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

E The Toro Company -- 2013

This page is intentionally blank.

Workman MDX--D

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

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

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.

Figure 1

1. Front frame 2. Towing tongue

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.

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.

1. Shift lever (in neutral)

2. Forward position

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

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: 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

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

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.

1. High speed screw

2. Speed control lever

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.

1. Diesel engine

2. Throttle cable

3. Shoulder bolt

Figure 2

4. Flange nut

5. Throttle cable mount

Workman MDX--D Page 3 -- 5 Diesel Engine

Service and Repairs

Air Cleaner

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.

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

Figure 4

4. Vacuator valve

5. Plug

6. Gasket

0.180” (4.6 mm)

Maximum

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. Engine

2. Exhaust header

3. Coupler spring (2 used)

4. Flange nut (4 used)

5. Muffler

6. Hex nut (4 used)

Figure 6

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. 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)

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.

1. Fuel tank

2. Fuel cap

3. Rollover valve

4. Bushing

5. Grommet

6. Stand pipe

7. Elbow fitting

8. Fuel gauge

9. Grommet

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

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

RIGHT

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

Figure 10

3. Knob

4. Slot

Diesel

Engine

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

RIGHT

FRONT

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

Engine Removal (Fig. 12)

1. Park machine on a level surface, stop engine, engage parking brake and remove key from the ignition switch.

CAUTION

The engine, radiator and exhaust system may be hot. To avoid possible injury, allow machine to cool before working on the engine.

2. Disconnect negative (black) cable from the battery. Then, disconnect positive (red) cable from the battery.

3. Remove cargo b ox to gain access to the engine (see Cargo Box in the Service and Repairs s ection of Chapter 6--Chassis).

4. Carefully remove drive belt from drive clutch.

5. Depending on needed engine repairs, it may be easier to drain oil from engine before engine removal.

IMPORTANT: To prevent contaminants from enter ing the engine and fuel system, make sure all hoses and engine openings are c overed or plugged after disconnecting.

6. Drain radiator into a suitable container by disconnecting lower radiator hose from the radiator. Then, remove upper radiator hose from the radiator.

7. Remove air intake hose from the air cleaner and engine intake (see Air Cleaner in this section).

8. Remove muffler and exhaust header from the vehicle (see Exhaust System in this section).

9. Remove shoulder bolt and flange nut that secure the throttle cable end to injector pump speed control lever (Fig. 13). Loosen nuts that secure throttle cable to cable mount. Position throttle cable away from e ngine.

1. Diesel engine

2. Throttle cable

3. Shoulder bolt

1. Alternator

2. Temperature switch

Figure 13

Figure 14

4. Flange nut

5. Throttle cable mount

3. Glow plug bus

4. Engine run solenoid

Diesel

Engine

CAUTION

Read safety precautions for handling fuel before working on the fuel system (see Safety Instructions in Chapter 1 -- Safety).

10.Disconnect fuel supply hose from the injector pump and fuel return hose from the #2 injector. Drain any fuel trapped in the hoses into a suitable container. Plug hoses and position them away from engine assembly.

1. Flange nut (8 used)

2. Flange screw (8 used)

Figure 15

3. Engine mount (4 used)

Workman MDX--D Page 3 -- 15 Diesel Engine

11. Disconnect electrical connections from the following engine components:

A. Disconnect main wire harness connections to glow plug bus, temperature sender and engine run solenoid (Fig. 14).

B. Disconnect main wire harness connection to fusible link harness.

C. Disconnect engine wire harness connector from themainwireharness.Theenginewireharnessincludes connectors for the alternator, oil pressure switch, starter solenoid and engine ground.

D. Remove flange head screw from front engine mount that secures negative battery cable and engine ground connector. Make sure to note location of lock washer when removing screw. Position negative battery cable away from engine.

12.Remove four (4) flange nuts, spacers, snubbing washers and cap screws that secure the engine to the engine mounts.

Figure 16

1. Front engine bracket

2. Rubber bumper

Engine Installation (Fig. 12)

1. Install all removed mounts, components and attach-

ments to the engine.

