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Toro Workman MDE 2008 Service Manual
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Toro Workman MDE 2008 Service Manual

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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 right to change product
specifications or this publication without notice.
E The Toro Company - - 2008, 2011
Service Manual
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. 08164SL (Rev. A)
R
MDE

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Summary of Contents for Toro Workman MDE 2008

  • Page 1 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 MDE...

  • Page 3: Table Of Contents

    Table Of Contents Chapter 1 - - Safety Safety Instructions ......1 -- 2 Jacking and Other Instructions .
  • Page 4 This page is intentionally blank. Workman MDE...
  • Page 5 Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS ..... . Before Operating ......While Operating .

  • Page 6: Safety Instructions

    Also tighten any loose nuts, bolts or screws to en- Additional copies of the Operator’s Manual are available sure machine is in safe operating condition. on the internet at www.Toro.com. While Operating 3. Before getting off the operator seat: WARNING A.

  • Page 7: Maintenance And Service

    13.To assure optimum performance and continued Carefully remove one of the battery cables from the bat- safety of the machine, use genuine Toro replacement tery pack as the first step in any repair. Once a battery parts and accessories. Replacement parts and acces-...

  • Page 8: Jacking And Other Instructions

    Jacking and Other Instructions Jacking Vehicle DANGER POTENTIAL HAZARD • A vehicle that is not properly supported may become unstable. WHAT CAN HAPPEN • The vehicle may move or fall. Personal injury or damage to the machine may result. HOW TO AVOID THE HAZARD •...

  • Page 9: Safety And Instruction Decals

    There 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...
  • Page 10 This page is intentionally blank. Safety Page 1 - - 6 Workman MDE...

  • Page 11: Product Records

    Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS ......MAINTENANCE ....... EQUIVALENTS AND CONVERSIONS .

  • Page 12: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 - - 2 Workman MDE...

  • 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 Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8 with Thin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts...
  • Page 15 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 Thread Size Regular Height Nuts Regular Height Nuts Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8...
  • Page 16 Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** Thread Size Thread Size Square Head Hex Socket 7/16 -- 20 UNF 65 + 10 ft--lb 88 + 14 N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb...

  • Page 17: General Information

    Chapter 3 Electrical System Table of Contents GENERAL INFORMATION ..... SERVICE AND REPAIRS ..... Operator’s Manual .

  • Page 18: General Information

    General Information The Workman MDE uses a 48 volt DC electrical system LED on the controller and the vehicle status light on the that is an isolated circuit. The vehicle frame is not used dash panel will flash a fault code to assist in identifying for any ground connections.

  • Page 19: Electrical Diagrams

    Electrical Diagrams The electrical schematic, circuit drawings and wire har- ness drawings for the Workman MDE are located in Chapter 6 -- Electrical Diagrams. Workman MDE Electrical System Page 3 - - 3...

  • Page 20: Vehicle Operation

    Vehicle Operation The Workman MDE electrical system uses a 48 volt bat- The vehicle controller is a sealed electronic logic device tery pack, an electric traction motor, a vehicle controller that uses inputs from several vehicle components to and numerous other electrical components to allow ve- control motor speed and direction.

  • Page 21: Special Tools

    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.
  • Page 22 Battery Watering Dispenser Use the battery watering dispenser when adding dis- tilled water to vehicle batteries. Toro Part Number: TOR4102 Figure 6 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte. Obtain hydrometer locally. Figure 7...
  • Page 23 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 Workman MDE Electrical System...

  • Page 24: Troubleshooting

    Troubleshooting For effective troubleshooting and repairs, there must be CAUTION 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 If the vehicle has any switches by--passed, they must be watches, before doing any electrical trouble- shooting or testing.

  • Page 25: Battery Charger Operation

    General Run Problems (Continued) Problem Possible Causes Traction motor stops during operation. 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.

  • Page 26: Battery Charger Problems

    Battery Charger Problems Problem Possible Causes Battery charger does not turn on. 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.

  • Page 27: Accelerator Switch Adjustment

    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.

  • Page 28: Accelerator Potentiometer Adjustment (Potentiometer With Short Lever)

    Accelerator Potentiometer Adjustment (Potentiometer with Short Lever) NOTE: The following adjustment procedure should be 5. Calibrate accelerator system after any accelerator used on vehicles that have a potentiometer that includes potentiometer adjustment (see Accelerator System Cal- a short lever (Figure 14). If potentiometer has a long le- ibration in this section).

