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.
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Page 3: Table Of Contents
Table Of Contents Chapter 1 - - Safety Chapter 5 - - Electrical System Safety Instructions ......1 -- 2 General Information .
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Page 5: Safety Instructions 1
Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS ..... . Supervisor’s Responsibilities ....Before Operating .
Page 6: Safety Instructions
Additional copies of the Operator’s Manual are available on the internet at www.Toro.com. WARNING The Workman is an off- -highway vehicle only. It is not designed, equipped or manufactured for use on public streets, roads or highways.
Page 7: While Operating
4. Never store the vehicle or fuel container inside 13.To assure optimum performance and continued where there is an open flame, such as near a water heat- safety of the vehicle, use genuine Toro replacement er or furnace. parts and accessories. Replacement parts and acces- sories made by other manufacturers may result in non- 5.
Page 8: Jacking And Other Instructions
Jacking and Other Instructions Jack 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: Transaxle Neutral Position
Transaxle Neutral Position When performing routine maintenance and/or engine testing, the transaxle must be shifted into the neutral position. 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 2. Move shift lever to the neutral position (Fig. 3). 3.
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 MDX--D...
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 MDX--D...
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)
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 Regular Height Nuts Regular Height Nuts (Class 8 or Stronger Nuts) (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm...
Page 16: Other Torque Specifications
Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Recommended Torque Thread Size Recommended Torque** 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 73 + 12 in--lb...
Page 17: General Information 3
Chapter 3 Diesel Engine Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Operator’s Manual .
Page 18: Workman Mdx--D
Specifications Item Description Make / Designation Kubota water--cooled, Diesel, Model Z602--E3B Number of Cylinders Bore x Stroke 2.83” x 2.9” (72mm x 73.6mm) Total Displacement 36.55 in (599 cc) Compression Ratio 24.0:1 Firing Order 1 (closest to gear case end) -- 2 (closest to flywheel end) Direction of Rotation Counterclockwise (viewed from flywheel) Fuel...
Page 19: Chapter 3 - - Diesel Engine
Service and repair parts for the Kubota engine in your commonly available in many service shops. Special Workman are supplied through your local Toro distribu- tools are described in the Kubota Workshop Manual, tor. If no parts list is available, be sure to provide your Diesel Engine, SM--E3B Series.
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Page 21: Adjustments
Adjustments Adjust Throttle Cable Proper throttle operation is dependent upon proper ad- justment of throttle control. Make sure throttle control is operating properly. NOTE: The shoulder bolt that secures the throttle cable to the engine speed control lever should be positioned in the lowest hole in the lever.
Page 22: Service And Repairs
Service and Repairs Air Cleaner FRONT RIGHT Figure 3 1. Air cleaner assembly 5. Air inlet hood 9. Shoulder bolt 2. Carriage screw (2 used) 6. Flange nut (2 used) 10. Throttle cable mount 3. Air intake hose 7. Hose clamp (2 used) 11.
Page 23 Air Cleaner Removal (Fig. 3) 1. Park machine on a level surface, stop the engine, en- gage parking brake and remove the key from the ignition switch. 2. Raise and support cargo bed to access air cleaner. 3. Remove air cleaner components as needed using Figure 3 as a guide.
Page 24: Exhaust System
Exhaust System RIGHT FRONT Figure 6 1. Engine 4. Flange nut (4 used) 7. Exhaust gasket 2. Exhaust header 5. Muffler 8. Flange head screw (4 used) 3. Coupler spring (2 used) 6. Hex nut (4 used) 9. Lock washer (4 used) Diesel Engine Page 3 - - 8 Workman MDX--D...
Page 25 Exhaust System Removal (Fig. 6) Exhaust System Installation (Fig. 6) 1. Park machine on a level surface, stop the engine, en- 1. Make sure the engine is off. gage parking brake and remove the key from the ignition IMPORTANT: If exhaust studs were removed from switch.
Page 26: Fuel Tank
Fuel Tank RIGHT FRONT Figure 7 1. Seat 5. Seat base 8. Flat washer (8 used) 2. Fuel tank 6. Web strapping 9. Parking brake support 3. Fuel hose (to fuel separator) 7. Hex head flange screw (8 used) 10. Shift bracket 4.
Page 27 Fuel Tank Removal (Fig. 7) CAUTION Read safety precautions for handling fuel before working on the fuel system (see Safety Instruc- tions in Chapter 1 - - Safety). 1. Remove seat base from the frame (see Seat Base in the Service and Repairs section of Chapter 6 -- Chas- sis).