3. Lock nut (3 used)

4. Carriage screw (3 used)

CAUTION

Make sure that hoist or lift used t o remove engine can properly support engine. Engine assembly weighs approximately 170 pounds (77 kg). Also, one person should operate the hoist while a second person guides the engine out of the vehicle.

13.Remove engine from the vehicle.

A. Attach a short section of chain between both engine lift tabs.

B. Connect hoist to center of chain.

IMPORTANT: Make sure to not damage the engine, fuel hoses, electrical harness or other parts while removing the engine.

C. Carefully move the engine assembly away from the r adiator and when the engine has cleared the radiator shrouds, carefully raise the engine from the vehicle.

14.Remove engine brackets, components and attachments a s necessary to repair the engine.

15.Inspect engine mounts (Fig. 15) and bumper assembly (Fig. 16) for wear or damage and replace components if necessary.

CAUTION

Make sure that hoist or lift u sed to install engine can properly support engine. Engine assembly weighs approximately 170 pounds (77 kg). Also, one person should operate the hoist while a second person guides the engine into the vehicle.

2. Install engine to the vehicle.

A. Attach a short section of chain between both engine lift tabs.

B. Connect a hoist at the center of the short section of chain.

IMPORTANT: Make sure to not damage engine, fuel lines, electrical harness or other parts while installing the engine.

C. Carefully lower engine assembly into the engine area of the vehicle. Align holes in engine brackets with engine mounts attached to frame.

3. Secure engine to engine mounts with four (4) cap

screws, snubbing washers, spacers and flange nuts.

Workman MDX--DPage 3 -- 16Diesel Engine

4. Connect the following electrical components:

A. Connect main wire harness connections to glow plug bus, temperature sender and engine run solenoid (Fig. 14).

8. Install exhaust header and muffler to the vehicle (see Exhaust System in this section).

9. Install air intake hose to the air cleaner and engine intake (see Air Cleaner in this section).

B. Connect main wire harness connection to fusible link harness.

C. Connect engine wire harness connector to the main wire harness.

D. Secure negative battery cable and engine ground connector to front engine mount with flange head screw. The order of assembly should be lock washer, negative battery cable, engine ground connector and then flange head screw. Coat connectors with skin over grease or terminal protector (see Special Tools in Chapter 5 -- Electrical System) after assembly.

5. Install drive belt to drive clutch.

IMPORTANT: Make sure to remove all plugs and covers that were placed on hose and engine openings during engine removal.

6. Connect fuel supply hose to the injector pump and fuel return hose to the #2 injector.

7. Position throttle cable to engine. Secure the throttle cable end to injector pump speed control lever with shoulder bolt and flange nut. Tighten cable nuts to secure cable to cable mount (Fig. 13). Check throttle cable adjustment (see Adjust Throttle Cable in the Adjustments section of this chapter).

10.Connecting lower and upper radiator hoses to t he radiator. Fill cooling system with coolant (see Radiator in this section). Check radiator and hoses for leaks.

11.Make sure that alternator belt tension is properly adjusted.

12.Check that the gap between the rubber bumper and front engine bracket is 0.090” (2.2 mm) (Fig.16).Ifgap is incorrect, loosen three (3) lock nuts and adjust bumper to provide correct gap. Tighten lock nuts to secure bumper after adjustment.

13.Make sure engine oil level is correct.

14.Install cargo box to the frame (see Cargo Box in the Service and Repairs section of Chapter 6 -- Chassis).

15.Connect positive (red) cable to the battery. Then, connect negative (black) cable to the battery.

Diesel

Engine

Workman MDX--D Page 3 -- 17 Diesel Engine

Engine Clutch Adapter

17 to 22 ft--lb

Loctite #242

(23to29N--m)

RIGHT

FRONT

1. Drive belt

2. Cap screw

3. Flange washer

4. Drive clutch

5. Cap screw (5 used)

Removal (Fig. 17)

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 engine.

3. Carefully remove drive belt from drive clutch.

4. Remove drive clutch from clutch adapter on engine (see Drive Clutch in the Service and Repairs section of Chapter 4 -- Drive Train).

