Toro MDX-D manual

Part No. 13200SL Service Manual W orkman R MDX - - D Preface The pur pose of t his public ation is to pr ovide the serv ice technic ian with i nfor mati on for tr oubleshooting, t est ing and repair of maj or syst ems and co mponents on the Workma n MDX- - D. REFE R TO THE OPERA TOR’S M ANUAL F OR O PER- A TI NG, MAI NTE NANCE AND ADJUST ME NT IN[...]

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Workma n MDX- - D T able Of Contents Chapter 1 - - Safety Safe ty Instru ctio ns 1 - - 2 .......................... Jack ing and Ot her I nst ruc tions 1 - - 4 ............... Safet y and I nst ruc tion Dec als 1 - - 6 ................ Cha pter 2 - - Pr oduct Re cords a nd Mainte nanc e Produc t Records 2 - - 1 ........................... Maint ena[...]

Workma n MDX- - D This page is intenti onally bl ank.[...]

Wor k m an M D X - - D Page 1 - - 1 Safety Chapter 1 Safety T able of Contents SAFETY INSTRUCTIONS 2 ...................... Supervisor ’s Respon sibilities 2 ................. Before Oper ating 2 ............................ While Operating 3 ............................ Maintenance and Service 3 .................... JACKING AND OTHER INSTRUCTION[...]

Wor k ma n M D X - - D Page 1 - - 2 Safety Safety Instructions Wo rkman MDX - - D vehicles are designed and te sted to offer s afe service when operated and maintained p ro- perly . Although hazard control an d accident prevention partially are depende nt upon the design and configura- tion of the machine, these factors are also de pendent upon the[...]

Wor k m an M D X - - D Page 1 - - 3 Safety While Operating 1. Sit on the operat or seat when starting and operating the vehicl e. 2. Before starting the eng ine: A. Sit on operator’s seat and depress the bra ke ped- al. Make sure that the par king brake is release d. B. T urn ignition switch to the ON position. When the glow plug indicator goes o[...]

Wor k ma n M D X - - D Page 1 - - 4 Safety Jacking and Other Instructions Jack V ehicle DANGER POTENTIAL HAZARD  A vehicle that is not properly suppor ted may become unstable. WHA T CAN HAPPEN  The vehicle may move or fall. Personal injury or damage to the machine m ay result. HOW TO A VOID THE HAZARD  Make sure v ehicle is p arked on a s [...]

Wor k m an M D X - - D Page 1 - - 5 Safety T ransaxle Neutral Position When performing ro utine maintenance and /or engine testing, the tran saxle must be shifted into the n eutral position. 1. Park machine on a l evel surface, stop engine, set parking brake and remove ke y from the ignition switch. 2. Move shift lever to the neutra l position (Fig[...]

Wor k ma n M D X - - D Page 1 - - 6 Safety Safety and Instruction Decals Numerous safe ty and instruction decals are af fixed to your Workman. If any decal becomes illegible or dam- aged, install a new decal. Part numb ers are listed in the Parts Catalog. Order repl acement decals from your Au- thorized T oro Distributor .[...]

Wor k m an M D X - - D Page 2 - - 1 Product Recor ds 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 M D X - - D Page 2 - - 2 Product Records a nd Maintenance Equivalents and Conversions[...]

Wor k m an M D X - - D Page 2 - - 3 Product Recor ds and Maintenance T orque Specifications Recommended fastener torque values are listed in t he following tables. For critical applications, as determined by T oro , either the recommended tor que or a torque that is unique to the application is clearly iden tified and spe- cified in this Service Ma[...]

Wor k ma n M D X - - D Page 2 - - 4 Product Records and Maintenance Standard T orque for Dry , Z inc Plate d 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 Hei ght Nuts (SAE J995 G rade 2 or St ronger Nuts) SAE Grade 5 Bolts, Scr ews, Studs & Se[...]

Wor k m an M D X - - D Page 2 - - 5 Product Recor ds and Maintenance Standard T orque for Dry , Zinc Plated a nd Steel Fasteners (Metric Series) Thre ad Siz e Class 8.8 Bolts, Screws and Studs with Regular Height Nuts (Class 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6i [...]

Wor k ma n M D X - - D Page 2 - - 6 Product Records and Maintenance Other T orque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended T orque 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 1/2 - - 13 U[...]

Wor k m an M D X - - D Page 3 - - 1 Diesel Engine Chapter 3 Diesel Engine T able of Contents SPECIFICA TIONS 2 ......... ................... GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... ADJUSTMENTS 5 .............................. Adjust Throttle Cable 5 ........................ SERVICE AND REP AIR[...]

Wor k ma n M D X - - D Page 3 - - 2 Diesel Engine Specifications Item Description Make / Designation Kubota water - -cooled, Diesel, Model Z602- - E3B Number of Cyl inder s 2 Bore x Stroke 2.83” x 2.9” (72mm x 73.6mm) T ota l Displ acemen t 36.55 in 3 (599 cc) Compre ssion Ratio 24.0:1 Firing Order 1 (closest to gear cas e end) - - 2 (closest t[...]

Wor k m an M D X - - D Page 3 - - 3 Diesel Engine General Information This Chapter gives informat ion about specifications, maintenance, troubl eshooting, testing and repair of the d i e s e le n g i n eu s e di nt h eW o r k m a nM D X - - D . Most repairs and adjustments require tools which are commonly available in many service shops. Special to[...]

Wor k ma n M D X - - D Page 3 - - 4 Diesel Engine This page is intentionally blank.[...]

Wor k m an M D X - - D Page 3 - - 5 Diesel Engine Adjustments Adjust Throttle Cable Proper throttle operation is depen dent upon proper ad- justment of throttle control. Make sure throttle control is operating pr operly . NOTE: The shoulder bolt th at secures the thr ottle cable to the engine speed c ontrol lever should b e positioned i nt h el o w[...]

Wor k ma n M D X - - D Page 3 - - 6 Diesel Engine Service and Repairs Air Cleaner Figure 3 1. Air cleaner assembly 2. Car riage s crew (2 u sed) 3. Air intake hose 4. Air cleaner mounting bracket 5. Air inlet hood 6. Flange nut (2 used) 7. Hose clamp (2 used) 8. Throttle cable 9. Shoulder bolt 10. Throttle cable mount 11 . F l a n g e n u t FRONT R[...]

Wor k m an M D X - - D Page 3 - - 7 Diesel Engine Air Cleaner Removal (Fig. 3) 1. Park mach ine on a level surface, stop the engine , en- gage parking brake and remove the key from the ignition switch. 2. Raise and support c argo bed to access air cleaner . 3. Remove air clea ner components as needed using Figure 3 as a guide. 4. Check air cleaner [...]

Wor k ma n M D X - - D Page 3 - - 8 Diesel Engine Exhaust S ystem Figure 6 1. Engine 2. Exhaust header 3. Coupler spring (2 used) 4. Flange nut (4 used) 5. Muffler 6. Hex nut (4 used) 7. Exhaust gasket 8. Flange head screw (4 used) 9. Lock washer (4 used) FRONT RIGHT 2 3 4 5 1 4 3 8 6 7 9[...]

