black cable to the battery 13 Install cargo bed to the frame see Cargo Bed and Tailgate Installation Chapter 7 14 Make sure engine oil level is correct see Check En gine Oil 15 When starting a new or re
141. ly 8 Moveable sheave 12 Pilot bolt Disassembly Fig 10 IMPORTANT Do not pry off cover damage may re sult Cover should pop off 1 Remove cap screws securing the cover to the mov able sheave Pull cover from clutch 2 Remove the engine pulley from the drive clutch Re move four cap screws and lock washers securing the pulley and starter spacer to the clutch 3 Use two 1 4 20 X 1 cap screws to secure the spider removal holding bar TOR4098 see Special Tools to drive clutch Fig 11 4 Place clutch with attached spider removal holding bar into vise 5 Matchmark position of spider and moveable sheave for reassembly IMPORTANT Use spider removal tool kit to remove spider Unequal pressure on the cam towers may damage them Remove spider from fixed sheave slowly The moveable sheave is under pressure from the spring Drive Train Page 5 10 6 Using spider removal spanner tool TOR4098 see Special Tools remove spider from the fixed sheave post Fig 11 Figure 11 1 Holding bar 2 Spanner Workman 1100 2100 2110 Inspection 1 Inspect the tapered ends of the crankshaft and pri mary fixed sheave for scratches If either is severely scratched replace component If scratches are minor burnish the component with emery cloth 2 Check the surface of the cam weights If worn re place all cam weights as a set Fig 14 3 Check the rollers If binding or uneven wear is
142. m make sure to clean components before disassembly Use Figure 28 as a guide for removal and installation of hydraulic brake components Chassis Wheels and Brakes Rev B Page 7 42 Workman 1100 1110 2100 2110 Bleed Brake System Workman 1110 and 2110 1 Connect a suitable transparent hose to bleeder valve on wheel cylinder or caliper and submerge other end of hose in a glass container partially filled with clean brake fluid 2 Have ahelper pump brake pedal several times then hold pedal down firmly 3 With pedal firmly depressed open bleeder valve of brake until pedal fades to floor Close bleeder valve be fore releasing pedal 4 Repeat procedure until a continuous flow of brake fluid with no air bubbles is released from bleeder valve Make sure fluid level is maintained in brake fluid res ervoir at all times Workman 1100 1110 2100 2110 Page 7 43 5 Repeat steps 1 to 4 for other brake cylinders and cali pers After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 6 After bleeding of brakes is completed road test ve hicle to make sure brakes are operating correctly and pedal is solid Chassis Wheels and Brakes Rev B a 33 x Ss 25 ac Front Hood Figure 29 1 Decal 12 Flange lock nut 23 Headlight mount 2 Power point 13 Fender LH Shown 24 Decal 3 Cap 14 Fender RH not
143. man 1100 1110 2100 2110 GF PONS Starter generator Flanged lock nut Pivot bolt Pivot Engine mount 6 17 Rev B Figure 21 6 7 8 9 10 15 to 25 ft Ibs 20 to 34 N m us Nut Lock washer Pulley Woodruff key Spacer Electrical System n o K System Starter Generator Service WIRING DIAGRAM DN E MOTOR TERMINAL gt F2 SERA AVV FIELD STATOR F TOO TOO DF 9 TOO ARMATURE 2 ROTOR 15 to 25 ft lb 20 to 34 N m 95 5 to 104 in Ib 10 8 to 11 8 N m 27 54 35 to 43 in Ib 4 0 to 4 9 jl j Figure 22 1 Yoke 9 Screw lock washer amp flat washer 17 Field coil stator assembly 2 Armature kit 10 Spring washer 18 Screw and mold assembly 3 Ball bearing 11 Hex nut 19 Screw set 4 Bearing retainer 12 Woodruff key 20 Screw set 5 Ball bearing 13 Screw and washer 21 End cover commutator 6 Spacer 14 End cover front 22 Brush holder kit 7 Through bolt amp flat washer 15 Pulley 23 Brush spring 8 Brush cover 16 Pole piece and set screw 24 Brush and screw set Electrical System Page 6 18 Workman 1100 1110 2100 2110 Brush and Brush Spring Service Fig 22 IMPORTANT When removing or installing the com mutator end cover make sure brushes do not con tact the commutator
144. mble cargo bed as necessary using Figure 30 as a guide Workman 1100 1110 2100 2110 Page 7 45 Chassis Wheels and Brakes Rev B This page is intentionally blank Chassis Wheels and Brakes Rev B Page 7 46 Workman 1100 1110 2100 2110 TORO Table of Contents ELECTRICAL SCHEMATICS Electrical Schematic Workman 1100 and 1110 3 Electrical Schematic Workman 2100 Serial No Under 220000000 4 Electrical Schematic Workman 2100 and 2110 Serial No Over 220000000 5 CIRCUIT DRAWINGS Start Circuits i eol Ye Nar eae 6 Run GIF GUlls eos e eror lg 7 ELECTRICAL HARNESS DRAWINGS and WIRING DIAGRAMS Main Electrical Harness Drawing Workman 1100 Serial No Under 220000000 Main Electrical Harness Wiring Diagram Workman 1100 Serial No Under 220000000 9 Main Electrical Harness Drawing Workman 2100 Serial No Under 220000000 Main Electrical Harness Wiring Diagram Workman 2100 Serial No Under 220000000 11 Main Electrical Harness Drawing Workman 1100 and 2100 Serial No From 220000001 To 220999999 12 Main Electrical Harness Wiring Diagram Workman 1100 and 2100 Serial No From 220000001 To 220999999 13 Main Electrical Harness Drawing Workman 1100 and 2100 Serial No From 230000001 To 230999999 Workman 2110 Serial No From 220000001 To 230999999 14 Workman 1100 1110 2100 2110 Page 8 1 Chapter 8 Electric
145. ment relative to the moveable sheave and drive belt Torque from the drive belt and spring pressure moves the movable sheave up the ramp of the fixed cam The drive belt becomes positioned closer to the outer diameter of the clutch sheaves Removal Fig 18 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch 2 Remove muffler from the engine and engine mount see Muffler Removal in Engine Chapter 3 Remove drive belt from the driven clutch see Ser vice Drive Belt in Service and Repairs section of Engine Chapter 4 Remove cap screw washer and spacer if equipped securing the driven clutch to the input shaft of the transaxle 5 Pull driven clutch from the input shaft Installation Fig 18 1 Coat input shaft of the transaxle with never seize bricant 2 Position driven clutch to the input shaft Make sure pulley side of the clutch faces away from the transaxle case 3 Apply Loctite 242 blue or equivalent to the cap screw threads Drive Train Page 5 12 Figure 17 1 Moveable sheave 4 Fixed sheave 2 Ramp fixed cam 5 Drive belt 3 Button Never seize Figure 18 1 screw 4 Driven clutch 2 Washer 5 Input shaft transaxle 3 Spacer if equipped Workman 1100 1110 2100 2110 4 Secure driven clutch to the transaxle input shaft with cap screw washer and spacer if equipped A For machines that have a 5 16 1
146. meter to the negative post of the battery IMPORTANT Run engine only long enough to get battery voltage reading and not for more than 15 seconds C Start and run engine at mid range RPM D Battery voltage should rise steadily to approxi mately 18 VDC identifying a correctly operating start er generator An incorrect reading indicates the need for starter generator repair E Stop engine and turn key to OFF Electrical System Page 6 10 7 Reconnect green wire connector from the regulator and test voltage regulator A Set multimeter to VDC Connect red probe of the multimeter into the green wire connection Con nect black probe of the multimeter to a known good ground B Start and run the engine at mid range RPM C The measured voltage should be approximately 2 VDC when battery is charging and 6 8 VDC when battery is fully charged This voltage may rise to 12 14 VDC when the accelerator pedal is released and the engine is coasting to a stop D If measured voltage is incorrect stop engine and replace voltage regulator Retest charging circuit Step 5 above 8 Stop engine and remove multimeter leads Figure 10 4 Cable to starter gen 5 Wire to voltage regulator 6 Green wire connector 1 Start run solenoid 2 Main contact post 3 Voltage regulator Figure 11 3 Terminal F1 location 4 Terminal DF location 1 Terminal A1 2 Terminal A2 Workman 1100 1110 2100 2110 Starter
