Toro 08160SL User Manual
Part No. 08160SL (Rev. A)
Service Manual
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 MD and Workman MDX.
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. Additional copies
of the Operator’s Manual and Parts Catalog are available on the internet at www.Toro.com.
The Toro Company reserves the right to change product
specifications or this publication without notice.
Workman
This safety symbol means DANGER, WARNING,
or CAUTION, PERSONAL SAFETY INSTRUCTION. 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 repair of the machine.
IMPORTANT: The IMPORTANT notice will give im portant instructions which must be followed to prevent damage to systems or components on the
machine.
MD&MDX
R
E The Toro Company -- 2008, 2011
This page is intentionally blank.
Workman MD/MDX
Table Of Contents
Chapter 1 -- Safety
Safety Instructions 1 -- 2..........................
Jacking and Other Instructions 1 -- 4...............
Safety and Instruction Decals 1 -- 6................
Chapter 2 -- Product Records and Maintenance
Product Records 2 -- 1...........................
Maintenance 2 -- 1...............................
Equivalents and Conversions 2 -- 2................
Torque Specifications 2 -- 3.......................
Chapter 3 -- Briggs & Stratton Gasoline Engine
General Information 3 -- 2........................
Specifications 3 -- 3..............................
Adjustments 3 -- 4...............................
Service and Repairs 3 -- 5........................
Briggs and Stratton Repair Manual for 4--Cycle, V--Twin
Cylinder, OHV Head Engines
Chapter 4 -- Single Cylinder Gasoline Engine
General Information 4 -- 2........................
Specifications 4 -- 3..............................
Adjustments 4 -- 4...............................
Service and Repairs 4 -- 5........................
Kohler Service Manual for COMMAND PRO CS Series
Engines
Chapter 5 -- Drive Train
General Information 5 -- 1........................
Specifications 5 -- 2..............................
Drive Train Operation 5 -- 3.......................
Special Tools 5 -- 6..............................
Adjustments 5 -- 7...............................
Service and Repairs 5 -- 10.......................
Chapter 6 -- Electrical System
General Information 6 -- 2........................
Electrical Schematics 6 -- 2.......................
Special Tools 6 -- 3..............................
Troubleshooting 6 -- 5............................
Electrical System Quick Checks 6 -- 7..............
Component Testing 6 -- 8.........................
Service and Repairs 6 -- 18.......................
Chapter 7 -- Chassis
General Information 7 -- 1........................
Specifications 7 -- 2..............................
Special Tools 7 -- 2..............................
Troubleshooting 7 -- 3............................
Adjustments 7 -- 6...............................
Service and Repairs 7 -- 9........................
Chapter 8 -- Electrical Drawings
Electrical Schematics 8 -- 3.......................
Circuit Diagrams 8 -- 5...........................
Electrical Harness Drawings 8 -- 7.................
SafetyProduct Records
Briggs & Stratton
Single Cylinder
Drive TrainElectrical
and Maintenance
Gasoline Engine
Gasoline Engine
Workman MD/MDX
Rev. A
Chassis
Electrical
System
Drawings
This page is intentionally blank.
Workman MD/MDX
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..........
Chapter 1
Safety
Safety
Workman MD/MDX Page 1 -- 1 Safety
Safety Instructions
The Workman MD and MDX series vehicles are designed and tested to offer safe service when operated
and maintained properly. Although hazard control and
accident prevention partially are 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.
Read and understand the contents of the Operator’s
Manual before starting and operating the machine. Become 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.
Supervisor’s Responsibilities
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 instruction may result in personal injury.
WARNING
To reduce the potential for injury or death, comply
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.
1. Make sure operators are thoroughly trained and familiar with the Operator’s Manual and all labels on the
vehicle.
Before Operating
1. Read and understand the contents of the Operator’s
Manual and Operator’s DVD before starting and operating the vehicle. Become familiar with the controls and
know how to stop the vehicle and engine quickly. Additional copies of the Operator’s Manual are available on
the internet at www.Toro.com.
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 vehicle. Also, tighten any loose nuts, bolts or screws to ensure vehicle is in safe operating condition.