  • Page 29: Accelerator Potentiometer Adjustment (Potentiometer With Long Lever)

    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 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.
  • Page 30 This page is intentionally blank. 12.2 Rev. A Electrical System Page 3 - - Workman MDE...

  • Page 31: Accelerator System Calibration

    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.

  • Page 32: Component Testing

    Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. disconnect the harness wire connectors from the vehicle on/off switch before doing a continuity check on the on/off switch). When testing electrical components for continu- ity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.

  • Page 33: Battery Discharge Indicator And Hour Meter Gauge

    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 of the bat- tery pack. The battery indicator reads full (10 bars) when the battery pack is fully charged (approximately 51 volts).

  • Page 34: Vehicle Direction (Forward/Reverse) And Headlight Switches

    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.

  • Page 35: Vehicle Status Light

    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).

  • Page 36: Supervisor Speed Limit Switch

    Supervisor Speed Limit Switch The supervisor speed limit switch is open in OFF posi- tion (key vertical) and closed in ON position (key rotated B&C clockwise). The speed limit switch is one of several in- puts for the vehicle controller and allows the speed of the A&D B&C vehicle to be limited.

  • Page 37: Charger Interlock Switch

    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 input to the vehicle controller to inhibit vehicle opera- tion.

  • Page 38: Main And Accessories Contactors

    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.
  • Page 39 6. Replace contactor if necessary. 45 to 50 in- -lb (5.1 to 5.6 N- -m) 7. Connect electrical connections to contactor. If main contactor connections were removed, use Figure 33 as a guide for reattaching cable and wire harness connec- tions.

  • Page 40: Fuses

    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.

  • Page 41: Fusible Links

    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.

  • Page 42: Accelerator Switch

    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 of the 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.

  • Page 43: Accelerator Potentiometer

    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.

  • Page 44: Controller

    10.2 N- -m) and torque screws at terminals F1 and F2 from 55 to 60 in- -lb (6.2 to 6.8 N- -m) (Fig. 41). Apply Toro battery terminal protector (see Special Tools) to controller connections after tightening terminal screws.
  • Page 45 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.

  • Page 46: Service And Repairs

    Service and Repairs Battery Service 115 to 125 in- -lb (13.0 to 14.1 N- -m) 115 to 125 in lb (13.0 to 14.1 N- -m) RIGHT FRONT Figure 42 1. Battery (8 used) 5. Hex nut (2 used per battery) 9.

  • Page 47: Battery Removal

    1. Position vehicle on a level surface, set parking brake, turn on/off switch OFF and remove key. 7. Apply Toro battery terminal protector (see Special Tools) to all battery posts and cable connectors to re- 2. Raise cargo box and secure with prop rod.

  • Page 48: Battery Charging

    Battery Charging 3. Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler When the vehicle is not in use, it is recommended to cap, overcharging, loose terminal post or overfilling. keep the batteries charged by connecting the battery charger that is included with the vehicle.

  • Page 49: Battery Testing

    Battery Testing B. Measure the specific gravity of each cell with a hydrometer. Fill and drain the hydrometer two to four When testing batteries in the Workman MDE, it is impor- times before drawing a sample. At the same time, tant to test all batteries.

  • Page 50: Battery Storage

    Battery Storage If the vehicle will be stored for more than 30 days and the battery charger cannot be used for some reason, charge If the vehicle will be stored for any period of time, check the batteries fully. Either store batteries on a shelf or in battery electrolyte level, adjust level if needed and then the vehicle.

  • Page 51: Traction Motor Brushes

    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.

  • Page 52: Traction Motor

    Traction Motor 115 to 125 in lb (13.0 to 14.1 N- -m) RIGHT FRONT 125 to 165 in- -lb (14.2 to 18.6 N- -m) Figure 50 1. Socket head screw (6 used) 8. Traction motor 14. Cable terminal boot 2. Flat washer (6 used) 9.
  • Page 53 4. Disconnect wires from traction motor (Fig. 51): 2. Make sure that rubber damper is installed into the motor shaft internal spline with the damper flat side to- A. While retaining lower nut, remove upper nut and ward the motor (Fig. 51). wire connector from motor terminals A1, A2, F1 and 85 to 90 in- -lb (9.6 to 10.2 N- -m)
  • Page 54 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. CAUTION To prevent motor damage and personal injury, make sure that traction motor is well sup- ported as it is installed.
  • Page 55 This page is intentionally blank. Workman MDE Electrical System Page 3 - - 37...