147. mount to lower the engine and transaxle Make sure lifting device is at tached to hold the full weight of the engine and mount Drive Train 1 2 1 2 3 4 Page 5 16 Figure 21 Scribe mark 4 Lock nuts Governor bracket 5 Cable bracket Set screw 1 b Figure 22 Select lever assembly 3 Lock nut Shift cable 4 Cable bracket Flange lock nut 5 Rear frame Flat washer 6 Flange lock nut Isolation mount 7 Hex head flange screw Cap screw 8 Transaxle Workman 1100 2100 2110 10 Remove both flange lock nuts flat washers isolation mounts and cap screws securing the engine mount to the rear frame Fig 23 11 Remove four flange lock nuts and hex head flange screws securing the transaxle to the engine mount Fig 24 12 Lower engine mount enough to allow the transaxle and driven clutch to be removed from the rear of the ve hicle 13 Remove four flange lock nuts and hex head flange screws securing the transaxle to the rear frame Re move transaxle from the rear of the vehicle Fig 23 Installation 1 Position transaxle and driven clutch to the rear frame Secure transaxle to the rear frame with four hex head flange screws and flange lock nuts Fig 23 2 Raise engine mount 3 Secure transaxle to the engine mount with four hex head flange screws and flange lock nuts Make sure R clamp with both shift cables is secured to the engine mount with screw Fig 24
148. ngine and fuel system and damaging the engine Figure 20 4 Disconnect the following components 1 Carburetor 3 Choke cable 9 2 Throttle cable 4 Cable bracket A Choke and throttle cables from the carburetor and cable bracket Fig 20 B Air intake hose from the carburetor Fig 21 Briggs amp Stratton Gasoline Engine C Breather hose from the crankcase Fig 21 Read safety precautions for handling gasoline before working on the fuel system see Fill Fuel Tank and Fuel Safety Precautions 5 Disconnect fuel hose from the fuel pump Remove cable tie securing the choke throttle and shift cables to the bracket on the front cylinder head Fig 21 Figure 21 6 Remove muffler and exhaust pipe from the cylinder 1 Choke cable 5 Fuel pump heads see Muffler Removal 2 Throttle cable 6 Cable tie al 3 Carburetor 7 Air intake hose 4 Fuel hose 8 Breather hose 7 Remove drive belt see Service Drive Belt 8 Remove V belt from the engine and starter genera tor by loosening the tension on the belt Disconnect starter rod from the torque arm see Adjust Starter Gen erator Belt 9 Remove torque arm from the engine and transaxle 10 Disconnect electrical connections from the following engine components A Disconnect ground cable to engine at starter generator terminal A1 Fig 22 B Disconnect engine harness connector from the main harness Figure 22 11 Remove four f
149. ngine gover nor for speed control Vehicles operating at ground speeds greater than the recommended speed will require further distances to fully stop Do not adjust ground speed greater than specified 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch Raise and latch cargo bed 2 Lock transaxle into neutral See Transaxle Neutral Position in Chapter 1 Safety 3 Verify engine speed to ensure correct ground speed as follows A Start engine and hold accelerator pedal to the floor B Using a tachometer verify that engine RPM is 3300 RPM with the accelerator pedal to the floor RPM is incorrect refer to the Briggs and Stratton Repair Manual found after Chapter 3 for governor adjustment procedure 4 Lower cargo bed Workman 1100 2100 2110 Page5 5 Rev A Figure 5 3 Governor control 1 Accelerator cable 2 Accelerator cable end Drive Train Adjust Shift Cables 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch Raise and latch cargo bed 2 Onvehicles with a shift lever neutral position Fig 6 A Set the shift lever into the Neutral position B The transaxle select lever assembly should be in a level position C Tighten the locknut on one of the shift cables just enough to take up any cable slack Note the locknut below the bracket must be held to allo
150. nt see Adjust Brakes in Chapter 7 Chassis Wheels and Brakes 2 1 Flange lock nut 4 Engine mount 2 Hex head flange screw 5 R clamp 3 Transaxle Figure 25 1 Iso mount top 5 Cap screw 2 Iso mount bottom 6 Flat washer 3 Engine mount 7 Flange lock nut 4 Rear frame channel Drive Train Transaxle Service 25 to 31 ft Ib 34 to 42 N m 40 to 45 ft lb 54 to 61 N m Figure 26 Drive Train Page 5 18 12 to 16 in Ib 1 4 to 1 8 N m 25 to 31 ft lb 34 to 42 N m Workman 1100 2100 2110 Case LH Oil seal Oil seal Snap ring Spacer Selector shaft Oil seal Flange bolt Oil check plug 10 Gasket 11 Oil drain plug 12 Gasket 13 Oil filler plug 14 Case RH 15 Oil seal 16 Governor shaft 17 Governor fork 18 Stopper 19 Screw and washer 20 Input shaft 21 Governor base 22 Lock pin 23 Governor plate unit 24 Ball bearing 25 Governor sleeve 26 Ball bearing gio mot Disassembly and Inspection 1 Disassemble case LH and RH 1 Drain plug amp gasket Make sure transaxle case is not hot prior to drain ing oil to prevent getting burned Workman 1100 2100 2110 Figure 26 Continued Spacer Gear 55 Cable bracket Pin clutch Center shaft Gear 47 Collar Gear Flange bolt Ball bearing Ball bearing Spacer Gear 34 Counter shaft Differential case
151. o cylinder when spark plug is removed 4 Pull spark plug wire off spark plug and remove plug from cylinder head IMPORTANT Replace cracked fouled dirty or mal functioning spark plug Do not clean plug Grit from the plug may damage the engine Clean Debris from Engine Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance IMPORTANT This engine is air cooled Operating the engine with dirty or plugged cooling fins a blocked debris screen or a plugged or dirty blower housing will result in overheating and engine dam age 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Raise bed and support with prop rod IMPORTANT Never clean engine with pressurized water Water could enter and contaminate the fuel system 3 Clean cooling fins on cylinder head 4 Clean static debris screen and blower housing of dirt and debris Remove screen and housing if necessary Fig 12 Kohler Gasoline Engine Page 4 10 5 Check condition of side electrode center electrode and center electrode insulator for damage 6 Set air gap between center and side electrodes at 0 030 0 76 mm Install correctly gapped spark plug and tighten plug to 14 ft lb 20 7 Install spark plug wire Figure 11 IMPORTANT Never operate engine without the blower housing ins
152. o the screw threads 12 to 16 in Ibs 1 4 to 1 8 N m Figure 66 1 Governor fork 3 Screw 2 Governor shaft greased surface E Adjust governor fork center to the center of the F Torque screws from 12 to 16 165 1 4 to 1 8 ball bearing hole Also adjust thrust clearance of N m the governor shaft to less than 0 5 mm Drive Train Page 5 40 Workman 1100 2100 2110 5 Install axle case to case RH and LH ee Figure 67 1 Axle shaft bearing 2 Snap ring IMPORTANT Do not reuse snap ring Replace snap A Insert axle shaft with snap rings collar and ball ring with new one bearings into the axle case Install snap ring to the axle case Ca E 25 to 31 ft lb 3 34 to 42 Figure 68 1 Axle case 3 Flange bolt 2 Case IMPORTANT Make sure to install the axle case to B Install axle case to the case Secure each axle the proper side of the case The right side of the case to the case with flange bolts Torque bolts from case takes the short axle case and the left side 25 to 31 ft lb 34 to 42 takes the long axle case IMPORTANT Make sure not to damage the oil seal when installing the axle case to the case Workman 1100 2100 2110 Page 5 41 Drive Train 6 Install input shaft center shaft and differential as semblies to the case Figure 69 2 Clutch groove 1 Shift shaft A Insert fork of the shift shaft to the clutch groove
153. o the shaft with washer spring washer and castle nut 5 Torque castle nut from 120 to 200 ft lb 163 to 271 N m while aligning nut to hole in transaxle shaft 6 Secure castle nut to shaft with cotter pin 7 Slide brake drum onto wheel hub 8 Position wheel assembly to the machine with valve stem facing out and secure with five lug nuts Torque lug nuts in a criss cross pattern from 45 to 65 ft lb 61 to 88 N m 9 Lower machine to ground 10 Check and adjust parking brake see Parking Brake Adjustment 11 Bleed brakes see Bleed Brake System After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 12 Check brake operation Burnish Brake Shoes Sintered metal linings may not provide maximum brake stopping distance after brake shoes are replaced It is necessary to burnish new brake shoe linings IMPORTANT Do not drive machine with the brakes applied The brake shoe linings will overheat IMPORTANT Do not allow the brakes to lock up Al low brakes to cool between applications 1 Drive machine while making 6 to 7 normal stops at about 200 ft 60 m intervals while traveling at 10 to 15 mph 16 to 24 KPH Chassis Wheels and Brakes Rev B a 33 Ss 25 ac Rear Brake Service Workman 1110 and 2110 110 to 120 in Ib 12 4 to 13 6 110 to 120 in Ib a 12 4 to 13 6 110
