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08160SL - Toro Media

1. LIGHT KIT auz OPTION 5 5 TERMINAL HEAD LIGHT HEAD LIGHT LIGHT amp LOCK HORN SWITCH POWER POINT LS RS INTERCONNECT 5 GND ACCELERATOR REVERSE SW P24 POI P22 P23 PI4 JO 04 P05 NC NO NO NC 2 I 2 A A a a Bc oe 2 45 1 2 34 x Fs x T x gt 2 H gt E amp u 5 5 Ze 18 2 53 2953548 23 S E d 35 of 106 YELLOW t a A o gt m m cz gt HORN JOT BLACK BLACK ENGINE GROUND lt gt a MAGNETO WHITE OIL PRESSURE P03 BLUE pF TO ENGINE HARNESS 2 YELLOW NO 3 VIOLET SP06 4 LIGHT SW P02 FIELD 5 GREEN PIO VOLTAGE REGULATOR 6 1 8 SP 02 PAST SPOS RED MAXI P25 FUSE RED BLUE PINK PII OPTIONAL FUSE BLOCK HOUR PIT 2 BLUE _ 3 BLACK SP0 SP05 PINK F
2. m t OR d EET lE 5 OPTIONAL R e ML w DPDT ON OFF ON 5 BOX LIFT STOP D E amp F 2 8 OPTIONAL RUN AC amp F NEP I 7 E START AB amp C BU 4 i 6 R BK DPOT ON OFF ON Son i zd ih l 2 cy PeR TAT REVERSE SWITCH IN FORWARD 7 PK A c VIO 3 2 ol NEUTRAL BY OPTIONAL KEY START MICRO SWITCH BY OPTIONAL Y BN BK re HORN OPTIONAL IGNITION SWITCH OPTIONAL 4 4 5 BN W FUSE BLOCK 4 WAY m o Y ACCELERATOR SWITCH HORN SWITCH PEDAL NOT PUSHED IN 5 7 re eae R OPTIONAL 2 F1 BK BU F 30A 194 204 of 3 AUTO Y Wa ru el RESETTING 5 ey POWER POINT 6 AMP BU HEED 4 4 n R R we OPTIONAL FUSES IN HARNESS NEAR MAIN RELAY Y 2 R BN T _ i B O BACKUP ALARM UE EE c OPTIONAL E SE BK 2 eh BU t PK HEADLIGH El gt SWITCH GROUND BLOCK P1 R R 4 W DPDT ON NONE ON 5 SOLENOID STSP BK Hour G D lt 4 METER are oll GN URE HAZARD SWITCH VOLTAGE ON NONE ON
3. m OR But REAR LIFT ym E E OPTIONAL R 5 o 2 ON OFF ON ad PAR E BOX LIFT STOP D E amp F pg OPTIONAL RUN AC amp F START AB amp C BU x NE R BK DPDT ON OFF ON OW x T vy T 7 8 VIO 1 o 2 GY OFF RUN staat REVERSE SWITCH A M E 2 IN FORWARD VIO BU OPTIONAL n KEY START KIT 0 o BU OPTIONAL MICRO SWITCH BN Bk 2 woe HORN IGNITION SWITCH OP IONAL 4 5 BN W OPTIONAL noi ACCELERATOR SWITCH FUSE BLOCK 4 WAY PEDAL NOT PUSHED IN E BU af PIS M OPTIONAL 4 2 F1 BK BU i 30A 194 m 4 3 4 AUTO Y n RESETTING w 5 60 AMP POWER POINT MAXI FUSE R R e OPTIONAL FUSES IN HARNESS NEAR MAIN RELAY Y 2 EE R BN _ _ So 2 BACKUP ALARM OPTIONAL Je as GN e i T ur n mE HEADLIGH Di p GROUND BOCK BK Cr SOLENOID STSP ak 5 HOUR D D 1 METER LOW OIL i EM PRESSURE HAZARD SWITCH REGULATOR HEAD 1 Q l i FLASHER LIGHTS FLASHER x MODULE STARTER
4. PaP OR pK cy lg REAR LIFT 8 OPTIONAL x 5 OR Ww DPDT ON OFF ON 1 T R BK 2 22 Is BOX LIF STOP D E amp F MEN z OPTIONAL RUN AC amp F D ty START AB amp C ae oS R BK ON OFF ON wae OR Ch de RS od E 7 7 7 7 VIO 2 GY OFF RUN START REVERSE SWITCH 5 2 IN FORWARD SS SSS Se P in ee ee a95 OPTIONAL d d NEUTRAL KEY START 1 BU F MICRO SWITCH pas Y Bk Pots i HORN IGNITION SWITCH OP IONAL 2 o 5 m ACCELERATOR SWITCH Fise Blocks HORN SWITCH PEDAL PUSHED IN p W OPTIONAL Fi BU Y 2 Le 60 AMP POWER POINT MAXI FUSE L 4 65 OPTIONAL FUSES HARNESS NEAR MAIN RELAY por R Y 4 a M BACKUP ALARM Pat OPTIONAL 5 o 5 2 e CN PK HEADLIGHT SWITCH GROUND BLOCK BK SOLENOIDISTSP ON NONE ON H ENERGIZED Y LOW OIL T PRESSURE HAZARD SWIT REGULATOR HEAD l FLASHER LIGHTS Q x MODULE STARTER GENERATOR TN fields 7 GN VIO LEFT FRONT armature B POWER C LEFT REAR BK D BRAKE SWITCH tE USED t W BK F RIGHT REAR rFG PILOT 4 RIGHT F
5. y one t OR 2 lg REAR LIFT lt gt s OPTIONAL R E 5 OR Ww DPDT ON OFF ON us 22 R BK 1 BOX LIFT STOP D E amp F ras OPTIONAL RUN AC amp F poene START ie ES ot R BK DPDT ON OFF ON a g E 2 zi iG 1 42 OFF RUN START REVERSE SWITCH 3 2 IN FORWARD Ke pim piss o c teat incl cc A M AD OPTIONAL 125 5 E el BU OPTIONAL MICRO SWITCH E Y 8d BN s o HORN 4 5 IGNITION SWITCH OP IONAL o BN W OPTIONAL ACCELERATOR SWITCH FUSE BLOCK 4 WAY HORN SWITCH PEDAL PUSHED IN BU Y 1 w OPTIONAL F4 F2 1 F3 BK BU a T zi s 1 AUTO Y La RESETTING 5 GY E 7 POWER POINT MAXI FUSE BU ee _ cce OPTIONAL FUSES on HARNESS NEAR MAIN RELAY di AT Y 4 25 z _ _ _ B BACKUP ALARM NETZ OPTIONAL m S88 d JEADLIGHT E HEADLIGH 01 SWITCH GROUND BLOCK BK c SOLENOID STSP 5k 4 is ENERGIZED so HOUR H D METER y LOW OIL LL gy C PRESSURE HAZARD SWITCH REGULATOR DPDT ON NONE ON HEAD C
6. LIGHTS FLASHER X MODULE STARTER GENERATOR MODULE P X BK 4 P C BU DF fields 7 GN Hm 2 A LEFT FRONT armature Y B POWER HR C LEFT REAR BK D BRAKE SWITCH io E USED R t W BK F RIGHT REAR rFG PILOT RIGHT FRONT SPARK PLUG sPARK PLUG _ MAC TURN SIGNAL SWITCH IGNITION MODULES TOP FRONT REAR BRAKE SS RPM FRAME FRAME SWITCH SHUTDOWN GROUND GROUND PK ooo GN ERAKE TURN A ENGINE OIL ENGINE 5 16 PRESSURE CONNECTION BK GROUND gi 4 ENGINE 3 er tme RE Tp SE 2 CY WARNING TURN D GN LIGHT KIT ae nw ENGINE BN P3 B 3 B BN OPTIONAL FRAME GROUND W BU ES P3 C W BU CN P3 D P3 D GN d BK BN W E3 E 3 BN W GN BRAKE TURN 4 BK GROUND B 0 5 H H TURNAND RUNNING EE Start Circuits o Workman MDX Schematic Shown B B A Power Current i cy W BK i o BK Control Current RIGHT FRONT Indication Current TURN AND RUNNING a 5 j 8 5
7. 1 4 Safety and Instruction Decals 1 6 Chapter 2 Product Records and Maintenance Product Records 2 1 Maintenance 2 1 Equivalents and Conversions 2 2 Torque Specifications 2 3 Chapter 3 Briggs amp Stratton Gasoline Engine General Information 3 2 Specifications 3 3 Adjustments che bee eee ep 3 4 Service and Repairs 3 5 Briggs and Stratton Repair Manual for 4 Cycle V Twin Cylinder OHV Head Engines Chapter 4 Single Cylinder Gasoline Engine General Information 4 2 Specifications 4 3 Adjustments gt 4 4 Service and Repairs 4 7 Kohler Service Manual for COMMAND PRO CS Series Engines Workman MD MDX Rev B Chapter 5 Drive Train General Information Specifications Drive Train Operation Special Tools Adjustments eat pa ee Service and Repairs Chapter 6 Electrical System General Information Electrical Schematics Special Tools 2 uc este ee itt ores Troubleshooting Electrical
8. 1 REGULATOR E 4 FLASHER LIGHTS 3 Q FLASHER x MODULE STARTER GENERATOR x MODULE TOP 9 F2 W BU d p G U orl fields HE Q DT onm VIO A2 L A LEFT FRON armature JA BK DIODE Y B POWER GY C LEFT REAR BK L D BRAKE SWITCH L E USED Lae F RIGHT REAR Se LR L G MAG T H RIGHT FRONT SPARK PLUG J6 TURN SIGNAL SWITCH FN J5 n S BRAKE ERONI FRAME FRAME SWITCH EOD Ge OUND PK o x CN BRAKE TURN A oj ENGINE OIL ENGINE 2 PRESSURE CONNECTION CY ia pum ix N 11 HP ENGINE P3 A P3 A BK EUM a ETHER ENGINE Es BN OPTIONAL FRAME GROUND w Bu E3 3 SU GN p3 D P3 D CN d 7 BK BN w 5 23 BN W GN BRAKEATURN og 5 BK GROUND B Lyig Ay gt t oy LEFT FRONT wek wancu oy TURN AND RUNNING rat cir B Workman MD A GY W BK S BUR BK Electrical Schematic CN RIGHT FRONT Solenoid is shown de energized TURN AND RUNNING Page8 3
9. System Workman MD MDX Page 6 33 Rev B Electrical System Battery Service The battery is the heart of the electrical system With regular and proper service battery life can be extended Additionally battery and electrical component failure can be prevented POTENTIAL HAZARD Either the battery terminals or metal tools could short against metal vehicle components WHAT CAN HAPPEN Sparks can cause the battery gasses to explode Damaged cables could short against metal ve hicle components and cause sparks HOW TO AVOID THE HAZARD When removing or installing the battery do not allow the battery terminals to touch any metal parts of the vehicle Always DISCONNECT the negative black bat tery cable before disconnecting the positive red cable Always CONNECT the positive red battery cable before connecting the negative black cable Do not allow metal tools to short between the battery terminals and metal parts of the ve hicle Always keep the battery retaining components secure to protect the battery Battery Specifications BCI Group Size U1 300 Amp Cranking Performance at 0 F 17 8 C Reserve Capacity at 25 Amps and 80 F 26 7 C is 28 Minutes Electrolyte Specific Gravity Fully charged 1 265 corrected to 80 F 26 7 C Discharged less than 1 240 Battery Removal Fig 50 IMPORTANT Be careful to not damage terminal posts or cable connectors when removing the bat tery cables
10. 14 Driven Clutch Service Serial Number Below 310000000 15 Driven Clutch Service Serial Number Above 310000000 15 1 Rer ce Mn 16 Removal 16 Installation 18 Transaxle Service 20 Transaxle Disassembly and Inspection 21 Transaxle Assembly 35 Drive Train Specifications Item Description Transaxle 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 mechanical fly weights Driven Clutch Torque sensing with spring loaded cam Drive Train Page 5 2 Workman MD MDX Drive Train Operation Clutch System Operation Figure 1 1 Drive clutch engine mounted 4 Fixed sheave drive clutch 7 Ramp fixed cam 2 Driven clutch transaxle mounted 5 Moveable sheave driven clutch 8 Spring 3 Moveable sheave drive clutch 6 Button Power is transferred from the engine to the transaxle by a variable clutch system that consists of two clutches connected by a drive belt The drive clutch respond
11. F Replace case if machined areas where the side and pinion gears mesh are scored or if the pinion shaft fits loosely in its bore G Replace pinion shaft if cracked or bent H Replace oil seal if cracked nicked or distorted such that it would not hold a proper seal Workman MD MDX 7 Workman MD disassemble governor fork and shaft Figure 48 3 1 Screw 2 used 2 Stopper 4 IMPORTANT Make sure to not damage the screw heads when removing screws Each screw is se cured with an adhesive Figure 49 1 Governor shaft 2 Boss IMPORTANT Make sure to not damage the oil seal when removing the governor shaft from the gover nor boss Governor fork Case RH A Remove both screws and washers securing the stopper and governor fork to the case RH Remove stopper and fork from the case 5 2 d 3 Oil seal B Carefully pull governor shaft from the boss C Replace oil seal if cracked nicked or distorted such that it would not hold a proper seal Workman MD MDX Page 5 33 Drive Train 1 Ball bearing 2 Case RH 3 Governor shaft Figure 50 4 5 6 D Remove ball bearing from the case Ball bearing roller balls must be free of deformation and scoring Ball bearing must spin freely and have minimum ax ial play Replace ball bearing as necessary Drive Train Page 5 34 Governor fork Stopper Screw 2 used E Replace governor shaft i
12. Spe aee EEE aee wame war 9 cm me 16 2 acr mec i ws acne we e acer NOTE Reduce torque values listed in the table above by 25 for lubricated fasteners Lubricated fasteners are defined as threads coated with a lubricant such as oil graphite or thread sealant such as Loctite NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Product Records and Maintenance Page2 4 NOTE The nominal torque values listed above for Grade 5 and 8 fasteners are based on 75 of the mini mum proof load specified in SAE J429 The tolerance is approximately 10 of the nominal torque value Thin height nuts include jam nuts Workman MD MDX Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners Class 8 8 Bolts Screws and Studs with Class 10 9 Bolts Screws and Studs with Thread Size Regular Height Nuts Regular Height Nuts Class 8 or Stronger Nuts Class 10 or Stronger Nuts M5 X 0 8 57 5 in Ib 640 60 N cm 885 80 N cm M6 X 1 0 96 9 in Ib 1018 100 N cm 133 13 in Ib 1500 150 N cm M8 X 1 25 19 2 ft lb 26 3N m 27 2 ft lb 36 3 N m M12 X 1 75 66 7 ft lb 90 10 N m 92 ft Ib 125
13. Chassis Front Hood 7 to 13 in Ib 0 8 to 1 4 N m 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 10 Hood pivot keeper 2 used 11 Screw 6 used Chassis Figure 27 Washer head screw 8 used Carriage screw 2 used Lock nut 2 used Pivot pin 2 used Spring pin 2 used Headlight bracket Flange head screw 2 used Washer head screw 20 used Washer head screw 4 used Flange nut 2 used Rubber latch 2 used Page 7 42 7 to 13 in Ib 0 8 to 1 4 N m Catch 2 used Flat washer 4 used Flange head screw 10 used Clip 3 used per headlight Flat washer 2 used Retainer 2 used Flange nut 2 used Tinnerman nut 10 used Headlight bulb 2 used Foam seal Workman MD MDX Removal Fig 27 Installation Fig 27 1 Park machine on a level surface stop engine set NOTE Do nottighten fasteners securing the hood until parking brake and remove key from the ignition all fasteners are in place 2 Remove hood using Figure 27 as a guide 1 Install hood using Figure 27 as a guide During as sembly use fastener torque specifications that are iden tified in Figure 28 Workman MD MDX Page 7 43 Chassis Cargo Box Serial Numbers Below 311000000 35 to 55 in Ib __ 24 4 0
14. 9 X Figure 5 1 Air cleaner assembly 7 Cap screw 2 used 2 Bolt 8 Air cleaner bracket 3 Compression spring 9 Flange head screw 4 used 4 Mounting band 10 Carburetor gasket 2 used 5 Nut 11 Carburetor adapter 6 Flange nut 2 used 12 Hose clamp Briggs amp Stratton Gasoline Engine Page 3 6 60 to 65 in Ib 6 8 to 7 3 N m Breather hose Adapter gasket Hose clamp Intake hose Hose clamp Intake hose Workman MDX Removal Fig 5 1 Make sure machine is parked on a level surface with the engine OFF 2 Raise cargo box and support with prop rod 3 Thoroughly clean junction of intake hose and carbu retor adapter on engine and air cleaner assembly 4 Remove air cleaner components as needed using Figure 5 as a guide Discard any removed gaskets and clean gasket mating surfaces Installation Fig 5 IMPORTANT Any leaks in the air filter system will allow dirt into 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 using Figure 5 as a guide A Install new gaskets items 10 and 14 ifthey were removed B If flange head screws item 9 were loosened or removed torque screws from 60 to 65 in Ib 6 8 to 7 3 N m C Make sure that air cleaner vacuator valve is pointed toward ground and slightly toward engine af ter as
15. C The reading should be 16 to 20 Ibf 71 to 89 N 6 Ifthe above specification is not met replace the driv en clutch 7 Install drive belt to driven clutch 8 Lower and secure cargo box 2 Figure 21 1 Moveable sheave 4 Fixed sheave 2 Ramp fixed cam 5 Drive belt 3 Button Drive Train E gt Driven Clutch Service Serial Number Above 310000000 NOTE Vehicles with a serial number above 310000000 are equipped with a TEAM brand driven clutch Fig 21 1 1 Use suitable press to compress the clutch spring enough to allow removal of the retaining ring item 7 2 Remove retaining ring 3 Carefully allow the spring to extend fully 4 Remove outer spring retainer spring and inner spring retainer from clutch 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 6 Separate the clutch sheaves Locate and retrieve thrust washer 7 Clean and inspect driven clutch components 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 if damaged or fa tigued C Check the rollers inthe fixed sheave for binding or wear If binding or uneven wear is found replace driven clutch assembly D Ch
16. ELECTRICAL SCHEMATICS Workman MD 3 Workman 4 CIRCUIT DIAGRAMS Start Circuits 5 R n GirCuits 2 ET CERTI Gra eee 6 ELECTRICAL HARNESS DRAWINGS Main Electrical Harness Drawing Serial Number Below 280999999 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 Serial Number From 290000001 to 310000800 10 Main Electrical Harness Drawing Serial Number Above 310000800 11 Main Electrical Harness Wiring Diagram Serial Number Above 310000800 12 Engine Electrical Harness Workman MD 13 Engine Electrical Harness Workman MDX 14 7 hz Electrical Workman MD MDX 8 1 Rev A Electrical Drawings This is intentionally blank Electrical Drawings Page 8 2 Workman MD MDX
17. man MD can be provided by your local Toro distributor Workman MD Specifications Item Description Make Designation 4 cycle Single Cylinder OHV Air Cooled Gasoline Engine Bore x Stroke 3 35 in x 2 48 in 85 mm x 63 mm Total Displacement 21 8 in 357 cc Governor Transaxle Ground Speed 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 1 Lubrication System Splash Lubrication Crankcase Oil Capacity 1 2 U S qt 1 11 Engine Oil See Operator s Manual Spark Plugs Champion RC 14YC or equivalent Spark Plug Gap 0 030 in 0 76 mm Starter Generator 10 5 VDC 100 Amps 14 VDC and 23 Amps Dry Weight approximate 70 5 Ib 31 9 kg Workman MD Page 4 3 Rev A Single Cylinder Gasoline Engine gt o 2 77 Gasoline Engine Adjustments Adjust Throttle Cable Serial Numbers Below 313000400 NOTE Workman MD vehicles with serial numbers be low 313000400 use a governor in the transaxle to con trol engine speed Releasing the accelerator pedal should allow the throttle cable to close the carburetor throttle control lever so that the lever touches the adjustment screw The adjustment screw keeps the throttle valve inside the carburetor open slightly to prevent the valve fr
18. 1 Position vehicle on a level surface set parking brake turn ignition switch off and remove key Electrical System Page 6 2 Raise cargo box and secure with prop rod 3 Disconnect negative black cable from battery first to prevent short circuiting the battery other components or operator s hands Then disconnect positive red cable 4 Remove wing nuts and hold down rod that secure battery 5 Make sure that filler caps are on tightly 6 Remove battery from chassis to a service area This will minimize possible battery damage and allow better access for battery inspection and service Figure 50 1 Wing nut 2 used 7 Battery tray 2 Hold down rod 8 Negative cable black 3 Positive cable red 9 Flange screw 2 used 4 Battery 10 Flange nut 2 used 5 Post 2 used 11 Battery cover 6 Battery base 34 Workman MD MDX Battery Inspection and Maintenance POTENTIAL HAZARD Battery electrolyte contains sulfuric acid which is a deadly poison and it causes severe burns WHAT CAN HAPPEN If you carelessly drink electrolyte you could die or if it gets onto your skin you will be burned HOW TO AVOID THE HAZARD Do not drink electrolyte and avoid contact with skin eyes or clothing Wear safety glasses to shield your eyes and rubber gloves to protect your hands Fill the battery where clean water is always available for flushing the skin Always RE CONNECT the positive red battery cable be f
19. 4 If caliper is equipped with anti rattle clip install clip to caliper pins and brake pads Chassis Page 7 34 Figure 22 3 Clip if equipped 1 Brake pad 2 Pin 2used Workman MD MDX This page is intentionally blank Workman MD MDX Page 7 35 Chassis Brake Master Cylinder Figure 23 1 Master cylinder 5 Cotter pin 8 Front brake line 2 Cap screw 6 Flange head nut 9 Rear brake line 3 Brake pedal 7 Pedal frame 10 Accelerator pedal 4 Clevis pin Chassis Page 7 36 Workman MD MDX Removal Fig 23 1 Raise front hood to gain access to master cylinder 2 Remove cotter pin from the clevis pin that connects master cylinder to brake pedal IMPORTANT To prevent contamination of the brake system make sure to clean components before dis assembly 3 Clean hydraulic brake line area of master cylinder to prevent contamination Remove both brake lines from master cylinder Cap ends of brake lines and position them away from master cylinder 4 Remove two 2 flange head nuts and cap screws that secure master cylinder to pedal frame 5 Pull master cylinder from machine Workman MD MDX Page 7 37 Installation Fig 23 1 Position master cylinder to pedal frame and secure with cap screws and flange nuts 2 Remove plugs from brake lines Install brake lines to master cylinder 3 Connect master cylinder to brake pedal with clevis pin and cotter pin 4 Install front hood to
20. Cap screw 2 Starter generator 7 Engine starter pulley 12 Plastic cap 3 Starter generator belt 8 Spacer 13 Drive belt 4 Starter generator pulley 9 Drive clutch 14 Engine tray 5 Cap screw 4 used 10 Washer 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 and support cargo box 2 Remove the three 3 cap screws that secure the cover to the drive clutch Fig 13 Remove the cover from the clutch When using compressed air for cleaning the clutch the dust in the clutch will become airborne and could damage your eyes or you could inhale it causing breathing difficulties Wear safety goggles and a dust mask or other eye and respiratory protection when performing this procedure Drive Train Page 5 10 Workman MD MDX NOTE Thedrive clutch on vehicles with serial numbers above 310000000 is different than the clutch used on earlier vehicles The procedure to remove or install the drive clutch is the same regardless of machine serial number Drive Clutch Removal Fig 13 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 Remove drive belt from the drive clutch 3 Remove starter generator V belt from the engine pulley 4 On vehicles with serial numbers below 310000
21. OIL PRESSURE TO ENGINE HARNESS GREEN 2 oF 2 YELLOW E SP06 3 VIOLET F 4 FIELD 5 PIO VOLTAGE REGULATOR 6 1 8 SP02 BLACK SP03 RED A T P25 FUSE RED B BLUE PINK PII OPTIONAL FUSE BLOCK BLUE 01 3 BLACK FI PINK SP05 3 4 F2 YELLOW P08 FUSE BLOCK S F3 7 F4 A PINK 8 YELLOW VIOLET D BLACK E BROWN RED BLACK Y BLACK 2 2 BLUE GREEN 3 4 BOX LIFT SWITCH 4 BLUE 5 6 F IB 8 2A Et 2B x x 5 5 x x g 8 Jo2 m 25 Q 4 m Pa 3 zi r9 a gt KEY START KIT 2 e C C 2 P06 P19 J03 J04 J05 PI2 BACKUP DIODE START RUN BOX LIFT ALARM SOLENOID ACTUATOR R23 POL ACCELERATOR P05 REVERSE Sw 15 NEUTRAL SW P24 HORN SWITCH J04 START RUN SOLENOID J07 HORN J03 START RUN SOLENOID P07 BOX LIFT P03 SWITCH TO ENGINE HARNESS J05 START RUN SOLENOID B P12 BOX LIFT ACTUATOR OPTIONAL P06 P18 FUSE BLOCK BACKUP IGNITION SWITCH P10 FIELD VOLTAGE REGULATOR 501 FUSE TERMINAL BLOCK GND BLOCK P09 LOW OIL PRESSURE WARNING r r Pt LIGHT moomoo LIGHT KIT LIGHT SW o OPTION cuc ccn P25 MAXI FUSE LIGHT INTERCONNECT Workman MD and MDX Main Electrical Harness Drawing Serial Number From 290000001 to 310000800 Page 8 9 Rev A
22. Setscrew Nut and washers 6 Pole piece Threaded terminal 7 Yoke Insulator Electrical System 2 System Rework Starter Generator Fig 24 NOTE Rework to the starter generator must be per motors and generators It may be more economically formed by a properly trained technician using the correct feasible to replace the starter generator than have it re tools and equipment for testing and reworking electrical worked at aan Electrical System Page 6 24 Workman MD MDX This page is intentionally blank 2 System Workman MD MDX Page 6 25 Electrical System Starter Generator Service Advanced Motors and Drives Starter Generator Figure 31 1 Drive head end 6 Brush kit 10 Wave washer 2 Bearing 7 Brush spring 4 used 11 Commutator end head 3 Retaining ring 8 Brush box assembly 12 Rubber plug 3 used 4 Armature assembly 9 Bearing 13 Rubber plug with weep hole 5 Frame and field assembly Electrical System Page6 26 Rev B Workman MD MDX NOTE A troubleshooting guide for the Advanced Mo tors and Drive starter generator is included at the end of this chapter Refer to this guide when diagnosing a starter generator problem on vehicles equipped with an Advanced Motors and Drive starter generator Brush and Brush Spring Service 1 Gain access to brushes by carefully removing rubber plugs from commutator end head of starter generator For assembly p
23. Spacer 5 Collar NOTE Before assembling apply molybdenum disul A Slide pin clutch onto the centershaft Install gears fide grease to the inside of gears 47 and 55 47 and 55 onto shaft noting correct orientation of gears Slide collars small gear and spacer onto the center shaft 2 Figure 56 1 Ball bearing 2 Ball bearing B Press ball bearings onto the center shaft using a C Make sure distance from one ball bearing outer bearing press edge to the other ball bearing outer edge is 136 8 to 137 1 mm Fig 55 Workman MD MDX Page 5 37 Drive Train Figure 57 The center shaft should appear as above when assembled 3 Assemble differential assembly 123 3 to 124 0 mm Figure 58 1 Pinion gear greased surface 6 Bolt 2 Pinion shaft 7 3 Side gear greased surface 8 Ball bearing 4 Differential case 9 5 Gear 62 A Apply molybdenum disulfide grease to the inside of both pinion gears where they contact the pinion shaft Apply molybdenum disulfide grease to the out side of both side gears where they contact the differ ential case and gear 62 Drive Train Page 5 38 Spring pin Ball bearing Workman MD MDX Figure 59 1 Side gear 3 Pinion shaft 2 Pinion gear 4 Differential case B Install side gear both pinion gears and pinion shaft into the differential case 5 2 Figure 60 1 Spring 3 Pinion shaft 2 Dif
24. Workman MD Page4 1 Rev B Single Cylinder Gasoline Engine General Information This Chapter gives information about specifications maintenance troubleshooting testing and repair of the single cylinder gasoline engine used in the Workman MD Workman MD vehicles with serial numbers below 311000000 have an engine that is identified as a Kohler Command Pro CS engine Workman MD vehicles with serial numbers above 311000000 have an engine that is identified as a Yamaha MZ360 engine From aservice standpoint these engines are essentially the same The Kohler Service Manual for COMMAND PRO CS Series Engines is included atthe end of this chapter and can be used when servicing either brand of engine Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Workman MD vehicle Refer to the Op erator s Manual for additional information when servic ing the machine Single Cylinder Gasoline Engine Page4 2 Rev A Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Kohler Service Manual for COMMAND PRO CS Series Engines and the use of some specialized test equipment is explained The cost of the test equipment and the specialized nature of some repairs may dictate that engine work be done at an engine repair facility Service and repair parts for the engine used in the Work
25. continued Problem Front wheel lug nuts are loose Front wheel bearings are loose or worn Steering linkage is loose or worn Tie rod ends are loose or worn Front wheel alignment toe in is incorrect Rubber shock insert or spindle bushings in A arm are loose or worn Steering is hard Tire pressure is low or uneven between tires Steering linkage is binding or damaged Front wheel alignment toe in is incorrect Steering gearbox is damaged or worn Vehicle pulls to one side when not braking Brakes Possible Cause Brake pedal goes to the floor Chassis Page 7 4 Workman MD MDX Brakes continued Workman MD MDX Chassis Adjustments Adjust Parking Brake 1 Pry the rubber cover off of the parking brake 2 Loosen the set screw securing the knob to the park ing brake lever Fig 1 3 Rotate the knob until a force from 30 to 40 Ib 133 to 177 N is required to actuate the lever 4 Tighten the set screw and install the rubber cover Figure 1 1 Parking brake lever 3 Set screw 2 Brake knob Chassis 7 6 Workman MD MDX Adjust Front Wheel Camber 1 Adjust front tire pressures to 12 PSI 82 kPa before checking front wheel camber 2 Either add weight to the driver s seat equal to the av erage operator who will run the machine or have an op erator on the vehicle operator s seat The weight or operator must remain on the seat for the duration of this front wheel
