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ManualsBrandsToro ManualsAutomobileAutomobile MDE

Part No. 08164SL (Rev. A)

Service Manual

Workman

MDE

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 MDE.

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.

The Toro Company reserves the right to change product

specifications or this publication without notice.

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.

NOTE: A NOTE will give general information about the

correct operation, maintenance, service, testing or re-

pair of the machine.

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 Th e Toro Company -- 2008, 2011

Summary of content (130 pages)

PAGE 1
Part No. 08164SL (Rev. A) Service Manual WorkmanR MDE 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 MDE. REFER TO THE OPERATOR’S MANUAL FOR OPERATING, MAINTENANCE AND ADJUSTMENT INSTRUCTIONS. For reference, insert a copy of the Operator’s Manual and Parts Catalog for your machine into Chapter 2 of this service manual.
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Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2 Jacking and Other Instructions . . . . . . . . . . . . . . . 1 -- 4 Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 5 Chapter 2 -- Product Records and Maintenance Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Equivalents and Conversions . . . . . . . . . . . . . . . . Torque Specifications . . . . . . . . . . . . .
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Safety Table of Contents SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and Service . . . . . . . . . . . . . . . . . . . . JACKING AND OTHER INSTRUCTIONS . . . . . . . . . Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Towing Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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Safety Instructions The Workman MDE is designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention are partially dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern and proper training of the personnel involved in the operation, transport, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
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1. Before servicing or making adjustments to the vehicle, stop vehicle, turn on/off switch to OFF, engage parking brake and remove key from the on/off switch. 10.Never use an open flame to check level or leakage of battery electrolyte. 3. Do not use open pans of flammable cleaning fluids for cleaning parts. 11. When connecting the battery charger to the vehicle, connect the charger cord to the vehicle charger receptacle before plugging the charger power cord into an outlet.
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Jacking and Other Instructions Jacking 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 on/off switch is OFF and key is removed from the switch before getting off the vehicle.
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Safety and Instruction Decals Workman MDE Page 1 -- 5 Safety There are several safety and instruction decals attached to your Workman vehicle. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed in the Parts Catalog. Order replacement decals from your Authorized Toro Distributor.
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Chapter 2 Product Records and Maintenance PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . Decimal and Millimeter Equivalents . . . . . . . . . . . . U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . Fastener Identification . . . . . . . . . . . . . . . . . . . . . . .
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Equivalents and Conversions 0.
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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 specified in this Service Manual. 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 Service Manual.
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Thread Size # 6 -- 32 UNC 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) in--lb in--lb N--cm 10 + 2 13 + 2 147 + 23 # 6 -- 40 UNF # 8 -- 32 UNC 13 + 2 25 + 5 282 + 30 # 8 -- 36 UNF # 10 -- 24 UNC 18 + 2 30 + 5 339 + 56 # 10 -- 32 UNF SAE Grade 5 Bolts, Screws, Studs & Sems with Regular Height Nuts (SAE J995 Grade 2 or Stronger N
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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 8 or Stronger Nuts) Class 10.9 Bolts, Screws and Studs with Regular Height Nuts (Class 10 or Stronger Nuts) M5 X 0.8 57 + 6 in--lb 644 + 68 N--cm 78 + 8 in--lb 881 + 90 N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 + 14 in--lb 1503 + 158 N--cm M8 X 1.25 19 + 2 ft--lb 26 + 3 N--m 28 + 3 ft--lb 38 + 4 N--m M10 X 1.
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Other Torque Specifications SAE Grade 8 Steel Set Screws Wheel Bolts and Lug Nuts Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb 18 + 3 ft--lb 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb Recommended Torque** 7/16 -- 20 UNF Grade 5 65 + 10 ft--lb 88 + 14 N--m 1/2 -- 20 UNF Grade 5 80 + 10 ft--lb 108 + 14 N--m M12 X 1.25 Class 8.
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Chapter 3 Electrical System GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Opening Battery Circuit . . . . . . . . . . . . . . . . . . . . . . 2 ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . 3 VEHICLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 4 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . .
PAGE 18
General Information The Workman MDE uses a 48 volt DC electrical system that is an isolated circuit. The vehicle frame is not used for any ground connections. LED on the controller and the vehicle status light on the dash panel will flash a fault code to assist in identifying the problem. The vehicle controller monitors operator and vehicle inputs to determine voltage to the traction motor.
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Electrical Diagrams Electrical System The electrical schematic, circuit drawings and wire harness drawings for the Workman MDE are located in Chapter 6 -- Electrical Diagrams.
