Part No. 13200SL
Service Manual
WorkmanR MDX--D
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Workman MDX--D.
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE AND ADJUSTMENT IN-
STRUCTIONS. For reference, insert a copy of the
Operator’s Manual and Parts Catalog for your machine
into Chapter 2 of this service manual. Additional copies
of the Operator’s Manual and Parts Catalog are avail-
able on the internet at www.Toro.com.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company -- 2013
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Table Of Contents
Chapter 1 -- Safety
Chapter 5 -- Electrical System
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2
Jacking and Other Instructions . . . . . . . . . . . . . . . 1 -- 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 6
General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 5
Electrical System Quick Checks . . . . . . . . . . . . . . 5 -- 7
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 8
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 5 -- 23
Chapter 2 -- Product Records and Maintenance
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 -- 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -- 3
Chapter 6 -- Chassis
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 5
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 8
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 6 -- 11
Chapter 3 -- Diesel Engine
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 5
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 6
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
SM--E3B SERIES
Chapter 7 -- Electrical Drawings
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 3
Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 -- 4
Electrical Harness Drawings . . . . . . . . . . . . . . . . . 7 -- 8
Chapter 4 -- Drive Train
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 2
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 3
Drive Train Operation . . . . . . . . . . . . . . . . . . . . . . . 4 -- 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 8
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 9
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 4 -- 10
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Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2
Supervisor’s Responsibilities . . . . . . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
JACKING AND OTHER INSTRUCTIONS . . . . . . . . 4
Jack Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transport Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Tow Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transaxle Neutral Position . . . . . . . . . . . . . . . . . . . 5
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 6
Workman MDX--D
Page 1 -- 1
Safety
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Safety Instructions
Workman MDX--D vehicles are designed and tested to
offer safe service when operated and maintained pro-
perly. Although hazard control and accident prevention
partially are dependent upon the design and configura-
tion of the machine, these factors are also dependent
upon the awareness, concern and proper training of the
personnel involved in the operation, transport, mainte-
nance and storage of the machine. Improper use or
maintenance of the machine can result in injury or
death.
The safety alert symbol means
CAUTION, WARNING or DANGER —
“personal safety instruction”. Read
and understand the instruction because it has to
do with safety. Failure to comply with the instruc-
tion may result in personal injury.
WARNING
Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Be-
come familiar with all controls and know how to stop it
quickly. Additional copies of the Operator’s Manual are
available on the internet at www.Toro.com.
To reduce the potential for injury or death, com-
ply with the following safety instructions.
WARNING
The Workman is an off--highway vehicle only. It is
not designed, equipped or manufactured for use
on public streets, roads or highways.
Supervisor’s Responsibilities
1. Make sure operators are thoroughly trained and fa-
miliar with the Operator’s Manual and all labels on the
vehicle.
2. Be sure to establish your own special procedures
and work rules for unusual operating conditions (e.g.
slopes too steep for vehicle operation).
Before Operating
1. Read and understand the contents of the Operator’s
Manual and Operator’s DVD before starting and operat-
ing the vehicle. Become familiar with the controls and
know how to stop the vehicle and engine quickly. Addi-
tional copies of the Operator’s Manual are available on
the internet at www.Toro.com.
3. Since diesel fuel used in your Workman MDX--D
vehicle is flammable, handle it carefully:
A. Store fuel in containers specifically designed for
this purpose.
B. Do not remove vehicle fuel tank cap while engine
is hot or running.
2. Keep all shields, safety devices and decals in place.
If a shield, safety device or decal is defective, illegible or
damaged, repair or replace it before operating the ve-
hicle. Also, tighten any loose nuts, bolts or screws to en-
sure vehicle is in safe operating condition.
C. Do not smoke while handling fuel.
D. Fill fuel tank outdoors and only to within an inch of
the top of the tank, not the filler neck. Do not overfill
the fuel tank.
E. Clean up any spilled fuel.
Safety
Page 1 -- 2
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While Operating
1. Sit on the operator seat when starting and operating
the vehicle.
4. Do not touch engine, radiator, exhaust system or
transaxle while engine is running or soon after it is
stopped. These areas could be hot enough to cause
burns.
2. Before starting the engine:
A. Sit on operator’s seat and depress the brake ped-
al. Make sure that the parking brake is released.
5. Before getting off the seat:
A. Stop movement of the vehicle.
B. Turn ignition switch to the ON position. When the
glow plug indicator goes off, the engine is ready to
start.
B. Turn ignition switch to OFF and wait for all move-
ment to stop.
C. Turn ignition switch to the START position. Re-
lease switch to the ON position once the engine
starts.
C. Apply parking brake.
D. Remove key from ignition switch.
E. Do not park on slopes unless wheels are chocked
or blocked.
3. Do not run engine in a confined area without ade-
quate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
Maintenance and Service
1. Before servicing or making adjustments, turn all ac-
cessories off, stop the engine, set parking brake and re-
move key from the ignition switch.
10.Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with a battery.
2. Make sure vehicle is in safe operating condition by
keeping all nuts, bolts and screws tight.
11.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
3. Never work under a raised bed without placing the
bed on the fully extended prop rod.
12.If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor.
4. Never store the vehicle or fuel container inside
where there is an open flame, such as near a water heat-
er or furnace.
13.To assure optimum performance and continued
safety of the vehicle, use genuine Toro replacement
parts and accessories. Replacement parts and acces-
sories made by other manufacturers may result in non-
conformance with safety standards, and the warranty
may be voided.
5. To reduce potential fire hazard, keep engine area
free of excessive grease, grass, leaves and dirt.
6. If engine must be running to perform maintenance or
an adjustment, keep clothing, hands, feet and other
parts of the body away from moving parts. Keep by-
standers away.
14.When raising the vehicle to change tires or to per-
form other service, use correct blocks, hoists and jacks.
Make sure vehicle is parked on a solid level surface such
as a concrete floor. Prior to raising the vehicle, remove
any attachments that may interfere with the safe and
proper raising of the vehicle. Always chock or block
wheels. Use appropriate jack stands to support the
raised vehicle. If the vehicle is not properly supported by
jack stands, the vehicle may move or fall, which may re-
sult in personal injury (see Jack Vehicle in this section).
7. Do not overspeed the engine by changing governor
setting. To assure safety and accuracy, check maximum
engine speed. Maximum engine speed is 3470 RPM.
8. Shut engine off before checking or adding oil to the
engine crankcase.
15.Make sure to dispose of potentially harmful waste
(e.g. fuel, oil, engine coolant, filters, battery) in an envir-
onmentally safe manner. Follow all local codes and reg-
ulations when recycling or disposing of waste.
9. Disconnect battery before servicing the vehicle. Dis-
connect negative (--) battery cable first and positive (+)
cable last. If battery voltage is required for troubleshoot-
ing or test procedures, temporarily connect the battery.
Attach positive (+) cable first and negative (--) cable last.
Workman MDX--D
Page 1 -- 3
Safety
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Jacking and Other Instructions
Jack Vehicle
DANGER
POTENTIAL HAZARD
A vehicle that is not properly supported
may become unstable.
WHAT CAN HAPPEN
The vehicle may move or fall. Personal
injury or damage to the machine may result.
HOW TO AVOID THE HAZARD
Make sure vehicle is parked on a solid level
surface, such as a concrete floor.
Make sure engine is off and key is removed
from the ignition switch before getting off
the vehicle.
2
1
Figure 1
1. Front frame
2. Towing tongue
Before raising the vehicle, remove any
attachments that may interfere with the safe
and proper raising of the vehicle.
Always chock or block wheels to prevent
the vehicle from rolling.
1
Do not start vehicle while it is on jack
stands without placing transaxle in neutral.
Make sure proper hoists, jacks and jack
stands are used to raise and support the
vehicle.
2
Jacking Locations
Figure 2
1. Transaxle case
2. Axle tube
1. Jack front of the vehicle on the front of the frame and
behind the towing tongue (Fig. 1).
2. Jack rear of the vehicle under each rear axle tube. Do
not jack vehicle below the transaxle case (Fig. 2).
Transport Vehicle
When moving the vehicle long distances, use a trailer or
flatbed truck. Make sure vehicle is secured to the trailer
properly. Refer to Operator’s Manual for transport infor-
mation.
Tow Vehicle
IMPORTANT: Frequent or long distance towing of
the Workman MDX--D is not recommended.
IMPORTANT: If vehicle is towed, make sure that
ignition switch is in the OFF position and key is re-
moved from switch.
In case of emergency, the vehicle can be towed for a
short distance. Refer to Operator’s Manual for towing
information.
Safety
Page 1 -- 4
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Transaxle Neutral Position
When performing routine maintenance and/or engine
testing, the transaxle must be shifted into the neutral
position.
2
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
2. Move shift lever to the neutral position (Fig. 3).
1
3. Make sure transaxle is in the neutral position by ro-
tating the driven clutch. The tires should not rotate when
the transaxle is in the neutral position. If tire rotation
does occur, see Adjust Shift Cables in the Adjustments
section of Chapter 4 -- Drive Train.
3
Figure 3
1. Shift lever (in neutral)
2. Forward position
3. Reverse position
Workman MDX--D
Page 1 -- 5
Safety
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Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
your Workman. If any decal becomes illegible or dam-
aged, install a new decal. Part numbers are listed in the
Parts Catalog. Order replacement decals from your Au-
thorized Toro Distributor.
Safety
Page 1 -- 6
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Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 3
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series). . . . . . . . . . . . . . . . 4
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners). . . . . . . . . . . 5
Other Torque Specifications . . . . . . . . . . . . . . . . . . 6
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product Records
Insert Operator’s Manual and Parts Catalog for your
Workman at the end of this chapter. Additionally, if any
optional equipment or accessories have been installed
to your machine, insert the Installation Instructions, Op-
erator’s Manuals and Parts Catalogs for those options
at the end of this chapter.
Maintenance
Maintenance procedures and recommended service in-
tervals for your Workman are covered in the Operator’s
Manual. Refer to that publication when performing regu-
lar equipment maintenance.
Workman MDX--D
Page 2 -- 1
Product Records and Maintenance
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Equivalents and Conversions
0.09375
Product Records and Maintenance
Page 2 -- 2
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Torque Specifications
Recommended fastener torque values are listed in the
following tables. For critical applications, as determined
by Toro, either the recommended torque or a torque that
is unique to the application is clearly identified and spe-
cified in this Service Manual.
As noted in the following tables, torque values should be
reduced by 25% for lubricated fasteners to achieve
the similar stress as a dry fastener. Torque values may
also have to be reduced when the fastener is threaded
into aluminum or brass. The specific torque value
should be determined based on the aluminum or brass
material strength, fastener size, length of thread en-
gagement, etc.
These Torque Specifications for the installation and
tightening of fasteners shall apply to all fasteners which
do not have a specific requirement identified in this Ser-
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature,
hardness of the surface underneath the fastener’s head
or similar condition which affects the installation.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Class 10.9
Inch Series Bolts and Screws
Figure 1
Metric Bolts and Screws
Figure 2
Workman MDX--D
Page 2 -- 3
Product Records and Maintenance
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Grade 1, 5 &
8 with Thin
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 with Regular Height Nuts
(SAE J995 Grade 2 or Stronger Nuts)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
Thread Size
in--lb
in--lb
N--cm
in--lb
15 + 2
N--cm
169 + 23
192 + 23
328 + 34
350 + 45
475 + 56
542 + 56
1130 + 113
1299 + 136
2260 + 282
2542 + 282
N--m
in--lb
23 + 3
N--cm
262 + 34
282 + 34
463 + 56
486 + 56
678 + 68
768 + 79
1582 + 169
1808 + 192
3390 + 339
3672 + 373
N--m
# 6 -- 32 UNC
# 6 -- 40 UNF
# 8 -- 32 UNC
# 8 -- 36 UNF
# 10 -- 24 UNC
# 10 -- 32 UNF
1/4 -- 20 UNC
1/4 -- 28 UNF
5/16 -- 18 UNC
5/16 -- 24 UNF
10 + 2
13 + 2
147 + 23
17 + 2
25 + 3
29 + 3
41 + 5
13 + 2
18 + 2
25 + 5
30 + 5
282 + 30
339 + 56
31 + 4
43 + 5
42 + 5
60 + 6
48 + 5
68 + 7
48 + 7
53 + 7
53 + 7
65 + 10
105 + 15
128 + 17
ft--lb
599 + 79
734 + 113
1186 + 169
1446 + 192
N--m
100 + 10
115 + 12
200 + 25
225 + 25
ft--lb
140 + 15
160 + 17
300 + 30
325 + 33
ft--lb
115 + 15
138 + 17
ft--lb
3/8 -- 16 UNC
3/8 -- 24 UNF
7/16 -- 14 UNC
7/16 -- 20 UNF
1/2 -- 13 UNC
1/2 -- 20 UNF
5/8 -- 11 UNC
5/8 -- 18 UNF
3/4 -- 10 UNC
3/4 -- 16 UNF
7/8 -- 9 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 5
58 + 7
17 + 2
18 + 2
24 + 3
35 + 4
47 + 5
50 + 6
68 + 8
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
29 + 3
29 + 3
39 + 4
55 + 6
75 + 8
77 + 8
104 + 11
142 + 15
163 + 16
285 + 28
325 + 33
508 + 52
569 + 58
813 + 81
904 + 89
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
115 + 12
203 + 20
230 + 24
359 + 37
407 + 41
583 + 61
644 + 65
105 + 11
120 + 12
210 + 21
240 + 24
375 + 38
420 + 43
600 + 60
667 + 66
32 + 4
53 + 7
72 + 9
85 + 9
65 + 10
75 + 10
93 + 12
115 + 15
140 + 20
155 + 25
88 + 12
95 + 15
140 + 20
165 + 25
225 + 25
260 + 30
119 + 16
129 + 20
190 + 27
224 + 34
305 + 34
353 + 41
150 + 15
170 + 18
265 + 27
300 + 30
430 + 45
475 + 48
7/8 -- 14 UNF
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above for
Grade 5 and 8 fasteners are based on 75% of the mini-
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Product Records and Maintenance
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
Class 10.9 Bolts, Screws and Studs with
Thread Size
Regular Height Nuts
(Class 8 or Stronger Nuts)
(Class 10 or Stronger Nuts)
M5 X 0.8
M6 X 1.0
57 + 6 in--lb
96 + 10 in--lb
19 + 2 ft--lb
644 + 68 N--cm
1085 + 113 N--cm
26 + 3 N--m
78 + 8 in--lb
881 + 90 N--cm
1503 + 158 N--cm
38 + 4 N--m
133 + 14 in--lb
28 + 3 ft--lb
M8 X 1.25
M10 X 1.5
M12 X 1.75
M16 X 2.0
M20 X 2.5
38 + 4 ft--lb
52 + 5 N--m
54 + 6 ft--lb
73 + 8 N--m
66 + 7 ft--lb
90 + 10 N--m
225 + 23 N--m
440 + 45 N--m
93 + 10 ft--lb
229 + 23 ft--lb
450 + 46 ft--lb
126 + 14 N--m
310 + 31 N--m
610 + 62 N--m
166 + 17 ft--lb
325 + 33 ft--lb
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Workman MDX--D
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Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Thread Size Recommended Torque**
65 + 10 ft--lb 88 + 14 N--m
Recommended Torque
Thread Size
Square Head
140 + 20 in--lb
215 + 35 in--lb
35 + 10 ft--lb
75 + 15 ft--lb
Hex Socket
73 + 12 in--lb
145 + 20 in--lb
18 + 3 ft--lb
7/16 -- 20 UNF
Grade 5
1/4 -- 20 UNC
5/16 -- 18 UNC
3/8 -- 16 UNC
1/2 -- 13 UNC
1/2 -- 20 UNF
Grade 5
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
M12 X 1.25
Class 8.8
50 + 10 ft--lb
M12 X 1.5
Class 8.8
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Threads per Inch
Size
Baseline Torque*
Thread Size
Baseline Torque*
20 + 5 in--lb
Type A Type B
No. 6 -- 32 UNC
No. 8 -- 32 UNC
No. 10 -- 24 UNC
1/4 -- 20 UNC
No. 6
No. 8
18
15
12
11
20
18
16
14
20 + 5 in--lb
30 + 5 in--lb
38 + 7 in--lb
85 + 15 in--lb
30 + 5 in--lb
38 + 7 in--lb
No. 10
No. 12
85 + 15 in--lb
110 + 20 in--lb
200 + 100 in--lb
5/16 -- 18 UNC
3/8 -- 16 UNC
* Hole size, material strength, material thickness and fin-
ish must be considered when determining specific
torque values. All torque values are based on non--lubri-
cated fasteners.
Conversion Factors
in--lb X 11.2985 = N--cm
N--cm X 0.08851 = in--lb
ft--lb X 1.3558 = N--m
N--m X 0.7376 = ft--lb
Product Records and Maintenance
Page 2 -- 6
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Chapter 3
Diesel Engine
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Adjust Throttle Cable . . . . . . . . . . . . . . . . . . . . . . . . 5
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 6
Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Exhaust System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine Installation . . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Clutch Adapter . . . . . . . . . . . . . . . . . . . . . . 18
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
SM--E3B SERIES
Workman MDX--D
Page 3 -- 1
Diesel Engine
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Specifications
Item
Description
Make / Designation
Kubota water--cooled, Diesel,
Model Z602--E3B
Number of Cylinders
Bore x Stroke
2
2.83” x 2.9” (72mm x 73.6mm)
3
Total Displacement
Compression Ratio
Firing Order
36.55 in (599 cc)
24.0:1
1 (closest to gear case end) -- 2 (closest to flywheel end)
Counterclockwise (viewed from flywheel)
Direction of Rotation
Fuel
Diesel Fuel with Low or
Ultra Low Sulfur Content
Fuel Injector Pump
Fuel Injection Nozzle
Fuel Capacity
Bosch MD Type Mini
Bosch Throttle Type
6.5 U.S. gallons (24.6 liters)
Mechanical
Governor
Low Idle (no load)
High Idle (no load)
Engine Oil
1300 + 70 RPM
3470 + 50 RPM
API CH--4, CI--4, CJ--4 or higher
See Operator’s Manual
Gear Driven Trochoid Type
2.6 U.S. quarts (2.5 liters) with filter
3.0 U.S. quarts (2.8 liters)
12 VDC 0.95 KW
Engine Oil Viscosity
Oil Pump
Crankcase Oil Capacity
Cooling System Capacity (including reserve tank)
Starter
Alternator/Regulator
Dry Weight (approximate)
12 VDC 40 AMP
132 lbs (60 kg)
Diesel Engine
Page 3 -- 2
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General Information
This Chapter gives information about specifications,
maintenance, troubleshooting, testing and repair of the
diesel engine used in the Workman MDX--D.
of the test equipment and the specialized nature of
some repairs may dictate that the work be done at an en-
gine repair facility.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools are described in the Kubota Workshop Manual,
Diesel Engine, SM--E3B Series. The use of some spe-
cialized test equipment is explained. However, the cost
Service and repair parts for the Kubota engine in your
Workman are supplied through your local Toro distribu-
tor. If no parts list is available, be sure to provide your
distributor with the Toro model and serial number.
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Workman MDX--D vehicle. Refer to the
Operator’s Manual for additional information when ser-
vicing the machine.
Workman MDX--D
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Diesel Engine
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Adjustments
Adjust Throttle Cable
Proper throttle operation is dependent upon proper ad-
justment of throttle control. Make sure throttle control is
operating properly.
NOTE: The shoulder bolt that secures the throttle cable
to the engine speed control lever should be positioned
in the lowest hole in the lever.
1. Fully depress throttle pedal to position engine speed
control lever in the high speed position.
3
1
2
2. Check position of the engine speed control lever on
the fuel injection pump (Fig. 1). The speed control lever
should contact the high speed screw when the throttle
pedal is fully depressed.
Figure 1
3. If necessary, throttle control can be adjusted by loos-
ening cable jam nuts and repositioning throttle cable un-
til speed control lever contacts high speed screw when
the throttle pedal is fully depressed (Fig. 2). Tighten
cable jam nuts after adjustment has been completed.
1. High speed screw
2. Speed control lever
3. Engine run solenoid
2
1
4. Release throttle pedal and make sure that cable is
loose enough to allow engine speed control lever to re-
turn to the idle position.
3
5
4
Figure 2
1. Diesel engine
2. Throttle cable
3. Shoulder bolt
4. Flange nut
5. Throttle cable mount
Workman MDX--D
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Service and Repairs
Air Cleaner
8
9
10
5
7
3
1
2
11
4
6
FRONT
RIGHT
Figure 3
5. Air inlet hood
6. Flange nut (2 used)
7. Hose clamp (2 used)
8. Throttle cable
1. Air cleaner assembly
2. Carriage screw (2 used)
3. Air intake hose
9. Shoulder bolt
10. Throttle cable mount
11. Flange nut
4. Air cleaner mounting bracket
Diesel Engine
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Air Cleaner Removal (Fig. 3)
1
1. Park machine on a level surface, stop the engine, en-
gage parking brake and remove the key from the ignition
switch.
2
5
2. Raise and support cargo bed to access air cleaner.
6
3. Remove air cleaner components as needed using
Figure 3 as a guide.
3
30 in--lb
(3.4 N--m)
4. Check air cleaner hose (item 3 in Fig. 3) for damage
or wear. Replace hose if damage is found.
5. Disassemble air cleaner as necessary (Fig. 4).
4
6. Check air cleaner housing and cover for damage that
could cause possible air leaks.
Figure 4
Air Cleaner Installation (Fig. 3)
1. Housing
2. Filter element
3. Cover
4. Vacuator valve
5. Plug
6. Gasket
IMPORTANT: Any leaks in the air cleaner system
will allow dirt into engine and will cause serious en-
gine damage. Make sure that all air cleaner compo-
nents are in good condition and are properly
secured during assembly.
0.180” (4.6 mm)
Maximum
1. Assemble air cleaner system using Figures 3 and 4
as guides.
A. If plug (item 5 in Fig. 4) was removed from air
cleaner housing, apply sealant to threads of plug be-
fore assembly. Torque plug to 30 in--lb (3.4 N--m).
2
3
B. Make sure that vacuator valve on air cleaner as-
sembly is pointed down after assembly.
1
C. Make sure that clearance between air intake
hose and air inlet hood is less than 0.180” (4.6 mm)
(Fig. 5). If this clearance is excessive, the intake
hose may contact secondary clutch during suspen-
sion movement. Rotate intake hose to modify clear-
ance as needed.
Figure 5
2. Lower and secure cargo bed.
1. Air cleaner assembly
2. Air inlet hood
3. Air intake hose
Workman MDX--D
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Exhaust System
RIGHT
FRONT
1
4
5
4
7
3
9
3
6
2
8
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)
Diesel Engine
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Exhaust System Removal (Fig. 6)
Exhaust System Installation (Fig. 6)
1. Park machine on a level surface, stop the engine, en-
gage parking brake and remove the key from the ignition
switch.