Wor k m an M D X - - D Page 3 - - 9 Diesel Engine Exhaust System Removal (Fig. 6) 1. Park mach ine 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 exhaust sys- tem. CAUTION The muffler and exhaust pipe may be hot. T o avoid possible burns, allow the e[...]

Wor k ma n M D X - - D Page 3 - - 10 Diesel Engine Fuel T ank 1. Seat 2. Fuel tank 3. Fuel hose (to fuel separator) 4. Fuel hose (return from engine) 5. Seat base 6. W eb strap ping 7. Hex head flange screw (8 used) 8. Flat washe r (8 used ) 9. Parking brake support 10. Shift bracket Figure 7 FRONT RIGHT 6 9 7 5 8 3 4 2 1 10[...]

Wor k m an M D X - - D Page 3 - - 1 1 Diesel Engine Fuel T ank Remova l (Fig. 7) CAUTION Read safety pr ecautions for handling fuel before working on the fuel system (see Safet y Instruc- tions in Chapter 1 - - Safety). 1. Remove seat base from the frame (see Sea t Base in the Service an d Repairs sec tion of Chapt er 6 - - Ch as- sis). 2. Use fuel[...]

Wor k ma n M D X - - D Page 3 - - 12 Diesel Engine Radiator Figure 9 1. Sur ge tank 2. T an k cap 3. Radiator 4. Washer head scre w (2 use d) 5. Flange nut (3 used) 6. Cap 7. Cap decal 8. Filler neck 9. Lower radiator hose 10. Upper radiator hose 1 1. Straight hose 12. Hose clamp (6 used) 13. Carriage screw (3 used) 14. Flange nut (3 used) 15. Cap [...]

Wor k m an M D X - - D Page 3 - - 13 Diesel E ngine 4. Remove caps (ite ms 2 and 6) from surge tank and ra- diator filler neck to allow complete draining of cooling system. 5. Drain radiator into a suitable contai ner by discon- necting lower radiator hose from the radia tor . 6. Disconnect uppe r radiator hose from the radiator . 7. Disconnect the[...]

Wor k ma n M D X - - D Page 3 - - 14 Diesel Engine Engine Figure 12 1. Engine 2. Engine wire harness connector 3. Hex n ut 4. Negative battery cable 5. Engine wire harness connector 6. Lock washer 7. Flange head screw (8 used) 8. Hex nut (4 used) 9. Lock washer (4 used) 10. Exhaust header 1 1. Flange nut (4 used) 12. Cap screw (4 used) 13. Snubbing[...]

Wor k m an M D X - - D Page 3 - - 15 Diesel E ngine Engine Removal (Fig. 12) 1. Park machine on a le vel surface, stop engine, en- gage parking brake and remove key fro m the ignition switch. CAUTION The engine, radiator and exhaust system may be hot. T o avoid possible injury , allow machine to cool before working on the engine. 2. Disconnect neg [...]

Wor k ma n M D X - - D Page 3 - - 16 Diesel Engine 1 1. Disconnect electrical connections from the following engine componen ts: A. Disconnect main wire harness connectio ns to glow plug bus, temp erature sender and engine run solenoid (Fig. 14). B. Disconnect main wire harness connectio n to fus- ible link harness. C. Disconnect engine wire harnes[...]

Wor k m an M D X - - D Page 3 - - 17 Diesel E ngine 4. Connect the fo llowing electrical components: A. Connect main wire harness connections to glow plug bus, temperature sender and engine run solen- oid (Fig. 14). B. Connect main wire harness connection to fusibl e link harness. C. Connect engine wire harness connector to the main wire harness. D[...]

Wor k ma n M D X - - D Page 3 - - 18 Diesel Engine Engine Clutch Adapte r Figure 17 1. Dri ve bel t 2. Cap s crew 3. Flange washer 4. Drive clutch 5. Cap screw (5 used) 6. Clutch adapter 7. Engine assembly 2 5 6 4 7 3 1 FRONT RIGHT 17 to 22 ft - - lb ( 2 3t o2 9N - - m ) Loctite #242 Removal (Fig. 17) 1. Park mach ine on a level surface, stop the e[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 1 Chapter 4 Drive T rain T able of Contents SPECIFICA TIONS 2 ......... ................... GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... DRIVE TRAIN OPERA TION 4 .................... Clutch System Op eration 4 ..................... Drive Clutc h Operat[...]

Wor k ma n M D X - - D Page 4 - - 2 Drive T rain Specifications Item Description T ransaxle T ransaxle Fluid Capa city 1.5 quarts (1.4 liters) T ransaxle Flu id SAE 10W - - 30 Motor Oil T ransaxle Dry W eight 73 poun ds (33 kilograms) Clutch System Continuously variable transmission type, torque convertor Drive Clutch Speed sensing with mecha nical[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 3 General Information Operator ’ s Manual The Operator ’s Manu al provides informatio n regarding the operation, general main tenance and maintenance intervals for your Workman MDX- - D vehicle. Refer to the Operator ’s Manual for additiona l informa tion when ser- vicing the m achine. Drive T ra[...]

Wor k ma n M D X - - D Page 4 - - 4 Drive T rain Drive T rain Operation Clutch System Operation Figure 1 v 1. Drive clutch 2. Dri ven clu tch 3. Moveable sheave (drive c lutch) 4. Fi xed she ave (dr ive cl utch ) 5. Moveable sheave (driven clutch) 6. Spring 7. Fixed sheave (driven clutch) 8. CVT drive belt 5 3 1 4 6 2 7 LOW ENGINE SPE ED LIGHT LOAD[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 5 Drive Clutch Op eration The operation of the drive clutch is af fected by engine shaft speed. With the engine not turnin g, the CVT drive belt rests low within the dri ve clutch sheaves as the pres- sure of the spring hold s the sheaves apart. A s the en- gine increases in speed, the clutch weig hts [...]

Wor k ma n M D X - - D Page 4 - - 6 Drive T rain Driven Clutch Operati on T h eo p e r a t i o no ft h ed r i v e nc l u t c hi sa f f e c t e db yt r a n s - axle load. When the vehi cle is stopped, the drive be lt is held at the outer diameter of the driven clutch sheaves from the pr essure of t he spring push ing the moveable sheave against the [...]

Wor k m an M D X - - D Drive T rain Page 4 - - 7 Special T ools Order special tools f rom your T oro D istributor . Drive Clutch Remov al T ool This tool is required t o remove the drive clutch f rom the tapered drive shaft of the engine . It is placed in the threaded hole of the fixed clutch sheave after the cl utch retaining screw is removed. T o[...]

Wor k ma n M D X - - D Page 4 - - 8 Drive T rain T roubleshooting Clutch Problem Possible Cause Poor upshifti ng. Gove rned engine speed is adjusted too low . D r i v ea n d / o rd r i v e nc l u t c ha s s e m b l i e sh a v ea c c u m u l a t i o no fd i r to r debris. Drive belt is worn. Clutch sheaves are worn or damage d. Poor downshifting. D [...]

