Toro MDX-D User Manual
Part No. 13200SL
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 MDX--D.
REFER TO THE OPERA T OR’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 instructionswhich must be followed to prevent damage to systems or components on the
machine.
MDX--D
R
E The Toro Company -- 2013
This page is intentionally blank.
Workman MDX--D
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 -- Diesel Engine
Specifications 3 -- 2..............................
General Information 3 -- 3........................
Adjustments 3 -- 5...............................
Service and Repairs 3 -- 6........................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
SM--E3B SERIES
Chapter 4 -- Drive Train
Specifications 4 -- 2..............................
General Information 4 -- 3........................
Drive Train Operation 4 -- 4.......................
Special Tools 4 -- 7..............................
Troubleshooting 4 -- 8............................
Adjustments 4 -- 9...............................
Service and Repairs 4 -- 10.......................
Chapter 5 -- Electrical System
General Information 5 -- 2........................
Special Tools 5 -- 3..............................
Troubleshooting 5 -- 5............................
Electrical System Quick Checks 5 -- 7..............
Component Testing 5 -- 8.........................
Service and Repairs 5 -- 23.......................
Chapter 6 -- Chassis
Specifications 6 -- 2..............................
General Information 6 -- 3........................
Special Tools 6 -- 4..............................
Troubleshooting 6 -- 5............................
Adjustments 6 -- 8...............................
Service and Repairs 6 -- 11.......................
Chapter 7 -- Electrical Drawings
Electrical Schematic 7 -- 3........................
Circuit Diagrams 7 -- 4...........................
Electrical Harness Drawings 7 -- 8.................
SafetyProduct Records
Diesel
Drive TrainElectrical
and Maintenance
Engine
System
Workman MDX--D
Chassis
Electrical
Drawings
This page is intentionally blank.
Workman MDX--D
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 MDX--D Page 1 -- 1 Safety
Safety Instructions
Workman MDX--D 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--h ighway 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 diesel fuel used in your Workman MDX--D
vehicle is flammable, handle it carefully:
A. Store fuel in containers specifically designed for
this purpose.
B. Do not r emove 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. Cleanupanyspilledfuel.
Workman MDX--DPage 1 -- 2Safety
While Operating
1. Sit on the operator seat when starting and operating
the vehicle.
2. Before starting the engine:
A. Sit on o perator’sseat and depress the brake pedal. Make sure that the parking brake is released.
B. Turn ignition switch to the ON position. When the
glow plug indicator goes off, the engine is ready to
start.
C. Turn ignition switch to the START position. Release switch to the ON position once the engine
starts.
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, stop the engine, set parking brake and remove key from the ignition switch.
4. Do not touch engine, radiator, exhaust system or
transaxle while engine is running or soon after it is
stopped. These areas could be hot enough to cause
burns.
5. Before getting off the seat:
A. Stop movement of the vehicle.
B. Turn ignition switch to OFF and wait for all movement to stop.
C. Apply parking brake.
D. Remove key from ignition switch.
E. Do not park on slopes unless 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.
Safety
2. Make sure vehicle is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Never work under a raised bed without placing the
bed on the fully extended prop rod.
4. Never store the vehicle or fuel container inside
where there is an open flame, such as near a water heater or furnace.
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. To assure safety and accuracy, check maximum
engine speed. Maximum engine speed is 3470 RPM.
8. Shut engine off before checking or adding oil to the
engine crankcase.
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.
Attach positive (+) cable first and negative (--) cable last.
11.Battery gases can explode. Keep cigarettes, sparks
and flames away from the battery.
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 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.
14.When raising the vehicle to change tires or to perform other service, use correct blocks, hoists and jacks.
Make sure vehicle is parked on a solid level surface such
as a concrete floor. Prior to raising the vehicle, remove
any attachments that may interfere with the safe and
proper raising of the vehicle. Always chock or block
wheels. Use appropriate jack stands to support the
raised vehicle. If the vehicle is not properly supported by
jack stands, the vehicle may move or fall, which may result in personal injury (see Jack Vehicle in this section).
15.Make sure to dispose of potentially harmful waste
(e.g. fuel, oil, engine coolant, filters, battery) in an environmentally safe manner. Follow a ll local codes and regulations when recycling or disposing of waste.