1. Make sure the engine is off.
IMPORTANT: If exhaust studs were removed from
engine cylinder head, thoroughly clean threads in
head and apply Loctite #277 (or equivalent) to stud
threads before installing studs into head.
2. Raise and support cargo bed to access exhaust sys-
tem.
NOTE: Make sure exhaust header flange and engine
exhaust manifold sealing surfaces are free of debris or
damage that may prevent a tight seal.
CAUTION
2. If exhaust gasket (item 7) was removed, place new
exhaust gasket on the engine exhaust manifold.
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and ex-
haust system to cool before working on the muf-
fler.
NOTE: To ensure proper exhaust system sealing,
mount all exhaust system components loosely before
fully tightening any fastener.
3. Remove exhaust system components as needed us-
ing Figure 6 as a guide.
3. Assemble all removed exhaust system components
using Figure 6 as a guide.
4. After all exhaust components have been assembled,
make sure that all fasteners are properly tightened.
Also, make sure that all electrical wires and control
cables are not contacted by exhaust components.
5. Lower and secure cargo bed.
Workman MDX--D
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Fuel Tank
RIGHT
FRONT
1
9
5
10
3
4
2
6
8
7
Figure 7
1. Seat
5. Seat base
8. Flat washer (8 used)
9. Parking brake support
10. Shift bracket
2. Fuel tank
6. Web strapping
7. Hex head flange screw (8 used)
3. Fuel hose (to fuel separator)
4. Fuel hose (return from engine)
Diesel Engine
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Fuel Tank Removal (Fig. 7)
17
12
8
9
10
6
CAUTION
16
11
3
Read safety precautions for handling fuel before
working on the fuel system (see Safety Instruc-
tions in Chapter 1 -- Safety).
12
7
14
15
12
5
1. Remove seat base from the frame (see Seat Base in
the Service and Repairs section of Chapter 6 -- Chas-
sis).
11
4
13
2. Use fuel transfer pump to remove fuel from fuel tank.
2
3. Loosen hose clamp and disconnect fuel return hose
(item 13 in Figure 8) from elbow fitting in fuel tank.
4. Loosen hose clamp and disconnect fuel supply hose
(item 17 in Figure 8) from the fuel pump.
1
5. Disconnect fuel pump electrical connector from
vehicle wire harness.
Figure 8
1. Fuel tank
2. Fuel cap
3. Rollover valve
4. Bushing
5. Grommet
6. Stand pipe
7. Elbow fitting
8. Fuel gauge
9. Grommet
10. Vent hose
11. Hose clamp
6. Release tank strap that secures fuel tank to frame.
Do not remove strap from floor plate and frame cross
member. Lift fuel tank assembly from frame.
12. Hose clamp
13. Fuel return hose
14. Fuel pump
15. Fuel pump holder
16. Fuel supply hose
17. Fuel supply hose
7. Remove fuel tank components as needed using Fig-
ure 8 as a guide.
8. Clean fuel tank before installing it back on vehicle.
Fuel Tank Installation (Fig. 7)
1. Install all removed fuel tank components using Fig-
ure 8 as a guide.
2. Position fuel tank to frame. Secure tank to frame and
cross member with tank strap.
3. Connect fuel supply hose (item 17 in Figure 8) to the
fuel pump and fuel return hose (item 13 in Figure 8) to
the elbow fitting. Secure hoses with hose clamps.
4. Connect fuel pump electrical connector to vehicle
wire harness.
5. Install seat base to the frame (see Seat Base in the
Service and Repairs section of Chapter 6 -- Chassis).
6. Fill fuel tank.
Workman MDX--D
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Radiator
2
16
15
21
1
23
13
22
23
12
7
4
14
20
19
3
20
10
12
9
6
13
23
18
5
12
8
14
17
12
11
12
19
RIGHT
5
FRONT
Figure 9
9. Lower radiator hose
10. Upper radiator hose
11. Straight hose
1. Surge tank
2. Tank cap
3. Radiator
17. Lower radiator shroud
18. Upper radiator shroud
19. Speed nut (4 used)
4. Washer head screw (2 used)
5. Flange nut (3 used)
6. Cap
12. Hose clamp (6 used)
13. Carriage screw (3 used)
14. Flange nut (3 used)
15. Cap
20. Washer head screw (4 used)
21. Coolant hose
22. Coolant hose
7. Cap decal
23. Hose clamp (4 used)
8. Filler neck
16. Hose clamp
Radiator Removal (Fig. 9)
CAUTION
1. Park machine on a level surface, stop the engine, en-
gage parking brake and remove the key from the ignition
switch.
DO NOT open radiator cap or drain coolant if the
engine or radiator is hot. Pressurized hot coolant
can escape and cause burns.
2. Raise and support cargo bed to access radiator.
3. Remove knob that secures radiator screen to right
side of rear frame (Fig. 10). Lift screen to separate tabs
on screen from slots in frame and then remove screen
from vehicle.
Ethylene--glycol antifreeze is poisonous. Dis-
pose of it properly or store it in a properly labeled
container away from children and pets.
Diesel Engine
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4. Remove caps (items 2 and 6) from surge tank and ra-
diator filler neck to allow complete draining of cooling
system.
IMPORTANT: Use a 50/50 mix of ethylene--glycol
and water when filling cooling system.
7. Fill cooling system with coolant as follows (Fig. 11):
5. Drain radiator into a suitable container by discon-
necting lower radiator hose from the radiator.
A. Make sure that surge tank cap is installed on
surge tank.
6. Disconnect upper radiator hose from the radiator.
B. Remove cap on radiator filler neck and fill cooling
system with coolant.
7. Disconnect the coolant hose (item 22) from the fitting
located on the lower radiator tube.
C. Install cap into radiator filler neck and tighten.
8. Remove four (4) washer head screws (item 20) and
three (3) flange nuts (item 14) that secure the radiator
shrouds. Also, disconnect wire harness clips from upper
radiator shroud. Carefully remove upper radiator shroud
from vehicle.
D. Remove surge tank cap and fill surge tank to the
bottom of the filler neck. Install surge tank cap.
8. Check radiator, surge tank, hoses and all connec-
tions for leaks.
9. Position lower radiator shroud away from the radiat-
or.
9. Lower and secure cargo bed.
10.Remove three (3) carriage head screws (item 13)
and flange nuts (item 14) that secure the radiator to the
rear frame.
1
11.Carefully remove radiator from vehicle.
4
Radiator Installation (Fig. 9)
1. Make sure that lower radiator shroud is positioned
under the engine fan.
2. Carefully position radiator to the rear frame. Secure
radiator to frame with three (3) carriage head screws
(item 13) and flange nuts (item 14).
2
4
3
3. Position upper and lower radiator shrouds around
the fan and to the radiator. Secure shrouds together with
four (4) washer head screws (item 20). Then, secure
shrouds to frame with three (3) flange nuts (item 14).
Make sure that equal clearance exists between shrouds
and fan at all points.
Figure 10
1. Rear frame
2. Radiator screen
3. Knob
4. Slot
1
4. Connect upper and lower radiator hoses to radiator
and secure with hose clamps.
2
5. Connect coolant hose (item 22) to the fitting located
on the lower radiator tube and secure with hose clamp.
Make sure that hose is not kinked at any point after in-
stallation.
6. Install radiator screen to rear frame and secure with
knob (Fig. 10).
Figure 11
1. Filler neck cap
2. Surge tank cap
Workman MDX--D
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Engine
17
1
11
2
3
9
10
8
7
4
6
16
15
5
7
RIGHT
14
13
12
FRONT
Figure 12
1. Engine
2. Engine wire harness connector
3. Hex nut
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
11. Flange nut (4 used)
12. Cap screw (4 used)
13. Snubbing washer (4 used)
14. Spacer (4 used)
15. Engine mount (4 used)
16. Engine bracket (front shown)
17. Drive belt
Diesel Engine
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Engine Removal (Fig. 12)
2
1
1. Park machine on a level surface, stop engine, en-
gage parking brake and remove key from the ignition
switch.
3
CAUTION
5
The engine, radiator and exhaust system may be
hot. To avoid possible injury, allow machine to
cool before working on the engine.
2. Disconnect negative (black) cable from the battery.
Then, disconnect positive (red) cable from the battery.
4
3. Remove cargo box to gain access to the engine (see
Cargo Box in the Service and Repairs section of Chapter
6 -- Chassis).
Figure 13
1. Diesel engine
2. Throttle cable
3. Shoulder bolt
4. Flange nut
5. Throttle cable mount
4. Carefully remove drive belt from drive clutch.
5. Depending on needed engine repairs, it may be easi-
er to drain oil from engine before engine removal.
IMPORTANT: To prevent contaminants from enter-
ing the engine and fuel system, make sure all hoses
and engine openings are covered or plugged after
disconnecting.
4
2
6. Drain radiator into a suitable container by discon-
necting lower radiator hose from the radiator. Then, re-
move upper radiator hose from the radiator.
7. Remove air intake hose from the air cleaner and en-
gine intake (see Air Cleaner in this section).
3
1
8. Remove muffler and exhaust header from the
vehicle (see Exhaust System in this section).
Figure 14
1. Alternator
3. Glow plug bus
4. Engine run solenoid
9. Remove shoulder bolt and flange nut that secure the
throttle cable end to injector pump speed control lever
(Fig. 13). Loosen nuts that secure throttle cable to cable
mount. Position throttle cable away from engine.
2. Temperature switch
2
2
3
CAUTION
Read safety precautions for handling fuel before
working on the fuel system (see Safety Instruc-
tions in Chapter 1 -- Safety).
10.Disconnect fuel supply hose from the injector pump
and fuel return hose from the #2 injector. Drain any fuel
trapped in the hoses into a suitable container. Plug
hoses and position them away from engine assembly.
1
1
Figure 15
1. Flange nut (8 used)
2. Flange screw (8 used)
3. Engine mount (4 used)
Workman MDX--D
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11.Disconnect electrical connections from the following
engine components:
2
1
A. Disconnect main wire harness connections to
glow plug bus, temperature sender and engine run
solenoid (Fig. 14).
4
B. Disconnect main wire harness connection to fus-
ible link harness.
C. Disconnect engine wire harness connector from
the main wire harness. The engine wire harness in-
cludes connectors for the alternator, oil pressure
switch, starter solenoid and engine ground.
3
D. Remove flange head screw from front engine
mount that secures negative battery cable and en-
gine ground connector. Make sure to note location of
lock washer when removing screw. Position negat-
ive battery cable away from engine.
Figure 16
1. Front engine bracket
2. Rubber bumper
3. Lock nut (3 used)
4. Carriage screw (3 used)
12.Remove four (4) flange nuts, spacers, snubbing
washers and cap screws that secure the engine to the
engine mounts.
Engine Installation (Fig. 12)
1. Install all removed mounts, components and attach-
ments to the engine.
CAUTION
CAUTION
Make sure that hoist or lift used to remove engine
can properly support engine. Engine assembly
weighs approximately 170 pounds (77 kg). Also,
one person should operate the hoist while a
second person guides the engine out of the
vehicle.
Make sure that hoist or lift used to install engine
can properly support engine. Engine assembly
weighs approximately 170 pounds (77 kg). Also,
one person should operate the hoist while a
second person guides the engine into the
vehicle.
13.Remove engine from the vehicle.
2. Install engine to the vehicle.
A. Attach a short section of chain between both en-
gine lift tabs.
A. Attach a short section of chain between both en-
gine lift tabs.
B. Connect hoist to center of chain.
B. Connect a hoist at the center of the short section
of chain.
IMPORTANT: Make sure to not damage the en-
gine, fuel hoses, electrical harness or other parts
while removing the engine.
IMPORTANT: Make sure to not damage engine,
fuel lines, electrical harness or other parts while
installing the engine.
C. Carefully move the engine assembly away from
the radiator and when the engine has cleared the ra-
diator shrouds, carefully raise the engine from the
vehicle.
C. Carefully lower engine assembly into the engine
area of the vehicle. Align holes in engine brackets
with engine mounts attached to frame.
14.Remove engine brackets, components and attach-
ments as necessary to repair the engine.
3. Secure engine to engine mounts with four (4) cap
screws, snubbing washers, spacers and flange nuts.
15.Inspect engine mounts (Fig. 15) and bumper as-
sembly (Fig. 16) for wear or damage and replace com-
ponents if necessary.
Diesel Engine
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4. Connect the following electrical components:
8. Install exhaust header and muffler to the vehicle (see
Exhaust System in this section).
A. Connect main wire harness connections to glow
plug bus, temperature sender and engine run solen-
oid (Fig. 14).
9. Install air intake hose to the air cleaner and engine
intake (see Air Cleaner in this section).
B. Connect main wire harness connection to fusible
link harness.
10.Connecting lower and upper radiator hoses to the ra-
diator. Fill cooling system with coolant (see Radiator in
this section). Check radiator and hoses for leaks.
C. Connect engine wire harness connector to the
main wire harness.
11.Make sure that alternator belt tension is properly ad-
justed.
D. Secure negative battery cable and engine ground
connector to front engine mount with flange head
screw. The order of assembly should be lock washer,
negative battery cable, engine ground connector
and then flange head screw. Coat connectors with
skin over grease or terminal protector (see Special
Tools in Chapter 5 -- Electrical System) after as-
sembly.
12.Check that the gap between the rubber bumper and
front engine bracket is 0.090” (2.2 mm) (Fig. 16). If gap
is incorrect, loosen three (3) lock nuts and adjust bump-
er to provide correct gap. Tighten lock nuts to secure
bumper after adjustment.
13.Make sure engine oil level is correct.
14.Install cargo box to the frame (see Cargo Box in the
Service and Repairs section of Chapter 6 -- Chassis).
5. Install drive belt to drive clutch.
IMPORTANT: Make sure to remove all plugs and
covers that were placed on hose and engine open-
ings during engine removal.
15.Connect positive (red) cable to the battery. Then,
connect negative (black) cable to the battery.
6. Connect fuel supply hose to the injector pump and
fuel return hose to the #2 injector.
7. Position throttle cable to engine. Secure the throttle
cable end to injector pump speed control lever with
shoulder bolt and flange nut. Tighten cable nuts to se-
cure cable to cable mount (Fig. 13). Check throttle cable
adjustment (see Adjust Throttle Cable in the Adjust-
ments section of this chapter).
Workman MDX--D
Page 3 -- 17
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Engine Clutch Adapter
7
17 to 22 ft--lb
(23 to 29 N--m)
1
6
Loctite #242
3
5
2
RIGHT
FRONT
4
Figure 17
1. Drive belt
2. Cap screw
3. Flange washer
4. Drive clutch
5. Cap screw (5 used)
6. Clutch adapter
7. Engine assembly
Removal (Fig. 17)
Installation (Fig. 17)
1. Park machine on a level surface, stop the engine, en-
gage parking brake and remove the key from the ignition
switch.
1. Position clutch adapter to engine flywheel and se-
cure with five (5) cap screws.
2. Secure drive clutch to clutch adapter on engine (see
Drive Clutch in the Service and Repairs section of
Chapter 4 -- Drive Train).
2. Raise and support cargo bed to access engine.
3. Carefully remove drive belt from drive clutch.
3. Install drive belt to drive clutch.
4. Lower and secure cargo bed.
4. Remove drive clutch from clutch adapter on engine
(see Drive Clutch in the Service and Repairs section of
Chapter 4 -- Drive Train).
5. Remove five (5) cap screws that secure clutch
adapter to engine flywheel. Remove clutch adapter from
engine.
Diesel Engine
Page 3 -- 18
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Chapter 4
Drive Train
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DRIVE TRAIN OPERATION . . . . . . . . . . . . . . . . . . . . 4
Clutch System Operation . . . . . . . . . . . . . . . . . . . . . 4
Drive Clutch Operation . . . . . . . . . . . . . . . . . . . . . . . 5
Driven Clutch Operation . . . . . . . . . . . . . . . . . . . . . 6
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 8
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Adjust Shift Cables . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 10
Drive Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive Clutch Service . . . . . . . . . . . . . . . . . . . . . . . . 12
Driven Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Driven Clutch Service . . . . . . . . . . . . . . . . . . . . . . . 15
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transaxle Disassembly and Inspection . . . . . . 21
Transaxle Assembly . . . . . . . . . . . . . . . . . . . . . . 32
Workman MDX--D
Page 4 -- 1
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Specifications
Item
Description
Transaxle
Transaxle Fluid Capacity
Transaxle Fluid
1.5 quarts (1.4 liters)
SAE 10W--30 Motor Oil
73 pounds (33 kilograms)
Transaxle Dry Weight
Clutch System
Drive Clutch
Driven Clutch
Continuously variable transmission type, torque convertor
Speed sensing with mechanical fly weights
Torque sensing with spring loaded cam
Drive Train
Page 4 -- 2
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General Information
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Workman MDX--D vehicle. Refer to the
Operator’s Manual for additional information when ser-
vicing the machine.
Workman MDX--D
Page 4 -- 3
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Drive Train Operation
Clutch System Operation
FULL ENGINE SPEED
DECREASING LOAD
1
LOW ENGINE SPEED
LIGHT LOAD
FULL ENGINE SPEED
INCREASING LOAD
4
3
v
6
2
5
8
7
Figure 1
1. Drive clutch
4. Fixed sheave (drive clutch)
5. Moveable sheave (driven clutch)
6. Spring
7. Fixed sheave (driven clutch)
8. CVT drive belt
2. Driven clutch
3. Moveable sheave (drive clutch)
Power is transferred from the engine to the transaxle by
a variable clutch system that consists of two (2) clutches
connected by a drive belt. The drive clutch responds to
engine speed and is mounted to the engine crankshaft.
The driven clutch responds to changes in load to the rear
axle and is mounted to the transaxle input shaft.
The two (2) clutches work together to automatically up--
shift and back--shift as changes in load and speed occur.
This shifting changes the turning ratio between the drive
and driven clutches and allows the engine to operate at
optimum efficiency.
Drive Train
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Drive Clutch Operation
The operation of the drive clutch is affected by engine
shaft speed. With the engine not turning, the CVT drive
belt rests low within the drive clutch sheaves as the pres-
sure of the spring holds the sheaves apart. As the en-
gine increases in speed, the clutch weights attached to
the moveable sheave move outward as they spin about
the engine driveshaft. The outward movement of the
clutch weights presses against the rollers and overcom-
es spring pressure through the spider assembly, which
forces the moveable sheave closer to the fixed sheave.
This inward movement of the sheave engages the drive
belt to drive the driven clutch.
1
3
2
4
7
With increasing engine speed, the moveable sheave
continues to move inward, which forces the drive belt to
ride towards the outer diameter of the clutch sheaves.
When engine speed is decreased, the clutch weights
exert less force on the rollers and thus the spring. The
spring pressure overcomes the force of the clutch
weights and shifts the moveable sheave away from the
fixed sheave. The drive belt disengages from the clutch
sheaves at a point where the force of the spring is great-
er than that of the clutch weights.
6
5
Figure 2
1. Fixed sheave
2. Moveable sheave
3. Spider assembly
4. Cover
5. Clutch weight (3 used)
6. Roller (3 used)
7. Spring
Workman MDX--D
Page 4 -- 5
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Driven Clutch Operation
The operation of the driven clutch is affected by trans-
axle load. When the vehicle is stopped, the drive belt is
held at the outer diameter of the driven clutch sheaves
from the pressure of the spring pushing the moveable
sheave against the fixed sheave and away from the
fixed cam.
2
3
Once the drive belt starts rotating, the driven clutch also
starts to rotate. With increasing speed of the drive clutch
on the engine, the drive belt begins to climb to the outer
diameter of the drive clutch sheaves. This increases the
tension on the drive belt and forces the moveable
sheave of the driven clutch to move away from the fixed
sheave against the pressure of the driven clutch spring.
As the belt tightens and the driven clutch sheaves open
up, the drive belt rides lower in the driven clutch
sheaves.
1
With increased load to the transaxle, the driven clutch
fixed cam resists forward movement relative to the
moveable sheave and drive belt. Torque from the drive
belt along with spring pressure moves the moveable
sheave up the ramp of the fixed cam. The drive belt be-
comes positioned closer to the outer diameter of the
driven clutch sheaves.
Figure 3
1. Moveable sheave
2. Fixed sheave
3. Spring
The fixed cam on the driven clutch moveable sheave ro-
tates on a pair of rollers in the fixed sheave base to allow
low friction movement of the moveable sheave (Fig. 3).
Drive Train
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Special Tools
Order special tools from your Toro Distributor.
Drive Clutch Removal Tool
This tool is required to remove the drive clutch from the
tapered drive shaft of the engine. It is placed in the
threaded hole of the fixed clutch sheave after the clutch
retaining screw is removed.
Toro Part Number: TOR6014
Figure 4
Workman MDX--D
Page 4 -- 7
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Troubleshooting
Clutch
Problem
Possible Cause
Poor upshifting.
Governed engine speed is adjusted too low.
Drive and/or driven clutch assemblies have accumulation of dirt or
debris.
Drive belt is worn.
Clutch sheaves are worn or damaged.
Poor downshifting.
Drive and/or driven clutch assembly has accumulation of dirt or
debris.
Drive belt is worn.
Clutch sheaves are worn or damaged.
Engine idle speed is too high.
Vehicle creeps at idle.
Rough clutch engagement.
Drive clutch has accumulation of dirt or debris preventing full back-
shifting.
Drive and driven clutches are not aligned.
Engine idle speed is too low.
Drive clutch assembly has accumulation of dirt or debris.
Drive belt is worn.
Drive clutch sheaves are worn or damaged.
Noisy clutch operation.
Engine idle speed is too low causing excess shaking.
Worn drive clutch roller or weight bushings.
Worn drive clutch spider slides (drive clutch replacement necessary
if found).
Drive Train
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Adjustments
Adjust Shift Cables
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
Raise and support cargo box.
2
2
2. Set the shift lever into the Neutral position. Rotate
driven clutch to insure transmission is in neutral.
1
3. The transaxle select lever assembly should be in a
level position and parallel to the cable mounting bracket.
4. While holding the cable below the lever, tighten the
lock nut on one of the shift cables to allow 0.030” to
0.060” (0.8 to 1.5 mm) freeplay in the cable (Fig. 6).
5. Repeat process for other shift cable.
6. Pull up on each shift cable to make sure that freeplay
is correct. If necessary, readjust nut (Fig. 6).
3
3
7. Start engine and verify transaxle engagement in for-
ward, reverse and neutral as the shift lever is moved.
Figure 5
8. Finally, check vehicle operation in forward, reverse
and neutral. Readjust shift cables if needed for correct
operation.