26. or pins is scaled off replace the damaged components 5 Check the contact surface of the moveable sheave for wear and or fraying If surface is worn frayed re place component 6 Inspect the clutch spring and replace if damaged or fatigued Drive Clutch Assembly Fig 14 1 If removed install rollers washers and roller pins to spider Roller pins should be lubricated with Toro part 31104 7011 see Special Tools 2 Lubricate cam weights with Toro part 4104 7011 see Special Tools Make sure lubricant penetrates to pilot bolts by rotating and sliding the weights sideto side or remove weights if needed to lubricate properly Workman MD MDX Figure 16 1 Holding bar 2 Spanner Drive Train Figure 17 2 Worn contact surface 1 Cam weight Page 5 13 Rev ej 5 46 Roller 3 Roller uneven wear 2 Weight contact surface Drive Train 3 Assemble cam weights to moveable sheave as fol lows A Make sure the threads of the pilot bolts are clean and dry Apply Loctite 271 or equivalent to the threads of each bolt IMPORTANT To maintain the balance of the clutch all pilot bolts must be installed with their threads pointing in a clockwise direction Fig 19 B Immediately install new lock nuts on the pilot bolts Tighten nuts until they just touch the sheave casting Never reuse lock nuts 4 Apply Loctite 271 or equivalent to the threads of the fixed s
27. see Rear Wheel and Brake Removal in Chapter 7 Chassis When removing engine tray make sure hoist can support the total weight of the engine transaxle engine tray and other attached components To tal weight is approximately 300 pounds 137 kg 10 Attach hoist to the engine tray to allow engine and transaxle to be lowered from the vehicle Make sure hoist is attached to hold the full weight of the engine transaxle and tray 11 Remove both flange nuts item 20 flat washers item 18 and cap screws item 19 that secure the en gine tray to the swing arm 12 Remove four 4 cap screws item 3 and flat wash ers item 2 that secure the transaxle to the swing arm Figure 23 1 Scribe mark 4 Lock nuts 2 Governor bracket 5 Cable bracket 3 Set screw 2 used m T EN oo E Figure 24 e 1 Select lever assembly 3 Shift cable 2 Lock nut location Figure 25 1 Cap screw 4 Isolation mount 2 Flat washer 5 Engine tray 3 Swing arm bracket 6 Flange nut Workman MD MDX Page 5 17 Drive Train IMPORTANT Take to not damage the engine fuel hoses electrical harness or other parts while lowering the engine tray assembly 13 Carefully move engine tray assembly toward the rear of the vehicle to clear mounts on swing arm Then lower engine tray enough to allow the transaxle and driven clutch to be removed from the rear of the vehicle Sup port engine tray in this po
28. 5 Disconnect the following components Fig 13 A Choke and throttle cables from the carburetor and cable brackets B Air intake hose from the air cleaner intake and machine frame 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 the fuel pump Fig 13 7 Remove muffler and exhaust coupler from the ma chine See Exhaust System Removal in this section 8 Remove drive belt from drive clutch 9 Loosen fasteners that secure starter generator Ro tate starter generator to loosen tension on starter belt and remove belt from the engine and starter generator pulleys 10 Remove two 2 cap screws and flange nuts that se cure oil filter adapter to filter bracket Fig 16 Carefully place filter and adapter to allow them to be removed with engine Workman MDX Page 3 15 Figure 13 4 Air intake hose 5 Fuel inlet hose 1 Throttle cable 2 Choke cable 3 Cable bracket Figure 14 1 Choke cable 4 Fuel hose 2 Throttle cable 5 Air intake hose 3 Carburetor 6 Breather hose Figure 15 1 Starter Generator ground cable to engine 2 Starter Generator terminal A1 Briggs amp Stratton Gasoline Engine sz D fe PRI Se oo nn eec 11 Disconnect electrical connections from the following engine components A Disconnect ground cable to engine at starte
29. 6 Remove both cap screws item 19 and lock nuts item 6 that secure A arm to frame Pull A arm from frame 7 If necessary remove flange bushings 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 arm to the frame with cap screws item 19 and lock nuts item 6 Insert front screw from front of machine and rear screw from rear of machine Do not fully tighten nuts 3 Position lower end of shock absorber to A arm and insert cap screw item 7 with flat washer item 5 from rear of shock Secure with lock nut item 6 4 Fully tighten lock nuts item 6 to secure A arm to machine frame 5 Install spindle and front wheel to the A arm see Lower Steering and Front Wheel Installation in this sec tion 6 Lower machine to ground Make sure that wheel lug nuts are properly torqued in a crossing pattern from 45 to 65 ft Ib 62 to 88 N m 7 Align front wheel toe in see Adjust Front Wheel Toe in in the Adjustments section of this chapter Workman MD MDX Page 7 19 Chassis Frame Pivot Yoke Figure 11 1 Flange nut 4 used 8 LH A arm 2 Shock absorber 2 used 9 Grease fitting 1 used per arm 3 Cap screw 4 used 10 Screw 4 Rubber bumper 11 Cap screw 5 Flat washer 12 RH A arm 6 Lock nut 4 used per side 13 Lock washer 7 Cap screw 2 used p
30. ARMATURE 2 ROTOR 15 to 25 ft lb 20 to 34 N m 96 to 104 in Ib dC I Sd j 35 to 43 in Ib 10 8 to 11 8 N m A 4 0 to 4 9 N m Figure 25 1 Yoke 9 Screw lock washer amp flat washer 17 Field coil stator assembly 2 Armature kit 10 Spring washer 18 Screw and mold assembly 3 Ball bearing 11 Hex nut 19 Screw set 4 Bearing retainer 12 Woodruff key 20 Screw set 5 Ball bearing 13 Screw and washer 21 End cover commutator 6 Spacer 14 End cover front 22 Brush holder kit 7 Through bolt amp flat washer 15 Pulley 23 Brush spring 8 Brush cover 16 Pole piece and set screw 24 Brush and screw set Electrical System Page6 20 Rev B Workman MD MDX Brush and Brush Spring Service Fig 24 IMPORTANT When removing or installing the com mutator end cover make sure brushes do not con tact the commutator Damage to the brushes may result 1 Remove brush covers from the commutator end cov er Lift brush springs from the notch at the end of the brushes while pulling the brushes out Allow springs to hold brushes out from the center Fig 25 2 Remove both through bolts and flat washers secur ing the commutator end cover to the yoke Separate end cover from the commutator and yoke IMPORTANT Use clean dry lint free rags when cleaning the starter generator When using com pressed air air shou
31. CANISTER FRESH AIR FILTER Figure 13 Workman MD vehicles with serial number above 310000000 are equipped with a fuel evaporative control system EVAP designed to collect and store evapora tive emissions from the fuel tank The EVAP uses a car bon canister to collect these evaporative emissions Fuel vapors from the fuel tank are vented to the canister where they are stored Vapors from the canister are con sumed when the engine is running which purges the 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 venting through the carbon canister NOTE Ifthere is restriction in the fresh air filter the car bon canister or the rollover valve the fuel tank may dis tort due to venting issues If the fuel tank returns to it s normal shape when the fuel cap is removed restriction in the evaporative control system is likely Figure 14 1 Hose from check valve 3 Hose from engine 2 Hose to air cleaner Machines with a carbon canister include a single engine connection to the engine intake system that is used to connect the evaporative system to the engine These machines use an inline check valve between the carbon canister and the engine fitting Evaporative control sys tem components for Workman MD vehicles are shown in Figure 15 Single Cylinder Gasoline Engine
32. INSTRUCTION DECALS 6 Workman MD MDX Page 1 1 Safety Safety Instructions The Workman MD and MDX series vehicles are de signed 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 opera tion transport maintenance and storage of the ma chine Improper use or maintenance ofthe machine can result in injury or death Read and understand the contents of the Operator s Manual before starting and operating the machine Be come familiar with all controls and know how to stop it quickly Additional copies of the Operator s Manual are available on the internet at www Toro com Supervisor s Responsibilities 1 Make sure operators are thoroughly trained and fa miliar with the Operator s Manual and all labels on the vehicle Before Operating 1 Read and understand the contents of the Operator s Manual and Operator s DVD before starting and operat ing the vehicle Become familiar with the controls and know how to stop the vehicle and engine quickly Addi tional copies of the Operator s Manual are available on the internet at www 2 Keep all shields safety devices and decals in place Ifa shield safety device or decal is defective illegib
33. Insert hot end of the allen wrench into the button so it melts around the end of the wrench Hold wrench in place until the button hardens 7 Pull and twist on the allen wrench to remove the but ton from the ramp NOTE If the new button is difficult to install sand its mounting tab 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 needed remove and install remaining buttons 10 Carefully remove block of wood that was placed to keep the clutch ramps apart 11 Install drive belt to the driven clutch 12 Lower and secure cargo box Workman MD MDX Page 5 15 Rev Check Driven Clutch Spring Tension Fig 21 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 Place transaxle in gear to prevent the fixed sheave from moving 3 Remove drive belt from the driven clutch IMPORTANT Use protective strips of soft metal when clamping the moveable sheave with locking pliers to prevent damage to the sheave 4 Clamp moveable sheave with locking pliers 5 Measure spring torsion A Pull scale tangentially to the outer diameter of the moveable sheave B When the button on the ramp of the moveable sheave is 0 125 inch 3 18 mm from the ramp of the fixed sheave read the scale
34. JOT LIGHT P02 SWITCH HOUR METER PIT IGNITION SWITCH PWR START LOADCIGN GND MAG LOAD NEUTRAL SWITCH Pls LOW OIL PRESSURE WARNING LIGHT 09 Workman MD and MDX LIGHT T Main Electrical Harness Wiring Diagram Serial Number Below 280999999 8 8 Rev A OPTION pe REVERSE HORN SWITCH POWER POINT HEAD LIGHT HEAD EIGHT NIMM 5 5 pu ACCELERATOR SW TCL P24 PoI GND P22 P23 Pld SiS P04 P05 o m 301 NC NO NO NC o o A B a BE acd Fo wu Bc 123 4 5 12 34 x 5 i x x x E Q ues 5 lt y Q ur x E lt a 9 5 Ow Fa 5 3 zi X 2 a I z Om 614 a 2 5 53 gt orans Dm m Sor gt YELLOW I BL Es I BLACK BLACK ENGINE GROUND i 8 MAGNETO 2 WHITE BLUE4
35. Loctite 242 Antiseize lubricant Figure 4 1 Hexnut 7 Lock washer 6 used 12 Steering column 2 Flat washer 8 Steering shaft 13 Dust cover 3 Steering wheel 9 Cap screw 4 used 14 Collar 4 Flange nut 4 used 10 Bearing 2 used 15 Set screw 5 Steering box assembly 11 Carriage bolt 4 used 16 Steering wheel cover 6 screw Disassembly Fig 4 3 Carefully remove steering wheel cover from the steering wheel Remove nut and flat washer securing 1 Park machine on a level surface stop engine set the steering wheel to the steering shaft Pull steering parking brake and remove key from the ignition switch wheel from the shaft 2 Raise front hood to gain access to the steering com 4 Remove cap screw and lock washer securing the ponents lower steering shaft knuckle to the steering gearbox in put shaft Pull knuckle from the gearbox shaft Chassis Page 7 10 Workman MD MDX 5 Support steering column to prevent it from falling Remove four 4 flange nuts and carriage screws secur ing the steering column to the mounting plate on the frame 6 Remove dust cover item 13 fromthe 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 Remove four 4 cap screws and lock washers that secure the steering gearbox to the tower plat
36. Secure driven clutch to the transaxle input shaft with cap screw and stepped washer Torque cap screw from 39 to 47 ft lb 53 to 63 N m 4 Install drive belt to the driven clutch 5 Install muffler to the engine and engine mount see Exhaust System Installation in the Service and Repairs section of Engine Chapter 6 Lower and secure cargo box Antiseize Lubricant 1 Cap screw 2 Stepped washer Drive Train 5 14 Rev Figure 20 3 4 39 to 47 ft Ib 53 to 63 N m Driven clutch Input shaft transaxle Workman MD MDX Driven Clutch Service Serial Number Below 310000000 NOTE Vehicles with a serial number below 310000000 are equipped with a Comet brand driven clutch Ramp Button Replacement Fig 21 1 Park vehicle on a level surface stop engine set parking brake and remove key from the ignition switch Raise and support cargo box 2 Remove drive belt from the driven clutch see Ser vice Drive Belt in Service and Repairs section of Engine Chapter 3 Turn fixed and moveable sheaves in opposite direc tions so button is separated sufficiently enough from the ramp to allow removal 4 Place small block of wood between the outer ramps to keep the ramps apart A CAUTION To prevent burns hold allen wrench with locking pliers when heating allen wrench 5 Clamp long end of a2 mm allen wrench with locking pliers Heat short end of the allen wrench until it is red hot 6
37. Stratton 4 cycle V Twin Cylinder OHV Air Cooled Gasoline Engine Model 303440 Bore x Stroke 2 68 x 2 60 68 mm x 66 mm Total Displacement 29 3 in 480 Governor Mechanical Governor 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 1 Lubrication System Pressure Lubrication Gear Driven Geroter Oil Pump Crankcase Oil Capacity 1 75 U S qt 1 66 I with new filter Engine Oil See Operator s Manual Ignition System Flywheel magneto twin electronic armatures Spark Plugs Champion RC 12YC or equivalent Spark Plug Gap 0 030 0 76 mm Starter Generator 10 5 VDC 100 Amps 14 VDC and 23 Amps Dry Weight approximate 72 Ib 32 4 kg Workman MDX Page 3 3 Briggs amp Stratton Gasoline Engine eo o o gt 2 a o Adjustments Adjust Throttle Cable NOTE The Workman is equipped with an engine governor Refer to the Briggs amp Stratton Repair Manual at the end of this chapter for governor information on these machines Depressing the accelerator pedal rotates the engine governor bellcrank which tensions the main governor spring to increase engine speed Releasing the acceler ator pedal decreases governor spring tension to reduce eng
38. System Workman MD MDX Page 6 11 Electrical System Accelerator Switch The accelerator switch is a four 4 terminal two 2 cir cuit switch The switch is attached to the pedal support Fig 11 When the accelerator pedal is pushed the switch allows current flow to the start run solenoid hour meter and en gine oil indicator and also provides an open circuit to the engine ignition system to allow the magneto ignition to operate With the accelerator pedal released the switch provides a grounding circuit for the engine ignition sys tem and also prevents current flow to the start run sole noid hour meter and engine oil indicator Testing 1 Place machine shift lever in the NEUTRAL position Turn ignition switch off remove key from ignition switch Figure 11 and engage parking brake 1 Pedal support 5 Accelerator switch 2 Accelerator pedal 6 Plate 2 Raise hood to gain access to accelerator switch 3 Nut 7 Cap screw 2 used 4 Cap screw 3 Unplug wiring harness connector from switch 4 With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the switch terminals for both switch positions Verify continuity between switch termi nals using the following table PLUNGER NO POSITION CONTINUITY CONTINUITY SIDE VIEW Adjustment 1 Adjust cap screw on accelerator pedal so switch Figure 12 plunger i
39. System Quick Checks Component Testing Service and Repairs ADVANCED MOTORS amp DRIVES STARTER GENERATOR TROUBLESHOOTING GUIDE Chapter 7 Chassis General Information 7 1 Specifications 7 2 Special Tools 7 2 Troubleshooting 7 3 Adj stinents keep s 7 6 Service and Repairs 7 9 Chapter 8 Electrical Drawings Electrical Schematics 8 3 Circuit Diagrams 8 5 Electrical Harness Drawings 8 7 Product Records and Maintenance Briggs amp Stratton Gasoline Engine Single Cylinder Gasoline Engine Drive Train Electrical lt This is intentionally blank Workman MD MDX Chapter 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS 2 Supervisor s Responsibilities 2 Before Operating 2 While 3 Maintenance and Service 3 JACKING AND OTHER INSTRUCTIONS 4 Jack Vehicle 4 Transport Vehicle 4 Tow Vehicle 000 cee ences 4 Transaxle Neutral 5 5 SAFETY AND
40. a new decal Part numbers are listed in the Parts Catalog Order replacement decals from your Au thorized Toro Distributor Safety Page 1 6 Workman MD MDX Chapter 2 TORO Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 MAINTENANCE RO ee d 1 LE EQUIVALENTS AND CONVERSIONS 2 Decimal and Millimeter Equivalents 2 E U S to Metric Conversions 2 5 TORQUE SPECIFICATIONS 3 Fastener Identification 3 Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series 4 Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Fasteners 5 Other Torque Specifications 6 Conversion 6 Product Records Insert Operator s Manual and Parts Catalog for your Workman at the end of this chapter Additionally if any optional equipment or accessories have been installed to your machine insert the Installation Instructions Op erator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals for your Workman are covered in the Operator s Manual Referto that publication when performing regu lar equipment maintenance Workman MD MDX Page 2 1 Product Records and Maintenance Decimal an
41. and obstructions 6 After bleeding of brakes is completed test vehicle to make sure brakes are operating correctly and pedal is solid Chassis Seat Base Seat 2 used Seat bracket 2 used Cap screw 8 used Seat base Shift cable 2 used Choke cable Shift bracket Short screw 4 used Long screw 4 used 10 Fuel tank 11 Web strapping Chassis Figure 25 Flange head screw 12 used Flat washer 4 used Shifter plate Rubber receptacle 2 used Holding post 2 used Screw 2 used Rivet 2 used Decal Parking brake support Cap screw Curved washer Page 7 40 Lock nut Parking brake lever Equalizer bracket Clevis pin Flat washer Cotter pin Parking brake cover Knob Screw 2 used Retaining ring 2 used Flat washer 2 used Workman MD MDX Seat Base Removal Fig 25 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Flip both seats forward and remove them from the seat base 3 Remove parking brake assembly from seat base see Parking Brake Disassembly in this section 4 Unscrew knob from the shift lever Remove four 4 short cap screws securing the shift plate to the shift bracket Fig 26 5 Remove four 4 long cap screws securing the shift plate to the seat base Fig 26 Separate shift bracket from the choke cable and sea
42. are aligned Torque spider from 190 to 220 ft Ib 258 to 298 N m 5 Install limiter shim item 2 onto the fixed sheave post 6 Position cover to clutch Make sure that the X mark cast into the cover spider and moveable sheave are aligned 7 Secure cover to the moveable sheave with three 3 cap screws Torque cap screws from 132 to 168 in Ib 15 0 to 18 9 N m Figure 19 2 1 Holding bar 2 Spanner 5 2 Workman 5 13 4 Rev A Drive Train Driven Clutch NOTE The driven clutch on vehicles with serial num bers above 310000000 is different than the clutch used on earlier vehicles The procedure to remove or install the driven clutch is the same regardless of machine seri al number Driven Clutch Removal Fig 20 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 Remove muffler from the engine and engine mount see Exhaust System Removal in Engine Chapter 3 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 5 Pull driven clutch from the transaxle input shaft Driven Clutch Installation Fig 20 1 Coat transaxle input shaft with antiseize lubricant 2 Position driven clutch to the input shaft Make sure pulley side of the clutch faces away from the transaxle case 3
43. beneath the cargo box to a bracket on the right hand side of the rear frame Fig 8 Testing NOTE Prior to taking small resistance readings with a digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from the measured value of the component you are testing 1 Place machine shift lever in the NEUTRAL position Apply parking brake Make sure engine is off 2 Raise cargo box and secure with prop rod Gain ac cess to start run solenoid by removing the electrical cov er 3 Disconnect negative black cable from battery and then disconnect positive red cable see Battery Ser vice in the Service and Repairs section of this chapter 4 Note wire 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 click as the solenoid coil is energized Make sure resistance across the main con tact posts copper is less than 1 ohm 6 Remove voltage from solenoid coil posts The sole noid should click as the solenoid coil is de energized Make sure resistance across the main contact posts is infinite ohms 7 Resistance across the solenoid coil posts steel should be approximately 13 5 ohms 8 Replace start r
44. camber procedure 3 Onalevel surface roll the vehicle straight back from 6 to 10 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 straight ahead 5 Measure the front wheel camber on both front wheels A Place a 90 square on the ground with the vertical edge touching the face of the tire Fig 4 B From the same part of the rim measure the dis tance from the top and bottom of the rim to the square Record the two 2 measurements C The measurement at the 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 measurement for either wheel is incorrect adjust shock absorber spring to correct camber for that wheel A Chock wheels to prevent the vehicle from mov ing Use a jack to raise vehicle and allow shock ab sorber to extend This will allow easier shock spring adjustment B Use spanner wrench TOR6010 see Special Tools in this chapter to rotate shock absorber collar which changes the length ofthe shock spring Fig 5 If the bottom camber measurement was too short rotate the collar to reduce the length of the shock spring If the bottom camber measurement was too long rotate the collar to increase the
45. care to not damage the engine transaxle fuel hoses electrical harness or other parts while lowering the swing arm and engine tray assembly 9 Carefully lower swing arm and engine tray assembly just enough to allow clearance for swing arm removal Workman MD MDX Page 7 23 Figure 14 1 Engine 6 Flange nut 2 used 2 Washer 4 used 7 Mount 2 used 3 screw 4 used 8 Transaxle 4 Swing arm 9 Cap screw 2 used 5 Engine tray 10 Washer 2 used Figure 15 1 Cap screw 4 Isolation mount 2 Flat washer 5 Engine tray 3 Swing arm bracket 6 Flange nut 10 Support swing arm and engine tray assembly in this slightly lowered position to prevent it from shifting or fal ling 11 Remove both flange nuts flat washers and cap screws that secure the engine tray to the swing arm Fig 14 12 Remove four 4 cap screws and flat washers that se cure the transaxle to the swing arm Fig 14 13 Remove swing arm from assembly Chassis Installation Fig 13 1 Position swing arm to engine tray assembly 2 Make sure that isolation mounts are positioned in the swing arm so that the flange is positioned between the swing arm bracket and engine tray location Fig 15 3 Secure engine tray to the swing arm with cap screws flat washers and flange nuts Fig 14 4 Secure transaxle to swing arm with four 4 cap screws and flat washers Fig 14 IMPORTANT Take care to not damage the e
46. case RH and lift up while lightly tapping boss too hard when separating the cases the boss the governor boss with a plastic hammer may get damaged Do not pry open the two cases with a screw driver damage may result to the seal ing surfaces 2 Remove input shaft center shaft and differential assemblies Figure 33 1 Gasket 2 Pipe knock A Remove gasket and pipe knocks Drive Train Page 5 24 Workman MD MDX Figure 34 1 Counter shaft 3 Needle bearing 2 Spacer 2 used 4 Gear 34 B Pull out counter shaft Remove spacer needle bearing gear 34 and spacer 4 Figure 35 1 Counter shaft 3 Needle bearing 2 Spacer 2 used 4 Gear 34 C Replace counter shaft if it has abnormal wear E Replace needle bearing if needles are bent do cracks or damage not rotate freely or do not remain in the bearing cage D Replace spacer if either one is cracked or bent F Replace gear 34 if worn or damaged Cracked broken missing or chipped gear teeth are not ac ceptable Workman MD MDX Page 5 25 Drive Train 5 2 Figure 36 1 Differential assembly 3 Center shaft assembly 2 Input shaft assembly 4 Shift shaft IMPORTANT Make sure not to damage the oil seal G Lift up differential assembly center shaft assem when removing the input shaft bly and input shaft assembly at the same time First remove input shaft assembly Then remove center shaft assembly
47. in cylinder bore Assembly Fig 24 1 Apply a film of clean brake fluid to cylinder bore and piston assemblies 2 Install secondary piston assembly and primary pis ton assembly into cylinder 3 Install retainer washer 4 Install push rod and secure in place with circlip Install lower end of dust cover to housing 5 Push in on push rod so stop pin can be installed to retain secondary piston assembly then install flange seal and reservoir Chassis Page 7 38 Workman MD MDX Bleed Brake System IMPORTANT To prevent contamination of the brake system make sure to clean components before dis assembly 1 Connecta suitable transparent hose to bleeder valve rear wheel brake cylinder or front brake caliper Sub merge other end of hose in a glass container partially filled with clean brake fluid 2 Have a helper pump brake pedal several times then hold pedal down firmly 3 With pedal firmly depressed open bleeder valve of brake until pedal fades to floor Close bleeder valve be fore releasing pedal 4 Repeat procedure until a continuous flow of brake fluid with no air bubbles is released from bleeder valve Make sure fluid level is maintained in brake fluid res ervoir at all times Workman MD MDX Page 7 39 5 Repeat steps 1 to 4 for other rear brake cylinders and front calipers After servicing the brakes always check the brakes in a wide open level area that is free of other persons
48. in the threaded hole of the fixed clutch sheave after the clutch holding cap screw is removed Toro 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 This kit is required to remove the drive clutch spider from the post of the fixed sheave Kit includes spanner and clutch holding bar Toro Part Number TOR6016 NOTE Vehicles with serial number above 310000000 are equipped with a TEAM brand drive clutch Figure 8 2 1 Holding bar 2 Spanner S 2 a Workman MD MDX 5 6 1 Rev A Drive Train This page is intentionally blank Drive Train 5 6 2 Rev A Workman MD MDX Adjustments Adjust Ground Speed Workman MD with Serial Number Below 313000400 Workman MD models with serial number below 313000400 are equipped with a transaxle governor Ad just ground speed using the following procedure for these vehicles Vehicles operating at ground speeds greater than the recommended speed will require further distances to fully stop Do not adjust ground speed greater than specified 1 Park machine on a level surface stop engine and re move key from the ignition switch Raise and support cargo box Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Jack up rear of vehicle so both rear
