Replacement Engine Kit Diesel-Powered Workman 3000/4000 Series Utility Vehicle

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1 Form Number Rev A Replacement Engine Kit Diesel-Powered Workman 3000/4000 Series Utility Vehicle Model No Parts Catalog Ordering Replacement Parts To order replacement parts, please supply the part number, the quantity, and the description of each part desired. Understanding Reference Numbers Each Identified part in an illustration has a reference number. The reference number for a part also appears in the parts list, along with other information about the part. This catalog uses two special reference number formats, one to indicate parts in a service assembly and another to indicate the quantity of a given part in an illustration. Service Assembly Reference Numbers Parts in service assemblies have reference numbers in the form a:b. The a represents the reference number of the entire service assembly and the b represents a sequential number unique to each part within the service assembly. For example, a wheel assembly might be identified by reference number 6, the tire by 6:1, the valve by 6:2, and the wheel by 6:3. When you order the assembly identified by reference number 6, you receive all parts identified by reference numbers 6:1, 6:2, and 6:3. However, you may also order any part individually. Reference numbers of this type appear in illustrations and in part lists. Reference Numbers Indicating Quantity In an illustration, if a reference number indicates more than one part, the reference number has the form nx y. The n represents the quantity of the part, the X is the multiplication symbol, and the y represents the reference number. For example, in an illustration, the reference number 2X 37 means that two of the parts identified by reference number 37 are indicated. Register your product at The Toro Company All Rights Reserved

2 Contents Description Cylinder Assembly Crankshaft Assembly Cylinder Head Assembly Injection Pump Assembly Camshaft Assembly Oil Pan Assembly Part Description Abbreviations Part descriptions in this catalog may include the following abbreviations. AR as required ASM assembly BBC blade brake clutch CARR carriage CCW counter clock wise CW clockwise DEG degrees ECM electronic control module EXT external FH flat head GA gauge HD heavy-duty HF hex flange HH hex head HHF hex head flange HHFTF hex head flange thread forming HJ hex jam HLH hex lag head HOC height-of-cut HSBH hex socket button head HSFH hex socket flat head HSH hex socket head HWH hex washer head Footnotes Not serviced separately Page Description Gear Cover Assembly Gear Housing Assembly Water Pump Assembly Manifold Assembly Starter Motor and Alternator Assembly Engine Gasket Set HWHTF hex washer head thread forming HYD hydraulic LH left hand NI nylon insert NPTF national pipe thread fine PFH phillips flat head PPH phillips pan head PPHTF phillips pan head thread forming PRH phillips round head PTH phillips truss head PTO power-take-off RH right hand ROPS roll-over protection system SFH slotted fillister head SHH slotted hex head SHWH slotted hex washer head SPH slotted pan head SQH square head SRH slotted round head STD standard TAP self tapping TTH torx truss head Page

3 Rev A Cylinder ASM (9Mm Head Bolts) Seal-Oil (PTO Side) Backing Plate ASM Plate-Shield, End Nut-Hex, Metric (Water Plate Seal) Screw (Water Plate Seal) Stud (Water Plate Seal) Plug-Welch 127A Plug-Welch (Cam) Screw-Hex (Crankshaft Bearing Cap) Screw-Hex (Back Plate) Screw-Hex (Seal Retainer) Bushing Pin-Locating 718A Pin-Locating 718B Pin-Locating Retainer-Seal Stud-Metric 818A Stud-Standard Label Kit Filter-Oil Adapter-Filter, Oil Cylinder Assembly Manual-Owners Nozzle-Oil Gasket-Retainer Nut-Hex 3

4 Rev A Crankshaft Bearing-Ball, Radial Flywheel ASM Piston ASM Piston ASM (Oversize) Ring Set Ring Set (.010 Oversized) Lock-Pin, Piston Rod-Connecting Screw Shim-Endplay Shim-Endplay (.005 Oversized) Nut-Hex Screw-Hex 718C Pin-Locating 718D Pin-Locating Gear-Drive Shaft-Gear Screw-Hex Screw-Hex Plate-Gear, Idler Pulley-Crankshaft Rod Bearing Set 1076A Rod Bearing Set 4 Crankshaft Assembly 1076A Rod Bearing Set (.010 Undersized) Main Bearing Set (Set Of 8) Main Bearing Set (.010 Undersized) Disc-Clutch Plate-Pressure, Clutch

5 Rev A Cylinder Head Assembly Head-Cylinder Gasket-Head, Cylinder Tube-Breather Screw-Metric (Cylinder Head) Cap-Fill, Oil Plug-Welch 127B Plug-Welch Stud-Metric (Exhaust Manifold) 151A Stud-Metric (Exhaust Manifold) Washer-Seal (Rocker Cover) Stud-Metric (Water Pump) Retainer (Valve Guide Bushing) Screw-Hex (Lifting Bracket) Nut-Hex, Metric (Rocker Cover) Stud (Rocker Cover) Bushing-Guide Gasket-Cover, Rocker Cover-Rocker Emission Label Kit Bracket-Lifting 1077A Bracket-Lifting Stud-Metric (Intake Manifold ) 5