1. Select lever assembly
2. Lock nut location
3. Shift cable
9. Lower and secure cargo box.
2
0.030” to 0.060”
(0.8 to 1.5 mm)
3
1
Figure 6
1. Select lever
2. Cable pull direction
3. Cable boot
Workman MDX--D
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Service and Repairs
Drive Clutch
1
4
5
2
v
Loctite #242
3
RIGHT
6
17 to 22 ft--lb
(23 to 29 N--m)
FRONT
7
Figure 7
1. Engine
2. Clutch adapter
3. Cap screw (5 used)
4. Drive belt
5. Drive clutch
6. Flange washer
7. Cap screw
Drive Train
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Drive Clutch Removal (Fig. 7)
Drive Clutch Installation (Fig. 7)
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
Raise and support cargo box.
1. Thoroughly clean the tapered surfaces of the clutch
adapter and drive clutch.
2. Slide drive clutch onto the clutch adapter.
2. Carefully remove drive belt from the drive clutch.
3. Apply Loctite #242 (or equivalent) to the threads of
the cap screw (item 7).
3. Remove cap screw (item 7) and flange washer (item
6) securing the drive clutch to the clutch adapter.
4. Secure clutch to clutch adapter with cap screw (item
7) and flange washer (item 6). Torque cap screw from 17
to 22 ft--lb (23 to 29 N--m).
IMPORTANT: Lightly grease end of clutch removal
tool to prevent wear or damage to removal tool and
clutch adapter. Prevent damage to clutch threads;
thread tool into clutch only enough to remove the
clutch.
5. Install drive belt to the drive clutch.
6. Lower and secure cargo box.
4. Use drive clutch removal tool (see Special Tools in
this chapter) to remove drive clutch from the tapered
clutch adapter.
5. Inspect the tapered ends of the clutch adapter and
fixed sheave of drive clutch. If either is severely dam-
aged, replace component as damage to the taper will al-
low loosening of the clutch during operation.
Workman MDX--D
Page 4 -- 11
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Drive Clutch Service
11
105 to 120 in--lb
(12 to 13.5 N--m)
7
v
9
8
4
2
1
6
10
5
40 to 50 in--lb
(4.6 to 5.6 N--m)
3
Figure 8
1. Flange head screw (6 used)
2. Cover
3. Compression spring
4. Limiter shim
5. Shoulder screw (3 used)
6. Lock nut (3 used)
7. Clutch weight (3 used)
8. Spider
9. Shim
10. Moveable sheave
11. Fixed sheave
Disassembly (Fig. 8)
IMPORTANT: Make note of the “X” mark cast into
the cover and spider before clutch disassembly.
These marks must be aligned during assembly for
proper clutch operation.
2
1. Make note of the “X” mark cast into the cover and spi-
der before clutch disassembly (Fig. 9). These marks
must be aligned during assembly for proper clutch op-
eration.
CAUTION
1
Loosen the flange head screws that secure cover
slowly. The cover is under pressure from the
compression spring.
Figure 9
2. Using a crossing pattern, loosen and remove six (6)
flange head screws (item 1) that secure the cover to the
movable sheave.
1. Spider
2. Cover
3. Carefully remove cover, compression spring and lim-
iter shim from clutch.
4. Remove lock nut (item 6) from each of the shoulder
screws (item 5). Discard lock nuts after removal.
Drive Train
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5. Slide shoulder screw from each of the clutch weights
(item 7) and then remove weights from clutch.
3. Position limiter shim, compression spring and cover
to clutch. Make sure that the “X” mark cast into the cover
and spider are aligned.
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. Remove any remaining debris
with a fast drying contact or brake parts cleaner. Focus
debris removal on and around moving clutch compon-
ents.
4. Secure cover to the movable sheave with six (6)
flange head screws in a crossing pattern and in three (3)
steps. Final torque on screws should be from 105 to 120
in--lb (12 to 13.5 N--m).
2
Inspection
1
NOTE: If drive clutch wear or damage occurs, clutch re-
placement may be necessary. Refer to your parts cata-
log to identify individual drive clutch components that
are available.
1. Inspect the tapered ends of the engine crankshaft
and fixed sheave of drive clutch. If either is severely
damaged, replace component as damage to the taper
will allow loosening of the clutch during operation.
Figure 10
1. Clutch weight
2. Contact surface
2. Inspect the compression spring (item 3) and replace
if damaged or fatigued.
2
3
3. Clean and inspect shoulder screws (item 5). If the
shoulder area of the screws is worn or if the threads are
damaged, replace the screws.
4. Check the contact surface of the clutch weights (Fig.
10). If surface is worn or damaged, replace all three (3)
clutch weights as a set.
1
Figure 11
5. Check the rollers in the spider assembly for binding
or wear (Fig. 11). If binding or uneven wear is found, re-
place clutch assembly.
1. Roller
3. Roller uneven wear
2. Weight contact surface
6. Check the belt contact surfaces of the movable and
fixed sheaves. Remove any belt material from sheave
faces with a fine abrasive pad or fine steel wool. If
sheave surfaces are worn, replace clutch assembly.
2
1
Assembly (Fig. 8)
2
IMPORTANT: For proper drive clutch operation, DO
NOT lubricate drive clutch components.
1
IMPORTANT: To maintain the balance of the clutch,
all shoulder screws must be installed with their
threads pointing in a clockwise direction (Fig. 12).
1. Position clutch weights to moveable sheave and
slide shoulder screw into sheave and weight. Make sure
that shoulder screw threads are pointing in a clockwise
direction.
1
2
Figure 12
1. Shoulder screw head
2. Lock nut
2. Install new lock nuts on the shoulder screws. DO
NOT reuse removed lock nuts. Tighten nuts until they
contact screw shoulder and then torque nuts from 40 to
50 in--lb (4.6 to 5.6 N--m).
Workman MDX--D
Page 4 -- 13
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Driven Clutch
Driven Clutch Removal (Fig. 13)
3
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
Raise and support cargo box.
2
4
2. Remove muffler from the vehicle (see Exhaust Sys-
tem in the Service and Repairs section of Chapter 3 --
Diesel Engine).
3. Carefully remove drive belt from the driven clutch.
4. Remove cap screw and stepped washer securing
the driven clutch to the input shaft of the transaxle.
1
5. Slide driven clutch from the transaxle input shaft.
Driven Clutch Installation (Fig. 13)
1. Coat transaxle input shaft with antiseize lubricant.
Antiseize
Lubricant
39 to 47 ft--lb
(53 to 63 N--m)
2. Position driven clutch to the input shaft. Make sure
pulley side of the clutch is next to the transaxle case.
Figure 13
1. Cap screw
2. Stepped washer
3. Driven clutch
4. Input shaft (transaxle)
3. Secure driven clutch to the transaxle input shaft with
cap screw and stepped washer. Torque cap screw from
39 to 47 ft--lb (53 to 63 N--m).
4. Install drive belt to the driven clutch.
5. Install muffler to the vehicle (see Exhaust System in
the Service and Repairs section of Chapter 3 -- Diesel
Engine).
6. Lower and secure cargo box.
Drive Train
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Driven Clutch Service
1. Use a suitable press to compress the clutch spring
enough to allow removal of the retaining ring.
2
3
2. Remove retaining ring.
3. Carefully, allow the spring to extend fully.
4
4. Remove outer spring retainer, spring and inner
spring retainer from clutch.
6
7
5. Make note of the “X” mark cast into the fixed sheave
and moveable sheave before removing the moveable
sheave. These marks must be aligned during assembly
for proper clutch operation.
1
5
6. Separate the clutch sheaves. Locate and retrieve
thrust washer.
Figure 14
1. Fixed sheave
2. Thrust washer
5. Spring
6. Outer spring retainer
7. Retaining ring
7. Clean and inspect driven clutch components:
3. Moveable sheave
4. Inner spring retainer
A. Clean all dust and debris from clutch compo-
nents. If necessary, use contact or brake cleaner to
remove any oil or other lubricants from clutch com-
ponents.
B. Inspect the spring and replace if damaged or fa-
tigued.
C. Check the rollers in the fixed sheave for binding or
wear. If binding or uneven wear is found, replace
driven clutch assembly.
D. Check the contact surface of the sheaves for
wear and/or fraying. If wear or damage is found, re-
place driven clutch assembly.
8. Assemble the driven clutch in the reverse order of
disassembly. Make sure that the “X” mark cast into the
fixed and moveable sheaves are aligned. Also, make
sure that the retaining ring is fully seated in groove after
installation.
Workman MDX--D
Page 4 -- 15
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Transaxle
13
39 to 47 ft--lb
(53 to 63 N--m)
Antiseize
Lubricant
Antiseize
Lubricant
2
7
6
17
1
14
12
Loctite #242
8
15
18
120 ft--lb
(162 N--m)
27
23
5
24
7
10
28
20
9
3
v
4
26
25
19
21
Antiseize
Lubricant
16
11
RIGHT
80 to 90 ft--lb
(109 to 122 N--m)
29
22
FRONT
Figure 15
1. Transaxle assembly
2. Driven clutch
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)
11. Cap screw (4 used)
12. Flat washer (2 used)
13. Swing arm
21. Slotted hex nut (2 used)
22. Cotter pin (2 used)
23. Select lever
14. Lock nut (2 used)
15. Flat washer
24. Wheel hub (2 used)
25. Wheel stud (5 used per hub)
26. Brake assembly (LH shown)
27. Rear brake line
16. Skid plate
17. R--clamp
18. Lock nut
28. Rear wheel assembly (2 used)
29. Lug nut (5 used per wheel)
19. Washer (2 used)
20. Spring washer (2 used)
Drive Train
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Removal (Fig. 15)
7. Support the transaxle to prevent it from shifting.
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
8. Remove four (4) cap screws (item 10) and flat wash-
ers (item 5) that secure the transaxle to the swing arm.
2. Raise and support cargo box.
IMPORTANT: Take care to not damage the
transaxle, brake hoses, electrical harness, cables or
other parts while lowering the transaxle assembly
from the vehicle.
3. Carefully remove drive belt from the driven clutch on
transaxle.
4. Separate shift cables from transaxle:
9. Carefully lower transaxle assembly and remove it
from the rear of the vehicle.
A. Loosen jam nuts securing both shift cables to the
cable bracket on the transaxle (Fig. 16).
B. Remove lock nut and flat washer that secures the
select lever to the transaxle selector shaft (Fig. 17).
1
C. Separate select lever and shift cable assembly
from the transaxle.
D. Remove cap screw (item 11 in Fig. 15) and flange
nut (item 7 in Fig. 15) that secure r--clamp (item 17 in
Fig. 15) to skid plate.
4
E. Note routing of shift cables for assembly pur-
poses. Position select lever with attached shift
cables away from transaxle assembly.
2
2
3
3
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
Figure 16
1. Select lever assembly
3. Shift cable
2. Cable jam nut location
4. Cable bracket
5. Jack up both sides of the frame enough to remove
rear wheels.
1
2
A. Chock the front and rear of both front tires to pre-
vent the vehicle from moving.
B. Support both sides of the frame with appropriate
jack stands positioned just in front of the transaxle
tubes.
6. Remove both rear wheels and brake assemblies
from the transaxle (see Rear Wheels and Brakes in the
Service and Repairs section of Chapter 6 -- Chassis).
5
4
3
CAUTION
Loctite #242
To prevent personal injury, make sure that
transaxle is properly supported as it is removed
from the machine. Transaxle weighs approxi-
mately 73 pounds (33 kg).
Figure 17
1. Transaxle assembly
2. Selector shaft
3. Select lever
4. Flat washer
5. Lock nut
Workman MDX--D
Page 4 -- 17
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Installation (Fig. 15)
B. Slide select lever with attached shift cables onto
transaxle selector shaft.
1. Position transaxle assembly under the vehicle swing
arm.
C. Apply Loctite #242 (or equivalent) to threads of
lock nut (item 18). Secure select lever assembly to
the selector shaft with flat washer (item 15) and lock
nut (item 18).
CAUTION
D. Secure both shift cables to the cable bracket with
jam nuts.
To prevent personal injury, make sure that
transaxle is properly supported as it is installed
into the machine. Transaxle weighs approxi-
mately 73 pounds (33 kg).
E. Secure r--clamp (item 17) with shift cables to skid
plate with cap screw (item 11) and flange nut (item 7).
F. Check shift cable adjustment and make neces-
sary cable adjustments (see Shift Cable Adjustment
in the Adjustments section of this chapter).
IMPORTANT: Take care to not damage the
transaxle, brake hoses, electrical harness, cables or
other parts while raising the transaxle assembly
into the vehicle.
5. Install drive belt to the driven clutch.
6. Install both brake assemblies and wheels to the
transaxle (see Rear Wheels and Brakes in the Service
and Repairs section of Chapter 6 -- Chassis). Make sure
that brakes are bled and parking brake is adjusted.
2. Carefully raise transaxle assembly and align it with
swing arm mounting points.
3. Secure the transaxle to the swing arm with four (4)
cap screws (item 10) and flat washers (item 5).
7. Lower vehicle to the ground.
4. Secure shift cables to transaxle:
8. Make sure transaxle oil level is correct.
9. Lower and secure cargo box.
A. Position select lever with attached shift cables to
transaxle assembly. Use notes taken before removal
to properly route cables around transaxle.
10.Check brakes for proper operation.
Drive Train
Page 4 -- 18
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Workman MDX--D
Page 4 -- 19
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Transaxle Service
16
57
55
52
55
25 to 31 ft--lb
(34 to 42 N--m)
50
35
29
17
53
8
15
56
13
3
6
2
4
24
5
58
20
11
12
26
9
26
10
18
27
38
39
47
38
1
40
28
41
30
40 to 45 ft--lb
(54 to 61 N--m)
31
7
43
46
32
48
36
33
42
34
21
49
33
45
44
42
37
59
43
22
23
25
7
12
17
25 to 31 ft--lb
(34 to 42 N--m)
19
59
14
11
35
51
56
10
57
9
16
15
55
54
8
55
52
Figure 18
Page 4 -- 20
Drive Train
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Figure 18 (Continued)
1. Case (LH)
21. Bolt
41. Differential case
42. Side gear (2 used)
43. Pinion gear (2 used)
44. Pinion shaft
45. Spring pin
46. Ball bearing
47. Needle bearing
48. Gear 62
49. Bolt (6 used)
50. Axle shaft (LH)
51. Axle shaft (RH)
52. Ball bearing (4 used)
53. Axle case (LH)
54. Axle case (RH)
55. Snap ring (4 used)
56. Flange nut (10 used)
57. Snap ring (2 used)
58. Shift shaft
2. Oil seal
22. Gasket
3. Oil seal
23. Spring
24. Ball bearing
25. Steel ball
26. Ball bearing (2 used)
27. Spacer
28. Gear 55
29. Cable bracket
30. Pin clutch
31. Center shaft
32. Gear 47
33. Collar (2 used)
34. Gear
4. Snap ring
5. Spacer
6. Selector shaft
7. Oil seal (2 used)
8. Flange bolt (4 used)
9. Oil check plug (2 used)
10. Gasket (2 used)
11. Oil drain plug (2 used)
12. Gasket (2 used)
13. Oil filler plug
14. Case (RH)
15. Axle bracket (2 used)
16. Collar (2 used)
17. Flange bolt (4 used)
18. Flange bolt (6 used)
19. Gasket
35. Flange bolt (6 used)
36. Ball bearing
37. Ball bearing
38. Spacer (2 used)
39. Gear 34
20. Input shaft
40. Counter shaft
59. Pipe knock (2 used)
Transaxle Disassembly and Inspection
1. Disassemble case (LH and RH)
15 to 18 ft--lb
(21 to 25 N--m)
1
2
Figure 19
1. Drain plug & gasket
2. Case (LH)
A. Remove drain plug. Drain oil completely from
transaxle. Replace drain plug gasket if damaged.
CAUTION
B. Reinstall drain plug to transaxle case. Torque
plug from 15 to 18 ft--lb (21 to 25 N--m).
Make sure transaxle case is not hot prior to drain-
ing oil to prevent getting burned.
Workman MDX--D
Page 4 -- 21
Drive Train
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2
1
Figure 20
1. Bolt (steel ball, spring & gasket)
2. Selector shaft
C. Remove bolt near the selector shaft. Remove
spring and steel ball. Replace gasket if damaged.
2
1
Figure 21
1. Input shaft
2. Oil seal
D. Wrap vinyl tape around the splined portion of the
input shaft. This should protect the oil seal from being
damaged.
Drive Train
Page 4 -- 22
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1
3
2
Figure 22
1. Flange bolts (3 used)
2. Axle bracket
3. Axle case
E. Remove three (3) flange bolts securing the axle
bracket and axle case to each case. Separate brack-
et from each axle case.
2
1
Figure 23
1. Flange bolt (10 used)
2. Flange nut
F. With the input shaft side down, loosen and re-
move flange bolts and nuts securing the case (RH)
and case (LH) together. Note location of cable brack-
et for assembly purposes.
Workman MDX--D
Page 4 -- 23
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1
2
Figure 24
1. Case (RH)
2. Governor boss
IMPORTANT: Make sure to not hit the governor
boss too hard when separating the cases, the boss
may get damaged. Do not pry open the two cases
with a screw driver, damage may result to the seal-
ing surfaces.
G. Hold the case (RH) and lift up while lightly tapping
the governor boss with a plastic hammer.
2. Remove input shaft, center shaft and differential assemblies.
2
1
Figure 25
1. Gasket
2. Pipe knock
A. Remove gasket and pipe knocks.
Drive Train
Page 4 -- 24
Workman MDX--D
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4
1
3
2
Figure 26
1. Counter shaft
2. Spacer (2 used)
3. Needle bearing
4. Gear 34
B. Pull out counter shaft. Remove spacer, needle
bearing, gear 34 and spacer.
3
2
2
1
4
Figure 27
1. Counter shaft
2. Spacer (2 used)
3. Needle bearing
4. Gear 34
C. Replace counter shaft if it has abnormal wear,
cracks or damage.
E. Replace needle bearing if needles are bent, do
not rotate freely or do not remain in the bearing cage.
D. Replace spacer if either one is cracked or bent.
F. Replace gear 34 if worn or damaged. Cracked,
broken, missing or chipped gear teeth are not ac-
ceptable.
Workman MDX--D
Page 4 -- 25
Drive Train
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1
3
4
2
Figure 28
1. Differential assembly
2. Input shaft assembly
3. Center shaft assembly
4. Shift shaft
IMPORTANT: Make sure to not damage the oil seal
when removing the input shaft.
G. Lift up differential assembly, center shaft assem-
bly and input shaft assembly at the same time. First,
remove input shaft assembly. Then, remove center
shaft assembly with the shift shaft and differential as-
sembly.
NOTE: If any of the assemblies can not be pulled out by
hand, hold the assembly while gently tapping the case
with a plastic hammer. Make sure to tap equally around
the case.
3. Remove axle case from case (RH and LH).
2
1
3
Figure 29
1. Flange bolt
2. Axle case
3. Transaxle case
A. Remove remaining two (2) flange bolts securing
each axle case to the case. Remove axle case from
the transaxle case.
Drive Train
Page 4 -- 26
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2
4
3
1
Figure 30
1. Snap ring
2. Axle case
3. Axle shaft
4. Ball bearing
IMPORTANT: Do not reuse snap ring. Discard and
replace ring with new one.
C. Ball bearing roller balls must be free of deforma-
tion and scoring. Ball bearing must spin freely and
have minimum axial play. Replace ball bearing as
necessary.
B. Remove snap ring from the axle case. Remove
axle shaft from case.
IMPORTANT: When replacing ball bearings, both
ball bearings must be replaced as a set.
4. Disassemble input shaft assembly.
1
2
Figure 31
1. Ball bearing
2. Input shaft
IMPORTANT: Do not reuse ball bearings that have
been removed.
A. Remove ball bearing from the input shaft with a
bearing puller.
Workman MDX--D
Page 4 -- 27
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1
2
Figure 32
1. Input shaft
2. Ball bearing
B. Replace input shaft if worn or damaged. Gear
teeth that are cracked, broken, chipped or missing
are not acceptable.
C. Ball bearing roller balls must be free of deforma-
tion and scoring. Ball bearing must spin freely and
have minimum axial play. Replace ball bearing as
necessary.
5. Disassemble center shaft assembly.
1
2
Figure 33
1. Ball bearing
2. Ball bearing
IMPORTANT: Do not reuse ball bearings that have
been removed.
A. Remove ball bearings from the center shaft as-
sembly. Discard removed bearings.
Drive Train
Page 4 -- 28
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5
8
3
8
2
7
4
9
1
6
Figure 34
1. Gear 55
6. Pin clutch
2. Gear 47
7. Center shaft
8. Collar (2 used)
9. Spacer
3. Gear (small)
4. Ball bearing
5. Ball bearing
B. Remove gears, pin clutch, collars and spacer
from the input shaft.
D. Replace center shaft if worn or damaged. Splines
that are cracked, broken, chipped or missing are not
acceptable.
C. Replace gears if worn or damaged. Cracked, bro-
ken, missing or chipped gear teeth are not accept-
able.
E. Replace pin clutch if cracked or bent.
F. Replace collars or spacer if excessively worn or
damaged. Replace both collars as a set.
Workman MDX--D
Page 4 -- 29
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6. Disassemble differential case assembly.
1
2
3
Figure 35
1. Bolt (6 used)
2. Gear 62
3. Differential case
A. Remove six (6) bolts securing gear 62 to the dif-
ferential case.
3
4
4
1
2
Figure 36
1. Spring pin
2. Differential case
3. Pinion shaft
4. Pinion gear
NOTE: The spring pin can be punched out from the hole
on the opposite side of gear 62.
C. Remove pinion shaft and gears from the case.
Separate gears from shaft.
B. Remove spring pin from the differential case. Dis-
card pin and replace it with new spring pin.
Drive Train
Page 4 -- 30
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5
4
3
6
2
8
1
7
Figure 37
1. Side gear (2 used)
2. Pinion gear (2 used)
3. Gear 34
5. Differential case
6. Pinion shaft
7. Spring pin
4. Ball bearing
8. Bolt (6 used)
D. Replace gears if worn or damaged. Cracked, bro-
ken, missing or chipped gear teeth are not accept-
able.
F. Replace case if machined areas where the side
and pinion gears mesh are scored or if the pinion
shaft fits loosely in its bore.
E. Ball bearing roller balls must be free of deforma-
tion and scoring. Ball bearing must spin freely and
have minimum axial play. Replace ball bearing as
necessary.
G. Replace pinion shaft if cracked or bent.
H. Replace oil seal if cracked, nicked or distorted
such that it would not hold a proper seal.
Workman MDX--D
Page 4 -- 31
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Transaxle Assembly
1. Assemble input shaft assembly.
1
2
Figure 38
1. Ball bearing
2. Input shaft
IMPORTANT: Make sure to press ball bearing at the
inner race to prevent damaging the ball bearing.
A. Press ball bearing onto the input shaft.
Drive Train
Page 4 -- 32
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2. Assemble the center shaft assembly.