2. Be sure to establish your own special procedures
and work rules for unusual operating conditions (e.g.
slopes too steep for vehicle operation).
3. Since fuel used in Workman vehicles is highly 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.
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.
Workman MD/MDXPage 1 -- 2Safety
While Operating
1. Sit on the operator seat when starting and operating
the vehicle.
2. Before starting the engine:
A. Sit on operator’s seat and apply the parking
brake.
B. Turn ignition key to ON.
C. Depress accelerator pedal to startengine and engage drive system.
3. Do not run engine in a confined area without adequate ventilation. Exhaust fumes are hazardous and
could possibly be deadly.
Maintenance and Service
1. Before servicing or making adjustments, turn all accessories off, release pressure from accelerator pedal,
allow engine to stop, set parking brake and remove key
from the ignition switch.
2. Make sure vehicle is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Never store the vehicle or fuel container inside
where thereis an openflame, such as near a waterheater or furnace.
4. If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
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 bystanders away.
7. Do not overspeed the engine by changing governor
setting. Toassure safety and accuracy, check maximum
engine speed.
4. Do not touch engine, muffler or exhaust pipe while
engine isrunning or soon after itis stopped. These areas
could be hot enough to cause burns.
Safety
5. Before getting off the seat:
A. Stop movement of the vehicle.
B. Turn ignition key to OFF and wait for all movement to stop.
C. Remove key from ignition switch.
D. Apply parking brake.
E. Do not park on slopesunless wheels are chocked
or blocked.
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.
11. Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
12.To assure optimum performance and continued
safety of the vehicle, use genuine Toro replacement
parts and accessories. Replacement parts and accessories made by other manufacturers may result in nonconformance with safety standards, and the warranty
may be voided.
13.When raising the vehicle to change tires or to perform other service, use correct blocks, hoists and jacks.
Make sure vehicle isparked 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 result in personal injury (see Jacking Instructions in this
section).
8. Shut engine off before checking or adding oil to the
engine crankcase.
9. Disconnect battery before servicing the vehicle. Disconnect negative (--) battery cable first and positive (+)
cable last. If battery voltage is required for troubleshooting or test procedures, temporarily connect the battery.
Reconnect positive (+) cable first and negative (--) cable
last.
Workman MD/MDX Page 1 -- 3 Safety
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.
• 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.
• 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.
1
Figure 1
1. Front frame 2. Towing tongue
2
2
1
Jacking Locations
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 information.
Tow Vehicle
IMPORTANT: Frequent or long distance towing of
the Workman is not recommended.
In case of emergency, the vehicle can be towed for a
short distance. Refer to Operator’s Manual for towing
information.
Figure 2
1. Transaxle case 2. Axle tube
IMPORTANT: If vehicle is towed, make sure that
ignition switch is in the OFF position and key is removed from switch.
Workman MD/MDXPage 1 -- 4Safety
Transaxle Neutral Position
When performing routine maintenance and/or engine
testing, the transaxle must be shifted into the neutral
position.
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
2
Safety
2. Move shift lever to the neutral position (Fig. 3).
3. Make sure transaxle is in the neutral position by rotating the driven clutch. The tires should not rotate. If tire
rotation does occur, see Adjust Shift Cables in the Adjustment section of Chapter 5 -- Drive Train.
3
1. Shift lever (in neutral)
2. Forward position
1
Figure 3
3. Reverse position
Workman MD/MDX Page 1 -- 5 Safety
Safety and Instruction Decals
Numerous safety and instruction decals are affixed to
your Workman. 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.
Workman MD/MDXPage 1 -- 6Safety
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
Chapter 2
and Maintenance
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, Operator’s Manuals and Parts Catalogs for those options
at the end of this chapter.
Maintenance
Maintenance procedures and recommended service intervals for your Workman are covered in the Operator’s
Manual. Refer to that publication when performing regular equipment maintenance.
Workman MD/MDX Page 2 -- 1 Product Records and Maintenance
Equivalents and Conversions
0.09375
Workman MD/MDXPage 2 -- 2Product Records and Maintenance
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 specified in this Service Manual.