49. length of the shock spring C Lower vehicle to level surface Workman MD MDX 7 7 Rev A 7 Repeat steps 2 through 6 until front wheel camber on both wheels is correct 8 After camber adjustment check front wheel toe in see Adjust Front Wheel Toe in in this section Figure 4 1 Front wheel 2 90 square 3 Top measurement 4 Bottom measurement Figure 5 1 Shock absorber spring 2 Collar 3 Spring length Chassis 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 2 Either add weight to the driver s seat equal to the av erage operator who will run the machine or have an op erator on the vehicle operator s seat The weight or operator must remain on the seat for the duration of this front wheel toe in procedure 3 Onalevel surface roll the vehicle straight back from 6 to 10 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 straight ahead 5 Measure distance between the front tires at axle height at both the front and rear ofthe tires Fig 6 Front wheel toe in should be from 0 to 1 4 inch
50. remove key from the ignition switch 2 Raise and support cargo box with prop rod 3 Remove muffler from machine see Exhaust System Removal in the Service and Repairs section of Engine Chapter 4 Disconnect parking brake cables from rear brake levers and swing arm Remove cable ties that secure rear brake lines to swing arm Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 5 Jack up both sides of the frame enough to lower swing arm and engine tray assembly A Chock the front and rear of both front tires to pre vent the vehicle from moving B After raising the machine support both sides of the frame with appropriate jack stands positioned just in front of the rear axle tubes This will allow the swing arm and engine tray assembly to be lowered from the vehicle When lowering swing arm and engine tray as sembly make sure hoist can support the total weight of the engine transaxle engine tray and other attached components Total weight is approximately 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 engine transaxle and tray 7 Remove cap screw and lock nut that secure both shock absorbers to swing arm 8 Remove cap screws thrust washers and lock nuts that secure swing arm to machine frame IMPORTANT Take
51. section of Chapter 7 Chassis 2 Use fuel transfer pump to remove gas from fuel tank 3 Loosen hose clamp and disconnect fuel hose from the fuel tank stand pipe 4 Release tank strap that secures fuel tank to frame Do not remove strap from floor plate and frame cross member Lift tank from frame NOTE Workman MDX vehicles with serial number above 310000000 are equipped with a fuel evaporative control system EVAP designed to collect and store evaporative emissions from the fuel tank Fuel tank components for these vehicles are shown in Fig 11 5 f necessary remove stand pipe fuel gauge and bushings from tank Fuel Tank Installation Fig 10 1 If removed install bushings stand pipe and fuel gauge to tank 2 Position fuel tank to frame Secure tank to frame and cross member with tank strap 3 Connect fuel hose to the tank stand pipe and secure with hose clamp 4 Install seat base to the frame see Seat Base Instal lation in the Service and Repairs section of Chapter 7 Chassis 5 Fill fuel tank Workman MDX 1 2 3 1 2 1 2 3 4 5 Page 3 11 Figure 9 Shift lever 4 Cap screw long Cap screw short 5 Choke cable Shift plate Briggs amp Stratton Gasoline Engine Figure 10 3 Tank strap Fuel hose Fuel tank Fuel tank 6 Fresh air filter Carbon canister 7 Fuel hose purge hose Rollover valve 8 Check valve Fuel hose tank vent 9 Fuel hose to e
52. sheave Pull cover from clutch 2 Remove four 4 cap screws and lock washers that secure the engine starter pulley and starter spacerto the drive clutch Remove pulley and spacer from clutch Workman MD MDX 3 Use two 1 4 20 X 1 cap screws to secure the spider removal holding bar See Special Tools to drive clutch Fig 16 4 Secure clutch with attached spider removal holding bar in a vise Matchmark position of spider and move able sheave for reassembly purposes A CAUTION Remove spider from fixed sheave slowly The moveable sheave is under pressure from the spring IMPORTANT Use spider removal spanner to re move spider Unequal pressure on the cam towers may damage them 5 Using spider removal spanner see Special Tools remove spider from the fixed sheave post Fig 16 6 As needed remove cam weights from moveable sheave and roller kits from spider using Figure 14 as a guide Drive Clutch Inspection 1 Inspect the tapered ends of the crankshaft and pri mary fixed sheave for scratches If either is severely scratched replace component If scratches are minor burnish the component with emery cloth 2 Check the surface of the cam weights Fig 17 If worn replace all cam weights as a set 3 Checkthe rollers Fig 18 If binding or uneven wear is found replace all rollers as a set 4 Clean pilot bolts and roller pins with 800 1000 grit abrasive paper Ifthe chrome plated surface ofthe bolts
53. so the diamond pattern faces up Secure yoke to front frame with four 4 flange head screws and flanged lock nuts Tighten lower two 2 fasteners first then tighten upper two 2 fasten ers 2 Secure pivot yoke to the front frame tab with cap screw and hardened washer Torque cap screw from 240 to 290 ft Ib 326 to 393 N m Workman MD MDX Page 7 21 3 Secure pivot yoke to the rear frame with four 4 cap screws and flat washers 4 Install seat base to the front frame see Seat Base Installation in this section 5 Install cargo box to the rear frame see Cargo Box Installation in this section Figure 12 1 Cap screw amp flat washer 2 Pivot yoke 3 Rear frame 4 Flange lock nut 5 Front frame 6 Diamond pattern Chassis Swing Arm 95 to 122 N m Flange nut 4 used Hitch Flange head screw 4 used Bushing 2 used Rear frame Retaining ring 2 used Washer head screw 2 used Chassis Figure 13 R clamp 2 used Rear shock assembly 2 used Cap screw 2 used Rubber bumper 2 used Swing arm Cable tie Lock nut 4 used Page 7 22 15 Lock nut 2 used 16 Thrust washer 4 used 17 Cap screw 2 used 18 Parking brake cable 2 used 19 Cap screw 2 used 20 Cotter pin 2 used 21 Clevis pin 2 used Workman MD MDX Removal Fig 13 1 Park machine on a level surface stop engine set parking brake and
54. the brushes so the brushes do not go into the brush box fully 13 Verify the correct position of the brushes If the brushes are not in the correct orientation the starter generator will not function A Terminal A1 connects to brush boxes 2 and 4 B Terminal A2 connects to brush boxes 1 and 3 14 Assemble the brush box to the commutator end head Make sure that the brush leads are dressed prop erly that the leads are not pinched under the brush box and that the copper shunts do not contact the aluminum end head Secure brush box to end head with two 2 screws Torque screws from 22 to 26 in Ib 2 5 to 2 9 N m Figure 42 Electrical System 6 30 Rev B Workman MD MDX 15 Secure A1 and A2 terminals to commutator end head with fiber washer flat washer lock washer and nut on each terminal Torque nuts from 40 to 50 in Ib 4 6 to 5 6 N m 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 in Ib 5 6 to 7 4 N m 17 Position the starter generator on the commutator end head and support the assembly to prevent damage to the terminals in the end head 2 System Workman MD MDX Page 6 31 Rev B Electrical System 18 Make sure that brushes are pushed back in brush holders so they will not interfere with armature installa tion 19 Position wave washer into
55. the ac celerator pedal decreases governor spring tension to reduce engine speed 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Lift cargo 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 speed DO NOT use driven clutch on transaxle for speed measurement 4 With ignition switch in the RUN position depress ac celerator pedal and allow engine to start Fully depress accelerator pedal and have a second person measure engine speed with a tachometer With pedal fully de pressed engine speed should be from 3250 to 3350 RPM If necessary adjust jam nuts on throttle cable so that engine speed is correct when the accelerator pedal is fully depressed 5 After throttle cable adjustment is correct lower and secure cargo box Workman MD Page4 5 Rev B Figure 3 1 Throttle cable 2 Throttle lever 3 Engine governor spring 4 Engine governor lever 5 Cable jam nut Single Cylinder Gasoline Engine gt 2 gt o Gasoline Engine This is intentionally blank Single Cylinder Gasoline Engine Page 4 6 Workman MD Service and Repairs Cooling System To ensure proper engine cooling make sure the grass screen cooling fins and other external surfaces of
56. tor s Manual for additional information when servicing the machine Workman MD MDX Page 7 1 Rev A Chassis Specifications Item Description Front Tire Workman MD and MDX Pressure Range 22 x 9 5 10 2 ply 8 to 22 PSI 56 to 151 kPa Rear Tire Workman MD Pressure Range 22 x 9 5 10 2 ply 8 to 22 PSI 56 to 151 kPa Rear Tire Workman MDX Pressure Range 24 x 12 10 2 ply 8 to 22 PSI 56 to 151 kPa Wheel Lug Nut Torque 45 to 65 ft Ib 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 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 exten sion before using spanner wrench Toro Part Number TOR6010 Shock Spring Compressor Use shock spring compressor to remove spring from front shock absorber Toro Part Number TOR6015 Chassis Page 7 2 Rev A Figure 1 Figure 2 Workman MD MDX Troubleshooting Suspension and Steering Front end is noisy Rear end is noisy Rear wheel lug nuts are loose Rear shocks are loose or worn Rear swing arm is loose Clutch or transaxle problem see Chapter 5 Drive Train Excessive steering play Workman MD MDX 7 3 Chassis Suspension and Steering
57. use solvent Make sure slots between com mutator bars are free of dust and metal particles 9 Inspect field coils Fig 29 A Replace field coils if insulation is blackened charred flaking or cracked B Make sure poles are tight Q Figure 28 1 Armature 3 Armature shaft 2 Commutator Workman MD MDX IMPORTANT Do not remove field coils unless they are to be replaced 10 To remove field coils Fig 29 A Remove nuts from threaded terminal Slide insu lator and terminal out of yoke B Remove four 4 pole piece screws and pole sets from the yoke Remove field coils from the yoke l Assemble starter generator as follows A Position field coil into yoke Make sure both insu lators that look similar go into the slots marked F1 and F2 The different looking insulator goes into the slot marked DF Seat insulators into slots Fig 29 IMPORTANT Make sure field coil terminal wire will not make contact with the armature B Install terminals through wire connectors and in sulators Secure flat washer lock washer and nut onto each terminal Torque nuts from 43 to 52 in Ib 4 9 to 5 9 N m Fig 29 C Position all four 4 pole pieces into the yoke Se cure pole pieces with set screws Torque screws to 9 ft Ib 12 N m Fig 29 D Position bearing retainer onto the output shaft of the armature Press new ball bearing onto the shaft being careful not to damage the retainer E Press new
58. wheels are at least 1 inch 25mm offthe ground Support the rear axle tubes on appropriate jack stands 3 Chock front and rear of both front tires to prevent the vehicle from moving 4 Make sure that the shift lever is in the neutral posi tion 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 should be from 3550 to 3650 RPM 6 If ground speed adjustment is necessary drill out an odized rivet and retain anti tamper bracket for rein stallation Fig 9 Workman MD MDX Page5 7 Rev B 7 Adjust throttle cable accelerator pedal transaxle at the cable bracket until the correct driven clutch RPM is obtained with the accelerator pedal fully to the floor Fig 9 8 Install anti tamper bracket to the cable bracket using a new anodized rivet Toro P N 99 7122 Fig 9 9 Lower machine to ground Lower and secure cargo box NOTE Ifunable to identify the driven clutch RPM an al ternate method to verify ground speed would be to de termine the distance that the vehicle will travel on level ground in three 3 seconds with the accelerator pedal to the floor The Workman MD should travel 62 feet 18 8 meters in three seconds If necessary adjust ground speed using steps 6 through 8 above Figure 9 3 Throttle cable 4 Cable bracket 1 Anodized riv
59. with the shift shaft and differential as sembly NOTE If any of the assemblies can not be pulled out by hand hold the assembly while gently tapping the case with a plastic hammer Make sure to tap equally around the case 3 Remove axle case from case RH and LH Figure 37 3 Transaxle case 1 Flange bolt 2 Axle case A Remove remaining two 2 flange bolts securing each axle case to the case Remove axle case from the transaxle case Drive Train Page 5 26 Workman MD MDX Figure 38 1 Snap ring 3 Axle shaft 2 Axle case 4 Ball bearing IMPORTANT Do not reuse snap ring Discard and C Ball bearing roller balls must be free of deforma replace ring with new one tion and scoring Ball bearing must spin freely and have minimum axial play Replace ball bearing as B Remove snap ring from the axle case Remove necessary axle shaft from case IMPORTANT When replacing ball bearings both ball bearings must be replaced as a set 4 Disassemble input shaft assembly a 2 Figure 39 1 Input shaft 2 Governor sleeve Workman MD A On Workman MD remove governor sleeve from the input shaft Workman MD MDX Page 5 27 Drive Train Figure 40 2 Input shaft 1 Ball bearing IMPORTANT Do not reuse ball bearings that have been removed B Remove ball bearing from the input shaft with a bearing puller Figure 41 2 Governor base 1 Governor plate assemb
60. 0 Page 8 11 Rev J06 HORN JOT LIGHT SW PO HOUR PIT IGNITION SW PWR START LOAD IGN PI8 GND MAG LOAD NEUTRAL SW PIS LOW OIL PRESSURE WARNING LIGHT 09 Workman MD and MDX Main Electrical Harness Wiring Diagram Serial Number Above 310000800 Page 8 12 Rev A LIGHT KIT ENGINE GROUND MAGNETO OIL PRESSURE P03 pr TO ENGINE HARNESS P25 MAXI FUSE PII OPTIONAL FUSE BLOCK FI F2 P08 FUSE BLOCK F3 5 OPTION um TERMINAL HEAD LIGHT HEAD LIGHT LIGHT ett se BLOCK HORN SWITCH POWER POINT LS RS INTERCONNECT an eee es GND ACCELERATOR REVERSE SW P24 POI P23 4 P13 J01 P04 P05 y oh NC NO NO NC o o A B a C D A 8 C DE 234 1 2 3 4 wd r e x x gt x orn x gt E g Wx Sky 2 23 9 4 9
61. 0 to 6 mm 6 Ifthefrontwheeltoe inis incorrect adjust as follows A Loosen jam nuts at both ends of tie rods Fig 7 B Rotate both tie rods to move front of tire inward or outward C Tighten tie rod jam nuts when toe in adjustment is correct 7 Ensure that there is full steering travel in both direc tions 1 1 Jam nut Chassis Page 7 8 Rev Figure 6 Tire center line back 3 Axle center line 2 Tire center line front Figure 7 2 Tie rod Workman MD MDX 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 compac tion a smoother ride and fewer tire marks Lower pres sure should not be used for heavy payloads at higher speeds Inspect Tires and Wheels Operating accidents such as hitting curbs can damage a tire or rim and also disrupt wheel alignment Inspect tire and rim condition after any accident Higher pressures should be used for heavier payloads at higher speeds Do not exceed the maximum tire pres sure Check wheels to ensure they are mounted securely Torque wheel lug nuts in a crossing pattern from 45 to 65 ft lb 62 to 88 N m Workman MD MDX 7 9 Chassis Upper Steering 18 to 22 ft lb NS 25 to 29 a Pd 175 to 225 in Ib Antiseize 20 to 25 N m lubricant
62. 000 carefully remove plastic cap item 12 from the drive clutch 5 Remove cap screw and washer securing the drive clutch to the engine 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 clutch 6 Use correct clutch removal tool see Special Tools to remove drive clutch from the engine tapered shaft Workman MD MDX 5 11 Rev A Drive Clutch Installation Fig 13 1 Thoroughly clean the tapered surfaces of the engine crankshaft and drive clutch 2 Slide drive clutch onto the engine shaft 3 Apply Loctite 242 or equivalent to the threads of the cap screw 4 Secure clutch to shaft with cap screw and washer Torque cap screw from 25 to 30 ft lb 34 to 40 N m 5 On vehicles with serial numbers below 310000000 carefully install plastic cap to the drive clutch 6 Install starter generator V belt to the engine and starter pulley Adjust belt tension 7 Install drive belt to the drive clutch 8 Lower and secure cargo box 2 Drive Train Drive Clutch Service Serial Number Below 310000000 100 ft lb 136 N m 4 75 to 100 in Ib 8 5 to 11 3 N m 9 Roller kit 3 used 10 Cam weight 3 used 11 Lock nut 3 used Figure 14 1 Fixed sheave 5 Cap screw 3 used 2 Spring 6 Plastic cap 3
63. 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 and Maintenance N E Ss gt a NOTE Reduce torque values listed in the table above NOTE The nominal torque values listed above are by 25 for lubricated fasteners Lubricated fasteners based on 75 of the minimum proof load specified in are defined as threads coated with a lubricant such as SAE J1199 The tolerance is approximately 10 ofthe oil graphite or thread sealant such as Loctite nominal torque value NOTE Torque values may have to be reduced when installing fasteners into threaded aluminum or brass The specific torque value should be determined based on the fastener size the aluminum or base material strength length of thread engagement etc Workman MD MDX 2 5 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Square Head Hex Socket 716 20 65 10 ft lb 88 14 N m Grade 5 5 16 18 UNC 215 35 in Ib 145 20 in Ib Grade 5 1 2 20 UNF 80 10 ft lb f 108 14 3 8 16 UNC 35 10 ft lb 18 3 ft lb 12 1 25 80 10 ft lb 108 14 N m Class 8 8 1 2 13 UNC 75 15 ft lb 50 10 ft lb 12 1 5 80 10 ft lb 108 14 N m Class 8 8 steel wheels and non lubricated fasteners Thread Cutting Screws T
64. 2 YELLOW FUSE BLOCK F3 IGNITION SW PWR A PINK F4 START 8 YELLOW LOADCIGN a VIOLET GND D BLACK MAG E BROWN LOAD F 2 BLUE RED BLACK gt NEUTRAL SW P15 3 BLACK 4 GREEN POT LIFT SW BLUE 1B LOW OIL PRESSURE pog WARNING LIGHT 2A 2B 5 lt x x x o 2 9 3 3 d 3 E Jo m mm m m c gt KEY START KIT 2 A B A B CY 47 2 B4 Workman MD and MDX P06 P19 203 J04 05 P12 af Main Electrical Harness Wiring Diagram BACKUP DIODE START RUN BOX LIFT ACTUATOR ALARM LENO Serial Number From 290000001 to 310000800 Page 8 10 Rev A POL ACCELERATOR POS REVERSE SW P15 NEUTRAL P22 Sw HEAD 2 1 LIGHT HORN M 2 SWITCH 0 START RUN SOLENOID BOX LIFT 0 SWITCH J03 START RUN SOLENOID 2 3 1 LIGHT RS TO ENGINE HARNESS 105 START RUN p12 SOLENOIO BOX 85 LIFT ACTUATOR p1 OPTIONAL FUSE BLOCK P06 BACKUP 208 SWITCHED SIDE OF 101 TERMINAL pai IGNITION BLOCK GND START RUN SOLENOID P10 ALARM SWITCH P09 VOLTAGE E LOW 0 ew Eee REGULATOR PRESSURE t W ARNING ES BLOCK LIGHT 1 28 P17 6 cococecal o LIGHT KIT HOUR omma OPTION METER 1A 2 25 FUSE LIGHT INTERCONNECT Workman MD and MDX Main Electrical Harness Drawing Serial Number Above 31000080
65. 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 16 0 4375 11 112 15 16 0 9375 23 812 29 64 0 453125 11 509 61 64 0 953125 24 209 15 32 0 46875 11 906 31 32 0 96875 24 606 31 64 0 484375 12 303 63 64 0 984375 25 003 1 2 0 5000 12 700 1 1 000 25 400 1 0 03937 in 0 001 0 0254 U S to Metric Conversions To Convert Into Multiply By Linear Miles Kilometers 1 609 Measurement Yards Meters 0 9144 Feet Meters 0 3048 Feet Centimeters 30 48 Inches Meters 0 0254 Inches Centimeters 2 54 Inches Millimeters 25 4 Area Square Miles Square Kilometers 2 59 Square Feet Square Meters 0 0929 Square Inches Square Centimeters 6 452 Acre Hectare 0 4047 Volume Cubic Yards Cubic Meters 0 7646 Cubic Feet Cubic Meters 0 02832 Cubic Inches Cubic Centimeters 16 39 Weight Tons Short Metric Tons 0 9078 Pounds Kilograms 0 4536 Ounces Avdp Grams 28 3495 Pressure Pounds Sq In Kilopascal 6 895 Pounds Sq In Bar 0 069 Work Foot pounds Newton Meters 1 356 Foot pounds Kilogram Meters 0 1383 Inch pounds Kilogram Centimeters 1 152144 Liquid Volume Quarts Liters 0 9463 Gallons Liters 3 785 Liquid Flow Gallons Minute Liters Minute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance 2 2 Workman MD MDX Torque Specifications Recommended fa
66. 33 Assembly Fig 21 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 cap screws and lock washers 3 Install brake hose to caliper 4 Install front wheel assembly 5 Lower machine to ground 6 Torque lug nuts in a crossing pattern from 45 to 65 ft Ib 62 to 88 N m 7 Bleed brakes see Bleed Brake System in this sec tion After servicing brake system components al ways check the brakes in a wide open level area that is free of other persons and obstructions 8 Check brake operation Chassis Front Brake Caliper Service Disassembly Fig 22 1 Ifcaliperis equipped with anti rattle clip remove clip from caliper pins and brake pads 2 Remove pins from caliper by prying with a flat blade screwdriver through loop in pins 3 Slide brake pads from caliper For assembly pur poses note orientation of inner and outer pads as the pads are not the same 4 Replacethe brake pads ifthe friction material is worn to less than 1 32 0 8 mm Assembly Fig 22 1 If brake pads are being replaced it will be necessary to push caliper pistons back into the caliper bore before installing new pads 2 Slide brake pads into caliper Make sure that lining material on pads is toward brake rotor position 3 Secure pads into caliper with two 2 pins Make sure that pins snap into caliper slots
67. Cap screw 2 used 3 Exhaust manifold 7 Drive clutch 11 Swing arm 4 Muffler 8 Engine tray 12 Nut 2 used Single Cylinder Gasoline Engine Page 4 8 Workman MD Removal Fig 5 1 Park machine on alevel surface stop the engine en gage parking brake and remove the key from the ignition switch 2 Raise cargo box and support with prop rod A CAUTION The muffler and exhaust pipe may be hot To avoid possible burns allow engine and exhaust system to cool before working on the muffler Figure 6 1 Exhaust manifold 3 Spring 2 Exhaust coupler 3 Remove four 4 springs securing the exhaust cou pler to the muffler and exhaust manifold Fig 6 4 Remove two 2 cap screws and lock washers secur ing the muffler to the swing arm 5 Remove exhaust coupler and muffler 6 If 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 gt gt o Gasoline Engine NOTE Mount all exhaust components loosely before tightening to ensure a proper fit of exhaust system 1 If the exhaust manifold was removed from engine install manifold to engine with new gasket Attach ex haust manifold loosely to the engine with removed nuts 2 Install muffler to the swing arm with two 2 cap screws and lock washers 3 Insert exhaust coupler between muffler and man ifold Install sp
68. GENERATOR W BU x MODULE TOP MN uU DF fields e E TT 2 LEFT FRON armature 1 DIODE Y B POWER gt GY C LEFT REAR BK i D BRAKE SWITCH rE NOT USED E LR t W BK F RIGHT REAR rG PILOT RIGHT FRONT SPARK PLUG spark T TURN SIGNAL SWITCH GRE I I 8 Op MODULES FRONT REAR BRAKE gt e RPM FRAME FRAME i SWITCH SHUTDOWN GROUND GROUND PK o GN BRAKEZTURN oy 5 16 9 ENGINE OIL ENGINE BK GROUND g ENGINE PRESSURE CONNECTION P3 A P3 A D GY WARNING TURN T Te i BK BK LIGHT KIT NES ENGINE 23 8 BN OPTIONAL FRAME GROUND w Bu P3 P3 C W BU GN P3 D P3 D GN t BK BN W E3 E P3 E BN W GN BRAKE TURN A 5 s BK GROUND B LEFT FRONT t W BK WARNING TURN y gt D cy Workman TURN AND RUNNING rai Electrical Schematic B BINA e c BK WBK BUG c BK Solenoid is shown de energized RIGHT FRONT TURN AND RUNNING Page 8 4
69. Make sure a good connection is made 4 Charge the battery following the battery charger manufacturer s instructions 5 Occasionally check the temperature of the battery electrolyte If the temperature exceeds 125 F 51 6 C or the electrolyte is violently gassing or spewing the charging rate must be lowered or temporarily stopped 6 Three 3 hours prior to the end of the charging mea sure the specific gravity of a battery cell once per hour The battery is fully charged when the cells are gassing freely at a low charging rate and there is less than a 0 003 change in specific gravity for three 3 consecu tive readings Battery Storage If the vehicle will be stored for more than 30 days re move the battery and charge it fully Either store it on the shelf or on the vehicle Leave the cables disconnected if it is stored on the vehicle Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery To prevent the battery from freezing make sure it is fully charged Electrical System 2 System This is intentionally blank Electrical System Page 6 38 Workman MD MDX Chapter 7 Chassis Table of Contents GENERAL INFORMATION 1 Front Shock Absorbers 17 Operator s Manual 1 A arms and Front Suspension 18 SPECIFICATIONS 2 Frame Pivo
70. O J05 RPM SHUTDOWN J01 GROUND J03 0IL PRESSURE A OJO oo B oot Workman Engine Electrical Harness Page 8 14 Rev A
71. Page 4 16 Rev B Workman MD Disassembly Gasoline is flammable Use caution when storing or handling it Wipe up any spilled fuel before starting the engine 1 Inspect carbon cannister and attached hoses for damage or obvious leaks A damaged or leaking cannis ter should be replaced 2 Remove components as needed using Figure 15 as a guide A If check valve item 8 in Fig 15 is removed note direction of arrow on valve body for assembly pur poses Fig 16 B Note location of hose clamps for assembly pur poses Figure 15 1 Fueltank 6 Fresh air filter 2 Carbon canister 7 Fuel hose purge hose Assembly 3 Rollover valve 8 Check valve 4 Fuel hose tank vent 9 Fuel hose to engine 1 Install all removed components using Figure 15 asa 5 Fuel hose guide gt i gt f check valve item 8 in Fig 15 was removed make sure that arrow on valve body points toward engine Gasoline Engine B Make sure that fuel hoses are not kinked after installation Also secure hoses with hose clamps Figure 16 1 Check valve 3 Fitting from canister 2 Directional arrow 4 Fitting to engine 00A 301019 Q 08 031 PAGE PA66 FUEL TANK Figure 17 1 Top of carbon canister 3 Fitting to engine 2 Fitting to rollover valve Workman MD 4 17 Rev B Single C
72. Part No 08160SL Rev Service Manual Workman MD amp MDX 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 MD and Workman MDX REFER TO THE OPERATOR S MANUAL FOR OPER ATING MAINTENANCE AND ADJUSTMENT IN STRUCTIONS For reference insert a copy of the Operator s Manual and Parts Catalog for your machine into Chapter 2 of this service manual Additional copies of the Operator s Manual and Parts Catalog are avail able on the internet at www Toro com The Toro Company reserves the rightto change product specifications or this publication without notice This safety symbol means DANGER WARNING or CAUTION PERSONAL SAFETY INSTRUC TION When you see this symbol carefully read the instructions that follow Failure to obey the instructions may result in personal injury NOTE A NOTE will give general information about the correct operation maintenance service testing or re pair of the machine IMPORTANT The IMPORTANT notice will give im portant instructions which must be followed to pre vent damage to systems or components on the machine The Toro Company 2008 2011 2014 This is intentionally blank Workman MD MDX Table Of Contents Chapter 1 Safety Safety 1 5 5 1 2 Jacking and Other Instructions
73. RONT SPARK PLUG PLUG _ MAC TURN SIGNAL SWITCH IGNITION OP MODULES OP FRONT 22 Y RPM FRAME SHUTDOWN GROUND op ony ENGINE OIL ENGINE ENE PRESSURE CONNECTION 2i mhea LICHT KIT cy WARNING TURN D P3 B ENGINE OPTIONAL FRAME GROUND 3 BK P3 E BN W GN BRAKE TURN OR bron 4 GROUND B gt i gt gy Run Circuits LEFT FRONT WARNING TURN TURN AND RUNNING rut uci RH Workman MDX Schematic Shown B Indication Current Page8 6 Power Current Control Current A pee a BU RIGHT FRONT TURN AND RUNNING POL ACCELERATOR P05 REVERSE Sw P15 NEUTRAL P22 HEAD SW P24 LIGHT HORN SWITCH 20 START RUN LIFT SOLENOID TO ENGINE SWITCH HARNESS 2 205 POWER d START RUN SOLENOID FOIT f Box SOLENOID C B2 ACTUATOR E 1 is IB p E P06 OPTIONAL BACKUP FUSE BLOCK L 01 TERMINAL BLOCK GND SW ITCH BOR FUSE pi 5 LIGHT SW Prd Low OIL VOLTAGE PRESSURE of Seo LIGHT KIT REGULATOR WARNING p17 mmm OPTION LIGHT HOUR METER P25 MAXI FUSE LIGHT INTERCONNECT Workman MD and MDX Main Electrical Harness Drawing Serial Number Below 280999999 Page 8 7 Rev A J06 HORN
