Toro Workman MD, Service Manual

Page 1: ...r s Manual and Parts Catalog are avail able on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol m...

Page 2: ...Workman MD MDX This page is intentionally blank...

Page 3: ...ND PRO CS Series Engines Chapter 5 Drive Train General Information 5 1 Specifications 5 2 Drive Train Operation 5 3 Special Tools 5 6 Adjustments 5 7 Service and Repairs 5 10 Chapter 6 Electrical Syst...

Page 4: ...Workman MD MDX This page is intentionally blank...

Page 5: ...SAFETY INSTRUCTIONS 2 Supervisor s Responsibilities 2 Before Operating 2 While Operating 3 Maintenance and Service 3 JACKING AND OTHER INSTRUCTIONS 4 Jack Vehicle 4 Transport Vehicle 4 Tow Vehicle 4 T...

Page 6: ...only It is not designed equipped or manufactured for use on public streets roads or highways Supervisor s Responsibilities 1 Make sure operators are thoroughly trained and fa miliar with the Operator...

Page 7: ...parts Keep by standers away 7 Do not overspeed the engine by changing governor setting To assure safety and accuracy check maximum engine speed 8 Shut engine off before checking or adding oil to the...

Page 8: ...xle in neutral Make sure proper hoists jacks and jack stands are used to raise and support the vehicle Jacking Locations 1 Jack front of the vehicle on the front of the frame and behind the towing ton...

Page 9: ...engine set parking brake and remove key from the ignition switch 2 Move shift lever to the neutral position Fig 3 3 Make sure transaxle is in the neutral position by ro tating the driven clutch The ti...

Page 10: ...ion Decals Numerous safety and instruction decals are affixed to your Workman If any decal becomes illegible or dam aged install a new decal Part numbers are listed in the Parts Catalog Order replacem...

Page 11: ...rs 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 opti...

Page 12: ...0 09375 Workman MD MDX Page 2 2 Product Records and Maintenance Equivalents and Conversions...

Page 13: ...ue feature hardness of the surface underneath the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubrica...

Page 14: ...22 3 30 3 41 4 43 4 58 5 3 8 24 UNF 17 2 18 2 24 3 35 3 47 4 50 4 68 5 7 16 14 UNC 27 3 27 3 37 4 50 5 68 7 70 7 95 9 7 16 20 UNF 29 3 29 3 39 4 55 5 75 7 77 7 104 9 1 2 13 UNC 30 3 48 7 65 9 75 8 10...

Page 15: ...0 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 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 37 ft lb 610 50 N m NOTE Reduce torque values listed in the table above b...

Page 16: ...Wheel Bolts and Lug Nuts Thread Size 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 8 80 10 ft lb 108 14 N m M12 X 1 5 Class...

Page 17: ...NS 3 ADJUSTMENTS 4 Adjust Throttle Cable 4 SERVICE AND REPAIRS 5 Cooling System 5 Air Cleaner 6 Exhaust System 8 Fuel Tank 10 Oil Filter Assembly 12 Engine 14 Engine Removal 15 Engine Installation 16...

Page 18: ...useofsomespecialized testequipmentisex 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...

Page 19: ...l Fuel Pump Pulsating Crankcase Vacuum Fuel Unleaded regular grade gasoline Fuel Tank Capacity 7 0 U S gal 26 5 l Lubrication System Pressure Lubrication Gear Driven Geroter Oil Pump Crankcase Oil Cap...

Page 20: ...ressed the engine governor bellcrank mechanism should have a gap from 0 030 to 0 080 0 8 to 2 0 mm Fig 2 If necessary adjust jam nuts on throttle cable so that gap is correct 4 Make sure that shift le...

Page 21: ...port with prop rod 3 Carefully remove spark plug wires from the spark plugs to prevent the engine from starting unexpectedly IMPORTANT Never clean engine with pressurized water Water could enter and c...

Page 22: ...ut 6 Flange nut 2 used 7 Cap screw 2 used 8 Air cleaner bracket 9 Flange head screw 4 used 10 Carburetor gasket 2 used 11 Carburetor adapter 12 Hose clamp 13 Breather hose 14 Adapter gasket 15 Hose cl...

Page 23: ...o engine and will cause serious engine damage Make sure that all air cleaner components are in good condition and are properly secured dur ing assembly 1 Assemble all removed air cleaner components us...

Page 24: ...Gasoline Engine Exhaust System Figure 7 1 Muffler 2 Swing arm 3 Cap screw 2 used 4 Lock washer 6 used 5 Exhaust coupler 6 Coupler spring 4 used 7 Exhaust manifold 8 Engine tray 9 Engine 10 Screw 4 use...

Page 25: ...ashers securing the manifold to the engine Remove exhaust manifold Remove exhaust gaskets and clean gasket surfaces of manifold and engine Installation Fig 7 NOTE Mount all exhaust components loosely...

Page 26: ...ng 4 Gas cap 5 Fuel tank 6 Bushing 7 Stand pipe 8 Hose clamp 9 Fuel hose to fuel filter 10 Fuel line conduit 11 Seat base 12 Web strapping 13 Hex head flange screw 8 used 14 Flat washer 15 Parking bra...

Page 27: ...and store evaporative emissions from the fuel tank Fuel tank components for these vehicles are shown in Fig 11 5 If necessary remove stand pipe fuel gauge and bushings from tank Fuel Tank Installatio...

