Toro Workman MD Service Manual
  1. Manuals
  2. Brands
  3. Toro Manuals
  4. Utility Vehicle
  5. Workman MD
  6. Service manual

Toro Workman MD Service Manual

Hide thumbs Also See for Workman MD:
Table of Contents

Advertisement

Quick Links

Download this manual See also: Operator's Manual
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Workman MD and Workman MDX.
REFER TO THE OPERATOR'S MANUAL FOR OPER-
ATING, MAINTENANCE AND ADJUSTMENT IN-
STRUCTIONS. For reference, insert a copy of the
Operator's Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator's Manual and Parts Catalog are avail-
able on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
E The Toro Company - - 2008, 2011, 2014
Workman
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.
Part No. 08160SL (Rev. B)

Service Manual

MD & MDX
R

Advertisement

Table of Contents

Troubleshooting

loading

Related Manuals for Toro Workman MD

Summary of Contents for Toro Workman MD

  • Page 1: Service Manual

    The Toro Company reserves the right to change product specifications or this publication without notice. IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine.
  • Page 2 This page is intentionally blank. Workman MD/MDX...
  • Page 3 ......8 -- 5 Electrical Harness Drawings ....8 -- 7 Rev. B Workman MD/MDX...
  • Page 4 This page is intentionally blank. Workman MD/MDX...

  • Page 5: Table Of Contents

    ....SAFETY AND INSTRUCTION DECALS ..Workman MD/MDX Page 1 - - 1 Safety...

  • Page 6: Safety Instructions

    Safety Instructions The Workman MD and MDX series vehicles are de- The safety alert symbol means signed and tested to offer safe service when operated CAUTION, WARNING or DANGER — and maintained properly. Although hazard control and “personal safety instruction”. Read...

  • Page 7: While Operating

    12.To assure optimum performance and continued 3. Never store the vehicle or fuel container inside safety of the vehicle, use genuine Toro replacement where there is an open flame, such as near a water heat- parts and accessories. Replacement parts and acces- er or furnace.

  • Page 8: Jacking And Other Instructions

    OFF position and key is re- moved from switch. In case of emergency, the vehicle can be towed for a short distance. Refer to Operator’s Manual for towing information. Safety Page 1 - - 4 Workman MD/MDX...

  • Page 9: Transaxle Neutral Position

    The tires should not rotate. If tire rotation does occur, see Adjust Shift Cables in the Ad- justment section of Chapter 5 -- Drive Train. Figure 3 1. Shift lever (in neutral) 3. Reverse position 2. Forward position Workman MD/MDX Page 1 - - 5 Safety...

  • Page 10: Safety And Instruction Decals

    Numerous safety and instruction decals are affixed to your Workman. If any decal becomes illegible or dam- aged, install a new decal. Part numbers are listed in the Parts Catalog. Order replacement decals from your Au- thorized Toro Distributor. Safety Page 1 - - 6 Workman MD/MDX...

  • Page 11: Product Records 2

    Maintenance Maintenance procedures and recommended service in- tervals for your Workman are covered in the Operator’s Manual. Refer to that publication when performing regu- lar equipment maintenance. Workman MD/MDX Page 2 - - 1 Product Records and Maintenance...

  • Page 12: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - - 2 Workman MD/MDX...

  • Page 13: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.
  • Page 14 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 Page 2 - - 4 Workman MD/MDX...
  • Page 15 The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Workman MD/MDX Page 2 - - 5 Product Records and Maintenance...
  • Page 16 Conversion Factors in- -lb X 11.2985 = N- -cm N- -cm X 0.08851 = in- -lb ft- -lb X 1.3558 = N- -m N- -m X 0.7376 = ft- -lb Product Records and Maintenance Page 2 - - 6 Workman MD/MDX...

  • Page 17: General Information 3

    Chapter 3 Briggs & Stratton Gasoline Engine Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......SPECIFICATIONS .

  • Page 18: General Information

    Service and repair parts for Briggs & Stratton engines commonly available in many service shops. Special are supplied through your local Toro distributor. If no tools are described in the Briggs & Stratton Repair parts list is available, be sure to provide your distributor Manual for 4--Cycle, V--Twin Cylinder, OHV Head En- with the Toro model and serial number.

  • Page 19: Specifications

    Specifications Item Description Make / Designation Briggs and Stratton, 4--cycle, V--Twin Cylinder, OHV, Air Cooled, Gasoline Engine -- Model 303440 Bore x Stroke 2.68” x 2.60” (68 mm x 66 mm) Total Displacement 29.3 in (480 cc) Governor Mechanical Governor Carburetor Float Feed, Single Barrel Fuel Pump...

  • Page 20: Adjustments

    Adjustments Adjust Throttle Cable NOTE: The Workman MDX is equipped with an engine governor. Refer to the Briggs & Stratton Repair Manual at the end of this chapter for governor information on these machines. Depressing the accelerator pedal rotates the engine governor bellcrank which tensions the main governor spring to increase engine speed.

  • Page 21: Service And Repairs

    Service and Repairs Cooling System To ensure proper engine cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. NOTE: Perform this maintenance procedure at the in- terval specified in the Operator’s Manual. IMPORTANT: The engine that powers the Workman MDX is air- -cooled.

  • Page 22: Air Cleaner

    Air Cleaner 60 to 65 in- -lb (6.8 to 7.3 N- -m) RIGHT FRONT Figure 5 1. Air cleaner assembly 7. Cap screw (2 used) 13. Breather hose 2. Bolt 8. Air cleaner bracket 14. Adapter gasket 3. Compression spring 9.
  • Page 23 Removal (Fig. 5) 1. Make sure machine is parked on a level surface with the engine OFF. 2. Raise cargo box and support with prop rod. 3. Thoroughly clean junction of intake hose and carbu- retor adapter on engine and air cleaner assembly. 4.

  • Page 24: Exhaust System

    Exhaust System RIGHT FRONT Figure 7 1. Muffler 5. Exhaust coupler 8. Engine tray 2. Swing arm 6. Coupler spring (4 used) 9. Engine 3. Cap screw (2 used) 7. Exhaust manifold 10. Screw (4 used) 4. Lock washer (6 used) Briggs &...
  • Page 25 Removal (Fig. 7) Installation (Fig. 7) 1. Park machine on a level surface, stop the engine, en- NOTE: Mount all exhaust components loosely before gage parking brake and remove the key from the ignition tightening to ensure a proper fit of exhaust system. switch.

  • Page 26: Fuel Tank

    Fuel Tank RIGHT FRONT Figure 8 1. Seat 7. Stand pipe 12. Web strapping 2. Fuel gauge 8. Hose clamp 13. Hex head flange screw (8 used) 3. Bushing 9. Fuel hose (to fuel filter) 14. Flat washer 4. Gas cap 10.
  • Page 27 Fuel Tank Removal (Fig. 10) CAUTION Read safety precautions for handling gasoline before working on the fuel system (see Safety In- structions in Chapter 1 - - Safety). 1. Remove seat base from the frame (see Seat Base Removal in the Service and Repairs section of Chapter 7 -- Chassis).