74. TANT During clutch disassembly note loca tion of shims items 2 3 and 9 for assembly pur poses Correct shim location is necessary for proper clutch operation IMPORTANT Make note of the X mark cast into the cover spider and moveable sheave before clutch disassembly These marks must be aligned during assembly for proper clutch operation 1 Remove three 3 cap screws securing the cover to the moveable sheave Note location of X marks caston the cover and spider for assembly purposes Pull cover from clutch 2 Remove limiter shim item 2 from clutch Label shim and its location for assembly purposes 3 Make sure that engine starter pulley item 11 has been removed from the drive clutch see Drive Clutch Removal in this section Drive Train 5 13 3 Rev moval holding bar see Special Tools to drive clutch 5 Secure clutch with attached spider removal holding bar in a vise Note location of X marks cast on the spi der and moveable sheave for assembly purposes IMPORTANT Use spider removal spanner to re move spider Unequal pressure on the spider during removal may damage the spider 6 Using spider removal spanner see Special Tools remove spider item 4 from the fixed sheave post Fig 19 2 7 Remove shims items 3 and 9 from fixed sheave post Label shims and their location for assembly pur poses 8 As needed remove rollers from moveable sheave 9 If necess
75. Washer 7 Cover 4 Spider assembly 8 Moveable sheave NOTE Vehicles with a serial number below 310000000 are equipped with a Comet brand drive clutch 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 and support cargo box 2 Remove the three 3 cap screws that secure the cover to the drive clutch Fig 14 Remove the cover from the clutch When using compressed air for cleaning the clutch the dust in the clutch will become airborne and could damage your eyes or you could inhale it causing breathing difficulties Wear safety goggles and a dust mask or other eye and respiratory protection when performing this pro cedure Drive Train Page 5 12 Rev 12 Pilot bolt 3 used 3 Using compressed air thoroughly clean the inside of the clutch cover and the clutch components 4 Lubricate the clutch components in areas shown in Figure 15 using Toro Dry Lubricant Spray see Special Tools Avoid getting lubricant on drive belt 5 Install cover to clutch and secure with three 3 cap screws Torque cap screws from 75 to 100 in Ib 8 5 to 11 3 N m 6 Lower and secure cargo box Drive Clutch Disassembly Fig 14 IMPORTANT Do not pry off cover damage may re sult Cover should pop off 1 Remove three 3 cap screws securing the cover to the moveable
76. ahead Slide steering wheel onto the steering shaft so that the leg of the Y formed by the wheel struts is directed towards the oper ator platform 10 Secure steering wheel to shaft with flat washer and nut Torque nut from 18 to 22 ft lb 25 to 29 Install steering wheel cover to wheel 11 Lower front hood 12 Check front wheel alignment see Adjust Front Wheel Toe in in the Adjustments section of this chap ter Chassis Steering Gearbox 27 to 33 ft lb 37 to 44 N m 90 to 110 in Ib 10 2 to 12 4 N m Figure 5 1 Gasket 8 Stepped washer 2 Hex washer head screw 3 used 9 Flange head screw with patch lock 3 Seal 10 Ball bearing 4 Sector gear 11 Input shaft spacer 5 Flat washer 12 Flat washer 6 Ball bearing 13 Flange head screw with patch lock 7 Output shaft spacer Chassis Page 7 12 175 to 225 in Ib 20 to 25 N m 14 15 16 17 18 19 Lube fitting Steering housing cover Steering housing Pinion gear Oil seal Pitman arm Workman MD MDX Disassembly Fig 5 IMPORTANT Do not reuse flange head screw with patch lock after it has 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 fro
77. ansaxle shaft Remove castle nut spring washer and washer from the shaft Remove the wheel hub from the shaft NOTE The brake assembly can be removed from the transaxle shaft for disassembly 5 If required remove brake assembly as follows A Remove cotter pin and clevis pin securing the parking brake cable to the parking brake lever on the rear of the brake assembly B Clean hydraulic brake line area of brake assem bly to prevent contamination Loosen and discon nect brake line from wheel cylinder Plug brake line and position it away from brake assembly Discard two 2 banjo washers 28 Workman MD MDX Remove four 4 socket head screws and flange lock nuts that secure the brake assembly to the transaxle D Remove brake assembly from the transaxle Installation Fig 18 IMPORTANT Parking brake levers must be posi tioned above the transaxle mount When positioned correctly brake lever will point toward the rear of the axle 1 Position brake assembly to the transaxle Secure backing plate of the brake assembly to the transaxle with four 4 socket head screws and flanged lock nuts Torque screws to 20 ft lb 27 N m 2 Position new banjo washer on each side of brake line fitting Fig 19 Insert banjo bolt into fitting and thread into wheel cylinder Torque banjo bolt from 15 to 21 ft Ib 21 to 28 N m 3 Secure parking brake cable to the brake lever with clevis pin and cotter pin IMPORTANT Do n
78. areful when installing springs to brake shoes The springs are under heavy load and may cause personal injury 6 Secure brake shoes with upper and lower springs Chassis Front Brake Calipers Loctite 242 45 to 65 ft lb 62 to 88 N m Figure 21 1 LH brake caliper 6 Brake rotor 10 Brake master cylinder 2 RH brake caliper 7 Socket head screw 4 per rotor used 11 Wheel assembly 3 Lock washer 2 per caliper used 8 Spindle LH shown 12 Lug nut 5 used per wheel 4 Cap screw 2 per caliper used 9 A arm LH shown 13 Front brake hose 5 Wheel hub assembly Chassis Page 7 32 Workman MD MDX Disassembly Fig 21 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being jacked up Jack front wheel off the ground and place appropriate jack stand beneath the frame to support vehicle 3 Remove front wheel from machine see Lower Steering and Front Wheel Removal 4 Clean hydraulic brake line area of brake caliper to prevent contamination Loosen and disconnect brake line from caliper Plug brake line and position it away from caliper 5 Remove two 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 machine Workman MD MDX Page 7
79. ary remove moveable sheave from fixed sheave Workman MD MDX Drive Clutch Inspection NOTE Ifdrive clutch wear or damage occurs clutch re placement may be necessary Refer to your parts cata log to identify individual drive clutch components that are available 1 Inspect the tapered ends of the engine crankshaft and fixed sheave of drive clutch If either is severely damaged replace component as damage to the taper will allow loosening of the clutch during machine opera tion 2 Check all of the rollers If binding or uneven wear is found replace all rollers as a set 3 Check the contact surface of the moveable sheave for wear and or fraying If surface is worn frayed re place component Drive Clutch Assembly Fig 19 1 IMPORTANT For proper clutch operation make sure to use the correct clutch components for 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 moveable sheave onto post of fixed sheave 2 If removed install rollers to pockets in moveable sheave Rollers should not be lubricated 3 Using labels made during disassembly to identify shims place shims items 3 and 9 onto fixed sheave post 4 Install spider to the fixed sheave post using spider tool kit see Special Tools Make sure that the X mark cast into the spider and moveable sheave
80. ative system to the engine These machines use an inline check valve between the carbon canister and the engine fitting Evaporative control sys tem components for Workman MDX vehicles are shown in Figure 19 Workman MDX Disassembly Fig 19 Gasoline is flammable Use caution when storing or handling it Wipe up any spilled fuel before starting the engine 1 Inspect carbon cannister and attached hoses for damage or obvious leaks A damaged or leaking cannis ter should be replaced 2 Remove components as needed using Figure 19 as a guide A If check valve item 8 in Fig 19 is removed note direction of directional arrow on valve body for as sembly purposes Fig 20 B If carbon canister is to be removed note hose positions on the canister for assembly purposes Fig 21 C Note location of hose clamps for assembly pur poses Assembly 1 Install all removed components using Figure 19 asa guide A If check valve item 7 in Fig 19 was removed make sure that directional arrow on valve body points toward engine Fig 20 B Make sure that fuel hoses are not kinked after installation Also secure hoses with hose clamps Workman MDX 3 19 Rev B Figure 19 1 Fueltank 6 Fresh air filter 2 Carbon canister 7 Fuel hose purge hose 3 Rollover valve 8 Check valve 4 Fuel hose tank vent 9 Fuel hose to engine 5 Fuel hose F
81. ball bearing onto the commutator end of the armature shaft F Position front end cover onto the output shaft Se cure bearing retainer to the end cover with flat wash ers lock washers and screws Torque screws from 35 to 43 in Ib 4 0 to 4 9 N m G Position armature carefully into the yoke Make sure not to damage field coils Align front end cover to the yoke with the locating pin IMPORTANT When installing the commutator end cover make sure brushes do not contact the commutator Damage to the brushes may result H Lift brush springs from the notch at the end of the brushes while pulling the brushes out Allow springs to hold brushes out from the center Fig 25 Workman MD MDX Page 6 23 BoN 1 Position commutator end cover carefully to the commutator and yoke Align end cover to the yoke with the locating pin J Secure both end covers to the yoke with both through bolts and flat washers Torque bolts from 96 to 104 in Ibs 10 8 to 11 8 N m K Slide brushes into holders Secure brushes by positioning brush springs into the notch at the end of the brushes Fig 27 L Install brush covers to the commutator end cover M Position spacer and woodruff key onto the shaft Place pulley onto the shaft N Secure pulley to the shaft with spring washer and nut Torque nut from 15 to 25 ft Ib 20 to 34 N m 9 ft Ib x 5 12 N m 43 to 52 in Ib 4 9 to 5 9 N m Figure 29 Field coils 5
82. bearing bore in commut ator end head 20 Carefully lower the armature and drive 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 orientate head Secure drive end head to frame housing with two 2 screws Torque screws from 49 to 66 in Ib 5 6 to 7 4 22 Release brushes and center the brush springs between the wire and the edge of the brush Make sure that brushes move freely in brush holders Electrical System 6 32 Rev B Figure 46 Figure 48 Workman MD MDX 23 Install rubber plugs to the commutator end head Make sure that the plug that includes a weep hole is placed as noted during disassembly 24 Make sure that the armature rotates freely after as sembly Figure 49 Starter Generator Specifications NOTE Rework to the starter generator must be per formed by a properly trained technician using the correct tools 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 Specification Armature Resistance at 75 24 0 0125 Ohms between bar 1 and 11 Field Resistance at 75 24 0 0069 Series Ohms Total 3 20 Shunt Ohms Total Maximum brush length 0 790 in 20 mm 1 Minimum brush length 0 375 in 9 5 mm 4 2
83. ble 2 Accelerator cable end Workman MD MDX 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 Set the shift lever into the Neutral position Rotate driven clutch to insure transmission is in neutral 3 The transaxle select lever assembly should be ina 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 0 030 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 correct If necessary readjust nut Fig 11 7 Start engine and verify transaxle engagement in for ward reverse and neutral as the shift lever is moved 8 Finally check vehicle operation in forward reverse and neutral Readjust shift cables if needed for correct operation 9 Lower and secure cargo box Figure 10 1 Shift cable 3 Lock nut 2 Select lever assembly 0 030 to 0 060 0 8 to 1 5 mm 1 O 1 gt Figure 11 1 Select lever 3 Cable boot 2 Cable pull direction Workman MD MDX 5 9 Drive Train Service and Repairs Drive Clutch 25 to 30 ft Ib 34 to 40 N m Figure 12 1 Engine V twin shown 6 Lock washer 4 used 11
84. buretor and cable bracket B Air intake hose item 38 from the carburetor C Breather hose item 42 from the engine valve cover Read safety precautions for handling gasoline before working on the fuel system see Safety In structions in Chapter 1 Safety 5 Disconnect fuel hose from the fuel pump Fig 12 Remove cable tie securing the choke and throttle cables to the fuel pump bracket 6 Remove muffler and exhaust 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 starter belt Remove belt from the engine and starter generator pulleys Workman MD Page 4 13 9 Remove cap screw item 49 and flat washer item 50 that secure r clamp item 51 and shift cables item 8 to engine Position shift cables away from engine 10 Disconnect engine electrical harness connector from the main harness 11 Remove four 4 flange nuts and cap screws secur ing the engine to the engine tray A CAUTION One person should operate the hoist while a sec ond person guides the engine out of the frame 12 Remove engine from the engine tray A Attach a short section of chain between fuel pump bracket lift hole and exhaust manifold Fig 12 B Connect hoist to center of chain IMPORTANT Make sure to not damage the en gine fuel hoses electrical harness or ot
85. ch 2 Raise cargo box and secure with prop rod to gain ac cess to the starter generator NOTE Place all fasteners back onto starter generator terminals after disconnecting wires to prevent loss of fasteners 3 Label all wires on the starter generator for assembly purposes Disconnect all wires from the starter genera tor 4 Loosen fasteners that secure starter generator to engine tray assembly 5 Pivot starter generator and remove drive belt from the pulley 6 Support starter generator to prevent it from shifting or falling 7 Remove lock nut item 2 and carriage bolt item 10 from upper starter generator flange and bracket on en gine tray Remove flange nut item 13 and pivot bolt item 11 from starter generator and engine tray 8 Remove starter generator from the vehicle 9 If necessary remove pulley from the starter genera tor shaft A Remove nut and spring washer from the shaft Use appropriate puller to remove pulley from the shaft B Remove woodruff key from the shaft NOTE Vehicles with serial number below 311000000 were produced with a Valeo brand starter generator Vehicles with serial 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 have been an Advanced Motors and Drives component Starter generators have an identification tag on them w
86. d Millimeter Equivalents Equivalents and Conversions Fractions Decimals mm Fractions Decimals mm 1 64 0 015625 0 397 33 64 0 515625 13 097 1 32 0 03125 0 794 17 32 0 53125 13 494 3 64 0 046875 1 191 35 64 0 546875 13 891 1 16 0 0625 1 588 9 16 0 5625 14 288 5 64 0 078125 1 984 37 64 0 578125 14 684 3 32 0 09375 2 381 19 32 0 59375 15 081 7 64 0 109275 2 778 39 64 0 609375 15 478 1 8 0 1250 3 175 5 8 0 6250 15 875 9 64 0 140625 3 572 41 64 0 640625 16 272 5 32 0 15625 3 969 21 32 0 65625 16 669 11 64 0 171875 4 366 43 64 0 671875 17 066 3 16 0 1875 4 762 11 16 0 6875 17 462 13 64 0 203125 5 159 45 64 0 703125 17 859 7 82 0 21875 5 556 23 32 0 71875 18 256 15 64 0 234375 5 953 47 64 0 734375 18 653 1 4 0 2500 6 350 3 4 0 7500 19 050 17 64 0 265625 6 747 49 64 0 765625 19 447 9 32 0 28125 7 144 25 32 0 78125 19 844 19 64 0 296875 7 541 51 64 0 796875 20 241 5 6 0 3125 7 938 13 16 0 8125 20 638 21 64 0 328125 8 334 53 64 0 828125 21 034 11 32 0 34375 8 731 27 32 0 84375 21 431 23 64 0 359375 9 128 55 64 0 859375 21 828 3 8 0 3750 9 525 7 8 0 8750 22 225 25 64 0 390625 9 922 57 64 0 890625 22 622 13 32 0 40625 10 319
87. e Cap screw 2 used per shock LH A arm Brake rotor 10 Wheel hub assembly 11 Tab washer Chassis Loctite 242 Figure 6 RH A arm Jam nut Front frame Nut retainer Dust cap Wheel assembly Lug nut 5 used per wheel Cap screw 2 used per A arm Cotter pin Wheel stud 5 used per hub Page 7 14 See text for tightening procedure 45 to 65 ft Ib 62 to 88 N m Socket head screw 4 used per rotor Brake caliper LH shown Lock washer 2 used per caliper Cap screw 2 used per caliper Grease fitting Ball joint LH threads Jam nut LH threads Tie rod Jam nut RH threads Ball joint RH threads Workman MD MDX Disassembly Fig 6 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition 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 ma chine 4 Remove brake caliper from spindle See Front Brake Caliper in this section Position caliper away from wheel hub and spindle 5 Carefully pry dust cap from wheel hub 6 Remove cotter pin and nut retainer from spindle 7 Remove jam nut that secures wheel hub to spindle Slide wheel hub with bearings and brake rotor from
88. e Valeo Starter Generator 20 Brush and Brush Spring Service 21 Armature and Field Coil Service 22 Rework Starter Generator 24 Starter Generator Service Advanced Motors and Drives 26 Brush and Brush Spring Service 27 Starter Generator Specifications 33 Battery Service 34 Battery 34 Battery Inspection and Maintenance 35 Battery Installation 35 Battery Testing 36 Battery Charging 37 Battery Storage 37 ADVANCED MOTORS amp DRIVES STARTER GENERATOR TROUBLESHOOTING GUIDE Electrical System 2 System 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 Opera tor s Manual for additional information when servicing the machine Electrical Schematics The electrical schematics and other electrical drawings for the Workman MD and MDX are located in Chapter 8 Electrical Diagrams Electrical System Page 6 2 Workman MD MDX Special Tools Order special tools from your Toro Distributor Some tools may also be available from a local suppl
89. e alarm may result from an improper connection 3 Disconnect wire harness connector from alarm Cor rectly connect 12VDC source to the terminals Fig 20 Alarm should sound Electrical System Page 6 16 4 fthe light is still on check for short circuiting in the indicating circuit see Electrical Schematic in Chapter 8 Electrical Diagrams 5 Refertothe Briggs and Stratton Repair Manual for 4 Cycle V Twin Cylinder OHV Head Engines for addi tional testing information F Figure 19 1 Oil pressure switch 2 Generator belt 4 Remove voltage source from the alarm Replace alarm if necessary Connect wire harness connector to alarm 5 Install electrical cover and lower cargo box Figure 20 3 Positive terminal 4 Negative terminal 1 Top view 2 Bottom view Workman MD MDX Reverse Switch Optional The optional reverse switch is a four 4 terminal two 2 circuit switch that is used to energize the audio alarm when the shift lever is in the reverse position The nor mally 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 21 Testing 1 Place machine shift lever in the NEUTRAL position Make sure that ignition switch is off remove key from ignition switch and engage parking brake 2 Remove four 4 screws and carefully slide shift bracket assembly from front of sea
90. e battery Reconnect positive cable first and negative cable last Workman MD MDX Page1 3 Rev B 4 Do not touch engine muffler or exhaust pipe 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 key to OFF and wait for all move ment to stop C Remove key from ignition switch D Apply parking brake E Donotpark on slopes unless wheels are chocked or blocked 10 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with a battery 11 Battery gases can explode Keep cigarettes sparks and flames away from the battery 12 To assure optimum performance and continued safety of the vehicle use genuine Toro replacement parts and accessories Replacement parts and acces sories made by other manufacturers may result in non conformance with safety standards and the warranty may be voided 13 When raising the vehicle to change tires or to per form other service use correct blocks hoists and jacks Make sure vehicle is parked on a solid level surface such as a concrete floor Prior to raising the vehicle remove any attachments that may interfere with the safe and proper raising of the vehicle Always chock or block wheels Use appropriate jack stands to support the raised vehicle If the vehicle i
91. e fixed sheave and slows the drive belt speed As engine speed continues to decrease the drive belt disengages from the clutch sheaves The drive clutch used on vehicles with serial numbers below 310000000 Fig 2 includes three 3 rollers three 3 cam weights and a spring to control operation of the moveable sheave The drive clutch used on vehicles with serial numbers above 310000000 Fig 3 controls moveable sheave operation with six 6 weighted rollers and ramp sur faces in the moveable sheave PONS Drive Train 5 4 Figure 2 Fixed sheave 5 Spring Moveable sheave 6 Cam weight 3 used Spider assembly 7 Roller 3 used Cover Figure 3 Fixed sheave 4 Cover Moveable sheave 5 Roller 6 used Spider assembly Rev A Workman MD MDX Driven Clutch Operation The operation of the driven clutch is affected by trans axle load When the vehicle is stopped the drive belt is held at the outer diameter of the driven clutch sheaves from the pressure of the spring pushing the moveable sheave against the fixed sheave and away from the fixed cam Once the drive belt starts rotating the driven clutch also starts to
92. e long distances use a trailer or flatbed truck Make sure vehicle is secured to the trailer properly Refer to Operator s Manual for transport infor mation Tow Vehicle IMPORTANT Frequent or long distance towing of the Workman is not recommended In case of emergency the vehicle can be towed for a short distance Refer to Operator s Manual for towing information Safety 1 4 Figure 1 1 Front frame 2 Towing tongue Figure 2 2 Axle tube 1 Transaxle case IMPORTANT If vehicle is towed make sure that ignition switch is in the OFF position and key is re moved from switch Workman MD MDX Transaxle Neutral Position When performing routine maintenance and or engine testing the transaxle must be shifted into the neutral position 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch 2 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 tires should not rotate If tire rotation does occur see Adjust Shift Cables in the Ad justment section of Chapter 5 Drive Train Figure 3 1 Shift lever in neutral 3 Reverse position 2 Forward position Workman MD MDX Page 1 5 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Workman If any decal becomes illegible or dam aged install
93. e matchmark position of the original gear and arm 4 Position sector gear item 4 onto the spline of the Pitman arm shaft IMPORTANT Make sure sector gear is centered to the pinion gear 5 Insert pinion gear item 17 into the small bearing in the steering housing 6 Fill steering housing with number 2 general purpose grease Make sure all gear teeth on the sector and pin ion gears are covered with grease 7 Place gasket and steering housing cover onto the housing Secure cover to housing with three 3 hex washer head screws item 2 Torque screws from 90 to 110 in Ib 10 2 to 12 4 N m IMPORTANT Flange head screws with patch lock items 9 and 13 should be replaced whenever they are removed 8 Secure stepped washer and flange head screw with patch lock item 9 to the Pitman arm item 8 Make sure to position stepped washer as shown Figure 5 Torque screw from 27 to 33 ft Ib 37 to 44 N m 9 Secure flat washer item 12 and flange head screw with patch lock item 13 to the pinion gear shaft Torque screw from 175 to 225 in Ib 20 to 25 N m 10 After assembly is completed make sure that pitman arm rotates freely from stop to stop without binding Chassis Lower Steering and Front Wheels oouommRON 20 to 25 ft Ib 28 to 33 N m 45 to 55 ft Ib 62 to 74 N m N Pd Steering gearbox pitman arm Shock absorber 2 used Cotter pin Slotted hex nut Flat washer Lock nut 3 used per sid
94. e on the front frame Remove gearbox from the tower plate Assembly Fig 4 1 Position steering gearbox to the tower plate of the front frame with the Pitman arm facing down and to the rear The gearbox shaft must be to the left side of the tower 2 Secure steering gearbox to the tower plate with four 4 cap screws and lock washers Torque screws from 175 to 225 in Ib 20 to 25 N m 3 Make sure that collar item 14 is positioned on steer ing shaft Insert steering shaft up through the steering column 4 Secure steering column to the mounting plate on the frame with four 4 carriage screws and flange nuts Workman MD MDX Page 7 11 NOTE Apply antiseize lubricant to the steering gear box input shaft before installing to steering shaft knuckle 5 Position knuckle of the lower steering shaft onto the gearbox input shaft Secure knuckle to the steering gearbox shaft with cap screw and lock washer 6 Make sure that collar item 14 is just below steering column If necessary re position collar on steering shaft Apply Loctite 242 or equivalent to collar set screw and secure collar with set screw 7 Place dust cover onto the steering shaft 8 Connect both tie rods to the Pitman arm on the steer ing gearbox see Lower Steering and Front Wheel Installation in this section NOTE Apply antiseize lubricant to the steering shaft taper before installing the steering wheel 9 Position front tires straight
95. eading For each 10 F 5 5 C above 80 F 26 7 add 0 004 to the specific gravity reading For each 10 F 5 5 C below 80 F 26 7 C subtract 0 004 from the specific grav ity reading Example Cell Temperature 100 F Cell Gravity 1 245 ADD 20 above 80 F 0 008 Correction to 80 F 1 253 C If the difference between the highest and lowest cell specific gravity is 0 050 or greater or the lowest cell specific gravity is less than 1 225 charge the bat tery Charge at the recommended rate and time giv en in Charging or until all cells specific gravity is 1 225 or greater with the difference in specific gravity between the highest and lowest cell less than 0 050 If these charging conditions can not be met replace the battery 2 Perform a high discharge test with an adjustable load tester Thisis one ofthe mostreliable means oftesting a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test A CAUTION Follow the battery load tester manufacturer s instructions when using a load tester A Check the voltage across the battery terminals prior to testing the battery If the voltage is less than 12 0 VDC recharge the battery before load testing B Make sure the battery terminals are free of corro sion Electrical System Page 6 36 C Ifthe battery has been charged apply a 150 amp load for 15 seconds to remove the surface charge Use a bat