Page 28: ...ose 2 Elbow fitting 3 Hose 4 Fitting 5 Oil pressure switch 6 Elbow fitting 7 Cap screw 4 used 8 Flange nut 4 used 9 Filter bracket 10 Oil filter 11 Oil filter adapter 12 Fitting 1 3 4 5 6 8 2 9 7 10 1...

Page 29: ...ion of engine lubrication sys temduring adapterremoval thoroughlyclean exteriorof filter adapter hoses and fittings 4 Remove oil filter adapter components as needed us ing Figure 11 as a guide Install...

Page 30: ...ge nut 4 used 23 Cap screw 24 Carriage screw 25 Engine tray 26 Washer 2 used 27 Starter generator pulley 28 Starter generator 29 Flange nut 3 used 30 Engine 31 Engine wire harness 32 Cap screw 2 used...

Page 31: ...cleaner intake and machine frame CAUTION Read safety precautions for handling gasoline before working on the fuel system see Safety In structions in Chapter 1 Safety 6 Disconnect fuel inlet hose from...

Page 32: ...ect a hoist at the center of the short section of chain IMPORTANT Make sure to not damage engine fuel lines electrical harness or other parts while installing the engine C Carefully lower engine onto...

Page 33: ...B Air intake hose to the air cleaner intake and ma chine frame 11 Install cargo box to the frame see Cargo Box and Tailgate Installation in the Service and Repairs section of Chapter 7 Chassis 12 Con...

Page 34: ...canister The fuel tank on these Workman vehicles uses a non vented fuel cap To connect the tank to the evaporative control system a rollover valve is positioned in the top of the tank that allows tank...

Page 35: ...er for assembly purposes Fig 21 C Note location of hose clamps for assembly pur poses Assembly 1 Install all removed components using Figure 19 as a guide A If check valve item 7 in Fig 19 was removed...

Page 36: ...Workman MDX Page 3 20 Briggs Stratton Gasoline Engine This page is intentionally blank...

Page 37: ...S 4 Adjust Throttle Cable Serial Numbers Below 313000400 4 Adjust Throttle Cable Serial Numbers Above 313000400 5 SERVICE AND REPAIRS 7 Cooling System 7 Exhaust System 8 Fuel Tank 10 Engine 12 Engine...

Page 38: ...he end of this chapter and can be used when servicing either brand of engine Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described i...

Page 39: ...ed Governing Carburetor Float Feed Single Barrel Fuel Pump Pulsating Crankcase Vacuum Fuel Unleaded regular grade gasoline Fuel Tank Capacity 7 0 U S gal 26 5 l Lubrication System Splash Lubrication C...

Page 40: ...nition switch 2 Lift cargo box and prop with rod to gain access to the engine and transaxle 3 Rotate governor arm on transaxle fully clockwise Fig 1 4 Make sure of the following A The carburetor throt...

Page 41: ...o box and prop with rod to gain access to the engine Fig 3 3 Make sure that shift lever is in the neutral position to prevent the machine from moving NOTE If phototac is to be used to measure engine s...

Page 42: ...Workman MD Page 4 6 Single Cylinder Gasoline Engine This page is intentionally blank...

Page 43: ...brake and remove key from the ignition switch 2 Raise bed and support with prop rod 3 Carefully remove spark plug wire from the spark plug to prevent the engine from starting unexpectedly IMPORTANT Ne...

Page 44: ...ust System Figure 5 1 Engine 2 Coupler spring 4 used 3 Exhaust manifold 4 Muffler 5 Exhaust coupler 6 Starter generator 7 Drive clutch 8 Engine tray 9 Lock washer 2 used 10 Cap screw 2 used 11 Swing a...

Page 45: ...needed remove exhaust manifold from engine by removing two 2 nuts Remove exhaust gasket and clean gasket surfaces of manifold and engine Installation Fig 5 NOTE Mount all exhaust components loosely b...

Page 46: ...ng 4 Gas cap 5 Fuel tank 6 Bushing 7 Stand pipe 8 Hose clamp 9 Fuel hose to fuel filter 10 Fuel line conduit 11 Seat base 12 Web strapping 13 Hex head flange screw 8 used 14 Flat washer 15 Parking bra...

Page 47: ...evaporative emissions from the fuel tank Fuel tank components for these vehicles are shown in Fig 10 5 If necessary remove stand pipe fuel gauge and bushings from tank Fuel Tank Installation Fig 7 1...

Page 48: ...washer 4 used 31 Washer 32 Cap screw 33 Mount 2 used 34 Washer 2 used 35 Flywheel guard 36 Flat washer 4 used 37 Flange head screw 4 used 38 Intake hose 39 Cap screw 2 used 40 Hose clamp 2 used 41 Ai...

Page 49: ...st coupler see Muffler Removal in this section 7 Remove drive belt from drive clutch 8 Loosen fasteners that secure starter generator Ro tate starter generator toward engine to loosen tension on start...

Page 50: ...and shift cables item 8 to engine Secure r clamp to engine with flat washer item 50 and cap screw item 49 6 Install starter belt to the engine and starter generator pulleys Tension the belt by rotatin...