154. of the center shaft assembly Figure 70 1 Center shaft assembly 3 Input shaft 2 Shift shaft 4 Differential assembly B Replace oil seals for the input and selector shafts on the case LH if cracked nicked or distorted such that they would not hold a proper seal C Install center shaft assembly with shift shaft and differential assembly Then install input shaft as sembly Lower differential assembly center shaft as sembly and input shaft assembly into the case at the IMPORTANT Make sure not to damage the oil seal same time when installing the input shaft Drive Train Page 5 42 Workman 1100 2100 2110 Figure 71 1 Fork selector shaft 2 Pin shift shaft D Make sure the selector shaft fork is contacting the pin on the shift shaft Figure 72 1 Spacer 2 Boss counter shaft E Place spacer on the counter shaft boss of the case LH so the oil groove faces up Workman 1100 2100 2110 Page 5 43 Drive Train Figure 73 1 Gear 34 3 Spacer 2 Counter shaft F Apply molybdenum disulfide grease to the inside G Place gear 34 onto the spacer Make sure not to of gear 34 and the contact surface between the case drop the spacer Insert needle bearing into gear In and the counter shaft sert counter shaft with remaining spacer through the needle bearing gear 34 and into the spacer and case 7 Assemble case LH and RH Figure 74 1 Case sealing surface 2 Pipe knock A Mak
155. of overheating Workman 2100 2110 Chapter 4 TORO Kohler Gasoline Engine Table of Contents 2 Service Air 8 SPECIFICATIONS 3 Service Drive Belt 9 GENERAL INFORMATION 4 Replace Fuel Filter 9 Fill Fuel Tank and Fuel Safety Precautions 4 Spark Plug iaces conet te 10 Check Engine Oil 5 Clean Debris from Engine 10 ADJUSTMENTS 6 11 Adjust Starter Generator Belt 6 Seat Base and Fuel Tank 12 Adjust Throttle Cable 6 Engirie c 14 SERVICE AND REPAIRS 7 KOHLER SERVICE MANUAL FOR COMMAND PRO Change Engine Oil 7 CS SERIES ENGINES E amp On a ou x Workman 1100 1110 Page 4 1 Kohler Gasoline Engine Introduction This Chapter gives information about specifications maintenance troubleshooting testing and repair of the Kohler gasoline engine used in the Workman 1100 and 1110 Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Kohle
156. oper 2 Never allow children to operate the vehicle Never ates the vehicle should have a motor vehicle license allow adults to operate it without proper instructions Safety Page 1 2 Workman 1100 2100 2110 3 This vehicle is designed to carry the operator and one passenger in the seat provided by the manufactur er Never carry more than one passenger on the vehicle 4 Never operate vehicle when under the influence of drugs or alcohol 5 Become familiar with the controls and know how to stop the engine quickly 6 Keep all shields safety devices and decals in place Repair or replace any shield safety device or decal if it is malfunctioning illegible or damaged before operat ing the machine 7 Always wear substantial shoes Do not operate ma chine while wearing sandals tennis shoes or sneakers Do not wear loose fitting clothing or jewelry which could get caught in moving parts and cause personal injury 8 Wearing safety glasses safety shoes long pants and a helmet is advisable and may be required by some local safety and insurance regulations While Operating POTENTIAL HAZARD e Engine exhaust contains carbon monoxide which is odorless colorless poisonous and deadly WHAT CAN HAPPEN Carbon monoxide can cause death It is known by the State of California to cause birth defects HOW TO AVOID THE HAZARD Do not run engine indoors or in closed area 1 Operator and passenger
157. orarily stopped 6 Three hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three consecutive readings Electrical System Page 6 26 Battery Storage If the vehicle will be stored for more than 30 days re move the battery and charge it fully Either store it on the shelf or on the vehicle Leave the cables disconnected if it is stored on the vehicle Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery To prevent the battery from freezing make sure it is fully charged Workman 1100 1110 2100 2110 TORO Table of Contents SPECIFICATIONS 2 TROUBLESHOOTING 3 Suspension and 3 Brake stb EDU NM eMe ied tp 5 ADJUSTMENTS 7 Adjust Brakes Workman 1100 and 2100 Serial Number Below 230000000 7 Adjust Brakes Workman 1100 and 2100 Serial Number Above 230000000 8 Adjust Parking Brake Workman 1110 and 2110 9 Check Front Ride Height 9 Adjust Front Ride Height 10 Adjust Front Wheel 11 SERVICE AND REPAIRS 13 Check Tire
158. ors in an open area when the engine is cold Wipe up any gasoline that spills Do not fill the fuel tank completely full Add gasoline to the fuel tank until the level is no higher than 1 inch 25 mm below the bottom of the filler neck This empty space in the tank allows gasoline to expand Never smoke when handling gasoline and stay away from an open flame or where gasoline fumes may be ignited by a spark Store gasoline in an approved container and keep it out of the reach of children Never buy more than a 30 day supply of gasoline Always place gasoline containers on the ground away from your vehicle before filling Do not fill gasoline containers inside a vehicle or on a truck or trailer bed because interior carpets or plastic truck bed liners may insulate the container and slow the loss of any static charge When practical remove gas powered equipment from the truck or trailer and refuel the equipment with its wheels on the ground If this is not possible then refuel such equipment on a truck or trailer from a portable container rather than from a gasoline dispenser nozzle If a gasoline dispenser nozzle must be used keep the nozzle in contact with the rim of the fuel tank or container opening at all times until fueling is complete Workman 1100 1110 Check Engine Oil Procedure Fig 2 The engine is shipped with oil in the crankcase howev er level of oil must be checked before and after the en gine is first s
159. own before starting up or down a hill E When loading the box distribute load evenly Use extra caution if the load exceeds the dimensions of the box Operate vehicle with extra caution when handling loads that cannot be centered Keep loads balanced and secure to prevent them from shifting F Avoid sudden stops and starts Do not go from re verse to forward or forward to reverse without first coming to a complete stop G Do not attempt sharp turns abrupt maneuvers or other unsafe driving actions that may cause a loss of vehicle control The weight of the box may be heavy and could crush hands or other body parts e Keep hands and other body parts clear when lowering the box Do not dump materials on bystanders H When dumping do not let anyone stand behind the vehicle Do not dump the load on anyone s feet Release tailgate latches from the side of the box not from behind the box Only operate drive vehicle when the cargo box is down and latched J Before backing up look to the rear of the vehicle Make sure no one is behind it Back up slowly K Watch out for traffic when near or crossing roads Always yield the right of way to pedestrians and other vehicles This vehicle is not designed for use on streets or highways Always signal your turns or stop early enough so other persons know what you plan to do Obey all traffic rules and regulations L Never operate vehicle in or near an area where