Figure 17

6. Clutch adapter

7. Engine assembly

Installation (Fig. 17)

1. Position clutch adapter to engine flywheel and se-

cure with five (5) cap screws.

2. Secure drive clutch to clutch adapter on engine (see

Drive Clutch in the Service and Repairs section of

Chapter 4 -- Drive Train).

3. Install drive belt to drive clutch.

4. Lower and secure cargo bed.

5. Remove five (5) cap screws that secure clutch adapter to engine flywheel. Remove clutch adapter from engine.

Workman MDX--DPage 3 -- 18Diesel Engine

SPECIFICATIONS 2............................

GENERAL INFORMATION 3.....................

Operator’s Manual 3..........................

DRIVE TRAIN OPERATION 4....................

Clutch System Operation 4.....................

Drive Clutch Operation 5.......................

Driven Clutch Operation 6.....................

SPECIAL TOOLS 7.............................

TROUBLESHOOTING 8.........................

Clutch 8.....................................

ADJUSTMENTS 9..............................

Adjust Shift Cables 9..........................

SERVICE AND REPAIRS 10.....................

Drive Clutch 10...............................

Drive Clutch Service 12........................

Driven Clutch 14..............................

Driven Clutch Service 15.......................

Transaxle 16.................................

Removal 17................................

Installation 18...............................

Transaxle Service 20..........................

Transaxle Disassembly and Inspection 21......

Transaxle Assembly 32......................

Chapter 4

Drive Train

Workman MDX--D Drive TrainPage 4 -- 1

Specifications

Item Description

Transaxle

Transaxle Fluid Capacity 1.5 quarts (1.4 liters) Transaxle Fluid SAE 10W--30 Motor Oil Transaxle Dry Weight 73 pounds (33 kilograms)

Clutch System Continuously variable transmission type, torque convertor

Drive Clutch Speed sensing with mechanical fly weights Driven Clutch Torque sensing with spring loaded cam

Workman MDX--DPage 4 -- 2Drive Train

General Information

Operator’s Manual

Drive Train

Workman MDX--D Drive TrainPage 4 -- 3

Drive Train Operation

Clutch System Operation

LOW ENGINE SPEED

LIGHT LOAD

FULL ENGINE SPEED DECREASING LOAD

FULL ENGINE SPEED

INCREASING LOAD

1. Drive clutch

2. Driven clutch

3. Moveable sheave (drive clutch)

4. Fixed sheave (drive clutch)

5. Moveable sheave (driven clutch)

6. Spring

Power is transferred from t he engine to the transaxle by a variable clutch system that consists of two (2) clutches connected by a drive belt. The drive clutch responds to engine speed and is mounted to the engine crankshaft. The driven clutch responds to changes in load to the rear axle and is mounted to the transaxle input shaft.

Figure 1

7. Fixed sheave (driven clutch)

8. CVT drive belt

The two (2) clutches work together to automatically up-shift and back--shift as changes in load and speed occur. This shifting changes the turning ratio between the drive and driven clutches and allows the engine to operate at optimum efficiency.

Workman MDX--DPage 4 -- 4Drive Train

Drive Clutch Operation

The operation of the drive clutch is affected by engine shaft speed. With the engine not turning, the CVT drive belt rests low within the drive clutch sheaves as the pressure of the spring holds the sheaves apart. As the engine increases in speed, the clutch weights attached to the moveable sheave move outward as they spin about the engine driveshaft. The outward movement of the clutch weights presses against the rollers and overcomes spring pressure through the spider assembly, which forces the moveable sheave closer to the fixed sheave. This inward movement of the sheave engages the drive belttodrivethedrivenclutch.

With increasing engine speed, the moveable sheave continues to move inward, which forces the drive belt to ride towards the outer diameter of the clutch sheaves.

When engine speed is decreased, the clutch weights exert less force on the rollers and thus the spring. The spring pressure overcomes the force of the clutch weights and shifts the moveable sheave away from the fixed sheave. The drive belt disengages from the clutch sheaves at a point where the force of the spring is greater than that of the clutch weights.