Page 28: Radiator
Radiator RIGHT FRONT Figure 9 1. Surge tank 9. Lower radiator hose 17. Lower radiator shroud 2. Tank cap 10. Upper radiator hose 18. Upper radiator shroud 3. Radiator 11. Straight hose 19. Speed nut (4 used) 4. Washer head screw (2 used) 12.
Page 29 4. Remove caps (items 2 and 6) from surge tank and ra- IMPORTANT: Use a 50/50 mix of ethylene- -glycol diator filler neck to allow complete draining of cooling and water when filling cooling system. system. 7. Fill cooling system with coolant as follows (Fig. 11): 5.
Page 30: Engine
Engine RIGHT FRONT Figure 12 1. Engine 7. Flange head screw (8 used) 13. Snubbing washer (4 used) 2. Engine wire harness connector 8. Hex nut (4 used) 14. Spacer (4 used) 3. Hex nut 9. Lock washer (4 used) 15.
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. CAUTION The engine, radiator and exhaust system may be hot. To avoid possible injury, allow machine to cool before working on the engine.
Page 32: Engine Installation
11. Disconnect electrical connections from the following engine components: A. Disconnect main wire harness connections to glow plug bus, temperature sender and engine run solenoid (Fig. 14). B. Disconnect main wire harness connection to fus- ible link harness. C. Disconnect engine wire harness connector from the main wire harness.
Page 33 4. Connect the following electrical components: 8. Install exhaust header and muffler to the vehicle (see Exhaust System in this section). A. Connect main wire harness connections to glow plug bus, temperature sender and engine run solen- 9. Install air intake hose to the air cleaner and engine oid (Fig.
Page 34: Chapter 4 - - Drive Train
Engine Clutch Adapter 17 to 22 ft- -lb (23 to 29 N- -m) Loctite #242 RIGHT FRONT Figure 17 1. Drive belt 4. Drive clutch 6. Clutch adapter 2. Cap screw 5. Cap screw (5 used) 7. Engine assembly 3. Flange washer Removal (Fig.
Page 35: Specifications
Chapter 4 Drive Train Table of Contents SPECIFICATIONS ......GENERAL INFORMATION ..... Operator’s Manual .
Page 36 Specifications Item Description Transaxle Transaxle Fluid Capacity 1.5 quarts (1.4 liters) Transaxle Fluid SAE 10W--30 Motor Oil Transaxle Dry Weight 73 pounds (33 kilograms) Clutch System Continuously variable transmission type, torque convertor Drive Clutch Speed sensing with mechanical fly weights Driven Clutch Torque sensing with spring loaded cam Drive Train...
Page 37: Operator's Manual
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman MDX--D vehicle. Refer to the Operator’s Manual for additional information when ser- vicing the machine. Workman MDX--D Page 4 - - 3 Drive Train...
Page 38: Clutch System Operation
Drive Train Operation Clutch System Operation FULL ENGINE SPEED LOW ENGINE SPEED DECREASING LOAD FULL ENGINE SPEED LIGHT LOAD INCREASING LOAD Figure 1 1. Drive clutch 4. Fixed sheave (drive clutch) 7. Fixed sheave (driven clutch) 2. Driven clutch 5. Moveable sheave (driven clutch) 8.
Page 39: Drive Clutch Operation
Drive Clutch Operation The operation of the drive clutch is affected by engine shaft speed. With the engine not turning, the CVT drive belt rests low within the drive clutch sheaves as the pres- sure of the spring holds the sheaves apart. As the en- gine increases in speed, the clutch weights attached to the moveable sheave move outward as they spin about the engine driveshaft.
Page 40: Driven Clutch Operation
Driven Clutch Operation The operation of the driven clutch is affected by trans- axle load. When the vehicle is stopped, the drive belt is held at the outer diameter of the driven clutch sheaves from the pressure of the spring pushing the moveable sheave against the fixed sheave and away from the fixed cam.
Page 41: Special Tools
Special Tools Order special tools from your Toro Distributor. Drive Clutch Removal Tool 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 retaining screw is removed.
Page 42: Troubleshooting
Troubleshooting Clutch Problem Possible Cause Poor upshifting. Governed engine speed is adjusted too low. Drive and/or driven clutch assemblies have accumulation of dirt or debris. Drive belt is worn. Clutch sheaves are worn or damaged. Poor downshifting. Drive and/or driven clutch assembly has accumulation of dirt or debris.
Page 43: Adjustments
Adjustments Adjust Shift Cables 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. Raise and support cargo box. 2. Set the shift lever into the Neutral position. Rotate driven clutch to insure transmission is in neutral. 3.
Page 44: Service And Repairs
Service and Repairs Drive Clutch Loctite #242 RIGHT 17 to 22 ft- -lb FRONT (23 to 29 N- -m) Figure 7 1. Engine 4. Drive belt 6. Flange washer 2. Clutch adapter 5. Drive clutch 7. Cap screw 3. Cap screw (5 used) Drive Train Page 4 - - 10 Workman MDX--D...
