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Toro MDE Automobile User Manual

1. BATT CHG INDICATOR ACCESSORY SOL FUSE 2 FUSE 1 MAIN SOL HORN SW B IGN NEG CONTACTS COIL COIL B TERM P27 8 OUT J03 J04 305 106 J08 J01 J01 J02 J09 22223 14 78 76 do B 1 1 1 1 1 1 1 1 1 1 1 7 2 a 2 zd PINK uj m x RED WHITE 9 o 5 ORANGE 03 SP02 01 ji WHITE ORANGE uj m 1 e 2 RED WHITE rs BLACK SP05 1 2 a 2 BLUE BLUE WHITE 3 3 B 4 5 BLACK x 9 8 2 m BROWN 1 Spit WHITE BLACK 3 BLUE WHITE 1 E BLACK YELLOW ORANGE BLUE PINK 2 X PINK BLUE 3 YELLOW 4 VIOLET BLACK 5 BLACK BLUE WHITE 3 B 1 WHITE 8 D 9
2. we ee oes nee BU PK FUSE a HOLDERS F2 10A R i ACCESSORIES HORN OPTIONAL SOLENOID ence NOT ENERGIZED OFF HORN SWITCH D1 BATT CHG OPTIONAL HOOKUP __ Bow R HEADLIGHTS 24V i Y Y 2 ets INTERLOCK STATE OF CHARGE FL2 gu OR AAN CHARGER INDICATOR 2 Iu SWITCH o CHARGER f PLUGGED IN LIGHT SWITCH OR M ERE HOUR METER Z BK 1 F1 355A ai Ec a BU W i nie a FL3 BU n sena FORWARD REVERSE 525555 FORWARD 3 NC oR 148VDCINPUT 123456 3 1 2 NO PROGRAMMER gtd ER 2 FOR REV PORT MAIN ACCELERATOR PEDAL SWITCH PK lt lt A PEDAL NOT PUSHED IN CONTACTOR IRE BU x lt SOLENOID E OPTIONS NOT ENERGIZED REAR HI LOW SPEED SWITCH Y lt e 4 HILOW IN OFF POSITION 5 CHARGER 10 GA N F1 48V BATT ARRAY BK os BU W 6 HIGH TEMP LOW BATTERY DEER E MOTOR TEMP SENSOR 7 BACKUP ALARM CHARGING 180 W BK x lt FIELD F1 A1 ARMATURE 8 MAIN CONTACTOR DIAGNOSTIC LED DRIVE MOTOR GO GN lt lt 9 DIAGNOSTIC LIGHT T lt 10 ACCELERATOR FIELD F2 A2 ARMATURE BACKUP ALARM cw NG 11 PROGRAMMING HORN ACCELERATOR P
3. J34 335 P26 J23 124 PIS PO Jes Pld DI HORN MOTOR TEMP SENSOR REV ALARM SEVCON MOTOR CONTROLLER INPUTS PROGRAMMING ACC Y LIFT ACTUATOR Serial Number Below 310000000 Electrical Harness BATT CHG INDICATOR ACCESSORY SOL FUSE 2 FUSE MAIN SOL B IGN NEG CONTACTS COIL COIL B TERM HORN SW PIB OUT J03 J04 J05 106 J08 JOT J01 J02 E 209 1234567 8 1 1 1 1 1 1 1 1 1 1 1 1 1 p g lt 5 x PINK uj m RED WHITE 2 w 2 ac ORANGE ORANGE m z x SP02 59012 m 4 am WHITE m ORANGE 9 1 IGN SW 333 RED WHITE BLACK SP05 2 a BLUE BLUE WHITE B 1 BLACK 5 FOR REV SW 3 5 x BROWN 6 5 1 1 ima 8 m WHITE BLACK BLUE WHITE splot 1 jis 2 YELLOW 4 ORANGE ACCELERATOR BLACK PINK 4 BLUE 3 YELLOW 4 gt 2 VIOLET BLACK 5 BLACK SPOG BLUE WHITE 5 HI LOW 8 1 SPEED SW WHITE 8 D 9 10 BROWN 12 13 GREEN E DIAGNOSTIC 15 LED 2h 16 28 o o 3 3 a a A BLACK ACEL ce SP09 GRAY SPI3 BLACK gt BLACK SPI 2 BLUE SPI29 ACC Y REAR Poe cS 8 BLACK Xn RED WHITE 8 BLUE BLUE j BLUE ORANGE 4 x HEAD LIGHT 5 x SECOND FOLE ORANGE GREEN m 9 mae BLUE x m 5
4. Or Figure 38 4 Terminal 4 5 Switch plunger 6 Mounting tab 1 Terminal 1 2 Terminal 2 3 Terminal 3 Workman MDE Accelerator Potentiometer The accelerator potentiometer is attached to the pedal frame under the dash Fig 39 This potentiometer is used as one of the inputs for the vehicle controller to command vehicle speed The accelerator pedal posi tions the accelerator potentiometer lever When the op erator presses or releases the accelerator pedal the potentiometer resistance changes This resistance change is used by the controller to determine current flow to the traction motor Two styles of potentiometer have been used on Work man MDE vehicles Vehicles with serial numbers below 310000000 have a potentiometer with a short lever Fig 40 This potentiometer is rotated by a roll pin that ex tends approximately 1 1 2 inches 38 mm outofthe col lar Vehicles with serial numbers above 310000000 have a potentiometer with a long lever Fig 41 This po 2 tentiometer is rotated by a roll pin that extends approxi Figure p zn 5 mately 3 inches 76 mm out of the collar If a 2 Accelerator pedal 7 Roll pin potentiometer on an earlier vehicle has been replaced it may have a potentiometer with a long lever Ifthe accelerator potentiometer is out of adjustment the diagnostic light on the dash will flash six 6 times Addi tionally if vehicle movement is
5. 4 Reine al mage 4 SERVICE AND REPAIRS 6 Rear Wheels and Brakes 6 Rear Brake 10 Hydraulic Brake 12 Bleed Brake System 13 Front Brake Calipers 14 Brake Master Cylinder 16 Brake Master Cylinder Service 17 Parking Brake 18 Trarisaxle DEA 20 Transaxle Service 24 o x m SPICER OFF HIGHWAY COMPONENTS MODEL 12 ELECTRIC MAINTENANCE MANUAL 2 x o Workman Page 4 1 Transaxle and Brakes General Information Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Workman MDE vehicle Refer to the Operator s Manual for additional information when ser vicing the machine Transaxle and Brakes 4 2 Workman Specifications Item Description Transaxle Transaxle Fluid Capacity 2 quarts 1 9 liters Transaxle Fluid 10W 30 Motor Brake Fluid DOT3 2 x o Workman 4 3 Troubleshooting Brakes Brake pedal is spongy Trans
6. 9 Electrical Harness Drawing Serial Number Above 310000000 10 Electrical Harness Wiring Diagram Serial Number Above 310000000 11 Diagrams Workman Page 6 1 Rev Electrical Diagrams This page is intentionally blank Electrical Diagrams Page 6 2 Workman MDE 10A C BU PK FUSE IGNITION SWITCH ioi pens OFF RUN d F2 10A i 1 o R ACCESSORIES F HORN CONTACTOR OPTIONAL SOLENOID e B os die D1 BATT CHG HOOKUP RW i R HEADLIGHTS 24V Y Y FLI 2 ots INTERLOCK STATE OF CHARGE C FL2 E OR AAN GN 2 CHARGER INDICATOR 7 VLA SWITCH C E CHARGER PLUGGED IN LIGHT SWITCH BU OR HOUR METER EE BK 2 ots N F1 355A 3 BU W A B T HC FL3 BU FORWARD REVERSE 522525215 C gt BK Y Y OPTIONS IN FORWARD 3 NO e
7. 6 4 Electrical Harness Drawings 6 8 Workman MDE Rev A This page is intentionally blank Workman MDE 1 TORO Safety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While 2 Maintenance and Service 3 JACKING AND OTHER INSTRUCTIONS 4 Jacking Vehicle 4 Towing Vehicle 4 Transporting Vehicle 4 SAFETY AND INSTRUCTION DECALS 5 Workman MDE Page 1 1 Safety Safety Instructions The Workman MDE is designed and tested to offer safe service when operated and maintained properly Al though hazard control and accident prevention are par tially dependent upon the design and configuration of the machine these factors are also dependent upon the awareness concern and proper training of the person nel involved in the operation transport maintenance and storage of the machine Improper use or mainte nance of the machine can result in injury or death To re duce the potential for injury or death comply with the following safety instructions Before Operating 1 Review and understand the contents of the Opera tor s Manual and Operator s DVD before starting and operating the vehicle Become familiar with the controls and know how to stop the vehi
8. 10 gt BK 12 12 VDC OUTPUT 100 mA F2 w 13 4GA 1 i E 4 NG 14 MILLIPAK WO SEVCON B 15 CONTROLLER 5 ME NG 16 es 7 PROGRAMMING 22 l i eset PEE eye 1 L EE E See Se ee SS E Workman MDE Page 6 4 On Off Switch Turned On Power Current Control Current Indication Current F3 10A HORN OPTIONAL BU BK A X OPTIONS REAR Y Y OPTIONS FRONT PK IGNITION SWITCH OFF RUN F2 10A ie SOLENOID ENERGIZED NRUN BK HORN SWITCH D1 I BATT CHG L 2 2 2 rm OR OPTIONAL HOOKUP See eee HEADLIGHTS 24V i Yo ei Es 4 2 51 INTERLOCK STATE OF CHARGE mE 1 3 OR y CHARGER CC INDICATOR SWITCH pee s Bs CHARGERNOT 4 PLUGGED IN LIGHT SWITCH cis AR TI BK 2 pue LL 5 222550002 1 2 22922 02 22 1 355A 3 i i BK M 71 FL3 FORWARD REVERSE IEEE EAS Q N FORWARD gnc SR 48 VDCINPUT 123145
9. 3 Transaxle mount plate Figure 55 1 Upper nut 4 Flat washer 2 Cable connector 5 Insulating washer 3 Lower nut 6 Motor housing Workman MDE System 2 o This page is intentionally blank Workman MDE Page 3 37 Electrical System Traction Motor Service 120 to 140 in Ib 13 6 to 15 8 N m 18 to 22 in Ib 2 0 to 2 5 N m Figure 56 Frame and field assembly Armature Brush lead 2 used Cap screw 2 used per brush lead Cap screw 4 used Headband 0 Bolt 4 used RON SP PND Disassembly Fig 56 1 Unlatch and slide headband from traction motor 2 Pull back the brush springs and latch them in the open position on the spring holders Slide brushes from the brush holders Use arbor press or a bearing puller to remove the armature from the commutator end head and frame and field assembly Fig 57 4 Remove four 4 bolts that secure the commutator end head to the frame and field assembly Remove com mutator end head from frame and field assembly Electrical System Cap screw 8 used Brush 8 used High temperature sensor Page 3 38 11 Commutator end head 12 Bearing 13 Retaining ring 14 Brush spring 8 used 15 Brush box 5 Remove the retaining ring and press bearing from the commutator end head Discard the bearing When using compressed air for cleaning motor components follow all safety instructions in cluding wearing ey
10. 7 16 20 UNF 29 3 78 14UNF 155 260490 353441 NOTE Reduce torque values listed in the table above NOTE The nominal torque values listed above for by 25 for lubricated fasteners Lubricated fasteners Grade 5 and 8 fasteners are based on 75 of the mini are defined as threads coated with a lubricant such as mum proof load specified in SAE J429 The tolerance is engine oil or thread sealant such as Loctite approximately 1096 of the nominal torque value Thin height nuts include jam nuts 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 Rev A Workman MDE Standard Torque for Dry Zinc Plated and Steel Fasteners Metric Series 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 6 in Ib 644 68 N cm 78 8 in Ib 881 90 M6 X 1 0 96 10 in Ib 1085 113 N cm 133 14 in Ib 1503 158 N cm M8 X 1 25 19 2 ft lb 26 3N m 28 3 ft lb 38 4 N m M12 X 1 75 66 7 ft lb 90 10 N m 93 10 ft lb 126 14 N m M16 X 2 0 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610
11. BLUE BLUE WHITE 3 3 B 4 5 BLACK x 9 8 2 m BROWN 1 Spit WHITE BLACK 3 BLUE WHITE 1 E BLACK YELLOW ORANGE BLUE PINK 2 X PINK BLUE 3 YELLOW 4 VIOLET BLACK 5 BLACK BLUE WHITE 3 B 1 WHITE 8 D 9 10 M BROWN 9 12 13 18 x GREEN 15 2 16 28 5 5 s3 3 T m BLACK TAN D 5 09 1 SP13 BLACK R BLACK SEIT BLUE 5 129 8 BLACK SK 04 RED WHITE BLUE BLUE BLUE 5 ORANGE 3 x 2 ORANGE GREEN ul 5 BLACK A BLUE x a VIOLET ORANGE 9 Y x GRAY c T 2 z E 2 ni g 5 3 3 3 S a GREEN gt gt tr N 23 4567 8 10203 1 3 1 1 A B 9 A B BOC A B a 8c pe F GH P09 24 P25 JIS P20 P2 Plo P29 aah HEADLIGH L HEADLIGHT R HEADLIGHT B TERM BOX LIFT BOX LIFT OPTIONS CHARGER ACC Y LIFT S mx SWITCH SWITCH ACTUATOR 48 VDC HOOK UP SWITCH Sp en SEVCON Po n 88 zz E LIGHT INTERCONNECT TET 12 V CONVERTER P26 J23 J24 PIS J34 J35 Pol 15 Pla PI3 DIODE DI HORN MOTOR TEMP SENSOR REV ALARM SEVCON MOTOR CONTROLLER INPUTS PROGRAMM I NG ACC Y LIFT ACTUATOR GND TAIL LIGHT LEFT TURN RIGHT TURN BRAKE LIGHT INTERCONNECT REAR Workman MDE Serial Number Above 310000000 Electrical Harness Wiring Diagram
12. Loctite 242 Antiseize lubricant Figure 1 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 1 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 Page5 6 Workman MDE 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 ofthe 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 plate on
13. 2 signs of pitting scoring or cracks are evident in cylinder 5 Clevis 11 Primary piston assy 6 Jam nut 12 Cylinder housing c ma S Assembly Fig 9 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 can be installed to retain secondary piston assembly then install flange seal and reservoir Workman MDE Page 4 17 Transaxle and Brakes Parking Brake Parking brake cover Operator seat Seat base Cable equalizer bracket Parking brake lever Curved washer gt Transaxle and Brakes Figure 10 Lock nut Flat washer Flange head screw 4 used Flat washer 2 used Screw 2 used Cap screw Page 4 18 13 14 15 16 17 Cotter pin Clevis pin Parking brake cable 2 used Parking brake support Cable retaining ring 2 used Workman MDE Disassembly Fig 10 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 parking brake cables from rear of machine A Remove cotter pin and clevis pin that secures each parking brake cable end to brake lever B R
14. 5 ORANGE 2 5 m m x z 3 5 x 3 9 m 4 a Q 3 t z3 gt m gt Workman EERTE 123 12033 1 1 A B 5 9 A B C A B m m P25 25 PR x HEADLIGHT LT HEADLIGHT RT HEADLIGHT B BOX LIFT BOX LIFT OPTIONS CHARGER ACC Y LIFT SWITCH SWITCH ACTUATOR 48 VDC HOOK UP SWITCH SEVCON Wiring Diagram Page 6 9 Rev A 24 L HEADLIGHT J24 HORN J23 P23 HI LOW SPEED SW P07 P26 DIAGNOSTIC D1 LED P09 HEADLIGHT SWITCH P29 LIGHT INTERCONNECT P27 12V CONVERTER HORN SW OPTIONS ACT HET 48 VDC J03 ACCESSORY SOL CONTACTS P20 BOX LIFT SWITCH 206 ACCESSORY SOL COIL 205 1 CHG INDICATOR J04 ACCESSORY 5 CONTAC TS L POT 1 205 5 ACCELERATOR Workman MDE Serial Number Above 310000000 Electrical Harness Drawing Page 6 10 Rev 2 3 P25 R HEADLIGHT PT CHARGER HOOK UP MOTOR TEMP SENSOR J25 PR GRAMMING 235 J34 REV REV ALARM ALARM BOX LIFT ACTUATOR PH 15 ACC Y LIFT TERM ACTUATOR SEVCON Pn Jn LIGHT INTERCONNECT REAR am m P06 REAR O J21 8 J09 5 TERM Pot SEVCON MOTOR CONTROLLER INPUTS J32 IGN S
15. 6 2 to 6 8 N m Figure 15 Workman MDE Workman This page is intentionally blank Page 4 23 Transaxle and Brakes 6 o 5 55 cm A Transaxle Service oouonBRONZ 125 to 140 ft Ib 170 to 190 N m 26 to 30 ft Ib 34 to 41 N m 16 to 24 ft Ib 22 to 33 N m Cil seal Bearing cap bolt 2 used per cap Input shaft Intermediate shaft amp gear Retaining ring 2 used O ring 2 used Cover plate Wheel hub 2 used Ball bearing Ball bearing Endcap plug 2 used Transaxle housing O ring 2 used ej Figure 16 Wheel stud 5 used per hub Ball bearing 2 used Differential assembly Hex screw 4 used Lock nut 4 used Bearing cap 2 used Final drive gear Screw 10 used Ball bearing Vent elbow Plug Socket head screw 4 used per brake Lock nut 4 used per brake NOTE For service of the transaxle see the Spicer Off Highway Components Model 12 Electric Maintenance Manual at the end of this chapter Transaxle and Brakes Page 4 24 20 to 30 ft Ib 27 to 41 N m LH brake assembly RH brake assembly Oil seal 2 used Axle shaft 2 used Cotter pin 2 used Bearing retaining ring 4 used Ball bearing 2 used Gasket Retaining ring Flange nut 2 used O ring Ball bearing Plug Workman MDE Chapter 5 TORO Chassis Table of Contents G
16. IMPORTANT Brake drum machining is not re commended 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 6 320 160 5 mm replace both brake drums B Replace drums that are cracked deeply grooved tapered significantly out of round scored heat spotted or excessively rusted C Minor scoring can be removed with sandpaper 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 overheat ing Overheating is indicated by aslight 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 plate 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 adjuste
17. Page 6 11 Rev A This page is intentionally blank Page 6 12 Rev A
18. Verify continuity between switch terminals SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS Figure 22 OFF FORWARD FORWARD NECEM 2 4 4 5 1 Headlight switch 3 Figure 23 Electrical System Page 3 16 Workman MDE Vehicle Status Light The vehicle status light is located on the control panel Fig 24 During normal operation the status light should be continuously illuminated A vehicle electrical problem will be identified by a flashing status light The vehicle status light and LED on the vehicle control ler should have the same condition off illuminated or flashing If the vehicle status light does not illuminate when the on off switch is turned ON check the LED on the vehicle controller to make sure it is illuminated If the controller LED is illuminated and the vehicle status light is not illuminated check the vehicle status light and cir cuit wiring See Controller in this section and your Operator s Figure 24 Manual for information on a flashing vehicle status light 1 Vehicle status light 5 Testing 8 gt 1 Make sure on off switch is turned OFF Remove key from switch 2 Disconnect wire harness from vehicle status light IMPORTANT The vehicle status light is a 12 volt DC component Do nottestthe light using jumper wires from the vehicle battery pack 48 VDC 3 Th
19. corroded Traction motor is faulty Controller is faulty Nothing happens when on off switch is turned to ON Battery charge is extremely low Battery cables are loose corroded or damaged Cable connection s at controller is are loose or corroded 10 ampere fuse F2 to the on off switch is loose or blown Fusible link FL2 is faulty Main fuse F1 is loose or blown The on off switch or circuit wiring is faulty Controller is faulty Electrical System Page3 8 Workman MDE General Run Problems Continued Traction motor stops during operation Vehicle runs slowly Vehicle movement is erratic or jerky Battery Charger Operation Light Status Green light on battery charger illuminated not flashing Green light on battery charger flashing Red light on battery charger flashing Workman MDE Page Possible Causes Wiring to the traction motor components e g main contactor controller traction motor loose corroded or damaged see Electrical Schematic in Chapter 6 Electrical Diagrams Battery cables are loose corroded or damaged Controller is overheated Traction motor is overheated Traction motor is faulty Brake or transaxle problem see Chapter 4 Transaxle and Brakes Supervisor speed limit switch in slow position Tire pressure is low see Chapter 5 Chassis Brakes improperly adjusted see Chapter 4 Transaxle and Brakes Battery charge is extremely low Contr