  • Page 56: Traction Motor Service

    Traction Motor Service 120 to 140 in- -lb (13.6 to 15.8 N- -m) 18 to 22 in- -lb (2.0 to 2.5 N- -m) Figure 56 1. Frame and field assembly 6. Cap screw (8 used) 11. Commutator end head 2. Armature 7.
  • Page 57 Brush Service 3. It is also recommended that the field be coated with PD George 1000--70 or RanBar B--535--5S varnish for 1. Check the brush springs for correct alignment on the proper insulation protection. Both recommended var- back of the brush. A brush spring that does not apply nishes are Class H water--soluble varnishes.
  • Page 58 Commutator Service MICA 1. Chuck armature on the commutator end--bearing COPPER SEGMENT 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 0.040”...
  • Page 59 Assembly (Fig. 56) ARMATURE PRESS FIXTURE NOTE: After the motor has been disassembled, it is ASSEMBLY MUST PRESS recommended that a new commutator end head bear- AGAINST OUTER RACE ing be installed because the removed bearing may have BEARING AND been damaged during disassembly.

  • Page 60: Battery Charger

    Battery Charger Figure 64 1. Upper case 5. Control board 9. DC cordset 2. Transformer 6. Relay 10. Ammeter 3. Lower case 7. Circuit breaker 11. Fuse 4. SCR assembly 8. AC cordset 12. Diode assembly For service of the battery charger, see the Lester Electri- cal Technician Service Guide at the end of this chapter.
  • Page 61 Chapter 4 Transaxle and Brakes Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......SPECIFICATIONS .

  • Page 62: General Information

    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. Page 4 - - 2 Workman MDE Transaxle and Brakes...

  • Page 63: Specifications

    Specifications Item Description Transaxle Transaxle Fluid Capacity 2 quarts (1.9 liters) Transaxle Fluid 10W--30 Motor Oil Brake Fluid DOT 3 Workman MDE Page 4 - - 3 Transaxle and Brakes...

  • Page 64: Troubleshooting

    Troubleshooting Brakes Problem Possible Cause Brake pedal goes to the floor. Rear brake shoes are excessively worn. Front brake pads are excessively worn. Brake fluid level low. Brake fluid leak at hose, caliper or wheel cylinder. Brake master cylinder faulty. Brake pedal is spongy.
  • Page 65 Brakes (continued) Problem Possible Cause Brakes drag. Parking brake is applied. Rear shoe--to--shoe springs are weak or broken. Brake pedal is binding. Brake linings are saturated. Rear brake drums are bent or out--of--round. Front brake calipers or rotors are damaged. Brake pedal is hard to push.

  • Page 66: Service And Repairs

    Service and Repairs Rear Wheels and Brakes 125 to 140 ft- -lb (170 to 190 N- -m) 45 to 65 ft- -lb (61 to 88 N- -m) 26 to 30 ft- -lb (34 to 41 N- -m) RIGHT FRONT Figure 1 1.
  • Page 67 Removal (Fig. 1) B. Position and secure hydraulic brake line to wheel cylinder (Fig. 3). Torque banjo bolt from 15 to 21 ft- - 1. Park vehicle on a level surface, turn on/off switch lb (21 to 28 N- -m). OFF and remove key from the on/off switch.
  • Page 68 5. Position wheel assembly to the vehicle with valve Burnish Brake Shoes stem facing out and secure with five (5) lug nuts. To provide maximum brake performance after rear 6. Lower vehicle to ground. Torque lug nuts in a cross- brake shoes are replaced, burnish new brake shoe lin- ing pattern from 45 to 65 ft- -lb (61 to 88 N- -m).
  • Page 69 This page is intentionally blank. Workman MDE Page 4 - - 9 Transaxle and Brakes...

