Instruction/ maintenance manual of the product MDE Toro
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Part No. 08164S L (Rev . A) Service Manual W orkman R MDE Preface The pur pose of this public ation is to pr ovide t he service technic ian with inf orm ation f or t roubles hooting, test ing and repair of maj or syst ems and co mponents on the Wo rkman MDE.
Wo rkman MDE This page is intenti onally bl ank..
Wo rkman MDE T able Of Contents Chapter 1 - - Safety Safe ty In stru cti o ns 1 - - 2 .......................... Jacki ng and Ot her I nst ruct ions 1 - - 4 ............... Safet y and I nst ruc tion Dec als 1 - - 5 ................ Cha pte r 2 - - Pr oduct R ec or ds and Ma inte nanc e Produc t Records 2 - - 1 .
Workma n MDE This page is intenti onally bl ank..
Wor k ma n MD E Page 1 - - 1 Safety Chapter 1 Safety T able of Contents SAFETY INSTRUCTIONS 2 ...................... Before Operating 2 ............................ While Operating 2 ............................. Maintenance and Service 3 ............
Wor k ma n MD E Page 1 - - 2 Safety Safety Instructions The Workman MDE is designed and tested to offer safe service when operated and maintained properly .
Wor k ma n MD E Page 1 - - 3 Safety Maintenance and Service 1. Before servicing or making adjustments to the ve- hicle, stop vehicle, turn on/of f switch to OFF , engage parking brake and remove key from the on/of f switch. 2. Make sure machine is i n safe operating condition by keeping all nuts, bolts and screws tight.
Wor k ma n MD E Page 1 - - 4 Safety Jacking and Other Instructions Jacking V ehicle DANGER POTENTIAL HAZARD • A vehicle that is not properly supported may become unstable. WHA T CAN HAPPEN • The vehicle may move or fall. Personal injury or damage to the machine may result.
Wor k ma n MD E Page 1 - - 5 Safety 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.
Wor k ma n MD E Page 1 - - 6 Safety This page is intentionally blank..
Wor k ma n MD E Page 2 - - 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance T able of Contents PRODUCT RECORDS 1 ......................... MAINTENANCE 1 ............................... EQUIV ALENTS AND CONVERSIONS 2 ........
0.09375 Wor k ma n MD E Page 2 - - 2 Product Records and Maintenance Equivalents and Conversions.
Wor k ma n MD E Page 2 - - 3 Product Records and Maintenance T orque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by T oro, either the recommended torque or a torque that is unique to the application is clearly identified and spe- cified in this Service Manual.
Rev . A Wor k ma n MD E Page 2 - - 4 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Inch Series) Thread Size Grade 1, 5 & 8w i t hT h i n Height Nuts S.
Wor k ma n MD E Page 2 - - 5 Product Records and Maintenance Standard T orque for Dry , Zinc Plated and Steel Fasteners (Metric Series) T h r e a d S i z e Class 8.
Wor k ma n MD E Page 2 - - 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws T h r e a d S i z e Recommended T orque Thread Size Square Head Hex Socket 1/4 - .
Rev . A Wor k ma n MD E Page 3 - - 1 Electrical System Chapter 3 Electrical System T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manual 2 .......................... Opening Battery Circuit 2 ...................... ELECTRICAL DIAGRAMS 3 .
Wor k ma n MD E Page 3 - - 2 Electrical System General Information The Workman MDE uses a 48 volt DC electrical system that is an isolated circuit. The vehicle frame is not used for any ground connections. The vehicle controller monitors operator and vehicle in- puts to determine voltage to the traction motor .
Wor k ma n MD E Page 3 - - 3 Electrical System Electrical Diagrams The electrical schematic, circuit drawings and wire har- ness drawings for the Workman MDE are located in Chapter 6 - - Electrical Diagrams.
Wor k ma n MD E Page 3 - - 4 Electrical System V ehicle Operation The Workman MDE electrical system uses a 48 volt bat- tery pack, an electric traction motor , a vehicle controller and numerous other electrical components to allow ve- hicle operation.
Wor k ma n MD E Page 3 - - 5 Electrical System Special T ools Order special tools from your T oro Distributor . Some tools may also be available from a local supplier . Multimeter The multimeter can test electrical components and cir- cuits for current, resistance or voltage.
Wor k ma n MD E Page 3 - - 6 Electrical System Battery W atering Dispenser Use the battery watering dispenser when adding dis- tilled water to vehicle batteries. T oro Part Number: TOR4102 Figure 6 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte.