These Torque Specifications for the installation and
tightening of fasteners s hall apply to all fasteners which
do not have a specific requirement identified in this Service 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.
Fastener Identification
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 engagement, etc.
The standard method of verifying torque shall be performed 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.
and Maintenance
Product Records
Grade 1 Grade 5 Grade 8
Inch Series Bolts and Screws
Figure 1
Class 8.8 Class 10.9
Metric Bolts and Screws
Figure 2
Workman MD/MDX Page 2 -- 3 Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
# 6 -- 32 UNC
# 6 -- 40 UNF
# 8 -- 32 UNC
# 8 -- 36 UNF
#10--24UNC
#10--32UNF
1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1125 + 100 140 + 15 1580 + 170
1/4 -- 28 UNF 53 + 7 65 + 10 734 + 11 3 11 5 + 10 1300 + 100 160 + 15 1800 + 170
5/16 -- 18 UNC 115 + 15 105 + 17 1186 + 169 200 + 25 2250 + 280 300 + 30 3390 + 340
5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2540 + 280 325 + 30 3670 + 340
3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 4 58 + 5
Grade 1, 5 &
8withThin
Height Nuts
in--lb in--lb N--cm in-- lb N--cm in-- lb N--cm
10 + 2 13 + 2 147 + 23
13 + 2 25 + 5 282 + 30
18 + 2 30 + 5 339 + 56
ft--lb ft--lb N--m ft--lb N--m ft--lb N--m
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)
15 + 2 170 + 20 23 + 2 260 + 20
17 + 2 190 + 20 25 + 2 280 + 20
29 + 3 330 + 30 41 + 4 460 + 45
31 + 3 350 + 30 43 + 4 485 + 45
42 + 4 475 + 45 60 + 6 675 + 70
48 + 4 540 + 45 68 + 6 765 + 70
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
3/8 -- 24 UNF 17 + 2 18 + 2 24 + 3 35 + 3 47 + 4 50 + 4 68 + 5
7/16 -- 14 UNC 27 + 3 27 + 3 37 + 4 50 + 5 68 + 7 70 + 7 95 + 9
7/16 -- 20 UNF 29 + 3 29 + 3 39 + 4 55 + 5 75 + 7 77 + 7 104 + 9
1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 10 142 + 14
1/2 -- 20 UNF 32 + 3 53 + 7 72 + 9 85 + 8 11 5 + 11 120 + 10 163 + 14
5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 20 285 + 27
5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 15 230 + 20 240 + 20 325 + 27
3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 25 359 + 34 375 + 35 508 + 47
3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 25 407 + 34 420 + 35 569 + 47
7/8 -- 9 UNC 140 + 20 225 + 25 305 + 34 430 + 45 583 + 61 600 + 60 813 + 81
7/8 -- 14 UNF 155 + 25 260 + 30 353 + 41 475 + 45 644 + 61 660 + 60 895 + 81
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
oil, graphite 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 minimum 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.
Workman MD/MDXPage 2 -- 4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Fasteners)
Class 8.8 Bolts, Screws and Studs with
Thread Size Regular Height Nuts
(Class 8 or Stronger Nuts)
M5 X 0.8 57 + 5in--lb 640 + 60 N--cm 78 + 7in--lb 885 + 80 N--cm
M6 X 1.0 96 + 9in--lb 1018 + 100 N--cm 133 + 13 in--lb 1500 + 150 N --cm
M8 X 1.25 19 + 2ft--lb 26 + 3N--m 27 + 2ft--lb 36 + 3N--m
M10 X 1.5 38 + 4ft--lb 52 + 5N--m 53 + 5ft--lb 72 + 7N--m
M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 92 + 9ft--lb 125 + 12 N--m
M16 X 2.0 166 + 15 ft--lb 225 + 20 N--m 229 + 22 ft--lb 310 + 30 N--m
M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 37 ft--lb 610 + 50 N--m
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
oil, graphite or thread sealant such as Loctite.
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.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately+
nominal torque value.