  • Page 70: Rear Brake Service

    Rear Brake Service 110 to 120 in- -lb (12.4 to 13.6 N- -m) 110 to 120 in- -lb (12.4 to 13.6 N- -m) 110 to 120 in- -lb (12.4 to 13.6 N- -m) Figure 4 1. Brake backing plate 6. Parking brake lever (LH shown) 10.
  • Page 71 Inspection (Fig. 4) Assembly (Fig. 4) 1. Inspect brake drums. IMPORTANT:Brake shoe lining surfaces must be free of grease, oil and other foreign matter. IMPORTANT:Brake drum machining is not re- commended. Replace brake drums as a set to 1. Apply a light film of lubricant to the following: maintain equal braking forces.

  • Page 72: Hydraulic Brake System

    Hydraulic Brake System Loctite #242 RIGHT FRONT 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.

  • Page 73: Bleed Brake System

    Bleed Brake System 1. Connect a suitable transparent hose to bleeder valve 5. Repeat steps 1 to 4 for other brake cylinders and cali- on a wheel cylinder or caliper. Submerge other end of pers. hose in a glass container partially filled with clean brake fluid.

  • Page 74: Front Brake Calipers

    Front Brake Calipers To rear brakes Loctite #242 45 to 65 ft- -lb (61 to 88 N- -m) RIGHT FRONT 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.
  • Page 75 Removal (Fig. 6) Installation (Fig. 6) 1. Park machine on a level surface, stop engine, set 1. If brake pads were removed from caliper, install pads parking brake and remove key from the ignition switch. (Fig. 7): A. If brake pads are being replaced, it will be neces- WARNING sary to push caliper pistons back into the caliper bore before installing new pads.

  • Page 76: Brake Master Cylinder

    Brake Master Cylinder RIGHT FRONT Figure 8 1. Master cylinder 4. Clevis pin 6. Flange head nut 2. Cap screw 5. Cotter pin 7. Pedal frame 3. Brake pedal Removal (Fig. 8) Installation (Fig. 8) 1. Raise and support front hood. 1.

  • Page 77: Brake Master Cylinder Service

    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.

  • Page 78: Parking Brake

    Parking Brake RIGHT FRONT Figure 10 1. Parking brake cover 7. Lock nut 13. Cotter pin 2. Operator seat 8. Flat washer 14. Clevis pin 3. Seat base 9. Flange head screw (4 used) 15. Parking brake cable (2 used) 4.
  • Page 79 Disassembly (Fig. 10) Assembly (Fig. 10) 1. Park machine on a level surface, stop engine and re- 1. Secure brake cables to parking brake support and move key from the ignition switch. Chock wheels to pre- cable equalizer bracket using Figure 10 as a guide. vent the machine from moving.

  • Page 80: Transaxle

    Transaxle 115 to 125 in- -lb (13.0 to 14.1 N- -m) 45 to 65 ft- -lb (61 to 88 N- -m) RIGHT FRONT Figure 11 1. Socket head screw (6 used) 9. Roll pin (2 used) 17. Cotter pin 2. Flange nut 10.
  • Page 81 Removal (Fig. 11) 8. Clean hydraulic brake line area of rear brake cylin- ders to prevent contamination. Loosen and disconnect 1. Park vehicle on a level surface, turn on/off switch hydraulic brake line from both wheel cylinders. Plug OFF, set parking brake and remove key from switch. brake lines and position them away from wheel cylin- ders.
  • Page 82 Installation (Fig. 11) 8. Carefully connect removed battery cable to battery terminals. Install lock washers and nuts on battery termi- 1. If removed, install traction motor to transaxle (see nals. Torque nuts from 115 to 125 in- -lb (13.0 to 14.1 Traction Motor Installation in Service and Repairs sec- N- -m).
  • Page 83 This page is intentionally blank. Workman MDE Page 4 - - 23 Transaxle and Brakes...

  • Page 84: Transaxle Service

    Transaxle Service 125 to 140 ft- -lb (170 to 190 N- -m) 26 to 30 ft- -lb (34 to 41 N- -m) 16 to 24 ft- -lb (22 to 33 N- -m) 20 to 30 ft- -lb (27 to 41 N- -m) Figure 16 1.
  • Page 85 Chapter 5 Chassis Table of Contents GENERAL INFORMATION ..... Operator’s Manual ......SPECIFICATIONS .

