Form No.
Revision History Revision Date -- 2013 A 02/2018 Updated Electrical, Chassis and Electrical Drawings chapters. Added revision history. B 03/2019 Updated Chassis chapter. C 04/2020 Updated Electrical, Chassis and Electrical Drawings chapters. © THE TORO COMPANY 2020 Description Initial Issue. This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies).
Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.
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Part No. 13200SL (Rev. C) Service Manual WorkmanR MDX--D 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 MDX--D. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts Catalog for your machine into Chapter 2 of this service manual.
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Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2 Jacking and Other Instructions . . . . . . . . . . . . . . . 1 -- 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 6 General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 5 Electrical System Quick Checks . . . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Supervisor’s Responsibilities . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING AND OTHER INSTRUCTIONS . . . . . . . . Jack Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Transport Vehicle . . . .
Safety Instructions Workman MDX--D vehicles are designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
1. Sit on the operator seat when starting and operating the vehicle. 2. Before starting the engine: A. Sit on operator’s seat and depress the brake pedal. Make sure that the parking brake is released. 4. Do not touch engine, radiator, exhaust system or transaxle while engine is running or soon after it is stopped. These areas could be hot enough to cause burns. 5. Before getting off the seat: A. Stop movement of the vehicle. B. Turn ignition switch to the ON position.
Jacking and Other Instructions Jack Vehicle DANGER 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.
When performing routine maintenance and/or engine testing, the transaxle must be shifted into the neutral position. Safety Transaxle Neutral Position 2 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 2. Move shift lever to the neutral position (Fig. 3). 1 3. Make sure transaxle is in the neutral position by rotating the driven clutch. The tires should not rotate when the transaxle is in the neutral position.
Safety and Instruction Decals Numerous safety and instruction decals are affixed 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.
Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
Equivalents and Conversions 0.
Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and specified in this Service Manual. These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Service Manual.
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC Grade 1, 5 & 8 with Thin Height Nuts SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series) Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
Chapter 3 Diesel Engine Table of Contents Workman MDX--D Page 3 -- 1 Diesel Engine SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Adjust Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . 5 SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Make / Designation Kubota water--cooled, Diesel, Model Z602--E3B Number of Cylinders 2 Bore x Stroke 2.83” x 2.9” (72mm x 73.6mm) Total Displacement 36.55 in3 (599 cc) Compression Ratio 24.
General Information This Chapter gives information about specifications, maintenance, troubleshooting, testing and repair of the diesel engine used in the Workman MDX--D. of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility. Most repairs and adjustments require tools which are commonly available in many service shops. Special tools are described in the Kubota Workshop Manual, Diesel Engine, SM--E3B Series.
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Adjustments Adjust Throttle Cable Proper throttle operation is dependent upon proper adjustment of throttle control. Make sure throttle control is operating properly. NOTE: The shoulder bolt that secures the throttle cable to the engine speed control lever should be positioned in the lowest hole in the lever. 3 2. Check position of the engine speed control lever on the fuel injection pump (Fig. 1). The speed control lever should contact the high speed screw when the throttle pedal is fully depressed. 3.
Service and Repairs Air Cleaner 8 9 10 5 7 3 1 2 11 4 6 FRONT RIGHT Figure 3 1. 2. 3. 4. Air cleaner assembly Carriage screw (2 used) Air intake hose Air cleaner mounting bracket Diesel Engine 5. 6. 7. 8. Air inlet hood Flange nut (2 used) Hose clamp (2 used) Throttle cable Page 3 -- 6 9. Shoulder bolt 10. Throttle cable mount 11.
Air Cleaner Removal (Fig. 3) 1. Park machine on a level surface, stop the engine, engage parking brake and remove the key from the ignition switch. 1 2 5 2. Raise and support cargo bed to access air cleaner. 6 3. Remove air cleaner components as needed using Figure 3 as a guide. 3 30 in--lb (3.4 N--m) 4. Check air cleaner hose (item 3 in Fig. 3) for damage or wear. Replace hose if damage is found. 5. Disassemble air cleaner as necessary (Fig. 4). 4 6.
Exhaust System RIGHT FRONT 1 5 4 4 7 3 9 3 6 2 8 Figure 6 1. Engine 2. Exhaust header 3. Coupler spring (2 used) Diesel Engine 4. Flange nut (4 used) 5. Muffler 6. Hex nut (4 used) Page 3 -- 8 7. Exhaust gasket 8. Flange head screw (4 used) 9.
Exhaust System Removal (Fig. 6) Exhaust System Installation (Fig. 6) 1. Park machine on a level surface, stop the engine, engage parking brake and remove the key from the ignition switch. 1. Make sure the engine is off. 2. Raise and support cargo bed to access exhaust system. IMPORTANT: If exhaust studs were removed from engine cylinder head, thoroughly clean threads in head and apply Loctite #277 (or equivalent) to stud threads before installing studs into head.
Fuel Tank RIGHT 1 FRONT 9 10 5 3 4 2 6 8 7 Figure 7 1. 2. 3. 4. Seat Fuel tank Fuel hose (to fuel separator) Fuel hose (return from engine) Diesel Engine 5. Seat base 6. Web strapping 7. Hex head flange screw (8 used) Page 3 -- 10 8. Flat washer (8 used) 9. Parking brake support 10.
Fuel Tank Removal (Fig. 7) 17 12 CAUTION 16 Read safety precautions for handling fuel before working on the fuel system (see Safety Instructions in Chapter 1 -- Safety). 8 11 3 12 6 15 1. Remove seat base from the frame (see Seat Base in the Service and Repairs section of Chapter 6 -- Chassis). 10 7 14 5 9 11 12 13 4 2. Use fuel transfer pump to remove fuel from fuel tank. 2 4. Loosen hose clamp and disconnect fuel supply hose (item 17 in Figure 8) from the fuel pump. 5.
Radiator 2 15 16 1 23 13 22 21 23 12 4 7 14 20 3 20 12 19 9 13 10 6 23 18 5 14 17 19 RIGHT 11 12 12 8 12 5 FRONT Figure 9 1. 2. 3. 4. 5. 6. 7. 8. Surge tank Tank cap Radiator Washer head screw (2 used) Flange nut (3 used) Cap Cap decal Filler neck 9. 10. 11. 12. 13. 14. 15. 16.
5. Drain radiator into a suitable container by disconnecting lower radiator hose from the radiator. 6. Disconnect upper radiator hose from the radiator. 7. Disconnect the coolant hose (item 22) from the fitting located on the lower radiator tube. 8. Remove four (4) washer head screws (item 20) and three (3) flange nuts (item 14) that secure the radiator shrouds. Also, disconnect wire harness clips from upper radiator shroud. Carefully remove upper radiator shroud from vehicle. 9.
Engine 17 1 11 2 9 3 10 8 7 4 6 7 16 15 5 RIGHT 14 FRONT 12 13 Figure 12 1. 2. 3. 4. 5. 6. Engine Engine wire harness connector Hex nut Negative battery cable Engine wire harness connector Lock washer Diesel Engine 7. 8. 9. 10. 11. 12. Flange head screw (8 used) Hex nut (4 used) Lock washer (4 used) Exhaust header Flange nut (4 used) Cap screw (4 used) Page 3 -- 14 13. 14. 15. 16. 17.
Engine Removal (Fig. 12) 2 1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch. 1 3 CAUTION 5 The engine, radiator and exhaust system may be hot. To avoid possible injury, allow machine to cool before working on the engine. 2. Disconnect negative (black) cable from the battery. Then, disconnect positive (red) cable from the battery. 4. Carefully remove drive belt from drive clutch. Figure 13 1. Diesel engine 2. Throttle cable 3.