  • Page 28: Oil Filter Assembly

    Oil Filter Assembly 40 to 50 in- -lb (4.6 to 5.6 N- -m) 40 to 50 in- -lb (4.6 to 5.6 N- -m) RIGHT FRONT Figure 11 1. Hose 5. Oil pressure switch 9. Filter bracket 2. Elbow fitting 6. Elbow fitting 10.
  • Page 29 Removal (Fig. 11) Installation (Fig. 11) 1. Park machine on a level surface, stop the engine, en- 1. Install removed oil filter adapter components using gage parking brake and remove the key from the ignition Figure 11 as a guide. Torque fittings (items 2, 4 and 6) switch.

  • Page 30: Engine

    Engine RIGHT FRONT 65 to 85 ft- -lb (88 to 115 N- -m) Loctite #242 Loctite #242 25 to 30 ft- -lb (34 to 40 N- -m) Figure 12 1. Hose clamp 16. Engine pulley 31. Engine wire harness 2. Fuel hose (from tank) 17.

  • Page 31: Engine Removal

    Engine Removal (Fig. 12) 1. Park machine on a level surface, stop engine, en- gage parking brake and remove key from the ignition switch. 2. Disconnect negative (black) cable from the battery. Then, disconnect positive (red) cable from the battery. 3.

  • Page 32: Engine Installation

    11. Disconnect electrical connections from the following engine components: A. Disconnect ground cable to engine at starter/ generator terminal A1 (Fig. 15). B. Disconnect engine harness connector from the main harness. 12.Remove four (4) flange nuts and cap screws secur- ing the engine to the engine tray.
  • Page 33 10.Connect the following components (Fig. 13): 11. Install cargo box to the frame (see Cargo Box and Tailgate Installation in the Service and Repairs section A. Choke and throttle cables to the carburetor and of Chapter 7 -- Chassis). cable bracket. 12.Connect positive (red) cable to the battery.

  • Page 34: Fuel Evaporative Control System (Serial Number Above 310000000)

    Fuel Evaporative Control System (Serial Number Above 310000000) ROLLOVER VALVE TO INTAKE MANIFOLD FUEL TANK CHECK VALVE CARBON CANISTER ENGINE FRESH AIR FILTER Figure 18 Workman MDX vehicles with serial number above Machines with a carbon canister include a single engine 310000000 are equipped with a fuel evaporative control connection to the engine intake system that is used to system (EVAP) designed to collect and store evapora-...
  • Page 35 Disassembly (Fig. 19) DANGER Gasoline is flammable. Use caution when storing or handling it. Wipe up any spilled fuel before starting the engine. 1. Inspect carbon cannister and attached hoses for damage or obvious leaks. A damaged or leaking cannis- ter should be replaced.
  • Page 36 This page is intentionally blank. Briggs & Stratton Gasoline Engine Page 3 - - 20 Workman MDX...
  • Page 37 ..... . . KOHLER SERVICE MANUAL FOR COMMAND PRO CS SERIES ENGINES Rev. B Workman MD Page 4 - - 1 Single Cylinder Gasoline Engine...

  • Page 38: General Information

    Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman MD vehicle. Refer to the Op- erator’s Manual for additional information when servic- ing the machine. Rev. A...

  • Page 39: Specifications

    Champion RC 14YC (or equivalent) Spark Plug Gap 0.030 in (0.76 mm) Starter/Generator 10.5 VDC 100 Amps/14 VDC and 23 Amps Dry Weight (approximate) 70.5 lb (31.9 kg) Rev. A Workman MD Page 4 - - 3 Single Cylinder Gasoline Engine...

  • Page 40: Adjustments

    Adjustments Adjust Throttle Cable (Serial Numbers Below 313000400) NOTE: Workman MD vehicles with serial numbers be- low 313000400 use a governor in the transaxle to con- trol engine speed. Releasing the accelerator pedal should allow the throttle cable to close the carburetor throttle control lever so that the lever touches the adjustment screw.

  • Page 41: Adjust Throttle Cable (Serial Numbers Above 313000400)

    Adjust Throttle Cable (Serial Numbers Above 313000400) NOTE: Workman MD vehicles with serial numbers above 313000400 use the engine governor to control engine speed. Refer to the Kohler Service Manual at the end of this chapter for governor information on these machines.
  • Page 42 This page is intentionally blank. Single Cylinder Gasoline Engine Page 4 - - 6 Workman MD...

  • Page 43: Service And Repairs

    6. Make sure static screen and blower housing are rein- stalled to the engine if removed. 7. Attach spark plug wire to spark plug. 8. Lower and secure bed. Workman MD Page 4 - - 7 Single Cylinder Gasoline Engine...

  • Page 44: Exhaust System

    2. Coupler spring (4 used) 6. Starter/generator 10. Cap screw (2 used) 3. Exhaust manifold 7. Drive clutch 11. Swing arm 4. Muffler 8. Engine tray 12. Nut (2 used) Single Cylinder Gasoline Engine Page 4 - - 8 Workman MD...
  • Page 45 3. Insert exhaust coupler between muffler and man- ifold. Install springs to attach exhaust coupler to the ex- haust manifold and muffler. 4. Tighten all exhaust system fasteners. 5. Lower and secure cargo box. Workman MD Page 4 - - 9 Single Cylinder Gasoline Engine...

  • Page 46: Fuel Tank

    9. Fuel hose (to fuel filter) 14. Flat washer 4. Gas cap 10. Fuel line conduit 15. Parking brake support 5. Fuel tank 11. Seat base 16. Shift bracket 6. Bushing Single Cylinder Gasoline Engine Page 4 - - 10 Workman MD...
  • Page 47 4. Release tank web strapping from fuel tank. Do not re- move strapping from floor plate and frame cross mem- ber. Lift tank from frame. NOTE: Workman MD vehicles with serial number above 310000000 are equipped with a fuel evaporative control system (EVAP) designed to collect and store evaporative emissions from the fuel tank.

  • Page 48: Engine

    19. Air filter mounting band 40. Hose clamp (2 used) 61. Plastic cap 20. Engine wire harness 41. Air cleaner assembly 21. Engine tray 42. Breather hose 62. Nut (2 used) Single Cylinder Gasoline Engine Page 4 - - 12 Workman MD...

  • Page 49: Engine Removal

    Remove belt from the engine and starter/ generator pulleys. Figure 12 1. Fuel pump bracket 5. Starter/generator belt 2. Exhaust manifold 6. Throttle cable 3. Fuel line 7. Governor cable 4. Drive belt Workman MD Page 4 - - 13 Single Cylinder Gasoline Engine...