  • Page 86: Specifications

    45 to 65 ft--lb (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.

  • Page 87: Troubleshooting

    Troubleshooting Suspension and Steering Problem Possible Cause Front end is noisy. Front wheel lug nuts are loose. Front wheel bearings are loose or worn. Front end components are loose or worn. Steering gearbox is damaged or worn. Rear end is noisy. Rear wheel lug nuts are loose.
  • Page 88 Suspension and Steering (continued) Problem Possible Cause Steering is hard. Tire pressure is low or uneven between tires. Front wheel alignment (toe--in) is incorrect. Steering linkage is binding or damaged. Steering gearbox is damaged or worn. Vehicle pulls to one side when not Tire pressure is low or uneven between tires.

  • Page 89: Adjustments

    Adjustments Adjust Front Wheel Camber 1. Adjust front tire pressures to 12 PSI (82 kPa) before 7. Repeat steps 2 through 6 until front wheel camber on checking front wheel camber. both wheels is correct. 2. Either add weight to the driver’s seat equal to the av- 8.

  • Page 90: Adjust Front Wheel Toe--In

    Adjust Front Wheel Toe- -in NOTE: Before adjusting front wheel toe--in, make sure that front wheel camber is correctly adjusted (see Adjust Front Wheel Camber in this section). 1. Adjust front tire pressures to 12 PSI (82 kPa) before checking front wheel camber. 2.

  • Page 91: Service And Repairs

    Service and Repairs Check Tire Pressure The tire pressure range for front and rear tires is 8 to 22 Higher pressures should be used for heavier payloads PSI (55 to 152 kPa). The tire pressure needed is deter- at higher speeds. Do not exceed the maximum tire pres- mined by the payload carried.

  • Page 92: Upper Steering

    Upper Steering 18 to 22 ft- -lb (25 to 29 N- -m) RIGHT FRONT 175 to 225 in lb Antiseize lubricant (20 to 25 N- -m) Loctite #242 Antiseize lubricant Figure 1 1. Hex nut 7. Lock washer (6 used) 12.
  • Page 93 5. Support steering column to prevent it from falling. 5. Position knuckle of the lower steering shaft onto the Remove four (4) flange nuts and carriage screws secur- gearbox input shaft. Secure knuckle to the steering ing the steering column to the mounting plate on the gearbox shaft with cap screw and lock washer.

  • Page 94: Steering Gearbox

    Steering Gearbox 27 to 33 ft- -lb (37 to 44 N- -m) 90 to 110 in- -lb (10.2 to 12.4 N- -m) 175 to 225 in- -lb (20 to 25 N- -m) Matchmark before disassembly Figure 2 1. Gasket 8. Stepped washer 14.
  • Page 95 Disassembly (Fig. 2) 2. If seals were removed, press new seals into housing. Seal lips should be facing up. IMPORTANT:Do not reuse flange head screw with patch lock after it has been removed. 3. Place flat washer (item 5) onto shaft of the Pitman arm (item 19).

  • Page 96: Lower Steering And Front Wheels

    Lower Steering and Front Wheels 20 to 25 ft- -lb (28 to 33 N- -m) See text for tightening procedure 45 to 55 ft- -lb (62 to 74 N- -m) Loctite #242 RIGHT FRONT 45 to 65 ft- -lb (62 to 88 N- -m) Figure 3 1.
  • Page 97 Removal (Fig. 3) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - - Safety. 2. Chock wheels not being jacked up. Jack front wheel Loctite #242 off the ground and support vehicle with appropriate jack stand beneath the frame.
  • Page 98 C. Install brake hose clip onto cap screw. Secure 4. Slide wheel hub assembly onto spindle. Install outer spindle to A--arm hub with cap screw and lock nut. bearing, tab washer and jam nut onto spindle. Torque fasteners from 75 to 100 ft- -lb (102 to 135 5.

  • Page 99: Front Shock Absorbers

    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 Camber in the Adjustments sec- tion of this chapter). Do not make shock spring adjustment without checking front wheel camber.