Wor k m an M D X - - D Drive T rain Page 4 - - 9 Adjustments Adjust Shift Cables 1. Park machine on a l evel surface, stop engine, set parking brake and remove ke y from the ignition switch. Raise and support cargo box. 2. Set the shift lever into the N eutral position. Rotate driven clutch to insure transmission is in neutral. 3. The transaxle sel[...]

Wor k ma n M D X - - D Page 4 - - 10 Drive T rain Service and Repairs Drive Clutch 1. Engine 2. Clu tch ada pter 3. Cap s crew (5 used) 4. Drive belt 5. Drive clutch 6. Flange washer 7. Cap screw Figure 7 v FRONT RIGHT 17 to 22 ft - - lb (23 to 29 N - - m) Loctite #242 1 2 6 4 7 5 3[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 1 1 Drive Clutch Removal (Fig. 7) 1. Park machine on a l evel surface, stop engine, set parking brake and remove ke y from the ignition switch. Raise and support cargo box. 2. Carefully remove drive belt from the drive clutch. 3. Remove cap screw (item 7) and flange washer (item 6) securing the drive c[...]

Wor k ma n M D X - - D Page 4 - - 12 Drive T rain Drive Clutch Service Figure 8 v 105 to 120 in - - lb ( 1 2t o1 3 . 5N - - m ) 40 to 50 in - - lb (4.6 to 5.6 N - - m) 1. Flange head screw (6 used) 2. Cover 3. Compression spring 4. Limite r shim 5. Shoulder screw (3 used) 6. Lock nut (3 used) 7. Clutch weight (3 used) 8. Spider 9. Shim 10. Moveable[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 13 5. Slide should er screw from each of the clutch weights (item 7) and then remove weights from cl utch. 6. Clean all dust and debris from clutch components with a soft bristle brush. If necessary , use water to re- move dirt and dry immediately with compressed air to remove all dirt and water . Remo[...]

Wor k ma n M D X - - D Page 4 - - 14 Drive T rain Driven Clutch Driven Clutch Removal (Fig. 13) 1. Park mach ine on a level surface, stop engine, set parking brake and remove key from the ignition switch. Raise and support carg o box. 2. Remove muf fler from the vehicle (see Exhaust Sys- tem in the Service a nd Repairs s ection of Cha pter 3 - - Di[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 15 Driven Clutc h Service 1. Use a suitab le press to c ompress the clutch spring enough to allow removal of the r etaining ring. 2. Remove retaining ring. 3. Carefully , allow the sp ring t o extend fully . 4. Remove outer sprin g retainer , spring and in ner spring re tainer from clutch. 5. Make note[...]

Wor k ma n M D X - - D Page 4 - - 16 Drive T rain T ransaxle 1. T ransaxle assembly 2. Dri ven clut ch 3. Parking brake cable (2 used) 4. Shift cable (2 used) 5. Hardened washer (4 used) 6. Stepped washer 7. Flange nut (4 used) 8. Cap screw 9. Brake drum (2 used) 10. Cap screw (4 used) 1 1. Cap screw (4 use d) 12. Flat wash er (2 use d) 13. Swi ng [...]

Wor k m an M D X - - D Drive T rain Page 4 - - 17 Removal (Fig. 15) 1. Park machine on a l evel surface, stop engine, set parking brake and remove ke y from the ignition switch. 2. Raise and suppor t cargo box. 3. Carefully remove d rive belt from the driven clutch on transaxl e. 4. Separate shift cables from tran saxle: A. Loosen jam nuts securing[...]

Wor k ma n M D X - - D Page 4 - - 18 Drive T rain Installation (Fig. 15) 1. Position tr ansaxle assembly under the v ehicle swing arm. CAUTION T o prevent personal injury , make sure that transaxle is pr operly supported as it is installed into the machine. T ransaxle weighs approxi- mately 73 pounds (3 3 kg). IMPORT ANT : T ake care to not damage [...]

Wor k m an M D X - - D Drive T rain Page 4 - - 19 This page is intent ionally blank. Drive T rain[...]

Wor k ma n M D X - - D Page 4 - - 20 Drive T rain T ransaxle Service 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 57 53 54 55 57 58 59 25 23 22 21 19 17 16 56 15 1 2 3 4 5 6 7 8 9 10 20 24 26 27 28 29 30 11 12 13 14 52 55 26 38 33 18 42 43 7 59 56 11 12 35 9 15 51 16 55 52 55 8 10 Figure 18 40 to 45 ft - - lb (54 to 61 N - - m) 25 to[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 21 1. Case ( LH) 2. Oil seal 3. Oil seal 4. Snap r ing 5. Spacer 6. Sele ctor sha ft 7. Oil seal (2 used) 8. Flange bolt (4 used) 9. Oil check plug (2 used) 10. Gasket (2 used) 1 1. Oil drain plug (2 used) 12. Gasket (2 used) 13. Oil filler plug 14. Case ( RH) 15. Axle bracket (2 used) 16. Col lar ( 2 [...]

Wor k ma n M D X - - D Page 4 - - 22 Drive T rain 1. Bolt (steel ball, spring & gasket) 2. Selector shaft Figure 20 1 2 C. Remove bo lt near the selector shaft. Remove spring and steel bal l. Replace gasket if damaged. 1. Input shaft 2. Oil seal Figure 21 1 2 D. Wrap vinyl ta pe around the splined portion of t he input shaft. This sho uld prote[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 23 1. Flange bolts (3 used) 2. Axle bracket 3. Axle case Figure 22 1 2 3 E. Remove thr ee (3) flan ge bolts securing t he axle bracket and axle case to each case. Separate b rack- et from each ax le case. 1. Flange bolt (10 used) 2. Flange nut Figure 23 1 2 F . With the input shaft sid e down, loosen a[...]

Wor k ma n M D X - - D Page 4 - - 24 Drive T rain 1. Case (RH) 2. Governor boss Figure 24 1 2 IMPORT ANT : Make sure to not hit the governor boss too hard when sepa rating the cases, the boss may get damage d. Do not pry open the two cases with a screw driver , damage may result to the seal- ing surface s. G. Hold the case (RH) and lift up while li[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 25 1. Counter shaft 2. Spacer (2 used) 3. Need le bea ring 4. Gear 34 Figure 26 1 2 3 4 B. Pull out counter shaft. Remove space r , needle bearing , gear 34 and spac er . 1. Counter shaft 2. Spacer (2 used) 3. Need le bea ring 4. Gear 34 Figure 27 1 2 4 2 3 C. Replace c ounter sha ft if it has ab norma[...]

Wor k ma n M D X - - D Page 4 - - 26 Drive T rain 1. Differential assembly 2. Input shaft assembly 3. Center shaft assembly 4. Shift shaft Figure 28 1 3 2 4 IMPORT ANT : Make sure to not dam age the oil seal when removing the input shaft. NOTE: If any of the assemblies can not be pulled out by hand, hold the assembly while gently tapping the case w[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 27 1. Snap ring 2. Axle case 3. Axle shaft 4. Ball bearing Figure 30 3 2 4 1 IMPORT ANT : Do not reuse snap r ing. Discard and replace ring w ith new one. B. Remove snap ring from the axle case. Remove axle shaft from case. IMPORT ANT : When replacing ball bearings, both ball bearings must be replac ed[...]