11. Disconnect electrical connections from the following engine components: 2 1 A. Disconnect main wire harness connections to glow plug bus, temperature sender and engine run solenoid (Fig. 14). 4 B. Disconnect main wire harness connection to fusible link harness. C. Disconnect engine wire harness connector from the main wire harness. The engine wire harness includes connectors for the alternator, oil pressure switch, starter solenoid and engine ground. D.
A. Connect main wire harness connections to glow plug bus, temperature sender and engine run solenoid (Fig. 14). B. Connect main wire harness connection to fusible link harness. C. Connect engine wire harness connector to the main wire harness. D. Secure negative battery cable and engine ground connector to front engine mount with flange head screw. The order of assembly should be lock washer, negative battery cable, engine ground connector and then flange head screw.
Engine Clutch Adapter 7 1 6 17 to 22 ft--lb (23 to 29 N--m) Loctite #242 3 5 2 RIGHT FRONT 4 Figure 17 1. Drive belt 2. Cap screw 3. Flange washer 4. Drive clutch 5. Cap screw (5 used) 6. Clutch adapter 7. Engine assembly Removal (Fig. 17) Installation (Fig. 17) 1. Park machine on a level surface, stop the engine, engage parking brake and remove the key from the ignition switch. 1. Position clutch adapter to engine flywheel and secure with five (5) cap screws. 2.
Chapter 4 Drive Train Table of Contents Workman MDX--D Page 4 -- 1 Drive Train SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3 DRIVE TRAIN OPERATION . . . . . . . . . . . . . . . . . . . . 4 Clutch System Operation . . . . . . . . . . . . . . . . . . . . . 4 Drive Clutch Operation . . . . . . . . . . . . . . . . . . . . . . .
Specifications Item Description Transaxle Transaxle Fluid Capacity Transaxle Fluid Transaxle Dry Weight 1.5 quarts (1.
General Information Operator’s Manual Drive Train The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman MDX--D vehicle. Refer to the Operator’s Manual for additional information when servicing the machine.
Drive Train Operation Clutch System Operation FULL ENGINE SPEED DECREASING LOAD 1 LOW ENGINE SPEED LIGHT LOAD FULL ENGINE SPEED INCREASING LOAD 4 3 v 6 7 8 2 5 Figure 1 1. Drive clutch 2. Driven clutch 3. Moveable sheave (drive clutch) 4. Fixed sheave (drive clutch) 5. Moveable sheave (driven clutch) 6. Spring Power is transferred from the engine to the transaxle by a variable clutch system that consists of two (2) clutches connected by a drive belt.
Drive Clutch Operation The operation of the drive clutch is affected by engine shaft speed. With the engine not turning, the CVT drive belt rests low within the drive clutch sheaves as the pressure of the spring holds the sheaves apart. As the engine increases in speed, the clutch weights attached to the moveable sheave move outward as they spin about the engine driveshaft.
Driven Clutch Operation The operation of the driven clutch is affected by transaxle load. When the vehicle is stopped, the drive belt is held at the outer diameter of the driven clutch sheaves from the pressure of the spring pushing the moveable sheave against the fixed sheave and away from the fixed cam. 2 3 Once the drive belt starts rotating, the driven clutch also starts to rotate.
Special Tools Order special tools from your Toro Distributor. Drive Clutch Removal Tool 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 retaining screw is removed.
Troubleshooting Clutch Problem Possible Cause Poor upshifting. Governed engine speed is adjusted too low. Drive and/or driven clutch assemblies have accumulation of dirt or debris. Drive belt is worn. Clutch sheaves are worn or damaged. Poor downshifting. Drive and/or driven clutch assembly has accumulation of dirt or debris. Drive belt is worn. Clutch sheaves are worn or damaged. Vehicle creeps at idle. Engine idle speed is too high.
Adjustments Adjust Shift Cables 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. Raise and support cargo box. 2 2. Set the shift lever into the Neutral position. Rotate driven clutch to insure transmission is in neutral. 2 1 3. The transaxle select lever assembly should be in a level position and parallel to the cable mounting bracket. 4. While holding the cable below the lever, tighten the lock nut on one of the shift cables to allow 0.
Service and Repairs Drive Clutch 1 4 5 2 v Loctite #242 3 RIGHT 6 17 to 22 ft--lb (23 to 29 N--m) FRONT 7 Figure 7 1. Engine 2. Clutch adapter 3. Cap screw (5 used) Drive Train 4. Drive belt 5. Drive clutch Page 4 -- 10 6. Flange washer 7.
Drive Clutch Removal (Fig. 7) Drive Clutch Installation (Fig. 7) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. Raise and support cargo box. 1. Thoroughly clean the tapered surfaces of the clutch adapter and drive clutch. 2. Carefully remove drive belt from the drive clutch. 3. Remove cap screw (item 7) and flange washer (item 6) securing the drive clutch to the clutch adapter.
Drive Clutch Service 11 105 to 120 in--lb (12 to 13.5 N--m) 7 9 v 8 4 2 1 6 10 40 to 50 in--lb (4.6 to 5.6 N--m) 5 3 Figure 8 1. 2. 3. 4. Flange head screw (6 used) Cover Compression spring Limiter shim 5. 6. 7. 8. Shoulder screw (3 used) Lock nut (3 used) Clutch weight (3 used) Spider 9. Shim 10. Moveable sheave 11. Fixed sheave Disassembly (Fig. 8) IMPORTANT: Make note of the “X” mark cast into the cover and spider before clutch disassembly.
5. Slide shoulder screw from each of the clutch weights (item 7) and then remove weights from clutch. 6. Clean all dust and debris from clutch components with a soft bristle brush. If necessary, use water to remove dirt and dry immediately with compressed air to remove all dirt and water. Remove any remaining debris with a fast drying contact or brake parts cleaner. Focus debris removal on and around moving clutch components. 3. Position limiter shim, compression spring and cover to clutch.
Driven Clutch Driven Clutch Removal (Fig. 13) 3 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. Raise and support cargo box. 2 4 2. Remove muffler from the vehicle (see Exhaust System in the Service and Repairs section of Chapter 3 -Diesel Engine). 3. Carefully remove drive belt from the driven clutch. 4. Remove cap screw and stepped washer securing the driven clutch to the input shaft of the transaxle. 1 5.
Driven Clutch Service 1. Use a suitable press to compress the clutch spring enough to allow removal of the retaining ring. 2 3 2. Remove retaining ring. 3. Carefully, allow the spring to extend fully. 4 4. Remove outer spring retainer, spring and inner spring retainer from clutch. 6 5. Make note of the “X” mark cast into the fixed sheave and moveable sheave before removing the moveable sheave. These marks must be aligned during assembly for proper clutch operation. 1 5 6.
Transaxle 13 Loctite #242 39 to 47 ft--lb (53 to 63 N--m) Antiseize Lubricant Antiseize Lubricant 2 7 6 17 14 Loctite #242 12 8 1 15 18 120 ft--lb (162 N--m) 27 23 5 24 7 10 20 3 4 28 9 v 26 25 19 21 Antiseize Lubricant 16 11 RIGHT 80 to 90 ft--lb (109 to 122 N--m) FRONT 29 22 Figure 15 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Removal (Fig. 15) 7. Support the transaxle to prevent it from shifting. 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 8. Remove four (4) cap screws (item 10) and flat washers (item 5) that secure the transaxle to the swing arm. 2. Raise and support cargo box. IMPORTANT: Take care to not damage the transaxle, brake hoses, electrical harness, cables or other parts while lowering the transaxle assembly from the vehicle. 4.