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Vehicle Operation The Workman MDE electrical system uses a 48 volt battery pack, an electric traction motor, a vehicle controller and numerous other electrical components to allow vehicle operation. Eight, 6 volt, deep cycle batteries that are connected in series provide current for a 48 volt DC, high torque traction motor, the vehicle controller and vehicle accessories (headlights, horn, various optional accessories).
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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 multimeter can test electrical components and circuits for current, resistance or voltage. NOTE: Workman MDE vehicles use a 48 volt, DC electrical system. If multimeter is not of the auto--range type, make sure to properly set multimeter range before performing any voltage test.
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Battery Watering Dispenser Use the battery watering dispenser when adding distilled water to vehicle batteries. Toro Part Number: TOR4102 Figure 6 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte. Obtain hydrometer locally. Figure 7 Battery Lift Strap Use the battery lift strap to remove and install batteries from the vehicle. Lift strap allows use of case loops on battery tops as safe battery lifting points. Obtain battery lift strap locally.
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36/48 Volt Battery Discharge Unit The 36/48 Volt Battery Discharge Unit is recommended for quick and accurate load testing for the batteries on the Workman MDE. This tool is used to determine the capacity of the Workman battery pack and also for finding a faulty battery (or batteries) in the battery pack.
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Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect a battery cable from the battery pack to open the battery circuit unless a test procedure requires battery voltage. For effective troubleshooting and repairs, there must be a good understanding of the electrical circuits and components used on this vehicle (see Electrical Schematic in Chapter 6).
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General Run Problems (Continued) Problem Possible Causes Traction motor stops during operation. Wiring to the traction motor components (e.g. main contactor, controller, traction motor) loose, corroded or damaged (see Electrical Schematic in Chapter 6 -Electrical Diagrams). Battery cables are loose, corroded or damaged. Controller is overheated. Traction motor is overheated. Brake or transaxle problem (see Chapter 4 -- Transaxle and Brakes). Vehicle runs slowly.
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Battery Charger Problems Problem Possible Causes Battery charger does not turn on. AC outlet fuse/circuit breaker blown. AC outlet is faulty. Vehicle wiring is loose or damaged (see electrical schematic in Chapter 6 -- Electrical Diagrams). Fusible link FL1 is faulty. Vehicle charger interlock switch or circuit wiring faulty. Vehicle charger receptacle or circuit wiring damaged. Battery charger is faulty. Battery charger does not turn off. Battery charger is faulty.
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Adjustments Accelerator Switch Adjustment 1. Position vehicle on a level surface, turn on/off switch OFF and remove key. 3 2 1 2. With the accelerator pedal released, check that the distance between the head of the accelerator switch stop cap screw and the body of the switch is 5/8 inch (15.9 mm) (Fig. 12). 6 5 3. If distance is incorrect, loosen lock nut and adjust accelerator switch stop cap screw position (Fig. 11). 5.
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Accelerator Potentiometer Adjustment (Potentiometer with Short Lever) NOTE: The following adjustment procedure should be used on vehicles that have a potentiometer that includes a short lever (Figure 14). If potentiometer has a long lever, use the procedure on the following page. 5. Calibrate accelerator system after any accelerator potentiometer adjustment (see Accelerator System Calibration in this section).
PAGE 29
Accelerator Potentiometer Adjustment (Potentiometer with Long Lever) NOTE: The following adjustment procedure should be used on vehicles that have a potentiometer with a long lever (Figure 15.1). If potentiometer has a short lever, use the procedure on the preceding page. 1 2 The accelerator potentiometer is used as one of the inputs for the vehicle controller and is attached to the pedal frame under the dash (Fig. 15.2).
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This page is intentionally blank. Electrical System Page 3 -- 12.2 Rev.
PAGE 31
Accelerator System Calibration The accelerator system on the Workman MDE includes the accelerator pedal assembly, the accelerator potentiometer, the accelerator switch and the controller. If any of these components are adjusted, removed or replaced, the following calibration procedure should be performed. Additionally, if vehicle movement is erratic, jerky or if the diagnostic light on the dash is flashing six (6) times, calibration of the accelerator system should be performed. 1 4 2.
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Component Testing For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. disconnect the harness wire connectors from the vehicle on/off switch before doing a continuity check on the on/off switch). CAUTION When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected. On/Off Switch The Workman on/off switch is located on the dash panel (Fig. 17).
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Battery Discharge Indicator and Hour Meter Gauge The combination battery discharge indicator and hour meter gauge is located on the dash panel (Fig. 19). 1 The battery indicator identifies state of charge of the battery pack. The battery indicator reads full (10 bars) when the battery pack is fully charged (approximately 51 volts). As battery pack voltage decreases with vehicle use, fewer battery indicator bars are shown. Figure 19 1.
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Vehicle Direction (Forward/Reverse) and Headlight Switches The vehicle direction (forward/reverse) switch (Fig. 21) and headlight switch (Fig. 22) are located on the control panel. These two switches have identical logic. The vehicle direction switch is one of several inputs for the vehicle controller and allows the direction (forward/ reverse) of the vehicle to be changed by the operator. The headlight switch allows the headlights to be turned on and off.