Class 10.9 Bolts, Screws and Studs with
Regular Height Nuts
(Class 10 or Stronger Nuts)
10% ofthe
and Maintenance
Product Records
Workman MD/MDX Page 2 -- 5 Product Records and Maintenance
Other Torque Specifications
*
SAE Grade 8 Steel Set Screws
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 + 3ft--lb
1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Size Baseline Torque*
No. 6 -- 32 UNC 20 + 5in--lb
Wheel Bolts and Lug Nuts
Thread Size
7/16 -- 20 UNF
Grade 5
1/2 -- 20 UNF
Grade 5
M12 X 1.25
Class 8.8
M12 X 1.5
Class 8.8
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread
Size
No. 6 18 20 20 + 5in--lb
Threads per Inch
Type A Typ e B
Recommended Torque**
65 + 10 ft--lb 88 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
Baseline Torque
No. 8 -- 32 UNC 30 + 5in--lb
No. 10 -- 24 UNC 38 + 7in--lb
1/4 -- 20 UNC 85 + 15 in--lb
5/16 -- 18 UNC 110 + 20 in--lb
3/8 -- 16 UNC 200 + 100 in--lb
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
No. 8 15 18 30 + 5in--lb
No. 10 12 16 38 + 7in--lb
No. 12 11 14 85 + 15 in--lb
* Holesize, material strength, material thickness and finish must be considered when determining specific
torque values. All torque values are based on non--lubricated fasteners.
Workman MD/MDXPage 2 -- 6Product Records and Maintenance
Briggs & Stratton Gasoline Engine
Table of Contents
GENERAL INFORMATION 2.....................
Operator’s Manual 2..........................
SPECIFICATIONS 3.............................
ADJUSTMENTS 4..............................
Adjust Throttle Cable 4........................
SERVICE AND REPAIRS 5......................
Cooling System 5.............................
Air Cleaner 6.................................
Exhaust System 8............................
Fuel Tank 10.................................
Oil Filter Assembly 12.........................
Engine 14....................................
Engine Removal 15..........................
Engine Installation 16........................
BRIGGS & STRATTON REPAIR MANUAL FOR
4--CYCLE, V--TWIN CYLINDER, OHV HEAD ENGINES
Chapter 3
Gasoline Engine
Briggs & Stratton
Workman MDX Page 3 -- 1 Briggs & Stratton Gasoline Engine
General Information
This Chapter gives information about specifications,
maintenance, troubleshooting, testing and repair of the
V--twin cylinder, gasoline engine used in the Workman
MDX.
Most repairs and adjustments require tools w hich are
commonly available in many service shops. Special
tools are described in the Briggs & Stratton Repair
Manual for 4--Cycle, V--Twin Cylinder, OHV Head En-
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Workman MDX vehicle. Refer to the
Operator’s Manual for additional information when servicing the machine.
gines. The use ofsome specialized test equipment isexplained. However, the cost of the test equipment and the
specialized nature of some repairs may dictate that the
work be done at an engine repair facility.
Service and repair parts for Briggs & Stratton engines
are supplied through your local Toro distributor. If no
parts list is available, be sure to provide your distributor
with the Toro model and serial number.
Workman MDXPage 3 -- 2Briggs & Stratton Gasoline Engine
Specifications
Item Description
Make / Designation Briggs and Stratton, 4--cycle, V--Twin Cylinder,
OHV, Air Cooled, Gasoline Engine -- Model 303440
Bore x Stroke 2.68” x 2.60” (68 mm x 66 mm)
Total Displacement 29.3 in3(480 cc)
Governor Mechanical Governor
Carburetor Float Feed, Single Barrel
Fuel Pump Pulsating Crankcase Vacuum
Fuel Unleaded, regular grade gasoline
Fuel Tank Capacity 7.0 U.S. gal (26.5 l)
Lubrication System Pressure Lubrication, Gear Driven Geroter Oil Pump
Crankcase Oil Capacity 1.75 U.S. qt (1.66 l) with new filter
Engine Oil See Operator’s Manual
Ignition System Flywheel magneto, twin electronic armatures
Spark Plugs Champion RC 12YC (or equivalent)
Gasoline Engine
Briggs & Stratton
Spark Plug Gap 0.030” (0.76 mm)
Starter/Generator 10.5 VDC 100 Amps/14 VDC and 23 Amps
Dry Weight (approximate) 72 lb (32.4 kg)
Workman MDX Page 3 -- 3 Briggs & Stratton Gasoline Engine
Adjustments
Adjust Throttle Cable
NOTE: The Workman MDX is equipped with an engine
governor. Refer to the Briggs & Stratton Repair Manual
at the end of this chapter for governor information on
these machines.