  • Page 50: Engine Installation

    14.Make sure engine oil level is correct. 8) to engine. Position r--clamp (item 51) and shift cables (item 8) to engine. Secure r--clamp to engine with flat washer (item 50) and cap screw (item 49). Single Cylinder Gasoline Engine Page 4 - - 14 Workman MD...
  • Page 51 This page is intentionally blank. Workman MD Page 4 - - 15 Single Cylinder Gasoline Engine...
  • Page 52 These machines use an inline check valve between the carbon canister and the engine fitting. Evaporative control sys- tem components for Workman MD vehicles are shown in Figure 15. Single Cylinder Gasoline Engine...
  • Page 53 3. Fitting from canister 2. Directional arrow 4. Fitting to engine Figure 17 1. Top of carbon canister 3. Fitting to engine 2. Fitting to rollover valve Workman MD Page 4 - - 17 Rev. B Single Cylinder Gasoline Engine...
  • Page 54 This page is intentionally blank. Single Cylinder Gasoline Engine Page 4 - - 18 Workman MD...
  • Page 55 Transaxle Service ......Adjust Ground Speed (Workman MD with Transaxle Disassembly and Inspection ..

  • Page 56: Specifications

    1.5 quarts (1.4 liters) Transaxle Fluid SAE 10W--30 Motor Oil Clutch System Continuously variable transmission type, torque convertor Drive Clutch Speed sensing with mechanical fly weights Driven Clutch Torque sensing with spring loaded cam Page 5 - - 2 Workman MD/MDX Drive Train...
  • Page 57 The driven clutch responds to changes in load to the rear mum efficiency. axle, and is mounted to the transaxle input shaft. Rev. A Workman MD/MDX Page 5 - - 3 Drive Train...

  • Page 58: Drive Clutch Operation

    310000000 (Fig. 3) controls moveable sheave operation with six (6) weighted rollers and ramp sur- faces in the moveable sheave. Figure 3 Fixed sheave Cover Moveable sheave Roller (6 used) Spider assembly Rev. A Page 5 - - 4 Workman MD/MDX Drive Train...

  • Page 59: Driven Clutch Operation

    (Fig. 5). Figure 5 1. Moveable sheave 3. Spring 2. Fixed sheave Rev. A Workman MD/MDX Page 5 - - 5 Drive Train...

  • Page 60: Special Tools

    Special Tools Order special tools from your Toro Distributor. Drive Clutch Removal Tool (Serial Number Below 310000000) This tool is required to remove the drive clutch from the tapered drive shaft of the engine. It is placed in the threaded hole of the fixed clutch sheave after the clutch holding cap screw is removed.
  • Page 61 This tool is required to remove the drive clutch from the tapered drive shaft of the engine. It is placed in the threaded hole of the fixed clutch sheave after the clutch holding cap screw is removed. Toro Part Number: TOR6013 NOTE: Vehicles with serial...
  • Page 62 This page is intentionally blank. Rev. A Drive Train Page 5 - - Workman MD/MDX...

  • Page 63: Adjustments

    (3) seconds with the accelerator pedal 1. Park machine on a level surface, stop engine and re- to the floor. The Workman MD should travel 62 feet (18.8 move key from the ignition switch. Raise and support meters) in three seconds.

  • Page 64: Adjust Ground Speed (Workman Mdx And Workman Md With Serial Number Above 313000400)

    Adjust Ground Speed (Workman MDX and Workman MD with Serial Number Above 313000400) All Workman MDX models and Workman MD models with serial number above 313000400 use an engine governor for speed control. Adjust ground speed using the following procedure for these vehicles.

  • Page 65: Adjust Shift Cables

    Readjust shift cables if needed for correct (0.8 to 1.5 mm) operation. 9. Lower and secure cargo box. Figure 11 1. Select lever 3. Cable boot 2. Cable pull direction Workman MD/MDX Page 5 - - 9 Drive Train...

  • Page 66: Service And Repairs

    2. Remove the three (3) cap screws that secure the Wear safety goggles and a dust mask or other eye cover to the drive clutch (Fig. 13). Remove the cover and respiratory protection when performing this from the clutch. procedure. Page 5 - - 10 Workman MD/MDX Drive Train...
  • Page 67 Prevent damage to clutch threads; thread tool only enough to remove the clutch. 6. Use correct clutch removal tool (see Special Tools) to remove drive clutch from the engine tapered shaft. Rev. A Workman MD/MDX Page 5 - - 11 Drive Train...

  • Page 68: Drive Clutch Service (Serial Number Below 310000000)

    Drive Clutch Lubrication 4. Lubricate the clutch components in areas shown in Figure 15 using Toro Dry Lubricant Spray (see Special NOTE: Lubricate drive clutch at the interval specified in Tools). Avoid getting lubricant on drive belt.
  • Page 69 Drive Clutch Assembly (Fig. 14) 1. If removed, install rollers, washers and roller pins to spider. Roller pins should be lubricated with Toro part #104--7011 (see Special Tools). 2. Lubricate cam weights with Toro part #104--7011 (see Special Tools). Make sure lubricant penetrates to...
  • Page 70 8. Position cover to clutch. Secure cover to the move- able sheave with three (3) cap screws. Torque cap screws from 75 to 100 in- -lb (8.5 to 11.3 N- -m). 13.1 Rev. A Drive Train Page 5 - - Workman MD/MDX...
  • Page 71 This page is intentionally blank. Workman MD/MDX Drive Train 13.2 Rev. A Page 5 - -...

  • Page 72: Drive Clutch Service (Serial Number Above 310000000)

    3. Make sure that engine starter pulley (item 11) has been removed from the drive clutch (see Drive Clutch Removal in this section). 13.3 Rev. A Drive Train Page 5 - - Workman MD/MDX...
  • Page 73 7. Secure cover to the moveable sheave with three (3) cap screws. Torque cap screws from 132 to 168 in- -lb (15.0 to 18.9 N- -m). Workman MD/MDX Drive Train 13.4 Rev. A Page 5 - -...

  • Page 74: Driven Clutch

    4. Install drive belt to the driven clutch. 5. Install muffler to the engine and engine mount (see Exhaust System Installation in the Service and Repairs section of Engine Chapter). 6. Lower and secure cargo box. Page 5 - - 14 Rev. A Workman MD/MDX Drive Train...

  • Page 75: Driven Clutch Service (Serial Number Below 310000000)

    Figure 21 11. Install drive belt to the driven clutch. 1. Moveable sheave 4. Fixed sheave 12.Lower and secure cargo box. 2. Ramp (fixed cam) 5. Drive belt 3. Button Rev. A Workman MD/MDX Page 5 - - 15 Drive Train...

  • Page 76: Driven Clutch Service (Serial Number Above 310000000)

    Make sure that the “X” mark cast into the fixed and moveable sheaves are aligned. Also, make sure that the retaining ring is fully seated in groove after installation. 15.1 Rev. A Drive Train Page 5 - - Workman MD/MDX...
  • Page 77 This page is intentionally blank. Workman MD/MDX Drive Train 15.2 Rev. A Page 5 - -...