96. eck the contact surface of the sheaves for wear and or fraying If wear or damage is found re place driven clutch assembly IMPORTANT For proper driven clutch operation DO NOT lubricate driven clutch components 8 Assemble the driven clutch in the reverse order of disassembly Make sure that the X mark cast into the fixed and moveable sheaves are aligned Also make sure that the retaining ring is fully seated in groove after installation Drive Train PONS Page5 15 1 Rev A Figure 21 1 5 Spring 6 Outer spring retainer 7 Retaining ring Fixed sheave Thrust washer Moveable sheave Inner spring retainer Workman MD MDX This page is intentionally blank 5 ec 2 Workman 5 15 2 Rev A Drive Train Transaxle Antiseize Lubricant 39 to 47 ft Ib 53 to 63 N m Figure 22 1 Engine 8 Transaxle 15 Drive clutch 2 Washer 4 used 9 Locknut 16 Flange head screw 4 used 3 Cap screw 4 used 10 Flat washer 17 Isolation mount 2 used 4 Drive belt 11 Shift cable 2 used 18 Flat washer 2 used 5 screw 12 Flange nut 4 used 19 Cap screw 2 used 6 Stepped washer 13 Engine tray 20 Flange nut 2 used 7 Driven clutch 14 Swing arm Removal Fig 22 4 Remove cable ties that secure both battery cables to the passenger side axle tube 1 Park machine on a level surface stop engine set parking brake and remove key from the igniti
97. een wire connector from voltage regulator Fig 14 Connect disconnected green wire lead from starter generator to ground with a jumper lead B Set multimeter to VDC Connect red probe of the multimeter to the positive battery post Con nect black probe of the multimeter to the negative battery post IMPORTANT Run engine only long enough to get battery voltage reading and not for more than 15 seconds C Start and run engine at mid range RPM D Battery voltage should rise steadily to approxi mately 18 VDC identifying a correctly operating start er generator An incorrect reading indicates the need for starter generator repair E Stop engine and turn key to OFF Workman MD MDX Page 6 13 7 Reconnect green wire connector from the regulator and test voltage regulator A Set multimeter to VDC Connect red probe of the multimeter into the green wire connection Con nect black probe of the multimeter to a known good ground B Start and run the engine at mid range RPM C The measured voltage should be approximately 2 VDC when battery is charging and from 6 to 8 VDC when battery is fully charged This voltage may rise to 14 VDC when the accelerator pedal is released and the engine is coasting to a stop D If measured voltage is incorrect stop engine and replace voltage regulator Retest charging circuit Step 5 above 8 Stop engine and remove multimeter leads Figure 14 4 Cab
98. eeve must extend through the bottom of the hub B Place thrust washer onto the bottom of the king pin sleeve Then place spindle over the A arm hub king pin sleeve and thrust washer NOTE Make sure cap screw is inserted down through the spindle and A arm hub Chassis 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 Ib 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 Ib 28 to 33 N m to secure ball joint while aligning castle nut slot with hole in ball joint stud If necessary to align holes castle nut torque may be slightly more than specifi cation Install cotter pin 3 Assemble wheel hub Fig 7 A bearing cups were removed from the wheel hub press inner and outer cups into the hub until they seat against the hub shoulder B Pack both bearings with grease Install inner bearing into the cup on inboard side of the wheel hub IMPORTANT The wheel hub seal must be pressed in so it is flush with the end of the hub The lip of the seal 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 Loctite 242 or equivalent to socket head screw
99. er shock 14 Front frame Chassis Page 7 20 240 to 290 ft Ib 326 to 393 N m Pivot yoke Flange head screw 4 used Flat washer 4 used Hardened washer Cap screw 2 used per arm Ground cable Workman MD MDX Pivot Yoke Removal Fig 11 and 12 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 Make sure all tires are chocked to prevent the machine from moving Before removing the pivot yoke make sure front and rear frames are supported with jack stands Support both the front and back of each frame 4 Remove four 4 cap screws and flat washers secur ing the pivot yoke to the rear frame 5 Remove cap screw and hardened washer securing the pivot yoke to the front frame tab Support pivot yoke while removing it from the front frame to prevent dropping and causing serious injury and damage to the machine 6 Remove four 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 Support pivot yoke while installing it to the front frame to prevent dropping and causing serious injury and damage to the machine 1 Position pivot yoke to the front frame
100. et 2 Anti tamper bracket Drive Train Adjust Ground Speed Workman and Workman MD with Serial Number Above 313000400 All Workman MDX models and Workman MD models with serial number above 313000400 use an engine governor for speed control Adjust ground speed using the following procedure for these vehicles Vehicles operating at ground speeds greater than the recommended speed will require further distances to fully stop Do not adjust ground speed greater than specified 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch Raise and 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 pedal to the floor B Using a tachometer verify that engine RPM is from 3250 to 3350 RPM with the accelerator pedal to the floor NOTE If phototac is to be used to measure engine speed DO NOT use driven clutch on transaxle for speed measurement C If engine RPM is incorrect refer to the appropri ate engine service manual Briggs and Stratton Re pair Manual for MDX vehicles or Kohler Service Manual for MD vehicles for governor adjustment procedure 4 Lower and secure cargo box after adjustments are complete Drive Train Page5 8 Rev B Figure 10 3 Governor control 1 Accelerator ca
101. f cracked bent or exces sively worn F Replace governor fork or stopper if bent or de formed Workman MD MDX Transaxle Assembly 1 Assemble input shaft assembly 12 to 16 in Ib Figure 51 1 Governor plate 3 Screw 2 Governor base 4 Governor sleeve IMPORTANT To prevent the screws that secure the A On Workman MD secure governor plate unit to governor plate to the governor from loosening ap the governor base with two 2 screws and lock pin ply Loctite 242 or equivalent to the screw threads Torque fasteners from 12 to 16 in Ib 1 4 to 1 8 N m a 2 L Figure 52 1 Ball bearing 2 Input shaft IMPORTANT Make sure to press ball bearing at the B Press ball bearing onto the input shaft inner race to prevent damaging the ball bearing Workman MD MDX Page 5 35 Drive Train Figure 53 1 Governor sleeve 2 Input shaft C On Workman MD apply molybdenum disulfide grease to the inside of the governor sleeve Slide sleeve onto the input shaft Make sure to engage sleeve slot with lock pin Figure 54 1 Pivot point 2 Governor plate D On Workman MD make sure to apply molybde num disulfide grease to the pivot points of the weights on the governor plate unit Drive Train Page 5 36 Workman MD MDX 2 Assemble the center shaft assembly 136 8 to 137 1 mm Figure 55 1 Pin clutch 6 Gear small 2 Center shaft 7 Bearing 3 Gear47 8 Bearing 4 Gear 55 9
102. ferential case C Align pinion shaft hole and install new spring pin through the differential case and pinion shaft Workman MD MDX Page 5 39 Drive Train Figure 61 1 Side gear 3 Gear 62 2 Pinion gear 4 Differential case D Install remaining side gear to the pinion gears E Secure gear 62 to the differential case with six 6 bolts Torque bolts a crossing pattern from 40 to 45 ft Ib 54 to 61 N m 40 to 45 ft Ib 54 to 61 N m Figure 62 IMPORTANT Thelength fromthe outer most side of G The differential assembly should appear as each ball bearing must be from 123 3 to 124 0 mm above when assembled Fig 58 F If ball bearings were removed press new ball bearings onto differential case and gear 62 Drive Train Page 5 40 Workman MD MDX 4 On Workman MD assemble governor fork Figure 63 1 Ball bearing 2 RHcase bearing bore A Install ball bearing into the bore of the case RH Figure 64 1 Governor shaft 2 Boss IMPORTANT Make sure to not damage the oil seal B Lubricate governor shaft with molybdenum disul when installing the governor shaft into the governor fide grease before installing boss C Install governor shaft into the boss Workman MD MDX Page 5 41 Drive Train 5 2 Figure 65 1 Screw 2 used 3 Governor fork 2 Stopper 4 Case RH IMPORTANT To prevent the screws that secure the D Secure stopper and governor for
103. ge Replace both bearings if either bearing meets any of the following conditions A Bearings do not spin smoothly are noisy when ro tated or have excessive end or axial play B The bearing balls or rolling surfaces are pitted or worn C The bearings are rusted worn cracked or show abnormal color due to overheating NOTE Individual components in the frame housing are not available separately Replace housing or complete starter generator if damage exists in frame and field as sembly Electrical System Page 6 28 Rev B Figure 35 Figure 36 Workman MD MDX 9 Remove nut lock washer flat washer and fiber washer from A1 and A2 terminals on commutator end head 10 Remove two 2 screws that secure the brush box to the commutator end head Carefully remove brush box from the commutator end head 11 Remove brush assemblies from the brush box Minimum brush length is 0 375 in 9 5 mm Maximum brush length is 0 790 in 20 mm 2 System Figure 39 Workman MD MDX Page 6 29 Rev B Electrical System 12 Assembly new brushes to the brush plate A First insert the brush with the short lead into one of the brush holders Then rotate the brush plate 180 to insert the brush with the longer lead Repeat for second brush assembly B Be sure that terminal insulator is positioned on each terminal bolt after assembly Also be sure to have the brush springs against the side of
104. gs and watches before doing any electrical trouble If the vehicle has any interlock switches by passed shooting or testing Disconnect the battery they must be reconnected for proper troubleshooting cables unless the test requires battery voltage and safety Starting Problems Starter solenoid clicks but starter will not crank Battery is discharged Battery cables are loose or corroded Battery ground to frame is loose or corroded Wiring at starter is faulty Starter solenoid is faulty Starter is faulty and causing an incomplete circuit for the solenoid Nothing happens when start attempt is made Battery is discharged Wiring to the start circuit components is loose corroded or damaged see Wiring Schematics in Chapter 8 Electrical Diagrams Battery cables are loose or corroded Battery ground to frame is loose or corroded Fuse block is faulty 10 ampere fuse to the ignition switch is loose or blown Electrical System The ignition switch is faulty Switch at accelerator pedal is faulty or needs adjustment Starter solenoid is faulty Shutdown module is faulty Workman MDX Engine cranks but does not start Wiring to start circuits is loose corroded or damaged see Wiring Schematics in Chapter 8 Electrical Diagrams Shutdown module is faulty Workman MDX Engine or fuel system is malfunctioning see Engine Chapter Engine and fuel may be too cold Workman MD MDX 6 5 Elect
105. gure 11 Negative cable Air cleaner bracket Flange nut 7 used Carriage screw Flange nut 2 used Hose clamp 2 used Hose clamp Cap screw 4 used Lock washer 4 used Washer Cap screw Mount 2 used Washer 2 used Flywheel guard Flat washer 4 used Flange head screw 4 used Intake hose Cap screw 2 used Hose clamp 2 used Air cleaner assembly Breather hose Page 4 12 25 to 30 ft Ib 34 to 40 N m Loctite 242 Intake hose Cap screw 4 used Fitting Lock nut Lock washer 2 used R clamp Cap screw Flat washer R clamp Cable tie 2 used Nut Spring Bolt Cap screw 2 used Governor cable Lock washer Nut Woodruff key Plastic cap Nut 2 used Workman MD Engine Removal Fig 11 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Disconnect ground black cable from the battery Then disconnect positive red cable from the battery 3 Remove cargo box to gain access to the engine see Cargo Box and Tailgate Removal in the Service and Re pairs section of Chapter 7 Chassis IMPORTANT Make sure all hoses and engine open ings are plugged after disconnecting This will pre vent contaminants from entering the engine and fuel system 4 Disconnect the following components A Choke and governor cables from the car
106. h Workman The oil pressure switch is located on the mounting adapter for the oil filter It is a normally closed switch that opens with pressure Oil pressure switch testing 1 Turn the ignition switch to ON The oil indicator light on the dash should be illuminated 2 Ifthe light is not on disconnect the wire from the oil pressure switch and ground the wire to the engine block 3 Ifthe light comes on the oil pressure switch is faulty 4 Ifthe light does not come on after step 2 check the indicating circuit see Electrical Schematic in Chapter 8 Electrical Diagrams If the oil indicator light comes on with the engine running 1 Shut off the engine immediately 2 Disconnect the wire from the oil pressure switch 3 Turn the ignition switch to ON The oil indicator light should go out Audio Alarm Reverse Optional If vehicle is equipped with the optional audio alarm whenever the shift lever is placed in the reverse position the audio alarm should sound The alarmis attached be neath the cargo box to a bracket on the right side of the frame Testing 1 Place machine shift lever in the NEUTRAL position Make sure that ignition switch is off remove key from ignition switch and engage parking brake 2 Raise cargo box and secure with prop rod Gain ac cess to audio alarm by removing the electrical cover IMPORTANT Make sure to observe polarity on the alarm terminals when testing Damage to th
107. h the needle bearing gear 34 and into the spacer and case 7 Assemble case LH and RH Figure 74 1 Case sealing surface 2 Pipe knock A Make sure gasket sealing surfaces of both cases B Install both pipe knocks to the case LH are clean Install gasket to case Drive Train Page 5 46 Workman MD MDX 15 to 18 ft Ib 21 to 25 N m Figure 75 1 Governor shaft Workman MD 2 Bolt NOTE When installing case RH to the case LH on C Install case RH so each shaft fits properly into Workman MD hold governor shaft so the ball bearing the case will not drop off Keep the gasket sealing surfaces of the cases as horizontal to each other as possible If the seal D Secure case RH to case LH with bolts Torque ing surfaces do not join to each other tap the case lightly bolts from 15 to 18 ft Ib 21 to 25 N m with a plastic hammer 25 to 31 ft lb 34 to 42 N m a 2 L Figure 76 1 Axle bracket 2 Flange bolt E Position axle bracket to each axle case Secure axle bracket to each axle case with flange bolts Torque bolts from 25 to 31 34 to 42 N m Workman MD MDX Page 5 47 Drive Train 12 to 15 ft lb 16 to 20 N m Figure 77 1 Cable bracket 2 Bolt steel ball spring amp gasket F Install cable bracket to the transaxle H Fill transaxle with 1 5 quarts 1 4 liters of new 10W 30 motor oil G Install steel ball spring gasket and bolt Torque bo
108. he circuit e g unplug the ignition switch connector before doing a continuity check on the switch When testing electrical components for continu NOTE See the Briggs and Stratton Repair Manual for ity with a multimeter ohms setting make sure 4 Cycle V Twin Cylinder OHV Head Engines Work that power to the circuit has been disconnected man MDX or the Kohler Service Manual for Command Pro CS Series Engines Workman MD for additional component testing information Ignition Switch The ignition switch used on the Workman has six 6 switch terminals and three 3 key switch positions Only RUN two of the positions are used OFF and RUN The switch terminals are identified as shown in Figure 5 NOT Orr 45 45 USED Testing The circuitry of the ignition switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various switch terminals REAR VIEW for each key position Verify continuity between switch terminals Figure 5 POSITION CIRCUIT OFF D E F Electrical System Page 6 8 Workman MD MDX 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 1 Unplug wire harness connector from hour meter 2 Connect positive terminal of a 12 VDC source to the positive termina
109. heave post 1 Pilot bolt 2 Pilot bolt threads 5 Install spider to the fixed sheave post using spider re moval tool kit see Special Tools Make sure to align matchmark made during disassembly 6 Torque spider to 100 ft Ib 136 N m 7 Install engine starter pulley to the drive clutch as fol lows A Insert four 4 cap screws through lock washers pulley and spacer B Apply Loctite 242 or equivalent to the threads of the cap screws C Secure pulley and starter spacer to the clutch with cap screws 8 Position cover to clutch Secure cover to the move able sheave with three 3 cap screws Torque cap screws from 75 to 100 in Ib 8 5 to 11 3 N m Drive Train 5 13 1 Rev Figure 19 3 Moveable sheave Workman MD MDX This page is intentionally blank 5 ec 2 Workman 5 13 2 Rev A Drive Train Drive Clutch Service Serial Number Above 310000000 0 o 11 132 to 168 in Ib 132 to 168 in Ib 15 0 to 18 9 N m 8 5 to 11 3 N m 258 to 298 N m Figure19 1 1 Fixed sheave 5 Cap screw 3 used 9 Shim 2 Limiter shim 6 Roller 6 used 10 Cap screw 4 used 3 Shim 7 Cover 11 Engine starter pulley 4 Spider 8 Moveable sheave NOTE Vehicles with a serial number above 4 Use starter pulley cap screws to secure the spider re 310000000 are equipped with a TEAM brand drive clutch Drive Clutch Disassembly Fig 19 1 IMPOR
110. her parts while removing the engine C Slowly raise engine and attachments from the machine 13 Remove engine parts and attachments as neces sary to repair the engine Figure 12 5 Starter generator belt 6 Throttle cable 7 Governor cable Fuel pump bracket Exhaust manifold Fuel line Drive belt PON gt Single Cylinder Gasoline Engine 7 gt 2 gt Gasoline Engine Engine Installation Fig 11 1 Install all removed engine parts and attachments to the engine One person should operate the hoist while a sec ond person guides the engine into the frame 2 Install engine to the frame A Attach a short section of chain between fuel pump bracket lift hole and exhaust manifold Fig 12 B Connect a hoist at the center of the chain IMPORTANT Make sure to not damage engine fuel lines electrical harness or other parts while installing the engine C Lower engine onto the engine tray 3 Install four 4 cap screws and flange nuts to engine and engine tray Position engine on engine tray to align clutch drive pulley and driven pulley on transaxle Tight en fasteners 4 Connect engine harness connector to the main elec trical harness 5 Remove cap screw item 49 and flat washer item 50 that secure r clamp item 51 and shift cables item 8 to engine Position r clamp item 51 and shift cables item 8 to engine Secure r clamp to engine with flat washe
111. hich identifies the brand Service informa tion for these two 2 types of starter generators is in cluded in this chapter Make sure to use the correct information for the component that is being serviced Workman MD MDX Page 6 19 Rev B Installation Fig 24 1 If removed install pulley to the starter generator shaft A Position woodruff key to the shaft Slide pulley onto the shaft with the larger diameter pulley hub installed toward starter generator B Secure pulley to the shaft with spring washer and nut Torque nut from 15 to 25 ft Ib 20 to 34 N m 2 Position starter generator to the engine tray assem bly A Insert pivot bolt through the starter generator front bracket engine mount and starter generator rear bracket Install flange nut onto the pivot bolt B Tighten flange nut enough so starter generator pivots with slight resistance C Install carriage bolt through upper starter flange and bracket on engine tray D Thread lock nut onto carriage bolt 3 Correctly connect all wires to the starter generator 4 Install drive beltto the pulley and adjust belt tension Make sure that all fasteners are tightened after belt ad justment 5 Lower and secure cargo box Electrical System 2 System Starter Generator Service Valeo Starter Generator WIRING DIAGRAM MOTOR Fe p TOO FIELD STATOR F1 CCD DF e THO
112. hread Cutting Screws Zinc Plated Steel Zinc Plated Steel Type 1 Type 23 or Type F Thread Size Baseline Torque No 6 32 UNC 20 5 in Ib No 8 32 UNC 30 5 in Ib Baseline Torque A Type B No 10 24 UNC 38 7 in Ib 1 4 20 UNC 85 15 in Ib 5 16 18 UNC 110 20 in Ib Hole size material strength material thickness and fin ish must be considered when determining specific 3 8 16 UNC 200 100 in Ib torque values All torque values are based on non lubri cated fasteners 85 15 in Ib 0 5in 16 7 in Conversion Factors in lb X 11 2985 N cm N cm X 0 08851 in Ib ft lb X 1 3558 N m N m X 0 7376 ft Ib Product Records and Maintenance Page2 6 Workman MD MDX Chapter 3 Briggs amp Stratton Gasoline Engine Table of Contents GENERAL INFORMATION 2 Operator s Manual 2 SPECIFICATIONS 3 ADJUSTMENTS 4 Adjust Throttle Cable 4 SERVICE AND REPAIRS 5 Cooling System 5 So ir Cleaner E E E 6 Exhaust System 8 UE wc 10 5 2 Oil Filter Assembly 12 59 14 59 Engine 15 Engine Installation 16 Fuel Evaporative Contro
113. ial Numbers Above 311000000 100 to 110 in Ib 11 3 to 12 4 N m Figure 34 1 Cargo box 7 Pivot bushing 2 used 2 Handle 8 Screw 4 used 3 Latch pin 2 used 9 Carriage screw 4 used 4 Lock nut 2 used 10 Flange nut 4 used 5 Carriage screw 4 used 11 Prop rod 6 Pivot bracket 12 Flange nut 6 used Chassis Page 7 46 Rev A 190 to 200 in Ib 21 5 to 22 6 N m 13 Carriage screw 2 used 14 Tension spring 2 used 15 Carriage screw 2 used 16 Prop rod bracket 17 Latch assembly Workman MD MDX Removal Fig 34 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch 2 Disassemble cargo box as necessary using Figures 34 and 35 as guides Installation Fig 34 1 Assemble cargo box using Figures 34 and 35 as gui des A When installing cargo box use torque specifica tions identified in Figure 34 B Adjustlatch pin item 3 in Figure 34 so that cargo box is tight to frame when latched Inner tailgate Outer tailgate RH latch rod Latch handle Screw 24 used Workman MD MDX Page 7 47 Rev A Figure 35 7 LH latch rod 8 Retainer 2 used 9 Striker mount 2 used 10 Strike latch 2 used 11 Screw 4 used 12 Screw 4 used Chassis This is intentionally blank Chassis Page 7 48 Rev A Workman MD MDX Chapter 8 TORO Electrical Drawings Table of Contents
114. ier Multimeter The meter can test electrical components and circuits for current resistance or voltage NOTE Toro recommends the use of a DIGITAL Volt Ohm Amp multimeter when testing electrical circuits The high impedance internal resistance of a digital me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Special non conductive grease which forms a light pro tective skin which helps waterproof electrical switches and contacts Toro Part Number 505 165 Figure 2 lt o 5 D System Battery Terminal Protector Aerosol spray that should be used on battery terminals to reduce corrosion problems Apply terminal protector after the battery cable has been secured to the battery terminal Toro Part Number 107 0392 FLEXIBL NON TACK Ev Figure 3 Workman MD MDX Page 6 3 Electrical System Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte Obtain this tool locally Figure 4 Electrical System Page 6 4 Workman MD MDX Troubleshooting For effective troubleshooting and repairs you must have a good understanding of the electrical circuits and components used on this vehicle see Wiring Schemat ics in Chapter 8 Electrical Diagrams Remove all jewelry especially rin
115. igure 20 3 Fitting from canister 4 Fitting to engine 1 Check valve 2 Directional arrow 00A 301019 Q 08 031 SAE PAGE gt PA66 lt E AH 7 FUEL O TANK Figure 21 1 Top of carbon canister 2 Fitting to rollover valve 3 Fitting to engine Briggs amp Stratton Gasoline Engine o D D o ui o D e This is intentionally blank Briggs amp Stratton Gasoline Engine Page 3 20 Workman MDX Chapter 4 Single Cylinder Gasoline Engine Table of Contents GENERAL INFORMATION 2 Operator s Manual 2 SPECIFICATIONS 3 ADJUSTMENTS 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 gto pact hte EIAS i 10 e EXE 12 Engine 13 52 Engine Installation 14 so Fuel Evaporative Control System Serial Numbers c5 Above 311000000 16 KOHLER SERVICE MANUAL FOR COMMAND PRO 23 CS SERIES ENGINES
116. ine speed 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Lift cargo box and prop with rod to gain access to the engine 3 When the accelerator pedal is fully depressed 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 lever is in the neutral position to prevent the machine from moving 5 With ignition switch in the RUN position depress celerator pedal and allow engine to start Fully depress accelerator pedal and have a second person measure engine speed with a tachometer With pedal fully de pressed engine speed should be from 3250 to 3350 RPM If necessary adjust throttle cable or engine gov ernor so that engine speed is correct when the acceler ator pedal is fully depressed 6 After throttle cable adjustment is correct lower and secure cargo box h ACCELERATOR PEDAL RELEASED Figure 1 1 Throttle cable 2 Governor bellcrank ACCELERATOR PEDAL DEPRESSED Figure 2 1 Throttle cable 3 Gap 2 Governor bellcrank Briggs amp Stratton Gasoline Engine Page3 4 Rev B Workman MDX Service and Repairs Cooling System To ensure proper engine cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times NOTE Perform
117. ixed sheave 5 Spring Figure 5 3 Spring Drive Train Drive Train Special Tools Order special tools from your Toro Distributor Drive Clutch Removal Tool Serial Number Below 310000000 This tool is required to remove the drive clutch from the tapered drive shaft of the engine It is placed in the threaded hole of the fixed clutch sheave after the clutch holding cap screw is removed Toro Part Number TOR4094 NOTE Vehicles with a serial number below 310000000 are equipped with a Comet brand drive clutch 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 holding bar Toro Part Number TOR4098 NOTE Vehicles with a serial number below 310000000 are equipped with a Comet brand drive clutch Figure 7 1 Holding bar 2 Spanner Clutch Dry Lubricant Serial Number Below 310000000 This lubricant should be used to properly lubricate drive clutch components on vehicles with serial numbers be low 310000000 Toro Part Number 104 7011 NOTE Vehicles with a serial number below 310000000 are equipped with a Comet brand drive clutch Figure 8 Drive Train 5 6 Rev A Workman MD MDX Drive Clutch Removal Tool Serial Number Above 310000000 This tool is required to remove the drive clutch from the tapered drive shaft of the engine It is placed