B. Slide select lever with attached shift cables onto transaxle selector shaft. Installation (Fig. 15) 1. Position transaxle assembly under the vehicle swing arm. C. Apply Loctite #242 (or equivalent) to threads of lock nut (item 18). Secure select lever assembly to the selector shaft with flat washer (item 15) and lock nut (item 18). CAUTION D. Secure both shift cables to the cable bracket with jam nuts.
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Transaxle Service 16 55 52 57 55 25 to 31 ft--lb (34 to 42 N--m) 50 35 29 17 53 56 3 4 5 13 9 18 11 10 8 6 2 58 26 1 39 47 38 24 20 12 38 15 26 27 40 28 41 7 30 40 to 45 ft--lb (54 to 61 N--m) 43 46 42 45 44 31 32 48 33 49 34 42 33 37 59 43 21 23 22 25 36 7 12 19 51 11 59 14 57 17 16 25 to 31 ft--lb (34 to 42 N--m) 35 56 10 9 15 55 8 54 55 52 Figure 18 Drive Train Page 4 -- 20 Workman MDX--D
Figure 18 (Continued) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. Case (LH) Oil seal Oil seal Snap ring Spacer Selector shaft Oil seal (2 used) Flange bolt (4 used) Oil check plug (2 used) Gasket (2 used) Oil drain plug (2 used) Gasket (2 used) Oil filler plug Case (RH) Axle bracket (2 used) Collar (2 used) Flange bolt (4 used) Flange bolt (6 used) Gasket Input shaft 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40.
2 1 Figure 20 1. Bolt (steel ball, spring & gasket) 2. Selector shaft C. Remove bolt near the selector shaft. Remove spring and steel ball. Replace gasket if damaged. 2 1 Figure 21 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.
1 3 2 Figure 22 1. Flange bolts (3 used) 2. Axle bracket 3. Axle case Drive Train E. Remove three (3) flange bolts securing the axle bracket and axle case to each case. Separate bracket from each axle case. 2 1 Figure 23 1. Flange bolt (10 used) 2. Flange nut F. With the input shaft side down, loosen and remove flange bolts and nuts securing the case (RH) and case (LH) together. Note location of cable bracket for assembly purposes.
1 2 Figure 24 1. Case (RH) 2. Governor boss G. Hold the case (RH) and lift up while lightly tapping the governor boss with a plastic hammer. IMPORTANT: Make sure to not hit the governor boss too hard when separating the cases, the boss may get damaged. Do not pry open the two cases with a screw driver, damage may result to the sealing surfaces. 2. Remove input shaft, center shaft and differential assemblies. 2 1 Figure 25 1. Gasket 2. Pipe knock A. Remove gasket and pipe knocks.
4 1 3 2 Figure 26 1. Counter shaft 2. Spacer (2 used) 3. Needle bearing 4. Gear 34 Drive Train B. Pull out counter shaft. Remove spacer, needle bearing, gear 34 and spacer. 3 2 2 1 4 Figure 27 1. Counter shaft 2. Spacer (2 used) 3. Needle bearing 4. Gear 34 C. Replace counter shaft if it has abnormal wear, cracks or damage. E. Replace needle bearing if needles are bent, do not rotate freely or do not remain in the bearing cage. D. Replace spacer if either one is cracked or bent. F.
4 1 3 2 Figure 28 1. Differential assembly 2. Input shaft assembly 3. Center shaft assembly 4. Shift shaft G. Lift up differential assembly, center shaft assembly and input shaft assembly at the same time. First, remove input shaft assembly. Then, remove center shaft assembly with the shift shaft and differential assembly. IMPORTANT: Make sure to not damage the oil seal when removing the input shaft.
2 4 3 1 Figure 30 3. Axle shaft 4. Ball bearing C. Ball bearing roller balls must be free of deformation and scoring. Ball bearing must spin freely and have minimum axial play. Replace ball bearing as necessary. 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. 1 2 Figure 31 1.
1 2 Figure 32 1. Input shaft 2. Ball bearing B. Replace input shaft if worn or damaged. Gear teeth that are cracked, broken, chipped or missing are not acceptable. C. Ball bearing roller balls must be free of deformation and scoring. Ball bearing must spin freely and have minimum axial play. Replace ball bearing as necessary. 5. Disassemble center shaft assembly. 1 2 Figure 33 1. Ball bearing 2. Ball bearing IMPORTANT: Do not reuse ball bearings that have been removed.
5 3 8 8 2 7 4 Gear 55 Gear 47 Gear (small) Ball bearing Ball bearing Figure 34 6. 7. 8. 9. B. Remove gears, pin clutch, collars and spacer from the input shaft. C. Replace gears if worn or damaged. Cracked, broken, missing or chipped gear teeth are not acceptable. Workman MDX--D Pin clutch Center shaft Collar (2 used) Spacer D. Replace center shaft if worn or damaged. Splines that are cracked, broken, chipped or missing are not acceptable. E. Replace pin clutch if cracked or bent. F.
6. Disassemble differential case assembly. 1 2 3 Figure 35 1. Bolt (6 used) 2. Gear 62 3. Differential case A. Remove six (6) bolts securing gear 62 to the differential case. 4 3 4 1 2 Figure 36 1. Spring pin 2. Differential case 3. Pinion shaft 4. Pinion gear NOTE: The spring pin can be punched out from the hole on the opposite side of gear 62. C. Remove pinion shaft and gears from the case. Separate gears from shaft. B. Remove spring pin from the differential case.
5 4 3 6 2 8 1 7 Figure 37 Side gear (2 used) Pinion gear (2 used) Gear 34 Ball bearing 5. 6. 7. 8. Differential case Pinion shaft Spring pin Bolt (6 used) D. Replace gears if worn or damaged. Cracked, broken, missing or chipped gear teeth are not acceptable. 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. E. Ball bearing roller balls must be free of deformation and scoring.
Transaxle Assembly 1. Assemble input shaft assembly. 1 2 Figure 38 1. Ball bearing 2. Input shaft IMPORTANT: Make sure to press ball bearing at the inner race to prevent damaging the ball bearing. A. Press ball bearing onto the input shaft.
2. Assemble the center shaft assembly. 3 4 7 1 8 6 9 5 5 2 5.386” to 5.398” (136.8 to 137.1 mm) 6. 7. 8. 9. Pin clutch Center shaft Gear 47 Gear 55 Collar NOTE: Before assembling, apply molybdenum disulfide grease to the inside of gears 47 and 55. Drive Train Figure 39 1. 2. 3. 4. 5. Gear (small) Bearing Bearing Spacer A. Slide pin clutch onto the centershaft. Install gears 47 and 55 onto shaft noting correct orientation of gears. Slide collars, small gear and spacer onto the center shaft.
Figure 41 D. The center shaft should appear as above when assembled. 3. Assemble differential assembly. 5 6 2 1 4 8 9 3 3 7 1 4.854” to 4.882” (123.3 to 124.0 mm) Figure 42 1. 2. 3. 4. 5. Pinion gear (greased surface) Pinion shaft Side gear (greased surface) Differential case Gear 62 6. 7. 8. 9. Bolt Spring pin Ball bearing Ball bearing A. Apply molybdenum disulfide grease to the inside of both pinion gears where they contact the pinion shaft.
1 4 3 2 Figure 43 1. Side gear 2. Pinion gear 3. Pinion shaft 4. Differential case 3 Drive Train B. Install side gear, both pinion gears and pinion shaft into the differential case. 1 2 Figure 44 1. Spring pin 2. Differential case 3. Pinion shaft C. Align pinion shaft hole and install new spring pin through the differential case and pinion shaft.