160. paired engine observe the following A After starting a cold engine let it warm up for about 15 seconds before applying any load to it B Check engine oil level regularly Be alert for con ditions of overheating Workman 1100 1110 TORO Table of Contents SPECIFICATIONS 2 SPEGIAE TOOLS ener Ege PEDES 3 ADJUSTMENTS 4 Adjust Ground Speed Vehicles With Transaxle GOVEIMON euo Na ese i 4 Adjust Ground Speed Vehicles Without Transaxle 5 Adjust Shift Cables 6 SERVICE AND REPAIRS 7 Clutch System Operation 7 Drive Glutch oie Eee ERE 8 Principles of Operation 8 FREMOVAl cor at La tb eee deh eR MERC 9 Installation 0 eee eee 9 Disassembly 10 INSPECHON i ct dade bete bebe 11 bp nU EE ER SUE 11 Workman 1100 2100 2110 Page5 1 Rev A Chapter 5 Drive Train Driven 12 Principles of Operation 12 Removal iss eee eR IUE 12 Installation 0 6 kee ee 12 Ramp Button Replacement 13 Check Driven Clutch Spring Torsion 14 Change Transaxle 15 usce ph eL ee ee eee 16 Removal
161. qualizer 3 Jack front of the vehicle off the ground 4 Tighten cable adjusting screw located beneath the floor panel until the cables are snug in the brake equal izer Do not overtighten There should be some free play in the brake pedal before the brake engages The actua tor levers on the brakes should fully return when the brake pedal is released a 33 x Ss 25 ac Workman 1100 1110 2100 2110 7 7 Chassis Wheels and Brakes Rev Adjust Brakes Workman 1100 and 2100 Serial Number Above 230000000 The recommended brake pedal travel is from 1 to 1 1 2 25 4 to 38 1 mm with a 75 to 100 pound 34 to 45 4 kg input force to the brake pedal Adjustment Procedure Fig 2 1 Park vehicle on a level surface turn on off switch OFF and remove key from the on off switch 2 Depress brake pedal lightly 10 to 15 pound input force until resistance is achieved Check the gap be tween the brake lever and the brake lever stop to deter mine the distance the brake equalizer needs to be adjusted 3 Remove the cotter pin and clevis pin that secure the brake rod clevis to the brake lever 4 Disconnect the spring from the hole near the end of the brake rod 5 Press the brake pedal down fully to raise the brake lever away from the brake rod clevis IMPORTANT When adjusting the brake rod do not overtighten The self adjusting mechanism on the brakes requires the brake lev
162. r Service Manual for COMMAND PRO CS Series Engines The use of some Kohler Gasoline Engine Page 4 2 specialized test equipment is explained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an en gine repair facility Service and repair parts for Kohler engines are supplied through your local Kohler dealer or distributor If no parts list is available be sure to provide your distributor with the Toro model and serial number Rev B Workman 1100 1110 Specifications Item Description Make Designation Kohler 4 Single Cylinder OHV Air Cooled Gasoline Engine Model CH12 PA 941521 Horsepower 12 HP 3600 RPM Torque N m ftHb 22 6 16 7 9 2000 RPM Bore x Stroke mm in 85 x 63 3 35 x 2 48 Total Displacement cc cu in 357 21 8 Dry Weight approximate kg Ib 81 9 70 5 Fuel Unleaded regular grade gasoline Fuel Capacity liters gallons 26 5 7 0 Fuel Pump Pulsating Crankcase Vacuum Carburetor Float Feed Single Barrel Governor Transaxle Ground Speed Governing Engine Oil See Change Engine Oil in Service and Repairs Section Lubrication System Splash Lubrication Crankcase Oil Capacity liters U S qt 1 1 1 2 Spark Plugs Champion RC 14YC or equivalent Spark Plug Gap mm inch 0 76 0 030 Starter Generator
163. ratton Gasoline Engine Page 3 2 plained 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 Service and repair parts for Briggs amp Stratton engines are supplied through your local Briggs and Stratton dealer or distributor If no parts list is available be sure to provide your distributor with the Toro model and serial number Workman 2100 2110 Specifications Item Description Make Designation Briggs and Stratton 4 V Twin Cylinder OHV Air Cooled Gasoline Engine Model 303440 Horsepower 16 HP 3600 RPM Torque kg m ft lb 4 76 34 5 2300 RPM Bore x Stroke mm in 68 x 66 2 68 x 2 60 Total Displacement cc cu in 480 29 3 Dry Weight approximate kg Ib 82 4 72 Fuel Unleaded regular grade gasoline Fuel Capacity liters gallons 26 5 7 0 Fuel Pump Pulsating Crankcase Vacuum Carburetor Float Feed Single Barrel Governor Serial Number Below 240000000 Serial Number Above 240000000 Transaxle Ground Speed Governing Mechanical Governor Engine Oil See Check Engine Oil in General Information section Oil Pump Gear Driven Geroter Type Crankcase Oil Capacity liters U S qt 1 66 1 75 with new filter Spark Plugs Champion RC 12YC or equivalent Spark Plug Gap mm inch 0 76 0 030
164. re resistance across the main contact posts is infinite ohms 4 Resistance across the solenoid coil posts should be approximately 15 5 ohms 5 Replace starter solenoid if necessary Figure 8 6 Reconnect electrical connections to solenoid posi 1 Main posts copper 2 Solenoid posts steel tive battery cable and wire to fuse block on one main contact post and starter generator cable and wire to reg ulator on the other main contact post Reconnect bat tery NOTE Voltage is supplied to the solenoid on the Work man whenever the key is in the RUN position and the ac celerator pedal is depressed Fuse Block There are 3 fuses in the vehicle s electrical system They are located beneath the bed in a box on the right hand side of the frame Fuses can be removed to check conti nuity The test meter should read less than 1 ohm Electrical System Fuses supply power to the following Fig 9 1 The extreme left 10 ampere fuse supplies power to the start run systems 2 The middle left 10 ampere fuse supplies power to the lights 3 The middle right 10 ampere fuse supplies power to the power point A maximum of a 15 ampere fuse is al Figure 9 lowed 1 Ignition system fuse 4 Option 2 Lights fuse 5 Positive battery cable 4 The extreme right fuse supplies power to an optional 3 Power point fuse 6 Wire to fuse block bed lift if equipped Workman 1100 1110 2100 2110 Page 6 9 Electrical Sys
165. removing the bat tery cables 1 Position vehicle on a level surface set parking brake turn ignition off and remove key 2 Raise bed and secure with prop rod Unhook battery strap 3 Disconnect negative black cable first to prevent short circuiting the battery other components or opera tor s hands Disconnect positive red cable Workman 1100 1110 2100 2110 Page 6 23 FILLER CAPS CAP TUBES CORRECT WATER LEVEL COVER SEAL Figure 28 4 Make sure that filler caps are on tightly 5 Remove battery from chassis to a service area This will minimize possible battery damage and allow better access for inspection and service POTENTIAL HAZARD Battery electrolyte contains sulfuric acid which is a deadly poison and it causes severe burns WHAT CAN HAPPEN If you carelessly drink electrolyte you could die or if it gets onto your skin you will be burned HOW TO AVOID THE HAZARD Do not drink electrolyte and avoid contact with skin eyes or clothing Wear safety glasses to shield your eyes and rubber gloves to protect your hands Fill the battery where clean water is always avail able for flushing the skin Always RECONNECT the positive red battery cable before recon necting the negative black cable Follow all instructions and comply with all safety messages on the electrolyte container Inspection Maintenance and Testing 1 Perform the following inspections and maintenance A Che
166. rkman 1100 1110 Page 4 13 Rev B 2 Loosen hose clamp and disconnect fuel hose from the tank 3 Release tank strap from fuel tank Do not remove strap from floor plate and frame cross member Remove tank from frame Fuel Tank Installation Fig 16 1 Position fuel tank to frame Secure tank to frame and cross member with tank strap 2 Connect fuel hose to the tank and secure with hose clamp 3 Install seat base to the frame see Seat Base Instal lation Figure 15 1 Shift lever 4 Cap screw long 2 Cap screw short 5 Choke cable 3 Shift plate Figure 16 3 Tank strap 1 Fuel hose 2 Fuel tank Kohler Gasoline Engine c Ll o D D o o Engine Kohler engine Exhaust spring Intake hose Hose clamp Hose clamp Muffler Exhaust manifold Exhaust coupler Cap screw 10 Lock washer 11 Washer 12 Drive clutch 13 Drive belt 14 Starter V belt 15 Cap screw 16 Cap screw 17 Fuel filter fom CO OB Kohler Gasoline Engine Figure 17 Engine pulley spacer Starter generator Starter pulley Engine pulley Screw Fuel hose Fuel hose conduit Engine mount assembly Frame spacer Lock nut Cap screw Flange head screw Flat washer Engine mount Engine base Iso mount Choke cable Page 4 14 Starter bracket Intake restrictor Flange nut