  • Page 78: Transaxle

    Removal in the Service and Repairs section of Engine 2. Remove cargo box from the frame (see Cargo Box Chapter). Removal in Chapter 7 -- Chassis). 3. Remove drive belt from the driven clutch. Page 5 - - 16 Workman MD/MDX Drive Train...
  • Page 79 6. On Workman MD, remove governor and cable brackets from the transaxle as follows (Fig. 23). A. Scribe mark across governor bracket and gover- nor shaft to help installation. Loosen both set screws securing the bracket to the shaft. B. Remove both lock nuts securing the cable brack- et to the transaxle case.

  • Page 80: Installation

    13.Carefully move engine tray assembly toward the rear of the vehicle to clear mounts on swing arm. Then, lower 7. On Workman MD, secure governor and cable brack- engine tray enough to allow the transaxle and driven ets to the transaxle as follows (Fig. 23).
  • Page 81 This page is intentionally blank. Workman MD/MDX Page 5 - - 19 Drive Train...

  • Page 82: Transaxle Service

    (1.4 to 1.8 N- -m) 17 18 40 to 45 ft- -lb (54 to 61 N- -m) 61 62 25 to 31 ft- -lb (34 to 42 N- -m) 69 55 Figure 26 Page 5 - - 20 Workman MD/MDX Drive Train...

  • Page 83: Transaxle Disassembly And Inspection

    B. Reinstall drain plug to transaxle case. Torque plug from 15 to 18 ft- -lb (21 to 25 N- -m). Make sure transaxle case is not hot prior to drain- ing oil to prevent getting burned. Workman MD/MDX Page 5 - - 21 Drive Train...
  • Page 84 Replace gasket if damaged. Figure 29 1. Input shaft 2. Oil seal D. Wrap vinyl tape around the splined portion of the input shaft. This should protect the oil seal from being damaged. Page 5 - - 22 Workman MD/MDX Drive Train...
  • Page 85 1. Flange bolt (10 used) 2. Flange nut F. With the input shaft side down, loosen and re- move flange bolts and nuts securing the case (RH) and case (LH) together. Workman MD/MDX Page 5 - - 23 Drive Train...
  • Page 86 2. Remove input shaft, center shaft and differential assemblies. Figure 33 1. Gasket 2. Pipe knock A. Remove gasket and pipe knocks. Page 5 - - 24 Workman MD/MDX Drive Train...
  • Page 87 D. Replace spacer if either one is cracked or bent. F. Replace gear 34 if worn or damaged. Cracked, broken, missing or chipped gear teeth are not ac- ceptable. Workman MD/MDX Page 5 - - 25 Drive Train...
  • Page 88 Figure 37 1. Flange bolt 3. Transaxle case 2. Axle case A. Remove remaining two (2) flange bolts securing each axle case to the case. Remove axle case from the transaxle case. Page 5 - - 26 Workman MD/MDX Drive Train...
  • Page 89 4. Disassemble input shaft assembly. Figure 39 1. Input shaft 2. Governor sleeve (Workman MD) A. On Workman MD, remove governor sleeve from the input shaft. Workman MD/MDX Page 5 - - 27 Drive Train...
  • Page 90 1. Governor plate assembly 2. Governor base IMPORTANT: Make sure to not damage the screw C. On Workman MD, remove two (2) screws and heads when removing screws. Each screw is se- lock pin securing the governor plate assembly to the cured with an adhesive.
  • Page 91 6. Screw (2 used) (Workman MD) D. Replace input shaft if worn or damaged. Gear F. On Workman MD, replace governor plate if teeth that are cracked, broken, chipped or missing cracked, bent or any weight is missing. Weights must are not acceptable.
  • Page 92 E. Replace pin clutch if cracked or bent. able. F. Replace collars or spacer if excessively worn or damaged. Replace both collars as a set. Page 5 - - 30 Workman MD/MDX Drive Train...
  • Page 93 C. Remove pinion shaft and gears from the case. on the opposite side of gear 62. Separate gears from shaft. B. Remove spring pin from the differential case. Dis- card pin and replace it with new spring pin. Workman MD/MDX Page 5 - - 31 Drive Train...
  • Page 94 Ball bearing must spin freely and H. Replace oil seal if cracked, nicked or distorted have minimum axial play. Replace ball bearing as such that it would not hold a proper seal. necessary. Page 5 - - 32 Workman MD/MDX Drive Train...
  • Page 95 7. On Workman MD, disassemble governor fork and shaft. Figure 48 1. Screw (2 used) 3. Governor fork 2. Stopper 4. Case (RH) IMPORTANT: Make sure to not damage the screw A. Remove both screws and washers securing the heads when removing screws. Each screw is se- stopper and governor fork to the case (RH).
  • Page 96 Ball bearing must spin freely and have minimum ax- F. Replace governor fork or stopper if bent or de- ial play. Replace ball bearing as necessary. formed. Page 5 - - 34 Workman MD/MDX Drive Train...

  • Page 97: Transaxle Assembly

    2. Governor base 4. Governor sleeve IMPORTANT: To prevent the screws that secure the A. On Workman MD, secure governor plate unit to governor plate to the governor from loosening, ap- the governor base with two (2) screws and lock pin.
  • Page 98 Figure 54 1. Pivot point 2. Governor plate D. On Workman MD, make sure to apply molybde- num disulfide grease to the pivot points of the weights on the governor plate unit. Page 5 - - 36...
  • Page 99 B. Press ball bearings onto the center shaft using a C. Make sure distance from one ball bearing outer bearing press. edge to the other ball bearing outer edge is 136.8 to 137.1 mm (Fig. 55). Workman MD/MDX Page 5 - - 37 Drive Train...
  • Page 100 Apply molybdenum disulfide grease to the out- side of both side gears where they contact the differ- ential case and gear 62. Page 5 - - 38 Workman MD/MDX Drive Train...
  • Page 101 Figure 60 1. Spring pin 3. Pinion shaft 2. Differential case C. Align pinion shaft hole and install new spring pin through the differential case and pinion shaft. Workman MD/MDX Page 5 - - 39 Drive Train...
  • Page 102 123.3 to 124.0 mm above when assembled. (Fig. 58). F. If ball bearings were removed, press new ball bearings onto differential case and gear 62. Page 5 - - 40 Workman MD/MDX Drive Train...
  • Page 103 4. On Workman MD, assemble governor fork. Figure 63 1. Ball bearing 2. RH case (bearing bore) A. Install ball bearing into the bore of the case (RH). Figure 64 1. Governor shaft 2. Boss IMPORTANT: Make sure to not damage the oil seal B.
  • Page 104 F. Torque screws from 12 to 16 in- -lbs (1.4 to 1.8 ball bearing hole. Also, adjust thrust clearance of N- -m). the governor shaft to less than 0.020” (0.5 mm). Page 5 - - 42 Workman MD/MDX Drive Train...
  • Page 105 25 to 31 ft- -lb (34 to 42 N- -m). takes the long axle case. IMPORTANT: Make sure to not damage the oil seal when installing the axle case to the case. Workman MD/MDX Page 5 - - 43 Drive Train...
  • Page 106 Lower differential assembly, center shaft as- sembly and input shaft assembly into the case at the IMPORTANT: Make sure to not damage the oil seal same time. when installing the input shaft. Page 5 - - 44 Workman MD/MDX Drive Train...
  • Page 107 Figure 72 1. Spacer 2. Boss (counter shaft) E. Place spacer on the counter shaft boss of the case (LH) so the oil groove faces up. Workman MD/MDX Page 5 - - 45 Drive Train...
  • Page 108 1. Case (sealing surface) 2. Pipe knock A. Make sure gasket sealing surfaces of both cases B. Install both pipe knocks to the case (LH). are clean. Install gasket to case. Page 5 - - 46 Workman MD/MDX Drive Train...
  • Page 109 NOTE: When installing case (RH) to the case (LH) on C. Install case (RH) so each shaft fits properly into Workman MD, hold governor shaft so the ball bearing the case. will not drop off. Keep the gasket sealing surfaces of the D.
  • Page 110 H. Fill transaxle with 1.5 quarts (1.4 liters) of new 10W--30 motor oil. G. Install steel ball, spring, gasket and bolt. Torque bolt from 12 to 15 ft- -lb (16 to 20 N- -m). Page 5 - - 48 Workman MD/MDX Drive Train...