Workman MDX--D 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 MDX--D 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 MDX--DPage 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 when
the transaxle is in the neutral position. If tire rotation
does occur, see Adjust Shift Cables in the Adjustments
section of Chapter 4 -- Drive Train.
3
1. Shift lever (in neutral)
2. Forward position
1
Figure 3
3. Reverse position
Workman MDX--D 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 MDX--DPage 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 MDX--D Page 2 -- 1 Product Records and Maintenance
Equivalents and Conversions
0.09375
Workman MDX--DPage 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 shall 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
thelinesmatchup.
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 MDX--D Page 2 -- 3 Product Records and Maintenance
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Thread Size
#6--32UNC
#6--40UNF 17 + 2 192 + 23 25 + 3 282 + 34
#8--32UNC
#8--36UNF 31 + 4 350 + 45 43 + 5 486 + 56
#10--24UNC
#10--32UNF 48 + 5 542 + 56 68 + 7 768 + 79
1/4 -- 20 UNC 48 + 7 53 + 7 599 + 79 100 + 10 1130 + 11 3 140 + 15 1582 + 169
1/4 -- 28 UNF 53 + 7 65 + 10 734 + 113 115 + 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
29 + 3 328 + 34 41 + 5 463 + 56
42 + 5 475 + 56 60 + 6 678 + 68
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.
Workman MDX--DPage 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
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 - -cm 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: 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.
Regular Height Nuts
(Class 8 or Stronger Nuts)
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% of the
and Maintenance
Product Records
Workman MDX--D 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
Typ e A Type 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 11 0 + 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
* Hole size, material strength, material thickness and fin-
ish must be considered when determining specific
torque values. All torque values are based on non--lubri-
cated fasteners.
Workman MDX--DPage 2 -- 6Product Records and Maintenance
Table of Contents
SPECIFICATIONS 2............................
GENERAL INFORMATION 3.....................
Operator’s Manual 3..........................
ADJUSTMENTS 5..............................
Adjust Throttle Cable 5........................
SERVICE AND REPAIRS 6......................
Air Cleaner 6.................................
Exhaust System 8............................
Fuel Tank 10.................................
Radiator 12..................................
Engine 14....................................
Engine Removal 15..........................
Engine Installation 16........................
Engine Clutch Adapter 18......................
KUBOTA WORKSHOP MANUAL, DIESEL ENGINE,
SM--E3B SERIES
Chapter 3
Diesel Engine
Diesel
Engine
Workman MDX--D Page 3 -- 1 Diesel Engine
Specifications
Item Description
Make / Designation Kubota water--cooled, Diesel,
Number of Cylinders 2
Bore x Stroke 2.83” x 2.9” (72mm x 73.6mm)
Total Displacement 36.55 in3(599 c c)
Compression Ratio 24.0:1
Firing Order 1 (closest to gear case end) -- 2 (closest to flywheel end)
Direction of Rotation Counterclockwise (viewed from flywheel)
Fuel Diesel Fuel with Low or
Fuel Injector Pump Bosch MD Type Mini
Fuel Injection Nozzle Bosch Throttle Type
Fuel Capacity 6.5 U.S. gallons (24.6 liters)
Governor Mechanical
Model Z602--E3B
Ultra Low Sulfur Content
Low Idle (no load) 1300 + 70 RPM
High Idle (no load) 3470 + 50 RPM
Engine Oil API CH--4, CI--4, CJ--4 or higher
Engine Oil Viscosity See Operator’s Manual
Oil Pump Gear Driven Trochoid Type
Crankcase Oil Capacity 2.6 U.S. quarts (2.5 liters) with filter
Cooling System Capacity (including reserve tank) 3.0 U.S. quarts (2.8 liters)
Starter 12 VDC 0.95 KW
Alternator/Regulator 12 VDC 40 AMP
Dry Weight (approximate) 132 lbs (60 kg)
Workman MDX--DPage 3 -- 2Diesel Engine
General Information
This Chapter gives information about specifications,
maintenance, troubleshooting, testing and repair of the
dieselengineusedintheWorkmanMDX--D.
Most repairs and adjustments require tools which are
commonly available in many service shops. Special
tools a re described in the Kubota Workshop Manual,
Diesel Engine, SM--E3B Series. The use of some specialized test equipment is explained. However, the cost
Operator’s Manual
The Operator’s Manual provides information regarding
the operation, general maintenance and maintenance
intervals for your Workman MDX--D vehicle. Refer to the
Operator’s Manual for additional information when servicing the machine.