3 1 2 4 Figure 45 1. Side gear 2. Pinion gear 3. Gear 62 4. Differential case D. Install remaining side gear to the pinion gears. E. Secure gear 62 to the differential case with six (6) bolts. Torque bolts in a crossing pattern from 40 to 45 ft--lb (54 to 61 N--m). 40 to 45 ft--lb (54 to 61 N--m) Figure 46 IMPORTANT: The length from the outer most side of each ball bearing must be from 4.854” to 4.882” (123.3 to 124.0 mm) (Fig. 42). G.
4. Install axle case to case (RH and LH). 2 3 1 Figure 47 3. Ball bearing A. Insert axle shaft with snap rings, collar and ball bearings into the axle case. Install snap ring to the axle case. IMPORTANT: Do not reuse snap ring. Replace snap ring with new one. 3 1 25 to 31 ft--lb (34 to 42 N--m) 2 Figure 48 1. Axle case 2. Case 3. Flange bolt IMPORTANT: Make sure to install the axle case to the proper side of the case.
5. Install input shaft, center shaft and differential assemblies to the case. 2 1 Figure 49 1. Shift shaft 2. Clutch groove A. Insert fork of the shift shaft to the clutch groove of the center shaft assembly. 3 1 2 4 Figure 50 1. Center shaft assembly 2. Shift shaft 3. Input 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.
1 2 Figure 51 1. Fork (selector shaft) 2. Pin (shift shaft) Drive Train D. Make sure the selector shaft fork is contacting the pin on the shift shaft. 1 2 Figure 52 1. Spacer 2. Boss (counter shaft) E. Place spacer on the counter shaft boss of the case (LH) so the oil groove faces up.
2 3 1 Figure 53 1. Gear 34 2. Counter shaft 3. Spacer F. Apply molybdenum disulfide grease to the inside of gear 34 and the contact surface between the case and the counter shaft. G. Place gear 34 onto the spacer. Make sure not to drop the spacer. Insert needle bearing into gear. Insert counter shaft with remaining spacer through the needle bearing, gear 34 and into the spacer and case. 6. Assemble case (LH and RH). 1 2 Figure 54 1. Case (sealing surface) 2. Pipe knock A.
1 2 15 to 18 ft--lb (21 to 25 N--m) Figure 55 1. Cable bracket 2. Flange bolt D. Position cable bracket to transaxle cases. E. Secure case (RH) to case (LH) with flange bolts and nuts. Torque bolts from 15 to 18 ft--lb (21 to 25 N--m). C. Install case (RH) so each shaft fits properly into the case. 25 to 31 ft--lb (34 to 42 N--m) 2 1 Figure 56 1. Axle bracket 2. Flange bolt F. Position axle bracket to each axle case. Secure axle bracket to each axle case with flange bolts.
12 to 15 ft--lb (16 to 20 N--m) 2 1 Figure 57 1. Cable bracket 2. Bolt (steel ball, spring & gasket) G. Install steel ball, spring, gasket and bolt. Torque bolt from 12 to 15 ft--lb (16 to 20 N--m). Drive Train Page 4 -- 42 H. Fill transaxle with 1.5 quarts (1.4 liters) of new SAE 10W--30 motor oil.
Chapter 5 Electrical System Table of Contents Workman MDX−D SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Inspection and Maintenance . . . . . . . . Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Charging . . . . . . . . . . . . . . . . . . . .
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Operator’s Manual for additional information when servicing the machine. Electrical Drawings The electrical schematic and other electrical drawings for the Workman MDX−D are located in Chapter 7 − Electrical Drawings.
Special Tools Order special tools from your Toro Distributor. 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 meter in the voltage mode will make sure that excess current is not allowed through the meter.
Dielectric Lubricant/Sealant Dielectric lubricant should be used to prevent corrosion of non−sealed connection terminals. To ensure complete coating of terminals, liberally apply lubricant to both component and wire harness connector, plug connector to component, unplug connector, reapply lubricant to both surfaces and reconnect harness connector to component. Connectors should be thoroughly packed with lubricant for effective results.
Troubleshooting For effective troubleshooting and repairs, you must have a good understanding of the electrical circuits and components used on this vehicle (see electrical drawings in Chapter 7 − Electrical Drawings). CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.
Starting Problems (Continued) Problem Possible Causes Engine cranks, but does not start. Fuel tank is empty. Wiring to start circuits is loose, corroded or damaged (see electrical drawings in Chapter 7 − Electrical Drawings). Engine or fuel system is malfunctioning (see Chapter 3 − Diesel Engine). 15 ampere fuse in fuse block is faulty. Fuel pump or circuit wiring is faulty. Glow plugs, glow relay or glow plug controller are faulty. Wire harness fusible link to run solenoid pull coil is faulty.
Electrical System Quick Checks Battery Test Use a multimeter to measure the voltage between the battery terminals. Voltage Measured Battery Charge Level 12.68 V (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery should be at a temperature of 60o to 100o F (16o to 38o C). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (−) meter lead to the negative battery post. 12.
Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check on the switch). NOTE: See the Kubota Workshop Manual, Diesel Engine, SM−E3B Series for engine component testing information. CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.
Indicator Lights Charge Indicator Light 3 2 The charge indicator light should come on when the ignition switch is in the ON position with the engine not running. Also, it should illuminate with an improperly operating charging circuit while the engine is running. Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not running.
Fuse Blocks The fuse block on Workman MDX−D vehicles is located beneath the dash panel. 3 In addition to the fuses in the fuse block, an in−line 10 amp fuse is included in the wire harness. This fuse protects the ignition switch circuits and also provides protection for the optional brake and signal light kit. The in−line fuse resides in a fuse holder under the dash panel near the fuse blocks (Fig. 11).
Fusible Links The Workman MDX−D uses four (4) fusible links for circuit protection. Three (3) of these fusible links are included in a wire harness that connects the starter B+ terminal to the vehicle wire harness (Fig. 12). The remaining fusible link is included in the engine wire harness and connects the starter G terminal to the engine run solenoid pull coil. If any of these links should fail, current to the protected circuit will cease.
Hour Meter Testing IMPORTANT: Make sure to observe polarity on the hour meter terminals when testing. Damage to the meter may result from an improper connection. QUARTZ 1. Unplug wire harness connector from hour meter. 00000 RUNNING: INDICATOR WINDOW 1 − 10 HOURS 2. Connect positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter. 1/10 WHEEL: WHITE W/BLACK NUMBERS HOUR WHEELS: BLACK W/WHITE NUMBERS 3.
Brake Switch The brake switch is a normally closed switch that opens when the brake pedal is not applied. When the brake pedal is applied, the brake pedal moves away from the switch plunger to allow the switch to be in its normally closed state. The brake switch is attached to the pedal support frame under the dash panel (Fig. 16). 1 Testing 1. Park vehicle on a level surface, stop engine, apply parking brake and remove key from ignition switch. 2 2. Locate brake switch for testing.
Main Power and Glow Relays The Workman MDX−D main and glow relays are attached to the front of the dash bracket and can be accessed by raising the hood (Fig. 17). The vehicle wire harness is attached to the main and glow relays with four (4) wire connectors. Relays can be identified by a tag on the wire harness. The main power relay is used to provide current to the fuse blocks. When the ignition switch is in the ON or START position, the main power relay is energized.