Depressing the accelerator pedal rotates the engine
governor bellcrank which tensions the main governor
spring to increase engine speed. Releasing the accelerator pedal decreases governor spring tension to reduce
engine speed.
1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition
switch.
2. Lift cargo box and prop with rod to gain access to the
engine.
3. When the accelerator pedal is fully depressed the
engine governor bellcrank mechanism should have a
gap from 0.030” to 0.080” (0.8 to 2.0 mm) (Fig. 2). If necessary, adjust jam nuts on accelerator cable so that gap
is correct.
2
ACCELERATOR
PEDAL RELEASED
1
Figure 1
1. Throttle cable 2. Governor bellcrank
2
4. After throttle cable adjustment is correct, lower and
secure cargo box.
ACCELERATOR
PEDAL DEPRESSED
1. Throttle cable
2. Governor bellcrank
3
1
Figure 2
3. Gap
Workman MDXPage 3 -- 4Briggs & Stratton Gasoline Engine
Service and Repairs
Cooling System
To ensure proper engine cooling, make sure the grass
screen, cooling fins and other external surfaces of the
engine are kept clean at all times.
NOTE: Perform this maintenance procedure at the interval specified in the Operator’s Manual.
IMPORTANT: The engine that powers the Workman
MDX is air--cooled. Operating the engine with dirty
or plugged cooling fins or a plugged or dirty blower
housing w ill result in engine overheating and damage.
1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition
switch.
2. Raise cargo box and support with prop rod.
3. Carefully remove spark plug wires from the spark
plugs to prevent the engine from starting unexpectedly.
IMPORTANT: Never clean engine with pressurized
water. Water could enter and contaminate the fuel
system.
4. Clean cooling fins on both cylinder heads (Fig. 3).
5. Clean rotating screen and blower housing of dirt and
debris.
6. If necessary remove rotating screen and blower
housing fromengine for more thorough engine cleaning.
2
1
1
Figure 3
1
Gasoline Engine
Briggs & Stratton
IMPORTANT: Never operate engine without the rotating screen and blower housing installed. Overheating and engine damage will result.
7. Make sure rotating screen and blower housing are
properly installed to the engine if removed.
8. Attach spark plug wires to spark plugs.
9. Lower and secure cargo box.
Workman MDX Page 3 -- 5 Briggs & Stratton Gasoline Engine
1. Rotating screen 2. Blower housing
Figure 4
Air Cleaner
18
17
5
4
6
3
2
8
7
9
60 to 65 in-- lb
(6.8 to 7.3 N-- m)
10
1
11
12
19
13
12
14
15
16
17
RIGHT
FRONT
1. Air cleaner assembly
2. Bolt
3. Compression spring
4. Mounting band
5. Nut
6. Flange nut (2 used)
Figure 5
7. Cap screw (2 used)
8. Air cleaner bracket
9. Flange head screw (4 used)
10. Carburetor gasket (2 used)
11. Carburetor adapter
12. Hose clamp
13. Breather hose
14. Adapter gasket
15. Hose clamp
16. Intake hose
17. Hose clamp
18. Intake hose
Workman MDXPage 3 -- 6Briggs & Stratton Gasoline Engine
Removal (Fig. 5)
1. Make sure machine is parked on a level surface with
the engine OFF.
2. Raise cargo box and support with prop rod.
3. Thoroughly clean junction of intake hose and carburetor adapter on engine and air cleaner assembly.
4. Remove air cleaner components as needed using
Figure 5 as a guide. Discard any removed gaskets and
clean gasket mating surfaces.
