Toro MDE manual

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. REFE R TO THE O PERA T OR’S MANUAL F O R OPER- A TI NG , MAI NTE NANCE AND A DJUST MENT I[...]

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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 ........................... Maint ena[...]

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 .................... JACKING AND OTHER INSTRUCTIONS 4 ......... Jacking V ehicle 4 ............................[...]

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 . Al- though hazard control and accident prevention are par- tially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and pr[...]

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. 3. Do not use open pans of f[...]

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. HOW TO A VOID THE HAZARD • Make sure vehicle is parked on a solid leve[...]

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. Order replacement decals from your Authorized T oro Distributor . Safety[...]

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 ........... Decimal and Millimeter Equivalents 2 ............ U.S. to Metric 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. These [...]

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 SAE Grade 1 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger Nuts) SAE Grade 5 Bolts, Screws, Studs & Sems wi[...]

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 8.8 Bolts, Screws and Studs with R e g u l a r H e i g h t N u t s Class 10.9 Bolts, Screws and Studs with R e g u l a r H e i g h t N u t s Thread Size Regular Height Nuts (Class 8 or Str[...]

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 - - 20 UNC 140 + 20 in - - lb 73 + 12 in - - lb 5/16 - - 18 UNC 215 + 35 in - - lb 145 + 20 in - - lb 3/8 - - 16 UNC 35 + 10 ft - - lb 18 + 3f t - - l b[...]

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 ...................... VEHICLE OPERA TION 4 ........................ SPECIAL TOOLS[...]

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 . If a prob- lem exists that will preve[...]

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. Electrical System[...]

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. Eight, 6 volt, deep cycle batteries that are connected in series provide current for a 48 volt DC,[...]

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. NOTE: T oro recommends the use of a D IGIT AL V olt - - Ohm - - Amp multi[...]

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. Obtain hydrometer locally . Figure 7 Battery Lift [...]

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. 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 batter[...]

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. For effective troubleshooting and repairs,[...]

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). Battery cables are loo[...]

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). Fusible link FL1 is faulty . V ehicle charger interlock sw[...]

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 (15.9 mm) (Fig. 12[...]

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). If potentiometer has a long le- ver , use the procedure on the following page. The accele[...]

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. The accelerator potentiometer i[...]

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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 . If any of these components are adjusted, removed or re- placed, the following calibration procedure should be[...]

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). CAUTION When testing electrical [...]

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. The battery indicator reads full (10 bars) when the battery pack is fully c[...]

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. The vehicle direction switch is one of several inputs for the vehicle controll[...]

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. The vehicle status light and LED on the vehicle control- l[...]

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. T est the switch [...]

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. 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 vehi[...]

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. The main contactor is located under the controller cover beneath the cargo box (F[...]

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. 8. Connect battery cable that was removed from bat- tery pack. 1. Main contactor 2. Cable to c[...]

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. The lower 10 ampere fuse (F[...]

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. The other fusible link (FL1) pro[...]

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). When the accelerator pedal is depressed, the switch allows a closed circuit (input) for th[...]

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. The accelerator pedal posi- tions the accelerator potentiometer lever . When the[...]

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. 40). The controller uses inputs from several vehicle switches (on/off, forward/reverse, accelerator pedal, supervisor , charger interlock, motor temperature, accelerator po- tentiome[...]

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. T urn on/of f switch OFF , releas[...]

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. Positive cable to vehicle 9. Cable terminal boot 10. Battery retainer (2 [...]

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. HOW TO A VOID THE HAZARD: Wh[...]

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. Indicator lights (green and red) a[...]

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. 1. The preferred testing procedure [...]

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. If the v[...]

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 . Raise and latch cargo box to allow access to trac tion motor . 2. Open the b[...]

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. W asher 12. Socket head screw 13. Plastic cap (fits in rear frame) 14. Cable terminal[...]

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. Note location of cable tie that secures temperature sensor wires to vehicle. C. Pos[...]

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. Motor weighs approxi - mately 62 pou[...]

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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. Headband 10. Bolt (4 used) 1 1. Commutator end head 12. Bearing 13. Retaining ring 14.[...]

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 . Check for correct clearance and freedom of brush movement in the holder . 2. Replace brushes tha[...]

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. T otal indicated run[...]

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 . Although the bear- ing may appear and feel good, the bearing could be ”bri- nelled” (races [...]

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. Circuit breaker 8. AC cordset 9. DC cordset 10. Ammeter 1 1. Fuse 12. Diode assembly Figure 64 3 4 5 8 6 7 9 1 2 10 11 12 For service of the battery charger , s ee the Lester Electri- cal T echnici[...]