Wor k ma n M D X - - D Page 4 - - 28 Drive T rain 1. Input shaft 2. Ball bearing Figure 32 1 2 B. Replace input shaf t if worn or damaged. Gear teeth that are cracke d, broken, chipped or missing are not accepta ble. C. Ball bearing roller balls must be fr ee of deforma- tion and scoring. Ball bearing must spin fre ely and have minimum axial play .[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 29 1. Gear 55 2. Gear 47 3. Gear (small) 4. Ball bearing 5. Ball bearing 6. Pin cl utch 7. Center shaft 8. Col lar (2 use d) 9. Spacer Figure 34 1 2 4 9 8 3 8 5 7 6 B. Remove gears, pin clutch, collars and spacer from the input shaft. C. Replace gears if worn or damaged. Cracked, bro- ken, missing or c[...]

Wor k ma n M D X - - D Page 4 - - 30 Drive T rain 6. Disassemble differential case assembly . 1. Bolt (6 used) 2. Gear 62 3. Differential case Figure 35 1 2 3 A. Remove six (6) bolts securing gear 62 to the dif- ferential case. 1. Spring pin 2. Differential case 3. Pinion shaft 4. Pinion gear Figure 36 1 2 3 4 4 NOTE: The spring pin can be punched [...]

Wor k m an M D X - - D Drive T rain Page 4 - - 31 1. Side gear (2 used) 2. Pinion gear (2 used) 3. Gear 34 4. Ball bearing 5. Dif feren tial c ase 6. Pinion shaft 7. Spring pin 8. Bol t (6 u sed) Figure 37 1 6 2 8 3 4 5 7 D. Replace gears if worn or damaged. Cracked, bro- ken, missing or chip ped gear teeth are n ot accept- able. E. Ball bearing ro[...]

Wor k ma n M D X - - D Page 4 - - 32 Drive T rain T ransaxle Assem bly 1. Assemble input s haft assembly . 1. Ball bearing 2. Input shaft Figure 38 1 2 IMPORT ANT : Make sure to press ball bearing at the inner race to prevent damaging the ball be aring. A. Press ball bea ring onto the input sh aft.[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 33 2. Assemble the cen ter shaft assembly . 1. Pin clutch 2. Center shaft 3. Gear 47 4. Gear 55 5. Collar 6. Gear (sma ll) 7. Beari ng 8. Beari ng 9. Spacer Figure 39 7 4 6 3 5 5 8 2 1 9 5.386” to 5.398” (136.8 to 137.1 mm) NOTE: Before assembling, apply molybdenu m disul- fide grease to the inside[...]

Wor k ma n M D X - - D Page 4 - - 34 Drive T rain Figure 41 D. The center shaft sh ould appear as above when assembled. 3. Asse mble differen tial assembly . 1. Pinion gear (greased surface) 2. Pinion shaft 3. Side gear (greased surface) 4. Differential case 5. Gear 62 6. Bolt 7. Spring pin 8. Ball bearing 9. Ball bearing Figure 42 8 3 7 1 9 1 6 5 [...]

Wor k m an M D X - - D Drive T rain Page 4 - - 35 1. Side gear 2. Pinion gear 3. Pinion shaft 4. Dif feren tial c ase Figure 43 1 4 3 2 B. Install side gear , both pinion gears and pinion shaft into the dif ferential case. 1. Spring pin 2. Differential case 3. Pinion shaft Figure 44 1 2 3 C. Align pinion shaft hole and instal l new spring pin throu[...]

Wor k ma n M D X - - D Page 4 - - 36 Drive T rain 1. Side gear 2. Pinion gear 3. Gear 62 4. Differential case Figure 45 1 2 4 3 D. Install remaining side gear to the pinion ge ars. E. Secure gear 62 to the differe ntial case with six (6) bolts. T orque bolts in a crossing pattern from 40 to 45 ft - - lb (54 to 61 N - - m) . Figure 46 40 to 45 ft - [...]

Wor k m an M D X - - D Drive T rain Page 4 - - 37 4 . I n s t a l la x l ec a s et oc a s e( R Ha n dL H ) . 1. Axle shaft 2. Snap ring 3. Ball bearing Figure 47 1 2 3 IMPORT ANT : Do not reuse snap ring. Replace snap ring with new one. A. Insert axle shaft with snap rings, collar and ball bearings into the axle case. Install snap ring to the axle [...]

Wor k ma n M D X - - D Page 4 - - 38 Drive T rain 5. Install input shaft, cent er shaft and differential as- semblies to the case. 1. Shift shaft 2. Clutch groove Figure 49 1 2 A. Insert fork of the s hift shaft to the clutch groo ve of the center shaft assembly . 1. Center shaft assembly 2. Shift shaft 3. Input shaft 4. Differential assembly Figur[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 39 1. Fork (selector shaft) 2. Pin (shift shaft) Figure 51 1 2 D. Make sure the selector shaft fork is contacting the p i no nt h es h i f ts h a f t . 1. Spacer 2. Boss (counter shaft) Figure 52 1 2 E. Place spacer on the counter shaft boss of the case (LH) so the oil groove faces up. Drive T rain[...]

Wor k ma n M D X - - D Page 4 - - 40 Drive T rain 1. Gear 34 2. Counter shaft 3. Spacer Figure 53 1 2 3 F . Apply molybdenum disulfide grease to the inside of gear 34 and the contact surface betwee n the case and the counter shaft. G. Place gear 34 onto the spacer . Make sure not to drop the spacer . Insert needle bea ring into gear . In- sert coun[...]

Wor k m an M D X - - D Drive T rain Page 4 - - 41 1. Cable bracket 2. Flange bolt Figure 55 15 to 18 ft - - lb (21 to 25 N - - m) 1 2 NOTE: Keep the gasket sealing s urfaces of the cases as horizontal to each oth er as possible. If the sealin g surfaces do not join t o each other , tap the case lightly with a plastic hammer . C. Install case (RH) s[...]

Wor k ma n M D X - - D Page 4 - - 42 Drive T rain 1. Cable bracket 2. Bolt (steel ball, spring & gasket) Figure 57 12 to 15 ft - - lb (16 to 20 N - - m) 1 2 G. Install steel ball, spring, gasket and bolt. T orque bolt from 12 to 15 ft - - lb (1 6 to 20 N - - m) . H. Fill transaxle with 1.5 quarts (1.4 li ters) of new SAE 10W - - 30 motor oil.[...]

Wor k m an M D X - - D Electrical S ystem Pa ge 5 - - 1 Chapter 5 Electrical System T able of Contents GENERAL INFORMA TION 2 ..................... Operator ’s Manu al 2 .......................... Electrical Drawings 2 .............. ............ SPECIAL TOOLS 3 ............................. TROUBLESHOOTING 5 ......................... Startin g P[...]