167. rough the opening at the front of the seat base 4 Position choke cable and shift plate to shift bracket making sure to capture cable flange Secure shift plate to shift bracket with four short cap screws Screw knob onto the shift lever Fig 17 5 Position shift plate with shift bracket to the seat base Secure shift plate to seat base with 4 long cap screws Fig 17 6 On Workman 2110 machines install parking brake assembly to seat base see Parking Brake Assembly in the Service and Repairs section of Chapter 7 Chassis Wheels and Brakes Fuel Tank Removal Fig 18 Use caution when working with fuel system com ponents see Fill Fuel Tank and Fuel Safety Pre cautions 1 Remove seat base from the frame see Seat Base Removal Workman 2100 2110 Page 3 15 Rev B 2 Loosen hose clamp and disconnect fuel hose from the tank 3 Release tank strap from fuel tank Do not remove strap from floor plate and frame cross member Remove tank from frame Fuel Tank Installation Fig 18 1 Position fuel tank to frame Secure tank to frame and cross member with tank strap 2 Connect fuel hose to the tank and secure with hose clamp 3 Install seat base to the frame see Seat Base Instal lation Figure 17 1 Shift lever 4 Cap screw long 2 Cap screw short 5 Choke cable 3 Shift plate Figure 18 3 Tank strap 1 Fuel hose 2 Fuel tank Briggs amp Stratton Gasoline Engine c
168. s 3 Remove drive belt from the driven clutch see Ser vice Drive Belt in Engine Chapter 4 Remove tie wraps securing both battery cables to the passenger side axle tube 5 Remove governor and cable brackets from the trans axle as follows Fig 21 A Scribe mark across governor bracket and gover nor shaft to help reinstallation Loosen both set screws securing the bracket to the shaft B Remove both lock nuts securing the cable brack et to the transaxle case Remove both brackets and cables as a complete unit from the transaxle case and governor shaft 6 Remove lock nut securing the select lever assembly to the selector shaft Loosen jam nuts securing both shift cables to the cable bracket Separate select lever as sembly and shift cables from the transaxle Fig 22 Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 7 Jack up both sides of the frame at the jacking point indicated enough to remove rear wheels Fig 23 A Chock the front and rear of both front tires to pre vent the vehicle from moving B Support both sides of the frame with jackstands positioned just in front of the axle tubes This will al low the transaxle to be removed from the rear of the vehicle 8 Remove both wheels and brake assemblies from the transaxle see Rear Wheel and Brake Removal in Chap ter 7 Chassis Wheels and Brakes 9 Attach hoist or chain fall to the engine
169. s Rev B Page 7 26 Rev A Workman 1100 1110 2100 2110 Removal Fig 18 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being jacked up Lift rear wheel off the ground using a jack and place blocks beneath the frame under the axle tube 3 Remove five lug nuts tire and wheel and brake drum from the wheel hub 4 Remove cotter pin from the castle nut and transaxle shaft Remove castle nut lock washer and spacer from the shaft Remove the wheel hub from the shaft NOTE The brake assembly can be removed from the transaxle shaft for disassembly 5 Remove brake assembly as follows A Remove cotter pin and clevis pin securing the cable bracket to the actuator lever Fig 19 B Remove four cap screws and flanged lock nuts securing the anchor plate of the brake assembly to the transaxle Remove brake assembly from the transaxle Installation Fig 18 IMPORTANT Brake actuator levers must be posi tioned above the transaxle mount When positioned correctly actuator lever will point toward the rear of the axle Fig 19 1 If brake assembly was removed from axle position brake assembly to the transaxle Secure backing plate of the brake assembly to the transaxle with four cap screws and flanged lock nuts Torque screws to 20 ft lb 27
170. s and rotor from spindle 8 Disassemble the wheel hub A Pull the seal out of the wheel hub B Remove bearings from both sides of the wheel hub Clean bearings in solvent Make sure bearings are in good operating condition Clean the inside of the wheel hub Check the bearing cups for wear pit ting or other noticeable damage Replace worn or damaged parts C If necessary remove four socket head screws and brake rotor from wheel hub 9 Remove spindle A Remove cotter pin and castle nut securing tie rod ball joint to the spindle Separate ball joint from the spindle Remove tie rod from Pitman arm if neces sary B Remove lock nut and cap screw 19 securing the spindle to the A arm Separate spindle from A arm C Locate and remove thrust washer from bottom of kingpin sleeve in A arm and brake hose bracket from top of A arm Remove kingpin sleeve from A arm if necessary Installation 1 Install spindle as follows A Position king pin sleeve into the pivot hub of the Sleeve must extend through the bottom of the hub B Place thrust washer onto the bottom of the king pin sleeve Then position spindle over the hub king pin sleeve and thrust washer NOTE Make sure cap screw 19 is inserted down through the spindle and A arm hub C Install brake hose bracket onto cap screw 19 Secure spindle to A arm hub with cap screw 19 and lock nut Torque fasteners from 75 to 100 ft Ib 102 to 13
171. s or blocks without transaxle locked in neutral Make sure proper hoists solid wooden blocks and jack stands are used to raise and support the vehicle Locations 1 Jack front of the vehicle on the front of the frame and behind the towing tongue Fig 1 2 Jack rear of the vehicle under each rear axle tube Do not jack vehicle below the transaxle case Fig 2 Transport Vehicle When moving the vehicle long distances use a trailer or flatbed truck Make sure vehicle is secured to the trailer properly 1 Secure front of the vehicle to trailer at the towing tongue Fig 1 2 Secure rear of the vehicle to the trailer at each rear axle tube Fig 2 Figure 1 1 Front frame 2 Towing tongue Figure 2 1 Axletube 2 Transaxle case Whenever the engine is run for testing that re quires the rear wheels to spin rear wheels should be at least 1 inch 25 mm off the ground with the axle supported on jack stands POTENTIAL HAZARD Seats may become loose and fall off the vehicle and trailer when transporting WHAT CAN HAPPEN Seats falling off the trailer may hit another vehicle or become a road hazard HOW TO AVOID THE HAZARD e Remove or secure seats with cord or strap Safety Page 1 6 Workman 1100 2100 2110 Tow Vehicle In case of emergency the vehicle can be towed for a short distance However Toro does not recommend this as a standard procedure POTENTIAL HAZARD Towing at excessive
172. s shipped with oil in the crankcase howev er level of oil must be checked before and after the en gine is first started 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Remove dipstick and wipe it with a clean rag Insert dipstick into tube and make sure it is seated fully Re move dipstick and check level of oil 3 If oil level is low remove filler cap from valve cover Pour oil with proper type and viscosity into the opening until the oil level is up to the FULL mark on the dipstick Add oil slowly and check the level often during this pro USE THESE SAE VISCOSITY OILS cess Do not overfill Figure 2 1 Dipstick 2 Filler cap D gc a s Se 26 0 aco 4 Install dipstick firmly in place Cil Type and Viscosity Fig 3 10W 30 Oil Type Detergent oil API service SF SG SH SJ or SYNTHETIC 5W 20 5W 30 higher 20 0 20 40 60 80 100 Figure 3 Workman 2100 2110 Page 3 5 Briggs amp Stratton Gasoline Engine Adjustments Adjust Starter Generator Belt Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Loosen starter generator pivot bolt 3 While pressing the belt