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Vehicle Status Light The vehicle status light is located on the control panel (Fig. 24). During normal operation, the status light should be continuously illuminated. A vehicle electrical problem will be identified by a flashing status light. See Controller (in this section) and your Operator’s Manual for information on a flashing vehicle status light. 1 Figure 24 1. Vehicle status light Testing 1. Make sure on/off switch is turned OFF. Remove key from switch. 1B (--) 2.
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Supervisor Speed Limit Switch The supervisor speed limit switch is open in OFF position (key vertical) and closed in ON position (key rotated clockwise). The speed limit switch is one of several inputs for the vehicle controller and allows the speed of the vehicle to be limited. OFF B&C 45 o ON A&D B&C Test the switch by disconnecting the wiring and connecting a continuity tester across switch terminals A and D (Fig. 26). Rotate key to ON position: there should be an indication of continuity.
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Charger Interlock Switch The charger interlock switch is located behind the charger receptacle plate on the front of the seat base (Fig. 28). When the battery charger is plugged into the charger receptacle, the interlock switch closes and provides an input to the vehicle controller to inhibit vehicle operation. NOTE: The vehicle should not operate if the charger plug is connected to the charger receptacle. 1. Make sure vehicle on/off switch is OFF. Remove key from switch. 1 4 2.
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Main and Accessories Contactors Two contactors (solenoids) are used on the Workman MDE for circuit control. 4 5 1 The main contactor provides current to the vehicle controller and is energized when the on/off switch is ON. The main contactor is located under the controller cover beneath the cargo box (Fig. 30). 2 The accessories contactor provides current to the headlights, horn and optional electrical accessories. The accessories contactor is energized when the on/off switch is ON.
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6. Replace contactor if necessary. 45 to 50 in--lb (5.1 to 5.6 N--m) 7. Connect electrical connections to contactor. If main contactor connections were removed, use Figure 33 as a guide for reattaching cable and wire harness connections. 3 5 4 4 6 8. Connect battery cable that was removed from battery pack. 3 2 7 1 Figure 33 1. 2. 3. 4. Workman MDE Page 3 -- 21 Main contactor Cable to controller B+ Lock nut Flat washer 5. 6. 7. 8.
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Fuses There are three (3) fuses in the Workman electrical system. Two (2) of the fuses are located beneath the steering column (Fig. 34). These fuses supply power to the following: 1 The upper 10 ampere fuse (F2) supplies power to the on/off switch and switched circuits. The lower 10 ampere fuse (F3) supplies power to optional accessories. The third fuse (F1) is located under the controller cover beneath the cargo box (Fig. 35).
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Fusible Links The wiring harness for the Workman includes three (3) fusible links for circuit protection (Fig. 36). 1 The third fusible link (FL3) is attached to the controller B+ terminal. This link provides protection for the charge indicator/hour meter gauge. 2 5 4 If any of these fusible links should fail, the affected circuit will not function. See Chapter 6 -- Electrical Diagrams for schematic and wire harness information. Figure 36 1. Main contactor 2. Main fuse contactor post 3.
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Accelerator Switch The accelerator switch is a four terminal, two circuit switch that is located on the control pedal frame (Fig. 37). The Workman MDE uses only one of the switch circuits (terminals 3 and 4). When the accelerator pedal is depressed, the switch allows a closed circuit (input) for the controller to allow traction motor operation. When the accelerator pedal is released, the switch provides an open circuit (no input) for the controller to prevent traction motor operation.
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Accelerator Potentiometer The accelerator potentiometer is attached to the pedal frame under the dash (Fig. 39). This potentiometer is used as one of the inputs for the vehicle controller to command vehicle speed. The accelerator pedal positions the accelerator potentiometer lever. When the operator presses or releases the accelerator pedal, the potentiometer resistance changes. This resistance change is used by the controller to determine current flow to the traction motor. 1 3 2 Figure 39 1.
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Controller The Workman controller is secured to the rear frame under the controller cover beneath the cargo box (Fig. 40). The controller uses inputs from several vehicle switches (on/off, forward/reverse, accelerator pedal, supervisor, charger interlock, motor temperature, accelerator potentiometer) to accurately control vehicle speed, vehicle direction (forward and reverse) and regenerative braking. An internal thermal sensor prevents overheating of the controller.
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1 Flash System inoperable. Turn on/off switch OFF, wait several seconds and turn on/off switch ON. If controller does not reset correctly, controller replacement may be necessary. 2 Flashes The accelerator pedal was depressed when on/off switch was turned ON. Turn on/off switch OFF, release accelerator pedal and turn on/off switch to ON. System inoperable. Turn on/off switch OFF, wait several seconds and turn on/off switch ON.
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Service and Repairs Battery Service 115 to 125 in--lb (13.0 to 14.1 N--m) 9 115 to 125 in lb (13.0 to 14.1 N--m) 11 5 12 10 4 1 8 6 7 5 4 3 2 RIGHT FRONT Figure 42 1. 2. 3. 4. Battery (8 used) Battery rod (2 used) Negative cable to vehicle Lock washer (2 used per battery) 5. 6. 7. 8. Hex nut (2 used per battery) Cable terminal boot Battery cable (6 used) Positive cable to vehicle The batteries are the heart of the Workman electrical system.