Wor k ma n M D X - - D Electrical S ystem Pag e 5 - - 2 General Information Operator ’ s Manual The Operator’s Manual provi des information regardi ng the operation, general maintenance and maintenance intervals for your W orkman vehicle. Refer to the Opera- tor ’s Manual for ad ditional inform ation when servicin g the machine. Electrical Dr[...]

Wor k m an M D X - - D Electrical S ystem Pa ge 5 - - 3 Special T ools Order special tools from your T oro Distributor . Some tools may also be avai lable from a local supplier . Multimeter The meter can test electrical components and circuits for current, resista nce or voltage. NOTE: T oro recommends the use of a DIGIT AL V olt - - Ohm - - Amp mu[...]

Wor k ma n M D X - - D Electrical S ystem Pag e 5 - - 4 Dielectric Lubricant/Sealant Dielectric lubrican t should be used to prevent corrosion of non - - sealed conn ection terminals. T o ensure com- plete coating of terminals, libera lly apply lubricant to both component and wire harness con nector , plug con- nector to component, unpl ug connecto[...]

Wor k m an M D X - - D Electrical S ystem Pa ge 5 - - 5 T roubleshooting CAUTION Remove all jewelry , especially rings and watches, before doing any elec trical trouble- shooting or testing. Disconnect the battery cables unless the tes t requires batter y voltage. For eff ective troubleshooting and repairs, you must have a good understanding of the[...]

Wor k ma n M D X - - D Electrical S ystem Pag e 5 - - 6 Starting Pr oblems (Continued) Problem Possible Causes Engine cranks, but d oes not start. Fuel tank is empty . Wiring to start circuits is loose, c orroded or damaged (see electrical drawing s in Chapter 7 - - Electrical Drawings). Engine or fuel system is malfunctioning (see Chapter 3 - - Di[...]

Wor k m an M D X - - D Electrical S ystem Pa ge 5 - - 7 Electrical System Quick Checks Battery T est Use a multimeter to measure the voltage between th e battery terminals. Set the multimeter to the DC volt s setting. The battery should be at a tempera ture of 60 o to 100 o F( 1 6 o to 38 o C). The ignition key should be of f and all accessories tu[...]

Wor k ma n M D X - - D Electrical S ystem Pag e 5 - - 8 Component T esting For accurate resistance and/or continuity checks, elec - trically disconne ct the component being tested from the circuit (e.g. unplug the ignition switch con nector before doing a continuity che ck on the switch). NOTE: See the Kubota W orkshop Manual, Diesel En- gine, SM -[...]

Wor k m an M D X - - D Electrical S ystem Pa ge 5 - - 9 Indicator Lights Charge Indicator Light The charge i ndicator light should come on wh en the igni- tion switch is in the ON position with the engine not run- ning. Also, it should illuminate with an impr operly operating charging circuit w hile the engine is running. Engine Oil Pressure Light [...]

Wor k ma n M D X - - D Electrical S ystem Page 5 - - 10 Fuse Blocks The fuse block on Workman M DX - - D vehicles is located beneath the dash panel. In addition to the fuses in the fuse b lock, an in - - line 10 amp fuse is inclu ded in the wire harnes s. This fuse pro- tects the ignition switch circuits and also provides pro- tection for the opti [...]

Wor k m an M D X - - D Electrical S ystem Page 5 - - 1 1 Fusible Links The Workman MDX- - D uses four (4) fusible links for cir- cuit protection. Three (3) of these fusible links are in- cluded in a wire ha rness that connects the sta rter B+ terminal to the vehicle wire harness (Fig. 12). The re- maining fusible link is inclu ded in the engine wir[...]

Wor k ma n M D X - - D Electrical S ystem Page 5 - - 12 Hour Meter T esting IMPORT ANT : Make sure to obser ve polarity on the hour meter ter minals when testing. Damage to the meter may result from an improper connection. 1. Unplug wire h arness connector from hour meter . 2. Connect positi ve (+) terminal of a 12 VDC source to the positive termin[...]

Wor k m an M D X - - D Electrical S ystem Page 5 - - 13 Brake Switch The brake switch is a normally clos ed switch that opens when the brake pedal is not applied. When the b rake pedal is applied , the brake pedal moves aw ay from the switch plunger to allow the switch to be in its normally closed state. The brake switch is attached to the pedal su[...]

Wor k ma n M D X - - D Electrical S ystem Page 5 - - 14 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 t he hood (Fig. 17). The vehi cle wire harness is attached to the main and gl ow relays with four (4) wire connectors. Relays can be identified [...]

Wor k m an M D X - - D Electrical S ystem Page 5 - - 15 Start Relay The Workman MDX - - D st art relay p rovide s electr ical current to the en gine starter solenoid when ene rgized. The relay is en ergized when th e ignition switch is in the ST AR T position and the brake pedal is dep ressed (brake switch closed). The start relay is attached to th[...]

Wor k ma n M D X - - D Electrical S ystem Page 5 - - 16 Glow Plug Controll er The glow plug c ontroller is attached to the front of the dash bracket and can be accessed by raising the hood (Fig. 21). NOTE: When troubleshooti ng the glow controller , refer to electrical drawings in Chapter 7 - - Electrical Drawings. Glow Plug Controller O peration 1[...]

Wor k m an M D X - - D Electrical S ystem Page 5 - - 17 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 t ot h ei n j e c t i o np u m po nt h e engine (Fig. 23). The run solenoid is e nergized when the ignition switch is in either the ON or ST[...]

Wor k ma n M D X - - D Electrical S ystem Page 5 - - 18 Over T emperature Switch The over temperature swit ch is located on the engine thermostat housing n ear the alternator (Fig. 24). If the engine coolant temperature reaches 230 o F( 1 1 0 o C) (approximate), the ove r temperature switch closes which causes the dash panel engine tempe rature lig[...]

Wor k m an M D X - - D Electrical S ystem Page 5 - - 19 Fuel Pump The MDX - - D fuel pum p is secured in a ca vity in the top of the fuel tank (Fig. 26). Electrical curre nt is available for the fuel pump when th e ignition switch is in either th e ON or ST ART position. IMPORT ANT : When testing fuel pum p, make sure that pump is not operated with[...]

Wor k ma n M D X - - D Electrical S ystem Page 5 - - 20 Oil Pressure Switch The engine oil pressure swit ch is located on the engine near the oil filter (Fig. 28). The oil pressure swi tch is a normally closed switch tha t opens with pressure. The oil pressure switch sh ould open at approximately 8 PSI (0.56 kg/cm 2 ). Switch T esting NOTE: Refer t[...]

Wor k m an M D X - - D Electrical S ystem Page 5 - - 21 Backup Alarm (Optional Kit) When the shift lever is placed in t he reverse position, the backup alarm should sound. The alarm is attached be- neath the cargo box to a bracke t on the right side of the frame. Alarm T esting 1. Park vehicle on a level surface, stop engine, apply parking brake an[...]