173. soline Engine Page 3 14 Rev B 3 On Workman 2110 machines remove parking brake assembly from seat base see Parking Brake Disas sembly in the Service and Repairs section of Chapter 7 Chassis Wheels and Brakes 4 Unscrew knob from the shift lever Remove four short cap screws securing the shift plate to the shift bracket Fig 17 Workman 2100 2110 5 Remove four long cap screws securing the shift plate to the seat base Fig 17 Separate shift bracket from the choke cable and seat base 6 Remove four hex head flange screws and flat wash ers securing the front of the seat base to the frame Re move four hex head flange screws securing the back of the seat base to the frame IMPORTANT Make sure shift bracket shift cables choke cable and fuel tank do not catch on the seat base during removal 7 Lift seat base carefully from the machine Seat Base Installation IMPORTANT Make sure shift bracket shift cables choke cable and fuel tank do not catch on the seat base during installation 1 Position seat base carefully to the frame Note Do not tighten fasteners securing the seat base to the frame until all of them are installed 2 Install four hex head flange screws and flat washers through the frame and to the front of the seat base Install four hex head flange screws through the frame and into the back of the seat base Tighten all fasteners 3 Place shift bracket shift cables and choke cable th
174. spacer and woodruff key from the armature shaft B Remove screws lock washers and flat washers securing the retainer to the end cover IMPORTANT Use clean dry lint free rags when cleaning the starter generator When using com pressed air air should be filtered and not exceed 15 PSI 1 Bar IMPORTANT Remove bearings only if they are to be replaced Use proper removal and installation tools 4 Clean bearings using a clean cloth Inspect bearings for damage Replace both bearings if either bearing meets any of the following conditions A Bearings do not spin smoothly are noisy when spinning or have excessive end or axial play B The balls or rolling surfaces are pitted or worn C Bearings are rusted worn cracked or show ab normal color due to overheating 5 Clean and inspect armature Replace armature if in sulation is burned or charred wires are broken shaft is damaged or bent armature core lamination is dam aged or solder is thrown IMPORTANT Never use emery cloth on the commu tator short circuiting of the commutator bars may result Never use oil or lubricants on the commuta tor or brushes Electrical System Page 6 20 6 Clean and inspect commutator A Remove carbon dust dirt and oil from the com mutator B Lightly remove slight roughness burning or glaz ing of the commutator with 400 grit or finer sandpa per Clean commutator after sanding C Replace armature and be
175. talled Overheating and engine damage will result 5 Make sure static screen and blower housing are rein stalled to the engine if removed Figure 12 2 Blower housing 1 Static debris screen Workman 1100 1110 Muffler Removal 1 Park machine on a level surface stop the engine en gage parking brake and remove the key from the igni tion switch 2 Raise bed and support with prop rod The muffler and exhaust pipe may be hot To avoid possible burns allow engine and exhaust system to cool before working on the muffler 3 Remove springs securing the exhaust coupler to the muffler and exhaust manifold Fig 13 4 Remove four screws securing the muffler to the frame 5 Remove exhaust coupler and muffler 6 If needed remove exhaust manifold from engine by removing two exhaust nuts Replace gasket if neces sary Installation 1 Make sure engine is off Note Mount all exhaust fasteners before tightening to ensure a proper fit 2 If the exhaust manifold was removed install man ifold to engine with new gasket Position manifold loose ly to the engine with exhaust nuts 3 Install muffler to the frame with four screws 4 Insert coupler between muffler and manifold Install springs to attach coupler to the exhaust manifold and muffler 5 Tighten all fasteners Figure 13 1 Exhaust manifold 3 Spring 2 Exhaust coupler o e 2 Workman 1100 111
176. tarted 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Remove dipstick and wipe it with a clean rag Insert dipstick into tube and make sure it is seated fully Re move dipstick and check level of oil 3 If oil level is low pour oil with proper type and viscos ity into the filler tube until the oil level is up to the FULL mark on the dipstick Add oil slowly and check the level often during this process Do not overfill 4 Install dipstick firmly in place Oil Type and Viscosity Fig 3 Oil Type Detergent oil API service SG SH SJ or high er 1 Dipstick Figure 2 2 Filler tube USE THESE SAE VISCOSITY OILS 20 0 20 OF 40 60 80 100 30 20 10 0 C 10 20 30 40 Figure 3 Workman 1100 1110 Page 4 5 Kohler Gasoline Engine o e 2 Adjustments Adjust Starter Generator Belt Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Lift cargo bed and prop with rod to gain access to the engine 3 Loosen starter generator pivot bolt 4 Wedge a pry bar between the engine mount and starter Loosen th
177. tch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being jacked up Jack front wheel off the ground and place blocks beneath the frame 3 Remove front wheel and spindle from A arm see Lower Steering and Front Wheel Removal 4 Remove lock nut 22 and travel limiting bolt 25 from the frame NOTE To aid reassembly note hole location of ride height adjustment bolt in A arm 5 Remove flanged nut 18 and ride height adjustment bolt 19 from the adjustment pattern of the and frame 6 Remove both cap screws 23 and lock washers 24 securing the A arm to the the frame Lower A arm from the frame A arm Installation Fig 14 and 15 1 Position A arm to the frame Secure A arm to the frame with cap screws 23 and lock washers 24 Do not tighten cap screws 2 Install spindle and front wheel to the see Lower Steering and Front Wheel Installation NOTE If A arm is being replaced look for number be tween 200 and 400 written next to the serial tag on the bottom of the replacement A arm This number should be used to identify the location of the ride height adjust ment bolt Fig 16 Number from 200 to 220 use hole 4 Number from 225 to 285 use hole 3 Number from 290 to 400 use hole 2 3 Lower machine to ground 4 Adjust front ride height see Adjust Front Ride Height 5 Align front wheel toe in see Adj
178. tem Starter Generator amp Voltage Regulator 1 Place machine in the NEUTRAL position see Oper ator s Manual Set parking brake 2 Raise bed and secure with prop rod Gain access to electric components by removing the electrical cover 3 Make sure all wires in the charging circuit are con nected correctly and tightly Note the correct location of starter generator cable and voltage regulator wire at the start run solenoid Fig 10 4 Make sure the battery is fully charged Operate the vehicle for several minutes so the voltage regulator is warmed up Stop engine and turn key to OFF 5 Test charging circuit A Set multimeter to VDC Connect red probe of the multimeter to the positive battery post Con nect black probe of the multimeter to the negative post of the battery B Start and run the engine at mid range RPM C Battery voltage should rise to approximately 14 5 VDC identifying a correctly operating charging cir cuit If the battery has a low charge this may take a few minutes D Stop engine and turn key to OFF 6 If battery voltage did not rise to 14 5 VDC test start er generator A Disconnect green wire connector from voltage regulator Fig 10 Connect disconnected green wire lead from starter generator to ground with a jumper lead B Set multimeter to VDC Connect red probe of the multimeter to the positive battery post Con nect black probe of the multi
179. the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch terminals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS Electrical System Page 6 8 QUARTZ RUNNING INDICATOR WINDOW 0000 HOURS 3 1 10 WHEEL WHITE W BLACK NUMBERS HOUR WHEELS BLACK W WHITE NUMBERS Figure 5 Figure 6 3 Positive terminal 4 Negative terminal 1 Top view 2 Bottom view quarts 0 aaanaa Figure 7 2 Back of switch 1 Headlight switch Workman 1100 1110 2100 2110 Starter Solenoid NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from the measured value of the component you are testing 1 Make sure engine is off Disconnect battery Discon nect solenoid electrical connections 2 Apply 12 VDC directly across the solenoid coil posts The solenoid should click Make sure resistance across the main contact posts is less than 1 ohm 3 Remove voltage from solenoid coil posts The sole noid should click Make su