Wor k ma n MD E Page 3 - - 7 Electrical System 36/48 V olt Battery Discharge Unit The 36/48 V olt Battery Discharge Unit is recommended for quick and accurate load testing for the batteries on the Workman MDE.
Wor k ma n MD E Page 3 - - 8 Electrical System T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect a battery cable from the battery pack to open the battery circuit unless a test procedure requires battery voltage.
Wor k ma n MD E Page 3 - - 9 Electrical System General Run Problems (Continued) Problem Possible Causes T raction 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).
Wor k ma n MD E Page 3 - - 10 Electrical System Battery Charger Problems Problem Possible Causes Battery charger does not turn on. AC outlet fuse/circuit breaker blown. AC outlet is faulty . V ehicle wiring is loose or damaged (see electrical schematic in Chapter 6 - - Electrical Diagrams).
Wor k ma n MD E Page 3 - - 1 1 Electrical System 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.
Rev . A Wor k ma n MD E Page 3 - - 12 Electrical System Accelerator Potentiometer Adjustment (Potentiometer with Short Lever) NOTE: The following adjustment procedure should be used on vehicles that have a potentiometer that includes a short lever (Figure 14).
Wor k ma n MD E Electrical System Page 3 - - 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.
Wor k ma n MD E Electrical System Page 3 - - This page is intentionally blank. Rev . A 12.2.
Wor k ma n MD E Page 3 - - 13 Electrical System 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 .
Wor k ma n MD E Page 3 - - 14 Electrical System Component T esting For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. disconnect the harness wire connectors from the vehicle on/off switch before doing a continuity check on the on/off switch).
Wor k ma n MD E Page 3 - - 15 Electrical System 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 s tate of charge of the bat- tery pack.
Wor k ma n MD E Page 3 - - 16 Electrical System V ehicle Direction (Forward/Reverse) and Headlight Switches The vehicle direction (forward/reverse) switch (Fig. 21) and headlight switch (Fig. 22) are located on the c ontrol panel. These two switches have identical logic.
Wor k ma n MD E Page 3 - - 17 Electrical System V ehicle 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.
Wor k ma n MD E Page 3 - - 18 Electrical System Supervisor Speed Limit Switch The supervisor speed limit switch is open in OFF posi- tion (key vertical) and closed in ON position (key rotated clockwise). The speed limit switch is one of several in- puts for the vehicle controller and allows the s peed of the vehicle to be limited.
Wor k ma n MD E Page 3 - - 19 Electrical System Charger Interlock Switch The charger interlock switch is located behind the char- ger receptacle plate on the front of the seat base (Fig.
Wor k ma n MD E Page 3 - - 20 Electrical System Main and Accessories Contactors T wo contactors (solenoids) are used on the Workman MDE for circuit control. The main contactor provides current to the vehicle c on- troller and is energized when the on/off switch is ON.
Wor k ma n MD E Page 3 - - 21 Electrical System 6. Replace contactor if necessary . 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.
Wor k ma n MD E Page 3 - - 22 Electrical System Fuses There are three (3) fuses in the Workman electrical sys- tem. T wo (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.
Wor k ma n MD E Page 3 - - 23 Electrical System Fusible Links The wiring harness for the Workman includes three (3) fusible links for circuit protection (Fig. 36). T wo (2) fusible links attach to the s ame main contactor post as the main fuse. One of these fusible links (FL2) is used for the switched power circuit.
Wor k ma n MD E Page 3 - - 24 Electrical System Accelerator Switch The accelerator switch is a four terminal, two circuit switch that is located on the control pedal frame (Fig. 37). The Workman MDE uses only one of the s witch cir- cuits (terminals 3 and 4).
Rev . A Wor k ma n MD E Page 3 - - 25 Electrical System 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.
Wor k ma n MD E Page 3 - - 26 Electrical System Controller The Workman controller is secured to the rear frame un- der the controller cover beneath the cargo box (Fig.
Wor k ma n MD E Page 3 - - 27 Electrical System 1F l a s h System inoperable. T urn on/of f switch OFF , wait s everal seconds and turn on/off switch ON. If controller does not reset correctly , controller replacement may be necessary . 2 Flashes The accelerator pedal was depressed when on/off switch was turned ON.
Wor k ma n MD E Page 3 - - 28 Electrical System Service and Repairs Battery Service 1. Battery (8 used) 2. Battery rod (2 used) 3. Negative cable to vehicle 4. Lock washer (2 used per battery) 5. Hex nut (2 used per battery) 6. Cable terminal boot 7. Battery cable (6 used) 8.