3
4
1
8
6
7
9
5
5
2
5.386” to 5.398”
(136.8 to 137.1 mm)
Figure 39
1. Pin clutch
6. Gear (small)
2. Center shaft
3. Gear 47
4. Gear 55
5. Collar
7. Bearing
8. Bearing
9. Spacer
NOTE: Before assembling, apply molybdenum disul-
fide grease to the inside of gears 47 and 55.
A. Slide pin clutch onto the centershaft. Install gears
47 and 55 onto shaft noting correct orientation of
gears. Slide collars, small gear and spacer onto the
center shaft.
1
2
Figure 40
1. Ball bearing
2. Ball bearing
B. Press ball bearings onto the center shaft using a
bearing press.
C. Make sure distance from one ball bearing outer
edge to the other ball bearing outer edge is 5.386” to
5.398” (136.8 to 137.1 mm) (Fig. 39).
Workman MDX--D
Page 4 -- 33
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Figure 41
D. The center shaft should appear as above when
assembled.
3. Assemble differential assembly.
5
6
1
2
4
9
8
3
3
7
1
4.854” to 4.882”
(123.3 to 124.0 mm)
Figure 42
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
A. Apply molybdenum disulfide grease to the inside
of both pinion gears where they contact the pinion
shaft. Apply molybdenum disulfide grease to the out-
side of both side gears where they contact the differ-
ential case and gear 62.
Drive Train
Page 4 -- 34
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1
4
3
2
Figure 43
1. Side gear
2. Pinion gear
3. Pinion shaft
4. Differential case
B. Install side gear, both pinion gears and pinion
shaft into the differential case.
1
3
2
Figure 44
1. Spring pin
2. Differential case
3. Pinion shaft
C. Align pinion shaft hole and install new spring pin
through the differential case and pinion shaft.
Workman MDX--D
Page 4 -- 35
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3
1
2
4
Figure 45
1. Side gear
2. Pinion gear
3. Gear 62
4. Differential case
D. Install remaining side gear to the pinion gears.
E. Secure gear 62 to the differential case with six (6)
bolts. Torque bolts in a crossing pattern from 40 to 45
ft--lb (54 to 61 N--m).
40 to 45 ft--lb
(54 to 61 N--m)
Figure 46
IMPORTANT: The length from the outer most side of
each ball bearing must be from 4.854” to 4.882”
(123.3 to 124.0 mm) (Fig. 42).
G. The differential assembly should appear as
above when assembled.
F. If ball bearings were removed, press new ball
bearings onto differential case and gear 62.
Drive Train
Page 4 -- 36
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4. Install axle case to case (RH and LH).
2
3
1
Figure 47
1. Axle shaft
2. Snap ring
3. Ball bearing
IMPORTANT: 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 case.
3
1
25 to 31 ft--lb
(34 to 42 N--m)
2
Figure 48
1. Axle case
2. Case
3. Flange bolt
IMPORTANT: Make sure to install the axle case to
the proper side of the case. The right side of the
case takes the short axle case, and the left side
takes the long axle case.
B. Install axle case to the case. Secure each axle
case to the case with flange bolts. Torque bolts from
25 to 31 ft--lb (34 to 42 N--m).
IMPORTANT: Make sure to not damage the oil seal
when installing the axle case to the case.
Workman MDX--D
Page 4 -- 37
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5. Install input shaft, center shaft and differential as-
semblies to the case.
2
1
Figure 49
1. Shift shaft
2. Clutch groove
A. Insert fork of the shift shaft to the clutch groove of
the center shaft assembly.
1
4
2
3
Figure 50
1. Center shaft assembly
2. Shift shaft
3. Input shaft
4. Differential assembly
B. Replace oil seals for the input and selector shafts
on the case (LH) if cracked, nicked or distorted such
that they would not hold a proper seal.
C. Install center shaft assembly with shift shaft and
differential assembly. Then, install input shaft as-
sembly. Lower differential assembly, center shaft as-
sembly and input shaft assembly into the case at the
same time.
IMPORTANT: Make sure to not damage the oil seal
when installing the input shaft.
Drive Train
Page 4 -- 38
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1
2
Figure 51
1. Fork (selector shaft)
2. Pin (shift shaft)
D. Make sure the selector shaft fork is contacting the
pin on the shift shaft.
1
2
Figure 52
1. Spacer
2. Boss (counter shaft)
E. Place spacer on the counter shaft boss of the
case (LH) so the oil groove faces up.
Workman MDX--D
Page 4 -- 39
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2
3
1
Figure 53
1. Gear 34
2. Counter shaft
3. Spacer
F. Apply molybdenum disulfide grease to the inside
of gear 34 and the contact surface between the case
and the counter shaft.
G. Place gear 34 onto the spacer. Make sure not to
drop the spacer. Insert needle bearing into gear. In-
sert counter shaft with remaining spacer through the
needle bearing, gear 34 and into the spacer and
case.
6. Assemble case (LH and RH).
1
2
Figure 54
1. Case (sealing surface)
2. Pipe knock
A. Make sure gasket sealing surfaces of both cases
are clean. Install gasket to case.
B. Install both pipe knocks to the case (LH).
Drive Train
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1
15 to 18 ft--lb
(21 to 25 N--m)
2
Figure 55
1. Cable bracket
2. Flange bolt
NOTE: Keep the gasket sealing surfaces of the cases
as horizontal to each other as possible. If the sealing
surfaces do not join to each other, tap the case lightly
with a plastic hammer.
D. Position cable bracket to transaxle cases.
E. Secure case (RH) to case (LH) with flange bolts
and nuts. Torque bolts from 15 to 18 ft--lb (21 to 25
N--m).
C. Install case (RH) so each shaft fits properly into
the case.
25 to 31 ft--lb
(34 to 42 N--m)
2
1
Figure 56
1. Axle bracket
2. Flange bolt
F. Position axle bracket to each axle case. Secure
axle bracket to each axle case with flange bolts.
Torque bolts from 25 to 31 ft--lb (34 to 42 N--m).
Workman MDX--D
Page 4 -- 41
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12 to 15 ft--lb
(16 to 20 N--m)
2
1
Figure 57
1. Cable bracket
2. Bolt (steel ball, spring & gasket)
G. Install steel ball, spring, gasket and bolt. Torque
bolt from 12 to 15 ft--lb (16 to 20 N--m).
H. Fill transaxle with 1.5 quarts (1.4 liters) of new
SAE 10W--30 motor oil.
Drive Train
Page 4 -- 42
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Chapter 5
Electrical System
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 5
Starting Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Run Problems . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRICAL SYSTEM QUICK CHECKS . . . . . . . . 7
Battery Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Charging System Test . . . . . . . . . . . . . . . . . . . . . . . 7
Glow Plug Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . . 8
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Fuse Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Main Power and Glow Relays . . . . . . . . . . . . . . . . 14
Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Glow Plug Controller . . . . . . . . . . . . . . . . . . . . . . . 16
Engine Run Solenoid . . . . . . . . . . . . . . . . . . . . . . . 17
Over Temperature Switch . . . . . . . . . . . . . . . . . . . 18
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Oil Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . 20
Backup Alarm (Optional Kit) . . . . . . . . . . . . . . . . . 21
Backup Switch (Optional Kit) . . . . . . . . . . . . . . . . 22
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 23
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Battery Inspection and Maintenance . . . . . . . . 24
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . 24
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . 26
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Workman MDX--D
Page 5 -- 1
Electrical System
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General Information
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Workman vehicle. Refer to the Opera-
tor’s Manual for additional information when servicing
the machine.
Electrical Drawings
The electrical schematic and other electrical drawings
for the Workman MDX--D are located in Chapter 7 --
Electrical Drawings.
Page 5 -- 2
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Electrical System
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Special Tools
Order special tools from your Toro Distributor. Some
tools may also be available from a local supplier.
Multimeter
The meter can test electrical components and circuits
for current, resistance or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt--
Ohm--Amp multimeter when testing electrical circuits.
The high impedance (internal resistance) of a digital me-
ter in the voltage mode will make sure that excess cur-
rent is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
Figure 1
Skin--Over Grease
Special non--conductive grease which forms a light pro-
tective skin which helps waterproof electrical switches
and contacts.
Toro Part Number: TOR50547
Figure 2
Battery Terminal Protector
Aerosol spray that should be used on battery terminals
to reduce corrosion problems. Apply terminal protector
after the battery cable has been secured to the battery
terminal.
Toro Part Number: 107--0392
Figure 3
Workman MDX--D
Page 5 -- 3
Electrical System
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Dielectric Lubricant/Sealant
Dielectric lubricant should be used to prevent corrosion
of non--sealed connection terminals. To ensure com-
plete coating of terminals, liberally apply lubricant to
both component and wire harness connector, plug con-
nector to component, unplug connector, reapply lubri-
cant to both surfaces and reconnect harness connector
to component. Connectors should be thoroughly
packed with lubricant for effective results.
Toro Part Number: 107--0342
Figure 4
Battery Hydrometer
Use the Battery Hydrometer when measuring specific
gravity of battery electrolyte. Obtain this tool locally.
Figure 5
Page 5 -- 4
Workman MDX--D
Electrical System
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Troubleshooting
CAUTION
For effective troubleshooting and repairs, you must
have a good understanding of the electrical circuits and
components used on this vehicle (see electrical draw-
ings in Chapter 7 -- Electrical Drawings).
Remove all jewelry, especially rings and
watches, before doing any electrical trouble-
shooting or testing. Disconnect the battery
cables unless the test requires battery voltage.
If the vehicle has any interlock switches by--passed,
they must be reconnected for proper troubleshooting
and safety.
Starting Problems
Problem
Possible Causes
Starter solenoid clicks, but starter will not crank.
Battery is discharged.
Battery cables are loose or corroded.
Battery ground to frame is loose or corroded.
Wiring at starter is faulty.
Starter solenoid is faulty.
Starter is faulty and causing an incomplete circuit for
the starter solenoid.
Nothing happens when start attempt is made.
Brake pedal is not depressed.
Battery is discharged.
In--line primary fuse (10 ampere) is loose or faulty.
Battery cables are loose or corroded.
Battery ground to frame is loose or corroded.
Wiring to the start circuit components is loose,
corroded or damaged (see electrical drawings in
Chapter 7 -- Electrical Drawings).
Brake pedal switch is out of adjustment or faulty.
Start relay or circuit wiring is faulty.
The ignition switch or circuit wiring is faulty.
Fuse block is faulty.
Fusible link harness at the engine starter motor has
faulty link(s) so battery power is not available to vehicle
electrical system.
Starter solenoid or circuit wiring is faulty.
Workman MDX--D
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Starting Problems (Continued)
Problem
Possible Causes
Engine cranks, but does not start.
Fuel tank is empty.
Wiring to start circuits is loose, corroded or damaged
(see electrical drawings in Chapter 7 -- Electrical
Drawings).
Engine or fuel system is malfunctioning (see Chapter 3
-- Diesel Engine).
15 ampere fuse in fuse block is faulty.
Fuel pump or circuit wiring is faulty.
Glow plugs, glow relay or glow plug controller are
faulty.
Wire harness fusible link to run solenoid pull coil is
faulty.
Engine and fuel may be too cold.
Run solenoid is faulty.
General Run Problems
Problem
Possible Causes
Battery does not charge.
Wiring to the charging circuit components is loose,
corroded or damaged (see electrical drawings in
Chapter 7 -- Electrical Drawings).
Alternator or circuit wiring is faulty.
Battery is faulty.
Engine stops during operation.
Wiring to the run circuit components became broken or
disconnected (see electrical drawings in Chapter 7 --
Electrical Drawings).
Engine or fuel system is malfunctioning (see Chapter 3
-- Diesel Engine).
Page 5 -- 6
Workman MDX--D
Electrical System
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Electrical System Quick Checks
Battery Test
Use a multimeter to measure the voltage between the
battery terminals.
Voltage Measured
12.68 V (or higher)
12.45 V
Battery Charge Level
Fully charged (100%)
75% charged
Set the multimeter to the DC volts setting. The battery
o
o
o
o
should be at a temperature of 60 to 100 F (16 to 38
12.24 V
50% charged
C). The ignition key should be off and all accessories
turned off. Connect the positive (+) meter lead to the
positive battery post and the negative (--) meter lead to
the negative battery post.
12.06 V
25% charged
11.89 V
0% charged
NOTE: This test provides a relative condition of the bat-
tery. Load testing of the battery will provide additional
and more accurate information.
Charging System Test
This is a simple test used to determine if a charging sys-
tem is functioning. It will tell you if the charging system
has an output, but not its capacity.
Make sure the shift lever is in the neutral position and the
parking brake is applied. Start the engine and run en-
gine at high idle (above 3000 RPM). Maintain engine
speed to allow the battery to charge for at least three (3)
minutes. Record the battery voltage.
Remove battery cover to gain access to battery. Use a
digital multimeter set to DC volts. Connect the positive
(+) multimeter lead to the positive battery post and the
negative (--) multimeter lead to the negative battery
post. Keep the test leads connected to the battery posts
and record the battery voltage.
After running the engine for at least three (3) minutes,
battery voltage should be at least 0.50 volt higher than
initial battery voltage.
An example of a charging system that is functioning:
NOTE: When starting the engine, the battery voltage
will drop and then should increase once the engine is
running.
At least 0.50 volt over initial battery voltage.
Initial Battery Voltage
Battery Voltage after 3 Minute Charge
Difference
= 12.30 v
= 12.95 v
= +0.65 v
NOTE: Depending upon the condition of the battery
charge and battery temperature, the battery voltage will
increase at different rates as the battery charges.
Glow Plug Test
This is a fast, simple test that can help to determine the
integrity and operation of your Workman MDX--D glow
plug system. The test should be run anytime hard start-
ing (cold engine) is encountered on a diesel engine
equipped with a glow plug system.
ammeter pickup around the main glow plug power sup-
ply wire and read the meter prior to activating the glow
plug system. Adjust the meter to read zero (if applica-
ble). Activate the glow plug system by turning the igni-
tion switch to ON and record the multimeter results.
Use a digital multimeter and/or inductive Ammeter (AC/
DC Current Transducer). Properly connect the ammeter
to the digital multimeter (refer to manufacturers’ instruc-
tions) and set the multimeter to the correct scale. With
the ignition switch in the OFF position, place the
The Workman MDX--D glow plug system should have a
reading of approximately nine (9) amps per glow plug
(18 amps total). If low current reading is observed, one
(or more) of the glow plugs is faulty.
Workman MDX--D
Page 5 -- 7
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Component Testing
For accurate resistance and/or continuity checks, elec-
trically disconnect the component being tested from the
circuit (e.g. unplug the ignition switch connector before
doing a continuity check on the switch).
CAUTION
When testing electrical components for continu-
ity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
NOTE: See the Kubota Workshop Manual, Diesel En-
gine, SM--E3B Series for engine component testing in-
formation.
Ignition Switch
The ignition (key) switch has three positions (OFF, ON
and START). The ignition switch is located on the dash
panel (Fig. 6).
1
Testing
The switch terminals are identified as shown in Figure
7. The circuit wiring of the ignition switch is shown in the
chart below. With the use of a multimeter (ohms setting),
the switch functions may be tested to determine whether
continuity exists between the various switch terminals
for each switch position. Disconnect wire harness con-
nector from key switch and verify continuity between
switch terminals in the different switch positions.
2
Figure 6
POSITION
OFF
CIRCUITS
NONE
1. Dash panel
2. Ignition switch
ON
B + C + F, D + E
A + B + C
RUN
START
o
o
45
45
OFF
START
After testing is completed, connect wire harness con-
nector to ignition switch.
F
A
B
C
E
D
REAR VIEW
FRONT VIEW
Figure 7
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Indicator Lights
Charge Indicator Light
3
2
The charge indicator light should come on when the igni-
tion switch is in the ON position with the engine not run-
ning. Also, it should illuminate with an improperly
operating charging circuit while the engine is running.
Engine Oil Pressure Light
The engine oil pressure light should come on when the
ignition switch is in the ON position with the engine not
running. Also, it should illuminate with the engine run-
ning if the engine oil pressure drops to an unsafe level.
4
1
IMPORTANT: If the oil pressure indicator light is il-
luminated with the engine running, shut off the en-
gine immediately.
Figure 8
1. Charge Indicator
2. Engine oil pressure
3. Engine temperature
4. Glow plug indicator
To test the oil pressure light and circuit wiring, ground the
wire attached to oil pressure switch located on the en-
gine near the oil filter. Turn ignition switch to the ON posi-
tion; the engine oil pressure light should come on
indicating correct operation of the indicator light and cir-
cuit wiring.
5
2
3
4
Engine Temperature Light
o
If the engine coolant temperature reaches 230 F
6
o
(110 C) (approximate), the engine temperature light will
1
come on.
To test the engine temperature light and circuit wiring,
turn ignition switch to the ON position and ground the
wire attached to over temperature switch located on the
engine water pump housing (see Over Temperature
Switch in this section). The engine temperature light
should illuminate while the wire is grounded.
1B (--)
2B (--)
1A (+)
2A (+)
Glow Plug Indicator Light
Figure 9
The glow plug light should come on when the ignition
switch is placed in the ON position prior to placing the
ignition switch in START. The light should stay lit for
approximately six (6) seconds while the ignition switch
is left in the ON position.
1. Charge indicator
2. Engine oil pressure
3. Engine temperature
4. Glow plug indicator
5. Indicator light front
6. Indicator light back
Testing Indicator Lights
1. Apply 12 VDC to indicator light terminals 1A and 2A
(Fig. 9).
2. Ground indicator light terminals 1B and 2B (Fig. 9).
3. Both indicator lights should illuminate.
Workman MDX--D
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Fuse Blocks
The fuse block on Workman MDX--D vehicles is located
beneath the dash panel.
3
In addition to the fuses in the fuse block, an in--line 10
amp fuse is included in the wire harness. This fuse pro-
tects the ignition switch circuits and also provides pro-
tection for the optional brake and signal light kit. The
in--line fuse resides in a fuse holder under the dash pan-
el near the fuse blocks (Fig. 11).
4
2
Fuse Identification and Function
1
Use Figure 10 to identify each individual fuse in the fuse
block.
The upper row of fuses protect circuits as follows:
1. The extreme left 10 ampere fuse protects the power
point circuit. This fuse also protects the circuit for the op-
tional backup alarm (if equipped).
Figure 10
1. Fuse blocks
2. Fuse decal
3. Upper fuses
4. Lower fuses
2. The middle left 10 ampere fuse protects the engine
start circuit.
3. The middle right 10 ampere fuse protects the light
circuit.
4. The extreme right 15 ampere fuse protects the cir-
cuits for engine electrical components and also dash in-
dicators (hour meter and indicator lights).
1
2
The lower row of fuses protect circuits as follows:
1. The extreme left fuse position is not used.
2. The middle left 15 ampere fuse protects the circuit for
the optional cargo box lift.
3. The middle right 15 ampere fuse protects the circuit
for the optional rear lift kit.
Figure 11
1. In--line fuse
2. Fuse block
4. The extreme right 30 ampere fuse protects the circuit
for the horn (if equipped).
Fuse Testing
Make sure that ignition switch is OFF and key is re-
moved from switch. Remove fuses from the fuse block
for testing. A fuse in usable condition should have conti-
nuity between the fuse terminals. A faulty fuse will not
have continuity between the fuse terminals.
Page 5 -- 10
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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 harness that connects the starter B+
terminal to the vehicle wire harness (Fig. 12). The re-
maining fusible link is included in the engine wire har-
ness and connects the starter G terminal to the engine
run solenoid pull coil. If any of these links should fail, cur-
rent to the protected circuit will cease. Refer to the elec-
trical schematic and wire harness drawings in Chapter
7 -- Electrical Drawings for additional circuit information.
FUSIBLE LINK
FUSIBLE LINK
FUSIBLE LINK
Figure 12
Testing
Make sure that ignition switch is OFF. Disconnect nega-
tive battery cable from battery terminal and then discon-
nect positive cable from battery (see Battery Service in
the Service and Repairs section of this chapter). Locate
and unplug fusible link connector. Use a multimeter to
make sure that continuity exists between the fusible link
terminals. If a fusible link is open, replace the link.
After testing is complete, make sure that fusible link is
securely attached to engine component and wire har-
ness. Connect positive battery cable to battery terminal
first and then connect negative cable to battery.
Workman MDX--D
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Hour Meter
Testing
IMPORTANT: Make sure to observe polarity on the
hour meter terminals when testing. Damage to the
meter may result from an improper connection.
QUARTZ
RUNNING: INDICATOR
WINDOW
1
--
1. Unplug wire harness connector from hour meter.
0 0 0 0 0
10
HOURS
2. Connect positive (+) terminal of a 12 VDC source to
the positive terminal of the hour meter.
1/10 WHEEL: WHITE W/BLACK NUMBERS
HOUR WHEELS: BLACK W/WHITE NUMBERS
3. Connect negative (--) terminal of the voltage source
to the other terminal of the hour meter.
Figure 13
4. The hour meter should move 1/10 of an hour in six
(6) minutes.
5. Disconnect voltage source from the hour meter. Re-
connect wire harness connector to hour meter.
Headlight Switch
The headlight switch is located on the dash panel (Fig.
14). This rocker switch allows the headlights to be
turned on and off.
1
2
Testing
The switch terminals are marked as shown in Figure 15.
The circuitry of the headlight switch is shown in the chart
below. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the various terminals for each
position. Verify continuity between switch terminals.
Figure 14
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
1. Dash panel
2. Headlight switch
ON
2 + 3
1 + 2
5 + 6
4 + 5
OFF
BACK OF SWITCH
Figure 15
Page 5 -- 12
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Brake Switch
The brake switch is a normally closed switch that opens
when the brake pedal is not applied. When the brake
pedal is applied, the brake pedal moves away from the
switch plunger to allow the switch to be in its normally
closed state. The brake switch is attached to the pedal
support frame under the dash panel (Fig. 16).
1
Testing
1. Park vehicle on a level surface, stop engine, apply
parking brake and remove key from ignition switch.
2
2. Locate brake switch for testing. Disconnect vehicle
wire harness electrical connector from the brake switch.
3. Check the continuity of the switch by connecting a
multimeter (ohms setting) across the connector termi-
nals.
4. When the switch plunger is extended (brake pedal is
applied), there should be continuity (closed) between
the switch terminals.
Figure 16
1. Brake pedal assembly
2. Brake switch
5. When the switch plunger is depressed (brake pedal
is not applied), there should not be continuity (open) be-
tween the switch terminals.
6. Replace brake switch if testing determines that it is
faulty. When installing switch, make sure that the brake
pedal does not bottom switch when the pedal is re-
leased.
7. If the brake switch tests correctly and a circuit prob-
lem still exists, check wire harness (see Electrical
Schematic and Circuit Drawings in Chapter 7 -- Electric-
al Drawings).
8. When switch testing is completed, connect switch
connector to vehicle wire harness.