Wor k ma n M D X - - D Electrical S ystem Page 5 - - 22 Backup Switch (Optional K it) The optional backup switch i s a four (4) terminal, two (2) circuit switch that is used to energize t he 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 no t used.[...]

Wor k m an M D X - - D Electrical S ystem Page 5 - - 23 Service and Repairs NOTE: For information on engin e electrical compon- ents, see the Kubota Workshop M anual, Diesel Engine, SM - - E3B Series. Battery Service The battery is the heart of the electrical system. With regular and proper service, batter y life can be extended. Additionally , bat[...]

Wor k ma n M D X - - D Electrical S ystem Page 5 - - 24 Battery Inspection and Mainte nance W ARNING POTENTIAL HAZARD: Battery electr olyte contains sulfuric acid which is a deadly poison and it causes severe burns. WHA T CAN HAPPEN: If you carelessly drink electrolyte you could die or if it gets onto your sk in you will be burned. HOW TO A VOID TH[...]

Wor k m an M D X - - D Electrical S ystem Page 5 - - 25 Battery T esting 1. If batte ry caps can be removed, conduct a hydrome- ter test o f the bat tery electr olyte: IMPORT ANT : Make sure the area around the cells is clean before opening the battery caps . A. Measure the specific gravity of each cell with a hydrometer . Draw electrolyte in and o[...]

Wor k ma n M D X - - D Electrical S ystem Page 5 - - 26 Battery Charging T o minimize possible damage to the battery and allow the battery to be fully charged , the slow charging meth- od is presented h ere. This char ging method can be ac- complished with a constant current battery charger which is available in most service shops. CAUTION Follow t[...]

Wor k m an M D X - - D Page 6 - - 1 Chassis Chapter 6 Chassis T able of Contents SPECIFICA TIONS 2 ......... ................... GENERAL INFORMA TION 3 ..................... Operator ’s Manu al 3 .......................... SPECIAL TOOLS 4 ............................. TROUBLESHOOTING 5 ......................... Suspension and Steering 5 .........[...]

Wor k ma n M D X - - D Page 6 - - 2 Chassis Specifications Item Description Front Tire (22 x 9.5 - - 10, 4 ply) Pressure Range 8t o2 2P S I( 5 5t o1 5 1k P a ) Rear T ire (24 x 12 - - 10, 2 ply) Pressure Range 8t o2 2P S I( 5 5t o1 5 1k P a ) Wheel Lug Nut T orque 80 to 90 ft- - lb (109 to 122 N- - m) Brake Fluid DOT 3[...]

Wor k m an M D X - - D Page 6 - - 3 Chassis General Information Operator ’ s Manual The Operator ’s Manu al provides informatio n regarding the operation, general main tenance and maintenance intervals for your Workman MDX- - D vehicle. Refer to the Operator ’s Manual for additiona l informa tion when ser- vicing the m achine. Chassis[...]

Wor k ma n M D X - - D Page 6 - - 4 Chassis Special T ools Order speci al tools from your T oro Distributor . Spanner W rench Use spanner wrench to rotate front sho ck absorber col- lar which chan ges 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 [...]

Wor k m an M D X - - D Page 6 - - 5 Chassis T roubleshooting Suspension and Steerin g Problem Possible Cause Front end is noisy . Front whee l lug nuts are loos e. Front wheel bearing s are loose or worn. Front shocks are loo se or worn. Front end components (e.g. tie - - rod, spin dle, A - - arm) are loose or worn. Steering gearbox i s damaged or [...]

Wor k ma n M D X - - D Page 6 - - 6 Chassis Suspension and Steering (continued) Problem Possible Cause Front end shimmies. Front wheel lug nuts are l oose. Front wheel beari ngs are loose or worn. Steering linkage is loose or worn. T ie rod ends ar e loose or worn. Front wheel alignment (toe- - in) is incorrect. Rubber shock insert or spin dle bush[...]

Wor k m an M D X - - D Page 6 - - 7 Chassis Brakes (continued) Problem Possible Cause Brakes pull to either side. T ire pressure is inco rrect or uneven between tires . Rear brake linings or front brake pads are contaminate d. Front wheel align ment (toe - - in) is incorrect. Rear brak e shoes are distorted . T ires on same axle are unmatched . Bra[...]

Wor k ma n M D X - - D Page 6 - - 8 Chassis Adjustments Adjust Park ing Brake 1. Pry the rubber cover off of the par king brake. 2. Loosen the set sc rew securing th e knob to the pa rk- ing brake lev er (Fig. 3 ). 3. Rotate the knob until a force fr om 30 to 35 lb. (1 33 to 1 5 6N )i sr e q u i r e dt oa c t u a t et h el e v e r . 4. T ighten the[...]

Wor k m an M D X - - D Page 6 - - 9 Chassis Adjust Front Wheel Cambe r 1. Adjust fron t tire pressures to 12 PSI (82 kPa) before checking front wheel camber . 2. Either add wei ght to the driver ’s seat equal to the av- erage operator who will run the machine or have an op- erator on the vehicle operator’s seat. The weight o r operator must rem[...]

Wor k ma n M D X - - D Page 6 - - 10 Chassis Adjust Front Whe el T oe - - in NOTE: Before adjusting front wheel toe - - in, make sure that front wheel c amber is corr ectly adjusted (see Adjust Front Wheel C amber in this section). 1. Adjust fr ont tire pressures to 12 PSI (82 kPa) before checking front wheel toe - - in. 2. Either ad d weight to th[...]

Wor k m an M D X - - D Page 6 - - 1 1 Chassis Service and Repairs Check Tir e Pressure See Specification s for tire pressure range for front and rear tires. The air press ure neede d is deter mined by the paylo ad carried. Lower air pressure will provide less compac- tion, a smoother ride and fewer tire marks. Lower pres- sure should not be used fo[...]

Wor k ma n M D X - - D Page 6 - - 12 Chassis Upper Steer ing 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 s crew (4 used) 10. Bear ing ( 2 used) 1 1 . C a r r i a g eb o l t( 4u s e d ) 12. Steering column 13. Dust cover 14. Collar 15. Set s[...]

Wor k m an M D X - - D Page 6 - - 13 Chassis 5. Support steering column to prevent it from falling. Remove four (4) flange nuts and carriage screws secur- ing the steeri ng column to the mou nting plate o n the frame. 6. Remove dust cover (i tem 13) from the steering shaft. Replace cover if damaged. S lide steering shaft out of th e steering column[...]

Wor k ma n M D X - - D Page 6 - - 14 Chassis Steering Ge arbox 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. Bal l bear ing 1 1. Input shaft spacer 12. Flat w asher 13. Flan ge head s crew w ith p atch lo ck 14. Lube[...]

Wor k m an M D X - - D Page 6 - - 15 Chassis Disassembly (Fig. 10) IMPORT ANT : Do not reuse flange head screws with patch lock (items 9 and 13) after they have been re- moved. 1. Remove flange hea d screw with patch lock (item 9 ) and stepped washer (item 8) from Pitman arm. Discard flange head screw . 2. Remove fl ange head screw with patch lock [...]