Installation (Fig. 5)
IMPORTANT: Any leaks in the air filter system will
allow dirt into engine and will cause serious engine
damage. Make sure that all air cleaner components
are in good condition and are properly secured during assembly.
1. Assemble all removed air cleaner components using
Figure 5 as a guide.
A. Install new gaskets (items 10 and 14) if they were
removed.
1
1. Air cleaner
2. Carburetor adapter
Figure 6
3. Breather hose
4. Intake hose
2
3
4
Gasoline Engine
Briggs & Stratton
B. If flange head screws ( item 9) were loosened or
removed, torque screws from 60 to 65 in--lb (6.8 to
7.3 N--m).
C. Make sure that air cleaner vacuator valve is
pointed toward ground and slightly toward engine after assembly.
D. Make sure to secure intake hoses with hose
clamps.
2. Lower and secure cargo box.
Workman MDX Page 3 -- 7 Briggs & Stratton Gasoline Engine
Exhaust System
RIGHT
FRONT
8
9
4
10
1
2
7
6
5
4
3
1. Muffler
2. Swing arm
3. Cap screw (2 used)
4. Lock washer (6 used)
Figure 7
5. Exhaust coupler
6. Coupler spring (4 used)
7. Exhaust manifold
8. Engine tray
9. Engine
10. Screw (4 used)
Workman MDXPage 3 -- 8Briggs & Stratton Gasoline Engine
Removal (Fig. 7)
Installation (Fig. 7)
1. Park machine on a level surface, stop theengine, engage parkingbrake and remove the key from the ignition
switch.
2. Raise cargo box and support with prop rod.
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow engine and exhaust
system to cool before working on the muffler.
3. Remove four (4) coupler springs securing the exhaust coupler to the muffler and exhaust manifold. Remove exhaust coupler.
4. Remove two (2) cap screws and lock washers securing the muffler to the swing arm. Remove muffler from
machine.
5. If exhaust manifold needs to be removed from engine, remove four (4) screws and lock washers securing
the manifold to the engine. Remove exhaust manifold.
Remove exhaust gaskets and clean gasket surfaces of
manifold and engine.
NOTE: Mount all exhaust components loosely before
tightening to ensure a proper fit of exhaust system.
1. If the exhaust manifold was removed from engine,
install manifold to engine with new gaskets. Make sure
that gaskets align with exhaust ports of cylinder heads.
Loosely attach exhaust manifold to the engine with removed fasteners.
2. Position muffler to the machine. Secure muffler
loosely to the swing arm with two (2) cap screws and
lock washers.
3. Position exhaust coupler to the muffler and exhaust
manifold. Secure coupler with four (4) coupler springs.
4. Tighten screws that secure exhaust manifold to the
engine.
5. Tighten cap screws that secure muffler to the swing
arm.
6. Lower and secure cargo box.
Gasoline Engine
Briggs & Stratton
Workman MDX Page 3 -- 9 Briggs & Stratton Gasoline Engine
Fuel Tank
RIGHT
FRONT
16
11
15
14
12
13
10
5
1
2
3
9
8
7
6
4
1. Seat
2. Fuel gauge
3. Bushing
4. Gas cap
5. Fuel tank
6. Bushing
7. Stand pipe
Figure 8
8. Hose clamp
9. Fuel hose (to fuel filter)
10. Fuel line conduit
11. Seat base
13
12. Web strapping
13. Hex head flange screw (8 used)
14. Flat washer
15. Parking brake support
16. Shift bracket
Workman MDXPage 3 -- 10Briggs & Stratton Gasoline Engine
Fuel Tank Removal (Fig. 10)
CAUTION
Read safety precautions for handling gasoline
before working on the fuel system (see Safety Instructions in Chapter 1 -- Safety).
4
2
5
1. Remove seat base from the frame (see Seat Base
Removal in the Service and Repairs section of Chapter
7 -- Chassis).
2. Use fuel transfer pump to remove gas from fuel tank.
3. Loosen hose clamp and disconnect fuel hose from
the fuel tank stand pipe.