118. k to the governor governor fork and stopper to the governor shaft shaft with both screws from loosening apply Loctite 242 or equivalent to the screw threads 12 to 16 in Ibs 1 4 to 1 8 N m Figure 66 1 Governor fork 3 Screw 2 used 2 Governor shaft greased surface E Adjust governor fork center to the center of the F Torque screws from 12 to 16 in Ibs 1 4 to 1 8 ball bearing hole Also adjust thrust clearance of N m the governor shaft to less than 0 020 0 5 mm Drive Train Page 5 42 Workman MD MDX 5 Install axle case to case RH and LH Figure 67 1 Axle shaft 3 Ball bearing 2 Snapring IMPORTANT Do not reuse snap ring Replace snap A Insert axle shaft with snap rings collar and ball ring with new one bearings into the axle case Install snap ring to the axle case 25 to 31 ft Ib A 34 to 42 N m 5 2 Figure 68 1 Axle case 3 Flange bolt 2 Case IMPORTANT Make sure to install the axle case to B Install axle case to the case Secure each axle the proper side of the case The right side of the case to the case with flange bolts Torque bolts from case takes the short axle case and the left side 25 to 31 ft lb 34 to 42 N m takes the long axle case IMPORTANT Make sure to not damage the oil seal when installing the axle case to the case Workman MD MDX Page 5 43 Drive Train 6 Install input shaft center shaft and differe
119. k washer Nut Starter V belt Cap screw 4 used Lock washer 4 used Briggs amp Stratton Gasoline Engine Figure 12 Engine pulley Negative cable Starter spacer Drive clutch Washer Cap screw Flange nut 4 used Cap screw Carriage screw Engine tray Washer 2 used Starter generator pulley Starter generator Flange nut 3 used Engine Page 3 14 65 to 85 ft Ib 88 to 115 N m Loctite 242 21 25 to 30 TE ad 34 to 40 N m Engine wire harness Cap screw 2 used Screw 4 used Mount 2 used Cap screw 4 used Fuel filter Fuel hose Lock nut Cable bracket Ball stud Cable Exhaust manifold Coupler spring 4 used Plastic cap Workman MDX Engine Removal Fig 12 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch 2 Disconnect negative black cable from the battery Then disconnect positive red cable from the battery 3 Remove cargo box to gain access to the engine see Cargo Box and Tailgate Removal in the Service and Re pairs section of Chapter 7 Chassis 4 Depending on needed engine repairs it may be easi er to drain engine oil from engine before engine remov al IMPORTANT To prevent contaminants from enter ing the engine and fuel system make sure all hoses and engine openings are covered or plugged after disconnecting
120. l System Serial Number Above 310000000 18 BRIGGS amp STRATTON REPAIR MANUAL FOR 4 CYCLE V TWIN CYLINDER OHV HEAD EN GINES Workman MDX 3 1 Rev B Briggs amp Stratton Gasoline Engine General Information This Chapter gives information about specifications maintenance troubleshooting testing and repair of the V twin cylinder gasoline engine used in the Workman MDX Most repairs and adjustments require tools which are commonly available in many service shops Special tools are described in the Briggs amp Stratton Repair Manual for 4 Cycle V Twin Cylinder OHV Head En Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Workman MDX vehicle Refer to the Operator s Manual for additional information when ser vicing the machine Briggs amp Stratton Gasoline Engine Page 3 2 gines The use of some specialized test equipmentis ex plained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an engine repair facility Service and repair parts for Briggs amp Stratton engines are supplied through your local Toro distributor If no parts list is available be sure to provide your distributor with the Toro model and serial number Workman MDX Specifications Item Description Make Designation Briggs and
121. l Tank Installation Fig 7 1 If removed install bushings stand pipe and fuel gauge to tank 2 Position fuel tank to frame Secure tank to frame and cross member with tank web strapping 3 Connect fuel hose to the tank stand pipe and secure with hose clamp 4 Install seat base to the frame see Seat Base Instal lation in the Service and Repairs section of Chapter 7 Chassis 5 Fill fuel tank Figure 8 1 Shift lever 4 Cap screw long 2 Cap screw short 5 Choke cable 3 Shift plate 1 2 5 Workman MD Page 4 11 Fuel hose Fuel tank Fuel tank Carbon canister Rollover valve Fuel hose tank vent Fuel hose Rev B Figure 9 3 Tank web strapping Figure 10 6 Fresh air filter 7 Fuel hose purge hose 8 Check valve 9 Fuel hose to engine Single Cylinder Gasoline Engine ES 2 gt 7 Gasoline Engine Engine N 18 o 207 17 65 to 85 ft lb 88 to 115 N m Loctite 242 Kohler engine Coupler spring 4 used Exhaust manifold Muffler Exhaust coupler Cap screw 2 used Drive clutch Shift cable 2 used Starter belt Cap screw Fuel filter Engine pulley spacer Starter generator Starter pulley Engine pulley Hose clamp 3 used Fuel hose Fuel hose conduit Air filter mounting band Engine wire harness Engine tray Single Cylinder Gasoline Engine Fi
122. l of the hour meter 3 Connect negative terminal of the voltage source to the other terminal of the hour meter 4 The hour meter should move 1 10 of an hour in six 6 minutes 5 Disconnect voltage source from the hour meter Re connect wire harness connector to hour meter Headlight Switch The headlight switch is located on the control panel Fig 7 This rocker switch allows the headlights to be turned on and off Testing The switch terminals are marked as shown in Figure 7 The circuitry of the headlight switch is shown in the chart below With the use of a multimeter ohms setting the switch functions may be tested to determine whether continuity exists between the various terminals for each position Verify continuity between switch terminals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS Workman MD MDX Page 6 9 QUARTZ RUNNING INDICATOR FJ WINDOW Ps 0000 HOURS Y 1 10 WHEEL WHITE W BLACK NUMBERS HOUR WHEELS BLACK W WHITE NUMBERS Figure 6 Figure 7 2 Back of switch 1 Headlight switch Electrical System System Start Run Solenoid The start run solenoid provides a current path between starter generator and the vehicle electrical circuits This solenoid is energized when the ignition switch is ON and the accelerator pedal is depressed The solenoid is at tached
123. late if grooves can not be re moved by light sanding with emery cloth or other suit able abrasive Replace plate if cracked warped or excessively rusted 4 Inspect adjuster levers for deformation Replace lev ers if deformation or excessive rust is found 5 Replace parking brake cables if frayed stretched or kinked Workman MD MDX Page 7 31 Assembly Fig 20 IMPORTANT Brake shoe lining surfaces must be free of grease oil and other foreign matter 1 Apply a light film of lubricant to the following A Ledges on which the brake shoes rest B Pin surfaces on adjuster levers C Anchor block surface that contacts shoe webs D Both surfaces of belleville washers that are posi tioned between adjuster levers and backing plate 2 If removed position lubricated belleville washer be tween lever adjuster and backing plate Secure adjuster to backing plate with washer and bolt Torque bolt from 110 to 120 in Ib 12 4 to 13 6 N m 3 If removed secure wheel cylinder to backing plate with two 2 washer head screws Torque screws from 110 to 120 in Ib 12 4 to 13 6 N m 4 Ifremoved from backing plate slide parking brake le ver into slot and dust cover in backing plate 5 Position brake shoes to backing plate Make sure that each shoe is properly positioned at anchor block parking brake lever wheel cylinder and pin on adjuster lever Secure shoes to backing plate with shoe hold down cups and springs Be c
124. ld be filtered and should not ex ceed 15 PSI 103 kPa 3 Remove brushes from their holders Clean carbon dust from the commutator end cover and brushes IMPORTANT Label armature leads connected to brush leads prior to disconnecting any brush leads 4 Inspect brushes for damage A Replace any brush that is cracked or severely chipped B Ifthe length from the end of the brush to the wear line is less than 0 063 inch 1 6 mm replace all four 4 brushes Fig 26 5 Inspectbrush springs for heat discoloration Replace all four brushes if any brush is straw or bluish colored 6 Check brush springs for correct tension A Secure all four 4 brushes into their holders with the brush springs B Using aspring scale check tension on all four 4 brushes in the direction of the spring Fig 27 C Replace all four 4 springs if any spring s tension is less than 24 ounces 1 6 N 7 Secure brush and armature leads with set screws and lock washers 8 Lift brush springs from the notch at the end of the brushes while pulling the brushes out Allow springs to hold brushes out from the center Fig 25 9 Position commutator end cover to the commutator and yoke Secure commutator end cover to the yoke with both through bolts and flat washers Torque bolts from 96 to 104 in Ibs 10 8 to 11 8 N m Workman MD MDX Page 6 21 10 Slide brushes into holders Secure brushes by posi tioning brush springs into
125. le or damaged repair or replace it before operating the ve hicle Also tighten any loose nuts bolts or screws to en sure vehicle is in safe operating condition Safety Page 1 2 The safety alert symbol means A CAUTION WARNING or DANGER personal safety instruction Read and understand the instruction because it has to do with safety Failure to comply with the instruc tion may result in personal injury reduce the potential for injury or death comply with the following safety instructions The Workman is an off highway vehicle only Itis not designed equipped or manufactured for use on public streets roads or highways 2 Be sure to establish your own special procedures and work rules for unusual operating conditions e g slopes too steep for vehicle operation 3 Since fuel used in Workman vehicles is highly flam mable handle it carefully A Store fuel in containers specifically designed for this purpose Do not remove vehicle fuel tank cap while engine is hot or running C Do not smoke while handling fuel D Fill fuel tank outdoors and only to within an inch of the top of the tank not the filler neck Do not overfill the fuel tank E Clean up any spilled fuel Workman MD MDX While Operating 1 Sit onthe operator seat when starting and operating the vehicle 2 Before starting the engine A Sit on operators seat and apply the parking brake B Turn ignition ke
126. le to starter gen 5 Green wire connector 1 Start run solenoid 2 Main contact post 3 Voltage regulator Figure 15 3 Terminal F1 location 4 Terminal DF location 1 Terminal A1 2 Terminal A2 Electrical System T o System Starter Generator Testing of starter generator field and armature windings is difficult with the starter generator still mounted in the Workman Follow the procedures for Starter Generator amp Voltage Regulator Component Testing prior to remov ing the starter generator for further testing and repairs Starter generator resistance tests are as follows NOTE Prior to taking small resistance readings witha digital multimeter short the meter test leads together The meter will display a small resistance value usually 0 5 ohms or less This resistance is due to the internal resistance of the meter and test leads Subtract this val ue from the measured value of the component you are testing 1 Disconnect wire connections on starter generator to separate circuits 2 Ifstarter generator is a Valeo brand identified by Va leo on commutator end cover of starter generator and through bolts that are in set from outer diameter of end cover Fig 16 A Measure resistance Ohms 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
127. level is correct So 2 gt ge Hm 7 Doa oO Workman MDX Page 3 17 Briggs amp Stratton Gasoline Engine Fuel Evaporative Control System Serial Number Above 310000000 ROLLOVER 4 CARBON CANISTER FRESH AIR TO INTAKE MANIFOLD Figure 18 Workman MDX vehicles with serial number above 310000000 are equipped with a fuel evaporative control system EVAP designed to collect and store evapora tive emissions from the fuel tank The EVAP uses a car bon canister to collect these evaporative emissions Fuel vapors from the fuel tank are vented to the canister where they are stored Vapors from the canister are con sumed when the engine is running which purges the 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 venting through the carbon canister NOTE Ifthere is restriction in the fresh air filter the car bon canister or the rollover valve the fuel tank may dis tort due to venting issues If the fuel tank returns to it s normal shape when the fuel cap is removed restriction in the evaporative control system is likely Briggs amp Stratton Gasoline Engine Page3 18 Rev B Machines with a carbon canister include a single engine connection to the engine intake system that is used to connect the evapor
128. lt from 12 to 15 ft Ib 16 to 20 N m Drive Train Page 5 48 Workman MD MDX Table of Contents GENERAL INFORMATION 2 Operator s Manual 2 ELECTRICAL SCHEMATICS 2 SPECIAL TOOLS 3 TROUBLESHOOTING 5 Starting Problems 5 General Run Problems 6 ELECTRICAL SYSTEM QUICK CHECKS 7 Battery Test 7 Charging System Test 7 COMPONENT TESTING 8 Ignition Switch 8 Hour Meter veo ete se eae ees 9 Headlight Switch 9 Start Run Solenoid 10 F se Block urere ven 11 Accelerator Switch 12 Starter Generator amp Voltage Regulator 13 Starter Generator 14 Diode Assembly 15 RPM Shutdown Module Workman MDX 15 Oil Pressure Switch Workman MDX 16 Audio Alarm Reverse Optional 16 Reverse Switch Optional 17 Workman MD MDX Page6 1 Rev B Chapter 6 Electrical System SERVICE AND REPAIRS 18 Starter Generator 18 Removal eee eee 19 Installation 19 Starter Generator Servic
129. ly IMPORTANT Make sure to not damage the screw C On Workman MD remove two 2 screws and heads when removing screws Each screw is se lock pin securing the governor plate assembly to the cured with an adhesive governor base Drive Train Page 5 28 Workman MD MDX Figure 42 1 Input shaft 4 Governor sleeve Workman MD 2 Ball bearing 5 Lock pin Workman MD 3 Governor plate weight WM MD 6 Screw 2 used Workman MD D Replace input shaft if worn or damaged Gear F On Workman MD replace governor plate if teeth that are cracked broken chipped or missing cracked bent or any weight is missing Weights must are not acceptable swing freely E Ball bearing roller balls must be free of deforma G On Workman MD replace governor sleeve if tion and scoring Ball bearing must spin freely and cracked or worn have minimum axial play Replace ball bearing as necessary 5 Disassemble center shaft assembly a 2 Figure 43 1 Ball bearing 2 Ball bearing IMPORTANT Do not reuse ball bearings that have A Remove ball bearings from the center shaft as been removed sembly Discard removed bearings Workman MD MDX Page 5 29 Drive Train Drive Train Figure 44 6 Gear 55 Gear 47 Gear small Ball bearing Ball bearing Remove gears pin clutch collars and spacer from the input shaft C Replace gears if worn or damaged Cracked bro ken missing or chipped gea
130. m SET 2 293g mm 5 dg YELLOW gt m gt duo gt I gt E I z BLACK BLACK A a B e WHITE BLUE GREEN D 2 YELLOW 3 VIOLET SP06 F 4 5 6 7 8 SP02 BACK SP03 RED A RED B BLUE PINK 2 BLUE SPO 3 BLACK PINK SP05 3 YELLOW 5 6 8 PINK TE 8 YELLOW BLACK A M RED 8 D BLACK BROWN F 1 RED BLACK BLUE BLACK 2 GREEN 3 4 4 BLUE 5 IA 6 IB jJ 2h 2B 5 X z x x x o u g J d d d d d ug J02 a KEY START KIT 2 l B G C2 6 tj B 06 PI9 403 J04 J05 PI2 BACKUP 0100 START RUN BOX LIFT ACTUATOR ALARM SOLENOID F4 VOLTAGE REGULATOR Jog SWITCHED SIDE OF START RUN SOLENOID POT LIFT SW GROUND J0 MAGNETO 204 OIL SWITCH J03 P01 BLACK WHITE BLUE GREEN BROWN WHITE BROWN BROWN a J05 108 IGNITION ACCELERATOR SWITCH SWITCH 102 101 GROUND J03 OIL SW ITCH JOL MAGNETO J05 IGNITION SWITCH J06 ACCELERATOR SWITCH Workman MD Engine Electrical Harness Page 8 13 Rev A EA GROUND Li 409 MAGNETO BLACK La 5 BROWN Pol WHITE BLUE i OIL PRESSURE D GREEN m BROWN WHITE F J04 DE xs RPM SHUTDOWN J02 MAGNET
131. m 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 Remove cover and gasket from the housing Replace gasket if damaged 4 Inspect gears Sector and pinion gear teeth must be free of damage that prevents them of free movement 5 Remove pinion gear item 17 from the housing IMPORTANT Matchmark pitman arm shaft and sec tor gear Their position is critical during reassembly 6 Separate Pitman arm item 19 from the sector gear item 4 and steering housing and remove from the housing 7 Inspect bearings Bearings must spin smoothly and be free of damage Press bearings and spacer out of housing if necessary 8 Inspect seals Seals must be free of rips and tears Replace seals if necessary Assembly Fig 5 IMPORTANT Always replace ball bearings as a set 1 If ball bearings were removed A Press new bearing into housing from the inside first B Turn housing over Insert spacer and press new bearing into housing Workman MD MDX Page 7 13 2 Ifseals 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 IMPORTANT The position of the Pitman arm and sector gear is critical during assembly If either or both of these parts is replaced make sure their alignment matches th
132. machine see Front Hood Instal lation in this section 5 Bleed brakes see Bleed Brake System in this sec tion After servicing brake system components al ways check the brakes in a wide open level area that is free of other persons and obstructions 6 Check brake operation Chassis Brake Master Cylinder Service Disassembly Fig 24 1 Thoroughly clean outside of master cylinder before disassembly 2 Remove reservoir and flange seal Push in on the push rod so the stop pin can be removed 3 Disconnect lower end of the dust cover from the housing 4 Push in on the push rod and remove circlip then re move push rod with dust cover and clevis Remove re tainer washer 5 Remove primary piston assembly and secondary piston assembly from cylinder housing Inspection Figure 24 CAUTION 1 Reservoir 7 Dust cover 2 Flange seal 8 Push rod 3 Stop pin 9 Circlip 4 Secondary piston assy 10 Retainer washer Use eye protection such as goggles when using 5 Clevis 11 Primary piston assy compressed air for master cylinder service Sammut 12 Cylinder housing 1 Clean all metal parts with isopropyl alcohol then clean out and dry grooves and passageways with com pressed air Make sure cylinder bore and component pieces are thoroughly clean 2 Check cylinder bore pistons and springs for damage or excessive wear Replace brake cylinder assembly if signs of pitting scoring or cracks are evident
133. me ter reading should be under 1 Ohm but not zero C Measure resistance between each terminal and ground The meter reading should be infinite no continuity 3 If starter generator is a Advanced Motor and Drives brand identified by through bolts that are near the outer diameter of commutator end cover Fig 17 A Measure resistance Ohms between starter generator terminals F1 and F2 The meter reading should be very low approximately 0 006 Ohms B Measure resistance Ohms between starter generator terminals DF and F1 The meter reading should be approximately 3 to 6 Ohms C Measure resistance between each terminal and ground The meter reading should be infinite no continuity 4 Starter generator disassembly and repair will be needed if readings are incorrect see Starter Generator Service in the Service and Repairs section of this chap ter Electrical System 6 14 Rev Figure 16 1 Valeo Starter Generator end cover view 2 Through bolt 2 used Figure 17 1 Advanced Motors Starter Generator end cover view 2 Through bolt 2 used Workman MD MDX Diode Assembly The diode D1 Fig 17 is used to protect the ignition switch from voltage spikes that can occur when the start er solenoid is de energized The diode plugs into the wiring harness Testing The diode can be tested using a digital multimeter diode test or ohms setting and the table to the right Fig
134. multimeter lead to the positive battery post and the negative multimeter lead to the negative bat tery post Keep the test leads connected to the battery posts and record the battery voltage NOTE When starting the engine the battery voltage will drop and then should increase once the engine is running NOTE Depending upon the condition of the battery charge and battery temperature the battery voltage will increase at different rates as the battery charges Workman MD MDX Page 6 7 Voltage Measured Battery Charge Level 12 68 V or higher Fully charged 100 12 45 V 75 charged 12 24V 50 charged 12 06 V 25 charged 11 89 V 0 charged Make sure the shift lever is inthe neutral position and the parking brake is applied Start the engine and run en gine at high idle above 3000 RPM Maintain engine speed to allow the battery to charge for at least 3 min utes Record the battery voltage After running the engine for at least 3 minutes battery voltage should be at least 0 50 volt higher than initial bat tery voltage An example of a charging system that is functioning At least 0 50 volt over initial battery voltage Initial Battery Voltage 12 30 Battery Voltage after 3 Minute Charge 12 85 Electrical System T 2 System Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from t
135. n the fastener until the lines match up Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance N E gt a and Maintenance Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series SAE Grade 8 Bolts Screws Studs amp Sems with Regular Height Nuts SAE Grade 5 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts Grade 1 5 amp 8 with Thin Height Nuts SAE Grade 1 Bolts Screws Studs amp Sems with Regular Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 5 or Stronger Nuts ovem omo inte 100 10 1125 100 140 15 1580 170 obo wm omo wm Thread Size 6 32UNC 147 23 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 339 56 10 32 UNF 1 4 20 UNC 48 7 599 79 1 4 28 UNF 65 10 734 113 5 16 18 UNC 115 15 105 17 1186 169 5 16 24 UNF 138 17 128 17 1446 192 3 8 16 UNC 16 2 3 8 24 UNF 7 16 14 UNC 27 3 7 16 20 UNF 29 3 39 4 430 45 583 61 600 60 813 81 475 45 644 61 660 60 895 81 1 2 13 UNC 30 3 65 9 1 2 20 UNF 72 9 5 8 11 UNC 65 10 88 12 119 16 5 8 18 UNF 75 10 95 15 129 20 3 4 10 UNC 93 12 140 20 190 27 3 4 16 UNF 115 15 165 25 224 34 7 8 9 UNC 140 20 225 25 305 34 7 8 14 UNF 155 25 260 30 353 41
136. ng disassembly 5 Secure brake cables to rear of machine Fig 17 A Secure each R clamp to rear frame with screw and flange nut B Secure each brake cable to frame with retaining ring C Secure each brake cable end to brake lever with clevis pin and cotter pin 6 Check parking brake operation and adjust if neces sary see Adjust Parking Brake in the Adjustments sec tion of this chapter Workman MD MDX Page 7 27 Chassis Rear Wheels and Brakes Antiseize Lubricant 120 ft Ib 163 N m 45 to 65 ft Ib 61 to 88 N m Figure 18 1 Wheel assembly 7 Clevis pin 13 Wheel hub 2 Lug nut 5 used per hub 8 Cotter pin 14 Washer 3 Castle nut 9 Cotter pin 15 Spring washer 4 Brake drum 10 Flange lock nut 4 used per brake 16 Wheel stud 5 used per hub 5 Socket head screw 4 used per brake 11 Transaxle 17 Retaining ring 6 Brake assembly LH shown 12 Parking brake cable 2 used Removal Fig 18 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being jacked up Lift rear wheel off the ground using a jack and support vehicle with ap propriate jack stand beneath the frame 3 Remove five 5 lug nuts wheel assembly and brake drum from the wheel hub Chassis Page 7 4 Remove cotter pin from the castle nut and tr
137. nge nuts to engine and engine tray Position engine on engine tray to align clutch drive pulley and driven pulley on transaxle Tight en fasteners 4 Carefully position oil filter assembly to filter bracket Fig 16 Secure filter adapter with two 2 cap screws and flange nuts 5 Connect the following electrical components A Connect ground cable from the engine at starter generator terminal A1 Fig 15 B Connect engine harness connector to the main harness connector 6 Install starter beltto the engine and starter generator pulleys Tension the belt by rotating the starter genera tor away from the engine Tighten fasteners to secure starter generator 7 Install drive belt to drive clutch IMPORTANT Make sure to remove all plugs and covers that were placed on hose and engine open ings during engine removal 8 Install muffler and exhaust coupler to the machine see Exhaust System Installation in this section 9 Connect fuel inlet hose to the fuel pump Fig 13 Workman MDX 10 Connect the following components Fig 13 11 Install cargo box to the frame see Cargo Box and Tailgate Installation in the Service and Repairs section A Choke and throttle cables to the carburetor and of Chapter 7 Chassis cable bracket 12 Connect positive red cable to the battery Then B Air intake hose to the air cleaner intake and ma connect negative black cable to the battery chine frame 13 Make sure engine oil
138. ngine Fuel hose Rev B Briggs amp Stratton Gasoline Engine Oil Filter Assembly 40 to 50 in Ib 4 6 to 5 6 N m gt l T 40 to 50 in Ib 3 4 6 to 5 6 N m Figure 11 1 Hose 5 Oil pressure switch 9 Filter bracket 2 Elbow fitting 6 Elbow fitting 10 Oil filter 3 Hose 7 Cap screw 4 used 11 Oil filter adapter 4 Fitting 8 Flange nut 4 used 12 Fitting Briggs amp Stratton Gasoline Engine Page 3 12 Workman MDX Removal Fig 11 Installation Fig 11 1 Park machine on a level surface stop the engine en 1 Install removed oil filter adapter components using gage parking brake and remove the key from the ignition Figure 11 as a guide Torque fittings items 2 4 and 6 switch from 40 to 50 in Ib 4 6 to 5 6 N m 2 Raise cargo box and support with prop rod 2 Check and adjust engine oil level 3 To prevent contamination of engine lubrication sys 3 Lower and secure cargo box tem during adapter removal thoroughly clean exterior of filter adapter hoses and fittings 4 Remove filter adapter components as needed us ing Figure 11 as a guide So 2 gt ge Hm 7 Doa oO Workman MDX Page 3 13 Briggs amp Stratton Gasoline Engine Engine WONAAPWONS Hose clamp Fuel hose from tank Cable bracket Cable clamp Cap screw Threaded insert Swing arm Lock washer 6 used Cap screw 2 used Woodruff key Loc
139. ngine transaxle fuel hoses electrical harness or other parts while raising the swing arm and engine tray assembly 5 Carefully raise swing arm and engine tray assembly to the machine frame Align swing arm pivots to frame mounting points Chassis Page 7 24 6 Secure swing arm to machine frame with cap screws thrust washers and lock nuts Torque lock nuts from 70 to 90 ft Ib 95 to 122 N m 7 Secure both shock absorbers to swing arm with cap screw and lock nut Insert cap screw from the inside of the swing arm brackets 8 Lower machine to ground 9 Connect parking brake cables to rear brake levers and swing arm 10 Install muffler to machine see Exhaust System Installation in the Service and Repairs section of Engine Chapter 11 Lower and secure cargo box 12 Check parking brake operation and adjust if neces sary see Adjust Parking Brake in the Adjustments sec tion of this chapter Workman MD MDX This page is intentionally blank Workman MD MDX Page 7 25 Chassis Parking Brake Parking brake cover Operator seat Seat base Cable equalizer bracket Parking brake lever Curved washer gt Chassis Figure 16 Lock nut Flat washer Flange head screw 4 used Flat washer 2 used Screw 2 used Cap screw Page 7 26 13 14 15 16 17 Cotter Clevis pin Parking brake cable 2 used Parking brake support Cable retaining ring 2 used W