Page 51: ...Workman MD Single Cylinder Gasoline Engine Page 4 15 This page is intentionally blank Single Cylinder Gasoline Engine...

Page 52: ...ses a non vented fuel cap To connect the tank to the evaporative control system a rollover valve is positioned in the top of the tank that allows tank venting through the carbon canister NOTE If there...

Page 53: ...ose clamps for assembly pur poses Assembly 1 Install all removed components using Figure 15 as a guide A If check valve item 8 in Fig 15 was removed make sure that arrow on valve body points toward en...

Page 54: ...Workman MD Page 4 18 Single Cylinder Gasoline Engine This page is intentionally blank...

Page 55: ...PAIRS 10 Drive Clutch 10 Drive Clutch Service Serial Number Below 310000000 12 Drive Clutch Service Serial Number Above 310000000 13 3 Driven Clutch 14 Driven Clutch Service Serial Number Below 310000...

Page 56: ...ansaxle Transaxle Fluid Capacity 1 5 quarts 1 4 liters Transaxle Fluid SAE 10W 30 Motor Oil Clutch System Continuously variable transmission type torque convertor Drive Clutch Speed sensing with mecha...

Page 57: ...ansferred 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 dr...

Page 58: ...outer diameter of the drive clutch sheaves which increases the drive belt speed When engine speed is decreased the weights exert less force on the moveable sheave The reduced force causesthemoveables...

Page 59: ...pen up the drive beltrideslower inthe driven clutch sheaves With increased load to the transaxle the fixed cam re sists forward movement relative to the moveable sheave and drive belt Torque from the...

Page 60: ...Figure 6 Drive Clutch Spider Removal Tool Kit Serial Number Below 310000000 This kit is required to remove the drive clutch spider from the post of the fixed sheave Kit includes spanner and clutch hol...

Page 61: ...oro Part Number TOR6013 NOTE Vehicles with a serial number above 310000000 are equipped with a TEAM brand drive clutch Figure 8 1 Drive Clutch Spider Removal Tool Kit Serial Number Above 310000000 Thi...

Page 62: ...Rev A 6 2 Workman MD MDX Drive Train Page 5 This page is intentionally blank...

Page 63: ...5 Verify ground speed as follows A Start engine and hold accelerator pedal to the floor B Verify driven clutch RPM with a tachometer With the accelerator pedal to the floor the driven clutch speed sh...

Page 64: ...n switch Raise and support cargo box 2 Make sure that the shift lever is in the neutral posi tion 3 Verify engine speed to ensure correct ground speed as follows A Start engine and hold accelerator pe...

Page 65: ...t on one of the shift cables to allow 0 030 to 0 060 0 8 to 1 5 mm freeplay in the cable Fig 11 5 Repeat process for other shift cable 6 Pull up on each shift cable to make sure that freeplay is corre...

Page 66: ...T Drive Clutch Lubrication NOTE Lubricate drive clutch at the interval specified in your Operator s Manual 1 Park machine on a level surface stop engine and re move key from the ignition switch Raise...

Page 67: ...e tapered shaft IMPORTANT Lightly grease end of clutch removal tool to prevent wear or damage to removal tool and crankshaft Prevent damage to clutch threads thread tool only enough to remove the clut...

Page 68: ...ssed 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 oth...

Page 69: ...ponent with emery cloth 2 Check the surface of the cam weights Fig 17 If worn replace all cam weights as a set 3 Check the rollers Fig 18 If binding or uneven wear is found replace all rollers as a se...

Page 70: ...or equivalent to the threads of the fixed sheave post 5 Installspider to the fixed sheave postusing spider re moval tool kit see Special Tools Make sure to align matchmark made during disassembly 6 To...

Page 71: ...Rev A 13 2 Workman MD MDX Drive Train Page 5 This page is intentionally blank Drive Train...

Page 72: ...ree 3 cap screws securing the cover to themoveablesheave Notelocationof X marks caston the cover and spider for assembly purposes Pull cover from clutch 2 Remove limiter shim item 2 from clutch Label...

Page 73: ...r your Workman model and serial number Do not mix clutch components from different vehicles IMPORTANT For proper drive clutch operation DO NOT lubricate drive clutch components 1 If removed install mo...

Page 74: ...tepped washer securing the driven clutch to the input shaft of the transaxle 5 Pull driven clutch from the transaxle input shaft Driven Clutch Installation Fig 20 1 Coat transaxle input shaft with ant...

Page 75: ...ab as necessary If the button is loose apply Loctite 242 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 As need...

Page 76: ...omponents A Clean all dust and debris from clutch compo nents If necessary use contact or brake cleaner to remove any oil or other lubricants from clutch com ponents B Inspect the spring and replace i...

Page 77: ...Rev A 15 2 Workman MD MDX Drive Train Page 5 This page is intentionally blank Drive Train...

Page 78: ...ange nut 2 used Figure 22 v FRONT RIGHT 13 14 19 6 11 15 16 18 10 9 7 5 12 3 4 2 1 8 14 17 20 Antiseize Lubricant 39 to 47 ft lb 53 to 63 N m Removal Fig 22 1 Park machine on a level surface stop engi...

Page 79: ...appropriate jack stands positioned just in front of the rear axle tubes This will allow the transaxle to be removed from the vehicle 9 Remove both rear wheels and brake assemblies from the transaxle...