6 Rev A Clamp-Casing Screw-Metric (Casing Clamp) Screw-Hex (Support Bracket) Gear-Drive Clamp Bracket-Support Clamp-Swivel Hose / Clamp ASM Plug-Glow Strap-Plug, Glow Injection Nozzle Seat-Injector 1108A Seat-Injector Pipe-Injector, No A Pipe-Injector, No B Pipe-Injector, No Pump-Injection Pipe-Return, Fuel O-Ring (Injection Pump Shaft) Nut-Hex, Metric (Injection Pump Shaft) 1164A Nut-Hex, Metric (Injection Pump) Nut (Injector Nozzle) Injection Pump Assembly 6

7 Rev A Camshaft Assembly Valve-Exhaust Valve-Intake Spring-Valve (Intake) Spring-Valve (Exhaust) Retainer-Valve Keeper-Valve (Set) 42A *obs* Keeper-Valve (Set Of 6) Tappet-Valve Shaft-Cam Key-Timing 154C Nut-Hex, Metric Adjuster-Arm, Rocker Washer-Spacer (Rocker Arm Shaft) Cap-Valve Screw-Metric (Rocker Arm Support) Gear-Cam Screw-Metric Seat-Spring, Valve 615A Retainer (Rocker Arm Shaft) Seal-Valve Rod-Push Arm-Rocker Shaft-Arm, Rocker Support-Arm, Rocker Spring-Shaft, Rocker Retainer-Camshaft Screw-Hex (Camshaft Retainer) Washer-Flat (Rocker Arm Support) Nut-Hex, Metric (Rocker Arm Support) 7

8 Rev A Plug-Drain, Oil Switch-Pressure, Oil 276A Washer-Seal (Oil Drain Plug) Screw-Hex (Dipstick Tube) Screw-Hex (Oil Pump Screen) Dipstick O-Ring (Dipstick) Tube-Dipstick Nut-Hex, Metric (Oil Pump Screen) Stud-Metric (Oil Pan) Nut-Hex, Metric (Oil Pan) Screen-Pump, Oil Screw-Hex (Oil Pan) Gasket-Strainer, Oil Gasket-Pan, Oil Pan-Oil (Dual Drain) Oil Pan Assembly 8

9 Rev A Seal-Oil (Magneto Side) Screw-Hex (Gear Cover To Gear Reduction Case) 85A Screw-Hex (Gear Cover To Gear Reduction Case) 85B Screw-Hex (Gear Cover To Gear Reduction Case) Gear Cover ASM Gasket-Cover, Gear 718B Pin-Locating Clamp Trigger-Ignition Nut-Hex, Metric (Gear Cover) Screw-Hex (Gear Cover To Gear Reduction Case) 1181A Screw-Phillips (Ignition Trigger) Gear Cover Assembly 9

10 Rev A Gasket-Cover, Gear 88A Gasket-Cover, Gear Reduction Housing-Gear Valve-Relief, Oil 743A Gear-Drive (Gear Housing) Stud-Metric (Gear Housing) Pump-Oil Stud-Metric (Gear Housing) Screw-Hex (Drive Gear) Screw-Hex (Gear Housing) 1191A Screw-Hex (Gear Housing) Stud-Metric (Injection Pump) Gear Housing Assembly 10

11 Rev A Thermostat Belt-Vee Switch-Temperature, Water Plug (Water Pump) 415A Plug (Outlet Housing) Gasket-Housing, Outlet Pulley-Pump Housing-Outlet Gasket-Housing, Inlet Housing-Inlet Gasket-Pump, Water Pump-Water Screw-Hex (Outlet Housing) Screw-Hex (Water Pump) Nut-Hex, Metric (Water Pump) Screw-Hex (Inlet Housing) Screw-Metric (Thermostat) Water Pump Assembly 11

12 Rev A Manifold-Intake Gasket-Intake Screw-Hex (Intake Manifold) 54A Screw-Hex (Intake Manifold) Stud-Manifold, Exhaust Manifold-Exhaust Gasket-Exhaust Nut-Hex, Metric (Intake Manifold) Nut-Hex, Metric (Exhaust Manifold) 1176A Nut-Hex (Muffler) Manifold Assembly 12

13 Rev A Starter Motor and Alternator Assembly Motor-Starter Nut-Hex, Metric (Starter Motor) Alternator-60Amp Strap-Adjusting Screw-Hex (Support Bracket) Timer-Glow Plug Bracket-Support Screw-Hex (Starter Motor) Screw-Hex, Metric (Alternator) Screw-Hex (Adjusting Strap) 1150A Screw-Hex, Metric (Alternator) Nut-Hex, Metric (Starting Switch) 13

14 Rev A Seal-Oil (Magneto Side) Gasket-Head, Cylinder Seal-Oil (PTO Side) Gasket-Intake Gasket-Cover, Gear 88A Gasket-Cover, Gear Reduction Washer-Seal (Rocker Cover) 276A Washer-Seal (Oil Drain Plug) Gasket Kit Seal-Valve Gasket-Exhaust (Exhaust Manifold) Gasket-Cover, Rocker Gasket-Strainer, Oil Gasket-Housing, Outlet Gasket-Housing, Inlet Gasket-Pump, Water Gasket-Pan, Oil Gasket-Retainer Valve Overhaul Kit Engine Gasket Set 14

15 NOTES

16

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