20. 10 M BROWN 9 12 13 18 x GREEN 15 2 16 28 5 5 s3 3 T m BLACK TAN D 5 09 1 SP13 BLACK R BLACK SEIT BLUE 5 129 8 BLACK SK 04 RED WHITE BLUE BLUE BLUE 5 ORANGE 3 x 2 ORANGE GREEN ul 5 BLACK A BLUE x a VIOLET ORANGE 9 Y x GRAY c T 2 z E 2 ni g 5 3 3 3 S a GREEN gt gt tr N 23 4567 8 10203 1 3 1 1 A B 9 A B BOC A B a 8c pe F GH P09 24 P25 JIS P20 P2 Plo P29 aah HEADLIGH L HEADLIGHT R HEADLIGHT B TERM BOX LIFT BOX LIFT OPTIONS CHARGER ACC Y LIFT S mx SWITCH SWITCH ACTUATOR 48 VDC HOOK UP SWITCH Sp en SEVCON Po n 88 zz E LIGHT INTERCONNECT TET 12 V CONVERTER P26 J23 J24 PIS J34 J35 Pol 15 Pla PI3 DIODE DI HORN MOTOR TEMP SENSOR REV ALARM SEVCON MOTOR CONTROLLER INPUTS PROGRAMM I NG ACC Y LIFT ACTUATOR GND TAIL LIGHT LEFT TURN RIGHT TURN BRAKE LIGHT INTERCONNECT REAR Workman MDE Serial Number Above 310000000 Electrical Harness Wiring Diagram Page 6 11 Rev A This page is intentionally blank Page 6 12 Rev A 10 Workman Battery Charging Circuit 6 Power Current Control Current Indication Current
21. 13 and flat washer item 12 from pinion gear shaft Discard flange head screw 3 Remove three 3 hex washer head screws item 2 securing the housing cover and gasket to the steering housing 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 2 IMPORTANT Always replace ball bearings as 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 MDE Page5 9 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 gearboxassembly If ei ther or both of these parts is replaced ma
22. 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 lb Product Records and Maintenance Page 2 6 Workman MDE Chapter 3 TORO Electrical System Table of Contents GENERAL INFORMATION 2 SERVICE AND REPAIRS Operator s Manual 2 Battery Service Opening Battery Circuit 2 Battery Specifications ELECTRICAL DIAGRAMS 3 Battery VEHICLE OPERATION 4 Battery Installation SPECIAL TOOLS olea E e ee 5 Battery TROUBLESHOOTING 8 Battery Inspection and Maintenance General Run 8 Battery Testing Battery Charger Operation 9 Battery 2 Batt
23. Ib 61 to 88 N m 7 Connect wires to traction motor Fig 15 IMPORTANT When connecting cables to motor terminals A1 A2 F1 and F2 use a back up wrench to retain lower nut before tightening up per nut Fig 12 If terminal studs are allowed to turn during upper nut installation internal motor damage can occur A Install cable connector and upper nut to motor terminals A1 and A2 While retaining lower nut torque upper nut on terminals A1 and A2 from 85 to 90 in Ib 9 6 to 10 2 N m B Install cable connector and upper nut to motor terminals F1 and F2 While retaining lower nut torque upper nut on terminals F1 and F2 from 55 to 60 in Ib 6 2 to 6 8 N m C Plug motor temperature sensor connector into vehicle wire harness Transaxle and Brakes Page 4 22 8 Carefully connect removed battery cable to battery terminals Install lock washers and nuts on battery termi nals Torque nuts from 115 to 125 in Ib 13 0 to 14 1 N m 9 Install cargo box to the rear frame see Cargo Box Installation in Service and Repairs section of Chapter 5 Chassis 10 Check brakes for proper operation Figure 14 1 Support bracket 3 Transaxle mount plate 2 Carriage screws nuts 85 to 90 in Ib 9 6 to 10 2 N m 55 to 60 in Ib E xm 6 2 to 6 8 N m 2777 0 3 1005 WO 02500 AND CURRENT DATE 55 to 60 in Ib
24. Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being jacked up Jack front wheel off the ground and support machine with appropriate jack stands 3 Remove front wheel from machine see Lower Steering and Front Wheel Removal in the the Service and Repairs section of Chapter 5 Chassis 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 7 If necessary remove brake pads from caliper Fig 7 A Remove anti rattle clip from caliper B Remove pins from caliper by prying with a flat blade screwdriver through loop in pins C Slide brake pads from caliper For assembly pur poses note orientation of inner and outer pads as the pads are not the same D Replace the brake pads if the friction material is worn to less than 1 32 0 8 mm 8 If brake rotor service is necessary see Lower Steer ing and Front Wheels inthe Service and Repairs section of Chapter 5 Chassis Workman MDE Page 4 15 Installation Fig 6 1 Ifbrake pads were removed from caliper install pads Fig 7 A If brake pads are being replaced it will be neces sary to push caliper pistons back into the caliper bore before install
25. Negative cable to vehicle 3 Flange nut 2 Positive cable to vehicle 4 Battery retainer Figure 44 Electrical System 2 Em o System Battery Charging When the vehicle is not in use it is recommended to keep the batteries charged by connecting the battery charger that is included with the vehicle The Workman MDE charger is designed to automatically charge the batteries fully without overcharging Indicator lights green and red and an ammeter on the charger give in formation about the charging operation Make sure to have the battery cell plates covered with electrolyte before charging the batteries Fig 45 Peri odically at least every 50 operating hours check elec trolyte level in the batteries and add distilled water to ensure proper charging and the best battery perfor mance and life Colder temperatures will increase the time needed to fully charge the batteries NEVER attempt to charge fro zen batteries Also if temperatures below freezing are expected do not add water to battery after charging as added water could freeze and damage battery For additional battery charging information see your Operator s Manual and the Battery Charger Operating Instructions 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
26. commutator end head bear ing be installed because the removed bearing may have been damaged during disassembly Although the bear ing may appear and feel good the bearing could be bri nelled races or balls deformed and may exhibit noise and vibration problems or fail within a relatively short pe riod of service When installing new bearing always press against the race that is absorbing the pressure or bearing damage may occur 1 After servicing the commutator and brushes re as semble the wiring in the commutator end head as origi nally found Ensure the wiring does not contact metal and rotating parts Also make sure that the wiring allows the brushes to move unrestricted in the brush holders 2 Press anew bearing into the commutator end head pressing on the bearing outer race only Fig 61 Secure bearing with retaining ring 3 Position the commutator end head to the frame and field assembly and secure with four 4 bolts Torque bolts from 120 to 140 in Ib 13 6 to 15 8 N m 4 Ensure the brushes are pushed out of the way 5 While supporting the inner race of the bearing in commutator end head carefully press the armature into the end head and bearing assembly Fig 61 6 Position brushes in brush holders and carefully re lease the brush springs allowing the brushes to contact the commutator Make sure brush shunts do not inter fere with spring movement 7 Repair or replace the headband if damaged Insta
27. erratic or jerky calibra tion ofthe accelerator system should be performed See Accelerator Potentiometer Adjustment and Accelerator System Calibration in the Adjustments section of this chapter Before suspecting a faulty potentiometer follow adjust ment procedures for the accelerator switch accelerator potentiometer and acceleration system calibration found in the Adjustments section of this chapter Figure 40 1 Potentiometer 2 Lever short Figure 41 1 Potentiometer 3 Retainer 2 Lever long Workman MDE 3 25 Rev Electrical System Controller The Workman controller is securedto the rear frame un der the controller cover beneath the cargo box Fig 40 The controller uses inputs from several vehicle switches on off forward reverse accelerator pedal supervisor charger interlock motor temperature accelerator po tentiometer to accurately control vehicle speed vehicle direction forward and reverse and regenerative brak ing An internal thermal sensor prevents overheating of the controller Cable connections for the controller are as follows Terminal B Negative battery cable and wire harness ground Terminal B Positive cable from main contac tor post and wire harness fusible link FL3 Terminal M1 Cable to traction motor armature A2 post Terminal M2 Cable to traction motor armature A1 post Terminal F1 Cable to traction motor field F1 post Terminal F2 C
28. frame is not used for any ground connections The vehicle controller monitors operator and vehicle in puts to determine voltage to the traction motor If a prob lem exists that will prevent normal vehicle operation an 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 Opening Battery Circuit To prevent allowing a current path through tools used during vehicle electrical circuit repairs remove one of the battery cables from the battery pack as the first step in any repair Fig 1 Once a cable has been removed the electrical system on the vehicle can be safely worked on Take care during repairs however to not al low tools or vehicle components to complete the battery circuit that was opened with the cable removal Reattach the removed cable to the battery pack as the last step in any repair Secure cable on each battery ter minal with lock washer and nut Torque nuts from 115 to 125 in Ib 13 0 to 14 1 Battery pack cable routing is shown in Figure 2 Electrical System Page 3 2 LED on the controller and the vehicle status light on the dash panel will flash a fault code to assist in identifying the problem After performing any repair on electrical components on the vehicle make sure that wiring is routed and
29. from master cylinder 4 Remove flange head nuts from cap screws that se cure master cylinder to pedal frame 5 Pull master cylinder from machine Transaxle and Brakes Page 4 16 6 Flange head nut 7 Pedal frame Installation Fig 8 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 Lower and secure front hood 5 Bleed brakes see Bleed Brake System in this chap ter Check brake operation Workman MDE Brake Master Cylinder Service Disassembly Fig 9 1 Remove reservoir and flange seal Push in on the push rod so the stop pin can be removed 2 Disconnect lower end of the dust cover from the housing 3 Push in on the push rod and remove circlip then re move push rod with dust cover and clevis Remove re tainer washer 4 Remove primary piston assembly and secondary piston assembly from cylinder housing Inspection 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 Figure 1 Reservoir 7 Dust cover 2 Check cylinder bore pistons and springs for damage 4 In 5 2 or excessive wear Replace brake cylinder assembly if 4 Secondary piston assy 10 Retainer washer
30. holders are loose on the brush plate 5 Brush springs should be checked for proper tension using the following procedure Fig 58 A Place paper strip between brush face and com mutator Hook spring scale as shown B Pull spring scale on a line directly opposite the line of force exerted by the brush spring When the paper strip begins to move freely read the spring ten sion on the scale Brush tension for a new brush should be 65 ounces 1820 grams and for a worn brush should be 40 ounces 1120 grams Frame and Field Service 1 Motors that have been disassembled for servicing should be given a complete inspection of the frame and field assembly If damage to the field coils or frame is found replace traction motor Individual frame and field components are not available 2 Accumulated carbon dust grease and other foreign material can produce a ground path from the field wind ing to the frame The frame and field should be cleaned with Safety Kleen 105 washing solvent or equivalent After cleaning the frame and field must be oven dried for one hour at 300 F 148 C to remove any cleaning residue Workman MDE Page 3 39 3 Itis also recommended that the field be coated with PD George 1000 70 or RanBar B 535 5S varnish for proper insulation protection Both recommended var nishes are Class H water soluble varnishes A similar air dry varnish may also be used providing it has a Class H rating 4 Screws secu
31. lt 148VDC INPUT 12314156 3 1 2 NO PROGRAMMER Bie 2 FOR REV PORT MAIN ACCELERATOR PEDAL SWITCH CONTACTOR 7 47 OPTIONS PEDAL NOT PUSHED IN B lt lt 8 ACCELERATOR PEDAL B4 SOLENOID Y REAR 7 HI LOW SPEED SWITCH Y lt lt 4 HIILOW IN OFF POSITION 5 CHARGER 10 GA nn F1 48V BATT ARRAY V e BU lt lt 1 6 HIGH TEMP LOW BATTERY 7 BACKUP ALARM 180 W BK x lt FIELD F1 A1 ARMATURE lt lt 8 MAIN CONTACTOR 2 3 DRIVE MOTOR CR GN 9 DIAGNOSTIC LIGHT 5 Rey 10 ACCELERATOR POT FIELD F2 A2 ARMATURE TATE OF CHARGE 1 S BACKUP ALARM 11 PROGRAMMING HORN ACCELERATOR POT 10 4 2 SENSA qua pss BK 12 12 VDC OUTPUT 100 mA F2 SETUP 25 2 3 6 IGN 13 4 GA HR ENABLE 3G 7 FET OUT 14 8 1 e o SEVCON B w NG 15 CONTROLLER HOUR METER BK NG 16 PROGRAMMING SPLICE Workman MDE Electrical Schematic Contactors shown de energized Page 6 3 BU PK FUSE DERS SES F2 10 E ACCESSORIES i HORN OPTIONAL SOLENOID ENERGIZED
32. necessary 4 Flashes Main contactor malfunction Turn on off switch OFF wait several seconds and turn on off switch ON If controller does not reset inspect main contactor see Main and Accessories Contactors in this section Check main contactor wire and cable connections If problem continues contactor replacement may be necessary Electrical System 5 Flashes The charger cord is plugged Turn on off switch OFF unplug charger cord from vehicle into the vehicle charger and turn on off switch ON receptacle If controller does not reset correctly check charger interlock switch 6 Flashes Accelerator control Adjust accelerator switch and potentiometer see accelerator switch and Accelerator Switch and Accelerator Potentiometer potentiometer is out of adjustment calibration in the Adjustments section of this adjustment chapter 7 Flashes Battery voltage is out of Inspect and test vehicle batteries and battery cable range connections see Battery Service in the Service and Repairs section of this chapter 8 Flashes The controller is overheated The vehicle will continue to operate but at reduced power until the controller temperature lowers 9 Flashes The traction motor is Stop vehicle and allow motor to cool before continuing overheated battery operation Traction motor high temperature switch may discharge indicator displays be faulty more than 1 bar The battery is nearly Charge the batteries immediately to preven
33. protec tion 5 After undercutting use No 00 sandpaper to lightly remove any burrs left from the undercutting operation Clean commutator with dry oil free compressed air and recheck commutator runout Armature Testing Before an armature is reassembled into the motor the following tests should be performed NOTE Armature is wave wound and can be short cir cuit tested in the following manner 1 Check for grounded circuits by placing one test lead of a dielectric tester on the commutator and the other lead at the armature shaft If the test light comes on the armature is grounded 2 Check for short circuits by placing the armature ona growler Use a long flat piece of metal such as a hack saw blade to locate any shorted windings If armature is found to be shorted grounded or other wise damaged replace the traction motor Electrical System Page 3 40 MICA COPPER SEGMENT ur o047 CL 1 0 UNDERCUT MICA MICA COPPER SEGMENT P NT J BAD UNDERCUT CUT TOO WIDE COPPER SEGMENT HIP BAD UNDERCUT CUT TOO NARROW Figure 60 Traction Motor Specifications BRUSH LENGTH 1 300 in 33 mm TENSION comoro 5 74 mm 2 800 in 71mm Minimum Diame ter for Reslotting Reject Diameter 2 750 in Workman MDE Assembly Fig 56 NOTE After the motor has been disassembled it is recommended that a new