Wor k ma n MD E Page 3 - - 29 Electrical System Battery Removal (Fig. 42) W ARNING POTENTIAL HAZARD: The battery terminals, metal tools and metal ve- hicle parts could short together . WHA T CAN HAPPEN: Sparks can cause battery gasses to explode. Damaged cables could short against metal ve- hicle parts and cause sparks.
Wor k ma n MD E Page 3 - - 30 Electrical System Battery Charging When the vehicle is not in use, it is recommended to keep the batteries charged by connecting the battery charger that is included with the vehicle. The Workman MDE charger is designed to automatically charge the batteries fully without overcharging.
Wor k ma n MD E Page 3 - - 31 Electrical System Battery T esting When testing batteries in the Workman MDE, it is impor- tant to test all batteries. Proper performance of the ve- hicle depends on all batteries being in good condition. T esting will determine if one (or more) of the batteries needs to be replaced.
Wor k ma n MD E Page 3 - - 32 Electrical System Battery Storage If the vehicle will be stored for any period of time, check battery electrolyte level, adjust level if needed and then connect battery charger to vehicle. Allow charger to re- main connected to vehicle during storage to prevent bat- tery discharge and potential battery damage.
Wor k ma n MD E Page 3 - - 33 Electrical System T raction Motor Brushes The traction motor in the Workman MDE uses eight (8) brushes. T raction motor brushes should be inspected every 500 hours of operation or annually . Inspection 1. Make sure that on/of f switch is OFF .
Wor k ma n MD E Page 3 - - 34 Electrical System T raction Motor 1. Socket head screw (6 used) 2. Flat washer (6 used) 3. Flange nut 4. Support bracket 5. Carriage screw 6. T ransaxle mount plate 7. Rubber damper 8. T raction motor 9. Fan 10. Roll pin (2 used) 1 1.
Wor k ma n MD E Page 3 - - 35 Electrical System 4. Disconnect wires from traction motor (Fig. 51): A. While retaining lower nut, remove upper nut and wire connector from motor terminals A1, A2, F1 and F2. B. Unplug motor temperature sensor from vehicle wire harness.
Wor k ma n MD E Page 3 - - 36 Electrical System 3. Apply antiseize lubricant or axle grease to the splines of the transaxle and motor shafts. Apply grease to lip of seal in transaxle bore. CAUTION T o prevent motor damage and personal injury , make sure that traction motor is well sup- ported as it is installed.
Wor k ma n MD E Page 3 - - 37 Electrical System This page is intentionally blank. Electrical System.
Wor k ma n MD E Page 3 - - 38 Electrical System T raction Motor Service 1. Frame and field assembly 2. Armature 3. Brush lead (2 used) 4. Cap screw (2 used per brush lead) 5. Cap screw (4 used) 6. Cap screw (8 used) 7. Brush (8 used) 8. High temperature sensor 9.
Wor k ma n MD E Page 3 - - 39 Electrical System Brush Service 1. Check the brush springs for correct alignment on the back of the brush. A brush spring that does not apply equal pressure on the center of the brush will cause the brush to wear unevenly .
Wor k ma n MD E Page 3 - - 40 Electrical System Commutator Service 1. Chuck armature on t he commutator end - - bearing journal and support the drive end of armature using the ”live” center of the shaft. With the armature supported on both ends, measure the commutator runout and the bar to bar differences with a dial gauge.
Wor k ma n MD E Page 3 - - 41 Electrical System Assembly (Fig. 56) NOTE: After the motor has been disassembled, it is recommended that a new commutator end head bear- ing be installed because the removed bearing may have been damaged during disassembly .
Wor k ma n MD E Page 3 - - 42 Electrical System Battery Charger 1. Upper case 2. T ransformer 3. Lower case 4. SCR assembly 5. Control board 6. Relay 7.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 1 Chapter 4 T ransaxle and Brakes T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manual 2 ........................... SPECIFICA TIONS 3 ............................. TROUBLESHOOTING 4 .
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 2 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.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 3 Specifications Item Description T ransaxle T ransaxle Fluid Capacity 2 quarts (1.9 liters) T ransaxle Fluid 10W - -30 Motor Oil Brake Fluid DOT 3 T r.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 4 T roubleshooting 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 .