140. ntial as semblies to the case Figure 69 1 Shift shaft 2 Clutch groove A Insert fork of the shift shaft to the clutch groove of the center shaft assembly Figure 70 1 Center shaft assembly 3 Input shaft 2 Shift shaft 4 Differential assembly B Replace oil seals for the input and selector shafts C Install center shaft assembly with shift shaft and on the case LH if cracked nicked or distorted such differential assembly Then install input shaft as that they would not hold a proper seal sembly Lower differential assembly center shaft as sembly and input shaft assembly into the case atthe IMPORTANT Make sure to not damage the oil seal same time when installing the input shaft Drive Train Page 5 44 Workman MD MDX Figure 71 1 Fork selector shaft 2 Pin shift shaft D Make sure the selector shaft fork is contacting the pin on the shift shaft 5 2 Figure 72 1 Spacer 2 Boss counter shaft E Place spacer on the counter shaft boss of the case LH so the oil groove faces up Workman MD MDX Page 5 45 Drive Train Figure 73 1 34 3 2 Counter shaft F Apply molybdenum disulfide grease to the inside G Place gear 34 onto the spacer Make sure not to of gear 34 and the contact surface between the case drop the spacer Insert needle bearing into gear In and the counter shaft sert counter shaft with remaining spacer throug
141. om binding 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition 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 throttle lever should be to the fully open position without contacting the stop Fig 2 B Adjust governor cable at the transaxle cable bracket as necessary so there is no compression of the cable Fig 1 This will allow the throttle lever to fully close when the accelerator pedal is released 5 Release the governor arm on transaxle and make sure that the carburetor throttle lever fully closes 6 After throttle cable adjustment is correct lower and secure cargo box Figure 1 1 Governor arm 3 Governor cable 2 Throttle cable 4 Cable bracket Figure 2 1 Throttle cable 3 Carb throttle lever 2 Governor cable Single Cylinder Gasoline Engine 4 4 Rev B Workman MD Adjust Throttle Cable Serial Numbers Above 313000400 NOTE Workman MD vehicles with serial numbers above 313000400 use the engine governor to control engine speed Refer to the Kohler Service Manual at the end of this chapter for governor information on these machines Depressing the accelerator pedal rotates the engine mounted throttle lever which tensions the engine gover nor spring to increase engine speed Releasing
142. on Fig 7 NOTE Mount all exhaust components loosely before tightening to ensure a proper fit of exhaust system 1 If the exhaust manifold was removed from engine install manifold to engine with new gaskets Make sure that gaskets align with exhaust ports of cylinder heads Loosely attach exhaust manifold to the engine with re moved fasteners 2 Position muffler to the machine Secure muffler loosely to the swing arm with two 2 cap screws and lock washers 3 Position exhaust coupler to the muffler and exhaust manifold Secure coupler with four 4 coupler springs 4 Tighten screws that secure exhaust manifold to the engine 5 Tighten cap screws that secure muffler to the swing arm 6 Lower and secure cargo box Briggs amp Stratton Gasoline Engine 2 cH RIT Se oz no nn aec Fuel Tank Figure 8 1 Seat 7 Stand pipe 12 Web strapping 2 Fuel gauge 8 Hose clamp 13 Hex head flange screw 8 used 3 Bushing 9 Fuel hose to fuel filter 14 Flat washer 4 Gas cap 10 Fuel line conduit 15 Parking brake support 5 Fuel tank 11 Seat base 16 Shift bracket 6 Bushing Briggs amp Stratton Gasoline Engine Page 3 10 Workman MDX Fuel Tank Removal Fig 10 Read safety precautions for handling gasoline before working on the fuel system see Safety In structions in Chapter 1 Safety 1 Remove seat base from the frame see Seat Base Removal in the Service and Repairs
143. on switch 5 Remove muffler from machine see Exhaust System Removal in the Service and Repairs section of Engine 2 Remove cargo box from the frame see Cargo Box Chapter Removal in Chapter 7 Chassis 3 Remove drive belt from the driven clutch Drive Train Page 5 16 Workman MD MDX 6 On Workman remove governor and cable brackets from the transaxle as follows Fig 23 A Scribe mark across governor bracket and gover nor shaft to help installation Loosen both set screws securing the bracket to the shaft B Remove both lock nuts securing the cable brack et to the transaxle case Remove both brackets and cables as a complete assembly from the transaxle case and governor shaft 7 Remove lock nut that secures the select lever as sembly to the transaxle selector shaft Fig 24 Loosen jam nuts securing both shift cables to the cable bracket on the transaxle Separate select lever and shift cables assembly from the transaxle Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 8 Jack up both sides of the frame enough to remove rear wheels A Chock the front and rear of both front tires to pre vent the vehicle from moving B Support both sides of the frame with 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
144. ore reconnecting the negative black cable Follow all instructions and comply with all safe ty messages on the electrolyte container 1 Check for cracks caused by overly tight or loose hold down rod Replace battery if cracked and leaking 2 Check battery terminal posts for corrosion Use ater minal brush or steel wool to clean corrosion from the bat tery terminal posts IMPORTANT Before cleaning the battery tape or block the vent holes to the filler caps and make sure the caps are on tightly 3 Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap overcharging loose terminal post or overfilling Also check the battery case for dirt and oil Clean the battery with a solution of baking soda and water then rinse it with clean water 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 the level is below the tops of the plates in any cell fill all cells with distilled water to the bottom ofthe cap tubes or fillline Charge at 15 to 25 amps for 15 minutes to allow suffi cient mixing of the electrolyte Workman MD MDX Page 6 35 FILLER CAPS CAP TUBES CORRECT WATER LEVEL COVER SEAL Figure 51 Battery Installation Fig 50 IMPORTANT To prevent possible electrical prob lems install only a fully charged battery 1 Make sure
145. orkman MD MDX Disassembly Fig 16 1 Park machine on a level surface stop engine and re move key from the ignition switch Chock wheels to pre vent the machine from moving 2 Disconnect both brake cables from rear of machine Fig 17 A Remove cotter pin and clevis pin that secures each brake cable end to brake lever B Remove retaining ring that secures each brake cable to frame C Remove screw and flange nut that secure each R clamp to rear frame 3 Note routing of brake cables for assembly purposes 4 Remove parking brake cover from seat base 5 Remove four 4 flange head screws that secure Figure 17 parking brake support to seat base d Rearframe 6 Retaining ring 2 Brake cable 7 Cotter pin 6 Carefully remove parking brake support and brake 3 Cable tie 8 Clevis pin cables from machine Take care to not damage brake E B screw cables while removing them from seat base opening 7 Remove brake cables from parking 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 brake cables through seat base opening tak ing care to not damage cables Position parking brake support to seat base 3 Secure parking brake support to seat base with four 4 flange head screws 4 Position brake cablestorear brake assemblies using cable routing noted duri
146. ot get antiseize lubricant onto brake shoes 4 Apply light coat of antiseize lubricant to the transaxle shaft splines 5 Secure wheel hub to the shaft with washer spring washer and castle nut 6 Torque castle nut 120 ft Ib 163 N m If slot in nut does not align with hole in transaxle shaft tighten nut to align next slot with hole in shaft Castle nut torque should not exceed 200 ft Ib 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 out and secure with five 5 lug nuts 10 Lower machine to ground 11 Torque lug nuts in a crossing pattern from 45 to 65 ft Ib 62 to 88 N m 12 Check parking brake operation Adjust parking brake if necessary see Parking Brake Adjustment in the Ad justments section of this chapter Workman MD MDX Page 7 29 13 Bleed brakes see Bleed Brake System in this sec tion After servicing brake system components al ways check the brakes in a wide open level area that is free of other persons and obstructions 14 Check brake operation Burnish Brake Shoes Sintered metal linings may not provide maximum brake stopping distance after brake shoes are replaced It is necessary to burnish new brake shoe linings IMPORTANT Do not drive machine with the brakes applied The brake shoe linings will overheat IMPORTANT During brake burnishing procedure do not allo
147. pring Gasket Bolt Gasket Flange bolt 6 used Flange bolt Flange bolt Bolt Collar 2 used Flange nut 11 used Axle bracket 2 used Lock nut Spring washer 2 used Washer 2 used Wheel hub assembly 2 used Select lever a 2 Remove drain plug Drain completely from transaxle Replace drain plug gasket if damaged B Reinstall drain plug to transaxle case Torque plug from 15 to 18 21 to 25 N m Drive Train Figure 28 1 Bolt steel ball spring amp gasket 2 Selector shaft C Remove bolt near the selector shaft Remove spring and steel ball Replace gasket if damaged Figure 29 1 Input shaft 2 Oil seal D Wrap vinyl tape around the splined portion of the input shaft This should protect the oil seal from being damaged Drive Train Page 5 22 Workman MD MDX a E Figure 30 1 Flange bolts 3 used 3 Axle case 2 Axle bracket E Remove three 3 flange bolts securing the axle bracket and axle case to each case Separate brack et from each axle case a 2 Figure 31 1 Flange bolt 10 used 2 Flange nut F With the input shaft side down loosen and re move flange bolts and nuts securing the case RH and case LH together Workman MD MDX Page 5 23 Drive Train Figure 32 1 2 Governor boss IMPORTANT Make sure to not hit the governor G Hold the
148. r generator terminal A1 Fig 15 B Disconnect engine harness connector from the main harness 12 Remove four 4 flange nuts and cap screws secur ing the engine to the engine tray A CAUTION One person should operate the hoist while the other person guides the engine out of the frame 13 Remove engine from the engine tray A Attach a short section of chain between both en gine lift tabs B Connect hoist to center of chain IMPORTANT Make sure to not damage the en gine fuel hoses electrical harness or other parts while removing the engine C Slowly remove engine from the machine 14 Remove engine parts and attachments as neces sary to repair the engine Engine Installation Fig 12 1 Install all removed parts and attachments to the en A CAUTION gine One person should operate the hoist while the other person guides the engine into the frame 2 Install engine to the engine tray A Attach a short section of chain between both en gine lift tabs B Connect 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 the engine tray Briggs amp Stratton Gasoline Engine Page 3 16 Figure 16 1 Oil filter adapter 2 Oil filter 3 Filter bracket 4 Cap screw 5 Flange nut 6 Engine 3 Install four 4 cap screws and fla
149. r item 50 and cap screw item 49 Single Cylinder Gasoline Engine Page 4 14 6 Install starter belt to the engine and starter generator pulleys Tension the belt by rotating the starter genera tor away from the engine Tighten fasteners to secure starter generator 7 Install drive belt to drive clutch IMPORTANT Make sure to remove all plugs and covers that were placed on hose and engine open ings during engine removal 8 Install muffler and exhaust coupler to the exhaust manifold see Muffler Installation in this section 9 Connect fuel hose to the fuel pump Fig 12 Make sure to secure hose with hose clamp 10 Connect the following components A Choke and throttle cables to the carburetor and cable bracket B Air intake hose to the carburetor C Breather hose to the engine valve cover 11 Secure choke and throttle cables to the fuel pump bracket with cable tie 12 Install cargo box to the frame see Cargo Box and Tailgate Installation in the Service and Repairs section of Chapter 7 Chassis 13 Connect positive red cable to the battery Then connect ground black cable to the battery 14 Make sure engine oil level is correct Workman MD gt 2 gt o Gasoline Engine This page is intentionally blank Workman MD Page 4 15 Single Cylinder Gasoline Engine Fuel Evaporative Control System Serial Number Above 310000000 ROLLOVER CARBON
150. r circuit voltage Battery Charge Specific Level Gravity Open Circuit Voltage 12 68 12 45 12 24 12 06 11 89 1005 rS 505 ax 2 Determine the charging time and rate using the bat tery charger manufacturer s instructions or the fol lowing table Battery Battery Charge Level Reserve Percent of Fully Charged Capacity uen 80 or 3 8 hrs 7 5 hrs 11 3 hrs 15 hrs less 3 amps 3amps 3amps 3 amps 81 125 5 3 hrs 10 5hrs 15 8 hrs 21 hrs 4 4amps 4amps 4 amps 11 hrs 16 5 hrs 22 hrs 5 amps 5 amps 5 amps 126 to 5 5 hrs 170 5 amps 171 to 5 8hrs 11 5 hrs 17 3hrs 23hrs 250 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 250 10 amps 10 amps 10 amps 10 amps Workman MD MDX Page 6 37 Do not charge a frozen battery because it can ex plode and cause injury Let the battery warm to 60 F 15 5 C before connecting to a charger Charge battery in a well ventilated place to dissi pate gases produced from charging These gases are explosive Keep open flame and electrical spark away from the battery Do not smoke Unplug the charger from the electrical outlet before connecting or disconnecting the charger leads from the battery posts Nausea may result if the gases are inhaled 3 Follow the battery charger manufacturer s in structions Connect charger cables to the battery
151. r teeth are not accept able 7 8 9 Page 5 30 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 Replace collars or spacer if excessively worn or damaged Replace both collars as a set Workman MD MDX 6 Disassemble differential case assembly AY TM 3 Figure 45 1 Bolt 6 used 3 Differential case 2 Gear 62 A Remove six 6 bolts securing gear 62 to the dif ferential case 5 2 Figure 46 1 Spring pin 3 Pinion shaft 2 Differential case 4 Pinion gear NOTE The spring can be punched out from the hole C Remove pinion shaft and gears from the case on the opposite side of gear 62 Separate gears from shaft B Remove spring pin from the differential case Dis card pin and replace it with new spring pin Workman MD MDX Page 5 31 Drive Train Figure 47 1 Side gear 2 used 5 2 Pinion gear 2 used 6 3 Gear 34 7 4 Ball bearing 8 D Replace gears if worn or damaged Cracked bro ken missing or chipped gear teeth are not accept able E Ball bearing roller balls must be free of deforma tion and scoring Ball bearing must spin freely and have minimum axial play Replace ball bearing as necessary Drive Train Page 5 32 Differential case Pinion shaft Spring pin Bolt 6 used
152. ransaxle as follows Fig 23 A Position governor and cable brackets with cables as a complete unit to the transaxle case and gover nor shaft B Secure cable bracket to the transaxle case with both lock nuts C Align scribe marks on the governor bracket and shaft Secure bracket to the shaft with both set Screws 8 Secure both battery cables to the passenger side axle tube with cable ties 9 Install drive belt to the driven clutch 10 Install muffler to machine see Exhaust System Installation in the Service and Repairs section of Engine Chapter 11 Install both brake assemblies and wheels to the transaxle see Rear Wheel and Brake Installation in Chapter 7 Chassis 12 Install cargo box to the frame see Cargo Box Instal lation in Chapter 7 Chassis 13 Verify proper ground speed see Adjust Ground Speed in the Adjustments section of this chapter 14 Check brakes for proper operation Workman MD MDX This page is intentionally blank 5 ec 2 Workman MD MDX Page 5 19 Drive Train Transaxle Service 25 to 31 ft lb 34 to 42 N m 12 to 16 in Ib 1 4 to 1 8 N m PA 5 1718 e ios do 19 pu E 26 ES 40 to 45 ft Ib 54 to 61 N m 25 to 31 ft Ib 34 to 42 N m Figure 26 Drive Train Page 5 20 Workman MD MDX 1 Case LH 27 2 Oil seal 28 3 Oil seal 29 4 Snap ring 30 5 Spacer 31 6 Selector shaft 32 7 Oil seal 2 u
153. rical System General Problems Battery does not charge Wiring to the charging circuit components is loose corroded or damaged 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 became broken or disconnected see Wiring Schematics in Chapter 8 Electrical Diagrams RPM shutdown module is faulty Workman MDX Engine or fuel system is malfunctioning see Engine Chapter Electrical System Page 6 6 Workman MD MDX Electrical System Quick Checks Battery Test Use a multimeter to measure the voltage between the battery terminals Set the multimeter to the DC volts setting The battery should be at a temperature of 60 to 100 F 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 the the negative battery post NOTE This test provides a relative condition of the bat tery Load testing of the battery will provide additional and more accurate information Charging System Test This is a simple test used to determine if a charging sys tem is functioning It will tell you if the charging system has an output but not its capacity Raise and support cargo box to gain access to battery Use digital multimeter set to DC volts Connect the positive
154. rings to attach exhaust coupler to the ex haust manifold and muffler 4 Tighten all exhaust system fasteners 5 Lower and secure cargo box Workman MD 4 9 Single Cylinder Gasoline Engine Fuel Tank Figure 7 1 Seat 7 Stand pipe 12 Web strapping 2 Fuel gauge 8 Hose clamp 13 Hex head flange screw 8 used 3 Bushing 9 Fuel hose to fuel filter 14 Flat washer 4 Gas cap 10 Fuel line conduit 15 Parking brake support 5 Fuel tank 11 Seat base 16 Shift bracket 6 Bushing Single Cylinder Gasoline Engine Page 4 10 Workman MD Fuel Tank Removal Fig 7 Read safety precautions for handling gasoline before working on the fuel system see Safety In structions in Chapter 1 Safety 1 Remove seat base from the frame see Seat Base Removal in the Service and Repairs section of Chapter 7 Chassis 2 Use fuel transfer pump to remove gas from fuel tank 3 Loosen hose clamp and disconnect fuel hose from the fuel tank stand pipe 4 Release tank web strapping from fuel tank Do not re move strapping from floor plate and frame cross mem ber Lift tank from frame NOTE Workman MD vehicles with serial number above 310000000 are equipped with a fuel evaporative control system EVAP designed to collect and store 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 Fue
155. rom backing plate Locate and remove belleville washers from between adjuster levers and backing plate Workman MD MDX Inspection Fig 20 1 Inspect brake drums IMPORTANT Brake drum machining is not recom mended Replace brake drums as a set to maintain equal braking forces A Clean drums with denatured alcohol Check braking surface diameter in at least three places If the diameter exceeds 6 320 inches 160 5 mm re place 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 2 Inspect brake shoe linings IMPORTANT Replace brake shoes as a set all four shoes to maintain equal braking forces A Replace brake shoes if damaged or if lining is worn to 1 16 1 6 mm Replace if lining is contami nated by oil grease or other fluids NOTE Overheated springs lose their tension and can cause brake linings to wear out prematurely B Inspect brake shoe webbing upper and lower springs and shoe hold down springs for overheating Overheating is indicated by a slight blue color In spect brake shoe webbing for deformation Replace parts as necessary C Inspect hold down pins on adjuster levers for bends rust and corrosion Replace as necessary 3 Inspect backing plate surfaces which contact with the brake shoes for grooves that may restrict shoe movement Replace p
156. rotate With increasing speed of the drive clutch the drive belt begins to climb to the outer diame ter of the drive clutch sheaves This increases the ten sion on the drive belt and forces the moveable sheave of the driven clutch to move away from the fixed sheave against the pressure of the spring As the belt tightens and the sheaves open up the drive belt rides lower 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 drive belt and spring pressure moves the moveable sheave up the ramp of the fixed cam The drive belt becomes posi tioned closer to the outer diameter of the driven clutch sheaves On vehicles with a serial number below 310000000 three 3 sets of buttons on the driven clutch moveable sheave provide a low friction surface on which the move able sheave can slide on the ramp of the fixed cam Fig 4 On vehicles with a serial number above 310000000 a fixed cam on the driven clutch moveable sheave rotates on a pair of rollers in the fixed sheave base to allow low friction movement of the moveable sheave Fig 5 d d d d d d d d a QN P 4 iS 1 Moveable sheave 2 Ramp fixed cam 3 Button 1 Moveable sheave 2 Fixed sheave Workman MD MDX Page5 5 Rev A no Figure 4 4 F
157. s for damage Replace both bearings if either bearing meets any of the following conditions A Bearings do not spin smoothly are noisy when spinning or have excessive end or axial play B The balls or rolling surfaces are pitted or worn C Bearings are rusted worn cracked or show ab normal color due to overheating 5 Clean and inspect armature Replace armature if in sulation is burned or charred wires are broken shaft is damaged or bent armature core lamination is damaged or solder is thrown IMPORTANT Never use emery cloth on the commu tator short circuiting of the commutator bars may result Never use oil or lubricants on the commuta tor or brushes Electrical System Page 6 22 6 Clean and inspect commutator A Remove carbon dust dirt and oil from the com mutator B Lightly remove slight roughness burning or glaz ing of the commutator with 400 grit or finer sandpa per Clean commutator after sanding C Replace armature and bearings if commutator bars are loose Raised bars may be reworked see Rework Starter Generator 7 Measure diameter of the commutator using a mi crometer A Measure diameter at two points along the axis of the commutator and shaft Measurements must also be 90 apart along the circumference of the commu tator B If diameter is less than 1 575 inches 40 mm re place armature and bearings 8 Clean armature completely with clean cloth and or air Do not
158. s and secure ro tor to hub Chassis Page 7 16 4 Slide wheel hub assembly onto spindle Install outer bearing tab washer and jam nut onto spindle 5 Rotate the wheel by hand and tighten the jam nut from 75 to 100 in Ib 8 5 to 11 3 N m to set the bear ings Then loosen the nut until the hub has end play 6 Again rotate the wheel by hand and tighten the jam nut from 15 to 20 in Ib 1 7 to 2 3 N m 7 Position nut retainer over jam nut and install cotter pin through spindle shaft hole Install dust cap to hub 8 Install brake caliperto spindle see Front Brake Cali per in this section 9 Install wheel assembly with valve stem facing out 10 Lower machine to ground 11 Torque wheel lug nuts in a crossing pattern from 45 to 65 ft Ib 62 to 88 N m 12 Align steering and toe in see Adjust Front Wheel Toe in in the Adjustments section of this chapter 13 Lubricate tie rod ball joints and king pin Workman MD MDX Front Shock Absorbers Shock Removal Fig 13 IMPORTANT Any adjustment to the shock spring preload will affect the front wheel camber see Ad just Front Wheel Camber in the Adjustments sec tion 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 Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock
159. s not bottomed out when accelerator pedal is 1 Terminal 1 4 Terminal 4 released Fig 13 Tighten nut to secure cap screw in 2 Terminal 2 5 Switch plunger position 3 Terminal 3 6 Mounting tab Figure 13 1 Accelerator switch 2 Adjustment screw Electrical System Page 6 12 Workman MD MDX Starter Generator amp Voltage Regulator 1 Place machine shift lever in the NEUTRAL position Apply parking brake 2 Raise cargo box and secure with prop rod Gain ac cess to electric components by removing the electrical cover 3 Make sure all wires in the charging circuit are con nected correctly and tightly Note the correct location of starter generator cable and voltage regulator wire at the start run solenoid Fig 14 4 Make sure the battery is fully charged Operate the vehicle for several minutes so the voltage regulator is warmed up Stop engine and turn key to OFF 5 Test charging circuit A Set multimeter to VDC Connect red probe of the multimeter to the positive battery post Con nect black probe of the multimeter to the negative battery post B Start and run the engine at mid range RPM C Battery voltage should rise to approximately 14 5 VDC identifying a correctly operating charging cir cuit If the battery has a low charge this may take a few minutes D Stop engine and turn key to OFF 6 If battery voltage did not rise to 14 5 VDC test start er generator A Disconnect gr
160. s not properly supported by jack stands the vehicle may move or fall which may re sult in personal injury see Jacking Instructions in this section 14 Make sure to dispose of potentially harmful waste e g fuel oil engine coolant filters battery in an envir onmentally safe manner Follow all local codes and reg ulations when recycling or disposing of waste Safety Jacking and Other Instructions Jack Vehicle POTENTIAL HAZARD A vehicle that is not properly supported may become unstable WHAT CAN HAPPEN The vehicle may move or fall Personal injury or damage to the machine may result HOW TO AVOID THE HAZARD Make sure vehicle is parked on a solid level surface such as a concrete floor Make sure engine is off and key is removed from the ignition switch before getting off the vehicle Before raising the vehicle remove any attachments that may interfere with the safe and proper raising of the vehicle Always chock or block wheels to prevent the vehicle from rolling Do not start vehicle while it is on jack stands without placing transaxle in neutral Make sure proper hoists jacks and jack stands are used to raise and support the vehicle Jacking Locations 1 Jackfront ofthe vehicle on the front of the frame and behind the towing tongue Fig 1 2 Jackrear ofthe vehicle under each rear axletube Do not jack vehicle below the transaxle case Fig 2 Transport Vehicle When moving the vehicl
161. s to engine speed and is mounted to the engine drive shaft The driven clutch responds to changes in load to the rear axle and is mounted to the transaxle input shaft 9 Fixed sheave driven clutch The two clutches work together to automatically up shift and back shiftas changes in load and speed occur This shifting changes the turning ratio between the drive and driven clutches and allows the engine to operate at opti mum efficiency Workman MD MDX Page5 3 Rev A Drive Train ec E e Drive Clutch Operation The operation of the drive clutch is affected by engine shaft speed When the engine is off and not turning the drive belt rests low within the drive clutch sheaves as the clutch sheaves are spaced apart As the engine is started and increases in speed the clutch weights move outward as they spin about the engine drive shaft The outward movement of the weights against the spider as sembly forces the moveable sheave closer to the fixed sheave This inward movement of the moveable sheave engages the drive belt which begins to rotate With increasing engine speed the moveable sheave continues to move inward This sheave movement forces the drive belt to ride towards the 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 causes the moveable sheave to shift away from th