Page 45 Drive Clutch Removal (Fig. 7) Drive Clutch Installation (Fig. 7) 1. Park machine on a level surface, stop engine, set 1. Thoroughly clean the tapered surfaces of the clutch parking brake and remove key from the ignition switch. adapter and drive clutch. Raise and support cargo box.
Page 46: Drive Clutch Service
Drive Clutch Service 105 to 120 in- -lb (12 to 13.5 N- -m) 40 to 50 in- -lb (4.6 to 5.6 N- -m) Figure 8 1. Flange head screw (6 used) 5. Shoulder screw (3 used) 9. Shim 2. Cover 6.
Page 47 5. Slide shoulder screw from each of the clutch weights 3. Position limiter shim, compression spring and cover (item 7) and then remove weights from clutch. to clutch. Make sure that the “X” mark cast into the cover and spider are aligned. 6.
Page 48: Driven Clutch
Driven Clutch Driven Clutch Removal (Fig. 13) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. Raise and support cargo box. 2. Remove muffler from the vehicle (see Exhaust Sys- tem in the Service and Repairs section of Chapter 3 -- Diesel Engine).
Page 49: Driven Clutch Service
Driven Clutch Service 1. Use a suitable press to compress the clutch spring enough to allow removal of the retaining ring. 2. Remove retaining ring. 3. Carefully, allow the spring to extend fully. 4. Remove outer spring retainer, spring and inner spring retainer from clutch.
Page 50: Transaxle
Transaxle 39 to 47 ft- -lb Antiseize (53 to 63 N- -m) Lubricant Antiseize Lubricant Loctite #242 120 ft- -lb (162 N- -m) Antiseize Lubricant RIGHT 80 to 90 ft- -lb (109 to 122 N- -m) FRONT Figure 15 1. Transaxle assembly 11.
Page 51: Removal
Removal (Fig. 15) 7. Support the transaxle to prevent it from shifting. 1. Park machine on a level surface, stop engine, set 8. Remove four (4) cap screws (item 10) and flat wash- parking brake and remove key from the ignition switch. ers (item 5) that secure the transaxle to the swing arm.
Page 52: Installation
Installation (Fig. 15) B. Slide select lever with attached shift cables onto transaxle selector shaft. 1. Position transaxle assembly under the vehicle swing arm. C. Apply Loctite #242 (or equivalent) to threads of lock nut (item 18). Secure select lever assembly to the selector shaft with flat washer (item 15) and lock CAUTION nut (item 18).
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Page 54: Transaxle Service
Transaxle Service 25 to 31 ft- -lb (34 to 42 N- -m) 40 to 45 ft- -lb (54 to 61 N- -m) 23 22 25 to 31 ft- -lb (34 to 42 N- -m) Figure 18 Drive Train Page 4 - - 20 Workman MDX--D...
Page 55: Transaxle Disassembly And Inspection
Figure 18 (Continued) 1. Case (LH) 21. Bolt 41. Differential case 2. Oil seal 22. Gasket 42. Side gear (2 used) 3. Oil seal 23. Spring 43. Pinion gear (2 used) 4. Snap ring 24. Ball bearing 44. Pinion shaft 5.
Page 56 Figure 20 1. Bolt (steel ball, spring & gasket) 2. Selector shaft C. Remove bolt near the selector shaft. Remove spring and steel ball. Replace gasket if damaged. Figure 21 1. Input shaft 2. Oil seal D. Wrap vinyl tape around the splined portion of the input shaft.
Page 57 Figure 22 1. Flange bolts (3 used) 3. Axle case 2. Axle bracket E. Remove three (3) flange bolts securing the axle bracket and axle case to each case. Separate brack- et from each axle case. Figure 23 1. Flange bolt (10 used) 2.
Page 58 Figure 24 1. Case (RH) 2. Governor boss IMPORTANT: Make sure to not hit the governor G. Hold the case (RH) and lift up while lightly tapping boss too hard when separating the cases, the boss the governor boss with a plastic hammer. may get damaged.
Page 59 Figure 26 1. Counter shaft 3. Needle bearing 2. Spacer (2 used) 4. Gear 34 B. Pull out counter shaft. Remove spacer, needle bearing, gear 34 and spacer. Figure 27 1. Counter shaft 3. Needle bearing 2. Spacer (2 used) 4.
Page 60 Figure 28 1. Differential assembly 3. Center shaft assembly 2. Input shaft assembly 4. Shift shaft IMPORTANT: Make sure to not damage the oil seal G. Lift up differential assembly, center shaft assem- when removing the input shaft. bly and input shaft assembly at the same time. First, remove input shaft assembly.
Page 61 Figure 30 1. Snap ring 3. Axle shaft 2. Axle case 4. Ball bearing IMPORTANT: Do not reuse snap ring. Discard and C. Ball bearing roller balls must be free of deforma- replace ring with new one. tion and scoring. Ball bearing must spin freely and have minimum axial play.
Page 62 Figure 32 1. Input shaft 2. Ball bearing B. Replace input shaft if worn or damaged. Gear C. Ball bearing roller balls must be free of deforma- teeth that are cracked, broken, chipped or missing tion and scoring. Ball bearing must spin freely and are not acceptable.