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2. Make sure the battery supports are clean and repainted if necessary. Make sure cables, terminals, rods and hold down retainers are in good condition. WARNING POTENTIAL HAZARD: The battery terminals, metal tools and metal vehicle parts could short together. WHAT CAN HAPPEN: Sparks can cause battery gasses to explode. Damaged cables could short against metal vehicle parts and cause sparks.
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Battery Charging When the vehicle is not in use, it is recommended to keep the batteries charged by connecting the battery charger that is included with the vehicle. The Workman MDE charger is designed to automatically charge the batteries fully without overcharging. Indicator lights (green and red) and an ammeter on the charger give information about the charging operation. Make sure to have the battery cell plates covered with electrolyte before charging the batteries (Fig. 45).
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B. Measure the specific gravity of each cell with a hydrometer. Fill and drain the hydrometer two to four times before drawing a sample. At the same time, take the temperature of the cell. Battery Testing When testing batteries in the Workman MDE, it is important to test all batteries. Proper performance of the vehicle depends on all batteries being in good condition. Testing will determine if one (or more) of the batteries needs to be replaced. C.
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Battery Storage If the vehicle will be stored for any period of time, check battery electrolyte level, adjust level if needed and then connect battery charger to vehicle. Allow charger to remain connected to vehicle during storage to prevent battery discharge and potential battery damage. Electrical System If the vehicle will be stored for more than 30 days and the battery charger cannot be used for some reason, charge the batteries fully. Either store batteries on a shelf or in the vehicle.
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Traction Motor Brushes The traction motor in the Workman MDE uses eight (8) brushes. Traction motor brushes should be inspected every 500 hours of operation or annually. 4 2 3 Inspection 1. Make sure that on/off switch is OFF. Raise and latch cargo box to allow access to traction motor. 2. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of this chapter). 3.
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Traction Motor 14 115 to 125 in lb (13.0 to 14.1 N--m) 15 16 18 3 17 4 5 6 15 7 5 8 9 16 10 19 11 12 13 1 RIGHT FRONT 2 125 to 165 in--lb (14.2 to 18.6 N--m) Figure 50 1. 2. 3. 4. 5. 6. 7. Socket head screw (6 used) Flat washer (6 used) Flange nut Support bracket Carriage screw Transaxle mount plate Rubber damper 8. 9. 10. 11. 12. 13. Traction motor Fan Roll pin (2 used) Washer Socket head screw Plastic cap (fits in rear frame) Removal (Fig. 50) 1.
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4. Disconnect wires from traction motor (Fig. 51): A. While retaining lower nut, remove upper nut and wire connector from motor terminals A1, A2, F1 and F2. B. Unplug motor temperature sensor from vehicle wire harness. Note location of cable tie that secures temperature sensor wires to vehicle. 2. Make sure that rubber damper is installed into the motor shaft internal spline with the damper flat side toward the motor (Fig. 51). 85 to 90 in--lb (9.6 to 10.2 N--m) 55 to 60 in--lb (6.2 to 6.8 N--m) 2 C.
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3. Apply antiseize lubricant or axle grease to the splines of the transaxle and motor shafts. Apply grease to lip of seal in transaxle bore. 3 CAUTION 1 To prevent motor damage and personal injury, make sure that traction motor is well supported as it is installed. Motor weighs approximately 62 pounds (28.1 kg). 4. Carefully lower motor into vehicle. Align motor shaft with transaxle input shaft and slide motor to transaxle. Take care to not damage thermal switch while installing motor. 2 Figure 54 1.
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Electrical System This page is intentionally blank.
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Traction Motor Service 15 14 120 to 140 in--lb (13.6 to 15.8 N--m) 11 13 1 12 3 10 2 5 4 6 7 18 to 22 in--lb (2.0 to 2.5 N--m) 8 9 Figure 56 1. 2. 3. 4. 5. Frame and field assembly Armature Brush lead (2 used) Cap screw (2 used per brush lead) Cap screw (4 used) 6. 7. 8. 9. 10. Cap screw (8 used) Brush (8 used) High temperature sensor Headband Bolt (4 used) Disassembly (Fig. 56) 1. Unlatch and slide headband from traction motor. 4.
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1. Check the brush springs for correct alignment on the back of the brush. A brush spring that does not apply equal pressure on the center of the brush will cause the brush to wear unevenly. Check for correct clearance and freedom of brush movement in the holder. 2. Replace brushes that are worn to a length of 0.620” (16 mm). Also, replace brushes if they show signs of uneven wear or show signs of overheating, such as discolored brush shunts and brush springs. 3.
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Commutator Service MICA 1. Chuck armature on the commutator end--bearing journal and support the drive end of armature using the ”live” center of the shaft. With the armature supported on both ends, measure the commutator runout and the bar to bar differences with a dial gauge. Total indicated runout should not exceed 0.003” (0.08 mm) and not more than 0.0005” (0.013 mm) between any two bars. If the readings fall outside this limit, the commutator must be turned and re--undercut. COPPER SEGMENT 0.
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Assembly (Fig. 56) PRESS FIXTURE MUST HOLD INNER RACE STATIONARY END HEAD MUST BE HELD STATIONARY Figure 61 1 2 2. Press a new bearing into the commutator end head, pressing on the bearing outer race only (Fig. 61). Secure bearing with retaining ring. 4. Ensure the brushes are pushed out of the way. BEARING AND RETAINING RING INSTALLED IN END HEAD BEARING 1. After servicing the commutator and brushes, re--assemble the wiring in the commutator end head as originally found.