  • Page 111: Electrical Schematics 6

    ... . Reverse Switch (Optional) ....Workman MD/MDX Page 6 - - 1 Rev. B...

  • Page 112: General Information

    Manual for additional information when servicing the machine. Electrical Schematics The electrical schematics and other electrical drawings for the Workman MD and MDX are located in Chapter 8 -- Electrical Diagrams. Electrical System Page 6 - - 2 Workman MD/MDX...

  • Page 113: Special Tools

    Multimeter The meter can test electrical components and circuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL Volt-- Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
  • Page 114 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 4 Electrical System Page 6 - - 4 Workman MD/MDX...

  • Page 115: Troubleshooting

    (see Wiring Schematics in Chapter 8 -- Electrical Diagrams). Shutdown module is faulty (Workman MDX). Engine or fuel system is malfunctioning (see Engine Chapter). Engine and fuel may be too cold. Workman MD/MDX Page 6 - - 5 Electrical System...

  • Page 116: General Run Problems

    Wiring to the run circuit components became broken or disconnected (see Wiring Schematics in Chapter 8 -- Electrical Diagrams). RPM shutdown module is faulty (Workman MDX). Engine or fuel system is malfunctioning (see Engine Chapter). Electrical System Page 6 - - 6 Workman MD/MDX...

  • Page 117: Electrical System Quick Checks

    NOTE: Depending upon the condition of the battery Battery Voltage after 3 Minute Charge = 12.85 v charge and battery temperature, the battery voltage will Difference = +0.55 v increase at different rates as the battery charges. Workman MD/MDX Page 6 - - 7 Electrical System...

  • Page 118: Component Testing

    4 Cycle, V--Twin Cylinder, OHV Head Engines (Work- that power to the circuit has been disconnected. man MDX) or the Kohler Service Manual for Command Pro CS Series Engines (Workman MD) for additional component testing information. Ignition Switch The ignition switch used on the Workman has six (6) switch terminals and three (3) key switch positions.

  • Page 119: Hour Meter

    Verify continuity between switch terminals. SWITCH NORMAL OTHER POSITION CIRCUITS CIRCUITS 2 + 3 5 + 6 Figure 7 1 + 2 4 + 5 1. Headlight switch 2. Back of switch Workman MD/MDX Page 6 - - 9 Electrical System...

  • Page 120: Service And Repairs 7

    Make sure to connect positive (red) cable first and then connect negative (black) cable. NOTE: Voltage is supplied to the solenoid on the Work- man whenever the key is in the ON position and the ac- celerator pedal is depressed. Electrical System Page 6 - - 10 Workman MD/MDX...

  • Page 121: Fuse Block

    2. Ignition system fuse 4. Power point fuse 4. The extreme right 10 ampere fuse protects the pow- er point circuit. A maximum of a 15 ampere fuse is al- lowed. Workman MD/MDX Page 6 - - 11 Electrical System...

  • Page 122: Accelerator Switch

    (Fig. 13). Tighten nut to secure cap screw in 2. Terminal 2 5. Switch plunger 3. Terminal 3 6. Mounting tab position. Figure 13 1. Accelerator switch 2. Adjustment screw Electrical System Page 6 - - 12 Workman MD/MDX...

  • Page 123: Starter/Generator & Voltage Regulator

    An incorrect reading indicates the need for starter/generator repair. Figure 15 E. Stop engine and turn key to OFF. 1. Terminal A1 3. Terminal F1 location 2. Terminal A2 4. Terminal DF location Workman MD/MDX Page 6 - - 13 Electrical System...

  • Page 124: Starter/Generator

    The meter reading should be infinite (no continuity). 4. Starter/generator disassembly and repair will be needed if readings are incorrect (see Starter/Generator Service in the Service and Repairs section of this chap- ter). Electrical System Page 6 - - 14 Rev. B Workman MD/MDX...

  • Page 125: Diode Assembly

    When engine speed de- creases to approximately 1300 RPM, the spark tester should register no spark and the engine should stop. Workman MD/MDX Page 6 - - 15 Electrical System...

  • Page 126: Electrical Schematics 8

    2. Bottom view 4. Negative (- -) terminal 3. Disconnect wire harness connector from alarm. Cor- rectly connect 12VDC source to the terminals (Fig. 20). Alarm should sound. Electrical System Page 6 - - 16 Workman MD/MDX...

  • Page 127: Reverse Switch (Optional)

    5. When testing is complete, connect wire harness con- nector to switch. Slide shift bracket into seat base and secure with four (4) screws. Figure 22 1. Reverse switch 2. Normally open contact Workman MD/MDX Page 6 - - 17 Electrical System...

  • Page 128: Service And Repairs

    Briggs and Stratton Vanguard Service and Repair Manual for 4--Cycle, V--Twin Cylinder, OHV Engines (Workman MDX) or the Kohler Service Manual for Command Pro CS Series Engines (Workman MD). Starter/Generator 15 to 25 ft- -lb (21 to 33 N- -m)

  • Page 129: Removal

    Service informa- tion for these two (2) types of starter/generators is in- cluded in this chapter. Make sure to use the correct information for the component that is being serviced. Workman MD/MDX Page 6 - - 19 Rev. B Electrical System...

  • Page 130: Starter/Generator Service (Valeo Starter/Generator)

    22. Brush holder kit 7. Through bolt & flat washer 15. Pulley 23. Brush spring 8. Brush cover 16. Pole piece and set screw 24. Brush and screw set Electrical System Page 6 - - 20 Rev. B Workman MD/MDX...