Page 80: ...the swing arm with four 4 cap screws item 3 and flat washers item 2 5 Secure engine tray to the swing arm A Align engine tray to swing arm Insert cap screw with flat washer up through swing arm brack...

Page 81: ...Workman MD MDX Drive Train Page 5 19 This page is intentionally blank Drive Train...

Page 82: ...9 60 61 62 63 64 65 66 67 69 70 71 72 73 74 75 76 1 2 3 4 5 6 7 8 9 10 16 1718 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 52 55 70 19 26 38 33 65 65 42 43 7 53 70 11 12 70 63 35 9 71 51 69 55...

Page 83: ...3 Pinion gear 2 used 44 Pinion shaft 45 Spring pin 46 Ball bearing 47 Needle bearing 48 Gear 62 49 Bolt 6 used 50 Axle shaft LH 51 Axle shaft RH 52 Ball bearing 4 used 53 Axle case LH 54 Axle case RH...

Page 84: ...Selector shaft Figure 28 1 2 C Remove bolt near the selector shaft Remove spring and steel ball Replace gasket if damaged 1 Input shaft 2 Oil seal Figure 29 1 2 D Wrap vinyl tape around the splined po...

Page 85: ...3 E Remove three 3 flange bolts securing the axle bracket and axle case to each case Separate brack et from each axle case 1 Flange bolt 10 used 2 Flange nut Figure 31 1 2 F With the input shaft side...

Page 86: ...the cases the boss may get damaged Do not pry open the two cases with a screw driver damage may result to the seal ing surfaces G Hold the case RH and lift up while lightly tapping the governor boss w...

Page 87: ...aft 2 Spacer 2 used 3 Needle bearing 4 Gear 34 Figure 35 1 2 4 2 3 C Replace counter shaft if it has abnormal wear cracks or damage D Replace spacer if either one is cracked or bent E Replace needle b...

Page 88: ...tapping the case with a plastic hammer Make sure to tap equally around the case G Lift up differential assembly center shaft assem bly and input shaft assembly at the same time First remove input sha...

Page 89: ...e shaft from case IMPORTANT When replacing ball bearings both ball bearings must be replaced as a set C Ball bearing roller balls must be free of deforma tion and scoring Ball bearing must spin freely...

Page 90: ...B Remove ball bearing from the input shaft with a bearing puller 1 Governor plate assembly 2 Governor base Figure 41 1 2 IMPORTANT Make sure to not damage the screw heads when removing screws Each sc...

Page 91: ...lls must be free of deforma tion and scoring Ball bearing must spin freely and have minimum axial play Replace ball bearing as necessary F On Workman MD replace governor plate if cracked bentor any we...

Page 92: ...rs pin clutch collars and spacer from the input shaft C Replace gears if worn or damaged Cracked bro ken missing or chipped gear teeth are not accept able D Replace center shaft if worn or damaged Spl...

Page 93: ...62 to the dif ferential case 1 Spring pin 2 Differential case 3 Pinion shaft 4 Pinion gear Figure 46 1 2 3 4 4 NOTE The spring pin can bepunched outfromthehole on the opposite side of gear 62 B Remov...

Page 94: ...ed 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 ball bearing as necessary F Rep...

Page 95: ...ed with an adhesive A Remove both screws and washers securing the stopper and governor fork to the case RH Remove stopper and fork from the case 1 Governor shaft 2 Boss 3 Oil seal Figure 49 1 2 3 IMPO...

Page 96: ...50 1 2 3 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...

Page 97: ...e governor plate to the governor from loosening ap ply Loctite 242 orequivalent tothe screw threads A On Workman MD secure governor plate unit to the governor base with two 2 screws and lock pin Torqu...

Page 98: ...denum disulfide grease to the inside of the governor sleeve Slide sleeve onto the input shaft Make sure to engage sleeve slot with lock pin 1 Pivot point 2 Governor plate Figure 54 1 2 D On Workman MD...

Page 99: ...disul fide grease to the inside of gears 47 and 55 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 on...

Page 100: ...ide gear greased surface 4 Differential case 5 Gear 62 6 Bolt 7 Spring pin 8 Ball bearing 9 Ball bearing Figure 58 8 3 7 1 9 1 6 5 2 4 3 123 3 to 124 0 mm A Apply molybdenum disulfide grease to the in...

Page 101: ...ntial case Figure 59 1 4 3 2 B Install side gear both pinion gears and pinion shaft into the differential case 1 Spring pin 2 Differential case 3 Pinion shaft Figure 60 1 2 3 C Align pinion shaft hole...

Page 102: ...ial case with six 6 bolts Torque bolts in a crossing pattern from 40 to 45 ft lb 54 to 61 N m Figure 62 40 to 45 ft lb 54 to 61 N m IMPORTANT The length from the outer most side of each ball bearing m...

Page 103: ...2 A Install ball bearing into the bore of the case RH 1 Governor shaft 2 Boss Figure 64 1 2 IMPORTANT Make sure to not damage the oil seal when installing the governor shaft into the governor boss B L...

Page 104: ...2 or equivalent to the screw threads D Secure stopper and governor fork to the governor shaft with both screws 1 Governor fork 2 Governor shaft greased surface 3 Screw 2 used Figure 66 0 5 mm 12 to 16...

