Toro MDE User Manual
Part No. 08164SL (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 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. 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.
MDE
R
E The Toro Company -- 2008, 2011
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Workman MDE
Table Of Contents
Chapter 1 -- Safety
Safety Instructions 1 -- 2..........................
Jacking and Other Instructions 1 -- 4...............
Safety and Instruction Decals 1 -- 5................
Chapter 2 -- Product Records and Maintenance
Product Records 2 -- 1...........................
Maintenance 2 -- 1...............................
Equivalents and Conversions 2 -- 2................
Torque Specifications 2 -- 3.......................
Chapter 3 -- Electrical System
General Information 3 -- 2........................
Electrical Diagrams 3 -- 3.........................
Vehicle Operation 3 -- 4..........................
Special Tools 3 -- 5..............................
Troubleshooting 3 -- 8............................
Adjustments 3 -- 11..............................
Component Testing 3 -- 14........................
Service and Repairs 3 -- 28.......................
LESTER ELECTRICAL TECHNICIAN
SERVICE GUIDE
Chapter 4 -- Transaxle and Brakes
SafetyProduct Records
and Maintenance
SystemBrakes
ElectricalChassisElectrical
Transaxle and
General Information 4 -- 2........................
Specifications 4 -- 3..............................
Troubleshooting 4 -- 4............................
Service and Repairs 4 -- 6........................
SPICER OFF--HIGHWAY COMPONENTS MODEL
12 (ELECTRIC) MAINTENANCE MANUAL
Chapter 5 -- Chassis
General Information 5 -- 1........................
Specifications 5 -- 2..............................
Troubleshooting 5 -- 3............................
Service and Repairs 5 -- 5........................
Chapter 6 -- Electrical Diagrams
Electrical Schematic 6 -- 3........................
Electrical Circuit Drawings 6 -- 4...................
Electrical Harness Drawings 6 -- 8.................
Diagrams
Workman MDE
Rev. A
This page is intentionally blank.
Workman MDE
Table of Contents
SAFETY INSTRUCTIONS 2......................
Before Operating 2............................
While Operating 2.............................
Maintenance and Service 3....................
JACKING AND OTHER INSTRUCTIONS 4.........
Jacking Vehicle 4.............................
Towing Vehicle 4..............................
Transporting Vehicle 4.........................
SAFETY AND INSTRUCTION DECALS 5..........
Chapter 1
Safety
Safety
Workman MDE Page 1 -- 1 Safety
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. To reduce the potential for injury or death, comply with the
following safety instructions.
Before Operating
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
1. Review 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.
While Operating
WARNING
The Workman MDE is an off-- highway vehicle
only. It is not designed, equipped or manufactured for use on public streets, roads or highways.
1. Sit on the operator seat when starting and operating
the vehicle.
2. Before starting the vehicle:
A. Make sure that the battery charger is disconnected from the vehicle charger receptacle.
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 machine. Also tighten any loose nuts, bolts or screws to ensure machine is in safe operating condition.
3. Before getting off the operator seat:
A. Stop vehicle, turn on/off switch OFF and remove
key from switch.
B. Apply the parking brake.
4. If vehicle is parked on incline, chock or block the
wheels after getting off the vehicle.
B. Engage the parking brake.
C. Make sure accelerator pedal is not depressed.
D. Check position of forward/reverse switch and Hi/
Low speed switch.
Workman MDEPage 1 -- 2Safety
Maintenance and Service
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.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Do not use open pans of flammable cleaning fluids
for cleaning parts.
4. Keep battery area free of excessive grease, grass,
leaves and dirt.
5. Disconnect batteries before servicing the machine.
Carefully remove one of the battery cables from the battery pack as the first step in any repair. Once a battery
cable has been removed, the electrical system on the
vehicle can be safely worked on. Take care during repairs, however, to not allow tools or vehicle components
to complete the battery circuit that was opened with the
cable removal. Reattach the removed cable to the battery pack as the last step in any repair.
6. When using metal, uninsulated tools around batteries, do not allow tools to contact both positive and negative battery terminals simultaneously.
7. Remove jewelry and watches before servicing electrical components of the vehicle.
8. Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with batteries.
10.Never use an open flame to check level or leakage
of battery electrolyte.
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. After charging the vehicle batteries, unplug the
charger power cord from theoutlet before disconnecting
the charger cord from the vehicle charger receptacle.