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 ......................... Brakes 4 ..................................... SERVICE AND R[...]

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 ransaxle and Brakes[...]

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 . Brake master cylinder faulty . Brake pedal is spongy . Rear brak[...]

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. Front brake calipers or rotors are damaged. Brake pedal is h[...]

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. Flange nut 8. Parking brake cable 9. Retaining ring 10. Cotter pin 1 1. Clevis pin 12. T ransaxl[...]

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 . 2. Chock wheels not being jacked up. Lift rear whee[...]

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) . 7. Bleed brakes (see Bleed Brake System in this sec- tion). CAUTION After servici[...]

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. Flat washer 11 . B o l t 12. Shoe hold down cup and spring 13. Upper spring Figure 4 3 12 4 12 [...]

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. Check braking surface diameter in at least three places. If the diameter exceeds 6.320” (160[...]

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. Cap screw 1 1. Thread forming screw (6 used) 12. Clip 13. T ee fitting 14. Rear b[...]

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. Have a second person pump brake pedal several times, then hold pedal down firmly . 3. With pedal f[...]

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. Spindle (LH shown) 9. A - - arm (LH shown) 10. Brake master cylinder 1 1. Wheel assembl[...]

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 . 2. Chock wheels not being jacked up. Jack front wheel off t he groun[...]

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. 2. Remove cotter pin from the clevis pin that connects master cylinder to brake pe[...]

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. 3. Push in on the push rod and remove circlip, then re- move push rod with dust cover and cle[...]

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. Screw (2 used) 12. Cap screw 13. Cotter pin 14. Clevis pin 15. Parking brake [...]

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. Remove cotter pin and clevis pin that secures each parking brake cabl[...]

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. Socket head screw 12. Lug nut (5 used per wheel) 13. Wheel assembly 14. Brake drum 15. T r[...]

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). 3. Open the battery circuit by carefully removing one o[...]

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. Loosely install all fasteners used to secure trans- axle to[...]

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. Ball bearing 10. Ball bearing 1 1. Endcap plug (2 used) 12. T ransaxle housing 13. O - - rin[...]

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 ............................. TROUBLESHOOTING 3 ......................... Suspension and Steering 3 .................[...]

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 9.5 - - 10, 4 ply) pressure 8 to 22 PSI (55 to 152 kPa) Wheel lug nut torque (front and rear) 4 5t o6 5f t - - l b( 6 1t o8 8N - - m ) Brake Fluid DOT 3 Special T ools Order special tools from[...]

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. Rear end is noisy . Rear wheel lug nuts are loose. T ransaxle problem (see Chap[...]

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. V ehicle pulls to one side when not braking. T ire pressure is [...]

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. The weight or opera[...]

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 . 2. Either add weight to the drive[...]

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. Lower pressure should not be used for he[...]

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. Steering column 13. Dust cover 14. Collar 15. Set screw 16. Steering wheel c[...]

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. Replace cover if damaged. Slide steering shaft out of the steering column. 7. Disconnec[...]

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. Input shaft spacer 12. Flat washer 13. Flange head screw with patch lock 14. Lube fitting 15. Stee[...]

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 . 2. Remove flange head screw with patch lock (item 13) and flat washer (item 12)[...]

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. Brake rotor 10. Wheel hub assembly 1 1. T ab washer 12. RH A - - arm 13. Jam nut 14. Front fr[...]

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 . 2. Chock wheels not being jacked up. Jack front wheel off t he ground and support vehicl[...]

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 ) . 2. Install tie rod: A. Position tie rod assembly to spindle and pitman arm so that tie rod groove (LH threads) is orientated toward the left s[...]

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). Do not make shock spring adjustment without checking front wheel camber . 1. Park machine on a[...]

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 . 2. Chock wheels not being jacked up. Jack front wheel off t h[...]

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. Screw 1 1. Cap screw 12. RH A - - arm 13. Lock washer 14. Front frame 15. Pivot yo[...]

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. 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 - - [...]

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. Screw (4 used) 14. Washer head screw (4 used) 15. Charger receptacle plate 16. Charg[...]

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. 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[...]

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. Screw (6 used) 12. Washer head screw (8 used) 13. Carriage screw (2 use[...]

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. 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)[...]

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. Screw (2 per bracket) 1 1. LH latch bracket 12. Screw (2 per bracket) 13. Spring 14. Flat washer[...]

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. 3. Release latch rod (item 33) from the latch pins (it[...]