1. Fixed sheave

2. Moveable sheave

3. Spider assembly

4. Cover

Figure 2

5. Clutch weight (3 used)

6. Roller (3 used)

7. Spring

Drive Train

Workman MDX--D Drive TrainPage 4 -- 5

Driven Clutch Operation

Theoperationofthedrivenclutchisaffectedbytransaxle load. When the vehicle is stopped, the drive belt is held at the outer diameter of the driven clutch sheaves from the pressure of the spring pushing the moveable sheave against the fixed sheave and away from the fixed cam.

Once the drive belt starts rotating, the driven clutch also starts to rotate. With increasing speed of the drive clutch on the engine, the drive belt begins to climb to the outer diameter of the drive clutch sheaves. This increases the tension on the drive belt and forces the moveable sheave of the driven clutch to move away from the fixed sheave against the pressure of the driven clutch spring. As the belt tightens and the driven clutch sheaves open up, the drive belt rides lower in the driven clutch sheaves.

With increased load to the transaxle, the driven clutch fixed cam resists forward movement relative to the moveable sheave and drive belt. Torque from the drive belt along with spring pressure moves the moveable sheave up the ramp of the fixed cam. The drive belt becomes positioned closer to the outer diameter of the driven clutch sheaves.

1. Moveable sheave

2. Fixed sheave

Figure 3

3. Spring

The fixed cam on the driven clutch moveable sheave rotates on a pair of rollers in the fixed sheave base to allow low friction movement of the moveable sheave (Fig. 3).

Workman MDX--DPage 4 -- 6Drive Train

Special Tools

Order special tools from your Toro Distributor.

Drive Clutch Removal Tool

This tool is required to remove the drive clutch from the tapered drive shaft of the engine. It is placed in the threaded hole of the fixed clutch sheave after the clutch retaining screw is removed.

Toro Part Number: TOR6014

Figure 4

Drive Train

Workman MDX--D Drive TrainPage 4 -- 7

Troubleshooting

Clutch

Problem Possible Cause

Poor upshifting. Governed engine speed is adjusted too low.

Driveand/ordrivenclutchassemblieshaveaccumulationofdirtor debris.

Drive belt is worn.

Clutch sheaves are worn or damaged.

Poor downshifting. Driveand/ordrivenclutchassembly has accumulation of dirt or

debris.

Drive belt is worn.

Clutch sheaves are worn or damaged.

Vehicle creeps at idle. Engine idle speed is too high.

Drive clutch has accumulation of dirt or debris preventing full backshifting.

Drive and driven clutches are not aligned.

Rough clutch engagement. Engine idle speed is too low.

Drive clutch assembly has accumulation of dirt or debris.

Drive belt is worn.

Drive clutch sheaves are worn or damaged.

Noisy clutch operation. Engine idle speed is too low causing excess shaking.

Worn drive clutch roller or weight bushings.

Worn drive clutch spider slides (drive clutch replacement necessary if found).

Workman MDX--DPage 4 -- 8Drive Train

Adjustments

Adjust Shift Cables

1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. Raise and support cargo box.

2. Set the shift lever into the Neutral position. Rotate driven clutch to insure transmission is in neutral.

3. The transaxle select lever assembly should be in a level position and parallel to the cable mounting bracket.

4. While holding the cable below the lever, tighten the lock nut on one of the shift cables to allow 0.030” to

0.060” (0.8 to 1.5 mm) freeplay in the cable (Fig. 6).

5. Repeat process for other shift cable.

6. Pull up on each shift cable to make sure that freeplay is correct. If necessary, readjust nut (Fig. 6).

7. Start engine and verify transaxle engagement in forward, reverse and neutral as the shift lever is moved.

8. Finally, check vehicle operation in forward, reverse and neutral. Readjust shift cables if needed for correct operation.