12.If major repairs are ever needed or assistance is desired, contact an Authorized Toro Distributor.
13.To assure optimum performance and continued
safety of the machine, 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.
14.When raising the machine to change tires or to perform other service, use correct blocks, hoists and jacks.
Make sure machine is parked on a solid level surface
such as a concrete floor.Prior to raising the machine, remove any attachments that may interfere with the safe
and proper raising of the machine. Always chock or
block wheels. Use jack stands to support the raised machine. If the machine is not properly supported b y jack
stands, the machine may move or fall, which may result
in personalinjury (see Jacking Instructions inthe Operator’s Manual and in this Chapter).
Safety
9. Battery gases can explode. Keep cigarettes, sparks
and flames away from the batteries. Always service,
store and charge thevehicle batteries in a wellventilated
area.
Workman MDE Page 1 -- 3 Safety
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.
• 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.
• Make sure proper hoists and jack stands
are used to raise and support the vehicle.
1
Figure 1
1. Front frame 2. Towing tongue
2
Jacking Locations
1. Jack front of the vehicle on the front of the frame 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).
Towing Vehicle
IMPORTANT: Frequent or long distance towing of
the Workman MDE is not recommended.
In case of emergency, the vehicle can be towed for a
short distance. See Operator ’s Manual for towing information.
Transporting Vehicle
When moving the vehicle long distances, use a trailer or
flatbed truck. Make sure vehicle is secured to the trailer
properly. See Operator’s Manual for transport information.
1
1. Rear axle tube 2. Transaxle case
IMPORTANT: If vehicle is towed, make sure that on/
off switch is in the OFF position and key is removed
from switch.
2
Figure 2
1
Workman MDEPage 1 -- 4Safety
Safety and Instruction Decals
There are several safety and instruction decals attached
to your Workman vehicle. If any decal becomes illegible
or damaged, install a new decal. Part numbers are listed
in the Parts Catalog. Order replacement decals from
your Authorized Toro Distributor.
Safety
Workman MDE Page 1 -- 5 Safety
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Workman MDEPage 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
Product Records
and Maintenance
Insert Operator’s Manual and Parts Catalog for your
Workman vehicle at the end of this chapter. Additionally,
if any optional equipment or accessories have been
installed to your Workman, 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 the Workman MDE are covered in the Operator’s Manual. Refer to that publication when performing
regular vehicle maintenance.
Workman MDE Page 2 -- 1 Product Records and Maintenance
Equivalents and Conversions
0.09375
Workman MDEPage 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
(e.g. Nylock nut), 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.
Product Records
and Maintenance
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 MDE 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 1130 + 113 140 + 15 1582 + 169
1/4 -- 28 UNF 53 + 7 65 + 10 734 + 11 3 11 5 + 12 1299 + 136 160 + 17 1808 + 192
5/16 -- 18 UNC 115 + 15 105 + 15 1186 + 169 200 + 25 2260 + 282 300 + 30 3390 + 339
5/16 -- 24 UNF 138 + 17 128 + 17 1446 + 192 225 + 25 2542 + 282 325 + 33 3672 + 373
3/8 -- 16 UNC 16 + 2 16 + 2 22 + 3 30 + 3 41 + 4 43 + 5 58 + 7
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 + 2 169 + 23 23 + 3 262 + 34
17 + 2 192 + 23 25 + 3 282 + 34
29 + 3 328 + 34 41 + 5 463 + 56
31 + 4 350 + 45 43 + 5 486 + 56
42 + 5 475 + 56 60 + 6 678 + 68
48 + 5 542 + 56 68 + 7 768 + 79
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 + 4 47 + 5 50 + 6 68 + 8
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 + 6 75 + 8 77 + 8 104 + 11
1/2 -- 13 UNC 30 + 3 48 + 7 65 + 9 75 + 8 102 + 11 105 + 11 142 + 15
1/2 -- 20 UNF 32 + 4 53 + 7 72 + 9 85 + 9 115 + 12 120 + 12 163 + 16
5/8 -- 11 UNC 65 + 10 88 + 12 119 + 16 150 + 15 203 + 20 210 + 21 285 + 28
5/8 -- 18 UNF 75 + 10 95 + 15 129 + 20 170 + 18 230 + 24 240 + 24 325 + 33
3/4 -- 10 UNC 93 + 12 140 + 20 190 + 27 265 + 27 359 + 37 375 + 38 508 + 52
3/4 -- 16 UNF 115 + 15 165 + 25 224 + 34 300 + 30 407 + 41 420 + 43 569 + 58
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 + 48 644 + 65 667 + 66 904 + 89
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 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.