Wor k ma n M D X - - D Page 6 - - 16 Chassis Lower Steering a nd 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 s ide) 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 nu t 14[...]

Wor k m an M D X - - D Page 6 - - 17 Chassis Disassembly (Fig. 1 1) 1. Park machine on a l evel surface, stop engine, set parking brake and re move key from the ignition. WA R N I N G Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - - Safety . 2. Chock wheel s not being jacked up. Jack front wheel off the ground [...]

Wor k ma n M D X - - D Page 6 - - 18 Chassis C. Install brake hose clip onto cap screw . Secure spindle to A - - arm hub with cap screw and lock nut. T orqu e fasteners from 75 to 100 ft - - lb (102 to 135 N- -m ) . 2. Install tie rod: A. Insert tie rod ball joints down through the spindle and up through th e Pitman arm. Sec ure with castl e nuts. [...]

Wor k m an M D X - - D Page 6 - - 19 Chassis Front Shock Absorbers Shock Removal (Fig. 14) IMPORT ANT : Any adjustment to the shock spring preload will affect the f ront 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 mach[...]

Wor k ma n M D X - - D Page 6 - - 20 Chassis A - - arms and Front Suspension Figure 15 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 80 to 90 ft - - lb (109 to 122 N - - m) 20 to 25 ft - - lb (28 to 33 N - - m) 45 to 55 ft - - lb (62 to 74 N - - m) See text for tightening p rocedure 6 1. Steerin[...]

Wor k m an M D X - - D Page 6 - - 21 Chassis A - - arm Removal (Fig. 15) 1. Park machine on a l evel surface, stop engine, set parking brake and remove ke y from the ignition switch. WA R N I N G Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - - Safety . 2. Chock wheel s not being jacked up. Jack front wheel off[...]

Wor k ma n M D X - - D Page 6 - - 22 Chassis Frame Pivot Y oke 1. Flange nut (4 used) 2. Shock absorber (2 used) 3. Cap s crew (4 used) 4. Rubber bumper 5. Flat w asher 6. Lock nut (4 used per side) 7. Cap s crew (2 used per shoc k) 8. LH A - - arm 9. Grease fitting (1 used per arm) 10. Screw 11 . C a p s c r e w 12. R H A - - arm 13. Lock washer 1[...]

Wor k m an M D X - - D Page 6 - - 23 Chassis Pivot Y oke Removal (Fig. 17 and 19) 1. Park machine on a l evel surface, stop engine, set parking brake and remove ke y from the ignition switch. 2. Remove cargo box from the rear frame (see Cargo Box Removal in this section). 3. Remove seat base from th ef r o n tf r a m e( s e eS e a t Base Removal in[...]

Wor k ma n M D X - - D Page 6 - - 24 Chassis Swing Arm 1. T ransaxle assembly 2. Cap screw (4 used) 3. Hardened washer (4 used) 4. Rear shock assembly (2 used) 5. Cap s crew (2 used) 6. Lock nut (4 used) 7. Thrust washer (4 used) 8. Cap s crew (2 used) 9. Swin g arm 10. Rear fra me 1 1. Cap scr ew (2 use d) 12. Lock nut (2 used) Figure 20 FRONT RIG[...]

Wor k m an M D X - - D Page 6 - - 25 Chassis Removal (Fig. 20) 1. Park machine on a l evel surface, stop engine, set parking brake and remove ke y from the ignition switch. 2. Raise and suppor t cargo box with prop rod. 3. Remove muf f ler from machine (see Exhaust Syste m in the Service and Repairs section of Chapter 3 - - Diesel Engine). WA R N I[...]

Wor k ma n M D X - - D Page 6 - - 26 Chassis 8. Bleed brake system (see Bleed Brake System in this section). 9. Install both wh eels to the transaxle (see Rear Wheels and Brakes in this se ction). 10. Lower machine to ground. 1 1. Install muf fler to machine (see Exhaust System in the Service and Repairs section of Chapter 3 - - Diesel En- gine). 1[...]

Wor k m an M D X - - D Page 6 - - 27 Chassis This page is intent ionally blank. Chassis[...]

Wor k ma n M D X - - D Page 6 - - 28 Chassis Parking Brake 1. Parking brake cover 2. Operator seat (2 used) 3. Seat base 4. Cable equalizer bracket 5. Parking brake lever 6. Curved washer 7. Lock nut 8. Flat w asher 9. Flange head screw (4 used) 10. Flat wash er (2 use d) 1 1. Screw (2 used) 12. Cap screw 13. Cot ter pi n 14. Clevis pin 15. Parking[...]

Wor k m an M D X - - D Page 6 - - 29 Chassis Disassembly (Fig. 22) 1. Park machine on a leve l surface, stop engine and re- move key from the ignition switch. Cho ck wheels to pre- vent the machine fro m moving. 2. Disconnect both p arking brake cables from rear of machine (Fig. 23): A. Remove cotter pin and clevis pin that secures each brake cable[...]

Wor k ma n M D X - - D Page 6 - - 30 Chassis Rear Wheels and Brakes 1. Wheel assembly 2. Lug nut (5 used per hub) 3. Castle nut 4. Brake drum 5. Socket head screw (4 used per brake) 6. Brake assembly (LH shown) 7. Clevis pin 8. Cot ter pi n 9. Cot ter pi n 10. Flange nut (4 used per brake) 1 1. T ransaxle 12. Parking brake cable (2 used) 13. Wheel [...]

Wor k m an M D X - - D Page 6 - - 31 Chassis C. Remove four (4) socke t head scr ews and fl ange nuts that secure the brake asse mbly to the transaxle. D. Remove brake assembl y from the transaxle. Installation (Fig. 24) IMPORT ANT : Parking brake l evers must be posi- tioned above the transaxle m ount. When positioned correctly , brake lever will [...]

Wor k ma n M D X - - D Page 6 - - 32 Chassis Rear Brake Service 1. Brake backing plate 2. W asher head screw 3. Brake shoe 4. Lower spring 5. Whee l cylin der 6. Parking brake lever (LH shown) 7. Belleville washe r 8. Adj uster l ever 9. Dust cover 10. Flat w asher 11 . B o l t 12. Shoe hold down cup and sp ring 13. Upper spring Figure 26 3 12 4 12[...]

Wor k m an M D X - - D Page 6 - - 33 Chassis Inspection (Fig. 26) 1. Insp ect brake drums. IMPORT ANT : Brake drum machining is not re com- mended. Replace brak e drums as a set to maintain equal braking forces. A. Clean drums with denatured alcohol. Check brakin g surface diam eter in at lea st three p laces. If the diameter exceeds 6.320 i nches [...]

Wor k ma n M D X - - D Page 6 - - 34 Chassis Front Brake Calipers 1. Brake master cylinder 2. Brake caliper (2 used) 3. Bleed screw 4. Brake rotor (2 used) 5. Front brake line 6. Brake line clip (4 used) 7. Cle vis pin 8. Cot ter pi n 9. Cap s crew (2 used) 10. Flange nut (2 used) 1 1. Flange screw (2 used) 12. Flan ge scr ew (2 p er cal iper ) 13.[...]