Page 105: ...the axle case 1 Axle case 2 Case 3 Flange bolt Figure 68 25 to 31 ft lb 34 to 42 N m 1 2 3 IMPORTANT Make sure to install the axle case to the proper side of the case The right side of the case takes...

Page 106: ...haft 4 Differential assembly Figure 70 1 2 3 4 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 IMPORTANT...

Page 107: ...shaft 2 Pin shift shaft Figure 71 1 2 D Make sure the selector shaft fork is contacting the pin on the shift shaft 1 Spacer 2 Boss counter shaft Figure 72 1 2 E Place spacer on the counter shaft boss...

Page 108: ...ft G Place gear 34 onto the spacer Make sure not to drop the spacer Insert needle bearing into gear In sert counter shaft with remaining spacer through the needle bearing gear 34 and into the spacer a...

Page 109: ...o each other as possible If the seal ing surfaces do not join to each other tap the case lightly with a plastic hammer C Install case RH so each shaft fits properly into the case D Secure case RH to c...

Page 110: ...eel ball spring gasket Figure 77 12 to 15 ft lb 16 to 20 N m 1 2 F Install cable bracket to the transaxle G Install steel ball spring gasket and bolt Torque bolt from 12 to 15 ft lb 16 to 20 N m H Fil...

Page 111: ...own Module Workman MDX 15 Oil Pressure Switch Workman MDX 16 Audio Alarm Reverse Optional 16 Reverse Switch Optional 17 SERVICE AND REPAIRS 18 Starter Generator 18 Removal 19 Installation 19 Starter G...

Page 112: ...rding the operation general maintenance and maintenance intervals for your Workman vehicle Refer to the Opera tor s Manual for additional information when servicing the machine Electrical Schematics T...

Page 113: ...e 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 Speci...

Page 114: ...Workman MD MDX Page 6 4 Electrical System Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte Obtain this tool locally Figure 4...

Page 115: ...loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter is faulty and causing an incomplete circuit for the solenoid Nothing happens when start attempt is made Battery is disc...

Page 116: ...d see Wiring Schematics in Chapter 8 Electrical Diagrams Voltage regulator and or starter generator is faulty Battery is faulty Engine stops during operation Wiring to the run circuit components becam...

Page 117: ...ain access to battery Use a digital multimeter set to DC volts Connect the positive multimeter lead to the positive battery post and the negative multimeter lead to the negative bat tery post Keep the...

Page 118: ...onents for continu ity with a multimeter ohms setting make sure that power to the circuit has been disconnected Ignition Switch The ignition switch used on the Workman has six 6 switch terminals and t...

Page 119: ...or to hour meter Figure 6 RUNNING INDICATOR WINDOW 1 10 WHEEL WHITE W BLACK NUMBERS HOUR WHEELS BLACK W WHITE NUMBERS 1 10 HOURS 0 0 0 0 0 QUARTZ Headlight Switch The headlight switch is located on th...

Page 120: ...re connector locations on start run solenoid for assembly purposes Disconnect wire harness con nectors from solenoid 5 Apply 12 VDC directly across the solenoid coil posts steel The solenoid should cl...

Page 121: ...The extreme left fuse protects the optional accesso ry circuit if equipped 2 The middle left 10 ampere fuse protects the ignition system and horn circuits 3 The middle right 10 ampere fuse protects t...

Page 122: ...engage parking brake 2 Raise hood to gain access to accelerator switch 3 Unplug wiring harness connector from switch 4 With the use of a multimeter ohms setting the switch functions may be tested to...

Page 123: ...d 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 multimeter to the negative battery post IMPORTANT Run engine o...

Page 124: ...hms between starter generator terminals DF and F1 field The meter reading should be 5 5 to 5 9 Ohms B Measure resistance Ohms between starter generator terminals A1 and A2 armature The me ter reading...

Page 125: ...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...

Page 126: ...fer to the Briggs and Stratton Repair Manual for 4 Cycle V Twin Cylinder OHV Head Engines for addi tional testing information Figure 19 1 Oil pressure switch 2 Generator belt 1 2 Audio Alarm Reverse O...

Page 127: ...witch and engage parking brake 2 Remove four 4 screws and carefully slide shift bracket assembly from front of seat base to gain access to reverse switch 3 Unplug wiring harness connector from reverse...

Page 128: ...Engines Workman MDX or the Kohler Service Manual for Command Pro CS Series Engines Workman MD Starter Generator 1 Engine 2 Lock nut 3 Woodruff key 4 Starter generator pulley 5 Starter generator belt 6...

Page 129: ...l number above 311000000 were pro duced with an Advanced Motors and Drives brand starter generator If a Valeo starter generator has been replaced for some reason the replacement starter gen erator may...

Page 130: ...sher 14 End cover front 15 Pulley 16 Pole piece and set screw 17 Field coil stator assembly 18 Screw and mold assembly 19 Screw set 20 Screw set 21 End cover commutator 22 Brush holder kit 23 Brush sp...

Page 131: ...e is less than 0 063 inch 1 6 mm replace all four 4 brushes Fig 26 5 Inspectbrushspringsforheatdiscoloration Replace all four brushes if any brush is straw or bluish colored 6 Check brush springs for...

Page 132: ...e 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...

Page 133: ...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 N m G Position armature carefull...