Rev. A
Workman MDEPage 2 -- 4Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Class 8.8 Bolts, Screws and Studs with
Thread Size 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 + 6in--lb 644 + 68 N--cm 78 + 8in--lb 881 + 90 N--cm
M6 X 1.0 96 + 10 in--lb 1085 + 113 N - -c m 133 + 14 in--lb 1503 + 158 N--cm
M8 X 1.25 19 + 2ft--lb 26 + 3N--m 28 + 3ft--lb 38 + 4N--m
M10 X 1.5 38 + 4ft--lb 52 + 5N--m 54 + 6ft--lb 73 + 8N--m
M12 X 1.75 66 + 7ft--lb 90 + 10 N--m 93 + 10 ft--lb 126 + 14 N--m
M16 X 2.0 166 + 17 ft--lb 225 + 23 N--m 229 + 23 ft--lb 310 + 31 N--m
M20 X 2.5 325 + 33 ft--lb 440 + 45 N--m 450 + 46 ft--lb 610 + 62 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
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 +
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.
10% ofthe
Product Records
and Maintenance
Workman MDE 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 fin-
ish must be considered when determining specific
torque values. All torque values are based on non--lubri-
cated fasteners.
Workman MDEPage 2 -- 6Product Records and Maintenance
Table of Contents
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 8.........................
General Run Problems 8.......................
Battery Charger Operation 9....................
Battery Charger Problems 10...................
ADJUSTMENTS 11.............................
Accelerator Switch Adjustment 11...............
Accelerator Potentiometer Adjustment
(Potentiometer with Short Lever) 12............
Accelerator Potentiometer Adjustment
(Potentiometer with Long Lever) 12.1..........
Accelerator System Calibration 13...............
COMPONENT TESTING 14......................
On/Off Switch 14..............................
Battery Discharge Indicator and Hour
Meter Gauge 15.............................
Vehicle Direction (Forward/Reverse) and
Headlight Switches 16.......................
Vehicle Status Light 17........................
Supervisor Speed Limit Switch 18...............
Audio Alarm (Reverse) 18......................
Charger Interlock Switch 19....................
Main and Accessories Contactors 20............
Fuses 22....................................
Fusible Links 23..............................
Accelerator Switch 24.........................
Accelerator Potentiometer 25...................
Controller 26.................................
SERVICE AND REPAIRS 28.....................
Battery Service 28............................
Battery Specifications 28.....................
Battery Removal 29..........................
Battery Installation 29........................
Battery Charging 30..........................
Battery Inspection and Maintenance 30.........
Battery Testing 31...........................
Battery Storage 32...........................
Traction Motor Brushes 33.....................
Traction Motor 34.............................
Traction Motor Service 38......................
Battery Charger 42............................
LESTER ELECTRICAL TECHNICIAN
SERVICE GUIDE
System
Electrical
Workman MDE
Page 3 -- 1
Rev. A
Electrical System
General Information
The Workman MDE uses a 48 volt DC electrical system
that is an isolated circuit. The vehicle frame is not used
for any ground connections.
The vehicle controller monitors operator and vehicle inputs to determine voltage to the traction motor. If a problem exists that will prevent normal vehicle operation, an
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Workman vehicle. Refer to the Operator’s Manual for additional information when servicing
the machine.
Opening Battery Circuit
To prevent allowing a current path through tools used
during vehicle electrical circuit repairs, remove one of
the battery cables from the battery pack as the first step
in any repair (Fig. 1). Once a cable has been removed,
the electrical system on the vehicle can be safely
worked on. Take care during repairs, however, to not allow tools or vehicle components to complete the battery
circuit that was opened with the cable r emoval.
LED on the controller and the vehicle status light on the
dash panel will flash a fault code to assist in identifying
the problem.
After performing any repair on electrical components on
the vehicle, make sure that wiring is routed and secured
so as to prevent abrasion or contact with moving parts.