34. specific gravity test Workman MDE Page 3 31 B Measure the specific gravity of each cell with a hydrometer Fill and drain the hydrometer two to four times before drawing a sample At the same time take the temperature of the cell C Have enough electrolyte in the hydrometer to completely support the hydrometer float Record the hydrometer reading and return the electrolyte to the battery cell D Repeat test for remaining battery cells E Temperature correct each cell reading For each 10 F 5 5 C above 80 F 26 7 C 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 Specific Gravity Reading 1 245 ADD 20 above 80 F 0 008 Correction to 80 F 1 253 F The specific gravity of all battery cells should be 1 277 0 007 If low cell readings exist see Fig 46 charge battery and take specific gravity readings again G If specific gravity of any cells remain low after complete charging battery should be replaced Level Gravity Voltage Figure 46 Electrical System lt System Battery Storage If the vehicle will be stored for any period of time check battery electrolyte level adjust level if needed and then connect battery charger to vehicle Allow charger to re main connectedto vehicle during storage to prevent bat tery discharge and
35. 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 tighten the fastener until the lines match up 8 8 Class 8 8 Class 10 9 Metric Bolts and Screws Figure 2 Product Records and Maintenance Product Records 8 E Standard Torque for Dry Zinc Plated and Steel Fasteners Inch Series Grade 1 5 amp SAE Grade 1 Bolts Screws Studs amp SAE Grade 5 Bolts Screws Studs amp SAE Grade 8 Bolts Screws Studs amp Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts SAE J995 Grade 2 or Stronger Nuts SAE J995 Grade 2 or Stronger Nuts 5 J995 Grade 5 or Stronger Nuts 147 23 339 56 599 79 100 10 1130 113 140 15 1582 169 734 113 115 12 1299 136 160 17 1808 192 1186 169 200 25 2260 282 300 30 3390 339 1446 192 225 25 2542 282 325 33 3672 373 6 32 UNC 6 40 UNF 8 32 UNC 8 36 UNF 10 24 UNC 10 32 UNF 1 4 20 UNC 48 7 1 4 28 UNF 5 5 16 18 UNC 115 15 105 15 5 16 24 UNF 138 17 128 17 pU mU car rae N co m a N A A lt 1342 65 10 88 12 3 8 16 UNC 16 2 3 8 24 UNF 7 16 14 UNC 27 3
36. transaxle and motor assembly from the rear of the vehicle 13 If necessary remove traction motor from transaxle see Traction Motor Removal in Service and Repairs section of Chapter 3 Electrical System Figure 12 1 Loosening tightening wrench upper nut 2 Retaining wrench lower nut Figure 13 1 Cotter pin 3 Brake cable bracket 2 Clevis pin 4 Brake actuator lever Transaxle and Brakes i x Installation Fig 11 1 If removed install traction motor to transaxle see Traction Motor Installation in Service and Repairs sec tion of Chapter 3 Electrical System 2 Position transaxle and motor assembly to the rear frame Loosely install all fasteners used to secure trans axle to vehicle Tighten fasteners in the following order A Tighten four 4 flange head screws and flange nuts that secure transaxle to the rear frame B Tighten two 2 flange nuts and carriage screws that secure transaxle mount plate item 5 to support bracket item 4 3 Install parking brake cables to brake actuator levers with clevis pins and cotter pins 4 Position and secure hydraulic brake lines to wheel cylinders Fig 3 Torque banjo bolts from 15 to 21 ft Ib 21 to 28 N m 5 Position wheel assemblies to the vehicle with valve stems facing out Secure each wheel with five 5 lug nuts 6 Lower vehicle from jackstands Torque lug nuts in a crossing pattern from 45 to 65 ft
37. 0 4 ply pressure 8 to 22 PSI 55 to 152 kPa Wheel lug nut torque front and rear 45 to 65 ft Ib 61 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 5 2 Rev A Figure 1 Figure 2 Workman MDE Troubleshooting Suspension and Steering Workman MDE Chassis Suspension and Steering continued Chassis Page5 4 Workman MDE Adjustments 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 camber procedure 3 Onalevel surface roll the vehicle straight back from 6to 10 feet 2 to 3 meters and then straight forward to the original starting position This will allow the suspen sion to settle into th
38. 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 29 32 0 90625 23 019 27 64 0 421875 10 716 59 64 0 921875 23 416 7 6 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 in 0 0254 mm 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 Min
39. 1 A2 F1 and F2 B Unplug motor temperature sensor from vehicle wire harness Note location of cable tie that secures temperature sensor wires to vehicle C Position disconnected wires away from motor 5 Remove plastic plug from rear frame to allow access to socket head screw that retains fan to traction motor Remove screw and washer and then remove fan from motor To prevent motor damage and personal injury make sure that traction motor is well supported as itis removed Motor weighs approximately 62 pounds 28 1 kg 6 Support traction motor to prevent it from falling Two suggestions for traction motor support are as follows IMPORTANT Damage to traction motor field coils will result if eyebolt is threaded into motor housing to far A Remove silver flange head screw from top of mo tor and carefully install a 3 8 16 eyebolt into motor Fig 53 Thread eyebolt into motor approximately four 4 turns taking care to not bottom eyebolt into internal field coils Secure eyebolt with jam nut Use eyebolt for support and as a lifting point for motor re moval B Use lifting strap wrapped around motor housing for support and as a lifting point for motor removal 7 Remove six 6 socket head screws item 1 and flat washers item 2 that secure motor to transaxle 8 Slide motor away from transaxle to disengage motor shaft from transaxle input shaft Carefully lift motor from vehicle Take care to not damage therma
40. 6 2 NO PROGRAMMER 12 FOR REV n DA SACCELERATOR PEDAL B4 m ees HI LOW SPEED SWITCH y lt lt HI LOW FF 4 GA IN OFF HI POSITION 5 CHARGER VIO BK NG I 48V ARRAY 6V x8 BUA 6 HIGH TEMP LOW BATTERY Eo E 7 BACKUP ALARM 180 W BK x lt FIELD F1 A1ARMATURE DIAGNOSTIC LED DRIVE MOTOR 5 5 e 8 PEE 24 t 10 ACCELERATOR POT HELD Ee AZ ARMATURE BACKUP ALARM cw NG 11 PROGRAMMING HORN ACCELERATORPOT 10 GA BK O bti GN a mpi e 12 12 VDC OUTPUT 100 mA F w NG 13 4GA do M 14 MILLIPAK E Se SEVCON B NG 15 CONTROLLER BK 16 PROGRAMMING E PO OE 25 2 532252062 9 Workman Run Circuit Forward Power Current Control Current Indication Current 6 5 This page is intentionally blank Page 6 7 Rev A 2 HEADLIGHT 3 P25
41. 62 N m Product Records 2 3 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 engine oil 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 MDE 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 716 200 65 10 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 108 14 N m 3 8 16 UNC 35 10 ft lb 18 3 ft lb M12 X 1 25 80 10 ft lb 108 14 N m Class 8 8 1 2 13 UNC 75 15 ft lb 50 10 ft Ib M12 X 1 5 80 10 ft lb 108 14 N m Class 8 8 For steel wheels and non lubricated fasteners Thread Cutting Screws Thread 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
42. 8 Volt Battery Discharge Unit The 36 48 Volt Battery Discharge Unit is recommended for quick and accurate load testing for the batteries on the Workman MDE This tool is used to determine the capacity of the Workman battery pack and also for find ing a faulty battery or batteries in the battery pack Toro Part Number TOR4106 Figure 9 System lt Workman Page 3 7 Electrical System Troubleshooting For effective troubleshooting and repairs there must be a good understanding of the electrical circuits and com ponents used on this vehicle see Electrical Schematic in Chapter 6 Remove all jewelry especially rings and watches before doing any electrical trouble Ifthe vehicle has any switches by passed they must be shooting or testing Disconnect a battery cable reconnected for proper vehicle operation troubleshoot from the battery pack to open the battery circuit ing and safety unless atest procedure requires battery voltage General Run Problems NOTE Check vehicle status light on dash panel and controller LED for possible faults whenever diagnosing vehicle problems see Controller in the Component Testing section of this chapter Main contactor clicks but vehicle will not operate Battery charge is low Battery cables are loose corroded or damaged Cable connection s at controller is are loose or corroded Cable connection s at traction motor is are loose or
43. Brakes 5 Connect charger wire harness to vehicle wire har ness Secure receptacle plate to seat base with four 4 screws item 12 6 Install seats to vehicle 7 Connectremoved battery cable to battery terminals Install lock washer and nut on battery terminals Torque nuts from 115 to 125 in Ib 13 0 to 14 1 N m Workman MDE Page 5 19 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 13 Washer head screw 8 used Carriage screw 2 used Lock nut 2 used Pivot pin 2 used Spring 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 5 20 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 24V 2 used Foam seal Workman MDE Removal Fig 13 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off Switch 2 Openthe battery cir
44. ENERAL INFORMATION 1 Operator s Manual 1 SPECIFICATIONS 2 SPEGIAL TOOLS 2 TROUBLESHOOTING 3 Suspension and 3 ADJUSTMENTS 41 Adjust Front Wheel Camber 4 1 Adjust Front Wheel 4 2 SERVICE AND REPAIRS 5 Check Tire Pressure 5 Inspect Tires and Wheels 5 Upper Steering 6 Steering Gearbox 8 Lower Steering and Front Wheels 10 Front Shock 13 A arms and Front Suspension 14 Frame Pivot Yoke 16 Seat Base beer ep Re 18 Front Hood dus etus idet ag a 20 Cargo Box Serial Number Below 311000000 22 Cargo Box Serial Number Above 311000000 24 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 MDE Page5 1 Rev A Chassis Specifications Item Description Front tire 22 x 9 5 10 4 ply pressure 8 to 22 PSI 55 to 152 kPa Rear tire 22 x 9 5 1
45. If necessary use press to remove wheel studs from hub 7 necessary remove brake assembly from trans axle A Remove cotter pin and clevis pin securing the parking brake cable bracketto the brake actuator le ver Fig 2 B Clean hydraulic brake line area of rear brake inder to prevent contamination Loosen and discon nect hydraulic brake line from wheel cylinder Plug brake line and position it away from wheel cylinder C Remove four 4 socket head screws and lock nuts securing the brake assembly to the transaxle Remove brake assembly from the transaxle Installation Fig 1 IMPORTANT The parking brake actuation levers should be positioned above the transaxle mount When positioned correctly the levers will point to ward the rear of the vehicle Fig 2 1 If brake assembly was removed from axle install brake assembly to transaxle A Secure brake assembly to the transaxle with four 4 socket head screws and lock nuts Torque lock nuts from 26 to 30 ft Ib 34 to 41 N m Workman MDE Page4 7 B Position and secure hydraulic brake line to wheel cylinder Fig 3 Torque banjo bolt from 15 to 21 ft Ib 21 to 28 N m C Secure parking brake cable bracket to the brake actuator lever with clevis pin and cotter pin Fig 2 2 f wheel studs were removed from wheel hub use press to install wheel studs into hub Make sure to fully press studs into hub 3 Slide wheel hub onto transaxle shaf
46. Motor Service in this section 5 In mostinstances wear of all traction motor brushes should be similar to wear found on the top brushes If in spection of remaining brushes is needed or if brushes require replacement traction motor should be removed from vehicle see Traction Motor and Traction Motor Service in this section 6 If vehicle is often operated in severely dirty environ ments brush should be removed from motor to allow in spection of mating surface of brush Fig 48 If brush surface is rough pitted arced or scored additional brush and or motor inspection should be completed see Traction Motor and Traction Motor Service in this section Figure 48 7 Visually inspect commutator surface of motor arma 1 Removed brush 2 Cap screw ture If commutator surface is rough pitted arced or scored additional motor inspection should be com pleted see Traction Motor and Traction Motor Service in this section 8 After brush inspection make sure brush is correctly installed in brush holder and tensioned by spring Refit headband to traction motor and latch headband 9 Carefully connect removed battery cable to battery terminals Install lock washer and nut on battery termi nals Torque nuts from 115 to 125 in Ib 13 0 to 14 1 N m 10 Lower and secure cargo box Figure 49 1 Brush holder side view 3 Worn brush 2 Normal brush 4 Brush shunt wire Workman MDE Page 3 33 Electrical Syst
47. NRUN BK HORN SWITCH l E Soda H OPTIONAL HOOK UP i HEADLIGHTS 24V i 0pY 4 H 2 2 2 2 v Q on 2 ots INTERLOCK STATE OF CHARGE OR Gu e f CHARGER INDICATOR SWITCH E Secr zl CHARGER NOT PLUGGED IN LIGHT SWITCH i Pcr BU wm OR u ws M M i 7 NETS ots 71 1_355 4 BK I 5 ZELUM BU W E Li i 4 8 NC OR 8 123456 2 Pi wt PROGRAMMER lt 2 FOR REV PORT MAIN 1 ACCELERATOR PEDAL SWITCH CONTACTOR Xx OPTIONS 1 PEDAL NOT PUSHED IN BU lt S ACCELERATOR PEDAL SOLENOID ENERGIZED E 1 HI LOW SPEED SWITCH y e 4HI LOW T 20A o IN OFF HI POSITION VIO BK 5 CHARGER 10 GA 6V x8 22252 lt 6 HIGH TEMP LOW BATTERY No s 3 180 C W BK 7 BACKUP ALARM FIELD F1 1 MAIN CONTACTOR D DIAGNOSTIC LED 3 DRIVE MOTOR 9 DIAGNOSTIC LIGHT 2 D lt lt 10 ACCELERATOR FIELD F2 A2 ARMATURE BACKUP ALARM cw 11 PROGRAMMING A HORN ACCELERATOR
48. OT 10 BK C 12V BN lt 1212 OUTPUT 100 mA F2 w 4GA 18 1 NG 14 MILLIPAK GY SEVCON B NG 15 CONTROLLER BK 16 PROGRAMMING SPLICE This page is intentionally blank Page 6 7 Rev A 2 HEADLIGHT 3 P25 RT HEADLIGHT 23 HI LOW SPEED Sw P12 CHARGER 224 HOOK UP HORN J23 P26 01 09 HEADLIGHT SWITCH POT DIAGNOSTIC LED SEVCON Jm COIL Pot SEVCON MOTOR CONTROLLER INPUTS 125 PROGRAMMING J12 HORN SW Q 203 ACCESSORY SOL CONTACTS J06 ACCESSORY 501 COIL 205 P18 BATT CHG INDICATOR 0 ACCESSORY SOL CONTACTS ACCEL POT POS ACCELERATOR Workman MDE Serial Number Below 310000000 Electrical Harness Drawing 6 8 Rev A
49. PUTS PROGRAMMING ACC Y LIFT ACTUATOR Serial Number Below 310000000 Electrical Harness BATT CHG INDICATOR ACCESSORY SOL FUSE 2 FUSE MAIN SOL B IGN NEG CONTACTS COIL COIL B TERM HORN SW PIB OUT J03 J04 J05 106 J08 JOT J01 J02 E 209 1234567 8 1 1 1 1 1 1 1 1 1 1 1 1 1 p g lt 5 x PINK uj m RED WHITE 2 w 2 ac ORANGE ORANGE m z x SP02 59012 m 4 am WHITE m ORANGE 9 1 IGN SW 333 RED WHITE BLACK SP05 2 a BLUE BLUE WHITE B 1 BLACK 5 FOR REV SW 3 5 x BROWN 6 5 1 1 ima 8 m WHITE BLACK BLUE WHITE splot 1 jis 2 YELLOW 4 ORANGE ACCELERATOR BLACK PINK 4 BLUE 3 YELLOW 4 gt 2 VIOLET BLACK 5 BLACK SPOG BLUE WHITE 5 HI LOW 8 1 SPEED SW WHITE 8 D 9 10 BROWN 12 13 GREEN E DIAGNOSTIC 15 LED 2h 16 28 o o 3 3 a a A BLACK ACEL ce SP09 GRAY SPI3 BLACK gt BLACK SPI 2 BLUE SPI29 ACC Y REAR Poe cS 8 BLACK Xn RED WHITE 8 BLUE BLUE j BLUE ORANGE 4 x HEAD LIGHT 5 x SECOND FOLE ORANGE GREEN m 9 mae BLUE x m 5 5 ORANGE 2 5 m m x z 3 5 x 3 9 m 4 a Q 3 t z3 gt m gt Workman EERTE 123 12033 1 1 A B 5 9 A B C A B m m P25 25 PR x HEADLIGHT LT HEADLIGHT RT HEADLIGHT B BOX LIFT BOX LIFT OPTIONS CHARGER ACC Y LIFT SWITCH SWI
50. Part 0816451 Rev Service Manual Workman MDE 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 MDE 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 This page is intentionally blank Workman MDE Table Of Contents Chapter 1 Safety Safety 1 5 5 1 2 Jacking and Other Instructions 1 4 Safety and Instruc
51. RT HEADLIGHT 23 HI LOW SPEED Sw P12 CHARGER 224 HOOK UP HORN J23 P26 01 09 HEADLIGHT SWITCH POT DIAGNOSTIC LED SEVCON Jm COIL Pot SEVCON MOTOR CONTROLLER INPUTS 125 PROGRAMMING J12 HORN SW Q 203 ACCESSORY SOL CONTACTS J06 ACCESSORY 501 COIL 205 P18 BATT CHG INDICATOR 0 ACCESSORY SOL CONTACTS ACCEL POT POS ACCELERATOR Workman MDE Serial Number Below 310000000 Electrical Harness Drawing 6 8 Rev A J34 335 P26 J23 124 PIS PO Jes Pld DI HORN MOTOR TEMP SENSOR REV ALARM SEVCON MOTOR CONTROLLER IN
52. TCH ACTUATOR 48 VDC HOOK UP SWITCH SEVCON Wiring Diagram Page 6 9 Rev A 24 L HEADLIGHT J24 HORN J23 P23 HI LOW SPEED SW P07 P26 DIAGNOSTIC D1 LED P09 HEADLIGHT SWITCH P29 LIGHT INTERCONNECT P27 12V CONVERTER HORN SW OPTIONS ACT HET 48 VDC J03 ACCESSORY SOL CONTACTS P20 BOX LIFT SWITCH 206 ACCESSORY SOL COIL 205 1 CHG INDICATOR J04 ACCESSORY 5 CONTAC TS L POT 1 205 5 ACCELERATOR Workman MDE Serial Number Above 310000000 Electrical Harness Drawing Page 6 10 Rev 2 3 P25 R HEADLIGHT PT CHARGER HOOK UP MOTOR TEMP SENSOR J25 PR GRAMMING 235 J34 REV REV ALARM ALARM BOX LIFT ACTUATOR PH 15 ACC Y LIFT TERM ACTUATOR SEVCON Pn Jn LIGHT INTERCONNECT REAR am m P06 REAR O J21 8 J09 5 TERM Pot SEVCON MOTOR CONTROLLER INPUTS J32 IGN SW J33 P03 FOR REV SW NC POS NO ACCELERATOR HI LOW SPEED SW P23 DIAGNOSTIC LED ACCEL POT Po ACC Y REAR 2 HEAD LIGHT SECOND POLE P2
53. W J33 P03 FOR REV SW NC POS NO ACCELERATOR HI LOW SPEED SW P23 DIAGNOSTIC LED ACCEL POT Po ACC Y REAR 2 HEAD LIGHT SECOND POLE P2 BATT CHG INDICATOR ACCESSORY SOL FUSE 2 FUSE 1 MAIN SOL HORN SW B IGN NEG CONTACTS COIL COIL B TERM P27 8 OUT J03 J04 305 106 J08 J01 J01 J02 J09 22223 14 78 76 do B 1 1 1 1 1 1 1 1 1 1 1 7 2 a 2 zd PINK uj m x RED WHITE 9 o 5 ORANGE 03 SP02 01 ji WHITE ORANGE uj m 1 e 2 RED WHITE rs BLACK SP05 1 2 a 2