4. Release tank strap that secures fuel tank to frame.
Do not remove strap from floor plate and frame cross
member. Lift tank from frame.
5. If necessary, remove stand pipe, fuel gauge and
bushings from tank.
Fuel Tank Installation (Fig. 10)
1. If removed, install bushings, stand pipe and fuel
gauge to tank.
2. Position fuel tank to frame. Secure tank to frame and
cross member with tank strap.
3. Connect fuel hose to the tank stand pipe and secure
with hose clamp.
4. Install seat base to the frame (see Seat Base Installation in the Service and Repairs section of Chapter 7 -Chassis).
3
1. Shift lever
2. Cap screw (short)
3. Shift plate
1
3
1. Fuel hose
2. Fuel tank
Figure 9
4. Cap screw (long)
5. Choke cable
Figure 10
3. Tank strap
1
Gasoline Engine
Briggs & Stratton
2
5. Fill fuel tank.
Workman MDX Page 3 -- 11 Briggs & Stratton Gasoline Engine
Oil Filter Assembly
40 to 50 in-- lb
(4.6 to 5.6 N-- m)
11
RIGHT
FRONT
4
10
1
1
2
3
40 to 50 in-- lb
(4.6 to 5.6 N-- m)
4
3
12
5
6
8
7
8
9
7
1. Hose
2. Elbow fitting
3. Hose
4. Fitting
Figure 11
5. Oil pressure switch
6. Elbow fitting
7. Cap screw (4 used)
8. Flange nut (4 used)
9. Filter bracket
10. Oil filter
11. Oil filter adapter
12. Fitting
Workman MDXPage 3 -- 12Briggs & Stratton Gasoline Engine
Removal (Fig. 11)
Installation (Fig. 11)
1. Park machine on a level surface, stop theengine, engage parkingbrake and remove the key from the ignition
switch.
2. Raise cargo box and support with prop rod.
3. To prevent contamination of engine lubrication system duringadapter removal, thoroughly clean exteriorof
filter adapter, hoses and fittings.
4. Remove oil filter adapter components as needed using Figure 11 as a guide.
1. Install removed oil filter adapter components using
Figure 11 as a guide. Torque fittings (items 2, 4 and 6)
from 40 to 50 in--lb (4.6 to 5.6 N--m).
2. Check and adjust engine oil level.
3. Lower and secure cargo box.
Gasoline Engine
Briggs & Stratton
Workman MDX Page 3 -- 13 Briggs & Stratton Gasoline Engine
Engine
5
4
3
41
6
40
30
39
RIGHT
FRONT
65 to 85 ft-- lb
(88 to 115 N--m)
8
33
8
31
9
28
10
13
42
Loctite #242
22
38
1
37
1
36
25
1
2
17
29
27
11
43
19
20
14
15
29
7
1. Hose clamp
2. Fuel hose (from tank)
3. Cable bracket
4. Cable clamp
5. Cap screw
6. Threaded insert
7. Swing arm
8. Lock washer (6 used)
9. Cap screw (2 used)
10. Woodruff key
11. Lock washer
12. Nut
13. Starter V-- belt
14. Cap screw (4 used)
15. Lock washer (4 used)
32
26
35
23
34
16. Engine pulley
17. Negative cable
18. Starter spacer
19. Drive clutch
20. Washer
21. Cap screw
22. Flange nut (4 used)
23. Cap screw
24. Carriage screw
25. Engine tray
26. Washer (2 used)
27. Starter/generator pulley
28. Starter/generator
29. Flange nut (3 used)
30. Engine
24
Figure 12
12
16
18
Loctite #242
25 to 30 ft-- lb
(34to40N--m)
31. Engine wire harness
32. Cap screw (2 used)
33. Screw (4 used)
34. Mount (2 used)
35. Cap screw (4 used)
36. Fuel filter
37. Fuel hose
38. Lock nut
39. Cable bracket
40. Ball stud
41. Cable
42. Exhaust manifold
43. Coupler spring (4 used)
44. Plastic cap
21
44
Workman MDXPage 3 -- 14Briggs & Stratton Gasoline Engine
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