Reattach the removed cable to the battery pack as the
last step in any repair. Secure cable on each battery terminal with lock washer and nut. Torque nuts from 115 to
125 in--lb (13.0 to 14.1 N--m).
Battery pack cable routing is shown in Figure 2.
Figure 1
1
A
Figure 2
1. Negative cable to vehicle 2. Positive cable to vehicle
2
4
Electrical System
Page 3 -- 2
Workman MDE
Electrical Diagrams
The electrical schematic, circuit drawings and wire harness drawings for the Workman MDE are located in
Chapter 6 -- Electrical Diagrams.
System
Electrical
Workman MDE
Page 3 -- 3
Electrical System
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).
The batteries are discharged as the vehicle is used so
charging the batteries after using the vehicle is necessary. A battery discharge indicator gauge on the dash
provides the operator with information on battery charge
level. Demands on the vehicle during use (speed, payload, incline use), battery condition (age, charge level),
ambient temperature and vehicle condition will all put
constraints onhow long a vehicle can be used beforethe
batteries are discharged.
An automatic, 115 VAC (230 VAC on international models) batterycharger is included with the vehicle. An interlock switch on the vehicle charger receptacle prevents
the vehicle from operating when the charger cord is
plugged into the vehicle.
The electric traction motor directly drives a double reduction transaxle with differential. Operator inputs for
forward/reverse, supervisor switch position (high or low
speed) and accelerator pedal position are used by the
controller to determine voltage to the traction motor.
The vehicle controller is a sealed electronic logic device
that uses inputs from several vehicle components to
control motor speed and direction. These inputs include
several switches (on/off, forward/reverse, accelerator,
supervisor, charger), a motor temperature sensor, an
accelerator pedal potentiometer and the vehicle contactor (solenoid). The controller also provides regenerative
braking to assist in slowing the vehicle. The controller
has fault detection capabilities to help identify system
problems. Battery current is available to the controller
whenever the on/off switch is ON which energizes the
main contactor. A high current fuse protects this high
current circuit.
The Workman controller also provides a roll off warning
in instances when the vehicle begins to move (roll away)
after being stopped. On an incline and with the on/off
switch in the ON position, if the vehicle starts moving,
the alarm will sound warning the operator that the vehicle is moving. When the vehicle goes into this roll--off
mode, regenerative braking will limit vehicle speed.
Vehicle accessories include headlights, horn and optional electrical equipment. The accessories contactor
(solenoid) on the vehicle provides battery current to
these components when the on/off switch is ON. Fuses
provide circuit protection for these accessories.
The traction motor is cooled with an external fan. Additionally, the motor is protected from overheating by a
thermal switch in the motor housing. If unsafe motor
temperature is sensed by the switch, the controller is
signaled to limit vehicle speed and torqueuntil the motor
temperature reduces to a normal level.
Electrical System
Page 3 -- 4
Workman MDE
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: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing e lectrical circuits.
The highimpedance (internal resistance) of a digital meter in the voltage mode will make sure that excess current is not allowed through the meter. This excess
current can cause damage to circuits not designed to
carry it.
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.
Figure 3
System
Electrical
Battery Terminal Protector
Battery Terminal Protector is an aerosol spray that
should be used on all battery and controller terminals to
reduce corrosion problems. Apply terminal protector after cable has been secured to terminal.
Toro Part Number: 107--0392
Dielectric Gel
Dielectric gel should be used to prevent corrosion of
connection terminals.To ensurecomplete coating of terminals, liberally apply gel to both component and wire
harness connector, plug connector to component, unplug connector, reapply gel to both surfaces and reconnect harness connector to c omponent. Connectors
should be thoroughly packed with gel for effective results.
Figure 4
Toro Part Number: 107--0342
Workman MDE
Page 3 -- 5
Figure 5
Electrical System
Battery Watering Dispenser
Use the battery watering dispenser when adding distilled water to vehicle batteries.
Toro Part Number: TOR4102
Battery Hydrometer
Use the battery hydrometer when measuring s pecific
gravity of battery electrolyte. Obtain hydrometer locally.
Figure 6
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.
Figure 7
Figure 8
Electrical System
Page 3 -- 6
Workman MDE
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.
Toro Part Number: TOR4106
Figure 9
System
Electrical
Workman MDE
Page 3 -- 7
Electrical System
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.