180. the Pitman arm facing down and to the rear The gearbox shaft must be to the left side of the tower 2 Secure steering gearbox to the tower plate with four cap screws and flange lock nuts 3 Insert steering shaft up through the steering column Place dust cover onto the shaft 4 Secure steering column to the mounting plate on the frame with four carriage screws and flange lock nuts Workman 1100 1110 2100 2110 NOTE Apply antiseize lubricant to the steering gear box shaft before installing to steering shaft knuckle 5 Position knuckle of the lower steering shaft onto the gearbox shaft Secure knuckle to the steering gearbox shaft with cap screw and lock washer 6 Connect both tie rods to the Pitman arm on the steer ing gearbox see Lower Steering and Front Wheel Installation NOTE Apply antiseize lubricant to the steering shaft taper before installing the steering wheel 7 Position front tires straight ahead Position steering wheel to the steering shaft so that the leg of the Y formed by the wheel struts is directed towards the oper ator platform 8 Secure steering wheel to shaft with lock washer and nut Torque nut from 13 to 17 ft Ib 18 to 23 N m Install steering wheel cover to wheel 9 Install front hoodto the frame and fenders see Front Hood Installation 10 Check front wheel alignment see Adjust Front Wheel Toe in 7 15 Chassis Wheels and Brakes a 9 lt
181. the filter toward a bright light 8 If filter element is being replaced inspect new filter for shipping damage Check sealing end of the filter Do not install a damaged filter 9 Insert new or cleaned filter correctly into the air cleaner body Make sure filter is sealed properly by ap plying pressure to the outer rim of the filter when instal ling Do not press on the flexible center of the filter 10 Reinstall cover and secure latches Figure 9 3 Filter element 1 Air cleaner latches 2 Cover Workman 2100 2110 Service Drive Belt Inspection Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Raise bed and support with prop rod see Operator s Manual 3 Put vehicle transmission in neutral see Set Neutral Lock Assembly in Chapter 1 Safety 4 Rotate and inspect belt for excessive wear or dam age Replace as necessary Replacement 1 Rotate and route belt over the driven clutch Remove belt from the drive clutch 2 Place new belt around drive clutch Rotate driven clutch while routing the belt on Replace Fuel Filter Note Perform this maintenance procedure at the in terval specified in the Operator s Manual or Chapter 2 Product Records and Maintenance A wARNING Use
182. there is dust or fumes in the air which are explosive The electrical and exhaust systems of the vehicle can produce sparks capable of igniting explosive materials Safety 4 M Always watch out for and avoid low overhangs such as tree limbs door jambs over head walkways etc Make sure there is enough room over head to easily clear the vehicle and your head N If ever unsure about safe operation stop vehicle and ask your supervisor Sudden changes in terrain may cause abrupt steering wheel movement possibly resulting in hand and arm injuries e Reduce your speed and the load when operating on rough terrain and near curbs e Grip the steering wheel loosely around the perimeter Keep your hands clear of the steering wheel spokes O When operating the vehicle over rough terrain or near curbs reduce your speed and grip the outside of the steering wheel Keep your hands and fingers away from the steering wheel spokes Do not touch engine or muffler while the engine is running or soon after it has stopped These components may be hot enough to cause burns 5 If the machine ever vibrates abnormally stop imme diately Wait for all motion to stop Inspect vehicle for damage Repair all damage before commencing opera tion 6 Page 1 4 Before getting off the seat A Stop movement of the machine B Set parking brake C Turn ignition key to OFF D Remove key from ignition switch If vehicle is
183. tification Grade 5 Grade 1 Inch Series Bolts and Screws Figure 1 Workman 1100 2100 2110 Page 2 3 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 en gagement etc The standard method of verifying torque shall be per formed 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 Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance Product Records i S 55 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts 15 2 170 20 260 20 147 23 339 56 599 79 100 10 1125 100 140 15 1580 170 65 10 7
184. tions C Make sure the battery terminals are free of corro sion D Measure the temperature of the center cell E Connect a battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply a test load of one half the Cranking Perfor mance see Battery Specifications rating of the bat tery for 15 seconds G Take a voltage reading at 15 seconds then re move the load H Using the table below determine the minimum voltage for the cell temperature reading Minimum Battery Electrolyte Voltage Temperature 96 70 F 21 1 C and up 60 F 15 6 C 89 20 F 6 79 l If the test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service Electrical System Page 6 24 Workman 1100 1110 2100 2110 Installation IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure the ignition switch and all accessories are off 2 Make sure the battery base is clean and repainted if necessary 3 Make sure battery cables battery connections and the battery hold down strap are in good condition 4 Set battery on the battery base with its posts toward the rear of the vehicle Push the positive cable red con nector onto positive battery post Do not hammer this will damage the battery
185. to the threads of the fixed sheave post Figure 16 4 Install spidertothe fixed sheave post using spider re 1 Pilot bolt 3 Moveable sheave moval tool kit TOR4098 see Special Tools Make sure DOIE threads to align matchmark 5 Torque spider to 100 ft lb 136 6 Position cover to clutch Secure cover to the mov able sheave with cap screws Torque cap screws from 75 to 100 in Ib 8 5 to 11 3 Workman 1100 2100 2110 5 11 Rev Drive Train Driven Clutch Principles of Operation Fig 17 The operation of the driven clutch is affected by trans axle load When the vehicle is stopped the drive belt is held at the outer diameter of the clutch sheaves from the pressure of the spring pushing the moveable sheave against the fixed sheave and away from the fixed cam Three sets of buttons on the moveable sheave provide a low friction surface on which the sheave can slide on the ramp of the fixed cam Once the drive belt starts rotating the drive clutch also starts to rotate With increasing speed of the drive clutch the drive belt begins to climb to the outer diame ter ofits sheaves This increases the tension on the drive belt and forces the moveable sheave to move away from the fixed sheave against the pressure of the spring As the belt tightens and the sheaves open up the drive belt rides lower in the clutch sheaves With increased load to the transaxle the cam resists for ward move
186. trailer see Transport Vehicle 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch 2 Remove drive belt from drive and driven clutches see Service Drive Belt 3 Secure a chain or tow line to tongue on front frame member Fig 1 4 Put vehicle in neutral see Set Neutral Lock Assem bly and release parking brake Figure 3 1 Shift lever w neutral 2 Shift lever w o neutral Figure 4 1 Locking pin if equipped 3 Driven clutch 2 Transaxle case Safety Safety and Instruction Decals There are several safety and instruction decals attached to your Workman If any decal becomes illegible or damaged install a new decal Part numbers are listed in the Parts Catalog Order replacement decals from your Authorized Toro Distributor Safety Page 1 8 Workman 1100 2100 2110 Chapter 2 TORO Product Records and Maintenance Table of Contents o PRODUCT RECORDS 1 LUBRICATION 7 EQUIVALENTS AND CONVERSIONS 2 Grease Fitting Location 7 E S Decimal and Millimeter Equivalents 2 came te U S to Metric Conversions 2 Drive Clutch Lubrication 8 3 TORQUE 3 8 Fast