Page 63 Figure 34 1. Gear 55 6. Pin clutch 2. Gear 47 7. Center shaft 3. Gear (small) 8. Collar (2 used) 4. Ball bearing 9. Spacer 5. Ball bearing B. Remove gears, pin clutch, collars and spacer D. Replace center shaft if worn or damaged. Splines from the input shaft.
Page 64 6. Disassemble differential case assembly. Figure 35 1. Bolt (6 used) 3. Differential case 2. Gear 62 A. Remove six (6) bolts securing gear 62 to the dif- ferential case. Figure 36 1. Spring pin 3. Pinion shaft 2. Differential case 4.
Page 65 Figure 37 1. Side gear (2 used) 5. Differential case 2. Pinion gear (2 used) 6. Pinion shaft 3. Gear 34 7. Spring pin 4. Ball bearing 8. Bolt (6 used) D. Replace gears if worn or damaged. Cracked, bro- F.
Page 66: Transaxle Assembly
Transaxle Assembly 1. Assemble input shaft assembly. Figure 38 1. Ball bearing 2. Input shaft IMPORTANT: Make sure to press ball bearing at the inner race to prevent damaging the ball bearing. A. Press ball bearing onto the input shaft. Drive Train Page 4 - - 32 Workman MDX--D...
Page 67 2. Assemble the center shaft assembly. 5.386” to 5.398” (136.8 to 137.1 mm) Figure 39 1. Pin clutch 6. Gear (small) 2. Center shaft 7. Bearing 3. Gear 47 8. Bearing 4. Gear 55 9. Spacer 5. Collar NOTE: Before assembling, apply molybdenum disul- A.
Page 68: Workman Mdx--D
Figure 41 D. The center shaft should appear as above when assembled. 3. Assemble differential assembly. 4.854” to 4.882” (123.3 to 124.0 mm) Figure 42 1. Pinion gear (greased surface) 6. Bolt 2. Pinion shaft 7. Spring pin 3. Side gear (greased surface) 8.
Page 69 Figure 43 1. Side gear 3. Pinion shaft 2. Pinion gear 4. Differential case B. Install side gear, both pinion gears and pinion shaft into the differential case. Figure 44 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.
Page 70 Figure 45 1. Side gear 3. Gear 62 2. Pinion gear 4. Differential case D. Install remaining side gear to the pinion gears. E. Secure gear 62 to the differential case with six (6) bolts. Torque bolts in a crossing pattern from 40 to 45 ft- -lb (54 to 61 N- -m).
Page 71 4. Install axle case to case (RH and LH). Figure 47 1. Axle shaft 3. Ball bearing 2. Snap ring IMPORTANT: Do not reuse snap ring. Replace snap A. Insert axle shaft with snap rings, collar and ball ring with new one. bearings into the axle case.
Page 72 5. Install input shaft, center shaft and differential as- semblies to the case. Figure 49 1. Shift shaft 2. Clutch groove A. Insert fork of the shift shaft to the clutch groove of the center shaft assembly. Figure 50 1. Center shaft assembly 3.
Page 73 Figure 51 1. Fork (selector shaft) 2. Pin (shift shaft) D. Make sure the selector shaft fork is contacting the pin on the shift shaft. Figure 52 1. Spacer 2. Boss (counter shaft) E. Place spacer on the counter shaft boss of the case (LH) so the oil groove faces up.
Page 74 Figure 53 1. Gear 34 3. Spacer 2. Counter shaft F. Apply molybdenum disulfide grease to the inside G. Place gear 34 onto the spacer. Make sure not to of gear 34 and the contact surface between the case drop the spacer. Insert needle bearing into gear. In- and the counter shaft.
Page 75 15 to 18 ft- -lb (21 to 25 N- -m) Figure 55 1. Cable bracket 2. Flange bolt NOTE: Keep the gasket sealing surfaces of the cases D. Position cable bracket to transaxle cases. as horizontal to each other as possible. If the sealing E.
Page 76 12 to 15 ft- -lb (16 to 20 N- -m) Figure 57 1. Cable bracket 2. Bolt (steel ball, spring & gasket) G. Install steel ball, spring, gasket and bolt. Torque H. Fill transaxle with 1.5 quarts (1.4 liters) of new bolt from 12 to 15 ft- -lb (16 to 20 N- -m).
Page 77: Electrical System Quick Checks 5
Chapter 5 Electrical System Table of Contents GENERAL INFORMATION ..... SERVICE AND REPAIRS ..... Operator’s Manual .
Page 78: General Information
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Opera- tor’s Manual for additional information when servicing the machine. Electrical Drawings The electrical schematic and other electrical drawings for the Workman MDX--D are located in Chapter 7 -- Electrical Drawings.
Page 79: 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 80 Connectors should be thoroughly packed with lubricant for effective results. Toro Part Number: 107- -0342 Figure 4 Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte.
Page 81: Troubleshooting
Troubleshooting For effective troubleshooting and repairs, you must CAUTION have a good understanding of the electrical circuits and components used on this vehicle (see electrical draw- ings in Chapter 7 -- Electrical Drawings). Remove all jewelry, especially rings and If the vehicle has any interlock switches by--passed, watches, before doing any electrical trouble- shooting or testing.
Page 82: General Run Problems