Start Relay The Workman MDX−D start relay provides electrical current to the engine starter solenoid when energized. The relay is energized when the ignition switch is in the START position and the brake pedal is depressed (brake switch closed). The start relay is attached to the front of the dash bracket and can be accessed by raising the hood (Fig. 19). The vehicle wire harness is attached to the start relay with a five (5) wire connector. The relay can be identified by a tag on the wire harness.
Glow Plug Controller The glow plug controller is attached to the front of the dash bracket and can be accessed by raising the hood (Fig. 21). 5. If any of the conditions in Step 3 are not met or electrical power to controller terminal 1 exists and any of the other conditions in Step 4 are not met: NOTE: When troubleshooting the glow controller, refer to electrical drawings in Chapter 7 − Electrical Drawings. A.
Engine Run Solenoid The engine run solenoid used on Workman MDX−D vehicles must be energized for the diesel engine to run. The run solenoid is mounted to the injection pump on the engine (Fig. 23). The run solenoid is energized when the ignition switch is in either the ON or START position. 1 The engine run solenoid includes two (2) coils for operation: the pull coil and the hold coil. When the ignition switch is turned to START, the fuel solenoid pull coil is energized and the solenoid plunger retracts.
Over Temperature Switch The over temperature switch is located on the engine thermostat housing near the alternator (Fig. 24). If the engine coolant temperature reaches 230oF (110oC) (approximate), the over temperature switch closes which causes the dash panel engine temperature light to come on. The over temperature switch has a gray wire connected to it. 2 1 Switch Testing CAUTION Make sure engine is cool before removing the temperature switch. 1.
Fuel Pump The MDX−D fuel pump is secured in a cavity in the top of the fuel tank (Fig. 26). Electrical current is available for the fuel pump when the ignition switch is in either the ON or START position. IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel. 9. Install fuel hose to the fuel/water separator. Make sure to secure fuel hose with hose clamp. 10.Connect wire harness electrical connector to the engine run solenoid. 11. Bleed the fuel system. 12.
Oil Pressure Switch The engine oil pressure switch is located on the engine near the oil filter (Fig. 28). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm2). 2 Switch Testing NOTE: Refer to Kubota Workshop Manual, Diesel Engine, SM−E3B Series for information regarding engine lubrication system and testing. 1. Turn the ignition switch to the ON position.
Backup Alarm (Optional Kit) When the shift lever is placed in the reverse position, the backup alarm should sound. The alarm is attached beneath the cargo box to a bracket on the right side of the frame. 4 3 Alarm Testing 1. Park vehicle on a level surface, stop engine, apply parking brake and remove key from ignition switch. Make sure that vehicle shift lever is in the NEUTRAL position. 2. Raise and support cargo box to allow access to backup alarm. 1 2 Figure 29 1. Alarm top view 2.
Backup Switch (Optional Kit) The optional backup switch is a four (4) terminal, two (2) circuit switch that is used to energize the backup alarm when the shift lever is in the reverse position. The normally open switch circuit is used while the normally closed switch circuit is not used. If equipped, this switch is attached to the shift bracket in the seat base (Fig. 30). Switch Testing 1. Position vehicle on a level surface, set parking brake, turn ignition switch OFF and remove key from switch.
Windshield Washer/Wiper Switch (Machines with Operator Cab) The windshield washer/wiper switch controls the operation of the windshield wiper and washer pump. The switch is located in the roof console (Fig. 32). 1 2 Testing 1. Park the machine on a level surface, lower the cutting deck, set the parking brake, and shut off the engine. 2. To access the switch, do as follows: A. Remove the 10 clips, 10 sealing washers, and 10 flange−head screws that secure the roof to the cab frame, and remove the roof. B.
Diode Assembly (Model 07236) 1 2 Figure 34 1. Diode 2. Dash panel The electrical system of the MD Workman (Model 07236) includes a diode. The maximum current allowed through a diode is 6 A. The diode assembly can be identified by a black color, diode symbol, and Toro Part Number on the end of the diode assembly body (Figure 35). The diode plugs into the heater kit wire harness near the dash panel (Figure 34); refer to the Heater Kit Wire Harness Drawing/Diagram in Chapter 7−Electrical Drawings . 5.
Service and Repairs NOTE: For information on engine electrical components, see the Kubota Workshop Manual, Diesel Engine, SM−E3B Series. Battery Service WARNING 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 vehicle components and cause sparks.
Battery Inspection and Maintenance FILLER CAPS CAP TUBES WARNING 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.
1. If battery caps can be removed, conduct a hydrometer test of the battery electrolyte: C. If the battery has been charged, apply a 270 amp load for fifteen (15) seconds to remove the surface charge. Use a battery load tester following the manufacturer’s instructions. IMPORTANT: Make sure the area around the cells is clean before opening the battery caps. D. Measure the temperature of the electrolyte in the center cell. A. Measure the specific gravity of each cell with a hydrometer.
Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging method is presented here. This charging method can be accomplished with a constant current battery charger which is available in most service shops. Follow the battery charger manufacturer’s instructions when using a battery charger. NOTE: Using specific gravity of the battery cells is the most accurate method of determining battery condition. 1.
Chapter 6 Chassis Table of Contents Steering Rack Assembly Service (Serial Numbers Above 316000001) . . . . . . . . Front Shock Absorbers . . . . . . . . . . . . . . . . . . . . . A−arms and Front Suspension (Serial Numbers Below 316000001) . . . . . . . . A−arms and Front Suspension (Serial Numbers Above 316000001) . . . . . . . . Frame Pivot Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parking Brake . . . . . . . . . .
Specifications Item Description Front Tire Pressure Range (22 x 9.
General Information Operator’s Manual Chassis The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman MDX−D vehicle. Refer to the Operator’s Manual for additional information when servicing the machine.
Special Tools Order special tools from your Toro Distributor. Spanner Wrench Use spanner wrench to rotate front shock absorber collar which changes the length of the shock spring to affect front wheel camber. Make sure that vehicle is jacked up off the ground to allow shock spring to be at full extension before using spanner wrench. Toro Part Number: TOR6010 Figure 1 Shock Spring Compressor Use shock spring compressor to remove spring from front shock absorber.
Troubleshooting Suspension and Steering ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Suspension and Steering (continued) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁ
Brakes (continued) ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Adjustments Adjust Parking Brake 1. Pry the rubber cover off of the parking brake. 2. Loosen the set screw securing the knob to the parking brake lever (Fig. 3). 1 3. Rotate the knob until a force from 30 to 35 lb. (133 to 156 N) is required to actuate the lever. 2 4. Tighten the set screw and install the rubber cover. 3 Figure 3 1. Parking brake lever 2. Brake knob Chassis Page 6 − 8 3.
Adjust Front Wheel Camber 1. Adjust front tire pressures to 12 PSI (82 kPa) before checking front wheel camber. 7. Repeat steps 2 through 6 until front wheel camber on both wheels is correct. 2. Either add weight to the driver’s seat equal to the average operator who will run the machine or have an operator on the vehicle operator’s seat. The weight or operator must remain on the seat for the duration of this front wheel camber procedure. 8.
Adjust Front Wheel Toe−in NOTE: Before adjusting front wheel toe−in, make sure that front wheel camber is correctly adjusted (see Adjust Front Wheel Camber in this section). 1. Adjust front tire pressures to 12 PSI (82 kPa) before checking front wheel toe−in. 1 2. Either add weight to the driver’s seat equal to the average operator who will run the machine or have an operator on the vehicle operator’s seat.
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. Lower air pressure will provide less compaction, a smoother ride and fewer tire marks. Lower pressure should not be used for heavy payloads at higher speeds. Higher pressures should be used for heavier payloads at higher speeds. Do not exceed the maximum tire pressure.
