Service Manual
Table Of Contents
- Title Page
- Revision History
- Reader Comments
- Preface
- Table Of Contents (Page 1)
- Table of Contents (Page 2)
- 1 - Safety
- 2 - Product Records and Maintenance
- 3 - Kubota EFI Gasoline Engine
- 4 - Kubota Diesel Engine
- 5 - Kohler Air Cooled Gasoline Engine
- 6 - Drive Train
- 7 - Chassis
- Specifications
- General Information
- Special Tools
- Troubleshooting
- Service and Repairs
- Wheel Assembly
- Brake System
- Brake Caliper Service
- Bleed Brake System
- Parking Brake Caliper Service
- Brake Master Cylinder
- Brake Master Cylinder Service
- Parking Brake Cable
- Wheel Hub
- Steering Assembly
- Front Control Arms
- Front Compression Spring Service
- Front Shock Absorber
- Rear Shock Absorber
- Rear Leaf Spring
- Front Wheel Alignment
- Steering Wheel
- Seat Base
- Hood
- Windshield Wiper Assembly (Machines with Operator Cab)1. Flange- head screw (10 each)2. Sealing washer (10 each)3. Cab roof4. Bulb trim seal5. Console foam6. Fuse block mount7. Wiper motor8. Wiper motor bracket9. Roof console10. Clip
- 8 - Electrical System
- Electrical Schematics
- Special Tools
- Troubleshooting
- Electrical System Quick Checks
- Component Testing
- Ignition (Key) Switch
- Gauge Cluster
- Fuses
- Headlight Switch
- Clutch Switch(s)
- Brake Switch(s)
- Hydraulic Lift Lever Interlock Switch
- 3rd - High Lockout Key Switch
- Transaxle Switches
- Power Relay (Four Terminals)
- Relay (Five Terminals)
- Fusible Link
- Diodes
- Electronic Throttle Control (Workman HDX)
- Fuel Run/Stop Solenoid (Workman HDX-D)
- Fuel Gauge Sender (Workman HD & HDX-D)
- Fuel Pump/Sender (Workman HDX)
- Fuel Pump (Workman HDX-D)
- Temperature Sender (Workman HDX and HDX-D)
- Electric Fan Thermal Switch (Workman HDX-D)
- Speed Sensor
- Glow Controller (Workman HDX-D)
- High Flow Hydraulics Kit Switch (High Flow Hydraulics Kit)
- Hydraulic Solenoid Valve Coil (High Flow Hydraulics Kit)
- Rear PTO Switch (Optional Kit)
- Interlock Switch (1/3 Area Lift Platform Kit)
- Windshield Washer/Wiper Switch (Machines with Operator Cab)
- Diode Assembly (Machines with Operator Cab)
- Service and Repairs
- 9 - Hydraulic System
- Specifications
- General Information
- Special Tools
- Hydraulic Schematics
- Hydraulic Circuit Operation
- Troubleshooting
- Testing
- Primary Hydraulic System Gear Pump Flow Test (Workman HDX and HDX-D)
- Primary Hydraulic System Gear Pump Flow Test (Workman HD)
- Primary Hydraulic System Relief Valve Pressure Test
- Steering Control Valve and Steering Cylinder Test
- Lift Cylinder Internal Leakage Test
- High Flow Hydraulic System Gear Pump Flow and Relief Pressure Tests
- Service and Repairs
- General Precautions for Removing and Installing Hydraulic System Components
- Check Hydraulic Lines and Hoses
- Primary Hydraulic System Gear Pump (Workman HDX and HDX-D)
- Primary Hydraulic System Gear Pump (Workman HD)
- Primary Hydraulic System Gear Pump Service
- High Flow Hydraulic System Gear Pump Service
- Lift Valve
- Lift Valve Service
- Steering Control Valve
- Steering Control Valve Service
- Steering Cylinder
- Steering Cylinder Service
- Lift Cylinder
- Lift Cylinder Service
- Hydraulic Manifold (High Flow Hydraulics Kit)
- 10 - Front Wheel Drive (4WD)
- 11 - Electrical Drawings
- Electrical Drawing Designations
- Workman HD (Serial Numbers313000001 to 404350000)
- Workman HD (Serial NumbersAbove 404350001)
- Workman HDX (Serial Numbers313000001 to 401400000)
- Workman HDX (Serial Numbers401400001 to 404350000)
- Workman HDX (Serial NumbersAbove 404350001)
- Workman HDX--D (Serial Numbers313000000 to 314000000)
- Workman HDX--D (Serial Numbers314000001 to 401420000)
- Workman HDX--D (Serial Numbers401420001 to 404350000)
- Workman HDX--D (Serial NumbersAbove 404350001)
- Front Wire Harness: Workman HD (SerialNumbers 313000000 to 314000000)
- Front Wire Harness: Workman HD (SerialNumbers 314000001 to 401406000)