Page 134: ...ave it re worked Detail Specification Minimum commutator diameter 1 575 inches 40 mm Commutator concentricity to the shaft 0 0003 inch 0 008 mm Commutator machining limit per cut 0 005 inch 0 127 mm I...

Page 135: ...Workman MD MDX Page 6 25 Electrical System This page is intentionally blank Electrical System...

Page 136: ...tarter Generator 1 Drive head end 2 Bearing 3 Retaining ring 4 Armature assembly 5 Frame and field assembly 6 Brush kit 7 Brush spring 4 used 8 Brush box assembly 9 Bearing 10 Wave washer 11 Commutato...

Page 137: ...starter generator For assembly purposes note location of the plug that in cludes a weep hole Figure 32 2 Check the length of the brush that extends from the top of the brush box If the brush is less t...

Page 138: ...103 kPa 7 Clean inside of the frame housing with compressed air IMPORTANT Remove bearings from armature only if they are to be replaced Use proper bearing re moval and installation tools 8 Clean bear...

Page 139: ...on commutator end head Figure 37 10 Remove two 2 screws that secure the brush box to the commutator end head Carefully remove brush box from the commutator end head Figure 38 11 Remove brush assemblie...

Page 140: ...es so the brushes do not go into the brush box fully Figure 40 13 Verify the correct position of the brushes If the brushes are not in the correct orientation the starter generator will not function A...

Page 141: ...n lb 4 6 to 5 6 N m Figure 43 16 Secure commutator end head assembly to frame housing with two 2 screws Use marks placed on end head and housing to properly orientate head Torque screws from 49 to 66...

Page 142: ...ve end head as sembly into the frame housing making sure that arma ture bearing is inserted into bearing bore in commutator end head 21 Use marks placed on drive end head and housing to properly orien...

Page 143: ...s and equipment for testing and reworking electrical motors and generators It may be more economically feasible to replace the starter generator than have it re worked Detail Specification Armature Re...

Page 144: ...protect the battery Battery Specifications BCI Group Size U1 300 Amp Cranking Performance at 0o F 17 8oC Reserve Capacity at 25 Amps and 80oF 26 7oC is 28 Minutes Electrolyte Specific Gravity Fully ch...

Page 145: ...baking soda and water then rinse it with clean water 4 Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking 5 Check the electrolyte level in each cell If...

Page 146: ...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 battery load tester manufacturer...

Page 147: ...x plode and cause injury Let the battery warm to 60oF 15 5o C before connecting to a charger Charge battery in a well ventilated place to dissi pate gases produced from charging These gases are explos...

Page 148: ...Workman MD MDX Page 6 38 Electrical System This page is intentionally blank...

Page 149: ...7 A arms and Front Suspension 18 Frame Pivot Yoke 20 Swing Arm 22 Parking Brake 26 Rear Wheels and Brakes 28 Rear Brake Service 30 Front Brake Calipers 32 Front Brake Caliper Service 34 Brake Master C...

Page 150: ...5 ft lb 62 to 88 N m Brake Fluid DOT 3 Special Tools Order special tools from your Toro Distributor Spanner Wrench Use spanner wrench to rotate front shock absorber col lar which changes the length of...

Page 151: ...ose Clutch or transaxle problem see Chapter 5 Drive Train Excessive steering play Front wheel lug nuts are loose Front wheel bearings are loose or worn Steering linkage is loose or worn Tie rod ends a...

Page 152: ...damaged or worn Vehicle pulls to one side when not braking Tire pressure is low or uneven between tires Front wheel alignment toe in is incorrect Steering or suspension component may be damaged Brakes...

Page 153: ...arking brake is applied or incorrectly adjusted Shoe to shoe spring s is are weak or broken Brake pedal is binding Parking brake cable is binding Brake linings are saturated Brake drums or rotors are...

Page 154: ...parking brake 2 Loosen the set screw securing the knob to the park ing brake lever Fig 1 3 Rotate the knob until a force from 30 to 40 lb 133 to 177 N is required to actuate the lever 4 Tighten the se...

Page 155: ...e bottom of the rim should be 0 090 2 3 mm larger than the top measure ment This measurement allows for a camber of 0 1 2 degree D Repeat measurement procedure for other front wheel 6 If camber measur...

Page 156: ...feet 2 to 3 meters and then straight forward to the original starting position This will allow the suspen sion to settle into the normal operating position 4 Make sure that the front wheels are facing...

Page 157: ...wer pres sure 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 pres sure Inspect Tires and Wh...

Page 158: ...o 29 N m 3 10 10 11 14 4 13 8 7 5 9 12 7 6 2 1 16 15 Loctite 242 175 to 225 in lb 20 to 25 N m Disassembly Fig 4 1 Park machine on a level surface stop engine set parking brake and remove key from the...

Page 159: ...o the mounting plate on the frame with four 4 carriage screws and flange nuts NOTE Apply antiseize lubricant to the steering gear box input shaft before installing to steering shaft knuckle 5 Position...

Page 160: ...rew with patch lock 10 Ball bearing 11 Input shaft spacer 12 Flat washer 13 Flange head screw with patch lock 14 Lube fitting 15 Steering housing cover 16 Steering housing 17 Pinion gear 18 Oil seal 1...