Upper Steering (Serial Numbers Below: 316000001) 18 to 22 ft−lb (25 to 29 N−m) 1 RIGHT 2 16 FRONT 11 175 to 225 in−lb (20 to 25 N−m) 3 Antiseize Lubricant 13 10 12 10 15 5 14 8 7 9 Loctite #242 4 7 6 Antiseize Lubricant Figure 8 1. 2. 3. 4. 5. 6. Hex nut Flat washer Steering wheel Flange nut (4 used) Steering box assembly Cap screw 7. 8. 9. 10. 11. Lock washer (6 used) Steering shaft Cap screw (4 used) Bearing (2 used) Carriage bolt (4 used) Disassembly (Fig. 8) 1.
5. Support steering column to prevent it from falling. Remove four (4) flange nuts and carriage screws securing the steering column to the mounting plate on the frame. 6. Remove dust cover (item 13) 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 in this section). 8.
Steering Gearbox (Serial Numbers Below: 316000001) 27 to 33 ft−lb (37 to 44 N−m) 9 90 to 110 in−lb (10.2 to 12.4 N−m) 8 3 6 2 18 17 10 15 16 7 14 1 6 11 10 175 to 225 in−lb (20 to 25 N−m) 5 12 4 13 19 Align marks during assembly Figure 10 1. 2. 3. 4. 5. 6. 7. Gasket Hex washer head screw (3 used) Seal Sector gear Flat washer Ball bearing Output shaft spacer Chassis 8. 9. 10. 11. 12. 13.
IMPORTANT: Do not reuse flange head screws with patch lock (items 9 and 13) after they have been removed. 1. Remove flange head screw with patch lock (item 9) and stepped washer (item 8) from Pitman arm. Discard flange head screw. 2. Remove flange head screw with patch lock (item 13) and flat washer (item 12) from pinion gear shaft. Discard flange head screw. 3. Remove three (3) hex washer head screws (item 2) securing the housing cover and gasket to the steering housing.
Lower Steering and Front Wheels (Serial Numbers Below: 316000001) 20 to 25 ft−lb (28 to 33 N−m) 12 3 4 14 7 6 1 19 8 30 2 7 5 9 6 45 to 55 ft−lb (62 to 74 N−m) 10 24 29 6 See text for tightening procedure 11 13 15 16 17 22 28 27 21 26 23 20 25 RIGHT 9 to 11 ft−lb (13 to 14 N−m) FRONT 80 to 90 ft−lb (109 to 122 N−m) 18 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Disassembly (Fig. 11) 6 4 5 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition. 3 7 WARNING 2 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 support vehicle with appropriate jack stand beneath the frame. 3. Remove lug nuts and pull wheel assembly from machine. 4.
C. Install brake hose clip onto cap screw. Secure spindle to A−arm hub with cap screw and lock nut. Torque fasteners from 75 to 100 ft−lb (102 to 135 N−m). 2. Install tie rod: A. Insert tie rod ball joints down through the spindle and up through the Pitman arm. Secure with castle nuts. B. Torque castle nuts from 20 to 25 ft−lb (28 to 33 N−m) to secure ball joint while aligning castle nut slot with hole in ball joint stud.
Steering Assembly (Serial Numbers Above: 316000001) 18 to 22 ft−lb (25 to 29 N−m) 1 2 3 4 5 6 7 8 11 to 16 ft−lb (15 to 22 N−m) 16 6 9 15 10 Antiseize lubricant 11 Antiseize lubricant 8 200 to 230 in−lb (23 to 26 N−m) 12 13 14 Figure 14 Steering wheel cap Lock nut Flat washer Steering wheel Dust cover Bearing (2 used) 7. 8. 9. 10. 11. Steering column Flange nut (8 used) Carriage bolt (4 used) Steering shaft Screws (4 used) Disassembly (Fig. 14) 1.
7. Lift up on steering column assembly, slide lower steering shaft joint from the steering rack assembly input shaft and remove steering column from vehicle. 8. Remove dust cover from the steering shaft. Replace cover if damaged. 9. Slide steering shaft and bearings out of the steering column. A. Check steering shaft universal joints for roughness that would indicate bearing wear or damage. Replace steering shaft if universal joint bearing damage exists. B.
Steering Rack Assembly Service (Serial Numbers Above: 316000001) 6 5 4 45 to 55 ft−lb (61 to 74 N−m) 7 2 8 3 1 Medium Strength Thread Locker Figure 15 1. Tie rod end (2 used) 2. Jam nut (2 used) 3. Tie rod track (2 used) 4. Bellows clamp (2 used) 5. Bellows (2 used) 6. Bellows clamp (2 used) 7. Input shaft seal 8. Steering rack assembly Chassis NOTE: Check parts catalog to identify individual components that are available for the steering rack assembly on your Workman vehicle.
Disassembly (Fig. 15) 1. For assembly purposes, measure the distance from shoulder on the tie rod track to the location of the tie rod end (Fig. 16). This will help to adjust front wheel toe−in during assembly of steering rack. 2. Loosen jam nut that secures tie rod end to tie rod track. Remove tie rod end and jam nut from end of tie rod track. 3. Remove clamps that secure bellows to the tie rod track and steering rack housing. Remove bellows from steering rack assembly. 4.
Front Shock Absorbers Shock Removal (Fig. 18) IMPORTANT: Any adjustment to the shock spring preload will affect the front wheel camber (see Adjust Front Wheel Camber in the Adjustments section of this chapter). Do not make shock spring adjustment without checking front wheel camber. 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition. 3 WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. 2 2.
A−arms and Front Suspension (Serial Number Below: 316000001) 20 to 25 ft−lb (28 to 33 N−m) 12 3 4 14 7 6 1 19 8 31 2 6 30 7 See text for tightening procedure 6 36 34 35 9 10 25 29 45 to 55 ft−lb (62 to 74 N−m) 5 11 13 15 17 16 32 28 33 27 26 22 24 21 23 20 RIGHT FRONT 9 to 11 ft−lb (13 to 14 N−m) 75 to 100 ft−lb (102 to 135 N−m) 80 to 90 ft−lb (109 to 122 N−m) 18 Figure 19 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
A−arm Removal (Fig. 19) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 2 WARNING 3 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 support vehicle with appropriate jack stand beneath the frame. 3. Remove front wheel and spindle from A−arm (see Lower Steering and Front Wheel Removal in this section). 1 Figure 20 1. A−arm 2.
A−arms and Front Suspension (Serial Number Above: 316000001) 14 14 22 24 23 10 67 to 83 ft−lb (91 to 112 N−m) 15 50 ft−lb (68 N−m) 16 11 12 11 10 50 ft−lb (68 N−m) 13 9 19 13 16 RIGHT 21 11 10 20 FRONT 11 10 10 18 11 8 6 7 6 5 2 10 17 1 11 4 3 Figure 21 1. 2. 3. 4. 5. 6. 7. 8. Dust cap Retainer Cotter pin Jam nut Tab washer Bearing (2 used) Hub assembly Oil seal 9. 10. 11. 12. 13. 14. 15. 16.
3. Chock wheels not being removed. Use a jack to raise front wheel that is to be removed off the ground. Support vehicle with appropriate jack stands beneath the frame. 4. Remove front wheel assembly and wheel hub from vehicle (see Front Wheels and Hubs in this section). 5. Remove spindle assembly from vehicle: A. Remove cotter pin and slotted hex nut securing steering rack tie rod ball joint stud to the spindle. Separate ball joint from the spindle. B.