54. able to traction motor field F2 post When installing cables to controller torque screws at terminals B B M1 and M2 from 85 to 90 in Ib 9 6 to 10 2 N m and torque screws at terminals F1 and F2 from 55 to 60 in Ib 6 2 to 6 8 N m Fig 41 Apply Toro battery terminal protector see Special Tools to controller connections after tightening terminal screws If wire harness connector is removed from controller both harness connector and controller socket should be filled with dielectric gel to prevent corrosion of connec tion terminals and potential controller damage Apply gel fully to both harness connector and controller sock et plug harness connector into controller to distribute gel unplug harness connector reapply gel to both sur faces and plug harness connector into controller A LED exists on the controller to identify normal opera tion or faults that will prevent the vehicle from operating correctly The vehicle status light on the dash panel dis plays the same information as the LED on the controller See chart below for light pattern fault codes identified by the controller LED and vehicle status light Light Pattern Cause Always on not flashing NOTE Ifthe controller LED and vehicle status light are flashing attemptto resetthe controller by turning the on off switch to OFF waiting a few seconds and then turn ing the switch to ON If LED and status light continue flashing proceed with fault code identi
55. ake 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 5 Remove four 4 cap screws and flat washers secur ing the pivot yoke to the rear frame 6 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 7 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 Workman MDE Page 5 17 Pivot Yoke Installation Fig 9 and 10 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 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 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
56. argo box and remove controller cov Figure 27 er 1 Controller 2 Audio alarm 2 Disconnect wire harness connectors from alarm Fig 27 Using jumper wires correctly connect 12VDC source to the alarm terminals noting polarity shown on alarm decal 3 Alarm should sound Remove voltage source from the alarm Reconnect alarm to the circuit or replace alarm if needed Electrical System Page 3 18 Workman MDE Charger Interlock Switch The charger interlock switch is located behind the char ger receptacle plate on the front of the seat base Fig 28 When the battery charger is plugged into the char ger receptacle the interlock switch closes and provides an inputto the vehicle controller to inhibit vehicle opera tion NOTE The vehicle should not operate if the charger plug is connected to the charger receptacle 1 Make sure vehicle on off switch is OFF Remove key from switch 2 Remove receptacle plate from front of seat base 3 Locate charger interlock switch on rear of receptacle plate Disconnect harness connector from the switch o System 4 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals Figure 28 5 When the switch plunger is extended there should 1 Receptacle plate 3 Charger receptacle not be continuity between the switch terminals 2 Screw 4 used 4 Charger interlock switch 6 When the switch plunger is depr
57. axle and Brakes Page 4 4 Workman MDE Brakes continued L4 Ze 55 Workman MDE 4 5 Transaxle and Brakes Service and Repairs Rear Wheels and Brakes 125 to 140 ft Ib 170 to 190 N m 45 to 65 ft Ib 61 to 88 N m 26 to 30 ft Ib 34 to 41 N m N Figure 1 1 Lock nut 4 used per side 6 Wheel hub 11 Clevis pin 2 Cotter pin 7 Flange nut 12 Transaxle 3 Brake assembly LH shown 8 Parking brake cable 13 Brake drum 4 Socket head screw 4 used per side 9 Retaining ring 14 Rear wheel assembly 5 Wheel stud 5 used per side 10 Cotter pin 15 Lug nut 5 used per side Transaxle and Brakes 4 6 Workman Removal Fig 1 1 Park vehicle on a level surface turn on off switch OFF and remove key from the on off switch Before jacking up the vehicle review and follow Jacking Instructions in Operator s Manual and Chapter 1 Safety 2 Chock wheels not being jacked up Lift rear wheel off the ground using ajack and place appropriate jack stand beneath the rear frame to support vehicle NOTE To remove brake drum it may be necessary to loosen parking brake cable adjustment or remove park ing brake cable from brake actuator lever 3 Remove five 5 lug nuts wheel assembly and brake drum from the wheel hub 4 Remove cotter pin and flange nut that secure wheel hub item 7 to the transaxle shaft 5 Remove wheel hub from transaxle 6
58. b 28 to 33 N m 45 to 55 ft Ib 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 Chassis Loctite 242 75 to 100 ft Ib 102 to 135 N m Figure 7 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 5 14 45 to 65 ft Ib 62 to 88 N m See text for tightening procedure 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 MDE A arm Removal Fig 7 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off 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 offthe ground and support vehicle with appropriate jack stand beneath the frame 3 Remo
59. ck front wheel toe in see Adjust Front Wheel Toe in in this section Figure 2 1 1 Front wheel 2 90 square 3 Top measurement 4 Bottom measurement Figure 2 2 1 Shock absorber spring 2 Collar 3 Spring length Rev Chassis Adjust Front Wheel NOTE Before adjusting front wheel toe in make sure thatfront wheel camberis correctly adjusted see Adjust Front Wheel Camber in this section 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 camber procedure 3 On a level 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 Figure 2 3 1 Tire center line back 3 Axle center line 2 Tire center line front 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 of the tires Fig 2 3 Front wheel toe in should be from 0 to 1 4 inch 0 to 6 mm 6 Ifthefrontwheeltoe inis incorrect adjust as follows A Loosen jam nuts at both e
60. cle and engine quickly Additional copies ofthe Operator s Manual are available on the internet at www Toro com While Operating The Workman MDE is an off highway vehicle only It is not designed equipped or manufac tured for use on public streets roads or high ways 1 Siton the operator seat when starting and operating the vehicle 2 Before starting the vehicle A Make sure that the battery charger is discon nected from the vehicle charger receptacle B Engage the parking brake C Make sure accelerator pedal is not depressed D Check position of forward reverse switch and Hi Low speed switch Safety Page 1 2 To reduce the potential for injury or death comply with the following safety instructions 2 Keep all shields safety devices and decals in place If ashield safety device or decal is defective illegible or damaged repair or replace it before operating the ma chine Also tighten any loose nuts bolts or screws to en sure machine is in safe operating condition 3 Before getting off the operator seat A Stop vehicle turn on off switch OFF and remove key from switch B Apply the parking brake 4 If vehicle is parked on incline chock or block the wheels after getting off the vehicle Workman MDE Maintenance and Service 1 Before servicing or making adjustments to the ve hicle stop vehicle turn on off switch to OFF engage parking brake and remove key from the on off swi
61. controller also provides a roll off warning instances when the vehicle begins to move roll away after being stopped On an incline and with the on off switch in the ON position if the vehicle starts moving the alarm will sound warning the operator that the ve hicle is moving When the vehicle goes into this roll off mode regenerative braking will limit vehicle speed Vehicle accessories include headlights horn and op tional electrical equipment The accessories contactor solenoid on the vehicle provides battery current to these components when the on off switch is ON Fuses provide circuit protection for these accessories Workman MDE Special Tools Order special tools from your Toro Distributor Some tools may also be available from a local supplier Multimeter The multimeter can test electrical components and cir cuits 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 NOTE Workman MDE vehicles use a 48 volt DC elec trical system If multimeter is not ofthe auto range type make sure to properly set multimeter range before per forming any voltage test Figure 3 lt Sys
62. controller cover 2 Check accelerator switch adjustment and adjust if necessary see Accelerator Switch Adjustment in this Figure 16 tion 9 section 1 Controller 3 Ground post B 2 Gray controller lead 4 Controller LED s 3 Check accelerator potentiometer adjustment and ca adjust if necessary see Accelerator Potentiometer Ad justment in this section 4 Using a jumper wire connect gray controller lead to ground post B on controller Fig 16 NOTE During calibration the vehicle status light on the dash should flash the same as the controller LED 5 Turn on off switch ON The alarm should sound and the controller LED should flash six 6 times 6 Slowly depress accelerator pedal until the alarm mo mentarily stops and hold pedal in position This should take a very small movement ofthe pedal Once alarm re sumes release accelerator pedal completely 7 Depress and hold accelerator pedal fully Alarm will momentarily stop while controller calibration occurs Hold pedal fully depressed until alarm resumes andthen release pedal 8 Ifcalibration process was successful alarm will chirp and diagnostic light onthe dash will be lit continuous not flashing If alarm continues to sound or if diagnostic light is flashing turn on off switch OFF and repeat steps 5 6 and 7 9 Turn on off switch OFF and remove key Disconnect jumper wire from gray controller lead and controller groun
63. correctly attached Vehicle charger receptacle polarity is reversed Battery charger is faulty Overloaded AC circuit Battery charger is faulty Workman MDE Adjustments Accelerator Switch Adjustment 1 Position vehicle on a level surface turn on off switch OFF and remove key 2 With the accelerator pedal released check that the distance between the head of the accelerator switch stop cap screw and the body of the switch is 5 8 inch 15 9 mm Fig 12 3 Ifdistance is incorrect loosen lock nut and adjust ac celerator switch stop cap screw position Fig 11 4 After adjustment make sure that switch plunger is not bottomed out when accelerator pedal is released 5 Calibrate accelerator system after adjusting acceler ator switch see Accelerator System Calibration in this section Workman MDE Page 3 11 Figure 10 1 Accelerator pedal 4 Screw 2 used 2 Accelerator switch 5 Switch stop cap screw 3 Plate 6 Locknut Figure 11 1 Accelerator switch 2 Switch stop cap screw 3 Accelerator stop cap screw 5 8 inch 15 9 mm Figure 12 1 Switch stop cap screw 2 Accelerator switch Electrical System 2 Em System Accelerator Potentiometer Adjustment Potentiometer with Short Lever NOTE The following adjustment procedure should be used on vehicles that have a potentiometer that includes a short lever Figure 14 If potentio
64. cuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of Chapter 3 Electrical System 3 Remove hood using Figure 13 as a guide Installation Fig 13 NOTE Do nottighten fasteners securing the hood until Figure 14 all fasteners are in place 1 Negative cable to vehicle 2 Positive cable to vehicle 1 Install hood using Figure 13 as a guide During as sembly use fastener torque specifications that are iden tified in Figure 13 2 Reconnect removed battery cable to battery termi nals Install lock washer and nut on battery terminals Torque nuts from 115 to 125 in Ib 13 0 to 14 1 N m Workman MDE Page 5 21 Chassis Cargo Box Serial Number Below 311000000 35to055in IDb 4 to 6 2 N m Cargo box Striker plate 2 used Screw 3 per striker plate Tailgate channel RH latch rod RH latch bracket Grip knob Tailgate LH latch rod 10 Screw 2 per bracket 11 LH latch bracket ooxon0BRONZ Chassis 35 to 55 in Ib 4 to 6 2 N m Figure 18 Screw 2 per bracket Spring Flat washer Flange head screw 2 per bracket Pivot bracket 2 used Flange head screw 6 used Box brace 3 used Flange head screw 5 per brace LH pivot bracket Flange head screw 2 per bracket Flange head screw 2 used Page5 22 Rev A 100 to 200 in Ib 11 3 to 22 6 N
65. d 17 Latch assembly 6 Pivot bracket 12 Flange nut 6 used Chassis 5 24 Rev A Workman Removal Fig 19 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 19 and 20 as guides Installation Fig 19 1 Assemble cargo box using Figures 19 and 20 as gui des A When installing cargo box use torque specifica tions identified in Figure 19 B Adjust latch pin item 13 in Figure 19 so that car go box is tight to frame when latched Cargo box Inner tailgate Outer tailgate RH latch rod Latch handle Screw 24 used Workman MDE Page 5 25 Rev Figure 20 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 page is intentionally blank Chassis Page5 26 Rev A Workman MDE Chapter 6 TORO Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC Electrical Schematic 3 ELECTRICAL CIRCUIT DRAWINGS On Off Switch Turned 4 Run Circuit Forward 5 Battery Charging 6 ELECTRICAL HARNESS DRAWINGS Electrical Harness Drawing Serial Number Below 310000000 8 Electrical Harness Wiring Diagram Serial Number Below 310000000
66. d Brakes 2 x o o o x a Hydraulic Brake System 30 4 Loctite 242 Figure 5 1 Brake caliper LH 14 Rear brake tube RH 26 Tube clamp 2 used 2 Brake caliper RH 15 Rear brake tube LH 27 R Clamp 3 Brake rotor 2 used 16 Insulated clip 5 used 28 Cap screw 2 per caliper used 4 Front brake tube 17 Cap screw 2 used 29 Lock washer 2 per caliper used 5 Front brake hose 18 Flange nut 2 used 30 Socket head screw 4 per rotor used 6 Carriage screw 19 Clevis pin 31 Washer head screw 2 used 7 Rear brake tube 20 Cotter pin 32 Lock nut 8 Carriage screw 21 Master cylinder 33 Cap screw 9 Rear brake hose bracket 22 Union fitting 34 Lock nut 10 Cap screw 23 Rear brake tube 35 Rear brake RH 11 Thread forming screw 6 used 24 Rear brake hose 36 Rear brake LH 12 Clip 25 Hose bracket 2 used 37 Wheel hub assembly 2 used 13 Tee fitting When performing service work on the Workman MDE hydraulic brake system make sure to thoroughly clean components before disassembly Use Figure 5 as a guide for removal and installation of hydraulic brake components Transaxle and Brakes Page 4 12 Workman MDE Bleed Brake System 1 Connecta suitable transparent hoseto bleeder valve on a wheel cylinder or caliper Submerge other end of hose in a glass container partially filled with clean brake fluid 2 Have a second person pump brake pedal s
67. d post B 10 Install controller cover and lower box 11 If vehicle operation continues to be erratic after com pleting the accelerator system calibration procedure evaluate the components in the accelerator system ac celerator switch accelerator potentiometer accelerator pedal circuit wiring and controller Workman MDE Page 3 13 Electrical System Component Testing For accurate resistance and or continuity checks elec trically disconnect the component being tested from the circuit e g disconnect the harness wire connectors from the vehicle on off switch before doing a continuity check on the on off switch On Off Switch The Workman on off switch is located on the dash panel Fig 17 The switch has two 2 positions OFF and ON and three 3 switch terminals Only two of the terminals are used on the Workman MDE The switch terminals are positioned as shown in Figure 18 Testing When testing the on off switch for continuity with a multimeter ohms setting make sure that power to the circuit has been disconnected When the on off switch is in the OFF position no conti nuity should exist between the common center switch terminal and the switched side terminal In the ON position continuity should exist between the common center switch terminal and the switched side termi nal Electrical System Page 3 14 When testing electrical components for continu ity with a multimeter ohms setti
68. de 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 N m Install steering wheel cover to wheel 11 Lower front hood 12 Checkfront wheel alignment and adjust if necessary 13 Make sure that front wheels move fully in both direc tions without contacting any front end components Chassis Steering Gearbox 27 to 33 ft Ib 37 to 44 N m 90 to 110 in Ib 10 2 to 12 4 N m Figure 2 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 Page5 8 175 to 225 in Ib 20 to 25 N m 14 15 16 17 18 19 Lube fitting Steering housing cover Steering housing Pinion gear Cil seal Pitman arm Workman MDE Disassembly Fig 2 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