General Run Problems
NOTE: Check vehicle status light on dash panel and
controller LED for possible faults whenever diagnosing
vehicle problems (see Controller in the Component
Testing section of this chapter).
For effective troubleshooting and repairs, there must be
a good understanding of the electrical c ircuits and components used on this vehicle (see Electrical Schematic
in Chapter 6).
If the vehicle has any switches by--passed, they must be
reconnected for proper vehicle operation, troubleshooting and safety.
Problem
Main contactor clicks, but vehicle will not operate. Battery charge is low.
Nothing happens when on/off switch is turned to ON. Battery charge is extremely low.
Possible Causes
Battery cables are loose, corroded or damaged.
Cable connection(s) at controller is/are loose or
corroded.
Cable connection(s) at traction motor is/are loose or
corroded.
Traction motor is faulty.
Controller is faulty.
Battery cables are loose, corroded or damaged.
Cable connection(s) at controller is/are loose or
corroded.
10 ampere fuse (F2) to the on/off switch is loose or
blown.
Fusible link FL2 is faulty.
Electrical System
Main fuse (F1) is loose or blown.
The on/off switch or circuit wiring is faulty.
Controller is faulty.
Page 3 -- 8
Workman MDE
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.
Traction motor is faulty.
Brake or transaxle problem (see Chapter 4 -- Transaxle
and Brakes).
Vehicle runs slowly. Supervisor speed limit switch in slow position.
Tire pressure is low (see Chapter 5 -- Chassis).
Brakes improperly adjusted (see Chapter 4 -Transaxle and Brakes).
System
Electrical
Battery charge is extremely low.
Controller is overheated.
Traction motor is overheated.
Vehicle movement is erratic or jerky. Collar on throttle is loose.
Accelerator potentiometer is improperly adjusted.
Accelerator system is out of adjustment.
Battery Charger Operation
Light Status Indicates
Green light on battery charger illuminated (not
flashing).
Green light on battery charger flashing. Slow flash (once per second): Batteries being charged
Batteries is fully charged. Vehicle ready to operate.
(batteries less than 80% charged). Continue charging.
Rapid flash (four times per second): Batteries being
charged (batteries more than 80% charged). Continue
charging.
Red light on battery charger flashing. Rapid flash: Charger timer shutoff has occurred after
20 hours of charging.
Slow flash: No current to charger. Check AC outlet.
Workman MDE
Page 3 -- 9
Electrical System
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.
NOTE: Charging new batteries or charging batteries in
cold temperatures may require extended charge time
to achieve full charge.
Battery charger fuse blows. Vehicle battery polarity is reversed (vehicle battery
cables incorrectly attached).
The AC outlet circuit breaker or fuse blows when using
the battery charger.
Vehicle charger receptacle polarity is reversed.
Battery charger is faulty.
Overloaded AC circuit.
Battery charger is faulty.
Electrical System
Page 3 -- 10
Workman MDE
Adjustments
Accelerator Switch Adjustment
1. Position vehicle on a level surface, turn on/off switch
OFF and remove key.
2. With the accelerator pedal released, check that the
distance between the head of the accelerator switch
stop cap screw and the body of the switch is 5/8 inch
(15.9 mm) (Fig. 12).
3. If distance is incorrect, loosen lock nut and adjust accelerator switch stop cap screw position (Fig. 11).
4. After adjustment, make sure that switch plunger is
not bottomed out when accelerator pedal is released.
5. Calibrate accelerator system after adjusting accelerator switch (see Accelerator System Calibration in this
section).
2
3
4
1. Accelerator pedal
2. Accelerator switch
3. Plate
Figure 10
2
1
6
5
4. Screw (2 used)
5. Switch stop cap screw
6. Lock nut
3
System
Electrical
1
Figure 11
1. Accelerator switch
2. Switch stop cap screw
3. Accelerator stop cap screw
5/8 inch
(15.9 mm)
1
2
Workman MDE
Page 3 -- 11
Figure 12
1. Switch stop cap screw 2. Accelerator switch
Electrical System
Accelerator Potentiometer Adjustment (Potentiometer with Short Lever)
NOTE: The following adjustment procedure should be
used onvehicles that have a potentiometer that includes
a short lever (Figure 14). If potentiometer has a long lever, use the procedure on the following page.