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Battery Charger 1 2 12 3 11 10 4 9 5 8 7 6 Figure 64 1. 2. 3. 4. Upper case Transformer Lower case SCR assembly 5. 6. 7. 8. Control board Relay Circuit breaker AC cordset 9. 10. 11. 12. DC cordset Ammeter Fuse Diode assembly For service of the battery charger, see the Lester Electrical Technician Service Guide at the end of this chapter.
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Chapter 4 Transaxle and Brakes Table of Contents Workman MDE Page 4 -- 1 Transaxle and Brakes GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 4 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 SERVICE AND REPAIRS . . . . . . . . . . . . . . .
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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 MDE vehicle. Refer to the Operator’s Manual for additional information when servicing the machine.
PAGE 63
Specifications Item Description Transaxle Transaxle Fluid Capacity Transaxle Fluid 2 quarts (1.
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Troubleshooting Brakes Problem Possible Cause Brake pedal goes to the floor. Rear brake shoes are excessively worn. Front brake pads are excessively worn. Brake fluid level low. Brake fluid leak at hose, caliper or wheel cylinder. Brake master cylinder faulty. Brake pedal is spongy. Rear brake drums are excessively worn or damaged. Rear brake shoes are not burnished. Air in brake lines. Brakes pull to either side. Tire pressure is incorrect or uneven between tires. Brake linings are contaminated.
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Brakes (continued) Problem Possible Cause Brakes drag. Parking brake is applied. Rear shoe--to--shoe springs are weak or broken. Brake pedal is binding. Brake linings are saturated. Rear brake drums are bent or out--of--round. Front brake calipers or rotors are damaged. Brake pedal is hard to push. Incorrect brake lining material. Brake pedal linkage is binding. Wheels lock--up when braking. Brake linings are contaminated, worn or damaged. Rear brake shoe--to--shoe springs are weak.
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Service and Repairs Rear Wheels and Brakes 12 2 125 to 140 ft--lb (170 to 190 N--m) 3 6 1 7 13 14 45 to 65 ft--lb (61 to 88 N--m) v 26 to 30 ft--lb (34 to 41 N--m) 4 5 8 15 11 RIGHT FRONT 10 9 Figure 1 1. 2. 3. 4. 5. Lock nut (4 used per side) Cotter pin Brake assembly (LH shown) Socket head screw (4 used per side) Wheel stud (5 used per side) Transaxle and Brakes 6. 7. 8. 9. 10. Wheel hub Flange nut Parking brake cable Retaining ring Cotter pin Page 4 -- 6 11. 12. 13. 14. 15.
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B. Position and secure hydraulic brake line to wheel cylinder (Fig. 3). Torque banjo bolt from 15 to 21 ft-lb (21 to 28 N--m). Removal (Fig. 1) 1. Park vehicle on a level surface, turn on/off switch OFF and remove key from the on/off switch. WARNING Before jacking up the vehicle, review and follow Jacking Instructions in Operator’s Manual and Chapter 1 -- Safety. 2. Chock wheels not being jacked up.
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5. Position wheel assembly to the vehicle with valve stem facing out and secure with five (5) lug nuts. Burnish Brake Shoes 6. Lower vehicle to ground. Torque lug nuts in a crossing pattern from 45 to 65 ft--lb (61 to 88 N--m). To provide maximum brake performance after rear brake shoes are replaced, burnish new brake shoe linings. 7. Bleed brakes (see Bleed Brake System in this section). IMPORTANT:To prevent brake overheating, do not drive vehicle with the brakes applied.
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Transaxle and Brakes This page is intentionally blank.
PAGE 70
Rear Brake Service 110 to 120 in--lb (12.4 to 13.6 N--m) 6 110 to 120 in--lb (12.4 to 13.6 N--m) 3 8 2 9 11 10 7 11 5 12 10 1 13 7 8 4 110 to 120 in--lb (12.4 to 13.6 N--m) 3 12 Figure 4 1. 2. 3. 4. 5. Brake backing plate Washer head screw Brake shoe Lower spring Wheel cylinder 6. 7. 8. 9. Parking brake lever (LH shown) Belleville washer Adjuster lever Dust cover 10. 11. 12. 13. Flat washer Bolt Shoe hold down cup and spring Upper spring 4.
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Inspection (Fig. 4) Assembly (Fig. 4) 1. Inspect brake drums. IMPORTANT:Brake shoe lining surfaces must be free of grease, oil and other foreign matter. A. Clean drums with denatured alcohol. Check braking surface diameter in at least three places. If the diameter exceeds 6.320” (160.5 mm), replace both brake drums. B. Replace drums that are cracked, deeply grooved, tapered, significantly out--of--round, scored, heat spotted or excessively rusted. C. Minor scoring can be removed with sandpaper. 2.
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Hydraulic Brake System 14 13 35 34 33 36 7 4 12 24 19 2 5 11 21 10 26 18 6 17 16 11 9 32 20 8 15 23 27 25 32 32 22 31 30 28 Loctite #242 29 3 37 RIGHT 1 FRONT Figure 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Brake caliper (LH) Brake caliper (RH) Brake rotor (2 used) Front brake tube Front brake hose Carriage screw Rear brake tube Carriage screw Rear brake hose bracket Cap screw Thread forming screw (6 used) Clip Tee fitting 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
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Bleed Brake System 1. Connect a suitable transparent hose to bleeder valve on a wheel cylinder or caliper. Submerge other end of hose in a glass container partially filled with clean brake fluid. 5. Repeat steps 1 to 4 for other brake cylinders and calipers. CAUTION 2. Have a second person pump brake pedal several times, then hold pedal down firmly. 3. With pedal firmly depressed, open bleeder valve until pedal fades to floor. Close bleeder valve before releasing pedal. 6.
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Front Brake Calipers 10 2 To rear brakes 9 8 7 Loctite #242 13 45 to 65 ft--lb (61 to 88 N--m) 6 3 5 4 RIGHT 1 12 FRONT 11 Figure 6 1. 2. 3. 4. 5. LH brake caliper RH brake caliper Lock washer (2 per caliper used) Cap screw (2 per caliper used) Wheel hub assembly Transaxle and Brakes 6. 7. 8. 9. Brake rotor Socket head screw (4 per rotor used) Spindle (LH shown) A--arm (LH shown) Page 4 -- 14 10. 11. 12. 13.