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 the Kubota engine in your
Workman 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.
Diesel
Engine
Workman MDX--D Page 3 -- 3 Diesel Engine
This page is intentionally blank.
Workman MDX--DPage 3 -- 4Diesel Engine
Adjustments
Adjust Throttle Cable
Proper throttle operation is dependent upon proper adjustment of throttle control. Make sure throttle control is
operating properly.
NOTE: The shoulder bolt that secures the throttle cable
to the engine speed control lever should be positioned
inthelowestholeinthelever.
1. Fully depress throttle pedal to position engine speed
control lever in the high speed position.
2. Check position of the engine speed control lever on
the fuel injection pump (Fig. 1). The speed control lever
should contact the high speed screw when the throttle
pedal is fully depressed.
3. If necessary, throttle control can be adjusted by loosening cable jam nuts and repositioning throttle cable until speed control lever contacts high speed screw when
the throttle pedal is fully depressed (Fig. 2). Tighten
cable jam nuts after adjustment has been completed.
3
1
1. High speed screw
2. Speed control lever
2
Figure 1
3. Engine run solenoid
Diesel
Engine
4. Release throttle pedal and make sure that cable is
loose enough to allow engine speed control lever to return to the idle position.
2
5
1. Diesel engine
2. Throttle cable
3. Shoulder bolt
1
3
4
Figure 2
4. Flange nut
5. Throttle cable mount
Workman MDX--D Page 3 -- 5 Diesel Engine
Service and Repairs
Air Cleaner
8
10
5
3
1
7
2
4
9
11
6
1. Air cleaner assembly
2. Carriage screw (2 used)
3. Air intake hose
4. Air cleaner mounting bracket
Figure 3
5. Air inlet hood
6. Flange nut (2 used)
7. Hose clamp (2 used)
8. Throttle cable
FRONT
RIGHT
9. Shoulder bolt
10. Throttle cable mount
11. Fla nge nut
Workman MDX--DPage 3 -- 6Diesel Engine
Air Cleaner Removal (Fig. 3)
1. Park machine on a level surface, stop the engine, engage parking brake and remove the key from the ignition
switch.
1
5
2
2. Raise and support cargo bed to access air cleaner.
3. Remove air cleaner components as needed using
Figure 3 as a guide.
4. Check air cleaner hose (item 3 in Fig. 3) for damage
or wear. Replace hose if damage is found.
5. Disassemble air cleaner as necessary (Fig. 4).
6. Check air cleaner housing and cover for damage that
could cause possible air leaks.
Air Cleaner Installation (Fig. 3)
IMPORTANT: Any leaks in the air cleaner 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 air cleaner system using Figures 3 and 4
as guides.
A. If plug (item 5 in Fig. 4) was removed from air
cleaner housing, apply sealant to threads of plug beforeassembly.Torqueplugto30 in-- lb (3.4 N--m).
B. Make sure that vacuator valve on air cleaner assembly is pointed down after assembly.
30 in--lb
(3.4 N--m)
1. Housing
2. Filter element
3. Cover
2
Figure 4
4. Vacuator valve
5. Plug
6. Gasket
0.180” (4.6 mm)
3
1
4
Maximum
6
3
Diesel
Engine
C. Make sure that clearance between air intake
hose and air inlet hood is less than 0.180” (4.6 mm)
(Fig. 5). If this clearance is excessive, the intake
hose may contact secondary clutch during suspension movement. Rotate intake hose to modify clearance as needed.
2. Lower and secure cargo bed.
1. Air cleaner assembly
2. Air inlet hood
Figure 5
3. Air intake hose
Workman MDX--D Page 3 -- 7 Diesel Engine
Exhaust System
RIGHT
FRONT
1
7
9
6
1. Engine
2. Exhaust header
3. Coupler spring (2 used)
3
2
4. Flange nut (4 used)
5. Muffler
6. Hex nut (4 used)
4
Figure 6
5
4
3
8
7. Exhaust gasket
8. Flange head screw (4 used)
9. Lock washer (4 used)
Workman MDX--DPage 3 -- 8Diesel Engine
Exhaust System Removal (Fig. 6)
Exhaust System Installation (Fig. 6)
1. Park machine on a level surface, stop the engine, engage parking brake and remove the key from the ignition
switch.