  • Page 131: Brush And Brush Spring Service

    Secure commutator end cover to the yoke 1. Brush spring 3. Brush holder with both through bolts and flat washers. Torque bolts 2. Brush from 96 to 104 in- -lbs (10.8 to 11.8 N- -m). Workman MD/MDX Page 6 - - 21 Electrical System...

  • Page 132: Armature And Field Coil Service

    IMPORTANT: Never use emery cloth on the commu- tator; short circuiting of the commutator bars may result. Never use oil or lubricants on the commuta- tor or brushes. Figure 28 1. Armature 3. Armature shaft 2. Commutator Electrical System Page 6 - - 22 Workman MD/MDX...
  • Page 133 Damage to the brushes may result. H. Lift brush springs from the notch at the end of the brushes while pulling the brushes out. Allow springs to hold brushes out from the center (Fig. 25). Workman MD/MDX Page 6 - - 23 Electrical System...

  • Page 134: Rework Starter/Generator

    500 VDC for one minute with no insulation break down Starter field coil resistance 2.38 to 2.44 ohms at 20 C (68 Generator field coil resistance 0.041 ohm for F1 and 0.043 ohm for F2 at 20 C (68 Electrical System Page 6 - - 24 Workman MD/MDX...
  • Page 135 This page is intentionally blank. Workman MD/MDX Page 6 - - 25 Electrical System...

  • Page 136: Starter/Generator Service (Advanced Motors And Drives Starter/Generator)

    11. Commutator end head 3. Retaining ring 8. Brush box assembly 12. Rubber plug (3 used) 4. Armature assembly 9. Bearing 13. Rubber plug (with weep hole) 5. Frame and field assembly Electrical System Page 6 - - 26 Rev. B Workman MD/MDX...

  • Page 137: Brush And Brush Spring Service

    Remove the two (2) screws that secure the drive end head to the frame housing. Figure 34 Workman MD/MDX Page 6 - - 27 Rev. B Electrical System...
  • Page 138 NOTE: Individual components in the frame housing are not available separately. Replace housing or complete starter/generator if damage exists in frame and field as- sembly. Electrical System Page 6 - - 28 Rev. B Workman MD/MDX...
  • Page 139 Figure 38 11. Remove brush assemblies from the brush box. Minimum brush length is 0.375 in (9.5 mm) Maximum brush length is 0.790 in (20 mm) Figure 39 Workman MD/MDX Page 6 - - 29 Rev. B Electrical System...
  • Page 140 Secure brush box to end head with two (2) screws. Torque screws from 22 to 26 in- -lb (2.5 to 2.9 N- -m). Figure 42 Electrical System Page 6 - - 30 Rev. B Workman MD/MDX...
  • Page 141 49 to 66 in- -lb (5.6 to 7.4 N- -m). Figure 44 17.Position the starter/generator on the commutator end head and support the assembly to prevent damage to the terminals in the end head. Figure 45 Workman MD/MDX Page 6 - - 31 Rev. B Electrical System...
  • Page 142 Figure 47 22.Release brushes and center the brush springs between the wire and the edge of the brush. Make sure that brushes move freely in brush holders. Figure 48 Electrical System Page 6 - - 32 Rev. B Workman MD/MDX...

  • Page 143: Starter/Generator Specifications

    0.375 in (9.5 mm) Commutator bars Commutator original maximum diameter (new) 1.780 in (45.2 mm) Commutator minimum diameter for reslotting 1.650 in (41.9 mm) Commutator replacement diameter 1.60 in (40.6 mm) Workman MD/MDX Page 6 - - 33 Rev. B Electrical System...

  • Page 144: Battery Service

    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 ignition switch off and remove key. Electrical System Page 6 - - 34 Workman MD/MDX...

  • Page 145: Battery Inspection And Maintenance

    9. Apply battery terminal protector (Toro part number 5. Check the electrolyte level in each cell. If the level is 107--0392) on battery posts and cable connectors to re- below the tops of the plates in any cell, fill all cells with duce corrosion after connections are made.

  • Page 146: Battery Testing

    A. Check the voltage across the battery terminals prior to testing the battery. If the voltage is less than 12.0 VDC, recharge the battery before load testing. B. Make sure the battery terminals are free of corro- sion. Electrical System Page 6 - - 36 Workman MD/MDX...

  • Page 147: Battery Charging

    11.5 hrs 17.3 hrs 23 hrs 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 10 amps 10 amps 10 amps 10 amps Workman MD/MDX Page 6 - - 37 Electrical System...
  • Page 148 This page is intentionally blank. Electrical System Page 6 - - 38 Workman MD/MDX...
  • Page 149 The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Opera- tor’s Manual for additional information when servicing the machine. Workman MD/MDX Page 7 - - 1 Rev. A Chassis...

  • Page 150: Specifications

    Specifications Item Description Front Tire (Workman MD and MDX) (22 x 9.5 -- 10, 2 ply) Pressure Range 8 to 22 PSI (56 to 151 kPa) Rear Tire (Workman MD) (22 x 9.5 -- 10, 2 ply) Pressure Range 8 to 22 PSI (56 to 151 kPa)

  • Page 151: Troubleshooting

    Front wheel bearings are loose or worn. Steering column bushings are worn. Steering gearbox is damaged or worn. Front wheel alignment (toe--in) is incorrect. Rubber shock insert or spindle bushings in A--arm are loose or worn. Workman MD/MDX Page 7 - - 3 Chassis...

  • Page 152: Brakes

    Air is trapped in brake lines. Ground speed is too fast (see Chapter 5 -- Drive Train). Engine has excessive run--on when accelerator pedal is released due to carburetor not fully closing (see Engine Chapter). Chassis Page 7 - - 4 Workman MD/MDX...
  • Page 153 Brake drums are grooved in the contact face with brake shoes. Brakes fade. Brake drums are overheated. Brake linings are saturated. Vehicle surges at slow speeds and Brake drums are bent or out--of--round. chatters at fast speeds. Workman MD/MDX Page 7 - - 5 Chassis...

  • Page 154: Adjustments

    3. Rotate the knob until a force from 30 to 40 lb. (133 to 177 N) is required to actuate the lever. 4. Tighten the set screw and install the rubber cover. Figure 1 1. Parking brake lever 3. Set screw 2. Brake knob Chassis Page 7 - - 6 Workman MD/MDX...

  • Page 155: Adjust Front Wheel Camber

    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 MD/MDX Page 7 - - 7 Rev. A Chassis...

  • Page 156: Adjust Front Wheel Toe--In

    C. Tighten tie rod jam nuts when toe--in adjustment is correct. Figure 7 7. Ensure that there is full steering travel in both direc- 1. Jam nut 2. Tie rod tions. Rev. B Chassis Page 7 - - 8 Workman MD/MDX...