Starting Problems (Continued) Problem Possible Causes Engine cranks, but does not start. Fuel tank is empty. Wiring to start circuits is loose, corroded or damaged (see electrical drawings in Chapter 7 -- Electrical Drawings). Engine or fuel system is malfunctioning (see Chapter 3 -- Diesel Engine).
Page 83: Electrical System Quick Checks
Electrical System Quick Checks Battery Test Use a multimeter to measure the voltage between the Voltage Measured Battery Charge Level battery terminals. 12.68 V (or higher) Fully charged (100%) Set the multimeter to the DC volts setting. The battery 12.45 V 75% charged should be at a temperature of 60 to 100...
Page 84: Component Testing
Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the CAUTION circuit (e.g. unplug the ignition switch connector before doing a continuity check on the switch). When testing electrical components for continu- NOTE: See the Kubota Workshop Manual, Diesel En- ity with a multimeter (ohms setting), make sure gine, SM--E3B Series for engine component testing in- that power to the circuit has been disconnected.
Page 85: Indicator Lights
Indicator Lights Charge Indicator Light The charge indicator light should come on when the igni- tion switch is in the ON position with the engine not run- ning. Also, it should illuminate with an improperly operating charging circuit while the engine is running. Engine Oil Pressure Light The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not...
Page 86: Fuse Blocks
Fuse Blocks The fuse block on Workman MDX--D vehicles is located beneath the dash panel. In addition to the fuses in the fuse block, an in--line 10 amp fuse is included in the wire harness. This fuse pro- tects the ignition switch circuits and also provides pro- tection for the optional brake and signal light kit.
Page 87: Fusible Links
Fusible Links The Workman MDX--D uses four (4) fusible links for cir- cuit protection. Three (3) of these fusible links are in- FUSIBLE LINK cluded in a wire harness that connects the starter B+ FUSIBLE LINK FUSIBLE LINK terminal to the vehicle wire harness (Fig. 12). The re- maining fusible link is included in the engine wire har- ness and connects the starter G terminal to the engine run solenoid pull coil.
Page 88: Hour Meter
Hour Meter Testing IMPORTANT: Make sure to observe polarity on the hour meter terminals when testing. Damage to the meter may result from an improper connection. QUARTZ RUNNING: INDICATOR WINDOW 0 0 0 0 0 1. Unplug wire harness connector from hour meter. HOURS 2.
Page 89: Brake Switch
Brake Switch The brake switch is a normally closed switch that opens when the brake pedal is not applied. When the brake pedal is applied, the brake pedal moves away from the switch plunger to allow the switch to be in its normally closed state.
Page 90: Main Power And Glow Relays
Main Power and Glow Relays The Workman MDX--D main and glow relays are at- tached to the front of the dash bracket and can be ac- cessed by raising the hood (Fig. 17). The vehicle wire harness is attached to the main and glow relays with four (4) wire connectors.
Page 91: Start Relay
Start Relay The Workman MDX--D start relay provides electrical current to the engine starter solenoid when energized. The relay is energized when the ignition switch is in the START position and the brake pedal is depressed (brake switch closed). The start relay is attached to the front of the dash bracket and can be accessed by raising the hood (Fig.
Page 92: Glow Plug Controller
Glow Plug Controller The glow plug controller is attached to the front of the 5. If any of the conditions in Step 3 are not met or electri- dash bracket and can be accessed by raising the hood cal power to controller terminal 1 exists and any of the (Fig.
Page 93: Engine Run Solenoid
Engine Run Solenoid The engine run solenoid used on Workman MDX--D vehicles must be energized for the diesel engine to run. The run solenoid is mounted to the injection pump on the engine (Fig. 23). The run solenoid is energized when the ignition switch is in either the ON or START position.
Page 94: Over Temperature Switch
Over Temperature Switch The over temperature switch is located on the engine thermostat housing near the alternator (Fig. 24). If the engine coolant temperature reaches 230 F (110 (approximate), the over temperature switch closes which causes the dash panel engine temperature light to come on.
Page 95: Fuel Pump
Fuel Pump The MDX--D fuel pump is secured in a cavity in the top 9. Install fuel hose to the fuel/water separator. Make of the fuel tank (Fig. 26). Electrical current is available sure to secure fuel hose with hose clamp. for the fuel pump when the ignition switch is in either the 10.Connect wire harness electrical connector to the en- ON or START position.
Page 96: Oil Pressure Switch