Frame Pivot Yoke 240 to 290 ft−lb (326 to 393 N−m) 15 1 3 17 18 11 10 20 13 16 4 12 14 7 6 19 RIGHT 19 FRONT 2 8 6 5 7 6 9 Figure 22 1. 2. 3. 4. 5. 6. 7. Flange nut (4 used) Shock absorber (2 used) Cap screw (4 used) Rubber bumper Flat washer Lock nut (4 used per side) Cap screw (2 used per shock) Chassis 8. 9. 10. 11. 12. 13. 14. LH A−arm Grease fitting (1 used per arm) Screw Cap screw RH A−arm Lock washer Front frame Page 6 − 28 15. 16. 17. 18. 19. 20.
Pivot Yoke Removal (Fig. 22 and 24) 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 rear frame (see Cargo Box Removal in this section). 3. Remove seat base from the front frame (see Seat Base Removal in this section). 2. Secure pivot yoke to the front frame tab with cap screw and hardened washer. Torque cap screw from 240 to 290 ft−lb (326 to 393 N−m). 3.
Swing Arm 11 10 12 4 6 7 8 4 7 70 to 90 ft−lb (95 to 122 N−m) 9 5 6 3 FRONT 2 RIGHT 3 1 2 Figure 25 1. 2. 3. 4. Transaxle assembly Cap screw (4 used) Hardened washer (4 used) Rear shock assembly (2 used) Chassis 5. 6. 7. 8. Cap screw (2 used) Lock nut (4 used) Thrust washer (4 used) Cap screw (2 used) Page 6 − 30 9. 10. 11. 12.
Removal (Fig. 25) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 1 2. Raise and support cargo box with prop rod. 3. Remove muffler from machine (see Exhaust System in the Service and Repairs section of Chapter 3 − Diesel Engine). 6 5 9 WARNING 7 3 Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. 8 FRONT RIGHT 2 4. Jack up and support both sides of the frame: B.
8. Bleed brake system (see Bleed Brake System in this section). 9. Install both wheels to the transaxle (see Rear Wheels and Brakes in this section). 12.Lower and secure cargo box. 13.Check parking brake operation and adjust if necessary (see Adjust Parking Brake in the Adjustments section of this chapter). 10.Lower machine to ground. 11. Install muffler to machine (see Exhaust System in the Service and Repairs section of Chapter 3 − Diesel Engine).
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Parking Brake 11 10 9 13 1 2 8 16 7 14 12 15 4 17 6 5 3 RIGHT FRONT Figure 27 1. 2. 3. 4. 5. 6. Parking brake cover Operator seat (2 used) Seat base Cable equalizer bracket Parking brake lever Curved washer Chassis 7. 8. 9. 10. 11. 12. Lock nut Flat washer Flange head screw (4 used) Flat washer (2 used) Screw (2 used) Cap screw Page 6 − 34 13. 14. 15. 16. 17.
Disassembly (Fig. 27) 1. Park machine on a level surface, stop engine and remove key from the ignition switch. Chock wheels to prevent the machine from moving. 4. Position brake cables to rear brake assemblies using cable routing noted during disassembly. 5. Secure parking brake cables to rear of machine (Fig. 28): 2. Disconnect both parking brake cables from rear of machine (Fig. 28): A. Secure each brake cable to swing arm with retaining ring. A.
Rear Wheels and Brakes 20 ft−lb (27 N−m) 11 10 120 ft−lb (163 N−m) 7 8 5 13 19 18 15 to 21 ft−lb (21 to 28 N−m) 15 20 1 4 6 12 16 17 14 Antiseize Lubricant 3 RIGHT FRONT 2 80 to 90 ft−lb (109 to 122 N−m) 9 Figure 29 1. 2. 3. 4. 5. 6. 7. Wheel assembly Lug nut (5 used per hub) Castle nut Brake drum Socket head screw (4 used per brake) Brake assembly (LH shown) Clevis pin 8. 9. 10. 11. 12. 13. 14.
C. Remove four (4) socket head screws and flange nuts that secure the brake assembly to the transaxle. 13.Bleed brakes (see Bleed Brake System in this section). D. Remove brake assembly from the transaxle. CAUTION Installation (Fig. 29) IMPORTANT: Parking brake levers must be positioned above the transaxle mount. When positioned correctly, brake lever will point toward the rear of the axle. 1. Position brake assembly to the transaxle.
Rear Brake Service 110 to 120 in−lb (12.4 to 13.6 N−m) 6 9 11 110 to 120 in−lb (12.4 to 13.6 N−m) 3 8 2 10 7 11 5 10 1 13 7 12 110 to 120 in−lb (12.4 to 13.6 N−m) 8 3 4 12 Figure 31 1. 2. 3. 4. 5. 6. 7. 8. 9. Brake backing plate Washer head screw Brake shoe Lower spring Wheel cylinder Parking brake lever (LH shown) Belleville washer Adjuster lever Dust cover 10. 11. 12. 13. Flat washer Bolt Shoe hold down cup and spring Upper spring 4.
Inspection (Fig. 31) Assembly (Fig. 31) 1. Inspect brake drums. IMPORTANT: Brake shoe lining surfaces must be free of grease, oil and other foreign matter. A. Clean drums with denatured alcohol. Check braking surface diameter in at least three places. If the diameter exceeds 6.320 inches (160.5 mm), replace both brake 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.
Front Brake Calipers 9 to 11 ft−lb (13 to 14 N−m) 16 9 4 6 15 10 12 1 7 5 2 11 14 14 3 8 13 4 54 to 66 in−lb (6.2 to 7.4 N−m) RIGHT 12 108 to 132 in−lb (12.3 to 14.9 N−m) 16 13 14 14 FRONT 54 to 66 in−lb (6.2 to 7.4 N−m) 3 2 Figure 32 1. 2. 3. 4. 5. 6. Brake master cylinder Brake caliper (2 used) Bleed screw Brake rotor (2 used) Front brake line Brake line clip (4 used) Chassis 7. 8. 9. 10. 11.
Disassembly (Fig. 32) Assembly (Fig. 32) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 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 two (2) flange head screws. WARNING 3. Connect brake line to caliper: Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 − Safety. 2. Chock wheels not being jacked up.
Front Brake Caliper Service 8 White Lithium Grease 4 27 to 33 ft−lb (37 to 44 N−m) 3 7 6 1 5 BAF−12 Assembly Lube 2 Figure 33 1. Bolt (2 used) 2. Caliper body 3. O−ring (4 used) Chassis 4. Caliper bracket 5. Square seal (2 used) 6. Piston (2 used) Page 6 − 42 7. Brake pad (2 used) 8.
Disassembly (Fig. 33) Assembly (Fig. 33) 1. Remove two (2) bolts that secure brake caliper assembly. 1. If caliper body was disassembled, install components in caliper body: 2. Remove caliper anvil and then slide brake pads from pins on caliper bracket. A. Apply hydraulic brake cylinder assembly lube (BAF−12 or equivalent) to square seals and piston before installation. 3. Slide caliper body assembly from caliper bracket. 4. If necessary, remove remaining components from caliper body: B.
Brake Master Cylinder 8 9 2 7 6 1 4 3 5 RIGHT FRONT Figure 34 1. Brake master cylinder 2. Cap screw (2 used) 3. Brake pedal Chassis 4. Clevis pin 5. Cotter pin 6. Flange head nut (2 used) Page 6 − 44 7. Pedal frame 8. Front brake line 9.