69. 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 Follow all instructions and comply with all safety messages on the electrolyte container 1 Check for cracks in battery case caused by overly tight or loose hold down retainer Replace any battery that is cracked and or leaking 2 Check battery terminal posts for corrosion Use a ter minal brush to clean corrosion from the battery terminal posts IMPORTANT Before cleaning the battery make sure the filler caps are on tightly Electrical System Page 3 30 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 4 Checkthe battery case for dirt and oil Clean the bat tery with a solution of baking soda and water then rinse battery with clean water 5 Checkthatthe battery cover seal is not broken away Replace the battery if the seal is broken or leaking IMPORTANT Make sure the area around the battery filler caps is clean before opening the caps IMPORTANT Do not add acid to the battery Use only distilled water to adjust the electrolyte level 6 Checkthe electrol
70. e and respiratory protection 6 Carefully blow out any accumulated carbon dust and dirt from the commutator end head and the frame and field assembly using clean oil free compressed air Workman MDE Brush Service 1 Checkthe brush springs for correct alignment on the back of the brush A brush spring that does not apply equal pressure on the center of the brush will cause the brush to wear unevenly Check for correct clearance and freedom of brush movement in the holder 2 Replace brushes that are worn to a length of 0 620 16 mm Also replace brushes ifthey show signs of un even wear or show signs of overheating such as discol ored brush shunts and brush springs 3 Brushes should always be replaced in complete sets of eight Use identical replacement parts do not substi tute brush grades as the brushes are matched to the motor type and application to provide the best service Substituting brushes ofthe wrong grade can cause pre mature commutator failure and excessive brush wear Remove old brushes and replace with identical replace ment parts Hold brush shunts in position and torque brush screws from 18 to 22 in Ibs 2 0 to 2 5 N m Fig 59 Make sure brushes move freely in the holders and thatshunts do not interfere with brush spring movement 4 Make sure the brush box assembly is tight on the commutator end head Replace brush box assemblies in the commutator end head if they are physically dam aged or brush
71. e 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 Placea90 square onthe ground with the vertical edge touching the face of the tire Fig 2 1 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 ofthe 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 of the shock spring Fig 2 2 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 length of the shock spring C Lower vehicle to level surface Workman MDE Page 5 4 1 7 Repeat steps 2 through 6 until front wheel camber both wheels is correct 8 After camber adjustment che
72. e terminals for the light are marked as shown in Figure 25 Correctly connect 12 VDC source to the light terminals Figure 25 4 Lightshould illuminate Remove voltage source from the light and reconnect wire harness Replace status light if needed Workman MDE Page 3 17 Electrical System Supervisor Speed Limit Switch The supervisor speed limit switch is open in OFF posi tion key vertical and closed in ON position key rotated clockwise The speed limit switch is one of several in puts forthe vehicle controller and allows the speed ofthe vehicle to be limited Testthe switch by disconnecting the wiring and connect ing a continuity tester across switch terminals A and D Fig 26 Rotate key to ON position there should be an indication of continuity Rotate key to OFF position there should be no continuity Audio Alarm Reverse The audio alarm sounds when the direction forward re verse switch is placed in the reverse position The alarm is located under the controller cover beneath the cargo box Testing IMPORTANT Make sure to observe polarity on the alarm terminals when testing Damage to the alarm may result from an improper connection IMPORTANT The audio alarm is a 12 volt DC com ponent Do not test the alarm using jumper wires from the vehicle battery pack 48 VDC 1 Make sure on off switch is turned OFF Remove key from switch Raise c
73. e 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 screws and secure ro tor to hub Chassis Page 5 12 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 Lubricate tie rod ball joints and king pin 13 Align steering and toe in 14 Make sure that front wheels move fully in both direc tions without contacting any front end components TIE ROD TUBE Figure 6 1 Tie rod groove 3 RHthreads 2 LHthreads Workman MDE Front Shock Absorbers Shock Removal Fig 9 IMPORTANT Any adjustment to the shock spring preload will affect the front wheel camber see Ad just Front Wheel Cambe
74. e with six 6 socket head screws item 1 and flat washers item 2 Torque screws from 125 to 165 in Ib 14 2 to 18 6 N m IMPORTANT When connecting wires to motor ter minals A1 A2 F1 and F2 use a wrench to retain lower nut while tightening upper nut Fig 52 If ter minal studs are allowed to turn during upper nut installation internal motor damage can occur 6 Connect wires to traction motor Fig 51 A Make sure that fasteners and cable connectors are properly positioned on motor terminals Fig 55 B Install correct cable connector and nut to motor terminals A1 and A2 While retaining lower nut torque upper nut on terminals A1 and A2 from 85 to 90 in Ib 9 6 to 10 2 N m C Install correct wire connector and nutto motorter minals F1 and F2 While retaining lower nut torque upper nut on terminals F1 and F2 from 55 to 60 in Ib 6 2 to 6 8 N m D Plug motor temperature sensor connector into vehicle wire harness 7 Position fan to traction motor and secure with socket head screw and washer Install plastic plug in hole in rear frame 8 Carefully connect removed battery cable to battery terminals Install lock washers and nuts on battery termi nals Torque nuts from 115 to 125 in Ib 13 0 to 14 1 N m 9 Install cargo box to the rear frame see Cargo Box Installation in Service and Repairs section of Chapter 5 Chassis Electrical System Page 3 36 1 Transaxle 2 Screw washer 6 used
75. eased the switch provides an open circuit no input for the controller to prevent trac tion motor operation Testing 1 Park vehicle on a level surface turn on off switch OFF and remove key from switch 2 Locate accelerator switch on pedal frame under dashboard of vehicle 3 Unplug wiring harness connector from accelerator 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 5 When reconnecting wiring harness connector to switch after testing harness connector and switch ter minal area should be filled with dielectric gel see Spe cial Tools to prevent corrosion of connection terminals Apply gel fully to both harness connector and switch ter minal area plug harness connector into switch to distrib ute gel unplug harness connector reapply gel to both surfaces and replug harness connector into switch 6 If switch replacement is needed see Accelerator Switch Adjustment procedure in the Adjustments sec tion of this chapter Electrical System Page 3 24 Figure 37 4 Screw 2 used 5 Stop screw 6 Locknut 1 Accelerator pedal 2 Accelerator switch 3 Plate ili END VIEW I of SIDE VIEW gt Uf
76. eeve is positioned into the pivot hub of the A arm Sleeve 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 C Install brake hose clip onto cap screw Secure spindle to A arm hub with cap screw and lock nut Torque fasteners from 75 to 100 ft Ib 102 to 135 N m 2 Install tie rod A Position tie rod assembly to spindle and pitman arm so that tie rod groove LH threads is orientated toward the left side of the machine Fig 6 B Inserttie rod ball joints down through the spindle and up through the Pitman arm Secure with castle nuts C 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 4 A If 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 ofthe 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 Lubricat
77. em 2 Em o System Traction Motor 115 to 125 in Ib 13 0 to 14 1 N m 125 to 165 in Ib 14 2 to 18 6 N m Pd Figure 50 1 Socket head screw 6 used 8 Traction motor 14 Cable terminal boot 2 Flat washer 6 used 9 Fan 15 Hex nut 3 Flange nut 10 Roll pin 2 used 16 Lock washer 4 Support bracket 11 Washer 17 Positive battery cable 5 Carriage screw 12 Socket head screw 18 Cable terminal boot 6 Transaxle mount plate 13 Plastic cap fits in rear frame 19 Negative battery cable 7 Rubber damper Removal Fig 50 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from switch 2 Remove cargo box from vehicle see Cargo Box Re moval in Service and Repairs section of Chapter 5 Chassis 3 Openthe battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of this chapter Electrical System Page 3 34 NOTE Label all electrical leads for assembly pur poses IMPORTANT When removing wires from motor ter minals A1 A2 F1 and F2 use a wrench to retain lower nut while loosening upper nut Fig 52 If ter minal studs are allowed to turn during upper nut re moval internal motor damage can occur Workman MDE 4 Disconnect wires from traction motor Fig 51 A While retaining lower nut remove upper nut and wire connector from motor terminals A
78. emove retaining ring that secures each parking 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 parking brake support to seat base 6 Carefully remove parking brake support and brake cables from machine Take care to not damage brake cables while removing them from seat base opening 7 Remove brake cables from parking brake support and cable equalizer bracket using Figure 10 as a guide Workman MDE Page 4 19 Assembly Fig 10 1 Secure brake cables to parking brake support and cable equalizer bracket using Figure 10 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 cablesto rear brake assemblies using cable routing noted during disassembly 5 Secure brake cables to rear of machine A Secure each R clamp to rear frame with screw and flange nut B Secure each parking brake cable to frame with retaining ring C Secure each parking brake cable end to brake le ver with clevis pin and cotter pin 6 Check parking brake operation and adjust if neces sary Transaxle and Brakes L4 52 55 cm T
79. er lock switch on the vehicle charger receptacle prevents the vehicle from operating when the charger cord is plugged into the vehicle The electric traction motor directly drives a double re duction transaxle with differential Operator inputs for forward reverse supervisor switch position high or low speed and accelerator pedal position are used by the controller to determine voltage to the traction motor The traction motor is cooled with an external fan Addi tionally the motor is protected from overheating by a thermal switch in the motor housing If unsafe motor temperature is sensed by the switch the controller is signaledto limit vehicle speed and torque until the motor temperature reduces to a normal level Electrical System Page3 4 The vehicle controller is a sealed electronic logic device that uses inputs from several vehicle components to control motor speed and direction These inputs include several switches on off forward reverse accelerator supervisor charger a motor temperature sensor an accelerator pedal potentiometer and the vehicle contac tor solenoid The controller also provides regenerative braking to assist in slowing the vehicle The controller has fault detection capabilities to help identify system problems Battery current is available to the controller whenever the on off switch is ON which energizes the main contactor A high current fuse protects this high current circuit The Workman
80. ere are several safety and instruction decals attached to your Workman vehicle If any decal becomes illegible or damaged install a new decal Part numbers are listed in the Parts Catalog Order replacement decals from your Authorized Toro Distributor Workman MDE Page 1 5 Safety This page is intentionally blank Safety Page 1 6 Workman MDE Chapter 2 TORO Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 55 MAINTENANCE c t oe eb etes ua 1 88 EQUIVALENTS AND CONVERSIONS 2 os Decimal and Millimeter Equivalents 2 32 U S to Metric Conversions 2 E E 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 vehicle at the end of this chapter Additionally if any optional equipment or accessories have been installed to your Workman insert the Installation In structions Operator s Manuals and Parts Catalogs for those options at the end of this chapter Maintenance Maintenance procedures and recommended service in tervals
81. ery Charger Problems 10 Traction Motor Brushes ADJUSTMENTS 11 Traction Motor ui Accelerator Switch Adjustment 11 Traction Motor Service Accelerator Potentiometer Adjustment Battery Charger Potentiometer with Short Lever 12 LESTER ELECTRICAL TECHNICIAN Accelerator Potentiometer Adjustment SERVICE GUIDE Potentiometer with Long Lever 12 1 Accelerator System Calibration 13 COMPONENT TESTING 14 On Off 14 Battery Discharge Indicator and Hour Meter 15 Vehicle Direction Forward Reverse and Headlight Switches 16 Vehicle Status Light 17 Supervisor Speed Limit Switch 18 Audio Alarm Reverse 18 Charger Interlock Switch 19 Main and Accessories Contactors 20 FUSES xui diet vat Mode e ei dut S 22 Fusible Links 23 Accelerator Switch 24 Accelerator Potentiometer 25 Controller na inima tcn hc Row 26 Workman MDE Page3 1 Rev Electrical System General Information The Workman MDE uses a 48 volt DC electrical system that is an isolated circuit The vehicle
82. essed there should be continuity between the switch terminals 7 Replace switch if needed 8 Reconnect harness connector to switch Install re ceptacle plate to front of seat base Figure 29 1 Charger interlock switch 5 Locknut 2 used 2 Switch plate 6 Socket head screw 3 Charger receptacle 7 Mount bracket 4 Rivet 2 used Workman MDE Page 3 19 Electrical System Main and Accessories Contactors Two contactors solenoids are used on the Workman MDE for circuit control The main contactor provides current to the vehicle con troller and is energized when the on off switch is ON The main contactor is located under the controller cover beneath the cargo box Fig 30 The accessories contactor provides currentto the head lights horn and optional electrical accessories The ac cessories contactor is energized when the on off switch is ON The accessories contactor is located beneath the dash panel 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 that is due to the internal resistance of the meter and test leads Subtract this value from the measured value of the component you are testing 1 Make sure on off switch is turned OFF Openthe bat tery circuit by removing one of the battery cables see Opening Battery Circuit in the General Information sec tion of t
83. everal times then hold pedal down firmly 3 With pedal firmly depressed open bleeder valve un til pedal fades to floor Close bleeder valve before re leasing 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 MDE Page 4 13 5 Repeatsteps 1 to 4 for other brake cylinders and cali pers After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 6 After bleeding of brakes is completed test vehicle to make sure brakes are operating correctly and brake pedal is solid Transaxle and Brakes 2 x o S o x m Front Brake Calipers To rear brakes ae Loctite 242 45 to 65 ft Ib 61 to 88 N m Figure 6 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 Transaxle and Brakes Page 4 14 Workman MDE Removal Fig 6 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
84. fication and nec essary action Figure 40 1 Controller 3 Wire harness connector 2 Controller LED 85 90 in Ib 9 6 10 2 N m 55 to 60 in Ib 6 2 to 6 8 N m Figure 41 Necessary Action Always off System inoperable Check for low battery voltage faulty fuse s loose battery cable connections damaged battery cables and or faulty main contactor If batteries cables and other electrical components are in good condition controller replacement may be necessary Electrical System Workman MDE Page 3 26 1 Flash System inoperable Turn on off switch OFF wait several seconds and turn on off switch ON If controller does not reset correctly controller replacement may be necessary 2 Flashes The accelerator pedal was Turn on off switch OFF release accelerator pedal and depressed when on off turn on off switch to ON Switch was turned ON If controller does not reset correctly accelerator switch adjustment may be necessary or switch may be faulty 3 Flashes System inoperable Turn on off switch OFF wait several seconds and turn on off switch ON If controller does not reset check battery pack voltage and all battery cable connections Also check main contactor wire and cable connections and main contactor NOTE If main contactor audibly clicks when on off switch is turned ON problem is most likely a faulty wire or cable connection Controller replacement may be