162. sed 33 8 Flange bolt 4 used 34 9 Oil check plug 2 used 35 10 Gasket 2 used 36 11 drain plug 2 used 37 12 Gasket 2 used 13 Oil filler plug d 14 Case RH 40 15 Oil seal if equipped 16 Governor shaft if equipped 17 Governor fork if equipped 42 18 Stopper if equipped 43 19 Screw and washer 4 used 44 20 Input shaft 45 21 Governor base if equipped 46 22 Lock pin if equipped 47 23 Governor plate unit if equipped 48 24 Ball bearing 49 25 Governor sleeve if equipped 50 26 Ball bearing 2 used 51 Transaxle Disassembly and Inspection 1 Disassemble case LH and RH 1 Drain plug amp gasket Make sure transaxle case is not hot prior to drain ing oil to prevent getting burned Workman MD MDX Figure 26 Continued Spacer Gear 55 Cable bracket Pin clutch Center shaft Gear 47 Collar 2 used Gear Flange bolt 6 used Ball bearing Ball bearing Spacer 2 used Gear 34 Counter shaft Differential case Side gear 2 used Pinion gear 2 used Pinion shaft Spring pin Ball bearing Needle bearing Gear 62 Bolt 6 used Axle shaft LH Axle shaft RH Figure 27 2 Case LH Page 5 21 15 to 18 ft lb 21 to 25 N m Ball bearing 4 used Axle case LH Axle case RH Snap ring 4 used Castle nut 2 used Snap ring 2 used Shift shaft Pipe knock 2 used Steel ball S
163. sembly D Make sure to secure intake hoses with hose clamps 2 Lower and secure cargo box Workman MDX Page 3 7 Figure 6 1 Air cleaner 3 Breather hose 2 Carburetor adapter 4 Intake hose Briggs amp Stratton Gasoline Engine So 2 2 gt BE o Se 0 0 lt Exhaust System Figure 7 1 Muffler 5 Exhaust coupler 8 Engine tray 2 Swing arm 6 Coupler spring 4 used 9 Engine 3 Cap screw 2 used 7 Exhaust manifold 10 Screw 4 used 4 Lock washer 6 used Briggs amp Stratton Gasoline Engine Page 3 8 Workman MDX Removal Fig 7 1 Park machine on alevel surface stop the engine en gage parking brake and remove the key from the ignition switch 2 Raise cargo box and support with prop rod A CAUTION The muffler and exhaust pipe may be hot To avoid possible burns allow engine and exhaust system to cool before working on the muffler 3 Remove four 4 coupler springs securing the ex haust coupler to the muffler and exhaust manifold Re move exhaust coupler 4 Remove two 2 cap screws and lock washers secur ing the muffler to the swing arm Remove muffler from machine 5 If exhaust manifold needs to be removed from en gine remove four 4 screws and lock washers securing the manifold to the engine Remove exhaust manifold Remove exhaust gaskets and clean gasket surfaces of manifold and engine Workman MDX Page 3 9 Installati
164. sis Loctite 242 75 to 100 ft Ib 102 to 135 N m Figure 9 14 Front frame 15 Nut retainer 16 Dust cap 17 Wheel assembly 18 Lug nut 5 used per wheel 19 Cap screw 2 used per A arm 20 Cotter pin 21 Wheel stud 5 used per hub 22 Socket screw 4 used per rotor 23 Brake caliper LH shown 24 Lock washer 2 used per caliper 25 Cap screw 2 used per caliper Page 7 18 See text for tightening procedure AQ 45 to 65 ft Ib 62 to 88 N m 18 Grease fitting Ball joint LH threads Jam nut LH threads Tie rod Jam nut RH threads Ball joint RH threads Kingpin sleeve Thrust washer Spindle LH shown Brake hose clip Cap screw Lock nut Workman MD MDX A arm Removal Fig 9 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being jacked up Jack front wheel off the ground and support vehicle with appropriate jack stand beneath the frame 3 Remove front wheel and spindle from A arm see Figure 10 Lower Steering and Front Wheel Removal in this sec 1 A arm 3 Straight bushing tion 2 Flange bushing 4 Remove cap screw item 7 flat washer item 5 and lock nut item 6 that secure lower end of shock absorber to A arm 5 Support A arm to prevent it from falling
165. sition to prevent it from shifting or falling 14 Remove four 4 flange nuts item 12 and flange head screws item 16 that secure the transaxle to the engine tray 15 Carefully remove transaxle assembly from the rear of the vehicle Installation Fig 22 1 Position transaxle assembly to the engine tray Se cure transaxle to the tray with four 4 flange nuts item 12 and flange head screws item 16 2 Make sure that isolation mounts item 17 are posi tioned in the swing arm so that the flange is positioned between the swing arm bracket and engine tray location Fig 25 IMPORTANT Take care to not damage the engine fuel hoses electrical harness or other parts while raising the engine tray assembly 3 Using hoist carefully raise engine tray assembly and align it with swing arm mounting points 4 Secure the transaxle to 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 bracket isola tion mount and engine tray Fig 25 B Secure cap screw with flange nut Drive Train Page 5 18 6 Position select lever assembly and shift cables to the transaxle Fig 24 Secure select lever assembly to the selector shaft with lock nut Secure both shift cables to the cable bracket with jam nuts 7 On Workman MD secure governor and cable brack ets to the t
166. spindle 8 Disassemble the wheel hub Fig 7 A Pull the seal out of the wheel hub B Remove bearings from both sides of the wheel hub Clean bearings in solvent Make sure bearings are in good operating condition Clean the inside of the wheel hub Check the bearing cups for wear pit ting or other noticeable damage Replace worn or damaged parts C If necessary remove 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 ball joint from the spindle Remove tie rod from steering gearbox pit man arm if necessary B Remove lock nut and cap screw securing the spindle to the A arm Separate spindle from A arm C Locate and remove thrust washer from bottom of kingpin sleeve in A arm and brake hose clip from top of A arm Remove kingpin sleeve from A arm if nec essary Workman MD MDX Page 7 15 Loctite 242 Figure 7 1 Outer bearing cone 6 Inner bearing cone 2 Outer bearing cup 7 Seal 3 Wheel hub 8 Socket screw 4 used 4 Brake rotor 9 Wheel stud 5 used 5 Inner bearing cup e 75to 100 ft Ib 102 to 135 N m Figure 8 1 Cap screw 2 Brake hose clip 3 LH shown 4 Kingpin sleeve 5 Thrust washer 6 Lock nut Assembly Fig 6 1 Install spindle as follows Fig 8 A Make sure king pin sleeve is positioned into the pivot hub of the A arm Sl
167. stener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or a torque that is unique to the application is clearly identified and spe cified in this Service Manual These Torque Specifications for the installation and tightening of fasteners shall apply to all fasteners which do not have a specific requirement identified in this Ser vice Manual The following factors shall be considered when applying torque cleanliness of the fastener use of a thread sealant e g Loctite degree of lubrication on the fastener presence of a prevailing torque feature hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 5 Grade 1 Inch Series Bolts and Screws Figure 1 Workman MD MDX 2 3 As noted in the following tables torque values should be reduced by 25 for lubricated fasteners to achieve the similar stress as a dry fastener Torque values may also have to be reduced when the fastener is threaded into aluminum or brass The specific torque value should be determined based on the aluminum or brass material strength fastener size length of thread en gagement etc The standard method of verifying torque shall be per formed by marking a line on the fastener head or nut and mating part then back off fastener 1 4 of a turn Measure the torque required to tighte
168. t Yoke 20 SPECIAL TOOLS 2 Swing Am RR ede eae ede teats 22 TROUBLESHOOTING 3 Parking Brake 26 Suspension and Steering 3 Rear Wheels and Brakes 28 Brakes rude eu eid 4 Rear Brake Service 30 ADJUSTMENTS 6 Front Brake Calipers 32 Adjust Parking Brake 6 Front Brake Caliper Service 34 Adjust Front Wheel Camber 7 Brake Master Cylinder 36 Adjust Front Wheel Toe in 8 Brake Master Cylinder Service 38 SERVICE AND REPAIRS 9 Bleed Brake System 39 Check Tire Pressure 9 SeatB s6 i ide e bp p ERE ERE DA 40 Inspect Tires and Wheels 9 Front Hood REL cake 42 Upper Steering 10 Cargo Box Serial Numbers Below 311000000 44 Steering Gearbox 12 Cargo Box Serial Numbers Above 311000000 46 Lower Steering and Front Wheels 14 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 Opera
169. t base 6 Remove eight 8 flange head screws and flat wash ers that secure the seat base to the frame IMPORTANT Make sure shift bracket shift cables choke cable and fuel tank do not catch on the seat base during removal 7 Lift seat base carefully from the machine Seat Base Installation Fig 25 IMPORTANT Make sure shift bracket shift cables choke cable and fuel tank do not catch on the seat base during installation 1 Position seat base carefully to the frame NOTE Do nottighten fasteners securing the seat base to the frame until all of them are installed 2 Install eight 8 flange head screws and flat washers through the frame and into the seat base Tighten screws from the middle of the vehicle to the outside 3 Place shift bracket shift cables and choke cable through the opening at the front of the seat base 4 Position choke cable and shift plate to shift bracket making sure to capture cable flange Secure shift plate to shift bracket with four 4 short cap screws Screw knob onto the shift lever Fig 26 5 Position shift plate with shift bracket to the seat base Secure shift plate to seat base with four 4 long cap screws Fig 26 6 Install parking brake assembly to seat base see Parking Brake Assembly in this section 7 Secure seats to seat base 1 Shift lever 2 Cap screw short 3 Shift plate Workman MD MDX Page 7 41 Figure 26 4 Cap screw long 5 Choke cable
170. t base to gain access to reverse switch Figure 21 3 Unplug wiring harness connector from reverse 1 Seat base 3 Shifter plate switch 2 Screw 4 used 4 Reverse switch 4 With the use of a multimeter ohms setting check that the normally open switch contacts Fig 22 do not have continuity when the switch plunger is extended The contacts should have continuity when the switch plunger is fully depressed 5 When testing is complete connect wire harness con nector to switch Slide shift bracket into seat base and secure with four 4 screws Figure 22 1 Reverse switch 2 Normally open contact T o System Workman MD MDX Page 6 17 Electrical System Service and Repairs NOTE For information on electrical engine compo nents see the Briggs and Stratton Vanguard Service and Repair Manual for 4 Cycle V Twin Cylinder OHV Engines Workman MDX or the Kohler Service Manual for Command Pro CS Series Engines Workman MD Starter Generator 15 to 25 ft lb 21 to 33 N m Figure 23 1 Engine 6 Drive belt 2 Lock nut 7 Drive clutch 3 Woodruff key 8 Nut 4 Starter generator pulley 9 Lock washer 5 Starter generator belt 10 Carriage bolt Electrical System Page 6 18 11 Pivot bolt 12 Engine tray 13 Flange nut 14 Starter generator Workman MD MDX Removal Fig 24 1 Park vehicle on a level surface stop engine set parking brake and remove key from the ignition swit
171. tery load tester following the manufactur er s instructions D Measure the temperature of the electrolyte in the center cell E Connecta battery load tester to the battery termi nals following the manufacturer s instructions Connect a digital multimeter to the battery terminals F Apply atest load of 150 amps one half the Crank ing Performance for 15 seconds G Take a battery voltage reading at 15 seconds then remove the load Record this test voltage read ing H Using the table below determine the minimum test voltage for the cell temperature reading Minimum Battery Electrolyte Test Voltage Temperature 70 F 21 1 C and up 9 4 50 F 10 0 C TO 89 20 F 6 79C 7225 Ifthe test voltage is below the minimum replace the battery If the test voltage is at or above the mini mum return the battery to service Workman MD MDX Battery Charging To minimize possible damage to the battery and allow the battery to be fully charged the slow charging meth od is presented here This charging method can be ac complished with a constant current battery charger which is available in most shops 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 Determine the battery charge level from either its open specific gravity o
172. the engine are kept clean at all times NOTE Perform this maintenance procedure at the in terval specified in the Operator s Manual IMPORTANT The engine that powers the Workman MD is air cooled Operating the engine with dirty or plugged cooling fins or a plugged or dirty blower housing will result in engine overheating and dam age 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition Figure 4 switch 1 Static debris screen 2 Blower housing 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 Never clean engine with pressurized water Water could enter and contaminate the fuel system ES D gt o Gasoline Engine 4 Clean cooling fins on cylinder head 5 Clean static debris screen and blower housing of dirt and debris Remove screen and housing if necessary Fig 4 IMPORTANT Never operate engine without the blower housing installed Overheating and engine damage will result 6 Make sure static screen and blower housing are rein stalled to the engine if removed 7 Attach spark plug wire to spark plug 8 Lower and secure bed Workman MD Page 4 7 Single Cylinder Gasoline Engine Exhaust System Figure 5 1 Engine 5 Exhaust coupler 9 Lock washer 2 used 2 Coupler spring 4 used 6 Starter generator 10
173. the ignition switch and all accessories are off 2 Make sure the battery tray is clean and repainted if necessary 3 Make sure battery cables battery connections and the battery hold down components are in good condi tion 4 Set battery on the battery base with its posts toward the right side of the vehicle 5 Secure positive cable red to positive battery post with flange screw and flange nut 6 Secure battery with hold down rod and wing nuts 7 Connect a digital multimeter set to amps between the negative battery post and the negative cable black connector The reading should be less than 0 1 amp If the reading is 0 1 amp or more the unit s electrical sys tem should be tested and repaired 8 Secure negative cable black to negative battery post with flange screw and flange nut 9 Apply battery terminal protector Toro part number 107 0392 on battery posts and cable connectors to re duce corrosion after connections are made Electrical System 2 System Battery Testing 1 Conduct a hydrometer test of the battery electrolyte IMPORTANT Make sure the area around the cells is clean before opening the battery caps A Measure the specific gravity of each cell with a hydrometer Draw electrolyte in and out of the hydrometer barrel prior to taking a reading to warm up the hydrometer At the same time take the tem perature of the cell B Temperature correct each cell r
174. the notch at the end of the brushes Fig 27 11 Install brush covers to the commutator end cover Figure 25 1 Brush 3 Brush holder 2 Spring 0 063 inch Figure 26 3 Wear line 4 Set screw 1 Brush 2 Brush holder Figure 27 3 Brush holder 1 Brush spring 2 Brush Electrical System Electrical System Armature and Field Coil Service Fig 24 IMPORTANT When removing the commutator end cover make sure brushes do not contact the com mutator Damage to the brushes may result 1 Remove brush covers from the commutator end cov er Lift brush springs from the notch at the end of the brushes while pulling the brushes out Allow springs to hold brushes out from the center Fig 25 2 Remove both through bolts and flat washers secur ing the commutator end cover to the yoke Separate end cover from the commutator and yoke 3 Separate front end cover from the armature shaft A Remove hex nut spring washer pulley spacer and woodruff key from the armature shaft B Remove screws lock washers and flat washers securing the retainer to the end cover IMPORTANT Use clean dry lint free rags when cleaning the starter generator When using com pressed air air should be filtered and should not ex ceed 15 PSI 103 kPa IMPORTANT Remove bearings only if they are to be replaced Use proper bearing removal and installa tion tools 4 Clean bearings using aclean cloth Inspect bearing
175. this maintenance procedure at the in terval specified in the Operator s Manual IMPORTANT The engine that powers the Workman MDxX is air cooled Operating the engine with dirty or plugged cooling fins or a plugged or dirty blower housing will result in engine overheating and dam age 1 Park machine on a level surface stop engine en gage parking brake and remove key from the ignition switch sz cH Se non mo 2 Raise cargo box and support with prop rod Figure 3 1 Cvlinder head coolina fins 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 contaminate the fuel system 4 Clean cooling fins on both cylinder heads Fig 3 5 Clean rotating screen and blower housing of dirt and debris 6 If necessary remove rotating screen and blower housing from engine for more thorough engine cleaning IMPORTANT Never operate engine without the ro Figure 4 tating screen and blower housing installed Over To Rot ting screen 2 Blowerhousing heating and engine damage will result 7 Make sure rotating screen and blower housing are properly installed to the engine if removed 8 Attach spark plug wires to spark plugs 9 Lower and secure cargo box Workman MDX 3 5 Briggs amp Stratton Gasoline Engine Air Cleaner
176. to 6 2 N m Cargo box Knob 2 used Rubber bumper 2 used Tailgate Flange head screw 31 used RH pivot bracket LH pivot bracket Flange head screw 4 used Box brace 3 used 10 Latch washer 4 used 11 Prop rod Chassis 31 30 Figure 33 Prop rod bracket Flat washer Push nut Washer head screw 2 used Prop rod bracket Latch rod Tension spring 2 used Carriage screw 2 used Latch pin 2 used Lock nut 2 used Page 7 44 Rev A 35 to 55 in Ib 4 0 to 6 2 N m 100 to 200 in Ib 11 3 to 22 6 N m Pivot bracket 2 used Spring 2 used Screw 10 used LH tailgate bracket Screw LH latch rod RH latch rod RH tailgate bracket Tailgate channel Striker plate 2 used Workman MD MDX Removal Fig 33 Installation Fig 33 NOTE If cargo box has been replaced with newer box 1 Assemble cargo box using Figure 33 as a guide design refer to Cargo Box Serial Numbers Above 311000000 in this section A When installing tailgate and tailgate hardware use torque specifications identified in Figure 33 1 Park machine on a level surface stop engine set parking brake and remove key from the ignition switch B Adjust latch pin item 20 so that cargo box is tight to frame when latched 2 Disassemble cargo box as necessary using Figure 33 as a guide Workman MD MDX Page 7 45 Rev A Chassis Cargo Box Ser
177. un solenoid if necessary 9 Connect electrical connections to solenoid positive battery cable and wire to fuse block on one main contact post and starter generator cable and wire to regulator on the other main contact post Connect battery cables Make sure to connect positive red cable first and then connect negative black cable NOTE Voltage is supplied to the solenoid on the Work man whenever the key is in the ON position and the ac celerator pedal is depressed Electrical System Page 6 10 Figure 8 1 Electrical cover 5 Nut 2 used 2 Flange nut 2 used 6 Lock washer 2 used 3 Start run solenoid 7 Nut 2 used 4 Screw 2 used 8 Rear frame Figure 9 2 Solenoid posts steel 1 Main posts copper Workman MD MDX Fuse Block The fuse block is located beneath the dash panel Fuses can be removed to check continuity The test meter should read less than 1 ohm Fuses protect circuits as follows Fig 10 1 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 the light Figure 10 circuit 1 Option 3 Lights fuse 2 Ignition system fuse 4 Power point fuse 4 The extreme right 10 ampere fuse protects the pow er point circuit A maximum of a 15 ampere fuse is al lowed T o
178. ure 17 1 Diode 3 Female terminal 2 Male terminal Multimeter Multimeter Red Lead Black Lead Continuity on Terminal on Terminal rmm S 1 Com HE RPM Shutdown Module Workman MDX The RPM shutdown module allows the engine to contin ue running briefly after the accelerator pedal is released and the vehicle is decelerating The module monitors engine speed at the engine stop switch terminal Through the RPM shutdown module the engine ignition system is not grounded until the engine speed has slowed to approximately 1300 RPM By allowing the en gine to continue running briefly during vehicle decelera tion better vehicle performance can be achieved Testing 1 Make sure that accelerator switch is working correct ly and is adjusted properly see Accelerator Switch in this section 2 Place drive system in the NEUTRAL position Figure 18 TROC 1 RPM shutdown module 2 Stop switch terminal 3 Connectan ignition spark tester in series between a spark plug and spark plug wire 4 Start engine and monitor engine speed with a tachometer Press the accelerator pedal to raise engine speed briefly and then release pedal while watching the tachometer and spark tester When engine speed de creases to approximately 1300 RPM the spark tester should register no spark and the engine should stop Workman MD MDX Page 6 15 Electrical System T E 5 gt Oil Pressure Switc
179. urposes 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 than 0 140 3 5 mm from the top of the brush box brush replacement is necessary 3 Use a marker to make a diagonal line across the frame housing and end heads for assembly purposes Position the starter generator on the commutator end head and support the assembly to prevent damage to the terminals in the end head Remove the two 2 screws that secure the drive end head to the frame housing 5 2 System Figure 34 Workman MD MDX Page 6 27 Rev Electrical System 4 Pull drive head end along with attached armature from the frame housing 5 Position the motor so the commutator end head is fa cing upwards and remove the two 2 screws that secure the commutator end head Lift commutator end head from frame housing 6 Locate and retrieve wave washer from between armature and commutator end head IMPORTANT Use clean dry lint free rags when cleaning the starter generator When using com pressed air air should be filtered and should not ex ceed 15 PSI 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 bearings using aclean cloth Inspect bearings for dama
180. w the brakes to lock up Allow brakes to cool between applications 1 Drive machine while making 6 to 7 normal stops at about 200 ft 60 m intervals while traveling at 10 to 15 mph 16 to 24 KPH 15 to 21 ft Ib 21 to 28 N m Figure 19 1 Brake assembly 2 Wheel cylinder 3 Banjo washer 4 Banjo bolt 5 Brake line Chassis Rear Brake Service 110 to 120 in Ib 12 4 to 13 6 N m 110 to 120 in Ib 12 4 13 6 N m 10 110 to 120 in Ib 12 4 to 13 6 N m Figure 20 1 Brake backing plate 6 2 Washer head screw 7 Belleville washer 3 Brake shoe 8 Adjuster lever 4 Lower spring 9 Dust cover 5 Wheel cylinder Disassembly Fig 20 Be careful 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 se cure the brake shoes to the backing plate 3 Remove brake shoes from backing plate Chassis Parking brake lever LH shown Page 7 30 10 Flat washer 11 Bolt 12 Shoe hold down cup and spring 13 Upper spring 4 If required slide parking brake lever from slot and dust cover in backing plate 5 If necessary remove two 2 washer head screws that secure wheel cylinder to backing plate Remove wheel cylinder from backing plate 6 If necessary remove bolts and washers to allow ad juster levers to be separated f
181. wheels not being jacked up Jack front wheel off the ground and support vehicle with appropriate jack stand beneath the frame 3 Support a arm 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 TOR6010 see Special Tools in this chapter if spring preload requires adjust ment If the spring is to be removed from the shock ab sorber shock spring compressor tool TOR6015 see Special Tools in this chapter can be used Shock Installation Fig 13 1 Position shock absorber to frame and a arm brack ets 2 Secure shock absorber to vehicle A Slide upper cap screw through frame mounting holes and upper shock eye B Slide lower cap screw through flat washer lower shock eye and a arm mounting hole C Secure cap screws with lock nuts 3 Lower vehicle to ground Figure 13 1 Shock absorber 4 A arm LH shown 2 Cap screw 5 Flat washer 3 Locknut Workman MD MDX Page 7 17 Rev Chassis A arms and Front Suspension 20 to 25 ft Ib 28 to 33 N m 45 to 55 ft lb 62 to 74 N m N Steering gearbox pitman arm Shock absorber 2 used Cotter pin Slotted hex nut Flat washer Lock nut 3 used per side Cap screw 2 used per shock LH A arm Brake rotor 10 Wheel hub assembly 11 Tab washer 12 RH A arm 13 Jam nut gt Chas
182. y to ON C Depress accelerator pedalto start engine and en gage drive system 3 Do not run engine in a confined area without ade quate ventilation Exhaust fumes are hazardous and could possibly be deadly Maintenance and Service 1 Before servicing or making adjustments turn all ac cessories off release pressure from accelerator pedal allow engine to stop set parking brake and remove key from the ignition switch 2 Make sure vehicle is in safe operating condition by keeping all nuts bolts and screws tight 3 Never store the vehicle or fuel container inside where there is an open flame such as near a water heat er or furnace 4 major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 5 To reduce potential fire hazard keep engine area free of excessive grease grass leaves and dirt 6 If engine must be running to perform maintenance or an adjustment keep clothing hands feet and other parts of the body away from moving 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 engine crankcase 9 Disconnect battery before servicing the vehicle Dis connect negative battery cable first and positive cable last If battery voltage is required for troubleshoot ing or test procedures temporarily connect th
183. ylinder Gasoline Engine This is intentionally blank Single Cylinder Gasoline Engine Page 4 18 Workman MD Table of Contents GENERAL INFORMATION 1 Operator s Manual 1 SPECIFICATIONS 2 DRIVE TRAIN OPERATION 3 Clutch System 3 Drive Clutch 4 Driven Clutch Operation 5 SPECIAL TOOLS ie cece eee ee RR ee iua 6 ADJUSTMENTS 7 Adjust Ground Speed Workman MD with Serial Number Below 313000400 7 Adjust Ground Speed Workman MDX and Workman MD with Serial Number Above 313000400 8 Adjust Shift Cables 9 SERVICE AND REPAIRS 10 Drive Clutch eee eens 10 Drive Clutch Service Serial Number Below 310000000 12 Drive Clutch Service Serial Number Above 310000000 13 3 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 Opera tor s Manual for additional information when servicing the machine Workman MD MDX 5 1 Rev Chapter 5 Drive Train Driven Clutch

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