Workman MDX--D
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Main Power and Glow Relays
The Workman MDX--D main and glow relays are at-
tached to the front of the dash bracket and can be ac-
cessed by raising the hood (Fig. 17). The vehicle wire
harness is attached to the main and glow relays with four
(4) wire connectors. Relays can be identified by a tag on
the wire harness.
The main power relay is used to provide current to the
fuse blocks. When the ignition switch is in the ON or
START position, the main power relay is energized.
1
2
The glow relay is used to provide current to the engine
glow plugs when the relay is energized by the glow plug
controller.
Testing
Figure 17
1. Main power relay
2. Glow relay
1. Park vehicle on a level surface, stop engine, apply
parking brake and remove key from ignition switch.
Open and support hood to access relays.
2. Make sure ignition switch is in the OFF position. Dis-
connect wire harness electrical connector from relay
that is to be tested. Remove relay from dash bracket for
easier testing.
30
85
86
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from the measured value of the relay being testing.
87
86
85
87
3. Verify coil resistance between terminals 85 and 86
with a multimeter (ohms setting). Resistance should be
approximately 72 ohms.
30
4. Connect multimeter (ohms setting) leads to relay ter-
minals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay should make and break
continuity between terminals 30 and 87 as +12 VDC is
applied and removed from terminal 85.
Figure 18
5. Disconnect voltage and leads from the relay termi-
nals. Replace relay if testing determines that it is faulty.
6. Secure relay to dash bracket and connect wire har-
ness electrical connector to relay after testing is com-
pleted.
7. Close and secure hood.
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Start Relay
The Workman MDX--D start relay provides electrical
current to the engine starter solenoid when energized.
The relay is energized when the ignition switch is in the
START position and the brake pedal is depressed
(brake switch closed). The start relay is attached to the
front of the dash bracket and can be accessed by raising
the hood (Fig. 19). The vehicle wire harness is attached
to the start relay with a five (5) wire connector. The relay
can be identified by a tag on the wire harness.
Testing
1
1. Park vehicle on a level surface, stop engine, apply
parking brake and remove key from ignition switch.
Open and support hood to access start relay.
2
Figure 19
2. Locate start relay and disconnect the machine wire
harness connector from the relay. Remove relay from
from dash bracket for easier testing.
1. Start relay
2. Wire harness
4
3
NOTE: Prior to taking small resistance readings with a
digital multimeter, short the meter test leads together.
The meter will display a small resistance value (usually
0.5 ohms or less). This resistance is due to the internal
resistance of the meter and test leads. Subtract this val-
ue from the measured value of the relay being testing.
1
86
85
87A
87
3. Using a multimeter (ohms setting), measure coil re-
sistance between terminals 85 and 86 (Fig. 20). Resist-
ance should be between 70 and 90 ohms.
30
1
2
4. Connect multimeter (ohms setting) leads to relay ter-
minals 30 and 87. Ground terminal 86 and apply +12
VDC to terminal 85. The relay terminals 30 and 87
should have continuity as +12 VDC is applied to terminal
85. The relay terminals 30 and 87 should not have conti-
nuity as +12 VDC is removed from terminal 85.
Figure 20
1. Coil terminal
2. Common terminal
3. Normally closed term.
4. Normally open term.
5. Disconnect voltage from terminal 85 and multimeter
lead from terminal 87.
6. Connect multimeter (ohms setting) leads to relay ter-
minals 30 and 87A. With terminal 86 grounded, apply
+12 VDC to terminal 85. The relay terminals 30 and 87A
should not have continuity as +12 VDC is applied to ter-
minal 85. The relay terminals 30 and 87A should have
continuity as +12 VDC is removed from terminal 85.
7. When relay testing is completed, disconnect voltage
and multimeter leads from the relay terminals. Replace
relay if testing determines that it is faulty.
8. Secure relay to machine and connect machine wire
harness connector to relay.
9. Lower and secure hood.
Workman MDX--D
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Glow Plug Controller
The glow plug controller is attached to the front of the
dash bracket and can be accessed by raising the hood
(Fig. 21).
5. If any of the conditions in Step 3 are not met or electri-
cal power to controller terminal 1 exists and any of the
other conditions in Step 4 are not met:
NOTE: When troubleshooting the glow controller, refer
to electrical drawings in Chapter 7 -- Electrical Drawings.
A. Verify continuity of the circuitry from the battery to
the glow relay and glow plugs (see Chapter 7 -- Elec-
trical Drawings).
Glow Plug Controller Operation
B. Verify continuity of the circuitry from the battery to
ignition switch, glow plug controller, glow plug indica-
tor light, glow relay and ground (see Chapter 7 --
Electrical Drawings).
1. When the ignition switch is initially placed in the ON
position, the glow plug controller energizes the glow
plugs for six (6) seconds. The console glow plug indica-
tor light will also be illuminated for six (6) seconds.
C. Repair or replace components as necessary.
2. When the ignition switch is turned to the START posi-
tion, the glow plugs will energize as long as the switch
is held in START. The console glow plug indicator light
will not be illuminated.
6. After testing is completed, connect wire harness
electrical connector to the engine run solenoid.
3. When the ignition switch is released from the START
to the ON position, the glow plugs will de--energize and
the console glow plug indicator light will remain off.
Glow Plug Controller Checks
1. Make sure there is electrical power from the battery.
1
2. Disconnect the wire harness electrical connector
from the engine run solenoid to prevent the engine from
starting (see Engine Run Solenoid in this section).
2
3. Place ignition switch in the ON position. Verify the fol-
lowing while in the ON position:
Figure 21
1. Glow plug controller
2. Wire harness
A. Glow plug indicator light is illuminated.
B. Glow relay is energized.
C. Glow plugs are energized.
D. Glow plug indicator light goes out and glow plugs
de--energize after approximately six (6) seconds.
4. Place ignition switch in the START position. Verify
the following while in the START position:
CONTROLLER
CONNECTIONS
1
2
A. Glow plug indicator light is not illuminated.
B. Glow relay is energized.
1
2
3
4
5
6
TEMP (not used)
GLOW
START
LAMP
+12V
VIOLET
ORANGE
GRAY
C. Glow plugs are energized.
GROUND
BLACK
PINK
D. Electrical power exists at terminal 1 of the glow
plug controller.
Figure 22
1. Controller top view
2. Controller end view
NOTE: If there is no electrical power at terminal 1 of the
glow plug controller, verify continuity of the circuitry from
the ignition switch to the controller and perform Step 4
again (see Chapter 7 -- Electrical Drawings).
Page 5 -- 16
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Engine Run Solenoid
The engine run solenoid used on Workman MDX--D
vehicles must be energized for the diesel engine to run.
The run solenoid is mounted to the injection pump on the
engine (Fig. 23). The run solenoid is energized when the
ignition switch is in either the ON or START position.
1
The engine run solenoid includes two (2) coils for opera-
tion: the pull coil and the hold coil. When the ignition
switch is turned to START, the fuel solenoid pull coil is
energized and the solenoid plunger retracts. Once the
plunger is retracted, the hold coil will keep it retracted for
continued engine operation. When the solenoid is de--
energized, the plunger extends to shut off fuel supply to
the engine causing the engine to stop running.
2
NOTE: A fusible link in the engine wire harness protects
the engine run solenoid pull coil circuit. If this link should
fail, the run solenoid will not function and the engine will
not run. Refer to electrical drawings in Chapter 7 -- Elec-
trical Drawings when troubleshooting the run solenoid.
Figure 23
1. Engine assembly
2. Engine run solenoid
NOTE: See Kubota Workshop Manual, Diesel Engine,
SM--E3B Series for information regarding engine run
solenoid testing procedure.
Workman MDX--D
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Over Temperature Switch
The over temperature switch is located on the engine
thermostat housing near the alternator (Fig. 24). If the
engine coolant temperature reaches 230 F (110 C)
(approximate), the over temperature switch closes
which causes the dash panel engine temperature light
to come on. The over temperature switch has a gray wire
connected to it.
2
o
o
1
Switch Testing
CAUTION
Make sure engine is cool before removing the
temperature switch.
1. Park vehicle on a level surface, stop engine, apply
parking brake and remove key from ignition switch.
Raise and support cargo box to allow access to engine.
Figure 24
1. Thermostat housing
2. Temperature switch
2. Lower coolant level in the engine and remove the
over temperature switch.
3. Put switch in a container of oil with a thermometer
and slowly heat the oil (Fig. 25).
CAUTION
Handle the hot oil with extreme care to prevent
personal injury or fire.
4. Check continuity of the switch with a multimeter
(ohms setting). The over temperature switch is normally
o
o
o
open and should close between 225 to 235 F (107 to
113 C).
Figure 25
o
5. Replace switch if necessary.
6. After testing, install over temperature switch to the
engine housing.
A. Clean threads of housing and switch thoroughly.
Apply thread sealant to the threads of the switch.
B. Thread temperature switch into the housing and
tighten.
C. Connect wire harness connector to over temper-
ature switch.
7. Fill engine cooling system. Lower and secure cargo
bed.
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Fuel Pump
The MDX--D fuel pump is secured in a cavity in the top
of the fuel tank (Fig. 26). Electrical current is available
for the fuel pump when the ignition switch is in either the
ON or START position.
9. Install fuel hose to the fuel/water separator. Make
sure to secure fuel hose with hose clamp.
10.Connect wire harness electrical connector to the en-
gine run solenoid.
IMPORTANT: When testing fuel pump, make sure
that pump is not operated without fuel.
11.Bleed the fuel system.
12.Lower and secure cargo box.
DANGER
1
Because diesel fuel is flammable, use caution
when handling it. Do not smoke while testing the
fuel pump. Do not test fuel pump while engine is
hot. Make sure that there is adequate ventilation
when testing. Always wipe up any spilled fuel be-
fore starting the engine.
3
Fuel Pump Capacity Test
1. Park vehicle on a level surface, stop engine, apply
parking brake and remove key from ignition switch.
Raise and support cargo box.
2
2. Disconnect wire harness electrical connector from
the engine run solenoid to prevent the engine from start-
ing (see Engine Run Solenoid in this section).
Figure 26
1. Fuel tank
2. Fuel pump
3. Fuel hose to filter
3. Disconnect fuel hose (fuel pump discharge) from the
fuel/water separator inlet fitting (Fig. 27).
4. Make sure fuel hoses attached to the fuel pump and
fuel tank suction tube screen are free of obstructions.
1
2
5. Place disconnected fuel hose into a large, graduated
cylinder sufficient enough to collect 1 quart (0.95 liter).
IMPORTANT: When testing the fuel pump, DO NOT
turn ignition switch to START.
6. Collect fuel in the graduated cylinder by turning igni-
tion switch to the ON position. Allow pump to run for fif-
teen (15) seconds, then turn ignition switch to OFF.
Figure 27
1. Fuel/water separator
2. Pump discharge hose
7. Fuel collected in the graduated cylinder should be
approximately 16 fl oz (475 ml) after fifteen (15) sec-
onds.
Fuel Pump Specifications
Pump Capacity
Pressure
64 fl oz/min (1.9 l/min)
7 PSI (48.3 kPa)
2.0 amp
8. Replace fuel pump if testing determines that it is
faulty. Remove seat base to access fuel pump (see Seat
Base in the Service and Repairs section of Chapter 6 --
Chassis).
Current Draw
Workman MDX--D
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Oil Pressure Switch
The engine oil pressure switch is located on the engine
near the oil filter (Fig. 28). The oil pressure switch is a
normally closed switch that opens with pressure.
The oil pressure switch should open at approximately 8
PSI (0.56 kg/cm2).
2
Switch Testing
NOTE: Refer to Kubota Workshop Manual, Diesel En-
gine, SM--E3B Series for information regarding engine
lubrication system and testing.
1. Turn the ignition switch to the ON position. The oil
pressure indicator light on the dash panel should be illu-
minated.
1
2. If the indicator light is not illuminated, raise and sup-
port cargo box to gain access to engine.
Figure 28
3. Locate oil pressure switch on engine and disconnect
the wire harness connector from the switch.
1. Oil filter
2. Oil pressure switch
4. With the ignition switch in the ON position, ground
the disconnected wire to the engine block.
5. If the indicator light comes on, the oil pressure switch
is faulty. Replace oil pressure switch.
6. If the indicator light does not come on after step 5,
check the oil pressure indicator light and circuit wiring
(see Indicator Lights in this section).
7. After testing is completed, connect the wire harness
connector to the oil pressure switch. Lower and secure
cargo box.
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Backup Alarm (Optional Kit)
When the shift lever is placed in the reverse position, the
backup alarm should sound. The alarm is attached be-
neath the cargo box to a bracket on the right side of the
frame.
4
3
Alarm Testing
1. Park vehicle on a level surface, stop engine, apply
parking brake and remove key from ignition switch.
Make sure that vehicle shift lever is in the NEUTRAL
position.
1
2
Figure 29
2. Raise and support cargo box to allow access to
backup alarm.
1. Alarm top view
2. Alarm bottom view
3. Positive (+) terminal
4. Negative (--) terminal
IMPORTANT: Make sure to observe polarity on the
alarm terminals when testing. Damage to the alarm
may result from an improper connection.
3. Disconnect wire harness connector from backup
alarm. Correctly connect 12VDC source to the terminals
(Fig. 29). Alarm should sound.
4. Remove voltage source from the alarm. Replace
alarm if testing determines that it is faulty. Connect wire
harness connector to alarm.
5. Lower and secure cargo box.
Workman MDX--D
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Backup Switch (Optional Kit)
The optional backup switch is a four (4) terminal, two (2)
circuit switch that is used to energize the backup alarm
when the shift lever is in the reverse position. The nor-
mally open switch circuit is used while the normally
closed switch circuit is not used. If equipped, this switch
is attached to the shift bracket in the seat base (Fig. 30).
Switch Testing
4
1. Position vehicle on a level surface, set parking
brake, turn ignition switch OFF and remove key from
switch. Make sure that vehicle shift lever is in the NEU-
TRAL position.
3
1
2
2. Remove four (4) screws and carefully slide shift
bracket assembly from front of seat base to gain access
to backup switch.
Figure 30
1. Seat base
2. Screw (4 used)
3. Shifter plate
4. Backup switch
3. Unplug vehicle wire harness connector from backup
switch.
4. With the use of a multimeter (ohms setting), check
that the normally open switch contacts (Fig. 31) do not
have continuity when the switch plunger is extended.
The contacts should have continuity when the switch
plunger is fully depressed.
1
2
5. When testing is complete, connect wire harness con-
nector to backup switch. Slide shift bracket into seat
base and secure with four (4) screws.
2
Figure 31
1. Backup switch
2. Normally open contact
Page 5 -- 22
Workman MDX--D
Electrical System
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Service and Repairs
NOTE: For information on engine electrical compon-
ents, see the Kubota Workshop Manual, Diesel Engine,
SM--E3B Series.
Battery Service
The battery is the heart of the electrical system. With
regular and proper service, battery life can be extended.
Additionally, battery and electrical component failure
can be prevented.
2. Remove battery cover.
3. Disconnect negative (black) cable from battery first
to prevent short circuiting the battery, other components
or operator’s hands. Then disconnect positive (red)
cable.
WARNING
4. Remove battery retainer that secures battery to bat-
tery tray.
POTENTIAL HAZARD:
5. Make sure that battery filler caps are on tightly.
Either the battery terminals or metal tools could
short against metal vehicle components.
WHAT CAN HAPPEN:
Sparks can cause the battery gasses to explode.
Damaged cables could short against metal ve-
hicle components and cause sparks.
HOW TO AVOID THE HAZARD:
6. Remove battery from chassis to a service area. This
will minimize possible battery damage and allow better
access for battery inspection and service.
When removing or installing the battery, do not
allow the battery terminals to touch any metal
parts of the vehicle.
4
7
Always DISCONNECT the negative (black) bat-
tery cable before disconnecting the positive
(red) cable.
Always CONNECT the positive (red) battery
cable before connecting the negative (black)
cable.
Do not allow metal tools to short between the
battery terminals and metal parts of the ve-
hicle.
8
FRONT
6
2
10
9
3
Always keep the battery retaining components
secure to protect the battery.
1
Battery Specifications
BCI Group Size 26
5
o
o
540 Amp Cranking Performance at 0 F (--18 C)
o
o
80 Minutes Reserve Capacity at 80 F (27 C)
Electrolyte Specific Gravity
o
o
Fully charged: 1.265 corrected to 80 F (27 C)
Discharged: less than 1.240
Figure 32
1. Battery tray
6. Battery
Battery Removal (Fig. 32)
2. Carriage screw (4 used)
3. Flange nut (4 used)
4. Battery cover
7. Positive cable (red)
8. Negative cable (black)
9. Battery retainer
10. Flange nut
IMPORTANT: Be careful to not damage terminal
posts or cable connectors when removing the bat-
tery cables.
5. Carriage screw
1. Position vehicle on a level surface, set parking
brake, turn ignition switch OFF and remove key.
Workman MDX--D
Page 5 -- 23
Electrical System
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Battery Inspection and Maintenance
FILLER CAPS
CAP TUBES
WARNING
POTENTIAL HAZARD:
Battery electrolyte contains sulfuric acid which
is a deadly poison and it causes severe
burns.
CORRECT
ELECTROLYTE
LEVEL
COVER
SEAL
WHAT CAN HAPPEN:
If you carelessly drink electrolyte you could die
or if it gets onto your skin you will be burned.
HOW TO AVOID THE HAZARD:
Do not drink electrolyte and avoid contact with
skin, eyes or clothing. Wear safety glasses to
shield your eyes and rubber gloves to protect
your hands.
Fill the battery where clean water is always
available for flushing the skin. Always RE-
CONNECT the positive (red) battery cable be-
fore reconnecting the negative (black) cable.
Follow all instructions and comply with all safe-
ty messages on the electrolyte container.
Figure 33
Battery Installation (Fig. 32)
IMPORTANT: To prevent possible electrical prob-
lems, install only a fully charged battery.
1. Make sure the ignition switch and all accessories are
off.
2. Make sure the battery tray is clean and repainted if
necessary.
1. Check for cracks caused by overly tight or loose hold
down rod. Replace battery if cracked and leaking.
3. Make sure battery cables, battery connections and
the battery hold down components are in good condi-
tion.
2. Check battery terminal posts for corrosion. Use a ter-
minal brush or steel wool to clean corrosion from the bat-
tery terminal posts.
4. Set battery on the battery base with its posts toward
the right side of the vehicle.
IMPORTANT: Before cleaning the battery, tape or
block the vent holes to the filler caps and make sure
the caps are on tightly.
5. Secure positive cable (red) to positive battery post.
6. Secure battery with retainer and fasteners.
3. Check for signs of wetness or leakage on the top of
the battery which might indicate a loose or missing filler
cap, overcharging, loose terminal post or overfilling.
Also, check the battery case for dirt and oil. Clean the
battery with a solution of baking soda and water, then
rinse it with clean water.
7. Connect a digital multimeter (set to amps) between
the negative battery post and the negative cable (black)
connector. The reading should be less than 0.1 amp. If
the reading is 0.1 amp or more, the vehicle’s electrical
system should be tested and repaired.
4. Check that the cover seal is not broken away. Re-
place the battery if the seal is broken or leaking.
8. Secure negative cable (black) to negative battery
post with flange screw and flange nut.
5. If battery caps can be removed, check the electrolyte
level in each cell. If the level is below the tops of the
plates in any cell, fill all cells with distilled water to the
bottom of the cap tubes (or fill line). Charge at 15 to 25
amps for 15 minutes to allow sufficient mixing of the
electrolyte.
9. Apply battery terminal protector (see Special Tools in
this chapter) on battery posts and cable connectors to
reduce corrosion after connections are made.
10.Install battery cover.
Page 5 -- 24
Workman MDX--D
Electrical System
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Battery Testing
C. If the battery has been charged, apply a 270 amp
load for fifteen (15) seconds to remove the surface
charge. Use a battery load tester following the
manufacturer’s instructions.
1. If battery caps can be removed, conduct a hydrome-
ter test of the battery electrolyte:
IMPORTANT: Make sure the area around the cells is
clean before opening the battery caps.
D. Measure the temperature of the electrolyte in the
center cell.
A. Measure the specific gravity of each cell with a
hydrometer. Draw electrolyte in and out of the
hydrometer barrel prior to taking a reading to warm--
up the hydrometer. At the same time take the tem-
perature of the cell.
E. Connect a battery load tester to the battery termi-
nals following the manufacturer’s instructions.
Connect a digital multimeter to the battery terminals.
F. Apply a test load of 270 amps (one half the battery
CCA performance) for fifteen (15) seconds.
B. Temperature correct each cell reading. For each
10oF (6oC) above 80oF (27oC) add 0.004 to the spe-
cific gravity reading. For each 10oF (6oC) below 80oF
(27oC) subtract 0.004 from the specific gravity read-
ing.
G. Take a battery voltage reading after fifteen (15)
seconds, then remove the load. Record this test volt-
age reading.
H. Using the table below, determine the minimum
test voltage for the cell temperature reading.
Example: Cell Temperature
Cell Gravity
100oF
1.245
0.008
1.253
ADD (20o above 80oF)
Correction to 80oF
Minimum
Test Voltage
Battery Electrolyte
Temperature
9.6
9.5
9.4
9.3
9.1
8.9
8.7
8.5
70oF (and up)
21oC (and up)
16oC
C. If the difference between the highest and lowest
cell specific gravity is 0.050 or greater or the lowest
cell specific gravity is less than 1.225, charge the bat-
tery. Charge at the recommended rate and time giv-
en in Battery Charging or until the specific gravity of
all cells is 1.225 or greater with the difference in spe-
cific gravity between the highest and lowest cell less
than 0.050. If these charging conditions can not be
met, replace the battery.
60oF
50oF
40oF
30oF
20oF
10oF
0oF
10oC
4oC
-- 1 oC
-- 7 oC
-- 1 2 oC
-- 1 8 oC
2. Perform a high--discharge test with an adjustable
load tester.
I. If the test voltage is below the minimum, replace
the battery. If the test voltage is at or above the mini-
mum, return the battery to service.
This is one of the most reliable means of testing a battery
as it simulates the cold--cranking test. A commercial bat-
tery load tester is required to perform this test.
CAUTION
Follow the battery load tester manufacturer’s
instructions when using a load tester.
A. Check the voltage across the battery terminals
prior to testing the battery. If the voltage is less than
12.0 VDC, recharge the battery before load testing.
B. Make sure the battery terminals are free of corro-
sion.
Workman MDX--D
Page 5 -- 25
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Battery Charging
CAUTION
To minimize possible damage to the battery and allow
the battery to be fully charged, the slow charging meth-
od is presented here. This charging method can be ac-
complished with a constant current battery charger
which is available in most service shops.
Do not charge a frozen battery because it can ex-
plode and cause injury. Let the battery warm to
60 F (16 C) before connecting to a charger.
o
o
Charge battery in a well--ventilated place to dissi-
pate gases produced from charging. These
gases are explosive.