Oil Pressure Switch The engine oil pressure switch is located on the engine near the oil filter (Fig. 28). The oil pressure switch is a normally closed switch that opens with pressure. The oil pressure switch should open at approximately 8 PSI (0.56 kg/cm Switch Testing NOTE: Refer to Kubota Workshop Manual, Diesel En-...
Page 97 Backup Alarm (Optional Kit) When the shift lever is placed in the reverse position, the backup alarm should sound. The alarm is attached be- neath the cargo box to a bracket on the right side of the frame. Alarm Testing 1.
Page 98 Backup Switch (Optional Kit) The optional backup switch is a four (4) terminal, two (2) circuit switch that is used to energize the backup alarm when the shift lever is in the reverse position. The nor- mally open switch circuit is used while the normally closed switch circuit is not used.
Page 99: Service And Repairs
Service and Repairs NOTE: For information on engine electrical compon- ents, see the Kubota Workshop Manual, Diesel Engine, SM--E3B Series. Battery Service The battery is the heart of the electrical system. With 2. Remove battery cover. regular and proper service, battery life can be extended. 3.
Page 100: Battery Inspection And Maintenance
Battery Inspection and Maintenance FILLER CAPS CAP TUBES WARNING CORRECT POTENTIAL HAZARD: ELECTROLYTE Battery electrolyte contains sulfuric acid which LEVEL COVER is a deadly poison and it causes severe SEAL burns. WHAT CAN HAPPEN: If you carelessly drink electrolyte you could die or if it gets onto your skin you will be burned.
Page 101: Battery Testing
Battery Testing C. If the battery has been charged, apply a 270 amp load for fifteen (15) seconds to remove the surface 1. If battery caps can be removed, conduct a hydrome- charge. Use a battery load tester following the ter test of the battery electrolyte: manufacturer’s instructions.
Page 102: Battery Charging
Battery Charging CAUTION To minimize possible damage to the battery and allow the battery to be fully charged, the slow charging meth- od is presented here. This charging method can be ac- Do not charge a frozen battery because it can ex- complished with a constant current battery charger plode and cause injury.
Page 103: General Information 6
Chapter 6 Chassis Table of Contents SPECIFICATIONS ......Lower Steering and Front Wheels .
Page 104: Specifications
Specifications Item Description Front Tire (22 x 9.5 -- 10, 4 ply) Pressure Range 8 to 22 PSI (55 to 151 kPa) Rear Tire (24 x 12 -- 10, 2 ply) Pressure Range 8 to 22 PSI (55 to 151 kPa) Wheel Lug Nut Torque 80 to 90 ft--lb (109 to 122 N--m) Brake Fluid...
Page 105: General Information
General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman MDX--D vehicle. Refer to the Operator’s Manual for additional information when ser- vicing the machine. Workman MDX--D Page 6 - - 3 Chassis...
Page 106: Special Tools
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.
Page 107: 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 shocks are loose or worn. Front end components (e.g. tie--rod, spindle, A--arm) are loose or worn.
Page 108: Brakes
Suspension and Steering (continued) Problem Possible Cause Front end shimmies. Front wheel lug nuts are loose. Front wheel bearings are loose or worn. Steering linkage is loose or worn. Tie rod ends are loose or worn. Front wheel alignment (toe--in) is incorrect. Rubber shock insert or spindle bushings in A--arm are loose or worn.
Page 109 Brakes (continued) Problem Possible Cause Brakes pull to either side. Tire pressure is incorrect or uneven between tires. Rear brake linings or front brake pads are contaminated. Front wheel alignment (toe--in) is incorrect. Rear brake shoes are distorted. Tires on same axle are unmatched. Brakes squeal.
Page 110: Adjustments
Adjustments Adjust Parking Brake 1. Pry the rubber cover off of the parking brake. 2. Loosen the set screw securing the knob to the park- ing brake lever (Fig. 3). 3. Rotate the knob until a force from 30 to 35 lb. (133 to 156 N) is required to actuate the lever.
Page 111: Adjust Front Wheel Camber
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 112: 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 toe--in. 2.
Page 113: Service And Repairs
Service and Repairs Check Tire Pressure See Specifications for tire pressure range for front and Higher pressures should be used for heavier payloads rear tires. at higher speeds. Do not exceed the maximum tire pres- sure. The air pressure needed is determined by the payload carried.
Page 114: Upper Steering
Upper Steering 18 to 22 ft- -lb (25 to 29 N- -m) RIGHT FRONT 175 to 225 in- -lb Antiseize (20 to 25 N- -m) Lubricant Loctite #242 Antiseize Lubricant Figure 8 1. Hex nut 7. Lock washer (6 used) 12.