Page 161: ...aring into housing 2 If seals were removed press new seals into housing Seal lips should be facing up 3 Place flat washer item 5 onto shaft of the Pitman arm item 19 Insert shaft into steering housing...

Page 162: ...ed per wheel 19 Cap screw 2 used per A arm 20 Cotter pin 21 Wheel stud 5 used per hub 22 Socket head screw 4 used per rotor 23 Brake caliper LH shown 24 Lock washer 2 used per caliper 25 Cap screw 2 u...

Page 163: ...worn or damaged parts C If necessary remove wheel studs and brake rotor from wheel hub 9 Remove spindle Fig 8 A Remove cotter pin and castle nut securing tie rod ball joint to the spindle Separate bal...

Page 164: ...eal must be toward the inner bear ing C Lubricate the inside of the new seal and press it into the wheel hub D If brake rotor was removed position rotor to hub with chamfered edge toward hub Apply Loc...

Page 165: ...m to prevent it from moving after the shock is removed 4 Remove lock nuts cap screws and flat washer that secure shock to frame and a arm Remove shock ab sorber from vehicle NOTE Use spanner wrench TO...

Page 166: ...r shock 8 LH A arm 9 Brake rotor 10 Wheel hub assembly 11 Tab washer 12 RH A arm 13 Jam nut 14 Front frame 15 Nut retainer 16 Dust cap 17 Wheel assembly 18 Lug nut 5 used per wheel 19 Cap screw 2 used...

Page 167: ...and straight bushings from A arm bores Fig 10 A arm Installation Fig 9 1 If bushings were removed from A arm press new bushings fully into bore of A arm Fig 10 2 Position A arm to the frame Secure A a...

Page 168: ...ap screw 2 used per shock 8 LH A arm 9 Grease fitting 1 used per arm 10 Screw 11 Cap screw 12 RH A arm 13 Lock washer 14 Front frame 15 Pivot yoke 16 Flange head screw 4 used 17 Flat washer 4 used 18...

Page 169: ...hine 6 Remove four 4 flange head screws and flanged lock nuts securing the pivot yoke to the front frame Re move pivot yoke from the machine Pivot Yoke Installation Fig 11 and 12 WARNING Support pivot...

Page 170: ...used 9 Rear shock assembly 2 used 10 Cap screw 2 used 11 Rubber bumper 2 used 12 Swing arm 13 Cable tie 14 Lock nut 4 used 15 Lock nut 2 used 16 Thrust washer 4 used 17 Cap screw 2 used 18 Parking bra...

Page 171: ...tely 325 pounds 148 kg 6 Attach hoist to the engine tray to allow swing arm en gine and transaxle to be lowered from the vehicle Make sure hoist is attached to hold the full weight of the swing arm en...

Page 172: ...e tray assembly 5 Carefully raise swing arm and engine tray assembly to the machine frame Align swing arm pivots to frame mounting points 6 Secure swing arm to machine frame with cap screws thrust was...

Page 173: ...Workman MD MDX Page 7 25 Chassis This page is intentionally blank Chassis...

Page 174: ...t 5 Parking brake lever 6 Curved washer 7 Lock nut 8 Flat washer 9 Flange head screw 4 used 10 Flat washer 2 used 11 Screw 2 used 12 Cap screw 13 Cotter pin 14 Clevis pin 15 Parking brake cable 2 used...

Page 175: ...rking brake support and cable equalizer bracket using Figure 16 as a guide Assembly Fig 16 1 Secure brake cables to parking brake support and cable equalizer bracket using Figure 16 as a guide 2 Route...

Page 176: ...w 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 support vehicle with ap propriate jack stand beneath the frame...

Page 177: ...haft Castlenuttorqueshould not exceed 200 ft lb 271 N m 7 Secure castle nut to shaft with cotter pin 8 Slide brake drum onto wheel hub 9 Position wheel assembly to the machine with valve stem facing o...

Page 178: ...ul when removing springs from brake shoes The springs are under heavy load and may cause personal injury 1 Remove upper and lower springs from brake shoes 2 Remove shoe hold down cups and springs that...

Page 179: ...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 deforma...

Page 180: ...d 4 Cap screw 2 per caliper used 5 Wheel hub assembly 6 Brake rotor 7 Socket head screw 4 per rotor used 8 Spindle LH shown 9 A arm LH shown 10 Brake master cylinder 11 Wheel assembly 12 Lug nut 5 use...

Page 181: ...rake line and position it away from caliper 5 Remove two 2 cap screws and lock washers that secure the brake caliper to the spindle 6 Slide brake caliper from brake rotor and remove cali per from mach...

Page 182: ...same 4 Replace the brake pads if the friction material is worn to less than 1 32 0 8 mm Assembly Fig 22 1 If brake pads are being replaced it will be necessary to push caliper pistons back into the c...

Page 183: ...Workman MD MDX Page 7 35 Chassis This page is intentionally blank Chassis...

Page 184: ...sis Brake Master Cylinder 1 Master cylinder 2 Cap screw 3 Brake pedal 4 Clevis pin 5 Cotter pin 6 Flange head nut 7 Pedal frame 8 Front brake line 9 Rear brake line 10 Accelerator pedal Figure 23 7 3...

Page 185: ...Remove two 2 flange head nuts and cap screws that secure master cylinder to pedal frame 5 Pull master cylinder from machine Installation Fig 23 1 Position master cylinder to pedal frame and secure wi...