2. Raise and support cargo bed to access exhaust system.
CAUTION
The muffler and exhaust pipe may be hot. To
avoid possible burns, allow the engine and exhaust system to cool before working on the muffler.
3. Remove exhaust system components as needed using Figure 6 as a guide.
1. Make sure the engine is off.
IMPORTANT: If exhaust studs were removed from
engine cylinder head, thoroughly clean threads in
head and apply Loctite #277 (or equivalent) to stud
threads before installing studs into head.
NOTE: Make sure exhaust header flange and engine
exhaust manifold sealing surfaces are free of debris or
damage that may prevent a tight seal.
2. If exhaust gasket (item 7) was removed, place new
exhaust gasket on the engine exhaust manifold.
NOTE: To ensure proper exhaust system sealing,
mount all exhaust system components loosely before
fully tightening any fastener.
3. Assemble all removed exhaust system components
usingFigure6asaguide.
4. After all exhaust components have been assembled,
make sure that all fasteners are properly tightened.
Also, make sure that all electrical wires and control
cables are not contacted by exhaust components.
Diesel
Engine
5. Lower and secure cargo bed.
Workman MDX--D Page 3 -- 9 Diesel Engine
Fuel Tank
RIGHT
FRONT
1
9
10
5
3
4
2
6
8
7
1. Seat
2. Fuel tank
3. Fuel hose (to fuel separator)
4. Fuel hose (return from engine)
Figure 7
5. Seat base
6. Web strapping
7. Hex head flange screw (8 used)
8. Flat washer (8 used)
9. Parking brake support
10. Shift bracket
Workman MDX--DPage 3 -- 10Diesel Engine
Fuel Tank Removal (Fig. 7)
17
CAUTION
Read safety precautions for handling fuel before
working on the fuel system (see Safety Instructions in Chapter 1 -- Safety).
1. Remove seat base from the frame (see Seat Base in
the Service and Repairs section of Chapter 6 -- Chassis).
2. Use f uel transfer pump to remove fuel from fuel tank.
3. Loosen hose clamp and disconnect fuel return hose
(item 13 in Figure 8) from elbow fitting in fuel tank.
4. Loosen hose clamp and disconnect fuel supply hose
(item 17 in Figure 8) from the fuel pump.
5. Disconnect fuel pump electrical connector from
vehiclewireharness.
6. Release tank strap that secures fuel tank to frame.
Do not remove strap from floor plate and frame cross
member. Lift fuel tank assembly from frame.
7. Remove fuel tank components as needed using Figure 8 as a guide.
12
15
12
1. Fuel tank
2. Fuel cap
3. Rollover valve
4. Bushing
5. Grommet
6. Stand pipe
7. Elbow fitting
8. Fuel gauge
9. Grommet
14
13
1
16
12
11
4
Figure 8
10. Vent hose
11. Hose clam p
12. Hose clamp
13. Fuel return hose
14. Fuel pump
15. Fuel pump holder
16. Fuel supply hose
17. Fuel supply hose
10
8
11
3
6
7
5
9
2
Diesel
Engine
8. Clean fuel tank before installing it back on vehicle.
Fuel Tank Installation (Fig. 7)
1. Install all removed fuel tank components using Figure 8 as a guide.
2. Position fuel tank to frame. Secure tank to frame and
cross member with tank strap.
3. Connect fuel supply hose (item 17 in Figure 8) to the
fuel pump and fuel return hose (item 13 in Figure 8) to
the elbow fitting. Secure hoses with hose clamps.
4. Connect fuel pump electrical connector to vehicle
wire harness.
5. Install seat base to the frame (see Seat Base in the
Service and Repairs section of Chapter 6 -- Chassis).
6. Fill fuel tank.
Workman MDX--D Page 3 -- 11 Diesel Engine
Radiator
13
3
13
RIGHT
2
16
15
23
21
23
4
18
14
14
20
5
22
1
12
7
20
10
12
19
17
19
12
5
12
9
6
23
8
12
11
FRONT
1. Surge tank
2. Tank cap
3. Radiator
4. Washer head screw (2 used)
5. Flange nut (3 used)
6. Cap
7. Cap decal
8. Filler neck
9. Lower radiator hose
10. Upper radiator hose
11. Straight hose
12. Hose clamp (6 used)
13. Carriage screw (3 used)
14. Flange nut (3 used)
15. Cap
16. Hose clamp
CAUTION
DO NOT open radiator cap or drain coolant if the
engine or radiator is hot. Pressurized hot coolant
can escape and cause burns.