CAUTION
Keep open flame and electrical spark away from
the battery. Do not smoke. Unplug the charger
from the electrical outlet before connecting or
disconnecting the charger leads from the battery
posts.
Follow the battery charger manufacturer’s
instructions when using a battery charger.
NOTE: Using specific gravity of the battery cells is the
most accurate method of determining battery condition.
Nausea may result if the gases are inhaled.
1. Determine the battery charge level from either its
open specific gravity or circuit voltage.
3. Follow the battery charger manufacturer’s in-
structions. Connect charger cables to the battery.
Make sure a good connection is made.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
4. Charge the battery following the battery charger
manufacturer’s instructions.
100%
75%
50%
25%
0%
1.265
1.225
1.190
1.155
1.120
12.68
12.45
12.24
12.06
11.89
5. Occasionally check the temperature of the battery
o
o
electrolyte. If the temperature exceeds 125 F (52 C) or
the electrolyte is violently gassing or spewing, the
charging rate must be lowered or temporarily stopped.
6. Three (3) hours prior to the end of the charging, mea-
sure the specific gravity of a battery cell once per hour.
The battery is fully charged when the cells are gassing
freely at a low charging rate and there is less than a
0.003 change in specific gravity for three (3) consecu-
tive readings.
2. Determine the charging time and rate using the bat-
tery charger manufacturer’s instructions or the fol-
lowing table.
Battery
Reserve
Capacity
(Minutes)
Battery Charge Level
(Percent of Fully Charged)
Battery Storage
75%
50%
25%
0%
If the vehicle will be stored for more than thirty (30) days,
remove the battery and charge it fully. Either store it on
the shelf or on the vehicle. Leave the cables discon-
nected if it is stored on the vehicle. Store the battery in
a cool atmosphere to avoid quick deterioration of the
charge in the battery. To prevent the battery from freez-
ing, make sure it is fully charged.
80 or
less
3.8 hrs 7.5 hrs 11.3 hrs 15 hrs
@
@
@
@
3 amps 3 amps 3 amps 3 amps
81 to 125 5.3 hrs 10.5 hrs 15.8 hrs 21 hrs
@
@
@
@
4 amps 4 amps 4 amps 4 amps
126 to
170
5.5 hrs
@
11 hrs
@
16.5 hrs 22 hrs
@
@
5 amps 5 amps 5 amps 5 amps
171 to
250
5.8 hrs 11.5 hrs 17.3 hrs 23 hrs
@
@
@
@
6 amps 6 amps 6 amps 6 amps
above
250
6 hrs
@
12 hrs
@
18 hrs
@
24 hrs
@
10 amps 10 amps 10 amps 10 amps
Page 5 -- 26
Workman MDX--D
Electrical System
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Chapter 6
Chassis
Table of Contents
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 3
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 5
Suspension and Steering . . . . . . . . . . . . . . . . . . . . 5
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjust Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjust Front Wheel Camber . . . . . . . . . . . . . . . . . . 9
Adjust Front Wheel Toe--in . . . . . . . . . . . . . . . . . . 10
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 11
Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 11
Inspect Tires and Wheels . . . . . . . . . . . . . . . . . . . . 11
Upper Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Steering Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Lower Steering and Front Wheels . . . . . . . . . . . . 16
Front Shock Absorbers . . . . . . . . . . . . . . . . . . . . . 19
A--arms and Front Suspension . . . . . . . . . . . . . . . 20
Frame Pivot Yoke . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Swing Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Rear Wheels and Brakes . . . . . . . . . . . . . . . . . . . . 30
Rear Brake Service . . . . . . . . . . . . . . . . . . . . . . . . 32
Front Brake Calipers . . . . . . . . . . . . . . . . . . . . . . . 34
Front Brake Caliper Service . . . . . . . . . . . . . . . . . 36
Brake Master Cylinder . . . . . . . . . . . . . . . . . . . . . . 38
Brake Master Cylinder Service . . . . . . . . . . . . . . . 40
Bleed Brake System . . . . . . . . . . . . . . . . . . . . . . . . 41
Seat Base . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Front Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Cargo Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Workman MDX--D
Page 6 -- 1
Chassis
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Specifications
Item
Description
Front Tire
Pressure Range
(22 x 9.5 -- 10, 4 ply)
8 to 22 PSI (55 to 151 kPa)
Rear Tire
Pressure Range
(24 x 12 -- 10, 2 ply)
8 to 22 PSI (55 to 151 kPa)
Wheel Lug Nut Torque
Brake Fluid
80 to 90 ft--lb (109 to 122 N--m)
DOT 3
Chassis
Page 6 -- 2
Workman MDX--D
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General Information
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Workman MDX--D vehicle. Refer to the
Operator’s Manual for additional information when ser-
vicing the machine.
Workman MDX--D
Page 6 -- 3
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Special Tools
Order special tools from your Toro Distributor.
Spanner Wrench
Use spanner wrench to rotate front shock absorber col-
lar which changes the length of the shock spring to affect
front wheel camber. Make sure that vehicle is jacked up
off the ground to allow shock spring to be at full exten-
sion before using spanner wrench.
Toro Part Number: TOR6010
Figure 1
Shock Spring Compressor
Use shock spring compressor to remove spring from
front shock absorber.
Toro Part Number: TOR6015
Figure 2
Chassis
Page 6 -- 4
Workman MDX--D
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Troubleshooting
Suspension and Steering
Problem
Possible Cause
Front end is noisy.
Front wheel lug nuts are loose.
Front wheel bearings are loose or worn.
Front shocks are loose or worn.
Front end components (e.g. tie--rod, spindle, A--arm) are loose or
worn.
Steering gearbox is damaged or worn.
Rear wheel lug nuts are loose.
Rear end is noisy.
Rear shocks are loose or worn.
Rear swing arm is loose.
Clutch or transaxle problem (see Chapter 4 -- Drive Train).
Front wheel lug nuts are loose.
Excessive steering play.
Front wheel bearings are loose or worn.
Steering linkage is loose or worn.
Tie rod ends are worn.
Steering gearbox is damaged or worn.
Spindle bushings in A--arm are loose or worn.
Tire pressure is low or uneven between tires.
Vehicle is unstable or wanders.
Wheel lug nuts are loose.
Front wheel bearings are loose or worn.
Steering column bushings are worn.
Steering gearbox is damaged or worn.
Front wheel alignment (toe--in) is incorrect.
Rubber shock insert or spindle bushings in A--arm are loose or
worn.
Workman MDX--D
Page 6 -- 5
Chassis
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Suspension and Steering (continued)
Problem
Possible Cause
Front end shimmies.
Front wheel lug nuts are loose.
Front wheel bearings are loose or worn.
Steering linkage is loose or worn.
Tie rod ends are loose or worn.
Front wheel alignment (toe--in) is incorrect.
Rubber shock insert or spindle bushings in A--arm are loose or
worn.
Steering is hard.
Tire pressure is low or uneven between tires.
Steering linkage is binding or damaged.
Front wheel alignment (toe--in) is incorrect.
Steering gearbox is damaged or worn.
Vehicle pulls to one side when not
braking.
Tire pressure is low or uneven between tires.
Front wheel alignment (toe--in) is incorrect.
Steering or suspension component may be damaged.
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 in master cylinder is low.
Brake fluid leak exists at hose, caliper or wheel cylinder.
Brake master cylinder is faulty.
Brake pedal is spongy.
Rear brake shoes or front brake pads are not burnished.
Air is trapped in brake lines.
Ground speed is too fast (see Chapter 4 -- Drive Train).
Chassis
Page 6 -- 6
Workman MDX--D
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Brakes (continued)
Problem
Possible Cause
Brakes pull to either side.
Tire pressure is incorrect or uneven between tires.
Rear brake linings or front brake pads are contaminated.
Front wheel alignment (toe--in) is incorrect.
Rear brake shoes are distorted.
Tires on same axle are unmatched.
Brakes squeal.
Rear brake linings or front brake pads is glazed or saturated.
Rear brake shoe--to--shoe spring(s) is (are) weak or broken.
Rear brake shoes are distorted.
Anchor plate is bent.
Rear brake drums and shoes are dusty.
Small rock or other debris is caught in brakes.
Rear brake drums are scored or out--of--round.
Front brake rotors are scored or damaged.
Brakes drag.
Parking brake is applied or incorrectly adjusted.
Rear brake shoe--to--shoe spring(s) is (are) weak or broken.
Brake pedal is binding.
Parking brake cable is binding.
Rear brake linings or front brake pads are saturated.
Rear brake drums or front brake rotors are bent or out--of--round.
Incorrect brake lining material.
Brake pedal is hard to push.
Wheels lock--up when braking.
Brake pedal linkage is binding.
Rear brake linings or front brake pads are contaminated.
Rear brake linings or front brake pads are damaged.
Wheel or transaxle bearings are damaged.
Rear brake shoe--to--shoe springs are weak.
Brake drums are grooved in the brake shoe contact area.
Brakes fade.
Rear brake drums or front brake rotors are overheated and warped.
Rear brake linings or front brake pads are saturated.
Vehicle surges at slow speeds and
chatters at fast speeds.
Rear brake drums or front brake rotors are bent or out--of--round.
Workman MDX--D
Page 6 -- 7
Chassis
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Adjustments
Adjust Parking Brake
1. Pry the rubber cover off of the parking brake.
2. Loosen the set screw securing the knob to the park-
ing brake lever (Fig. 3).
1
3. Rotate the knob until a force from 30 to 35 lb. (133 to
156 N) is required to actuate the lever.
2
4. Tighten the set screw and install the rubber cover.
3
Figure 3
1. Parking brake lever
2. Brake knob
3. Set screw
Chassis
Page 6 -- 8
Workman MDX--D
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Adjust Front Wheel Camber
1. Adjust front tire pressures to 12 PSI (82 kPa) before
checking front wheel camber.
7. Repeat steps 2 through 6 until front wheel camber on
both wheels is correct.
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 vehicle operator’s seat. The weight or
operator must remain on the seat for the duration of this
front wheel camber procedure.
8. After camber adjustment, check front wheel toe--in
(see Adjust Front Wheel Toe--in in this section).
1
3. On a level surface, roll the vehicle straight back from
6 to 10 feet (2 to 3 meters) and then straight forward to
the original starting position. This will allow the suspen-
sion to settle into the normal operating position.
3
4. Make sure that the front wheels are facing straight
ahead.
5. Measure the front wheel camber on both front
wheels:
4
o
A. Place a 90 square on the ground with the vertical
2
edge touching the face of the tire (Fig. 4).
B. From the same part of the rim, measure the dis-
tance from the top and bottom of the rim to the
square. Record the two (2) measurements.
Figure 4
1. Front wheel
3. Top measurement
4. Bottom measurement
o
2. 90 square
C. The measurement at the bottom of the rim should
be 0.090” (2.3 mm) larger than the top measure-
ment. This measurement allows for a camber of
0+1/2 degree.
D. Repeat measurement procedure for other front
wheel.
3
1
6. If camber measurement for either wheel is incorrect,
adjust shock absorber spring to correct camber for that
wheel:
A. Chock wheels to prevent the vehicle from mov-
ing. Use a jack to raise vehicle and allow shock ab-
sorber to extend. This will allow easier shock spring
adjustment.
2
B. Use spanner wrench TOR6010 (see Special
Tools in this chapter) to rotate shock absorber collar
which changes the length of the shock spring (Fig. 5).
If the bottom camber measurement was too short,
rotate the collar to reduce the length of the shock
spring. If the bottom camber measurement was too
long, rotate the collar to increase the length of the
shock spring.
Figure 5
1. Shock absorber spring
2. Collar
3. Spring length
C. Lower vehicle to level surface.
Workman MDX--D
Page 6 -- 9
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Adjust Front Wheel Toe--in
NOTE: Before adjusting front wheel toe--in, make sure
that front wheel camber is correctly adjusted (see Adjust
Front Wheel Camber in this section).
1. Adjust front tire pressures to 12 PSI (82 kPa) before
checking front wheel toe--in.
1
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 vehicle operator’s seat. The weight or
operator must remain on the seat for the duration of this
front wheel toe--in procedure.
2
3
3. On a level surface, roll the vehicle straight back from
6 to 10 feet (2 to 3 meters) and then straight forward to
the original starting position. This will allow the suspen-
sion to settle into the normal operating position.
Figure 6
1. Tire center line (back)
3. Axle center line
2. Tire center line (front)
4. Make sure that the front wheels are facing straight
ahead.
5. Measure distance between the front tires at axle
height at both the front and rear of the tires (Fig. 6). Front
wheel toe--in should be from 0 to 1/4 inch (0 to 6 mm).
2
6. If the front wheel toe--in is incorrect, adjust as follows:
A. Loosen jam nuts at both ends of tie rods (Fig. 7).
1
B. Rotate both tie rods to move front of tire inward or
outward.
1
C. Tighten tie rod jam nuts when toe--in adjustment
is correct.
Figure 7
7. Ensure that there is full steering travel in both direc-
tions.
1. Jam nut
2. Tie rod
Chassis
Page 6 -- 10
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Service and Repairs
Check Tire Pressure
See Specifications for tire pressure range for front and
rear tires.
Higher pressures should be used for heavier payloads
at higher speeds. Do not exceed the maximum tire pres-
sure.
The air pressure needed is determined by the payload
carried. Lower air pressure will provide less compac-
tion, a smoother ride and fewer tire marks. Lower pres-
sure should not be used for heavy payloads at higher
speeds.
Inspect Tires and Wheels
Operating accidents, such as hitting curbs, can damage
a tire or rim and also disrupt wheel alignment. Inspect
tire and rim condition after any accident.
Check wheels to ensure they are mounted securely.
Torque wheel lug nuts in a crossing pattern from 80 to
90 ft-lb (109 to 122 N--m).
Workman MDX--D
Page 6 -- 11
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Upper Steering
18 to 22 ft--lb
(25 to 29 N--m)
1
RIGHT
2
16
FRONT
11
3
175 to 225 in--lb
(20 to 25 N--m)
Antiseize
Lubricant
13
10
12
10
15
5
14
8
Loctite #242
7
9
4
7
6
Antiseize
Lubricant
Figure 8
1. Hex nut
7. Lock washer (6 used)
8. Steering shaft
9. Cap screw (4 used)
10. Bearing (2 used)
11. Carriage bolt (4 used)
12. Steering column
13. Dust cover
2. Flat washer
3. Steering wheel
4. Flange nut (4 used)
5. Steering box assembly
6. Cap screw
14. Collar
15. Set screw
16. Steering wheel cover
Disassembly (Fig. 8)
3. Carefully remove steering wheel cover from the
steering wheel. Remove nut and flat washer securing
the steering wheel to the steering shaft. Pull steering
wheel from the shaft.
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
2. Raise front hood to gain access to the steering com-
ponents.
4. Remove cap screw and lock washer securing the
lower steering shaft knuckle to the steering gearbox in-
put shaft. Pull knuckle from the gearbox shaft.
Chassis
Page 6 -- 12
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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.
7. Place dust cover onto the steering shaft.
8. Connect both tie rods to the Pitman arm on the steer-
ing gearbox (see Lower Steering and Front Wheel
Installation in this section).
6. Remove dust cover (item 13) from the steering shaft.
Replace cover if damaged. Slide steering shaft out of the
steering column.
NOTE: Apply antiseize lubricant to the steering shaft
taper before installing the steering wheel.
9. Position front tires straight ahead. Slide steering
wheel onto the steering shaft so that the leg of the “Y”
formed by the wheel struts is directed towards the oper-
ator platform.
7. Disconnect both tie rods from the Pitman arm on the
steering gearbox (see Lower Steering and Front Wheel
Removal in this section).
8. Remove four (4) cap screws and lock washers that
secure the steering gearbox to the tower plate on the
front frame. Remove gearbox from the tower plate.
10.Secure steering wheel to shaft with flat washer and
nut. Torque nut from 18 to 22 ft--lb (25 to 29 N--m).
Install steering wheel cover to wheel.
9. Inspect the cover above the location of the gearbox
Pitman arm (Fig. 9). Make sure that the cover is secure
to the frame. If necessary, remove cover, thoroughly
clean frame and secure cover with new adhesive gas-
ket.
11.Lower and secure front hood.
12.Check front wheel alignment (see Adjust Front
Wheel Toe--in in the Adjustments section of this chap-
ter).
Assembly (Fig. 8)
2
3
1. Position steering gearbox to the tower plate of the
front frame with the Pitman arm facing down and to the
rear. The gearbox shaft must be to the left side of the
tower.
2. Secure steering gearbox to the tower plate with four
(4) cap screws and lock washers. Torque screws from
175 to 225 in--lb (20 to 25 N--m).
3. Make sure that collar (item 14) is positioned on steer-
ing shaft. Insert steering shaft up through the steering
column.
1
4. Secure steering column to the mounting plate on the
frame with four (4) carriage screws and flange nuts.
NOTE: Apply antiseize lubricant to the steering gear-
box input shaft before installing to steering shaft
knuckle.
Figure 9
1. Top of Pitman arm
2. Cover
3. Adhesive gasket
5. Position knuckle of the lower steering shaft onto the
gearbox input shaft. Secure knuckle to the steering
gearbox shaft with cap screw and lock washer.
6. Make sure that collar (item 14) is just below steering
column. If necessary, re--position collar on steering
shaft. Apply Loctite #242 (or equivalent) to collar set
screw and secure collar with set screw.
Workman MDX--D
Page 6 -- 13
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Steering Gearbox
27 to 33 ft--lb
(37 to 44 N--m)
90 to 110 in--lb
(10.2 to 12.4 N--m)
9
8
3
6
2
18
15
17
10
16
7
14
11
10
1
4
6
175 to 225 in--lb
(20 to 25 N--m)
5
12
13
19
Align marks during assembly
Figure 10
8. Stepped washer
1. Gasket
14. Lube fitting
2. Hex washer head screw (3 used)
3. Seal
9. Flange head screw with patch lock
10. Ball bearing
15. Steering housing cover
16. Steering housing
17. Pinion gear
4. Sector gear
11. Input shaft spacer
5. Flat washer
12. Flat washer
13. Flange head screw with patch lock
18. Oil seal
6. Ball bearing
19. Pitman arm
7. Output shaft spacer
Chassis
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Disassembly (Fig. 10)
2. If seals were removed, press new seals into housing.
Seal lips should be facing up.
IMPORTANT: Do not reuse flange head screws with
patch lock (items 9 and 13) after they have been re-
moved.
3. Place flat washer (item 5) onto shaft of the Pitman
arm (item 19). Insert shaft into steering housing.
1. Remove flange head screw with patch lock (item 9)
and stepped washer (item 8) from Pitman arm. Discard
flange head screw.
IMPORTANT: The position of the Pitman arm and
sector gear is critical during assembly. Make sure
that the marks on these components are aligned
during assembly.
2. Remove flange head screw with patch lock (item 13)
and flat washer (item 12) from pinion gear shaft. Discard
flange head screw.
4. Position sector gear (item 4) onto the spline of the
Pitman arm shaft.
3. Remove three (3) hex washer head screws (item 2)
securing the housing cover and gasket to the steering
housing. Remove cover and gasket from the housing.
Replace gasket if damaged.
IMPORTANT: Make sure sector gear is centered to
the pinion gear.
5. Insert pinion gear (item 17) into the small bearing in
the steering housing.
4. Inspect gears. Sector and pinion gear teeth must be
free of damage that prevents them of free movement.
6. Fill steering housing with Mobil High Temperature
XHP--222 grease (or equivalent). Make sure all gear
teeth on the sector and pinion gears are covered with
grease.
5. Remove pinion gear (item 17) from the housing.
IMPORTANT: Note that mark on Pitman arm shaft
and sector gear are aligned. Their position is critical
during assembly.
7. Place gasket and steering housing cover onto the
housing. Secure cover to housing with three (3) hex
washer head screws (item 2). Torque screws from 90 to
110 in--lb (10.2 to 12.4 N--m).
6. Separate Pitman arm (item 19) from the sector gear
(item 4) and steering housing and remove from the
housing.
IMPORTANT: Flange head screws with patch lock
(items 9 and 13) should be replaced whenever they
are removed.
7. Inspect bearings. Bearings must spin smoothly and
be free of damage. Press bearings and spacer out of
housing if necessary.
8. Secure stepped washer and flange head screw with
patch lock (item 9) to the Pitman arm (item 8). Make sure
to position stepped washer as shown in Figure 10.
Torque screw from 27 to 33 ft--lb (37 to 44 N--m).
8. Inspect seals. Seals must be free of rips and tears.
Replace seals if necessary.
Assembly (Fig. 10)
9. Secure flat washer (item 12) and flange head screw
with patch lock (item 13) to the pinion gear shaft. Torque
screw from 175 to 225 in--lb (20 to 25 N--m).
IMPORTANT: Always replace ball bearings as a set.
1. If ball bearings were removed:
10.After assembly is completed, make sure that pitman
arm rotates freely from stop to stop without binding.
A. Press new bearing into housing from the inside
first.
B. Turn housing over. Insert spacer and press new
bearing into housing.
Workman MDX--D
Page 6 -- 15
Chassis
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Lower Steering and Front Wheels
20 to 25 ft--lb
(28 to 33 N--m)
12
14
7
4
3
19
See text for
tightening procedure
6
1
7
6
5
8
9
2
30
6
10
17
16
15
13
11
24
29
22
28
45 to 55 ft--lb
(62 to 74 N--m)
27
26
21
23
20
25
RIGHT
9 to 11 ft--lb
(13 to 14 N--m)
FRONT
80 to 90 ft--lb
(109 to 122 N--m)
18
Figure 11
1. Steering gearbox pitman arm
2. Shock absorber (2 used)
3. Cotter pin
11. Tab washer
12. RH A--arm
13. Jam nut
21. Wheel stud (5 used per hub)
22. Socket head screw (4 used per rotor)
23. Brake caliper (LH shown)
24. Flange screw (2 used per caliper)
25. Grease fitting
26. Ball joint (LH threads)
27. Jam nut (LH threads
28. Tie rod
4. Slotted hex nut
14. Front frame
15. Nut retainer
16. Dust cap
17. Wheel assembly
18. Lug nut (5 used per wheel)
19. Cap screw (2 used per A--arm)
20. Cotter pin
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
29. Jam nut (RH threads)
30. Ball joint (RH threads)
Chassis
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Disassembly (Fig. 11)
6
4
5
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition.
3
7
WARNING
2
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
8
2. Chock wheels not being jacked up. Jack front wheel
off the ground and support vehicle with appropriate jack
stand beneath the frame.
9
9 to 11 ft--lb
(13 to 14 N--m)
1
Figure 12
3. Remove lug nuts and pull wheel assembly from ma-
chine.
1. Outer bearing cone
2. Outer bearing cup
3. Wheel hub
6. Inner bearing cone
7. Seal
8. Socket screw (4 used)
9. Wheel stud (5 used)
4. Remove brake caliper from spindle (see Front Brake
Caliper in this section). Position caliper away from wheel
hub and spindle.