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. Flange nut (4 used) 11 . P r o p ro d 12. Flange nut (6 used) 13. Latch pin (2 [...]

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. 19) 1. Assemble cargo box using Figures 19 and 20 as gui- des. A. When installing cargo box, u[...]

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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 ........................ Battery Charging Circuit 6 ...................... ELEC[...]

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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 (PEDAL NOT PUS HED IN) (+) 4 HR ENABLE 3 SETUP + 2 SENSE A 1 CW 7F E T O U T 8( - - ) 6I G N+ 5 SENSE B T VIO/ BK Y PK OR NC NC NC OR R/W OFF 1 1 PROGR AM[...]

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 OST IC LI GHT 8 MA IN C ONT AC TOR 5 CHARGER 2F O R / R E V F3 1 0 A SEVCO N B+ 10 GA R A1 ARMA TURE MAIN 48V BA TT ARRA Y A OPTI ONS LIGHT SWITCH OR [...]

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 IC LI GHT 8 MA IN C ONT AC TOR 5 CHARGER 2F O R / R E V F3 10 A SEVCO N B+ 10 GA R A1 ARMA TURE MAIN 48V BA TT ARRA Y A OPTI ONS LIGHT SWITCH OR BK IN[...]

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Rev . A Page 6 - - 8 Electr ical Har ness Drawing Serial N umber Below 310000000 W orkman MD E[...]

Rev . A Page 6 - - 9 Electr ical Har ness Serial N umber Below 310000000 Wiri n g Di ag ra m YELLOW BLUE ORA NGE PINK RED/WHITE ORA NGE BLUE BLACK BLACK ORA NGE PINK ORA NGE BLACK BRO WN RED/WHITE BLUE BLACK BLUE/W HITE FUSI BLE LIN K FUSI BLE LIN K RED WHIT E BLACK WHIT E BLUE/W HITE WHIT E/BLAC K ORA NGE BLUE/W HITE BRO WN WHIT E VIOL ET/ BLACK T[...]

Rev . A Page 6 - - 10 Electr ical Har ness Drawing Serial Number Above 310000000 W orkman MD E[...]

Rev . A Page 6 - - 1 1 Electr ical Har ness Serial Number Above 310000000 Wiri n g Di ag ra m W orkman MD E BLUE BLACK GR EEN BLACK TA N TA N BLACK BLUE BLUE BLUE BLUE ORA NGE ORA NGE ORA NGE GREEN BLACK BLACK YELLOW ORA NGE RED/WHITE ORA NGE BLUE BLACK BLACK ORA NGE PINK ORA NGE BLACK BRO WN YELLOW PINK RED/WHITE BLACK BLUE/W HITE FUSI BLE LIN K F[...]

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Page 6 - - 6 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 DI AGN OST IC LI GHT 8 MA IN C ONT AC TOR 5 CHARGER 2F O R / R E V F3 1 0 A SEVCO N B+ 10 GA R A1 ARMA TURE MAIN 48V BA TT ARRA Y A OPTI ONS LIGHT SWITCH OR [...]

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Rev . A Page 6 - - 8 Electr ical Har ness Drawing Serial N umber Below 310000000 W orkman MD E[...]

Rev . A Page 6 - - 9 Electr ical Har ness Serial N umber Below 310000000 Wiri n g Di ag ra m YELLOW BLUE ORA NGE PINK RED/WHITE ORA NGE BLUE BLACK BLACK ORA NGE PINK ORA NGE BLACK BRO WN RED/WHITE BLUE BLACK BLUE/W HITE FUSI BLE LIN K FUSI BLE LIN K RED WHIT E BLACK WHIT E BLUE/W HITE WHIT E/BLAC K ORA NGE BLUE/W HITE BRO WN WHIT E VIOL ET/ BLACK T[...]

Rev . A Page 6 - - 10 Electr ical Har ness Drawing Serial Number Above 310000000 W orkman MD E[...]

Rev . A Page 6 - - 1 1 Electr ical Har ness Serial Number Above 310000000 Wiri n g Di ag ra m W orkman MD E BLUE BLACK GR EEN BLACK TA N TA N BLACK BLUE BLUE BLUE BLUE ORA NGE ORA NGE ORA NGE GREEN BLACK BLACK YELLOW ORA NGE RED/WHITE ORA NGE BLUE BLACK BLACK ORA NGE PINK ORA NGE BLACK BRO WN YELLOW PINK RED/WHITE BLACK BLUE/W HITE FUSI BLE LIN K F[...]

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