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Removal (Fig. 6) Installation (Fig. 6) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 1. If brake pads were removed from caliper, install pads (Fig. 7): A. If brake pads are being replaced, it will be necessary to push caliper pistons back into the caliper bore before installing new pads. Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 -- Safety. B. Slide brake pads into caliper.
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Brake Master Cylinder 1 4 2 5 3 6 7 RIGHT FRONT Figure 8 1. Master cylinder 2. Cap screw 3. Brake pedal 4. Clevis pin 5. Cotter pin 6. Flange head nut 7. Pedal frame Removal (Fig. 8) Installation (Fig. 8) 1. Raise and support front hood. 1. Position master cylinder to pedal frame and secure with cap screws and flange nuts. 2. Remove cotter pin from the clevis pin that connects master cylinder to brake pedal. 3. Clean hydraulic brake line area of master cylinder to prevent contamination.
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Brake Master Cylinder Service Disassembly (Fig. 9) 1 1. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 2 12 3 2. Disconnect lower end of the dust cover from the housing. 3. Push in on the push rod and remove circlip, then remove push rod with dust cover and clevis. Remove retainer washer. 4 11 4. Remove primary piston assembly and secondary piston assembly from cylinder housing. Inspection 2.
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Parking Brake 11 10 8 2 1 9 7 6 17 16 5 14 4 12 3 15 13 RIGHT FRONT Figure 10 1. 2. 3. 4. 5. 6. Parking brake cover Operator seat Seat base Cable equalizer bracket Parking brake lever Curved washer Transaxle and Brakes 7. 8. 9. 10. 11. 12. Lock nut Flat washer Flange head screw (4 used) Flat washer (2 used) Screw (2 used) Cap screw Page 4 -- 18 13. 14. 15. 16. 17.
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Disassembly (Fig. 10) Assembly (Fig. 10) 1. Park machine on a level surface, stop engine and remove key from the ignition switch. Chock wheels to prevent the machine from moving. 1. Secure brake cables to parking brake support and cable equalizer bracket using Figure 10 as a guide. 2. Disconnect both parking brake cables from rear of machine: 2. Route brake cables through seat base opening taking care to not damage cables. Position parking brake support to seat base. A.
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Transaxle 23 115 to 125 in--lb (13.0 to 14.1 N--m) 2 3 4 5 3 6 7 8 22 9 10 11 20 16 15 14 1 45 to 65 ft--lb (61 to 88 N--m) 2 19 21 13 18 12 RIGHT 17 FRONT v 24 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. Socket head screw (6 used) Flange nut Carriage screw (5 used) Support bracket Transaxle mount plate Rubber damper Traction motor Fan Transaxle and Brakes 9. 10. 11. 12. 13. 14. 15. 16.
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Removal (Fig. 11) 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from switch. 2. Remove cargo box from vehicle (see Cargo Box Removal in Service and Repairs section of Chapter 5 -Chassis). 3. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 -- Electrical System). 8. Clean hydraulic brake line area of rear brake cylinders to prevent contamination.
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Installation (Fig. 11) 1. If removed, install traction motor to transaxle (see Traction Motor Installation in Service and Repairs section of Chapter 3 -- Electrical System). 2. Position transaxle and motor assembly to the rear frame. Loosely install all fasteners used to secure transaxle to vehicle. Tighten fasteners in the following order: A. Tighten four (4) flange head screws and flange nuts that secure transaxle to the rear frame. 8. Carefully connect removed battery cable to battery terminals.
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Transaxle Service 37 22 3 38 1 35 31 30 27 8 11 25 5 32 26 36 14 33 32 9 10 5 11 13 4 15 19 125 to 140 ft--lb (170 to 190 N--m) 6 23 13 29 12 6 28 24 20 2 30 15 26 18 26 to 30 ft--lb (34 to 41 N--m) 16 19 17 7 16 to 24 ft--lb (22 to 33 N--m) 21 25 2 34 33 32 29 32 39 31 36 14 8 20 to 30 ft--lb (27 to 41 N--m) Figure 16 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
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Chapter 5 Chassis Table of Contents Chassis GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 1 Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3 Suspension and Steering . . . . . . . . . . . . . . . . . . . . . 3 ADJUSTMENTS . . . . . . . . . . . . . . . .
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Specifications Item Description Front tire (22 x 9.5 -- 10, 4 ply) pressure 8 to 22 PSI (55 to 152 kPa) Rear tire (22 x 9.5 -- 10, 4 ply) pressure 8 to 22 PSI (55 to 152 kPa) Wheel lug nut torque (front and rear) 45 to 65 ft--lb (61 to 88 N--m) Brake Fluid DOT 3 Special Tools Order special tools from your Toro Distributor. Spanner Wrench Use spanner wrench to rotate front shock absorber collar which changes the length of the shock spring to affect front wheel camber.
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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 end components are loose or worn. Steering gearbox is damaged or worn. Rear end is noisy. Rear wheel lug nuts are loose. Transaxle problem (see Chapter 4 -- Transaxle and Brakes). Excessive steering play. 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.
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Suspension and Steering (continued) Problem Possible Cause Steering is hard. Tire pressure is low or uneven between tires. Front wheel alignment (toe--in) is incorrect. Steering linkage is binding or damaged. Steering gearbox is damaged or worn. 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 is bent or damaged.
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Adjustments 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 average operator who will run the machine or have an operator 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.
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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 camber. 1 2. Either add weight to the driver’s seat equal to the average operator who will run the machine or have an operator on the vehicle operator’s seat.