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 5 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.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 6 Service and Repairs Rear Wheels and Brakes 1. Lock nut (4 used per side) 2. Cotter pin 3. Brake assembly (LH shown) 4. Socket head screw (4 used per side) 5. Wheel stud (5 used per side) 6. Wheel hub 7.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 7 Removal (Fig. 1) 1. Park vehicle on a level surface, turn on/of f switch OFF and remove key from the on/of f switch. W ARNING Before jacking up the vehicle, review and follow Jacking Instructions in Operator ’ s Manual and Chapter 1 - - Safety .
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 8 5. Position wheel assembly to the vehicle with valve stem facing out and secure with five (5) lug nuts. 6. Lower vehicle to ground. T orque lug nuts in a cross- ing pattern from 45 to 65 ft - - lb (61 to 88 N - - m) .
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 9 This page is intentionally blank. T ransaxle and Brakes.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 10 Rear Brake Service 1. Brake backing plate 2. W asher head screw 3. Brake shoe 4. Lower spring 5. Wheel cylinder 6. Parking brake lever (LH shown) 7. Belleville washer 8. Adjuster lever 9. Dust cover 10.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 1 1 Inspection (Fig. 4) 1. Inspect brake drums. IMPORT ANT : Brake drum machining is not re - commended. Replace brake drums as a set to maintain equal braking forces. A. Clean drums with denatured alcohol.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 12 Hydraulic Brake System 1. Brake caliper (LH) 2. Brake caliper (RH) 3. Brake rotor (2 used) 4. Front brake tube 5. Front brake hose 6. Carriage screw 7. Rear brake tube 8. Carriage screw 9. Rear brake hose bracket 10.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 13 Bleed Brake System 1. Connect a suitable transparent hose to bleeder valve on a wheel cylinder or caliper . Submerge other end of hose in a glass container partially filled with clean brake fluid. 2.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 14 Front Brake Calipers 1. LH brake caliper 2. RH brake caliper 3. Lock washer (2 per caliper used) 4. Cap screw (2 per caliper used) 5. Wheel hub assembly 6. Brake rotor 7. Socket head screw (4 per rotor used) 8.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 15 Removal (Fig. 6) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. W ARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - - Safety .
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 16 Brake Master Cylinder 1. Master cylinder 2. Cap screw 3. Brake pedal 4. Clevis pin 5. Cotter pin 6. Flange head nut 7. Pedal frame Figure 8 7 3 5 6 2 1 4 FRONT RIGHT Removal (Fig. 8) 1. Raise and support front hood.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 17 Brake Master Cylinder Service Disassembly (Fig. 9) 1. Remove reservoir and flange seal. Push i n on the push rod so the stop pin can be removed. 2. Disconnect lower end of the dust cover from the housing.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 18 Parking Brake 1. Parking brake cover 2. Operator seat 3. Seat base 4. Cable equalizer bracket 5. Parking brake lever 6. Curved washer 7. Lock nut 8. Flat washer 9. Flange head screw (4 used) 10. Flat washer (2 used) 1 1.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 19 Disassembly (Fig. 10) 1. Park machine on a level surface, stop engine and re- move key from the ignition switch. Chock wheels to pre- vent the machine from moving. 2. Disconnect both parking brake cables from rear of machine: A.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 20 T ransaxle 1. Socket head screw (6 used) 2. Flange nut 3. Carriage screw (5 used) 4. Support bracket 5. T ransaxle mount plate 6. Rubber damper 7. T raction motor 8. Fan 9. Roll pin (2 used) 10. W asher 1 1.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 21 Removal (Fig. 1 1) 1. Park vehicle on a level surface, turn on/of f switch OFF , set parking brake and remove key from switch. 2. Remove cargo box from vehicle (see Cargo Box Re- moval in Service and Repairs section of Chapter 5 - - Chassis).
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 22 Installation (Fig. 1 1) 1. If removed, install traction motor to transaxle (see T raction Motor Installation in Service and Repairs sec- tion of Chapter 3 - - Electrical System). 2. Position transaxle and motor assembly to the rear frame.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 23 This page is intentionally blank. T ransaxle and Brakes.
Wor k ma n MD E T ransaxle and Brakes Page 4 - - 24 T ransaxle Service 1. Oil seal 2. Bearing cap bolt (2 used per cap) 3. Input shaft 4. Intermediate shaft & gear 5. Retaining ring (2 used) 6. O - - ring (2 used) 7. Cover plate 8. Wheel hub (2 used) 9.
Wor k ma n MD E Page 5 - - 1 Chassis Chapter 5 Chassis T able of Contents GENERAL INFORMA TION 1 ..................... Operator ’s Manual 1 .......................... SPECIFICA TIONS 2 ............................. SPECIAL TOOLS 2 ..................