  • Page 100: A--Arms And Front Suspension

    A- -arms and Front Suspension 20 to 25 ft- -lb (28 to 33 N- -m) See text for tightening procedure 9 10 45 to 55 ft- -lb (62 to 74 N- -m) Loctite #242 RIGHT FRONT 75 to 100 ft- -lb 45 to 65 ft- -lb (102 to 135 N- -m) (62 to 88 N- -m)
  • Page 101 A- -arm Removal (Fig. 7) 3. Position A--arm to the frame. Secure A--arm to the frame with cap screws (item 19) and lock nuts (item 6). 1. Park vehicle on a level surface, turn on/off switch Insert front screw from front of machine and rear screw OFF, set parking brake and remove key from the on/off from rear of machine.

  • Page 102: Frame Pivot Yoke

    Frame Pivot Yoke RIGHT FRONT 240 to 290 ft- -lb (326 to 393 N- -m) Figure 9 1. Flange nut (4 used) 9. Grease fitting (1 used per arm) 16. Flange head screw (4 used) 2. Shock absorber (2 used) 10.
  • Page 103 Pivot Yoke Removal (Fig. 9 and 10) Pivot Yoke Installation (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 WARNING switch. 2. Open the battery circuit by carefully removing one of Support pivot yoke while installing it to the front the battery cables (see Opening Battery Circuit in the frame to prevent dropping and causing serious...

  • Page 104: Seat Base

    Seat Base RIGHT FRONT Figure 11 1. Seat 13. Screw (4 used) 25. Cotter pin 2. Seat bracket 14. Washer head screw (4 used) 26. Parking brake cover 3. Rubber receptacle 15. Charger receptacle plate 27. Screw (2 used) 4. Rivet 16.
  • Page 105 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. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 -- Electrical System).

  • Page 106: Front Hood

    Front Hood 7 to 13 in- -lb (0.8 to 1.4 N- -m) 7 to 13 in- -lb (0.8 to 1.4 N- -m) RIGHT FRONT Figure 13 1. Fender (LH shown) 12. Washer head screw (8 used) 23. Catch (2 used) 2.
  • Page 107 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. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 -- Electrical System).

  • Page 108: Cargo Box (Serial Number Below 311000000)

    Cargo Box (Serial Number Below 311000000) 35 to 55 in- -lb (4 to 6.2 N- -m) 35 to 55 in- -lb (4 to 6.2 N- -m) 100 to 200 in- -lb (11.3 to 22.6 N- -m) RIGHT FRONT Figure 18 1.
  • Page 109 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 2. Position cargo box to the frame locking the latch rod switch.

  • Page 110: Cargo Box (Serial Number Above 311000000)

    Cargo Box (Serial Number Above 311000000) 200 to 210 in- -lb (22.6 to 23.7 N- -m) 200 to 210 in- -lb (22.6 to 23.7 N- -m) RIGHT FRONT 200 to 210 in- -lb (22.6 to 23.7 N- -m) Figure 19 1.
  • Page 111 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.
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  • Page 113 Chapter 6 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC Electrical Schematic ......ELECTRICAL CIRCUIT DRAWINGS On/Off Switch Turned On .
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  • Page 115: Electrical Schematic

    10 A FUSE IGNITION- -SWITCH HOLDERS 10 A ACCESSORIES CONTACTOR HORN (SOLENOID) HORN SWITCH BATT. CHG. HOOK UP HEADLIGHTS, 24V INTERLOCK STATE OF CHARGE CHARGER INDICATOR SWITCH (CHARGER PLUGGED IN) LIGHT SWITCH HOUR METER 355 A BU/W FORWARD/REVERSE (IN FORWARD) OPTIONS 3 (NC) 1 48 VDC INPUT...

  • Page 116: On/Off Switch Turned On

    F3 10 A FUSE IGNITION- -SWITCH HOLDERS F2 10 A ACCESSORIES CONTACTOR HORN (SOLENOID) (ENERGIZED) (IN RUN) HORN SWITCH BATT. CHG. HOOK UP HEADLIGHTS, 24V INTERLOCK STATE OF CHARGE CHARGER INDICATOR SWITCH (CHARGER NOT PLUGGED IN) LIGHT SWITCH HOUR METER 355 A BU/W FORWARD/REVERSE...