4. Brake rotor
5. Inner bearing cup
5. Carefully pry dust cap from wheel hub.
75 to 100 ft--lb
(102 to 135 N--m)
6. Remove cotter pin and nut retainer from spindle.
1
7. Remove jam nut that secures wheel hub to spindle.
Slide wheel hub with bearings and brake rotor from
spindle.
2
8. Disassemble the wheel hub (Fig. 12):
A. Pull the seal out of the wheel hub.
3
B. Remove bearings from both sides of the wheel
hub. Clean bearings in solvent. Make sure bearings
are in good operating condition. Clean the inside of
the wheel hub. Check the bearing cups for wear, pit-
ting or other noticeable damage. Replace worn or
damaged parts.
4
5
6
Figure 13
C. If necessary, remove wheel studs and brake rotor
from wheel hub.
1. Cap screw
2. Brake hose clip
3. A--arm (LH shown)
4. Kingpin sleeve
5. Thrust washer
6. Lock nut
9. Remove spindle (Fig. 13):
Assembly (Fig. 11)
A. Remove cotter pin and castle nut securing tie rod
ball joint to the spindle. Separate ball joint from the
spindle. Remove tie rod from steering gearbox pit-
man arm if necessary.
1. Install spindle as follows (Fig. 13):
A. Make sure king pin sleeve is positioned into the
pivot hub of the A--arm. Sleeve must extend through
the bottom of the hub.
B. Remove lock nut and cap screw securing the
spindle to the A--arm. Separate spindle from A--arm.
B. Place thrust washer onto the bottom of the king
pin sleeve. Then place spindle over the A--arm hub,
king pin sleeve and thrust washer.
C. Locate and remove thrust washer from bottom of
kingpin sleeve in A--arm and brake hose clip from top
of A--arm. Remove kingpin sleeve from A--arm if nec-
essary.
NOTE: Make sure cap screw is inserted down
through the spindle and A--arm hub.
Workman MDX--D
Page 6 -- 17
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C. Install brake hose clip onto cap screw. Secure
spindle to A--arm hub with cap screw and lock nut.
Torque fasteners from 75 to 100 ft--lb (102 to 135
N--m).
4. Slide wheel hub assembly onto spindle. Install outer
bearing, tab washer and jam nut onto spindle.
5. Rotate the wheel by hand and tighten the jam nut
from 75 to 100 in-lb (8.5 to 11.3 N--m) to set the bear-
ings. Then, loosen the nut until the hub has end play.
2. Install tie rod:
A. Insert tie rod ball joints down through the spindle
and up through the Pitman arm. Secure with castle
nuts.
6. Again, rotate the wheel by hand and tighten the jam
nut from 15 to 20 in-lb (1.7 to 2.3 N--m).
7. Position nut retainer over jam nut and install cotter
pin through spindle shaft hole. Install dust cap to hub.
B. Torque castle nuts from 20 to 25 ft--lb (28 to 33
N--m) to secure ball joint while aligning castle nut slot
with hole in ball joint stud. If necessary to align holes,
castle nut torque may be slightly more than specifi-
cation. Install cotter pin.
8. Install brake caliper to spindle (see Front Brake Cali-
per in this section).
9. Install wheel assembly with valve stem facing out.
10.Lower machine to ground.
3. Assemble wheel hub (Fig. 12):
A. If bearing cups were removed from the wheel
hub, press inner and outer cups into the hub until
they seat against the hub shoulder.
11.Torque wheel lug nuts in a crossing pattern from 80
to 90 ft--lb (109 to 122 N--m).
12.Align steering and toe--in (see Adjust Front Wheel
Toe--in in the Adjustments section of this chapter).
B. Pack both bearings with grease. Install inner
bearing into the cup on inboard side of the wheel hub.
13.Lubricate tie rod ball joints and king pin.
IMPORTANT: The wheel hub seal must be
pressed in so it is flush with the end of the hub.
The lip of the seal must be toward the inner bear-
ing.
C. Lubricate the inside of the new seal and press it
into the wheel hub.
D. If brake rotor was removed, position rotor to hub
with chamfered edge toward hub. Secure rotor to
hub with four (4) socket head screws. Torque screws
from 9 to 11 ft--lb (13 to 14 N--m).
Chassis
Page 6 -- 18
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Front Shock Absorbers
Shock Removal (Fig. 14)
IMPORTANT: Any adjustment to the shock spring
preload will affect the front wheel camber (see Ad-
just Front Wheel Camber in the Adjustments sec-
tion of this chapter). Do not make shock spring
adjustment without checking front wheel camber.
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition.
3
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
2
2. Chock wheels not being jacked up. Jack front wheel
off the ground and support vehicle with appropriate jack
stand beneath the frame.
2
5
1
FRONT
3. Support a--arm to prevent it from moving after the
shock is removed.
4
3
4. Remove lock nuts, cap screws and flat washer that
secure shock to frame and a--arm. Remove shock ab-
sorber from vehicle.
Figure 14
1. Shock absorber
2. Cap screw
3. Lock nut
4. A--arm (LH shown)
5. Flat washer
NOTE: Use spanner wrench TOR6010 (see Special
Tools in this chapter) if spring preload requires adjust-
ment. If the spring is to be removed from the shock ab-
sorber, shock spring compressor tool TOR6015 (see
Special Tools in this chapter) can be used.
Shock Installation (Fig. 14)
1. Position shock absorber to frame and a--arm brack-
ets.
2. Secure shock absorber to vehicle.
A. Slide upper cap screw through frame mounting
holes and upper shock eye.
B. Slide lower cap screw through flat washer, lower
shock eye and a--arm mounting hole.
C. Secure cap screws with lock nuts.
3. Lower vehicle to ground.
Workman MDX--D
Page 6 -- 19
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A--arms and Front Suspension
20 to 25 ft--lb
(28 to 33 N--m)
12
14
7
4
3
19
6
1
7
See text for
6
5
tightening procedure
8
2
36
34
31
30
6
35
9
10
17
25
15
16
13
11
29
32
45 to 55 ft--lb
(62 to 74 N--m)
28
27
22
33
24
21
26
23
20
RIGHT
9 to 11 ft--lb
(13 to 14 N--m)
FRONT
75 to 100 ft--lb
(102 to 135 N--m)
80 to 90 ft--lb
(109 to 122 N--m)
18
Figure 15
1. Steering gearbox pitman arm
2. Shock absorber (2 used)
3. Cotter pin
13. Jam nut
25. Flange screw (2 used per caliper)
26. Grease fitting
27. Ball joint (LH threads)
28. Jam nut (LH threads
29. Tie rod
14. Front frame
15. Nut retainer
16. Dust cap
4. Slotted hex nut
5. Flat washer
17. Wheel assembly
6. Lock nut (3 used per side)
7. Cap screw (2 used per shock)
8. LH A--arm
18. Lug nut (5 used per wheel)
19. Cap screw (2 used per A--arm)
20. Cotter pin
21. Wheel stud (5 used per hub)
22. Socket screw (4 used per rotor)
23. Brake caliper (LH shown)
24. Lock nut
30. Jam nut (RH threads)
31. Ball joint (RH threads)
32. Kingpin sleeve
9. Brake rotor
33. Thrust washer
10. Wheel hub assembly
11. Tab washer
12. RH A--arm
34. Spindle (LH shown)
35. Brake hose clip
36. Cap screw
Chassis
Page 6 -- 20
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A--arm Removal (Fig. 15)
2
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
WARNING
3
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
2. Chock wheels not being jacked up. Jack front wheel
off the ground and support vehicle with appropriate jack
stand beneath the frame.
1
3. Remove front wheel and spindle from A--arm (see
Lower Steering and Front Wheel Removal in this sec-
tion).
Figure 16
1. A--arm
2. Flange bushing
3. Straight bushing
4. Remove cap screw (item 7), flat washer (item 5) and
lock nut (item 6) that secure lower end of shock absorber
to A--arm.
5. Support A--arm to prevent it from falling.
6. Remove both cap screws (item 19) and lock nuts
(item 6) that secure A--arm to frame. Pull A--arm from
frame.
7. If necessary, remove flange bushings and straight
bushings from A--arm bores (Fig. 16).
A--arm Installation (Fig. 15)
1. If bushings were removed from A--arm, press new
bushings fully into bore of A--arm (Fig. 16).
2. Position A--arm to the frame. Secure A--arm to the
frame with cap screws (item 19) and lock nuts (item 6).
Insert front screw from front of machine and rear screw
from rear of machine. Do not fully tighten nuts.
3. Position lower end of shock absorber to A--arm and
insert cap screw (item 7) with flat washer (item 5) from
rear of shock. Secure with lock nut (item 6).
4. Fully tighten lock nuts (item 6) to secure A--arm to
machine frame.
5. Install spindle and front wheel to the A--arm (see
Lower Steering and Front Wheel Installation in this sec-
tion).
6. Lower machine to ground. Make sure that wheel lug
nuts are properly torqued in a crossing pattern from 80
to 90 ft--lb (109 to 122 N--m).
7. Align front wheel toe--in (see Adjust Front Wheel
Toe--in in the Adjustments section of this chapter).
Workman MDX--D
Page 6 -- 21
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Frame Pivot Yoke
240 to 290 ft--lb
(326 to 393 N--m)
15
1
17
11
3
18
10
20
13
16
4
12
14
7
19
6
RIGHT
7
6
19
5
2
FRONT
8
6
9
Figure 17
1. Flange nut (4 used)
8. LH A--arm
9. Grease fitting (1 used per arm)
10. Screw
11. Cap screw
12. RH A--arm
13. Lock washer
14. Front frame
15. Pivot yoke
2. Shock absorber (2 used)
3. Cap screw (4 used)
4. Rubber bumper
16. Flange head screw (4 used)
17. Flat washer (4 used)
18. Hardened washer
5. Flat washer
6. Lock nut (4 used per side)
7. Cap screw (2 used per shock)
19. Cap screw (2 used per arm)
20. Ground cable
Chassis
Page 6 -- 22
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Pivot Yoke Removal (Fig. 17 and 19)
2. Secure pivot yoke to the front frame tab with cap
screw and hardened washer. Torque cap screw from
240 to 290 ft--lb (326 to 393 N--m).
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
3. Secure pivot yoke to the rear frame with four (4) cap
screws and flat washers (Fig. 18).
2. Remove cargo box from the rear frame (see Cargo
Box Removal in this section).
4. Install seat base to the front frame (see Seat Base
Installation in this section).
3. Remove seat base from the front frame (see Seat
Base Removal in this section).
5. Install cargo box to the rear frame (see Cargo Box
Installation in this section).
WARNING
Make sure all tires are chocked to prevent the
machine from moving. Before removing the pivot
yoke, make sure front and rear frames are
supported with jack stands. Support both the
front and back of each frame.
4
1
4. To prevent vehicle from shifting, use jack stands to
support front and back of both front and rear frames.
5. Remove four (4) cap screws and flat washers secur-
ing the pivot yoke to the rear frame (Fig. 18).
FRONT
3
6. Remove cap screw and hardened washer securing
the pivot yoke to the front frame tab.
2
Figure 18
1. Pivot yoke
2. Cap screw (4 used)
3. Flat washer (4 used)
4. Rear frame
WARNING
Support pivot yoke while removing it from the
front frame to prevent dropping and causing
serious injury and damage to the machine.
1
7. Remove four (4) flange head screws and flanged
lock nuts securing the pivot yoke to the front frame. Re-
move pivot yoke from the machine.
3
Pivot Yoke Installation (Fig. 17 and 19)
2
WARNING
Support pivot yoke while installing it to the front
frame to prevent dropping and causing serious
injury and damage to the machine.
5
6
4
Figure 19
1. Position pivot yoke to the front frame so the diamond
pattern faces up. Secure yoke to front frame with four (4)
flange head screws and flanged lock nuts. Tighten lower
two (2) fasteners first, then tighten upper two (2) fasten-
ers.
1. Cap screw & flat washer
2. Pivot yoke
4. Flange lock nut
5. Front frame
6. Diamond pattern
3. Rear frame
Workman MDX--D
Page 6 -- 23
Chassis
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Swing Arm
11
10
12
4
7
6
8
4
7
70 to 90 ft--lb
(95 to 122 N--m)
9
5
6
3
FRONT
RIGHT
2
3
1
2
Figure 20
1. Transaxle assembly
2. Cap screw (4 used)
5. Cap screw (2 used)
6. Lock nut (4 used)
7. Thrust washer (4 used)
8. Cap screw (2 used)
9. Swing arm
10. Rear frame
3. Hardened washer (4 used)
11. Cap screw (2 used)
12. Lock nut (2 used)
4. Rear shock assembly (2 used)
Chassis
Page 6 -- 24
Workman MDX--D
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Removal (Fig. 20)
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
1
2. Raise and support cargo box with prop rod.
3. Remove muffler from machine (see Exhaust System
in the Service and Repairs section of Chapter 3 -- Diesel
Engine).
6
4
3
5
9
7
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
FRONT
RIGHT
8
2
4. Jack up and support both sides of the frame:
Figure 21
A. Chock the front and rear of both front tires to pre-
vent the vehicle from moving.
1. Swing arm
6. Clip (6 used)
2. Rear brake (LH shown)
3. Brake cable (2 used)
4. Rear brake line
7. R -- clamp (2 used)
8. Screw (2 used)
B. Use jack or hoist to raise the rear of the vehicle.
9. Retaining ring (2 used)
5. Cable tie (2 used)
C. After raising the machine, support both sides of
the frame with appropriate jack stands positioned
just in front of the swing arm pivot area.
Installation (Fig. 20)
IMPORTANT: Take care to not damage the engine,
fuel hoses, electrical harness, control cables or oth-
er parts while raising the swing arm to the rear
frame.
5. Remove both rear wheels from transaxle. Also, dis-
connect parking brake cables and brake lines from both
rear wheel brake assemblies on transaxle (see Rear
Wheels and Brakes in this section).
1. Position swing arm under vehicle and carefully raise
it to rear frame.
6. Remove transaxle from vehicle (see Transaxle in the
Service and Repairs section of Chapter 4 -- Drive Train).
Brake assemblies, brake drums and wheel hubs can re-
main on the transaxle.
2. Align swing arm pivots to frame mounting points. Se-
cure swing arm to machine frame with cap screws,
thrust washers and lock nuts. Torque lock nuts from 70
to 90 ft--lb (95 to 122 N--m).
7. Note routing of parking brake cables, rear brake line
and shift cables for assembly purposes. Separate
cables and brake line from swing arm as needed to allow
swing arm removal. Note location of cable ties and
clamps for assembly purposes.
3. Secure both shock absorbers to swing arm with cap
screw and lock nut. Insert cap screw from the inside of
the swing arm brackets.
4. Install transaxle to vehicle (see Transaxle in the Ser-
vice and Repairs section of Chapter 4 -- Drive Train).
Make sure that shift cables are correctly adjusted.
8. Remove cap screw and lock nut that secure both
shock absorbers to swing arm.
9. Support swing arm to prevent it from falling.
5. Use notes taken before removal to properly route
and secure parking brake cables and brake lines to rear
brake assemblies.
10.Remove cap screws, thrust washers and lock nuts
that secure swing arm pivots to machine frame.
IMPORTANT: Take care to not damage the engine,
fuel hoses, electrical harness, control cables or oth-
er parts while removing the swing arm from the
vehicle.
6. Secure parking brake cables to the rear brakes (see
Parking Brake in this section).
7. Secure brake lines to the rear brakes (see Rear
Wheels and Brakes in this section).
11.Carefully, lower swing arm from rear frame and re-
move from vehicle.
Workman MDX--D
Page 6 -- 25
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8. Bleed brake system (see Bleed Brake System in this
section).
12.Lower and secure cargo box.
13.Check parking brake operation and adjust if neces-
sary (see Adjust Parking Brake in the Adjustments sec-
tion of this chapter).
9. Install both wheels to the transaxle (see Rear
Wheels and Brakes in this section).
10.Lower machine to ground.
11.Install muffler to machine (see Exhaust System in the
Service and Repairs section of Chapter 3 -- Diesel En-
gine).
Chassis
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This page is intentionally blank.
Workman MDX--D
Page 6 -- 27
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Parking Brake
11
10
9
1
13
2
8
16
7
14
12
15
4
17
6
5
3
RIGHT
FRONT
Figure 22
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
13. Cotter pin
8. Flat washer
14. Clevis pin
9. Flange head screw (4 used)
10. Flat washer (2 used)
11. Screw (2 used)
15. Parking brake cable (2 used)
16. Parking brake support
17. Cable retaining ring (2 used)
12. Cap screw
Chassis
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Disassembly (Fig. 22)
4. Position brake cables to rear brake assemblies using
cable routing noted during disassembly.
1. Park machine on a level surface, stop engine and re-
move key from the ignition switch. Chock wheels to pre-
vent the machine from moving.
5. Secure parking brake cables to rear of machine (Fig.
23):
2. Disconnect both parking brake cables from rear of
machine (Fig. 23):
A. Secure each brake cable to swing arm with re-
taining ring.
A. Remove cotter pin and clevis pin that secures
each brake cable end to brake lever.
B. Secure each brake cable end to brake lever with
clevis pin and cotter pin.
B. Remove retaining ring that secures each brake
cable to swing arm.
C. Secure each R--clamp to rear frame with washer
head screw.
C. Remove washer head screw that secures each
R--clamp to rear frame.
D. Secure each rear brake line to parking brake
cable with cable tie.
D. For assembly purposes, note location of cable
ties that secure each rear brake line to parking brake
cables. Remove cable ties.
6. Check parking brake operation and adjust if neces-
sary (see Adjust Parking Brake in the Adjustments sec-
tion of this chapter).
3. Remove parking brake cover from seat base.
10
4. Remove four (4) flange head screws that secure
parking brake support to seat base.
8
5. Carefully lift parking brake support with brake cables
attached from machine. Take care to not damage brake
cables while removing them from seat base opening.
9
5
2
3
6. Remove brake cables from parking brake support
and cable equalizer bracket using Figure 22 as a guide.
7
4
7. Note routing of brake cables for assembly purposes.
8. Remove brake cables from machine.
Assembly (Fig. 22)
FRONT
RIGHT
1
6
Figure 23
1. Secure brake cables to parking brake support and
cable equalizer bracket using Figure 22 as a guide.
1. Brake cable
2. Cotter pin
3. Clevis pin
6. Washer head screw
7. R--clamp
8. Cable tie
9. Rear brake line
10. Swing arm
2. Route brake cables through seat base opening tak-
ing care to not damage cables. Position parking brake
support to seat base.
4. Rear brake assembly
5. Retaining ring
3. Secure parking brake support to seat base with four
(4) flange head screws.
Workman MDX--D
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Rear Wheels and Brakes
20 ft--lb
(27 N--m)
11
10
120 ft--lb
(163 N--m)
7
8
5
13
15
19
18
1
20
4
15 to 21 ft--lb
(21 to 28 N--m)
6
12
16
17
14
Antiseize
Lubricant
3
RIGHT
2
FRONT
80 to 90 ft--lb
(109 to 122 N--m)
9
Figure 24
1. Wheel assembly
2. Lug nut (5 used per hub)
3. Castle nut
8. Cotter pin
9. Cotter pin
15. Spring washer
16. Wheel stud (5 used per hub)
17. Retaining ring
18. Rear brake line
19. Banjo bolt
20. Banjo washer (2 used per brake)
10. Flange nut (4 used per brake)
11. Transaxle
12. Parking brake cable (2 used)
13. Wheel hub
4. Brake drum
5. Socket head screw (4 used per brake)
6. Brake assembly (LH shown)
7. Clevis pin
14. Washer
Removal (Fig. 24)
4. Remove cotter pin from the castle nut and transaxle
shaft. Remove castle nut, spring washer and washer
from the shaft. Remove the wheel hub from the shaft.
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
NOTE: The brake assembly can be removed from the
transaxle shaft for disassembly.
WARNING
5. If required, remove brake assembly as follows:
A. Remove cotter pin and clevis pin securing the
parking brake cable to the parking brake lever on the
rear of the brake assembly.
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
2. Chock wheels not being jacked up. Lift rear wheel off
the ground using a jack and support vehicle with ap-
propriate jack stand beneath the frame.
B. Clean hydraulic brake line area of brake assem-
bly to prevent contamination (Fig. 25). Loosen and
disconnect brake line from wheel cylinder. Plug
brake line and position it away from brake assembly.
Discard two (2) banjo washers.
3. Remove five (5) lug nuts, wheel assembly and brake
drum from the wheel hub.
Chassis
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C. Remove four (4) socket head screws and flange
nuts that secure the brake assembly to the transaxle.
13.Bleed brakes (see Bleed Brake System in this sec-
tion).
D. Remove brake assembly from the transaxle.
CAUTION
Installation (Fig. 24)
IMPORTANT: Parking brake levers must be posi-
tioned above the transaxle mount. When positioned
correctly, brake lever will point toward the rear of the
axle.
After servicing brake system components, al-
ways check the brakes in a wide open, level area
that is free of other persons and obstructions.
14.Check brake operation.
1. Position brake assembly to the transaxle. Secure
backing plate of the brake assembly to the transaxle with
four (4) socket head screws and flanged nuts. Torque
screws to 20 ft--lb (27 N--m).
Burnish Brake Shoes
Sintered metal linings may not provide maximum brake
stopping distance after brake shoes are replaced. It is
necessary to burnish new brake shoe linings.
2. Position new banjo washer on each side of brake line
fitting (Fig. 25). Insert banjo bolt into fitting and thread
into wheel cylinder. Torque banjo bolt from 15 to 21 ft--lb
(21 to 28 N--m).
IMPORTANT: Do not drive machine with the brakes
applied. The brake shoe linings will overheat.
3. Secure parking brake cable to the brake lever with
clevis pin and cotter pin.
IMPORTANT: During brake burnishing procedure,
do not allow the brakes to lock up. Allow brakes to
cool between applications.
IMPORTANT: Do not get antiseize lubricant onto
brake shoes.
1. Drive machine while making 6 to 7 normal stops at
about 200 ft (60 m) intervals while traveling at 10 to 15
mph (16 to 24 KPH).
4. Apply light coat of antiseize lubricant to the transaxle
shaft splines.
5. Secure wheel hub to the transaxle shaft with washer,
spring washer and castle nut.
1
2
3
6. Torque castle nut 120 ft--lb (163 N--m). If slot in nut
does not align with hole in transaxle shaft, continue tight-
ening nut to align next slot with hole in shaft. Castle nut
torque should not exceed 200 ft--lb (271 N--m).
5
7. Secure castle nut to transaxle shaft with cotter pin.
8. Slide brake drum onto wheel hub.
9. Position wheel assembly to the machine with valve
stem facing out and secure with five (5) lug nuts.
4
10.Lower machine to ground.