- Front Wire Harness: Workman HD (SerialNumbers 401406001 to 404350000)
- Front Wire Harness: Workman HD (Serial Numbers 404350001 to 409080000)
- Front Wire Harness Drawing(Serial Number above 409080000)
- Rear Wire Harness Drawing Serial Number below 409080000)
- Rear Wire Harness Drawing(Serial Number above 409080000)
- Front Wire Harness: Workman HDX (SerialNumbers 313000001 to 314000000)
- Front Wire Harness: Workman HDX (SerialNumbers 314000001 to 316000000)
- Front Wire Harness: Workman HDX (SerialNumbers 316000001 to 316999999)
- Front Wire Harness: Workman HDX (SerialNumbers 400000000 to 401400000)
- Front Wire Harness: Workman HDX (SerialNumbers 401400001 to 404350000)
- Front Wire Harness: Workman HDX (SerialNumbers 404350001 to 409100000)
- Front Wire Harness Drawing(Serial Number above 409100000)
- Rear Wire Harness: Workman HDX (SerialNumbers 313000001 to 315000500)
- Rear Wire Harness: Workman HDX (SerialNumbers 315000501 to 316999999)
- Rear Wire Harness: Workman HDX (SerialNumbers 400000000 to 401420000)
- Rear Wire Harness: Workman HDX (SerialNumbers 401420001 to 409100000)
- Rear Wire Harness Drawing(Serial Number above 409100000)
- Front Wire Harness: Workman HDX--D (SerialNumber 313000000 to 314000000)
- Front Wire Harness: Workman HDX--D (SerialNumber 314000001 to 316000000)
- Front Wire Harness: Workman HDX--D (SerialNumber 316000001 to 400000000)
- Front Wire Harness: Workman HDX--D (SerialNumber 400000001 to 401420000)
- Front Wire Harness: Workman HDX--D (SerialNumber 401420001 to 404350000)
- Front Wire Harness: Workman HDX--D (SerialNumber 4043500001 to 408000000)
- Workman HDX--D Front Wire Harness Drawing(Serial Number above 408000000)
- Rear Wire Harness: Workman HDX--D (SerialNumbers 313000000 to 400000000)
- Rear Wire Harness: Workman HDX--D (SerialNumbers 400000001 to 401420000)
- Rear Wire Harness: Workman HDX--D (SerialNumbers 401420001 to 408000000)
- Workman HDX--D Rear Wire Harness Drawing(Serial Number above 408000000)
- Front Wire Harness:Workman HDX--D (Industrial)
- Rear Wire Harness:Workman HDX--D (Industrial)
- Heater Kit--Wire Harness DrawingWorkman HD Series
Workman HDXPage 3 − 12Kubota EFI Gasoline Engine
Fuel Pump Removal (Fig. 8)
1. Park vehicle on a level surface, raise bed and en-
gage parking brake. Stop the engine and remove key
from ignition switch. Allow engine to cool.
2. Install bed support on bed lift cylinder to prevent bed
from lowering.
3. Disconnect vehicle wire harness connectors from
fuel pump/sender assembly on fuel tank.
CAUTION
The fuel supply hose will contain pressurized
fuel. Be careful when disconnecting fuel supply
hose. Wipe up any spilled fuel before starting the
engine.
4. Disconnect fuel supply hose from fuel pump/sender.
Plug fuel hose to prevent leakage or system contamina-
tion.
5. Note orientation of fuel fitting on fuel pump for as-
sembly purposes.
6. Remove cap that secures fuel pump/sender assem-
bly in fuel tank.
NOTE: Do not allow fuel pump/sender assembly to ro-
tate during removal or damage to the sender float arm
may result.
7. Carefully remove fuel pump/sender and gasket from
tank.
Fuel Pump Installation (Fig. 8)
1. Make sure that fuel tank and fuel pump/sender gas-
ket surfaces are thoroughly clean.
2. Position gasket to sealing surface of fuel pump/
sender.
3. Carefully insert fuel pump/sender and gasket into
tank. Orientate fuel fitting so that it is pointing toward the
vehicle frame.
4. Secure fuel pump/sender to fuel tank with cap.
Torque cap from 175 to 200 in−lb (20 to 22 N−m).
5. Remove plug placed in fuel supply hose and connect
supply hose to fuel pump/sender. Secure fuel hose with
hose clamp.
6. Connect vehicle wire harness connectors to fuel
pump/sender assembly on fuel tank.
7. Remove bed support from lift cylinder and lower bed.
1. Fuel pump/sender
2. Wire harness
3. Fuel supply hose
1
2
3
Figure 10