187. ust Front Wheel Toe in Figure 15 1 Travel limiting bolt 3 A arm 2 Centering bolt 4 Ride hgt adj bolt Figure 16 1 Front A arm LH shown Workman 1100 1110 2100 2110 Page 7 23 Chassis Wheels and Brakes Rev B a 33 x Ss 25 ac Pivot Yoke Removal Fig 14 and 17 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch 2 Remove cargo bed from the rear frame see Cargo Bed and Tailgate Removal 3 Remove seat base from the front frame see Seat Base Removal in Engine Chapter Make sure all tires are chocked to prevent the machine from moving Before removing the pivot yoke make sure front and rear frames are supported with jack stands Support both the front and back of each frame 4 Remove four cap screws and flat washers securing the pivot yoke to the rear frame 5 Remove cap screw and hardened washer securing the pivot yoke to the front frame tab Support pivot yoke while removing it from the front frame to prevent dropping and causing serious injury and damage to the machine 6 Remove four flange head screws and flanged lock nuts securing the pivot yoke to the front frame Remove pivot yoke from the machine Pivot Yoke Installation Fig 14 and 17 Support pivot yoke while installing it to the front frame to prevent dropping and causing serious injury and damage to the machine
188. ust system 2 If the exhaust manifold was removed from engine install manifold to engine with new gaskets Attach ex haust manifold loosely to the engine with fasteners 3 Position muffler to the frame and exhaust coupler 4 Carefully attach muffler to the exhaust coupler Se cure muffler loosely to the frame bracket with two flange head screws 5 Install two coupler springs securing the muffler to the coupler 6 Tighten socket head screws that secure exhaust manifold to the engine 7 Tighten flange head screws that secure muffler to the frame Briggs amp Stratton Gasoline Engine Page 3 12 Workman 2100 2110 gc Seo 6 aco This page is intentionally blank Workman 2100 2110 Page 3 13 Briggs amp Stratton Gasoline Engine Seat Base and Fuel Tank Figure 16 1 Seat 9 Gas cap 16 Shift bracket 2 Seat bracket 10 Fuel tank 17 Shifter plate 3 Cap screw 11 Web strapping 48 inch 18 Long cap screw 4 used 4 Seat base 12 Hex head flange screw 19 Knob 5 Fuel hose to filter 13 Flat washer 20 Short cap screw 4 used 6 Clamp 14 Fuel gauge 21 Choke cable 7 Stand pipe 15 Grommet 22 Shift cable 2 used 8 Bushing Seat Base Removal Fig 16 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Flip both seats forward and remove them from the seat base Briggs amp Stratton Ga
189. ut 12 4 Secure center lower hood to the front frame support with two self tapping screws 15 5 Connect each headlight to the wire harness with screws Tighten all fasteners securing the hood Workman 1100 1110 2100 2110 Cargo Bed and Tailgate Figure 30 1 Tailgate rod RH 13 Tailgate channel 25 Prop rod bracket 2 Tailgate latch bracket RH 14 Hex flange head screw 26 Flat washer 3 Tailgate 15 Pivot bracket RH 27 Push on retainer 4 Cap screw 16 Striker plate RH 28 Cap screw 5 Striker plate LH 17 Pivot bracket LH 29 Prop rod clip 6 Decal 18 Hex flange head screw 30 Latch rod 7 Tailgate rod LH 19 Box brace short 31 Spring 8 Screw 20 Box brace long 32 Insert nut 9 Tailgate latch bracket LH 21 Heat shield 33 Latch bracket 10 Latch washer 22 Screw 34 Latch hook RH 11 Spring 23 Decal 35 Cargo bed 12 Tailgate pivot bracket 24 Prop rod a f 2 Removal Installation 5 v 1 Park machine on a level surface stop engine set 1 Reassemble cargo bed using Figure 30 as a guide 2 parking brake and remove key from the ignition switch 5 2 Position cargo bed to the frame locking the latch rod 2 Remove hex flange head screws securing both pivot to the latch bracket brackets to the rear frame 3 Secure both pivot brackets to the rear frame with hex 3 Release latch rod from the latch bracket Remove flange head screws cargo bed from the frame Disasse
190. values All torque values are based on non lubricated fasteners 0 5 in 16 7 in X 0 08851 in Ib X 0 7376 ft lb Workman 1100 2100 2110 Lubrication Note Perform this maintenance procedure at the in terval specified in the WORKMAN Maintenance Schedule Lubricate more frequently when using this vehicle for heavy duty operations and after each wash ing Grease Fitting Locations 1 Each tie rod has a grease fitting on each ball joint the one that secures the tie rod to the Pitman arm Fig 3 and the joint that secures the tie rod to the front wheel spindle Fig 4 2 A arm has a grease fitting for the king pin Fig 4 3 The throttle and brake pedal pivots each have one grease fitting Note These fittings are not greased at the factory Grease them only when and if the pedals be gin to stick Fig 5 Greasing IMPORTANT Use No 2 general purpose lithium base grease 1 Wipe grease fitting clean so foreign matter cannot be forced into the bearing or bushing 2 Pump grease into the bearing or bushing 3 Wipe off excess grease 1 Pitman arm 2 Grease fitting Figure 4 1 Tie rod 3 Grease fitting 2 A arm Figure 5 1 Grease fitting brake 2 Grease fitting throttle Workman 1100 2100 2110 Page2 7 Product Records and Maintenance Product Records o o 2 c Drive Clutch Lubrication Note After every 400 hours of
191. w adjustment D Repeat process for other shift cable E Pullup on each shift cable to make sure that there Figure 6 is no gap between the nut washer and the select le 1 Shift cable 3 Locknut ver If a gap exists tighten nut further Fig 7 2 Select lever assembly F Start engine and check operation in forward re verse and neutral Readjust if needed for correct op eration 3 Onvehicles without a shift lever neutral position Fig CETTE A Move shift lever to forward B Extended spring length on shift cable should be 1 to 1 1 8 25 to 25 mm Adjust lock nut as needed C Move shift lever to reverse Check other shift cable as in Step 3 Adjust lock nut as needed Figure 7 j M 1 Select lever 4 Incorrect adjustment D Start engine and check operation in forward and 2 Cable pull direction 5 Correct adjustment reverse Readjust if needed for correct operation 3 Cable boot Ww um 1 to 1 1 8 25 to 28 mm Figure 8 1 Select lever assembly 2 Shift cable Drive Train Page 5 6 Rev A Workman 1100 2100 2110 Service and Repairs Clutch System Operation Figure 7 1 Drive clutch 4 Fixed sheave drive clutch 7 Ramp fixed cam 2 Driven clutch 5 Moveable sheave driven clutch 8 Spring 3 Moveable sheave drive
192. wheel hub 4 Remove cotter pin from the castle nut and transaxle shaft Remove castle nut spring washer and washer from the shaft Remove the wheel hub from the shaft NOTE The brake assembly can be removed from the transaxle shaft for disassembly 5 If required remove brake assembly as follows A Remove cotter pin and clevis pin securing the parking brake cable to the parking brake lever on the rear of the brake assembly B Clean hydraulic brake line area of brake assem bly to prevent contamination Loosen and discon nect brake line from wheel cylinder Plug brake line and position it away from brake assembly C Remove four socket head screws and flange lock nuts that secure the brake assembly to the transaxle D Remove brake assembly from the transaxle Installation Fig 22 IMPORTANT Parking brake levers must be posi tioned above the transaxle mount When positioned correctly brake lever will point toward the rear of the axle 1 Position brake assembly to the transaxle Secure backing plate of the brake assembly to the transaxle with four socket head screws and flanged lock nuts Torque screws to 20 ft lb 27 2 Secure parking brake cable to the brake lever with clevis pin and cotter pin Workman 1100 1110 2100 2110 7 33 IMPORTANT Do not get antiseize lubricant onto brake shoes 3 Apply light coat of antiseize lubricant to the transaxle shaft splines 4 Secure wheel hub t

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