85. for the Workman MDE are covered in the Opera tor s Manual Refer to that publication when performing regular vehicle maintenance Workman MDE Page 2 1 Product Records and Maintenance Decimal and 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
86. guide for reattaching cable and wire harness connec tions 8 Connect battery cable that was removed from bat tery pack Figure 33 1 Main contactor 5 Wire harness connector 5 2 Cable to controller 6 Fuse F1 LU o 3 Lock nut 7 Positive battery cable 4 Flat washer 8 Isolator Workman MDE Page 3 21 Electrical System Fuses There are three 3 fuses in the Workman electrical sys tem Two 2 of the fuses are located beneath the steering column Fig 34 These fuses supply power to the fol lowing The upper 10 ampere fuse F2 supplies power to the on off switch and switched circuits The lower 10 ampere fuse supplies power to op tional accessories The third fuse F1 is located under the controller cover beneath the cargo box Fig 35 This fuse is rated at 355 amperes continuous and allows current flow between the batteries and the vehicle If this fuse has failed ve hicle operation will not occur Testing Whentesting fuses for continuity with a multime ter ohms setting make sure that fuse is re moved from circuit IMPORTANT Before removing fuse F1 355 Amp fortesting open the battery circuit by removing one of the battery cables see Opening Battery Circuit in the General Information section of this chapter Make sure on off switch is turned OFF Remove fuse to check continuity The test meter should read less than 1 ohm If fuse F1 was removed torq
87. he battery supports are clean and re painted if necessary Make sure cables terminals rods and hold down retainers are in good condition IMPORTANT When installing batteries into vehicle do not lift batteries using battery terminals as lift points battery damage may occur 3 Using case loops on battery tops as lifting points set batteries on the battery supports with battery posts properly orientated Fig 44 Make sure that battery rods are positioned to allow installation of retainers 4 Install two 2 battery retainers and nuts to secure batteries to vehicle Fig 43 Torque nuts from 115 to 125 in Ib 13 0 to 14 1 N m 5 Install all but one of the battery cables used to con nect battery pack including the positive red cable and negative black cable from vehicle Figures 42 and 44 Make sure that cables are connected to correct battery terminal noting battery polarity Install lock washer and nut on each battery terminal Torque nuts from 115 to 125 in Ib 13 0 to 14 1 N m to secure cables 6 Connect final battery cable to battery terminals Install lock washer and nut on battery terminals Torque nuts from 115 to 125 in Ib 13 0 to 14 1 N m 7 Apply Toro battery terminal protector see Special Tools to all battery posts and cable connectors to re duce corrosion after connections are made Make sure that terminal boots are positioned over all connections 8 Lower and secure cargo box Figure 43 1
88. he vehicle connect the charger cord to the vehicle charger recep tacle before plugging the charger power cord into an outlet After charging the vehicle batteries unplug the charger power cord from the outlet before disconnecting the charger cord from the vehicle charger receptacle 12 If major repairs are ever needed or assistance is de sired contact an Authorized Toro Distributor 13 To assure optimum performance and continued safety of the machine 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 14 When raising the machine to change tires or to per form other service use correct blocks hoists and jacks Make sure machine is parked on a solid level surface such asa concrete floor Priorto raising the machine re move any attachments that may interfere with the safe and proper raising of the machine Always chock or block wheels Use jack stands to support the raised ma chine If the machine is not properly supported by jack stands the machine may move or fall which may result in personal injury see Jacking Instructions inthe Opera tor s Manual and in this Chapter Safety Jacking and Other Instructions Jacking Vehicle POTENTIAL HAZARD A vehicle that is not properly supported may become unstable WHAT CAN HAPPEN The vehicle may move or fall Personal inju
89. his chapter and Fig 31 2 Locate contactor that is to be tested Disconnect all vehicle harness electrical connections from contactor Note wire connector locations on contactor for reas sembly purposes 3 Using jumper wires apply 48 VDC directly across the contactor coil posts Fig 32 The contactor should click With the contactor coil energized resistance across the main contact posts should be less than 1 ohm 4 Remove voltage from contactor coil posts The con tactor should click With the contactor coil not energized resistance across the main contact posts should be infi nite ohms 5 Measure resistance across the contactor coil posts Fig 32 A For the main contactor the resistance should be approximately 126 ohms B For the accessories contactor the resistance should be approximately 200 ohms Electrical System Page 3 20 Figure 30 4 Fuse F1 5 Positive battery cable 1 Main contactor 2 Cable to controller 3 Wire harness connector 6 Isolator Figure 31 1 Negative cable to vehicle 2 Positive cable to vehicle Figure 32 3 Main contact posts 4 Contactor coil posts 1 Main contactor 2 Accessories contactor Workman MDE 6 Replace contactor if necessary 45 to 50 in Ib Ie 5 1 to 5 6 N m 3 7 Connect electrical connections to contactor If main contactor connections were removed use Figure 33 as a
90. inalsto short against metal parts of the vehicle Do notallow metal tools or metal vehicle parts to short between the battery terminals or battery cables Always keep the battery retainers in place to protect and secure the batteries IMPORTANT Be careful to not damage terminal posts or cable connectors when removing the bat tery cables 1 Position vehicle on a level surface set parking brake turn on off switch OFF and remove key 2 Raise cargo box and secure with prop rod 3 Openthe battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of this chapter 4 Once initial cable has been removed from vehicle disconnect and remove remaining battery cables from all battery terminals 5 Remove flange nuts item 11 and battery retainers item 10 used to secure batteries to vehicle Fig 43 6 Make sure that all battery filler caps are on tightly IMPORTANT When removing batteries from ve hicle do not lift batteries using battery terminals as lift points battery damage may occur 7 Using case loops on battery tops as lifting points re move batteries from vehicle Battery Installation Fig 42 IMPORTANT To prevent possible electrical prob lems install only fully charged batteries 1 Make sure vehicle on off switch and all accessories are OFF Raise cargo box and secure with prop rod Workman MDE Page 3 29 2 Make sure t
91. ing new pads B Slide brake pads into caliper Make sure that fric tion material on pads is toward brake rotor position C Secure pads into caliper with two 2 pins Make sure that pins snap into caliper slots Install anti rattle clip to caliper pin and brake pads 2 Slide brake caliper onto brake rotor Make sure that rotor is between brake pads 3 Align caliper mounting holes with spindle Secure caliper with two 2 cap screws and lock washers 4 Install brake hose to caliper 5 Install front wheel assembly 6 Lower machineto ground Torque lug nuts in a cross ing pattern from 45 to 65 ft Ib 61 to 88 N m 7 Bleed brakes see Bleed Brake System in this sec tion After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 8 Check brake operation Figure 7 1 Brake pad 2 Pin 2 used 3 Anti rattle clip Transaxle and Brakes 5 2 x A o o x a Brake Master Cylinder Figure 8 4 Clevis pin 5 Cotter pin 1 Master cylinder 2 screw 3 Brake pedal Removal Fig 8 1 Raise and support front hood 2 Remove cotter pin from the clevis pin that connects master cylinder to brake pedal 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
92. ke sure their alignment matches the 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 in Figure 2 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 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 nu
93. l switch while motor is removed 9 Locate and retrieve rubber damper from motor shaft internal spline 10 If needed remove two 2 roll pins from motor shaft Installation Fig 50 1 If removed install two 2 roll pins into motor shaft Workman MDE Page 3 35 2 Make sure that rubber damper is installed into the motor shaft internal spline with the damper flat side to ward the motor Fig 51 85 to 90 in Ib 9 6 to 10 2 N m 55 to 60 in Ib i a a 6 2 to 6 8 N m 55 to 60 in Ib 6 2 to 6 8 N m Figure 51 3 Rubber damper 4 Transaxle input shaft 1 Thermal switch 2 Motor shaft spline Figure 52 1 Loosening tightening wrench upper nut 2 Retaining wrench lower nut Figure 53 2 Jamnut 1 Eyebolt Electrical System System 3 Apply antiseize lubricant or axle grease to the splines of the transaxle and motor shafts Apply grease to lip of seal in transaxle bore To prevent motor damage and personal injury make sure that traction motor is well sup ported as itis installed Motor weighs approxi mately 62 pounds 28 1 kg 4 Carefully lower motor into vehicle Align motor shaft with transaxle input shaft and slide motor to transaxle Take care to not damage thermal switch while installing motor 5 Align mounting holes of motor transaxle and trans axle mount plate Secure motor to transaxl
94. le Slide wheel hub with bearings and brake rotor from spindle 8 Disassemble the wheel hub Fig 4 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 5 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 MDE Loctite 242 Figure 4 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 EXT 75 to 100 ft lb 102 to 135 N m Figure 5 1 screw 2 Brake hose clip 3 A arm LH shown 4 Kingpin sleeve 5 Thrust washer 6 Locknut Installation Fig 3 1 Page 5 11 Install spindle as follows Fig 5 A Make sure king pin sl
95. ll the headband on the motor 8 Make sure that lower nuts are properly tightened on traction motor terminals Fig 62 and 63 Lower nuts on F1andF2terminals should be torqued from 50 to 60 in Ib 5 7 to 6 8 N m Lower nuts on A1 and A2 terminals should be torqued from 110 to 140 in Ib 12 4 to 15 8 N m PRESS FIXTURE MUST PRESS AGAINST oye OUTER RACE BEARING END HEAD MUST BE HELD STATIONARY 1 Terminal 2 Lower nut 3 Flat washer 1 A2terminal 2 F2terminal Workman MDE Page 3 41 ARMATURE ASSEMBLY BEARING AND RETAINING RING INSTALLED IN END HEAD PRESS FIXTURE MUST HOLD INNER RACE STATIONARY Figure 61 Figure 62 4 Insulating washer 5 Motor housing Figure 63 3 F1terminal 4 1 terminal Electrical System 2 Em o System Battery Charger Figure 64 1 Upper case 5 Control board 9 cordset 2 Transformer 6 10 Ammeter 3 Lower case 7 Circuit breaker 11 Fuse 4 SCRassembly 8 cordset 12 Diode assembly For service ofthe battery charger see the Lester Electri cal Technician Service Guide at the end of this chapter Electrical System Page 3 42 Workman MDE Chapter 4 TORO Transaxle and Brakes Table of Contents GENERAL INFORMATION 2 Operator s Manual 2 SPECIFICATIONS 3 TROUBLESHOOTING
96. m Prop rod bracket Flat washer Push nut Latch pin 2 used Lock nut 2 used Carriage screw 2 used Rear frame RH pivot bracket Flange head screw 4 used Tension spring Latch rod Workman MDE Removal Fig 18 Installation Fig 18 1 Park vehicle on a level surface turn on off switch 1 Assemble cargo box using Figure 18 as a guide OFF set parking brake and remove key from the on off Switch 2 Position cargo box to the frame locking the latch rod item 33 to the latch pins item 26 2 Remove two 2 flange head screws item 21 that secure RH and LH pivot brackets items 20 and 30 to 3 Secure both pivot brackets items 20 and 30 to the the rear frame rear frame with flange head screws item 21 3 Release latch rod item 33 from the latch pins item 26 Remove cargo box from the frame Disassemble cargo box as necessary using Figure 18 as a guide Workman MDE 5 23 Rev Chassis Cargo Box Serial Number Above 311000000 200 to 210 in Ib 22 6 to 23 7 N m 200 to 210 in Ib 22 6 to 23 7 N m 200 to 210 in Ib 22 6 to 23 7 N m Figure 19 1 Cargo box 7 Pivot bushing 2 used 13 Latch pin 2 used 2 Handle 8 Screw 4 used 14 Tension spring 2 used 3 Carriage screw 2 used 9 Carriage screw 4 used 15 Carriage screw 2 used 4 Locknut 2 used 10 Flange nut 4 used 16 Prop rod bracket 5 Carriage screw 4 used 11 Prop ro
97. meter has a long le ver use the procedure on the following page The accelerator potentiometer is used as one of the in puts for the vehicle controller and is attached to the ped al frame under the dash Fig 13 A collar with roll pin on the accelerator pedal shaft positions the accelerator po tentiometer lever Potentiometers with a short lever use a roll pin that extends approximately 1 1 2 inches 38 mm out of the collar Ifthe accelerator potentiometer is out of adjustment the diagnostic light on the dash will flash six 6 times Addi tionally if vehicle movement is erratic and jerky poten tiometer adjustment and calibration of the accelerator system should be performed Adjustment 1 Position vehicle on a level surface turn on off switch OFF and remove key Make sure that accelerator poten tiometer is securely attached to the pedal frame of the machine 2 Check accelerator switch adjustment and adjust if necessary see Accelerator Switch Adjustment in this section 3 Check movement of the potentiometer lever A With the accelerator pedal released the roll pin on the throttle position collar should keep the poten tiometer lever from 0 050 to 0 100 1 3 to 2 5 mm from the lower stop on the potentiometer body Fig ure 14 B Withthe accelerator pedal fully depressed the in put lever of the potentiometer should not contact the upper stop on the potentiometer body Figure 15 4 If potentiometer le
98. meter is used as one of the in puts forthe vehicle controller and is attached to the ped al frame under the dash Fig 15 2 A collar with roll pin attached to the accelerator pedal shaft positions the ac celerator potentiometer lever Potentiometers with a long lever use a roll pin that extends approximately 3 inches 76 mm out of the collar If the accelerator potentiometer is out of adjustment the diagnostic light on the dash will flash six 6 times Addi tionally if vehicle movement is erratic and jerky poten tiometer adjustment and calibration of the accelerator system should be performed Adjustment 1 Position vehicle on a level surface turn on off switch OFF and remove key Make sure that accelerator poten tiometer assembly is securely attached to the pedal frame of the machine 2 Check accelerator switch adjustment and adjust if necessary see Accelerator Switch Adjustment in this section With the accelerator pedal released inspect location ofroll pin onthrottle position collar and potentiometer le ver The roll pin should just contact the potentiometer le ver without rotating the lever Figure 15 2 4 If necessary adjust location of collar on accelerator pedal shaft so that roll pin is properly positioned A Loosen two 2 set screws that secure throttle position collar to throttle pedal shaft and reposition collar so that roll pin on the throttle position collar just contacts the potentiometer le
99. minals A1 A2 F1 and F2 B Unplug motor temperature sensor from vehicle wire harness C Position disconnected cables away from motor Before jacking up the vehicle review and follow Jacking Instructions in Operator s Manual and in Chapter 1 Safety 5 Jack up rear of vehicle 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 rear frame with jack stands positioned just in front of the axle tubes This will allow thetransaxleto be removed from the rear of the vehicle 6 Remove rear wheels from vehicle 7 Remove cotter pins and clevis pins that secure park ing brake cables to brake actuator levers Fig 13 Posi tion brake cables away from transaxle assembly Workman MDE Page 4 21 8 Clean hydraulic brake line area of rear brake cylin ders to prevent contamination Loosen and disconnect hydraulic brake line from both wheel cylinders Plug brake lines and position them away from wheel cylin ders 9 Attach hoist to the transaxle and motor assembly Make sure lifting device is attached so it can hold the full weight of the transaxle and traction motor 10 Loosen and remove two 2 flange nuts and carriage screws that secure transaxle mount plate item 5 to support bracket item 4 Fig 14 11 Remove four 4 flange head screws and flange nuts securing the transaxle to the rear frame 12 Carefully lower