Page 115 5. Support steering column to prevent it from falling. 7. Place dust cover onto the steering shaft. Remove four (4) flange nuts and carriage screws secur- 8. Connect both tie rods to the Pitman arm on the steer- ing the steering column to the mounting plate on the ing gearbox (see Lower Steering and Front Wheel frame.
Page 116: 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) Align marks during assembly Figure 10 1. Gasket 8.
Page 117 Disassembly (Fig. 10) 2. If seals were removed, press new seals into housing. Seal lips should be facing up. IMPORTANT: Do not reuse flange head screws with patch lock (items 9 and 13) after they have been re- 3. Place flat washer (item 5) onto shaft of the Pitman moved.
Page 118: 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) RIGHT 9 to 11 ft- -lb (13 to 14 N- -m) FRONT 80 to 90 ft- -lb (109 to 122 N- -m)
Page 119 Disassembly (Fig. 11) 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 off the ground and support vehicle with appropriate jack 9 to 11 ft- -lb (13 to 14 N- -m)
Page 120 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 121: Front Shock Absorbers
Front Shock Absorbers Shock Removal (Fig. 14) 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 122: 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) RIGHT 9 to 11 ft- -lb (13 to 14 N- -m) FRONT 75 to 100 ft- -lb 80 to 90 ft- -lb...
Page 123 A- -arm Removal (Fig. 15) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - - Safety. 2.
Page 124: Frame Pivot Yoke
Frame Pivot Yoke 240 to 290 ft- -lb (326 to 393 N- -m) RIGHT FRONT Figure 17 1. Flange nut (4 used) 8. LH A- -arm 15. Pivot yoke 2. Shock absorber (2 used) 9. Grease fitting (1 used per arm) 16.
Page 125 Pivot Yoke Removal (Fig. 17 and 19) 2. Secure pivot yoke to the front frame tab with cap screw and hardened washer. Torque cap screw from 1. Park machine on a level surface, stop engine, set 240 to 290 ft- -lb (326 to 393 N- -m). parking brake and remove key from the ignition switch.
Page 126: Swing Arm
Swing Arm 70 to 90 ft- -lb (95 to 122 N- -m) FRONT RIGHT Figure 20 1. Transaxle assembly 5. Cap screw (2 used) 9. Swing arm 2. Cap screw (4 used) 6. Lock nut (4 used) 10. Rear frame 3.
Page 127 Removal (Fig. 20) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 2. Raise and support cargo box with prop rod. 3. Remove muffler from machine (see Exhaust System in the Service and Repairs section of Chapter 3 -- Diesel Engine).
Page 128 8. Bleed brake system (see Bleed Brake System in this 12.Lower and secure cargo box. section). 13.Check parking brake operation and adjust if neces- 9. Install both wheels to the transaxle (see Rear sary (see Adjust Parking Brake in the Adjustments sec- Wheels and Brakes in this section).
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Page 130: Parking Brake
Parking Brake RIGHT FRONT Figure 22 1. Parking brake cover 7. Lock nut 13. Cotter pin 2. Operator seat (2 used) 8. Flat washer 14. Clevis pin 3. Seat base 9. Flange head screw (4 used) 15. Parking brake cable (2 used) 4.
Page 131 Disassembly (Fig. 22) 4. Position brake cables to rear brake assemblies using cable routing noted during disassembly. 1. Park machine on a level surface, stop engine and re- move key from the ignition switch. Chock wheels to pre- 5. Secure parking brake cables to rear of machine (Fig. vent the machine from moving.
Page 132: Rear Wheels And Brakes
Rear Wheels and Brakes 20 ft- -lb (27 N- -m) 120 ft- -lb (163 N- -m) 15 to 21 ft- -lb (21 to 28 N- -m) Antiseize Lubricant RIGHT FRONT 80 to 90 ft- -lb (109 to 122 N- -m) Figure 24 1.
Page 133 C. Remove four (4) socket head screws and flange 13.Bleed brakes (see Bleed Brake System in this sec- nuts that secure the brake assembly to the transaxle. tion). D. Remove brake assembly from the transaxle. CAUTION Installation (Fig. 24) IMPORTANT: Parking brake levers must be posi- After servicing brake system components, al- tioned above the transaxle mount.
Page 134: 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 26 1. Brake backing plate 6. Parking brake lever (LH shown) 10.
Page 135 Inspection (Fig. 26) Assembly (Fig. 26) 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 recom- mended. Replace brake drums as a set to maintain 1.
Page 136: Front Brake Calipers
Front Brake Calipers 9 to 11 ft- -lb (13 to 14 N- -m) 54 to 66 in- -lb (6.2 to 7.4 N- -m) 108 to 132 in- -lb RIGHT (12.3 to 14.9 N- -m) FRONT 54 to 66 in- -lb (6.2 to 7.4 N- -m) Figure 27 1.
Page 137 Disassembly (Fig. 27) Assembly (Fig. 27) 1. Park machine on a level surface, stop engine, set 1. Slide brake caliper onto brake rotor. Make sure that parking brake and remove key from the ignition switch. rotor is between brake pads. 2.
Page 138: Front Brake Caliper Service
Front Brake Caliper Service White Lithium Grease 27 to 33 ft- -lb (37 to 44 N- -m) BAF- -12 Assembly Lube Figure 28 1. Bolt (2 used) 4. Caliper bracket 7. Brake pad (2 used) 2. Caliper body 5. Square seal (2 used) 8.