Wor k m an M D X - - D Page 6 - - 35 Chassis Disassembly (Fig. 27) 1. Park machine on a l evel surface, stop engine, set parking brake and remove ke y from the ignition switch. WA R N I N G Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 - - Safety . 2. Chock wheel s not being jacked up. Jack front wheel off the g[...]

Wor k ma n M D X - - D Page 6 - - 36 Chassis Front Brake Caliper Service 1. Bolt (2 used) 2. Caliper body 3. O - - ring (4 used) 4. Caliper bracket 5. Square seal (2 used) 6. Pist on (2 used ) 7. Brake pad (2 used) 8. Cali per anv il Figure 28 2 3 6 8 1 5 7 4 ( 3 7t o4 4N - - m ) 27 to 33 ft - - lb BAF - - 12 Assembly Lube White Lithium Grease[...]

Wor k m an M D X - - D Page 6 - - 37 Chassis Disassembly (Fig. 28) 1. Remove two (2) bolts tha t secure brake caliper as- sembly . 2. Remove caliper anvil and then slide brake pad s from pins on caliper bracket. 3. Slide caliper body assembly fro m caliper bracket. 4. If necessary , remove remaining components fro m caliper body: A. Carefully remov[...]

Wor k ma n M D X - - D Page 6 - - 38 Chassis Brake Master Cylinder 1. Brake master cylinder 2. Cap screw (2 used) 3. Brake pedal 4. Cle vis pin 5. Cot ter pi n 6. Flange head nut (2 used) 7. Pedal fr ame 8. Front brake line 9. Rear brak e line Figure 29 FRONT RIGHT 3 1 8 4 5 2 6 7 9[...]

Wor k m an M D X - - D Page 6 - - 39 Chassis Removal (Fig. 29) 1. Raise front hood to gain access to brake master cyl- inder . 2. Remove cotter pin from the clevis pin that conne cts master cylinder to brake pedal. IMPORT ANT : T o prevent contamination of the brake system, make sure to clean components before dis- assembly . 3. Clean hydraulic bra[...]

Wor k ma n M D X - - D Page 6 - - 40 Chassis Brake Master Cylinder Servi ce Disassembly (Fig. 30) 1. Thoroughly clean out side of master cylin der before disassembly . 2. Remove reservoir and flange seal . Push in on the push rod so the stop pin c an be removed. 3. Disconnect lower end of th e dust cover from the housing . 4. Push in on the push r [...]

Wor k m an M D X - - D Page 6 - - 41 Chassis Bleed Brake System IMPORT ANT : T o prevent contamination of the brake system, make sure to clean components before dis- assembly . 1. Connect a suitable tr ansparent h ose to bleeder valve on front brake caliper (Fig. 31) or rear wheel brake cylin- der (Fig . 32). Subm erge oth er end of hos e in a glas[...]

Wor k ma n M D X - - D Page 6 - - 42 Chassis Seat Base 1. Seat (2 used) 2. Seat bracket (2 used) 3. Cap screw (8 used) 4. Seat base 5. Shift cable (2 used) 6. Shift lever 7. Shift bracket 8. Flange screw (1/2” long) (4 used) 9. Flange screw (3/4” long) (4 used) 10. Fuel tank assembly 11 . W e b s t r a p p i n g 12. Flan ge head s crew ( 12 use[...]

Wor k m an M D X - - D Page 6 - - 43 Chassis Seat Base Remo val (Fig . 33) 1. Park machine on a le vel surface, stop engine, en- gage parking brake and remove key fro m 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). 4. Unscrew k[...]

Wor k ma n M D X - - D Page 6 - - 44 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 . S crew ( 6 used) 12. W asher head screw (8 used) 13. Car riage [...]

Wor k m an M D X - - D Page 6 - - 45 Chassis Removal (Fig. 35) 1. Park machine on a l evel surface, stop engine, set parking brake and re move key from the ignition. 2. Remove hood using Figure 35 as a guide. Installation (Fig. 35) NOTE: Do not tighten fasteners securing the hood until all fastener s are in place. 1. Install hoo d using Figure 35 a[...]

Wor k ma n M D X - - D Page 6 - - 46 Chassis Cargo Bo x Figure 36 1 17 6 7 2 14 3 11 16 12 10 8 5 13 15 9 4 12 190 to 210 in - - lb (21.5 to 23.7 N - - m) 190 to 210 in - - lb (21.5 to 23.7 N - - m) 1. Car go box 2. Handle 3. Latch pin (2 used) 4. Lock nut (2 used) 5. Car riage s crew (4 u sed) 6. Pivot bracket 7. Pivot bushing (2 used) 8. Screw (4[...]

Wor k m an M D X - - D Page 6 - - 47 Chassis Removal (Fig. 36) 1. Park machine on a l evel surface, stop engine, set parking brake and remove ke y from the ignition switch. 2. Disassemble cargo box as nece ssary using Figures 36 and 37 as guides. Installation (Fig. 36) 1. Assemble cargo box using Figures 36 and 37 as gui- des. A. When installing ca[...]

Wor k ma n M D X - - D Page 6 - - 48 Chassis This page is intentionally blank.[...]

Wor k m an M D X - - D Page 7 - - 1 Electrical Drawings Chapter 7 Electrical Drawings T able of Contents ELECTRI CAL SCHEMA TIC 3 ........ ............ CIRCUIT DIAGRAMS Glow Plug Circuits 4 .. ......................... Start Circuits 5 ................................ Run Circuits 6 ..................... ............ ELECTRICAL HARNESS DRA WI NGS M[...]

Page 7 - - 2 Wo r km a n M D X - - D Electrical Dr awings This page is intentionally blank.[...]

Page 7 - - 3 Elect rical S chemat ic Workman MDX - - D Relays ar e show n as de - - energiz ed[...]

Page 7 - - 4 Glow Plug Circuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent[...]

Page 7 - - 5 Start C ircuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent[...]

Page 7 - - 6 Run Circuits Power C urr ent Contr ol Curr ent Indicat ion Cur rent[...]

Page 7 - - 7 This page is intenti onally bl ank.[...]

Page 7 - - 8 Main Ele ctrical Ha rne ss Workma n M DX - - D Wiring Dr awing[...]

Page 7 - - 9 Main Ele ctrical Ha rne ss Workma n M DX - - D VIOLET BLACK VIOLET BLACK VIOLET PINK RED PINK RED YELLO W BLACK GREEN VIOLET PINK YELLO W RED BLUE YELLO W GREEN BLACK PINK ORANGE ORANGE BLACK BLACK BLUE PINK ORANGE BLACK BLACK GREEN YELLO W TA N BLUE BLUE WHITE YELLO W RED/BL ACK YELLO W WHITE YELLO W RED/BL ACK BLACK YELLO W BLUE YELL[...]

Page 7 - - 10 Engine E lectrical Harness Workma n M DX - - D BRO WN BLACK FUSI BLE LINK RED BLUE WHIT E BLUE[...]