Wor k ma n MD E Page 5 - - 2 Chassis Specifications Item Description Front tire (22 x 9.5 - - 10, 4 ply) pressure 8 to 22 PSI (55 to 152 kPa) Rear tire (22 x 9.
Wor k ma n MD E Page 5 - - 3 Chassis T roubleshooting 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.
Wor k ma n MD E Page 5 - - 4 Chassis Suspension and Steering (continued) Problem Possible Cause Steering is hard. T ire 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.
Rev . A 4.1 Wor k ma n MD E Chassis Page 5 - - Adjustments Adjust Front Wheel Camber 1. Adjust front tire pressures to 12 PSI (82 kPa) before checking front wheel camber . 2. Either add weight to the driver’s seat equal to the av- erage operator who will run the machine or have an op- erator on the v ehicle operator ’s seat.
Rev . A 4.2 Wor k ma n MD E Chassis Page 5 - - Adjust Front Wheel T oe - - 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 .
Wor k ma n MD E Page 5 - - 5 Chassis Service and Repairs Check Tire Pressure The tire pressure range for front and rear tires is 8 to 22 PSI (55 to 152 kPa). The tire pressure needed is deter- mined by the payload carried. Lower air pressure will provide less compaction, a smoother ride and fewer tire marks.
Wor k ma n MD E Page 5 - - 6 Chassis Upper Steering 1. Hex nut 2. Flat washer 3. Steering wheel 4. Flange nut (4 used) 5. Steering box assembly 6. Cap screw 7. Lock washer (6 used) 8. Steering shaft 9. Cap screw (4 used) 10. Bearing (2 used) 1 1. Carriage bolt (4 used) 12.
Wor k ma n MD E Page 5 - - 7 Chassis 5. Support steering column to prevent it from falling. Remove four (4) flange nuts and carriage screws secur- ing the steering column to the mounting plate on the frame. 6. Remove dust cover (item 13) from the steering shaft.
Wor k ma n MD E Page 5 - - 8 Chassis Steering Gearbox 1. Gasket 2. Hex washer head screw (3 used) 3. Seal 4. Sector gear 5. Flat washer 6. Ball bearing 7. Output shaft spacer 8. Stepped washer 9. Flange head screw with patch lock 10. Ball bearing 1 1.
Wor k ma n MD E Page 5 - - 9 Chassis Disassembly (Fig. 2) IMPORT ANT : Do not reuse flange head screw with patch lock after it has been removed. 1. Remove flange head screw with patch lock (item 9) and stepped washer (item 8) from Pitman arm. Discard flange head screw .
Wor k ma n MD E Page 5 - - 10 Chassis Lower Steering and Front Wheels 1. Steering gearbox pitman arm 2. Shock absorber (2 used) 3. Cotter pin 4. Slotted hex nut 5. Flat washer 6. Lock nut (3 used per side) 7. Cap screw (2 used per shock) 8. LH A - - arm 9.
Wor k ma n MD E Page 5 - - 1 1 Chassis Removal (Fig. 3) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition. W ARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - - Safety .
Wor k ma n MD E Page 5 - - 12 Chassis C. Install brake hose clip onto cap screw . Secure spindle to A - - arm hub with cap screw and lock nut. T orque fasteners from 75 to 100 ft - - lb (102 to 135 N- -m ) .
Wor k ma n MD E Page 5 - - 13 Chassis Front Shock Absorbers Shock Removal (Fig. 9) IMPORT ANT : 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).
Wor k ma n MD E Page 5 - - 14 Chassis A - - arms and Front Suspension Figure 7 FRONT RIGHT 6 19 2 5 7 6 14 7 8 12 4 16 11 18 3 17 1 15 23 22 9 10 13 20 21 24 25 26 27 28 29 30 31 45 to 65 ft - - lb ( 6 2t o8 8N - - m ) Loctite #242 20 to 25 ft - - lb ( 2 8t o3 3N - - m ) 45 to 55 ft - - lb ( 6 2t o7 4N - - m ) See text for tightening procedure 6 1.
Wor k ma n MD E Page 5 - - 15 Chassis A - - arm Removal (Fig. 7) 1. Park vehicle on a level surface, turn on/of f switch OFF , set parking brake and remove key from the on/off switch. W ARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - - Safety .
Wor k ma n MD E Page 5 - - 16 Chassis Frame Pivot Y oke 1. Flange nut (4 used) 2. Shock absorber (2 used) 3. Cap screw (4 used) 4. Plug 5. Flat washer 6. Lock nut (4 used per side) 7. Cap screw (2 used per shock) 8. LH A - - arm 9. Grease fitting (1 used per arm) 10.