  • Page 117: Run Circuit (Forward)

    10 A FUSE IGNITION- -SWITCH HOLDERS 10 A ACCESSORIES CONTACTOR HORN (SOLENOID) (ENERGIZED) (IN RUN) HORN SWITCH BATT. CHG. HOOK UP HEADLIGHTS, 24V INTERLOCK STATE OF CHARGE CHARGER INDICATOR SWITCH (CHARGER NOT PLUGGED IN) LIGHT SWITCH HOUR METER 355 A BU/W FORWARD/REVERSE (IN FORWARD)
  • Page 118 This page is intentionally blank. Page 6 - - 7 Rev. A...
  • Page 119 Workman MDE Serial Number Below 310000000 Electrical Harness Drawing Page 6 - - 8 Rev. A...
  • Page 120 PINK RED/WHITE ORANGE ORANGE WHITE ORANGE RED/WHITE BLACK BLUE BLUE/WHITE BLACK BROWN WHITE/BLACK BLUE/WHITE YELLOW ORANGE BLACK PINK BLUE YELLOW VIOLET/BLACK BLACK BLUE/WHITE WHITE BROWN GREEN BLACK GRAY BLACK BLACK BLUE RED/WHITE BLACK BLUE BLUE BLUE ORANGE ORANGE GREEN BLUE ORANGE Workman MDE Serial Number Below 310000000...
  • Page 121 Workman MDE Serial Number Above 310000000 Electrical Harness Drawing Page 6 - - 10 Rev. A...
  • Page 122 PINK RED/WHITE ORANGE ORANGE WHITE ORANGE RED/WHITE BLACK BLUE/WHITE BLUE BLACK BROWN WHITE/BLACK BLUE/WHITE BLACK YELLOW ORANGE BLUE PINK PINK BLUE YELLOW VIOLET/BLACK BLACK BLUE/WHITE WHITE BROWN GREEN BLACK GRAY BLACK BLACK BLUE BLACK RED/WHITE BLUE BLUE BLUE ORANGE ORANGE GREEN BLACK BLUE...
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  • Page 124: Battery Charging Circuit

    F3 10 A FUSE IGNITION- -SWITCH HOLDERS F2 10 A ACCESSORIES CONTACTOR HORN (SOLENOID) (NOT ENERGIZED) (OFF) HORN SWITCH BATT. CHG. HOOK UP HEADLIGHTS, 24V INTERLOCK STATE OF CHARGE CHARGER INDICATOR SWITCH (CHARGER PLUGGED IN) LIGHT SWITCH HOUR METER 355 A BU/W FORWARD/REVERSE (IN FORWARD)
  • Page 125 This page is intentionally blank. Page 6 - - 7 Rev. A...

  • Page 126: Electrical Harness Drawing (Serial Number Below 310000000)

    Workman MDE Serial Number Below 310000000 Electrical Harness Drawing Page 6 - - 8 Rev. A...

  • Page 127: Electrical Harness Wiring Diagram (Serial Number Below 310000000)

    PINK RED/WHITE ORANGE ORANGE WHITE ORANGE RED/WHITE BLACK BLUE BLUE/WHITE BLACK BROWN WHITE/BLACK BLUE/WHITE YELLOW ORANGE BLACK PINK BLUE YELLOW VIOLET/BLACK BLACK BLUE/WHITE WHITE BROWN GREEN BLACK GRAY BLACK BLACK BLUE RED/WHITE BLACK BLUE BLUE BLUE ORANGE ORANGE GREEN BLUE ORANGE Workman MDE Serial Number Below 310000000...

  • Page 128: Electrical Harness Drawing (Serial Number Above 310000000)

    Workman MDE Serial Number Above 310000000 Electrical Harness Drawing Page 6 - - 10 Rev. A...

  • Page 129: Electrical Harness Wiring Diagram (Serial Number Above 310000000)

    PINK RED/WHITE ORANGE ORANGE WHITE ORANGE RED/WHITE BLACK BLUE/WHITE BLUE BLACK BROWN WHITE/BLACK BLUE/WHITE BLACK YELLOW ORANGE BLUE PINK PINK BLUE YELLOW VIOLET/BLACK BLACK BLUE/WHITE WHITE BROWN GREEN BLACK GRAY BLACK BLACK BLUE BLACK RED/WHITE BLUE BLUE BLUE ORANGE ORANGE GREEN BLACK BLUE...
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Workman mde 2011