Removal (Fig. 34) Installation (Fig. 34) 1. Raise front hood to gain access to brake master cylinder. 1. Position master cylinder to pedal frame and secure with two (2) cap screws and flange nuts. 2. Remove cotter pin from the clevis pin that connects master cylinder to brake pedal. 2. Remove plugs from brake lines. Install brake lines to master cylinder. IMPORTANT: To prevent contamination of the brake system, make sure to clean components before disassembly. 3.
Brake Master Cylinder Service Disassembly (Fig. 35) 1. Thoroughly clean outside of master cylinder before disassembly. 1 2 2. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 12 3 3. Disconnect lower end of the dust cover from the housing. 4. Push in on the push rod and remove circlip, then remove push rod with dust cover and clevis. Remove retainer washer. 4 11 5 5. Remove primary piston assembly and secondary piston assembly from cylinder housing.
Bleed Brake System IMPORTANT: To prevent contamination of the brake system, make sure to clean components before disassembly. 3 1. Connect a suitable transparent hose to bleeder valve on front brake caliper (Fig. 36) or rear wheel brake cylinder (Fig. 37). Submerge other end of hose in a glass container partially filled with clean brake fluid. 1 2. Have a second person pump brake pedal several times, then hold pedal down firmly. 2 3.
Seat Base 31 6 33 5 30 29 28 27 12 1 23 14 22 20 7 26 24 25 21 32 19 9 17 8 2 16 4 15 18 3 10 11 13 12 13 12 Figure 38 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Seat (2 used) Seat bracket (2 used) Cap screw (8 used) Seat base Shift cable (2 used) Shift lever Shift bracket Flange screw (1/2” long) (4 used) Flange screw (3/4” long) (4 used) Fuel tank assembly Web strapping Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Seat Base Removal (Fig. 38) 4 1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch. 2 2. Flip both seats forward and remove them from the seat base. 1 3. Remove parking brake assembly from seat base (see Parking Brake in this section). 4. Unscrew knob from the shift lever. Remove four (4) flange head screws (item 8 in Fig. 38) that secure the shift plate to the shift bracket (Fig. 39). 5. Remove four (4) flange head screws (item 9 in Fig.
Front Hood 7 32 7 to 13 in--lb (0.8 to 1.4 N--m) 2 24 23 20 28 22 40 to 50 in--lb (4.5 to 5.6 N--m) 11 16 15 RIGHT 12 19 FRONT 27 12 14 3 8 29 17 9 25 12 30 1 26 18 4 6 21 5 10 31 13 Figure 40 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Fender (LH shown) Lock nut (4 used) Flat washer (2 used) Front bumper Headlight (2 used) Washer (3 used per headlight) Hood Fender well (LH shown) Cap screw (2 used) Hood pivot keeper (2 used) Screw (6 used) Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Installation (Fig. 40) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition. NOTE: Do not tighten fasteners securing the hood until all fasteners are in place. 2. Remove hood using Figure 40 as a guide. 1. Install hood using Figure 40 as a guide. During assembly, use fastener torque specifications that are identified in Figure 40. Chassis Removal (Fig.
Cargo Box 190 to 210 in−lb (21.5 to 23.7 N−m) 13 5 7 1 10 9 6 15 8 18 16 3 4 14 12 12 17 11 190 to 210 in−lb (21.5 to 23.7 N−m) 2 RIGHT FRONT 190 to 210 in−lb (21.5 to 23.7 N−m) Figure 41 1. 2. 3. 4. 5. 6. Cargo box Handle Latch pin (2 used) Lock nut (2 used) Carriage screw (4 used) Pivot bracket Chassis 7. 8. 9. 10. 11. 12. Pivot bushing (2 used) Screw (4 used) Carriage screw (4 used) Flange nut (4 used) Prop rod Flange nut (6 used) Page 6 − 52 13. 14. 15. 16. 17. 18.
Removal (Fig. 41) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 4 45 to 55 in−lb (5.1 to 6.2 N−m) 3 6 5 2 2. Disassemble cargo box as necessary using Figures 41 and 42 as guides. Installation (Fig. 41) 1 11 12 10 1. Assemble cargo box using Figures 41 and 42 as guides. 7 6 9 A. When installing cargo box, use torque specifications identified in Figure 41. 8 B.
Windshield Wiper Assembly (Machines with Operator Cab) 1 2 3 26 4 5 6 20 to 22 N m (177 to 194 in-−lb) 16 25 5 to 6 N m (45 to 53 in-−lb) 7 8 24 22 23 21 19 20 17 18 12 14 13 9 7 to 8 N m (62 to 70 in-−lb) 15 10 11 Figure 43 1. 2. 3. 4. 5. 6. 7. 8. 9. Flange−head screw (10 each) Sealing washer (10 each) Cab roof Bulb trim seal Console foam Fuse block mount Wiper motor Wiper motor bracket Roof console Chassis 10. 11. 12. 13. 14. 15. 16. 17. 18.
Removal (Fig. 43) 1. Park the machine on a level surface, shut off the engine, set the parking brake, and remove the key from the key switch. 2. Remove the wiper blade (item 15 in Fig. 43) from the wiper arm. 3.05 mm (0.12 inch) 3.05 mm (0.12 inch) 3. If necessary, remove the wiper arm as follows: A. Disconnect the washer hose from the wiper arm. B. Lift the cap at the top of the wiper arm and remove the wiper stud nut that secure the wiper arm to the wiper motor. C.
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Chapter 7 Electrical Drawings Table of Contents Electrical Drawings ELECTRICAL SCHEMATIC Electrical Schematic (Serial Number Below 315000000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical Schematic (Serial Number 315000001 to 403450000) . . . . . . . . . . . . . . . . . . . . 4 Electrical Schematic (Serial Number Above 403450001) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CIRCUIT DIAGRAMS Glow Plug Circuits . . . . . . . . . . . . . . . . . . . . . . . . . .
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Workman MDX--D Electrical Schematic (Serial Number Below 315000000) Relays are shown as de-- energized Page 7 -- 3
119--5798 Rev.
122--1430 Rev.
Glow Plug Circuits Power Current Control Current Indication Current Page 7 -- 6
Start Circuits Power Current Control Current Indication Current Page 7 -- 7
Run Circuits Power Current Control Current Indication Current Page 7 -- 8
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Workman MDX-- D Main Electrical Harness Wiring Drawing (Serial Number Below 315000000) Page 7 -- 10
BLACK GREEN GRAY BLACK RED ORANGE BLACK BLACK VIOLET BLACK GRAY WHITE/BLACK RED GREEN PINK YELLOW VIOLET VIOLET BLACK GRAY VIOLET BLACK YELLOW BLUE VIOLET BLUE BLUE BROWN PINK WHITE BLACK BLACK RED PINK RED WHITE BLACK YELLOW YELLOW PINK YELLOW BLACK RED VIOLET YELLOW GREEN YELLOW BLACK YELLOW BLACK YELLOW WHITE BLUE RED/BLACK BLACK YELLOW GREEN YELLOW RED/BLACK YELLOW WHITE YELLOW BLACK GREEN BLACK BLUE BLUE TAN YELLOW ORANGE PINK BLUE BLACK ORANGE BLACK PINK ORANGE BLU
122--0734 Rev.
122--0734 Rev.
122--1431 Rev.
122--1431 Rev.
BLUE BROWN WHITE BLUE RED FUSIBLE LINK BLACK Workman MDX--D Engine Electrical Harness Page 7 -- 16
6 5 4 3 2 1 D D C C B B A Drawing No: 120--3996 Rev.
6 5 4 3 2 1 D D C C B B A A Drawing No.: 122--0843 Rev.