100. nds of tie rods Fig 2 4 B Rotate both tie rods to move front oftire inward or outward C Tighten tie rod jam nuts when toe in adjustment Figure 2 4 is correct 1 Jam nut 2 Tie rod 7 Ensure that there is full steering travel in both direc tions Chassis 5 4 2 Rev A Workman Service and Repairs Check Tire Pressure The tire pressure range for front and rear tires is 8 to 22 PSI 55 to 152 kPa The tire pressure needed is deter mined by the payload carried Lower air pressure will provide less compaction a smoother ride and fewer tire marks Lower pressure should not be used for heavy payloads at higher speeds Inspect Tires and Wheels Operating accidents such as hitting curbs can damage atire or rim and also disrupt wheel alignment so inspect wheel condition tire and rim and wheel alignment toe in after any accident Check wheels to ensure they are mounted securely Torque wheel lug nuts front and rear from 45 to 65 ft Ib 61 to 88 N m Workman MDE Page5 5 Higher pressures should be used for heavier payloads at higher speeds Do not exceed the maximum tire pres sure If desired tires can be moved from one position of the vehicle to another to extend tread life e g front tires to rear and rear tires to front All tires are the same size Chassis Upper Steering NS 18 to 22 ft Ib 25 to 29 N m Pd 175 to 225 in Ib Antiseize 20 to 25 N m lubricant
101. ng make sure that power to the circuit has been disconnected Figure 17 1 On Off switch m x NOT USED BACK OF SWITCH Figure 18 Workman MDE Battery Discharge Indicator and Hour Meter Gauge The combination battery discharge indicator and hour meter gauge is located on the dash panel Fig 19 The battery indicator identifies state of charge ofthe bat tery pack The battery indicator reads full 10 bars when the battery pack is fully charged approximately 51 volts As battery pack voltage decreases with vehicle use fewer battery indicator bars are shown When the battery indicator reaches 2 bars a warning light illuminates and a battery icon flashes on the gauge face to identify that battery charge level is extremely low Figure 19 At this point the batteries should be charged 1 Battery discharge indicator and hour meter If the battery indicator reaches 1 bar the warning light begins flashing and the vehicle will go into an energy saving mode vehicle speed will be reduced to 3 MPH At this point the batteries should be charged to prevent serious battery damage Electrical System The hour meter registers operating time of the vehicle Whenever the vehicle is in motion the hour meter should increase one tenth every six 6 minutes of op eration If the vehicle remains stationary for thirty 30 seconds even if
102. oller is overheated Traction motor is overheated Collar on throttle is loose Accelerator potentiometer is improperly adjusted Accelerator system is out of adjustment Batteries is fully charged Vehicle ready to operate Slow flash once per second Batteries being charged batteries less than 8096 charged Continue charging Rapid flash four times per second Batteries being charged batteries more than 8096 charged Continue charging Rapid flash Charger timer shutoff has occurred after 20 hours of charging Slow flash No current to charger Check AC outlet 3 9 Electrical System Electrical System Battery Charger Problems Battery charger does not turn on Battery charger does not turn off Battery charger fuse blows The AC outlet circuit breaker or fuse blows when using the battery charger Electrical System Page 3 10 Possible Causes AC outlet fuse circuit breaker blown AC outlet is faulty Vehicle wiring is loose or damaged see electrical schematic in Chapter 6 Electrical Diagrams Fusible link FL1 is faulty Vehicle charger interlock switch or circuit wiring faulty Vehicle charger receptacle or circuit wiring damaged Battery charger is faulty Battery charger is faulty NOTE Charging new batteries or charging batteries in cold temperatures may require extended charge time to achieve full charge Vehicle battery polarity is reversed vehicle battery cables in
103. potential battery damage Electrical System Page 3 32 Ifthe vehicle will be stored for more than 30 days and the battery charger cannot be used for some reason charge the batteries fully Either store batteries on a shelf or in the vehicle Store the batteries in a cool atmosphere to avoid quick deterioration of the charge in the batteries To prevent batteries from freezing make sure they are fully charged before storage During the storage period charge the batteries at least once every three 3 months to prevent battery damage Before returning the vehicle to service make sure to fully charge the batter ies Workman MDE Traction Motor Brushes The traction motor in the Workman MDE uses eight 8 brushes Traction motor brushes should be inspected every 500 hours of operation or annually Inspection 1 Make sure that on off switch is OFF Raise and latch cargo box to allow access to traction motor 2 Openthe battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of this chapter 3 Unlatch headband of traction motor and reposition headband to allow inspection of a brush atthe top of the motor Figure 47 4 If end of brush is even with the brush holder Figs 47 i Brush 3 Brush spring tensioned and 49 brushes should be removed from motor for in 2 Brush holder 4 Brush spring released spection and measurement see Traction
104. r 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 wheels not being jacked up Jack front wheel offthe 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 Figure 9 sorber from vehicle 1 Shock absorber 4 A arm LH shown 2 Cap screw 5 Flat washer NOTE Use spanner wrench TOR6010 see Special 3 Locknut 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 9 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 Workman MDE 5 13 Rev Chassis A arms and Front Suspension 20 to 25 ft I
105. r levers for deformation Replace lev ers if deformation or excessive rust is found 5 Replace parking brake cables if frayed stretched or kinked Workman MDE Page 4 11 Assembly Fig 4 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 careful 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 Transaxle an
106. r 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 8 Lubricate tie rod ball joints and king pin 9 Align steering and toe in 10 Make sure that front wheels move fully in both direc tions without contacting any front end components Figure 8 3 Straight bushing 1 A arm 2 Flange bushing Chassis Frame Pivot Yoke ONDARON Flange nut 4 used Shock absorber 2 used Cap screw 4 used Plug Flat washer Lock nut 4 used per side Cap screw 2 used per shock LH A arm Chassis Figure 9 Grease fitting 1 used per arm Screw Cap screw RH A arm Lock washer Front frame Pivot yoke Page 5 16 240 to 290 ft Ib 326 to 393 N m Flange head screw 4 used Flat washer 4 used Hardened washer Cap screw 2 used per arm Ground cable Rear frame Parking brake cable LH shown Workman MDE Pivot Yoke Removal Fig 9 and 10 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off Switch 2 Openthe battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of Chapter 3 Electrical System 3 Remove cargo box from the rear frame see Cargo Box Removal in this section 4 Remove seat base from the front frame see Seat Base Removal in this section M
107. ransaxle 45 to 65 ft Ib 61 to 88 N m Figure 11 1 Socket head screw 6 used 9 Roll pin 2 used 17 Cotter pin 2 Flange nut 10 Washer 18 Clevis pin 3 Carriage screw 5 used 11 Socket head screw 19 Parking brake cable 4 Support bracket 12 Lug nut 5 used per wheel 20 Transaxle vent hose 5 Transaxle mount plate 13 Wheel assembly 21 Flat washer 6 used 6 Rubber damper 14 Brake drum 22 Negative battery cable 7 Traction motor 15 Transaxle 23 Positive battery cable 8 Fan 16 Flange head screw 4 used 24 Retaining ring Transaxle and Brakes Page 4 20 Workman MDE Removal Fig 11 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from switch 2 Remove cargo box from vehicle see Cargo Box Re moval in Service and Repairs section of Chapter 5 Chassis 3 Openthe battery circuit by carefully removing one of the battery cables see Opening Battery Circuit in the General Information section of Chapter 3 Electrical System NOTE Label all electrical leads for assembly pur poses IMPORTANT When removing cables from traction motor terminals A1 A2 F1 and F2 use a wrench to retain lower nut before loosening upper nut Fig 12 If terminal studs are allowed to turn during up per nut removal internal motor damage can occur 4 Disconnect cables from traction motor A While retaining lower nut remove upper nut and cable connector from motorter
108. rear frame see Cargo Box Installation in this section 6 Reconnect removed battery cable to battery termi nals Install lock washer and nut on battery terminals Torque nuts from 115 to 125 in Ib 13 to 14 1 N m Figure 10 4 Flange lock nut 5 Front frame 6 Diamond pattern 1 Pivot yoke 2 Cap screw amp flat washer 3 Rear frame Chassis Seat Base Seat bracket Rubber receptacle Rivet Cap screw 4 used per seat Screw Holding post Seat base Seat base tray 10 Flange head screw 8 used 11 Flat washer 4 used 12 Front frame Chassis Figure 11 Screw 4 used Washer head screw 4 used Charger receptacle plate Charger receptacle Socket mount bracket Charger interlock switch Pop rivet 2 used Lock nut 2 used Charger wire harness Socket head screw 2 used Lock nut Flat washer Page 5 18 25 26 27 28 29 30 31 32 33 34 35 36 Cotter pin Parking brake cover Screw 2 used Flat washer 2 used Retaining ring 2 used Parking brake support Clevis pin Cap screw Flange head screw 4 used Brake cable equilizer Curved washer Parking brake lever Workman MDE Removal Fig 11 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from the on off Switch 2 Openthe battery circuit by carefully removing one of the ba
109. ring the pole pieces to the frame should be torqued from 250 to 300 in Ib 28 3 to 33 9 N m Fig 59 1 Motor housing 2 Puller 1 Spring scale 2 Brush spring 3 Paper Figure 59 2 Pole piece screw 1 Brush screw Electrical System 2 Em o System Commutator Service 1 Chuck armature on the commutator end bearing journal and support the drive end of armature using the live center of the shaft With the armature supported on both ends measure the commutator runout and the bar to bar differences with a dial gauge Total indicated run out should not exceed 0 003 0 08 mm and not more than 0 0005 0 013 mm between any two bars If the readings fall outside this limit the commutator must be turned and re undercut 2 If the commutator must be turned use only high quality cutting tools with a controlled cutting rate Re move only enough copper to bring total indicated runout and bar to bar height differences into specification 3 The minimum commutator diameter is 2 750 70 mm Ifthe commutator diameter falls below this diame ter after turning the armature must be replaced 4 After the commutator is turned undercut the mica to auniform depth of 0 040 1 0 mm Be careful to only cut the mica and not increase the slot width Fig 60 When using compressed air for cleaning mo tor components follow all safety instructions including wearing eye and respiratory
110. ry 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 on off switch is OFF and key is removed from the 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 Make sure proper hoists and jack stands are used to raise and support the vehicle Jacking Locations 1 Jack front of the vehicle on the front of the frame be hind the towing tongue Fig 1 2 Jackrear ofthe vehicle under each rear axletube Do not jack vehicle below the transaxle case Fig 2 Towing Vehicle IMPORTANT Frequent or long distance towing of the Workman MDE is not recommended In case of emergency the vehicle can be towed for a short distance See Operator s Manual for towing in formation Transporting Vehicle When moving the vehicle long distances use a trailer or flatbed truck Make sure vehicle is secured to the trailer properly See Operator s Manual for transport informa tion Safety 1 4 Figure 1 1 Front frame 2 Towing tongue Figure 2 2 Transaxle case 1 Rear axle tube IMPORTANT If vehicle is towed make sure that on off switch is in the OFF position and key is removed from switch Workman MDE Safety and Instruction Decals Th
111. secured so as to prevent abrasion or contact with moving parts Figure 2 1 Negative cable to vehicle 2 Positive cable to vehicle Workman MDE Electrical Diagrams The electrical schematic circuit drawings and wire har ness drawings for the Workman MDE are located in Chapter 6 Electrical Diagrams System 2 o Workman 3 3 Electrical System Vehicle Operation The Workman MDE electrical system uses a 48 volt bat tery pack an electric traction motor a vehicle controller and numerous other electrical components to allow ve hicle operation Eight 6 volt deep cycle batteries that are connected in series provide current for a 48 volt DC high torque trac tion motor the vehicle controller and vehicle accesso ries headlights horn various optional accessories The batteries are discharged as the vehicle is used so charging the batteries after using the vehicle is neces sary A battery discharge indicator gauge on the dash provides the operator with information on battery charge level Demands on the vehicle during use speed pay load incline use battery condition age charge level ambient temperature and vehicle condition will all put constraints on how long a vehicle can be used beforethe batteries are discharged An automatic 115 VAC 230 VAC on international mod els battery charger is included with the vehicle An int
112. t 3 used per side Cap screw 2 used per shock LH A arm Brake rotor 10 Wheel hub assembly 11 Tab washer Chassis See text for tightening procedure Loctite 242 45 to 65 ft lb __ yis 62 to 88 N m Figure 3 RH A arm 23 Brake caliper LH shown Jam nut 24 Lock washer 2 used per caliper Front frame 25 Cap screw 2 used per caliper Nut retainer 26 Grease fitting Dust cap 27 Ball joint LH threads Wheel assembly 28 Jam nut LH threads Lug nut 5 used per wheel 29 Tie rod tube Cap screw 2 used per A arm 30 Jam nut RH threads Cotter pin 31 Ball joint RH threads Wheel stud 5 used per hub 32 Spindle LH shown Socket head screw 4 used per rotor Page 5 10 Workman MDE Removal Fig 3 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 spind
113. t Install flange nut to secure wheel hub to the transaxle shaft Torque nutfrom 125to 140 ft Ib 170to 190 N m Install cotter pin 4 Slide brake drum onto wheel hub Figure 2 1 Cotter pin 3 Brake cable bracket 2 Clevis pin 4 Brake actuator lever 15 to 21 ft Ib 21 to 28 N m Figure 3 4 Banjo bolt 5 Brake line Brake assembly Wheel cylinder Banjo washer Transaxle and Brakes L x 5 Position wheel assembly to the vehicle with valve stem facing out and secure with five 5 lug nuts 6 Lower vehicle to ground Torque lug nuts in a cross ing pattern from 45 to 65 ft Ib 61 to 88 N m 7 Bleed brakes see Bleed Brake System in this sec tion After servicing the brakes always check the brakes in a wide open level area that is free of other persons and obstructions 8 Check brake operation Transaxle and Brakes Page4 8 Burnish Brake Shoes To provide maximum brake performance after rear brake shoes are replaced burnish new brake shoe lin ings IMPORTANT To prevent brake overheating do not drive vehicle with the brakes applied IMPORTANT When burnishing brake shoes do not allow the brakes to lock up Also allow brakes to cool between stops 1 Drive vehicle 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 2 Make several normal stops with the vehicle going in