Wor k ma n MD E Page 5 - - 17 Chassis Pivot Y oke Removal (Fig. 9 and 10) 1. Park vehicle on a level surface, turn on/of f switch OFF , set parking brake and remove key from the on/off switch.
Wor k ma n MD E Page 5 - - 18 Chassis Seat Base 1. Seat 2. Seat bracket 3. Rubber receptacle 4. Rivet 5. Cap screw (4 used per seat) 6. Screw 7. Holding post 8. Seat base 9. Seat base tray 10. Flange head screw (8 used) 1 1. Flat washer (4 used) 12. Front frame 13.
Wor k ma n MD E Page 5 - - 19 Chassis Removal (Fig. 1 1) 1. Park vehicle on a level surface, turn on/of f switch OFF , set parking brake and remove key from the on/off switch.
Wor k ma n MD E Page 5 - - 20 Chassis Front Hood 1. Fender (LH shown) 2. Lock nut (4 used) 3. Flat washer (2 used) 4. Front bumper 5. Headlight (2 used) 6. W asher (3 used per headlight) 7. Hood 8. Fender well (LH shown) 9. Cap screw (2 used) 10. Hood pivot keeper (2 used) 1 1.
Wor k ma n MD E Page 5 - - 21 Chassis Removal (Fig. 13) 1. Park vehicle on a level surface, turn on/of f switch OFF , set parking brake and remove key from the on/off switch.
Wor k ma n MD E Page 5 - - 22 Chassis Cargo Box (Serial Number Below 31 1000000) 1. Cargo box 2. Striker plate (2 used) 3. Screw (3 per striker plate) 4. T ailgate channel 5. RH latch rod 6. RH latch bracket 7. Grip knob 8. T ailgate 9. LH latch rod 10.
Wor k ma n MD E Page 5 - - 23 Chassis Removal (Fig. 18) 1. Park vehicle on a level surface, turn on/of f switch OFF , set parking brake and remove key from the on/off switch. 2. Remove two (2) flange head screws (item 21) that secure RH and LH pivot brackets (items 20 and 30) to the rear frame.
Wor k ma n MD E Page 5 - - 24 Chassis Cargo Box (Serial Number Above 31 1000000) 1. Cargo box 2. Handle 3. Carriage screw (2 used) 4. Lock nut (2 used) 5. Carriage screw (4 used) 6. Pivot bracket 7. Pivot bushing (2 used) 8. Screw (4 used) 9. Carriage screw (4 used) 10.
Wor k ma n MD E Page 5 - - 25 Chassis 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.
Wor k ma n MD E Page 5 - - 26 Chassis This page is intentionally blank. Rev . A.
Wor k ma n MD E Electrical Diagrams Page 6 - - 1 Chapter 6 Electrical Diagrams T able of Contents ELECTRICAL SCHEMA TIC Electrical Schematic 3 ......................... ELECTRICAL CIRCUIT DRA WINGS On/Off Switch T urned On 4 ..................... Run Circuit (Forward) 5 .
Wor k ma n MD E Electrical Diagrams Page 6 - - 2 This page is intentionally blank..
Page 6 - - 3 Electr ical Schem atic W orkman MD E Contactors shown de - - energized RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 12 45 F2 F1 FL1 FL2 F1 FRONT HORN SWITCH W HORN SWITC H HOOK UP R (PED.
Page 6 - - 4 RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 12 45 F2 F1 FL1 FL2 F1 FRONT W SWITC H HOOK UP R (PEDAL NOT PUS HED IN) CW T VIO/ BK Y PK OR NC NC NC OR R/W OFF 1 1 PROGR AM M ING 9 DIA GN .
Page 6 - - 5 RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 12 45 F2 F1 FL1 FL2 F1 FRONT W SWITC H HOOK UP R (PEDAL PU SHED IN) CW T VIO/ BK Y PK OR NC NC NC OR R/W OFF 1 1 PROGR AM M ING 9 DIA GN OST .
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An important point after buying a device Toro MDE (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Toro MDE yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Toro MDE - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Toro MDE you will learn all the available features of the product, as well as information on its operation. The information that you get Toro MDE will certainly help you make a decision on the purchase.
If you already are a holder of Toro MDE, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Toro MDE.
However, one of the most important roles played by the user manual is to help in solving problems with Toro MDE. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Toro MDE along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