  • Page 157: Service And Repairs

    Inspect Torque wheel lug nuts in a crossing pattern from 45 to tire and rim condition after any accident. 65 ft-lb (62 to 88 N- -m). Workman MD/MDX Page 7 - - 9 Chassis...

  • Page 158: Upper Steering

    2. Raise front hood to gain access to the steering com- 4. Remove cap screw and lock washer securing the ponents. lower steering shaft knuckle to the steering gearbox in- put shaft. Pull knuckle from the gearbox shaft. Chassis Page 7 - - 10 Workman MD/MDX...
  • Page 159 4. Secure steering column to the mounting plate on the 12.Check front wheel alignment (see Adjust Front frame with four (4) carriage screws and flange nuts. Wheel Toe--in in the Adjustments section of this chap- ter). Workman MD/MDX Page 7 - - 11 Chassis...

  • Page 160: Steering Gearbox

    11. Input shaft spacer 17. Pinion gear 5. Flat washer 12. Flat washer 18. Oil seal 6. Ball bearing 13. Flange head screw with patch lock 19. Pitman arm 7. Output shaft spacer Chassis Page 7 - - 12 Workman MD/MDX...
  • Page 161 A. Press new bearing into housing from the inside 10.After assembly is completed, make sure that pitman first. arm rotates freely from stop to stop without binding. B. Turn housing over. Insert spacer and press new bearing into housing. Workman MD/MDX Page 7 - - 13 Chassis...

  • Page 162: Lower Steering And Front Wheels

    29. Tie rod 9. Brake rotor 20. Cotter pin 30. Jam nut (RH threads) 10. Wheel hub assembly 21. Wheel stud (5 used per hub) 31. Ball joint (RH threads) 11. Tab washer Chassis Page 7 - - 14 Workman MD/MDX...
  • Page 163 A--arm and brake hose clip from top of A--arm. Remove kingpin sleeve from A--arm if nec- NOTE: Make sure cap screw is inserted down essary. through the spindle and A--arm hub. Workman MD/MDX Page 7 - - 15 Chassis...
  • Page 164 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 7 - - 16 Workman MD/MDX...

  • Page 165: Front Shock Absorbers

    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 MD/MDX Page 7 - - 17 Rev. A Chassis...

  • Page 166: A--Arms And Front Suspension

    35. Brake hose clip 11. Tab washer 24. Lock washer (2 used per caliper) 36. Cap screw 12. RH A- -arm 25. Cap screw (2 used per caliper) 37. Lock nut 13. Jam nut Chassis Page 7 - - 18 Workman MD/MDX...
  • Page 167 45 to 65 ft- -lb (62 to 88 N- -m). 7. Align front wheel toe--in (see Adjust Front Wheel Toe--in in the Adjustments section of this chapter). Workman MD/MDX Page 7 - - 19 Chassis...

  • Page 168: Frame Pivot Yoke

    12. RH A- -arm 19. Cap screw (2 used per arm) 6. Lock nut (4 used per side) 13. Lock washer 20. Ground cable 7. Cap screw (2 used per shock) 14. Front frame Chassis Page 7 - - 20 Workman MD/MDX...
  • Page 169 (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- -lb (326 to 393 N- -m). Workman MD/MDX Page 7 - - 21 Chassis...

  • Page 170: Swing Arm

    19. Cap screw (2 used) 6. Retaining ring (2 used) 13. Cable tie 20. Cotter pin (2 used) 7. Washer head screw (2 used) 14. Lock nut (4 used) 21. Clevis pin (2 used) Chassis Page 7 - - 22 Workman MD/MDX...
  • Page 171 (Fig. 14). 9. Carefully, lower swing arm and engine tray assembly 13.Remove swing arm from assembly. just enough to allow clearance for swing arm removal. Workman MD/MDX Page 7 - - 23 Chassis...
  • Page 172 12.Check parking brake operation and adjust if neces- to the machine frame. Align swing arm pivots to frame sary (see Adjust Parking Brake in the Adjustments sec- mounting points. tion of this chapter). Chassis Page 7 - - 24 Workman MD/MDX...
  • Page 173 This page is intentionally blank. Workman MD/MDX Page 7 - - 25 Chassis...

  • Page 174: Parking Brake

    4. Cable equalizer bracket 10. Flat washer (2 used) 16. Parking brake support 5. Parking brake lever 11. Screw (2 used) 17. Cable retaining ring (2 used) 6. Curved washer 12. Cap screw Chassis Page 7 - - 26 Workman MD/MDX...
  • Page 175 C. Secure each brake cable end to brake lever with clevis pin and cotter pin. 6. Check parking brake operation and adjust if neces- sary (see Adjust Parking Brake in the Adjustments sec- tion of this chapter). Workman MD/MDX Page 7 - - 27 Chassis...

  • Page 176: Rear Wheels And Brakes

    Plug brake line and position it away from brake assembly. Discard 3. Remove five (5) lug nuts, wheel assembly and brake two (2) banjo washers. drum from the wheel hub. Chassis Page 7 - - 28 Workman MD/MDX...
  • Page 177 -lb (62 to 88 N- -m). 2. Wheel cylinder 5. Brake line 3. Banjo washer 12.Check parking brake operation. Adjust parking brake if necessary (see Parking Brake Adjustment in the Ad- justments section of this chapter). Workman MD/MDX Page 7 - - 29 Chassis...

  • Page 178: Rear Brake Service

    1. Remove upper and lower springs from brake shoes. levers and backing plate. 2. Remove shoe hold down cups and springs that se- cure the brake shoes to the backing plate. 3. Remove brake shoes from backing plate. Chassis Page 7 - - 30 Workman MD/MDX...
  • Page 179 Replace plate if cracked, warped or excessively rusted. 4. Inspect adjuster levers for deformation. Replace lev- ers if deformation or excessive rust is found. 5. Replace parking brake cables if frayed, stretched or kinked. Workman MD/MDX Page 7 - - 31 Chassis...

  • Page 180: Front Brake Calipers

    3. Lock washer (2 per caliper used) 8. Spindle (LH shown) 12. Lug nut (5 used per wheel) 4. Cap screw (2 per caliper used) 9. A- -arm (LH shown) 13. Front brake hose 5. Wheel hub assembly Chassis Page 7 - - 32 Workman MD/MDX...
  • Page 181 6. Slide brake caliper from brake rotor and remove cali- 8. Check brake operation. per from machine. Workman MD/MDX Page 7 - - 33 Chassis...

  • Page 182: Front Brake Caliper Service

    3. Secure pads into caliper with two (2) pins. Make sure that pins snap into caliper slots. 4. If caliper is equipped with anti--rattle clip, install clip to caliper, pins and brake pads. Chassis Page 7 - - 34 Workman MD/MDX...
  • Page 183 This page is intentionally blank. Workman MD/MDX Page 7 - - 35 Chassis...