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. 13). A collar with roll pin on
the accelerator pedal shaft positions the accelerator potentiometer lever. Potentiometers with a short lever use
a roll pin that extends approximately 1 1/2 inches (38
mm) out of the collar.
If the accelerator potentiometer is out of adjustment, the
diagnostic light on the dash will flash six (6) times. Additionally, if vehicle movement is erratic and jerky, potentiometer adjustment and calibration of the accelerator
system should be performed.
Adjustment
1. Position vehicle on a level surface, turn on/off switch
OFF and remove key.Make sure that acceleratorpotentiometer is securely attached to the pedal frame of the
machine.
5. Calibrate accelerator system after any accelerator
potentiometer adjustment(see Accelerator SystemCalibration in this section).
4
1
5
3
2
Figure 13
1. Potentiometer
2. Accelerator pedal
3. Throttle position collar
4. Roll pin
5. Set screw (2 used)
2. Check accelerator switch adjustment and adjust if
necessary (see Accelerator Switch Adjustment in this
section).
3. Check movement of the potentiometer lever:
A. With the accelerator pedal released, the roll pin
on the throttle position collar should keep the potentiometer lever from 0.050” to 0.100” (1.3 to 2.5 mm)
from the lower stop on the potentiometer body (Figure 14).
B. With the accelerator pedal fully depressed, theinput lever of the potentiometer should not contact the
upper stop on the potentiometer body (Figure 15).
4. If potentiometer lever movement is incorrect, adjust
location of collar on accelerator pedal shaft:
A. Loosen two (2) set screws that secure throttle
position collar to throttle pedal shaft and reposition
collar to allow correct potentiometer movement.
Make sure that there is clearance between roll pin
and side of potentiometer lever to prevent binding.
B. Remove set screws one at a time from collar and
apply Loctite #242 (or equivalent) to set screw
threads. Install and tighten set screws to secure collar to accelerator pedal shaft.
C. Recheck potentiometer lever movement.
1
3
2
Figure 14
1. Potentiometer lever (accelerator pedal released)
2. Potentiometer lower stop
3. Gap of 0.050” to 0.100” (1.3 to 2.5 mm)
1
3
2
Figure 15
1. Potentiometer lever (accelerator pedal fully depressed)
2. Potentiometer upper stop
3. No lever contact with stop
Electrical System
Page 3 -- 12
Rev. A
Workman MDE
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
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). A collar with roll p in
attached to the accelerator pedal shaft positions the accelerator potentiometer lever. Potentiometers with a
long lever use a roll pin that extends approximately 3
inches (76 mm) out of the collar.
If the accelerator potentiometer is out of adjustment, the
diagnostic light on the dash will flash six (6) times. Additionally, if vehicle movement is erratic and jerky, potentiometer adjustment and calibration of the accelerator
system should be performed.
Adjustment
1. Position vehicle on a level surface, turn on/off switch
OFF and remove key. Make sure that accelerator potentiometer assembly is securely attached to the pedal
frame of the machine.
2. Check accelerator switch adjustment and adjust if
necessary (see Accelerator Switch Adjustment in this
section).
1. Potentiometer
2. Lever
Figure 15.1
3. Retainer
4
2
3
System
Electrical
3
3. With the accelerator pedal released, inspect location
of roll pin on throttle position collar and potentiometer lever. The roll pin should just contact the potentiometer lever without rotating the lever (Figure 15.2).
4. If necessary, adjust location of collar on accelerator
pedal shaft so that roll pin is properly positioned:
A. Loosen two (2) set screws that secure throttle
position collar to throttle pedal shaft and reposition
collar so that roll pin on the throttle position collar just
contacts the potentiometer lever without rotating the
lever. Make sure that there is clearance between roll
pin and side of potentiometer lever to prevent binding.
B. Remove set screws one at a time from collar and
apply Loctite #242 (or equivalent) to set screw
threads. Install and tighten set screws to secure collar to accelerator pedal shaft.
C. Recheck potentiometer lever movement.
5. Calibrate accelerator system after any accelerator
potentiometer adjustment(see Accelerator SystemCalibration in this section).
1. Potentiometer
2. Collar
3. Lever
1
2
5
Figure 15.2
4. Roll pin
5. Accelerator pedal
Workman MDE Electrical System
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Rev. A12.1
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Rev. A12.2
Workman MDEElectrical System Page 3 --
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