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Service and Repairs Check Tire Pressure The tire pressure range for front and rear tires is 8 to 22 PSI (55 to 152 kPa). The tire pressure needed is determined by the payload carried. Higher pressures should be used for heavier payloads at higher speeds. Do not exceed the maximum tire pressure. Lower air pressure will provide less compaction, a smoother ride and fewer tire marks. Lower pressure should not be used for heavy payloads at higher speeds.
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Upper Steering 18 to 22 ft--lb (25 to 29 N--m) RIGHT 1 2 16 FRONT 11 175 to 225 in lb (20 to 25 N--m) 3 Antiseize lubricant 13 10 12 10 15 5 14 8 7 9 Loctite #242 4 7 6 Antiseize lubricant Figure 1 1. 2. 3. 4. 5. 6. Hex nut Flat washer Steering wheel Flange nut (4 used) Steering box assembly Cap screw 7. 8. 9. 10. 11. Lock washer (6 used) Steering shaft Cap screw (4 used) Bearing (2 used) Carriage bolt (4 used) Disassembly (Fig. 1) 1.
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6. Remove dust cover (item 13) from the steering shaft. Replace cover if damaged. Slide steering shaft out of the steering column. 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. Assembly (Fig. 1) 1.
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Steering Gearbox 27 to 33 ft--lb (37 to 44 N--m) 9 90 to 110 in--lb (10.2 to 12.4 N--m) 8 3 6 2 18 17 15 10 16 7 14 1 6 11 175 to 225 in--lb (20 to 25 N--m) 10 5 12 4 13 19 Matchmark before disassembly Figure 2 1. 2. 3. 4. 5. 6. 7. Gasket Hex washer head screw (3 used) Seal Sector gear Flat washer Ball bearing Output shaft spacer Chassis 8. 9. 10. 11. 12. 13.
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IMPORTANT:Do not reuse flange head screw with patch lock after it has been removed. 1. Remove flange head screw with patch lock (item 9) and stepped washer (item 8) from Pitman arm. Discard flange head screw. 2. Remove flange head screw with patch lock (item 13) and flat washer (item 12) from pinion gear shaft. Discard flange head screw. 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.
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Lower Steering and Front Wheels 20 to 25 ft--lb (28 to 33 N--m) 12 3 4 14 7 6 1 19 2 8 31 6 30 5 6 See text for tightening procedure 9 32 10 25 24 29 45 to 55 ft--lb (62 to 74 N--m) 7 11 13 15 17 16 22 28 21 27 23 26 Loctite #242 20 RIGHT FRONT 45 to 65 ft--lb (62 to 88 N--m) 18 Figure 3 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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Removal (Fig. 3) 6 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition. 4 5 3 7 WARNING 2 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. 3. Remove lug nuts and pull wheel assembly from machine. 4. Remove brake caliper from spindle (see Front Brake Caliper in this section).
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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). 2. Install tie rod: A. Position tie rod assembly to spindle and pitman arm so that tie rod groove (LH threads) is orientated toward the left side of the machine (Fig. 6). B. Insert tie rod ball joints down through the spindle and up through the Pitman arm. Secure with castle nuts. C.
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Front Shock Absorbers Shock Removal (Fig. 9) IMPORTANT: Any adjustment to the shock spring preload will affect the front wheel camber (see Adjust Front Wheel Camber in the Adjustments section 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 2 2. Chock wheels not being jacked up.
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A--arms and Front Suspension 20 to 25 ft--lb (28 to 33 N--m) 12 3 4 14 7 6 1 19 8 31 2 6 7 29 See text for tightening procedure 6 36 34 35 9 10 25 24 30 45 to 55 ft--lb (62 to 74 N--m) 5 11 13 15 17 16 32 28 33 27 26 22 37 21 23 20 Loctite #242 RIGHT FRONT 75 to 100 ft--lb (102 to 135 N--m) 45 to 65 ft--lb (62 to 88 N--m) 18 Figure 7 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
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A--arm Removal (Fig. 7) 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 -- Safety. 2. Chock wheels not being jacked up. Jack front wheel off the ground and support vehicle with appropriate jack stand beneath the frame. 3. Remove front wheel and spindle from A--arm (see Lower Steering and Front Wheel Removal in this section). 4.
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Frame Pivot Yoke RIGHT 21 4 FRONT 15 1 10 18 3 17 22 11 20 13 16 240 to 290 ft--lb (326 to 393 N--m) 12 7 6 14 19 19 8 2 6 5 7 6 9 Figure 9 1. 2. 3. 4. 5. 6. 7. 8. Flange nut (4 used) Shock absorber (2 used) Cap screw (4 used) Plug Flat washer Lock nut (4 used per side) Cap screw (2 used per shock) LH A--arm Chassis 9. 10. 11. 12. 13. 14. 15. Grease fitting (1 used per arm) Screw Cap screw RH A--arm Lock washer Front frame Pivot yoke Page 5 -- 16 16. 17. 18. 19. 20. 21. 22.
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Pivot Yoke Installation (Fig. 9 and 10) Pivot Yoke Removal (Fig. 9 and 10) 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. WARNING 2. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 -- Electrical System). Support pivot yoke while installing it to the front frame to prevent dropping and causing serious injury and damage to the machine.
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Seat Base 24 RIGHT 36 35 23 26 25 27 28 FRONT 29 30 19 31 33 32 34 18 17 16 20 1 15 14 2 13 12 3 5 22 21 4 7 6 8 9 10 10 11 Figure 11 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Seat Seat bracket Rubber receptacle Rivet Cap screw (4 used per seat) Screw Holding post Seat base Seat base tray Flange head screw (8 used) Flat washer (4 used) Front frame Chassis 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
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Removal (Fig. 11) 1 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. 2. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 -- Electrical System). 2 A 3. Remove seats from seat base. 4. Remove four (4) screws (item 12) that secure receptacle plate to front of seat base.
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Front Hood 32 7 7 to 13 in--lb (0.8 to 1.4 N--m) 2 24 23 20 28 22 7 to 13 in--lb (0.8 to 1.4 N--m) 11 16 15 12 19 27 12 14 3 8 29 17 9 25 12 RIGHT 30 1 26 18 4 FRONT 6 21 5 10 31 13 Figure 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Fender (LH shown) Lock nut (4 used) Flat washer (2 used) Front bumper Headlight (2 used) Washer (3 used per headlight) Hood Fender well (LH shown) Cap screw (2 used) Hood pivot keeper (2 used) Screw (6 used) Chassis 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