114. t battery discharged and the vehicle damage is in the energy saving mode reduced speed and battery discharge indicator displays 1 bar with red light illuminated Workman MDE Page 3 27 Electrical System Service and Repairs Battery Service 115 to 125 in Ib gs 13 0 to 14 1 N m 12 115 125 lb gt 5 13 0 to 14 1 N m RT Figure 42 1 Battery 8 used 5 Hexnut 2 used per battery 9 Cable terminal boot 2 Battery rod 2 used 6 Cable terminal boot 10 Battery retainer 2 used 3 Negative cable to vehicle 7 Battery cable 6 used 11 Flange nut 2 used 4 Lock washer 2 used per battery 8 Positive cable to vehicle 12 Battery cable The batteries are the heart of the Workman electrical Battery Specifications system With regular and proper service battery life can Trojan model T 145 Battery 6 Volt Deep Cycle be extended Additionally battery and electrical compo Weight 72 16 33 kg nent failure can be prevented Capacity 210minutes 56 25 amps discharge Electrical System Page 3 28 Workman MDE Battery Removal Fig 42 POTENTIAL HAZARD The battery terminals metal tools and metal ve hicle parts could short together WHAT CAN HAPPEN Sparks can cause battery gasses to explode Damaged cables could short against metal ve hicle parts and cause sparks HOW TO AVOID THE HAZARD When removing or installing the batteries do notallowthe battery term
115. tch 2 Make sure machine is in safe operating condition by keeping all nuts bolts and screws tight 3 Do not use open pans of flammable cleaning fluids for cleaning parts 4 Keep battery area free of excessive grease grass leaves and dirt 5 Disconnect batteries before servicing the machine Carefully remove one of the battery cables from the bat tery pack as the first step in any repair Once a battery cable has been removed the electrical system on the vehicle can be safely worked on Take care during re pairs however to not allow tools or vehicle components to complete the battery circuit that was opened with the cable removal Reattach the removed cable to the bat tery pack as the last step in any repair 6 When using metal uninsulated tools around batter ies do not allow tools to contact both positive and nega tive battery terminals simultaneously 7 Remove jewelry and watches before servicing elec trical components of the vehicle 8 Battery acid is poisonous and can cause burns Avoid contact with skin eyes and clothing Protect your face eyes and clothing when working with batteries 9 Battery gases can explode Keep cigarettes sparks and flames away from the batteries Always service store and charge the vehicle batteries in a well ventilated area Workman MDE Page 1 3 10 Never use an open flame to check level or leakage of battery electrolyte 11 When connecting the battery charger to t
116. tem Battery Terminal Protector Battery Terminal Protector is an aerosol spray that should be used on all battery and controller terminals to reduce corrosion problems Apply terminal protector af ter cable has been secured to terminal Toro Part Number 107 0392 Figure 4 Dielectric Gel Dielectric gel should be used to prevent corrosion of connection terminals To ensure complete coating ofter minals liberally apply gel to both component and wire harness connector plug connector to component un plug connector reapply gel to both surfaces and recon nect harness connector to component Connectors should be thoroughly packed with gel for effective re sults DOW CORNING 111 SILICONE COMPOUND TEMPORARY OF EVE CONTACT FLUSH 55 IMMEDIATELY WITH CE WATER 7 Toro Part Number 107 0342 Figure 5 Workman MDE Page3 5 Electrical System Battery Watering Dispenser Use the battery watering dispenser when adding dis tilled water to vehicle batteries Toro Part Number 4102 Figure 6 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte Obtain hydrometer locally Figure 7 Battery Lift Strap Use the battery lift strap to remove and install batteries from the vehicle Lift strap allows use of case loops on battery tops as safe battery lifting points Obtain battery lift strap locally Electrical System Page3 6 Workman MDE 36 4
117. the front frame Remove gearbox from the tower plate Assembly Fig 1 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 NOTE Apply antiseize lubricant to the steering gear box input shaft before installing to steering shaft knuckle Workman MDE Page5 7 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 ahead Sli
118. the battery Results received from using load testers should follow the recommenda tions of the load tester manufacturer 2 If the Lester Battery Discharge Unit or other load tester is not available an alternate battery test can be done using a multimeter to perform a voltage test of each battery Use the following procedure A Foraccurate voltage testing allow batteries to re main idle no charging no discharging for at least 6 hours and preferably 24 hours B Open the battery circuit by carefully removing one of the battery cables see Opening Battery Cir cuit in the General Information section of this chap ter Then disconnect both cables from battery to be tested C Measure the battery voltage with the multimeter Record battery voltage The measured voltage will determine battery state of charge D If voltage readings below 70 charged see Fig 46 exist charge battery and take voltage measure ments again If voltage remains low after charging consider battery replacement 3 Athird option for battery testing is to perform a specif ic gravity test of the battery electrolyte using a hydrome ter Use the following procedure IMPORTANT Make sure the area around the battery fill caps is clean before removing the caps A Remove battery filler caps Do not add water prior to testing specific gravity of battery electrolyte If electrolyte level is low add distilled water and charge battery before performing
119. the on off switch is ON the hour meter quits increasing BACK OF GAUGE The back of the gauge is shown in Figure 20 A wire har ness connector plugs into the gauge Terminals 1 2 and Figure 20 5 are not used on the Workman MDE See Chapter 6 Electrical Diagrams for schematic and wire harness in formation Ifthe battery discharge indicator or the hour meter prove to be inaccurate the gauge should be replaced Workman MDE Page 3 15 Electrical System Vehicle Direction Forward Reverse and Headlight Switches The vehicle direction forward reverse switch Fig 21 and headlight switch Fig 22 are located on the control panel These two switches have identical logic The vehicle direction switch is one of several inputs for the vehicle controller and allows the direction forward reverse of the vehicle to be changed by the operator The headlight switch allows the headlights to be turned on and off NOTE The headlight system on the Workman MDE consists of two 2 24 volt lamps connected in series If one lamp is burned out or disconnected neither lamp will illuminate Figure 21 Testing 1 Direction switch The switch terminals for these switches are marked as shown in Figure 23 The circuitry of the 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 switch position
120. the reverse direction Workman MDE Workman This page is intentionally blank Page4 9 Transaxle and Brakes 6 o 5 55 cm A Rear Brake Service 110 to 120 in Ib 12 4 to 13 6 N m m 110 to 120 in Ib 12 4 to 13 6 N m 10 110 to 120 in Ib 12 4 to 13 6 N m Figure 4 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 4 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 Transaxle and Brakes Parking brake lever LH shown Page 4 10 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 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 from backing plate Locate and remove belleville washers from between adjuster levers and backing plate Workman MDE Inspection Fig 4 1 Inspect brake drums
121. tion Decals 1 5 Chapter 2 Product Records and Maintenance 85 Product Records 2 1 E 5 Maintenance wis cos Rs 2 1 5 Equivalents and Conversions 2 2 5 Torque Specifications 2 3 E g Chapter 3 Electrical System General Information 3 2 Electrical Diagrams 3 3 Vehicle Operation 3 4 3 Special Tools 3 5 Troubleshooting 3 8 Adjustments c 3 11 Component Testing 3 14 Service and Repairs 3 28 LESTER ELECTRICAL TECHNICIAN SERVICE GUIDE 9 x G S E Chapter 4 Transaxle and Brakes General Information 4 2 Specifications 4 3 Troubleshooting 4 4 Service and Repairs 4 6 SPICER OFF HIGHWAY COMPONENTS MODEL 12 ELECTRIC MAINTENANCE MANUAL Chapter 5 Chassis General Information 5 1 Specifications 5 2 g Troubleshooting 5 3 Service and Repairs 5 5 Chapter 6 Electrical Diagrams Electrical Schematic 6 3 Electrical Circuit Drawings
122. ttery cables see Opening Battery Circuit in the General Information section of Chapter 3 Electrical System 3 Remove seats from seat base 4 Remove four 4 screws item 12 that secure recep tacle plate tofront of seatbase Unplug charger wire har ness from vehicle wire harness and remove receptacle Figure 12 plate assembly from vehicle 1 Negative cable to vehicle 2 Positive cable to vehicle 5 Remove parking brake assembly from seat base see Parking Brake in the Service and Repairs section of Chapter 4 Transaxle and Brakes 6 Remove eight 8 flange head screws item 10 that secure seat base to vehicle Locate and retrieve flat washers item 11 from screws that secure front of seat base 7 Carefully lift seat base from vehicle Installation Fig 11 1 Position seat base to the vehicle NOTE Do nottighten fasteners securing the seat base until all fasteners are in place 2 Install four 4 flange head screws item 10 through holes in front frame and into rear seat base threaded in serts Install four 4 flange head screws item 10 and flat washers item 11 through holes in front frame and into front seat base threaded inserts 3 Starting at the middle of the vehicle tighten flange head screws to secure seat base to vehicle 4 Install parking brake assembly to seat base see Parking Brake in the Service and Repairs section of Chapter 4 Transaxle and
123. ue the nuts that secure the fuse from 45 to 50 in Ib 5 1 to 5 6 N m 1 Fuse F2 1 Controller 2 Fuse F1 Electrical System Page 3 22 Figure 35 3 Main contactor Workman MDE Fusible Links The wiring harness for the Workman includes three 3 fusible links for circuit protection Fig 36 Two 2 fusible links attach to the same main contactor post as the main fuse One of these fusible links FL2 is used for the switched power circuit The other fusible link FL1 protects the charger circuit The third fusible link FL3 is attached to the controller B terminal This link provides protection for the charge indicator hour meter gauge If any of these fusible links should fail the affected circuit will not function See Chapter 6 Electrical Diagrams for schematic and wire harness information 8 Figure 36 1 Main contactor 4 Fusible links FL1 amp FL2 2 Main fuse contactor post 5 Fusible link FL3 3 Switched contactor post o System Workman MDE Page 3 23 Electrical System Accelerator Switch The accelerator switch is a four terminal two circuit switch that is located on the control pedal frame Fig 37 The Workman MDE uses only one ofthe switch cir cuits terminals 3 and 4 When the accelerator pedal is depressed the switch allows a closed circuit input for the controller to allow traction motor operation When the accelerator pedal is rel
124. ute 3 785 Temperature Fahrenheit Celsius 1 Subract 32 2 Multiply by 5 9 Product Records and Maintenance Page 2 2 Workman Torque Specifications Recommended fastener torque values are listed in the following tables For critical applications as determined by Toro either the recommended torque or atorque 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 e g Nylock nut hardness of the surface underneath the fastener s head or similar condition which affects the installation Fastener Identification Grade 5 Inch Series Bolts and Screws Figure 1 Workman MDE 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
125. ve front wheel and spindle from A arm see Lower Steering and Front Wheel Removal in this sec tion 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 6 Remove both cap screws item 19 and lock nuts item 6 that secure A arm to frame Pull A arm from frame 7 f necessary remove flange bushings and straight bushings from A arm bores Fig 8 8 If necessary remove cap screw and lock nut that se cure upper end of shock absorber to frame Remove shock absorber A arm Installation Fig 7 1 If bushings were removed from A arm press new bushings fully into bore of A arm Fig 8 2 If shock absorber was removed from frame position shock to frame insert cap screw from front of machine and secure with lock nut Workman MDE Page 5 15 3 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 4 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 5 Fully tighten lock nuts item 6 to secure A arm to machine frame 6 Install spindle and front wheel to the A arm see Lower Steering and Front Wheel Installation in this sec tion 7 Lowe
126. ver movement is incorrect adjust location of collar on accelerator pedal shaft A Loosen two 2 set screws that secure throttle position collar to throttle pedal shaft and reposition collar to allow correct potentiometer movement Make sure that there is clearance between roll pin and side of potentiometer lever to prevent binding B Remove set screws one at a time from collar and apply Loctite 242 or equivalent to set screw threads Install and tighten set screws to secure col lar to accelerator pedal shaft C Recheck potentiometer lever movement Electrical System Page 3 12 Rev A 5 Calibrate accelerator system after any accelerator potentiometer adjustment see Accelerator System Cal ibration in this section Figure 13 1 Potentiometer 2 Accelerator pedal 3 Throttle position collar 4 Roll pin 5 Set screw 2 used Figure 14 1 Potentiometer lever accelerator pedal released 2 Potentiometer lower stop 3 Gap of 0 050 to 0 100 1 3 to 2 5 mm Figure 15 Potentiometer lever accelerator pedal fully depressed Potentiometer upper stop No lever contact with stop Workman Accelerator Potentiometer Adjustment Potentiometer with Long Lever NOTE The following adjustment procedure should be used on vehicles that have a potentiometer with a long lever Figure 15 1 If potentiometer has a short lever use the procedure on the preceding page The accelerator potentio
127. ver without rotating the lever Make sure that there is clearance between roll pin and side of potentiometer lever to prevent bind ing B Remove set screws one at a time from collar and apply Loctite 242 or equivalent to set screw threads Install and tighten set screws to secure col lar to accelerator pedal shaft C Recheck potentiometer lever movement 5 Calibrate accelerator system after any accelerator potentiometer adjustment see Accelerator System Cal ibration in this section Workman MDE Figure 15 1 1 Potentiometer 3 Retainer 2 Lever 3 12 1 Rev Figure 15 2 1 Potentiometer 4 Roll pin 2 Collar 5 Accelerator pedal 3 Lever Electrical System o System This page is intentionally blank Electrical System Page 3 12 2 Rev A Workman MDE Accelerator System Calibration The accelerator system on the Workman MDE includes the accelerator pedal assembly the accelerator poten tiometer the accelerator switch and the controller If any of these components are adjusted removed or re placed the following calibration procedure should be performed Additionally if vehicle movement is erratic jerky or if the diagnostic light on the dash is flashing six 6 times calibration of the accelerator system should be performed 1 Position vehicle on a level surface turn on off switch OFF and remove key Raise box and secure with prop rod Remove
128. yte level in each cell If the level is below the tops ofthe plates in any cell add just enough distilled water to the cell to cover the plates Replace filler caps and charge the battery After charging check electrolyte level in all cells and add distilled water until the level is 1 8 3 mm below the bottom of the fill well Fig 45 1 8 inch 3 IN o Figure 45 3 Electrolyte level 4 Battery terminal 1 Battery plates 2 Filler cap Workman MDE Battery Testing When testing batteries in the Workman MDE it is impor tant to test all batteries Proper performance of the ve hicle depends on all batteries being in good condition Testing will determine if one or more of the batteries needs to be replaced 1 The preferred testing procedure is to use the Lester Electrical 36 48 Volt Battery Discharge Unit Model 17770 This instrument puts a known discharge load 56 25 Amps on the battery pack until the battery pack reaches 42 volts Atimer incorporated into the discharg er measures the time needed to reach that voltage level Battery capacity and remaining life can be determined from the test results Refer to Discharge Unit Operating Instructions for further information Other types of battery load testers can also be used to test the Workman batteries Many locally available bat tery load testers do not however have any adjustment on the load that is put on

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