15 to 21 ft--lb
(21 to 28 N--m)
11.Torque lug nuts in a crossing pattern from 80 to 90
ft--lb (109 to 122 N--m).
Figure 25
1. Brake assembly
2. Wheel cylinder
3. Banjo washer
4. Banjo bolt
5. Brake line
12.Check parking brake operation. Adjust parking brake
if necessary (see Parking Brake Adjustment in the Ad-
justments section of this chapter).
Workman MDX--D
Page 6 -- 31
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Rear Brake Service
110 to 120 in--lb
(12.4 to 13.6 N--m)
6
9
11
2
110 to 120 in--lb
(12.4 to 13.6 N--m)
10
3
7
8
11
10
5
1
13
4
7
12
110 to 120 in--lb
(12.4 to 13.6 N--m)
8
3
12
Figure 26
1. Brake backing plate
2. Washer head screw
3. Brake shoe
6. Parking brake lever (LH shown)
7. Belleville washer
8. Adjuster lever
10. Flat washer
11. Bolt
12. Shoe hold down cup and spring
13. Upper spring
4. Lower spring
9. Dust cover
5. Wheel cylinder
Disassembly (Fig. 26)
4. If required, slide parking brake lever from slot and
dust cover in backing plate.
5. If necessary, remove two (2) washer head screws
that secure wheel cylinder to backing plate. Remove
wheel cylinder from backing plate.
CAUTION
Be careful when removing springs from brake
shoes. The springs are under heavy load and
may cause personal injury.
6. If necessary, remove bolts and washers to allow ad-
juster levers to be separated from backing plate. Locate
and remove belleville washers from between adjuster
levers and backing plate.
1. Remove upper and lower springs from brake shoes.
2. Remove shoe hold down cups and springs that se-
cure the brake shoes to the backing plate.
3. Remove brake shoes from backing plate.
Chassis
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Inspection (Fig. 26)
Assembly (Fig. 26)
1. Inspect brake drums.
IMPORTANT: Brake shoe lining surfaces must be
free of grease, oil and other foreign matter.
IMPORTANT: Brake drum machining is not recom-
mended. Replace brake drums as a set to maintain
equal braking forces.
1. Apply a light film of lubricant to the following:
A. Ledges on which the brake shoes rest.
B. Pin surfaces on adjuster levers.
A. Clean drums with denatured alcohol. Check
braking surface diameter in at least three places. If
the diameter exceeds 6.320 inches (160.5 mm), re-
place both brake drums.
C. Anchor block surface that contacts shoe webs.
D. Both surfaces of belleville washers that are posi-
tioned between adjuster levers and backing plate.
B. Replace drums that are cracked, deeply grooved,
tapered, significantly out--of--round, scored, heat
spotted or excessively rusted.
2. If removed, position lubricated belleville washer be-
tween lever adjuster and backing plate. Secure adjuster
to backing plate with washer and bolt. Torque bolt from
110 to 120 in--lb (12.4 to 13.6 N--m).
C. Minor scoring can be removed with sandpaper.
2. Inspect brake shoe linings.
3. If removed, secure wheel cylinder to backing plate
with two (2) washer head screws. Torque screws from
110 to 120 in--lb (12.4 to 13.6 N--m).
IMPORTANT: Replace brake shoes as a set (all four
shoes) to maintain equal braking forces.
A. Replace brake shoes if damaged or if lining is
worn to 1/16” (1.6 mm). Replace if lining is contami-
nated by oil, grease or other fluids.
4. If removed from backing plate, slide parking brake le-
ver into slot and dust cover in backing plate.
5. Position brake shoes to backing plate. Make sure
that each shoe is properly positioned at anchor block,
parking brake lever, wheel cylinder and pin on adjuster
lever. Secure shoes to backing plate with shoe hold
down cups and springs.
NOTE: Overheated springs lose their tension, and
can cause brake linings to wear out prematurely.
B. Inspect brake shoe webbing, upper and lower
springs and shoe hold down springs for overheating.
Overheating is indicated by a slight blue color. In-
spect brake shoe webbing for deformation. Replace
parts as necessary.
CAUTION
Be careful when installing springs to brake
shoes. The springs are under heavy load and
may cause personal injury.
C. Inspect hold down pins on adjuster levers for
bends, rust and corrosion. Replace as necessary.
3. Inspect backing plate surfaces, which contact with
the brake shoes for grooves that may restrict shoe
movement. Replace plate if grooves can not be re-
moved by light sanding with emery cloth or other suit-
able abrasive. Replace plate if cracked, warped or
excessively rusted.
6. Secure brake shoes with upper and lower springs.
4. Inspect adjuster levers for deformation. Replace lev-
ers if deformation or excessive rust is found.
5. Replace parking brake cables if frayed, stretched or
kinked.
Workman MDX--D
Page 6 -- 33
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Front Brake Calipers
9 to 11 ft--lb
(13 to 14 N--m)
16
9
1
4
6
15
10
5
12
7
2
11
8
14
14
3
13
4
54 to 66 in--lb
(6.2 to 7.4 N--m)
12
16
13
108 to 132 in--lb
(12.3 to 14.9 N--m)
14
RIGHT
14
FRONT
3
54 to 66 in--lb
2
(6.2 to 7.4 N--m)
Figure 27
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. Clevis pin
12. Flange screw (2 per caliper)
13. Banjo bolt (2 used)
8. Cotter pin
9. Cap screw (2 used)
10. Flange nut (2 used)
11. Flange screw (2 used)
14. Banjo washer (4 used)
15. Socket head screw (4 per rotor)
16. Wheel hub assembly
Chassis
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Disassembly (Fig. 27)
Assembly (Fig. 27)
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
1. Slide brake caliper onto brake rotor. Make sure that
rotor is between brake pads.
2. Align caliper mounting holes with spindle. Secure
caliper with two (2) flange head screws.
WARNING
3. Connect brake line to caliper:
A. Position brake line to caliper.
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
B. Place banjo washer on each side of brake line fit-
ting.
2. Chock wheels not being jacked up. Jack front wheel
off the ground and place appropriate jack stand beneath
the frame to support vehicle.
C. Install banjo bolt through brake line fitting and
banjo washers and then thread into caliper. Torque
banjo bolt from 108 to 132 in--lb (12.3 to 14.9 N--m).
3. Remove front wheel from machine (see Lower
Steering and Front Wheel Removal in this section).
4. Install front wheel assembly (see Lower Steering
and Front Wheel Removal in this section).
4. Disconnect brake line from caliper:
A. Clean hydraulic brake line area of brake caliper to
prevent contamination.
5. Lower machine to ground.
6. Torque wheel lug nuts in a crossing pattern from 80
to 90 ft--lb (109 to 122 N--m).
B. Remove banjo bolt from caliper brake line from
caliper.
7. Bleed brakes (see Bleed Brake System in this sec-
tion).
C. Carefully separate brake line from caliper. Locate
and retrieve two (2) banjo washers from sides of
brake line fitting.
CAUTION
D. Plug brake line and position it away from caliper.
5. Remove two (2) flange head screws that secure the
brake caliper to the spindle.
After servicing brake system components, al-
ways check the brakes in a wide open, level area
that is free of other persons and obstructions.
6. Slide brake caliper from brake rotor and remove cali-
per from machine.
8. Check brake operation.
Workman MDX--D
Page 6 -- 35
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Front Brake Caliper Service
8
White
Lithium
Grease
4
27 to 33 ft--lb
(37 to 44 N--m)
3
7
6
1
5
BAF--12
Assembly
Lube
2
Figure 28
4. Caliper bracket
5. Square seal (2 used)
6. Piston (2 used)
1. Bolt (2 used)
2. Caliper body
3. O--ring (4 used)
7. Brake pad (2 used)
8. Caliper anvil
Chassis
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Disassembly (Fig. 28)
Assembly (Fig. 28)
1. Remove two (2) bolts that secure brake caliper as-
sembly.
1. If caliper body was disassembled, install compon-
ents in caliper body:
2. Remove caliper anvil and then slide brake pads from
pins on caliper bracket.
A. Apply hydraulic brake cylinder assembly lube
(BAF--12 or equivalent) to square seals and piston
before installation.
3. Slide caliper body assembly from caliper bracket.
B. Fit lubricated square seals into grooves of caliper
body. Make sure that seals are not twisted in groove
after installation.
4. If necessary, remove remaining components from
caliper body:
A. Carefully remove pistons from caliper body mak-
ing sure that outer surface of pistons are not dam-
aged during removal.
C. Install lubricated pistons into caliper body bores.
Pistons should slide into bores with light resistance.
D. Lubricate O--rings with white lithium grease and
install into grooves in caliper body.
B. Carefully, remove and discard O--rings and
square seals from caliper body. Make sure that cal-
iper body is not damaged during removal of O--rings
and seals.
E. Slide caliper body assembly onto pins on caliper
bracket.
5. Clean caliper components with brake cleaner.
NOTE: If brake pads are being replaced, it will be nec-
essary to push caliper pistons back into the caliper bore
before installing new pads.
Inspection
1. Check brake pads for uneven wear that would indic-
ate binding in the caliper assembly. Replace the brake
pads if the friction material is worn to less than 1/16” (1.6
mm). Also, if pads are contaminated with grease or oil,
they must be replaced.
2. Slide brake pads onto pins on caliper bracket. Make
sure that friction material on pads is toward brake rotor
position.
3. Fit caliper anvil to assembly and secure caliper com-
ponents with two (2) bolts. Torque bolts from 27 to 33 ft--
lb (37 to 44 N--m).
2. Inspect brake pistons and piston bores in caliper
body for damage or wear. Replace brake pistons or
complete brake caliper assembly if necessary.
3. Check that pins on caliper bracket are not worn or
damaged. Wear on the pins will prevent smooth brake
operation.
Workman MDX--D
Page 6 -- 37
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Brake Master Cylinder
9
8
2
1
7
6
4
3
5
RIGHT
FRONT
Figure 29
1. Brake master cylinder
2. Cap screw (2 used)
3. Brake pedal
4. Clevis pin
5. Cotter pin
6. Flange head nut (2 used)
7. Pedal frame
8. Front brake line
9. Rear brake line
Chassis
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Removal (Fig. 29)
Installation (Fig. 29)
1. Raise front hood to gain access to brake master cyl-
inder.
1. Position master cylinder to pedal frame and secure
with two (2) cap screws and flange nuts.
2. Remove cotter pin from the clevis pin that connects
master cylinder to brake pedal.
2. Remove plugs from brake lines. Install brake lines to
master cylinder.
IMPORTANT: To prevent contamination of the brake
system, make sure to clean components before dis-
assembly.
3. Connect master cylinder to brake pedal with clevis
pin and cotter pin.
4. Bleed brakes (see Bleed Brake System in this sec-
tion).
3. Clean hydraulic brake line area of master cylinder to
prevent contamination. Remove both brake lines from
master cylinder. Cap ends of brake lines and position
them away from master cylinder.
5. Lower and secure front hood.
4. Remove two (2) flange head nuts and cap screws
that secure master cylinder to pedal frame.
CAUTION
5. Remove master cylinder from machine.
After servicing brake system components, al-
ways check the brakes in a wide open, level area
that is free of other persons and obstructions.
6. Check brake operation.
Workman MDX--D
Page 6 -- 39
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Brake Master Cylinder Service
Disassembly (Fig. 30)
1
2
1. Thoroughly clean outside of master cylinder before
disassembly.
12
2. Remove reservoir and flange seal. Push in on the
push rod so the stop pin can be removed.
3
3. Disconnect lower end of the dust cover from the
housing.
4
9
4. Push in on the push rod and remove circlip, then re-
move push rod with dust cover and clevis. Remove re-
tainer washer.
11
5
5. Remove primary piston assembly and secondary
piston assembly from cylinder housing.
10
Inspection
8
7
6
Figure 30
CAUTION
1. Reservoir
2. Flange seal
3. Stop pin
7. Dust cover
8. Push rod
9. Circlip
Use eye protection such as goggles when using
compressed air for master cylinder service.
4. Secondary piston assy
5. Clevis
10. Retainer washer
11. Primary piston assy
12. Cylinder housing
6. Jam nut
1. Clean all metal parts with isopropyl alcohol, then
clean out and dry grooves and passageways with com-
pressed air. Make sure cylinder bore and component
pieces are thoroughly clean.
2. Check cylinder bore, pistons and springs for damage
or excessive wear. Replace brake cylinder assembly if
signs of pitting, scoring or cracks are evident in cylinder
bore.
Assembly (Fig. 30)
1. Apply a film of clean brake fluid to cylinder bore and
piston assemblies.
2. Install secondary piston assembly and primary pis-
ton assembly into cylinder.
3. Install retainer washer.
4. Install push rod and secure in place with circlip.
Install lower end of dust cover to housing.
5. Push in on push rod so stop pin can be installed to
retain secondary piston assembly, then install flange
seal and reservoir.
Chassis
Page 6 -- 40
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Bleed Brake System
IMPORTANT: To prevent contamination of the brake
system, make sure to clean components before dis-
assembly.
3
1. Connect a suitable transparent hose to bleeder valve
on front brake caliper (Fig. 31) or rear wheel brake cylin-
der (Fig. 32). Submerge other end of hose in a glass
container partially filled with clean brake fluid.
1
2. Have a second person pump brake pedal several
times, then hold pedal down firmly.
2
3. With pedal firmly depressed, open bleeder valve of
brake until pedal fades to floor. Close bleeder valve be-
fore releasing pedal.
4. Repeat procedure until a continuous flow of brake
fluid, with no air bubbles, is released from bleeder valve.
Make sure fluid level is maintained in brake fluid res-
ervoir at all times.
Figure 31
1. Front caliper (LH shown)
2. Banjo bolt
3. Bleed valve
5. When brake bleeding is completed, torque caliper
bleed valve as follows:
3
2
A. Torque caliper bleed valve on front brakes from
54 to 66 in--lb (6.2 to 7.4 N--m).
B. Torque caliper bleed valve on rear brakes to 38
in--lb (4.3 N--m).
6. Repeat steps 1 to 4 for other front calipers and rear
brake cylinders.
1
CAUTION
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
Figure 32
1. Rear brake (LH shown)
2. Banjo bolt
3. Bleed valve
7. After bleeding of brakes is completed, test vehicle to
make sure brakes are operating correctly and brake
pedal is solid.
Workman MDX--D
Page 6 -- 41
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Seat Base
31
33
29
28
6
5
30
27
23
12
1
14
22
20
26
7
24
21
32
25
9
17
16
19
8
2
4
15
18
3
10
11
13
12
13
12
Figure 33
1. Seat (2 used)
12. Flange head screw (12 used)
13. Flat washer (8 used)
14. Shift plate
15. Rubber receptacle (2 used)
16. Holding post (2 used)
17. Screw (2 used)
18. Rivet (2 used)
19. Shifter decal
20. Parking brake support
21. Cap screw
22. Curved washer
23. Lock nut
2. Seat bracket (2 used)
3. Cap screw (8 used)
4. Seat base
24. Parking brake lever
25. Equalizer bracket
26. Clevis pin
5. Shift cable (2 used)
6. Shift lever
7. Shift bracket
27. Flat washer
28. Cotter pin
29. Parking brake cover
30. Knob
31. Screw (2 used)
32. Retaining ring (2 used)
33. Flat washer (2 used)
8. Flange screw (1/2” long) (4 used)
9. Flange screw (3/4” long) (4 used)
10. Fuel tank assembly
11. Web strapping
Chassis
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Seat Base Removal (Fig. 33)
4
1. Park machine on a level surface, stop engine, en-
gage parking brake and remove key from the ignition
switch.
2
2. Flip both seats forward and remove them from the
seat base.
1
3. Remove parking brake assembly from seat base
(see Parking Brake in this section).
4. Unscrew knob from the shift lever. Remove four (4)
flange head screws (item 8 in Fig. 33) that secure the
shift plate to the shift bracket (Fig. 34).
3
5. Remove four (4) flange head screws (item 9 in Fig.
33) that secure the shift plate to the seat base (Fig. 34).
Separate shift bracket from the seat base.
Figure 34
1. Shift lever
2. Cap screw (short)
3. Shift plate
4. Cap screw (long)
6. Remove eight (8) flange head screws and flat wash-
ers that secure the seat base to the frame.
IMPORTANT: Make sure shift bracket, shift cables
and fuel tank do not catch on the seat base during
removal.
7. Carefully lift seat base from the machine.
Seat Base Installation (Fig. 33)
IMPORTANT: Make sure shift bracket, shift cables
and fuel tank do not catch on the seat base during
installation.
1. Carefully lower seat base to the vehicle frame.
NOTE: Do not tighten fasteners securing the seat base
to the frame until all of them are installed.
2. Install eight (8) flange head screws and flat washers
through the frame and into the seat base. Tighten
screws from the middle of the vehicle to the outside.
3. Place shift bracket and shift cables through the
opening at the front of the seat base.
4. Position shift plate to shift bracket making sure to
capture cable flange. Secure shift plate to shift bracket
with four (4) flange head screws (item 8 in Fig. 33).
Screw knob onto the shift lever (Fig. 34).
5. Position shift plate with shift bracket to the seat base.
Secure shift plate to seat base with four (4) flange head
screws (item 9 in Fig. 33) (Fig. 34).
6. Install parking brake assembly to seat base (see
Parking Brake in this section).
7. Secure seats to seat base.
Workman MDX--D
Page 6 -- 43
Chassis
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Front Hood
7
32
7 to 13 in--lb
(0.8 to 1.4 N--m)
2
24
23
20
22
28
7 to 13 in--lb
(0.8 to 1.4 N--m)
11
16
15
RIGHT
12
19
27
FRONT
12
14
3
8
9
29
17
25
12
30
26
1
6
21
4
18
5
10
31
Figure 35
13
1. Fender (LH shown)
2. Lock nut (4 used)
3. Flat washer (2 used)
4. Front bumper
5. Headlight (2 used)
6. Washer (3 used per headlight)
7. Hood
8. Fender well (LH shown)
9. Cap screw (2 used)
10. Hood pivot keeper (2 used)
11. Screw (6 used)
12. Washer head screw (8 used)
13. Carriage screw (2 used)
14. Lock nut (2 used)
23. Catch (2 used)
24. Flat washer (4 used)
25. Flange head screw (10 used)
26. Clip (3 used per headlight)
27. Flat washer (2 used)
28. Retainer (2 used)
15. Pivot pin (2 used)
16. Spring pin (2 used)
17. Headlight bracket
18. Flange head screw (2 used)
19. Washer head screw (20 used)
20. Washer head screw (4 used)
21. Flange nut (2 used)
29. Flange nut (2 used)
30. Tinnerman nut (10 used)
31. Headlight bulb (2 used)
32. Foam seal
22. Rubber latch (2 used)
Chassis
Page 6 -- 44
Workman MDX--D
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Removal (Fig. 35)
Installation (Fig. 35)
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition.
NOTE: Do not tighten fasteners securing the hood until
all fasteners are in place.
2. Remove hood using Figure 35 as a guide.
1. Install hood using Figure 35 as a guide. During as-
sembly, use fastener torque specifications that are iden-
tified in Figure 35.
Workman MDX--D
Page 6 -- 45
Chassis
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Cargo Box
190 to 210 in--lb
(21.5 to 23.7 N--m)
13
5
7
1
10
6
9
15
8
18
16
3
4
14
12
12
17
11
190 to 210 in--lb
(21.5 to 23.7 N--m)
2
RIGHT
190 to 210 in--lb
(21.5 to 23.7 N--m)
FRONT
Figure 36
1. Cargo box
7. Pivot bushing (2 used)
8. Screw (4 used)
13. Carriage screw (2 used)
14. Tension spring (2 used)
15. Carriage screw (2 used)
16. Prop rod bracket
2. Handle
3. Latch pin (2 used)
4. Lock nut (2 used)
5. Carriage screw (4 used)
6. Pivot bracket
9. Carriage screw (4 used)
10. Flange nut (4 used)
11. Prop rod
17. Latch assembly
12. Flange nut (6 used)
18. Rear frame
Chassis
Page 6 -- 46
Workman MDX--D
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Removal (Fig. 36)
4
45 to 55 in--lb
(5.1 to 6.2 N--m)
3
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
6
5
2
2. Disassemble cargo box as necessary using Figures
36 and 37 as guides.
11
10
12
Installation (Fig. 36)
1
7
1. Assemble cargo box using Figures 36 and 37 as gui-
des.
6
9
A. When installing cargo box, use torque specifica-
tions identified in Figure 36.
8
B. When installing tailgate latches, use torque spe-
cifications identified in Figure 37.
6
13
C. Adjust latch pin (item 3 in Figure 36) so that cargo
box is tight to frame when latched.
14
15
Figure 37
1. Cargo box
9. Striker mount (2 used)
10. Strike latch (2 used)
11. Screw (4 used)
2. Inner tailgate
3. Outer tailgate
4. RH latch rod
5. Latch handle
6. Screw (24 used)
7. LH latch rod
8. Retainer (2 used)
12. Screw (4 used)
13. RH inside support
14. LH inside support
15. Pop rivet (18 used)
Workman MDX--D
Page 6 -- 47
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This page is intentionally blank.
Chassis
Page 6 -- 48
Workman MDX--D
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Chapter 7
Electrical Drawings
Table of Contents
ELECTRICAL SCHEMATIC . . . . . . . . . . . . . . . . . . . . 3
CIRCUIT DIAGRAMS
Glow Plug Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Start Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Run Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRICAL HARNESS DRAWINGS
Main Electrical Harness . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Electrical Harness . . . . . . . . . . . . . . . . . . . . 10
Workman MDX--D
Page 7 -- 1
Electrical Drawings
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Electrical Drawings
Page 7 -- 2
Workman MDX--D
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Workman MDX--D
Electrical Schematic
Relays are shown as de -energized
Page 7 -- 3
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Glow Plug Circuits
Power Current
Control Current
Indication Current
Page 7 -- 4
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Start Circuits
Power Current
Control Current
Indication Current
Page 7 -- 5
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Run Circuits
Power Current
Control Current
Indication Current
Page 7 -- 6
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Page 7 -- 7
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Workman MDX--D
Main Electrical Harness
Wiring Drawing
Page 7 -- 8
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GRAY
VIOLET
BLACK
YELLOW
BLUE
VIOLET
BLUE
BLUE
BROWN
WHITE
PINK
RED
BLACK
BLACK
PINK
RED
WHITE
BLACK
YELLOW
YELLOW
BLACK
PINK
YELLOW
RED
VIOLET
GREEN
YELLOW
YELLOW
BLACK
YELLOW
BLACK
YELLOW
WHITE
BLUE
RED/BLACK
BLACK
GREEN
YELLOW
YELLOW
BLUE
Workman MDX--D
Main Electrical Harness
Wiring Diagram
Page 7 -- 9
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BLUE
BROWN
WHITE
BLUE
RED
FUSIBLE LINK
BLACK
Workman MDX--D
Engine Electrical Harness
Page 7 -- 10
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