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Removal (Fig. 13) 1 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. 2. Open the battery circuit by carefully removing one of the battery cables (see Opening Battery Circuit in the General Information section of Chapter 3 -- Electrical System). 2 A 3. Remove hood using Figure 13 as a guide. Installation (Fig. 13) 4 NOTE: Do not tighten fasteners securing the hood until all fasteners are in place. Figure 14 1.
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Cargo Box (Serial Number Below 311000000) 35 to 55 in--lb (4 to 6.2 N--m) 3 2 5 6 4 7 8 10 9 1 11 12 13 17 14 35 to 55 in--lb (4 to 6.2 N--m) 15 15 16 100 to 200 in--lb (11.3 to 22.6 N--m) 33 32 31 18 30 19 20 21 22 29 23 RIGHT 24 26 28 FRONT 25 27 Figure 18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.
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Removal (Fig. 18) Installation (Fig. 18) 1. Park vehicle on a level surface, turn on/off switch OFF, set parking brake and remove key from the on/off switch. 1. Assemble cargo box using Figure 18 as a guide. 2. Remove two (2) flange head screws (item 21) that secure RH and LH pivot brackets (items 20 and 30) to the rear frame. 2. Position cargo box to the frame locking the latch rod (item 33) to the latch pins (item 26). 3.
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Cargo Box (Serial Number Above 311000000) 15 5 9 1 14 2 12 17 11 200 to 210 in--lb (22.6 to 23.7 N--m) 16 200 to 210 in--lb (22.6 to 23.7 N--m) 12 6 7 10 8 RIGHT FRONT 3 13 200 to 210 in--lb (22.6 to 23.7 N--m) 4 Figure 19 1. 2. 3. 4. 5. 6. Cargo box Handle Carriage screw (2 used) Lock nut (2 used) Carriage screw (4 used) Pivot bracket Chassis 7. 8. 9. 10. 11. 12.
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Removal (Fig. 19) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 4 3 2. Disassemble cargo box as necessary using Figures 19 and 20 as guides. 6 5 2 12 Installation (Fig. 19) 1 1. Assemble cargo box using Figures 19 and 20 as guides. 9 11 10 7 6 A. When installing cargo box, use torque specifications identified in Figure 19. B. Adjust latch pin (item 13 in Figure 19) so that cargo box is tight to frame when latched.
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Chapter 6 Electrical Diagrams Table of Contents Electrical Diagrams ELECTRICAL SCHEMATIC Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 3 ELECTRICAL CIRCUIT DRAWINGS On/Off Switch Turned On . . . . . . . . . . . . . . . . . . . . . 4 Run Circuit (Forward) . . . . . . . . . . . . . . . . . . . . . . . . 5 Battery Charging Circuit . . . . . . . . . . . . . . . . . . . . . . 6 ELECTRICAL HARNESS DRAWINGS Electrical Harness Drawing (Serial Number Below 310000000) . . . . . . . . . . .
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F3 IGNITION--SWITCH OFF RUN FUSE HOLDERS F2 W 10 A R ACCESSORIES CONTACTOR (SOLENOID) HORN BK HORN SWITCH 10 A PK BU OR BATT. CHG.
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F3 BU IGNITION--SWITCH OFF RUN FUSE HOLDERS F2 W 10 A R ACCESSORIES CONTACTOR (SOLENOID) (ENERGIZED) HORN (IN RUN) BK HORN SWITCH 10 A PK OR BATT. CHG.
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F3 IGNITION--SWITCH OFF RUN FUSE HOLDERS F2 (IN RUN) BK HORN SWITCH 10 A R ACCESSORIES CONTACTOR (SOLENOID) (ENERGIZED) HORN W 10 A PK BU OR BATT. CHG.
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Workman MDE Serial Number Below 310000000 Electrical Harness Drawing Page 6 -- 8 Rev.
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ORANGE ORANGE FUSIBLE LINK RED ORANGE WHITE RED/WHITE BLACK FUSIBLE LINK RED RED ORANGE PINK WHITE RED/WHITE BLUE BLACK BLUE BLUE/WHITE BLACK BLACK BLACK BROWN WHITE/BLACK BLUE/WHITE ORANGE YELLOW PINK BLACK BLUE YELLOW VIOLET/BLACK BLACK BLUE/WHITE WHITE BROWN BLACK BLACK GREEN BLACK TAN TAN TAN GRAY BLACK BLACK BLUE RED/WHITE BLACK YELLOW/BLACK BLACK RED BLACK YELLOW BLACK GREEN BLACK ORANGE BLUE ORANGE FUSIBLE LINK BLUE ORANGE RED/BLACK BLUE BLUE Workman
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Workman MDE Serial Number Above 310000000 Electrical Harness Drawing Page 6 -- 10 Rev.
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ORANGE BLACK FUSIBLE LINK RED/WHITE ORANGE WHITE RED RED ORANGE PINK FUSIBLE LINK RED ORANGE RED/WHITE WHITE BLUE BLACK BLUE/WHITE BLUE BLACK BLACK BLACK BROWN WHITE/BLACK BLUE/WHITE BLACK YELLOW BLUE PINK ORANGE PINK BLUE YELLOW VIOLET/BLACK BLACK BLUE/WHITE WHITE BROWN BLACK TAN BLACK TAN BLACK GREEN TAN GRAY BLACK BLACK BLUE RED/WHITE YELLOW/BLACK BLACK RED BLACK GREEN BLACK ORANGE BLUE ORANGE YELLOW BLUE ORANGE BLACK BLUE FUSIBLE LINK BLUE RED/BLACK BLA
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F3 BU IGNITION--SWITCH OFF RUN FUSE HOLDERS F2 (OFF) BK HORN SWITCH 10 A R ACCESSORIES CONTACTOR (SOLENOID) (NOT ENERGIZED) HORN W 10 A PK OR BATT. CHG.
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Workman MDE Serial Number Below 310000000 Electrical Harness Drawing Page 6 -- 8 Rev.
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ORANGE ORANGE FUSIBLE LINK RED ORANGE WHITE RED/WHITE BLACK FUSIBLE LINK RED RED ORANGE PINK WHITE RED/WHITE BLUE BLACK BLUE BLUE/WHITE BLACK BLACK BLACK BROWN WHITE/BLACK BLUE/WHITE ORANGE YELLOW PINK BLACK BLUE YELLOW VIOLET/BLACK BLACK BLUE/WHITE WHITE BROWN BLACK BLACK GREEN BLACK TAN TAN TAN GRAY BLACK BLACK BLUE RED/WHITE BLACK YELLOW/BLACK BLACK RED BLACK YELLOW BLACK GREEN BLACK ORANGE BLUE ORANGE FUSIBLE LINK BLUE ORANGE RED/BLACK BLUE BLUE Workman
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Workman MDE Serial Number Above 310000000 Electrical Harness Drawing Page 6 -- 10 Rev.
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ORANGE BLACK FUSIBLE LINK RED/WHITE ORANGE WHITE RED RED ORANGE PINK FUSIBLE LINK RED ORANGE RED/WHITE WHITE BLUE BLACK BLUE/WHITE BLUE BLACK BLACK BLACK BROWN WHITE/BLACK BLUE/WHITE BLACK YELLOW BLUE PINK ORANGE PINK BLUE YELLOW VIOLET/BLACK BLACK BLUE/WHITE WHITE BROWN BLACK TAN BLACK TAN BLACK GREEN TAN GRAY BLACK BLACK BLUE RED/WHITE YELLOW/BLACK BLACK RED BLACK GREEN BLACK ORANGE BLUE ORANGE YELLOW BLUE ORANGE BLACK BLUE FUSIBLE LINK BLUE RED/BLACK BLA
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