Page 139 Disassembly (Fig. 28) Assembly (Fig. 28) 1. Remove two (2) bolts that secure brake caliper as- 1. If caliper body was disassembled, install compon- sembly. ents in caliper body: 2. Remove caliper anvil and then slide brake pads from A. Apply hydraulic brake cylinder assembly lube pins on caliper bracket.
Page 140: Brake Master Cylinder
Brake Master Cylinder RIGHT FRONT Figure 29 1. Brake master cylinder 4. Clevis pin 7. Pedal frame 2. Cap screw (2 used) 5. Cotter pin 8. Front brake line 3. Brake pedal 6. Flange head nut (2 used) 9. Rear brake line Chassis Page 6 - - 38 Workman MDX--D...
Page 141 Removal (Fig. 29) Installation (Fig. 29) 1. Raise front hood to gain access to brake master cyl- 1. Position master cylinder to pedal frame and secure inder. with two (2) cap screws and flange nuts. 2. Remove cotter pin from the clevis pin that connects 2.
Page 142: Brake Master Cylinder Service
Brake Master Cylinder Service Disassembly (Fig. 30) 1. Thoroughly clean outside of master cylinder before disassembly. 2. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 3. Disconnect lower end of the dust cover from the housing.
Page 143: Bleed Brake System
Bleed Brake System IMPORTANT: To prevent contamination of the brake system, make sure to clean components before dis- assembly. 1. Connect a suitable transparent hose to bleeder valve on front brake caliper (Fig. 31) or rear wheel brake cylin- der (Fig. 32). Submerge other end of hose in a glass container partially filled with clean brake fluid.
Page 144: Seat Base
Seat Base Figure 33 1. Seat (2 used) 12. Flange head screw (12 used) 23. Lock nut 2. Seat bracket (2 used) 13. Flat washer (8 used) 24. Parking brake lever 3. Cap screw (8 used) 14. Shift plate 25. Equalizer bracket 4.
Page 145 Seat Base Removal (Fig. 33) 1. Park machine on a level surface, stop engine, en- gage parking brake and remove key from the ignition switch. 2. Flip both seats forward and remove them from the seat base. 3. Remove parking brake assembly from seat base (see Parking Brake in this section).
Page 146: 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 35 1. Fender (LH shown) 12. Washer head screw (8 used) 23. Catch (2 used) 2.
Page 147 Removal (Fig. 35) Installation (Fig. 35) 1. Park machine on a level surface, stop engine, set NOTE: Do not tighten fasteners securing the hood until parking brake and remove key from the ignition. all fasteners are in place. 2. Remove hood using Figure 35 as a guide. 1.
Page 148: Cargo Box
Cargo Box 190 to 210 in- -lb (21.5 to 23.7 N- -m) 190 to 210 in- -lb (21.5 to 23.7 N- -m) RIGHT 190 to 210 in- -lb (21.5 to 23.7 N- -m) FRONT Figure 36 1. Cargo box 7. Pivot bushing (2 used) 13.
Page 149 Removal (Fig. 36) 45 to 55 in- -lb 1. Park machine on a level surface, stop engine, set (5.1 to 6.2 N- -m) parking brake and remove key from the ignition switch. 2. Disassemble cargo box as necessary using Figures 36 and 37 as guides.
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Page 151: Electrical Schematic 7
Chapter 7 Electrical Drawings Table of Contents ELECTRICAL SCHEMATIC ....CIRCUIT DIAGRAMS Glow Plug Circuits ......Start Circuits .
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Page 153: Electrical Schematic
Workman MDX- -D Electrical Schematic Relays are shown as de- - energized Page 7 - - 3...
Page 154: Glow Plug Circuits
Glow Plug Circuits Power Current Control Current Indication Current Page 7 - - 4...
Page 155: Start Circuits
Start Circuits Power Current Control Current Indication Current Page 7 - - 5...
Page 156: Run Circuits
Run Circuits Power Current Control Current Indication Current Page 7 - - 6...
Page 157 This page is intentionally blank. Page 7 - - 7...
Page 158: Main Electrical Harness
Workman MDX- -D Main Electrical Harness Wiring Drawing Page 7 - - 8...
Page 159 VIOLET GRAY BLACK YELLOW BLUE VIOLET BLUE BLUE BROWN PINK BLACK WHITE BLACK PINK WHITE BLACK YELLOW YELLOW PINK YELLOW BLACK VIOLET YELLOW GREEN YELLOW YELLOW BLACK BLACK YELLOW WHITE BLUE RED/BLACK GREEN BLACK YELLOW YELLOW BLUE Workman MDX- -D Main Electrical Harness Wiring Diagram Page 7 - - 9...
Page 160: Engine Electrical Harness
BLUE BROWN WHITE BLUE FUSIBLE LINK BLACK Workman MDX- - D Engine Electrical Harness Page 7 - - 10...

Toro Workman MDX-D Service Manual

This Page Is Intentionally Blank.

Chapter 1 -- Safety

Chapter 2 Product Records and Maintenance

Chapter 3 Diesel Engine

Chapter 6 -- Chassis

Chapter 4 - - Drive Train

Chapter 7 -- Electrical Drawings

Chapter 4 Drive Train

Chapter 5 -- Electrical System

Chapter 5 Electrical System

Chapter 6 Chassis

Quick Links

Chapters

Troubleshooting

Related Manuals for Toro Workman MDX-D

Summary of Contents for Toro Workman MDX-D

Table of Contents