Page 186: ...geways with com pressed air Make sure cylinder bore and component pieces are thoroughly clean 2 Check cylinder bore pistons and springs for damage or excessive wear Replace brake cylinder assembly if...

Page 187: ...dal 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...

Page 188: ...er 4 used 14 Shifter plate 15 Rubber receptacle 2 used 16 Holding post 2 used 17 Screw 2 used 18 Rivet 2 used 19 Decal 20 Parking brake support 21 Cap screw 22 Curved washer 23 Lock nut 24 Parking bra...

Page 189: ...MPORTANT 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 secu...

Page 190: ...ng pin 2 used 17 Headlight bracket 18 Flange head screw 2 used 19 Washer head screw 20 used 20 Washer head screw 4 used 21 Flange nut 2 used 22 Rubber latch 2 used 23 Catch 2 used 24 Flat washer 4 use...

Page 191: ...and remove key from the ignition 2 Remove hood using Figure 27 as a guide Installation Fig 27 NOTE Do not tighten fasteners securing the hood until all fasteners are in place 1 Install hood using Fig...

Page 192: ...rew 2 used 16 Prop rod bracket 17 Latch rod 18 Tension spring 2 used 19 Carriage screw 2 used 20 Latch pin 2 used 21 Lock nut 2 used 22 Pivot bracket 2 used 23 Spring 2 used 24 Screw 10 used 25 LH tai...

Page 193: ...surface stop engine set parking brake and remove key from the ignition switch 2 Disassemble cargo box as necessary using Figure 33 as a guide Installation Fig 33 1 Assemble cargo box using Figure 33 a...

Page 194: ...et 7 Pivot bushing 2 used 8 Screw 4 used 9 Carriage screw 4 used 10 Flange nut 4 used 11 Prop rod 12 Flange nut 6 used 13 Carriage screw 2 used 14 Tension spring 2 used 15 Carriage screw 2 used 16 Pro...

Page 195: ...x using Figures 34 and 35 as gui des A When installing cargo box use torque specifica tions identified in Figure 34 B Adjust latch pin item 3 in Figure 34 so that cargo box is tight to frame when latc...

Page 196: ...Page 7 48 Workman MD MDX Chassis This page is intentionally blank Rev A...

Page 197: ...0999999 7 Main Electrical Harness Wiring Diagram Serial Number Below 280999999 8 Main Electrical Harness Drawing Serial Number From 290000001 to 310000800 9 Main Electrical Harness Wiring Diagram Seri...

Page 198: ...Workman MD MDX Electrical Drawings Page 8 2 This page is intentionally blank...

Page 199: ...Page 8 3 Electrical Schematic Workman MD Solenoid is shown de energized F3 F4 F2 F1 10A 20A 15A 30A AUTO RESETTING...

Page 200: ...Page 8 4 Electrical Schematic Workman MDX Solenoid is shown de energized F3 F4 F2 F1 10A 20A 15A 30A AUTO RESETTING...

Page 201: ...Page 8 5 F3 F4 F2 F1 10A 20A 15A 30A AUTO RESETTING Start Circuits Power Current Control Current Indication Current Workman MDX Schematic Shown ENERGIZED...

Page 202: ...Page 8 6 Run Circuits Power Current Control Current Indication Current Workman MDX Schematic Shown F3 F4 F2 F1 10A 20A 15A 30A AUTO RESETTING ENERGIZED...

Page 203: ...Rev A Page 8 7 Main Electrical Harness Drawing Workman MD and MDX Serial Number Below 280999999...

Page 204: ...BLACK YELLOW PINK VIOLET YELLOW VIOLET BLUE BLUE BLACK YELLOW BLACK BROWN BLUE BLACK BLACK BLUE BLUE BLACK YELLOW BLACK GREEN BLUE RED BLACK YELLOW YELLOW PINK PINK RED RED BLACK GREEN WHITE BLUE BRO...

Page 205: ...Rev A Page 8 9 Main Electrical Harness Drawing Workman MD and MDX Serial Number From 290000001 to 310000800...

Page 206: ...YELLOW BLUE WHITE BLACK BLACK VIOLET YELLOW WHITE BLUE BLACK BLUE BROWN BLACK PINK YELLOW VIOLET BLACK BLUE BLACK YELLOW RED BLACK RED BLACK BLACK GREEN BLUE PINK YELLOW RED RED PINK BLACK WHITE BLUE...

Page 207: ...Rev A Page 8 11 Main Electrical Harness Drawing Workman MD and MDX Serial Number Above 310000800...

Page 208: ...BLACK YELLOW VIOLET BLUE BLACK WHITE BLACK BLACK VIOLET WHITE YELLOW BLUE PINK YELLOW BLACK BROWN BLUE BLACK BLUE BLACK YELLOW BLUE RED BLACK BLACK GREEN BLACK RED PINK YELLOW PINK RED RED BLACK BLAC...

Page 209: ...Rev A Page 8 13 Engine Electrical Harness Workman MD WHITE BLUE BROWN BLACK GREEN BROWN WHITE BROWN...

Page 210: ...Rev A Page 8 14 Engine Electrical Harness Workman MDX WHITE BLUE BROWN BLACK GREEN BROWN WHITE...