Ethylene--glycol antifreeze is poisonous. Dispose of it properly or store it in a properly labeled
container away from children and pets.
Figure 9
17. Lower radiator shroud
18. Upper radiator shroud
19. Speed nut (4 used)
20. Washer head screw (4 used)
21. Coolant hose
22. Coolant hose
23. Hose clamp (4 used)
Radiator Removal (Fig. 9)
1. Park machine on a level surface, stop the engine, en-
gage parking brake and remove the key from the ignition
switch.
2. Raise and support cargo bed to access radiator.
3. Remove knob that secures radiator screen to right
side of rear frame (Fig. 10). Lift screen to separate tabs
on screen from slots in frame and then remove screen
from vehicle.
Workman MDX--DPage 3 -- 12Diesel Engine
4. Remove caps (items 2 and 6) from surge tank and radiator filler neck to allow complete draining of cooling
system.
5. Drain radiator into a suitable container by disconnecting lower radiator hose from the radiator.
6. Disconnect upper radiator hose from the radiator.
7. Disconnect the coolant hose (item 22) from the fitting
located on the lower r adiator tube.
8. Remove four (4) washer head screws (item 20) and
three (3) flange nuts (item 14) that secure the radiator
shrouds. Also, disconnect wire harness clips from upper
radiator shroud. Carefully remove upper r adiator shroud
from vehicle.
9. Position lower radiator shroud away from the radiator.
IMPORTANT: Use a 50/50 mix of ethylene--glycol
and water when filling cooling system.
7. Fill cooling system with coolant as follows (Fig. 11):
A. Make sure that surge tank cap is installed on
surge tank.
B. Remove cap on radiator filler neck and fill cooling
system with coolant.
C. Install cap into radiator filler neck and tighten.
D. Remove surge tank cap and fill surge tank to the
bottom of the filler neck. Install surge tank cap.
8. Check radiator, surge tank, hoses and all connections for leaks.
9. Lower and secure cargo bed.
10.Remove three (3) carriage head screws (item 13)
and flange nuts (item 14) that secure the radiator to the
rear frame.
11. Carefully remove radiator from vehicle.
Radiator Installation (Fig. 9)
1. Make sure that lower radiator shroud is positioned
under the engine fan.
2. Carefully position radiator to the rear frame. Secure
radiator to frame with three (3) carriage head screws
(item 13) and flange nuts (item 14).
3. Position upper and lower radiator shrouds around
the fan and to the radiator. Secure shrouds together with
four (4) washer head screws (item 20). Then, secure
shrouds to frame with three (3) flange nuts (item 14).
Make sure that equal clearance exists between shrouds
and fan at all points.
4. Connect upper and lower radiator hoses to radiator
and secure with hose clamps.
5. Connect coolant hose (item 22) to the fitting located
on the lower radiator tube and s ecure with hose clamp.
Make sure that hose is not kinked at any point after installation.
1. Rear frame
2. Radiator screen
1
4
Figure 10
3. Knob
4. Slot
Diesel
Engine
1
4
2
3
2
6. Install radiator screen to rear frame and secure with
knob (Fig. 10).
Figure 11
1. Filler neck cap 2. Surge tank cap
Workman MDX--D Page 3 -- 13 Diesel Engine
Engine
17
1
11
2
9
10
8
7
4
3
6
16
15
5
7
RIGHT
14
FRONT
13
12
1. Engine
2. Engine wire harness connector
3. Hex nut
4. Negative battery cable
5. Engine wire harness connector
6. Lock washer
Figure 12
7. Flange head screw (8 used)
8. Hex nut (4 used)
9. Lock washer (4 used)
10. Exhaust header
11. Flange nut (4 used)
12. Cap screw (4 used)
13. Snubbing washer (4 used)
14. Spacer (4 used)
15. Engine mount (4 used)
16. Engine bracket (front shown)
17. Drive belt
Workman MDX--DPage 3 -- 14Diesel Engine
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