  • Page 184: Brake Master Cylinder

    1. Master cylinder 5. Cotter pin 8. Front brake line 2. Cap screw 6. Flange head nut 9. Rear brake line 3. Brake pedal 7. Pedal frame 10. Accelerator pedal 4. Clevis pin Chassis Page 7 - - 36 Workman MD/MDX...
  • Page 185 5. Pull master cylinder from machine. After servicing brake system components, al- ways check the brakes in a wide open, level area that is free of other persons and obstructions. 6. Check brake operation. Workman MD/MDX Page 7 - - 37 Chassis...

  • Page 186: Brake Master Cylinder Service

    4. Install push rod and secure in place with circlip. Install lower end of dust cover to housing. 5. Push in on push rod so stop pin can be installed to retain secondary piston assembly, then install flange seal and reservoir. Chassis Page 7 - - 38 Workman MD/MDX...

  • Page 187: Bleed Brake System

    4. Repeat procedure until a continuous flow of brake fluid, with no air bubbles, is released from bleeder valve. Make sure fluid level is maintained in brake fluid res- ervoir at all times. Workman MD/MDX Page 7 - - 39 Chassis...

  • Page 188: Seat Base

    9. Long screw (4 used) 20. Parking brake support 31. Screw (2 used) 10. Fuel tank 21. Cap screw 32. Retaining ring (2 used) 11. Web strapping 22. Curved washer 33. Flat washer (2 used) Chassis Page 7 - - 40 Workman MD/MDX...
  • Page 189 Secure shift plate to seat base with four (4) long cap screws (Fig. 26). 6. Install parking brake assembly to seat base (see Parking Brake Assembly in this section). 7. Secure seats to seat base. Workman MD/MDX Page 7 - - 41 Chassis...

  • Page 190: Front Hood

    20. Washer head screw (4 used) 31. Headlight bulb (2 used) 10. Hood pivot keeper (2 used) 21. Flange nut (2 used) 32. Foam seal 11. Screw (6 used) 22. Rubber latch (2 used) Chassis Page 7 - - 42 Workman MD/MDX...
  • Page 191 2. Remove hood using Figure 27 as a guide. 1. Install hood using Figure 27 as a guide. During as- sembly, use fastener torque specifications that are iden- tified in Figure 28. Workman MD/MDX Page 7 - - 43 Chassis...

  • Page 192: Cargo Box (Serial Numbers Below 311000000)

    9. Box brace (3 used) 20. Latch pin (2 used) 30. Tailgate channel 10. Latch washer (4 used) 21. Lock nut (2 used) 31. Striker plate (2 used) 11. Prop rod Chassis Page 7 - - 44 Rev. A Workman MD/MDX...
  • Page 193 B. Adjust latch pin (item 20) so that cargo box is tight parking brake and remove key from the ignition switch. to frame when latched. 2. Disassemble cargo box as necessary using Figure 33 as a guide. Rev. A Workman MD/MDX Page 7 - - 45 Chassis...

  • Page 194: Cargo Box (Serial Numbers Above 311000000)

    4. Lock nut (2 used) 10. Flange nut (4 used) 16. Prop rod bracket 5. Carriage screw (4 used) 11. Prop rod 17. Latch assembly 6. Pivot bracket 12. Flange nut (6 used) Chassis Page 7 - - 46 Rev. A Workman MD/MDX...
  • Page 195 3. Outer tailgate 9. Striker mount (2 used) 4. RH latch rod 10. Strike latch (2 used) 5. Latch handle 11. Screw (4 used) 6. Screw (24 used) 12. Screw (4 used) Rev. A Workman MD/MDX Page 7 - - 47 Chassis...
  • Page 196 This page is intentionally blank. Chassis Page 7 - - 48 Rev. A Workman MD/MDX...

  • Page 197: Circuit Diagrams 8

    Main Electrical Harness Wiring Diagram (Serial Number Above 310000800) ....Engine Electrical Harness: Workman MD ..Engine Electrical Harness: Workman MDX .
  • Page 198 This page is intentionally blank. Page 8 - - 2 Workman MD/MDX Electrical Drawings...

  • Page 199: Electrical Schematics

    AUTO RESETTING Workman MD Electrical Schematic Solenoid is shown de- - energized Page 8 - - 3...

  • Page 200: Workman Mdx

    AUTO RESETTING Workman MDX Electrical Schematic Solenoid is shown de- - energized Page 8 - - 4...

  • Page 201: Start Circuits

    AUTO RESETTING (ENERGIZED) Start Circuits (Workman MDX Schematic Shown) Power Current Control Current Indication Current Page 8 - - 5...

  • Page 202: Run Circuits

    AUTO RESETTING (ENERGIZED) Run Circuits (Workman MDX Schematic Shown) Power Current Control Current Indication Current Page 8 - - 6...

  • Page 203: Main Electrical Harness Drawing (Serial Number Below 280999999)

    Workman MD and MDX Main Electrical Harness Drawing (Serial Number Below 280999999) Page 8 - - 7 Rev. A...

  • Page 204: Main Electrical Harness Wiring Diagram (Serial Number Below 280999999)

    SP02 SP03 BLUE PINK BLUE SP01 BLACK PINK SP05 YELLOW PINK YELLOW VIOLET BLACK BROWN RED/BLACK BLACK BLUE GREEN BLUE Workman MD and MDX Main Electrical Harness Wiring Diagram (Serial Number Below 280999999) Page 8 - - 8 Rev. A...

  • Page 205: Main Electrical Harness Drawing (Serial Number From 290000001 To 310000800)

    Workman MD and MDX Main Electrical Harness Drawing (Serial Number From 290000001 to 310000800) Page 8 - - 9 Rev. A...
  • Page 206 GREEN BLACK BLUE PINK BLUE BLACK PINK YELLOW PINK YELLOW VIOLET BLACK BROWN RED/BLACK BLUE BLACK GREEN BLUE Workman MD and MDX Main Electrical Harness Wiring Diagram (Serial Number From 290000001 to 310000800) Page 8 - - 10 Rev. A...

  • Page 207: Main Electrical Harness Drawing (Serial Number Above 310000800)

    Workman MD and MDX Main Electrical Harness Drawing (Serial Number Above 310000800) Page 8 - - 11 Rev. A...

  • Page 208: Main Electrical Harness Wiring Diagram (Serial Number Above 310000800)

    GREEN YELLOW VIOLET BLACK BLUE PINK BLUE BLACK PINK YELLOW PINK YELLOW BLACK BLACK BROWN RED/BLACK BLUE BLACK GREEN BLUE Workman MD and MDX Main Electrical Harness Wiring Diagram (Serial Number Above 310000800) Page 8 - - 12 Rev. A...
  • Page 209 BLACK BROWN WHITE/BLUE GREEN BROWN/WHITE Workman MD Engine Electrical Harness Page 8 - - 13 Rev. A...
  • Page 210 BLACK BROWN WHITE/BLUE GREEN BROWN/WHITE Workman MDX Engine Electrical Harness Page 8 - - 14 Rev. A...

This manual is also suitable for:

Workman mdx

Table of Contents