1. Select lever assembly

2. Lock nut location

Figure 5

3. Shift cable

Drive Train

9. Lower and secure cargo box.

1. Select lever

2. Cable pull direction

0.030” to 0.060” (0.8 to 1.5 mm)

Figure 6

3. Cable boot

Workman MDX--D Drive TrainPage 4 -- 9

Service and Repairs

Drive Clutch

RIGHT

FRONT

1. Engine

2. Clutch adapter

3. Cap screw (5 used)

4. Drive belt

5. Drive clutch

Loctite #242

17 to 22 ft--lb

(23 to 29 N--m)

Figure 7

6. Flange washer

7. Cap screw

Workman MDX--DPage 4 -- 10Drive Train

Drive Clutch Removal (Fig. 7 )

Drive Clutch Installation (Fig. 7)

1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. Raise and support cargo box.

2. Carefully remove drive belt from the drive clutch.

3. Remove cap screw (item 7) and flange washer (item

6) securing the drive clutch to the clutch adapter.

IMPORTANT: Lightly grease end of clutch removal tool to prevent wear or damage to removal tool and clutch adapter. Prevent damage to clutch threads; thread tool into clutch only enough to remove the clutch.

4. Use drive clutch removal tool (see Special Tools in this chapter) to remove drive clutch from the tapered clutch adapter.

5. Inspect the tapered ends of the clutch adapter and fixed sheave of drive clutch. If e ither is severely damaged, replace component as damage to the taper will allow loosening of the clutch during operation.

1. Thoroughly clean the tapered surfaces of the clutch adapter and drive clutch.

2. Slide drive clutch onto the clutch adapter.

3. Apply Loctite #242 (or equivalent) to the threads of the cap screw (item 7).

4. Secure clutch to clutch adapter with cap screw (item

7) and flange washer (item 6). Torque cap screw from 17 to 22 ft--lb (23 to 29 N--m).

5. Install drive belt to the drive clutch.

6. Lower and secure cargo box.

Drive Train

Workman MDX--D Drive TrainPage 4 -- 11

Drive Clutch Service

40 to 50 in--lb

(4.6 to 5.6 N-- m)

1. Flange head screw (6 used)

2. Cover

3. Compression spring

4. Limiter shim

Disassembly (Fig. 8)

105 to 120 in--lb

(12to13.5N--m)

Figure 8

5. Shoulder screw (3 used)

6. Lock nut (3 used)

7. Clutch weight (3 used)

8. Spider

9. Shim

10. Moveable sheave

11. Fixed sheave

IMPORTANT: Make note of the “X” mark cast into the cover and spider before clutch disassembly. These marks must be aligned during assembly for proper clutch operation.

1. Make note of the “X” mark cast into the cover and spider before clutch disassembly (Fig. 9). These marks must be aligned during assembly for proper clutch operation.

CAUTION

Loosen the flange head screws that secure cover slowly. The cover is under pressure from the compression spring.

2. Using a crossing pattern, loosen and remove six (6) flange head screws (item 1) that secure the cover to the movable sheave.

3. Carefully remove cover, compression spring and limiter shim from clutch.

Figure 9

1. Spider 2. Cover

4. Remove lock nut (item 6) from each of the shoulder screws (item 5). Discard lock nuts after removal.

Workman MDX--DPage 4 -- 12Drive Train

5. Slide shoulder screw from each of the clutch weights (item 7) and then remove weights from clutch.

6. Clean all dust and debris from clutch components with a soft bristle brush. If necessary, use water to remove dirt and dry immediately with compressed air to remove all dirt and water. Remove any remaining debris with a fast drying contact or brake parts cleaner. Focus debris removal on and around moving clutch components.

Inspection

NOTE: Ifdriveclutchwearordamageoccurs,clutchre-

placement may be necessary. Refer to your parts catalog to identify individual drive clutch components that are available.

3. Position limiter shim, compression spring and cover to clutch. Make sure that the “X” mark cast into the cover and spider are aligned.

4. Secure cover to the movable sheave with six (6) flange head screws in a crossing pattern and in three (3) steps. Final torque on screws should be from 105 to 120

in--lb (12 to 13.5 N--m).

1. Inspect the tapered ends of the engine crankshaft and fixed sheave of drive clutch. If either is severely damaged, replace component as damage to the taper will allow loosening of the clutch during operation.

2. Inspect the compression spring (item 3) and replace if damaged or fatigued.

3. Clean and inspect shoulder screws (item 5). If the shoulder area of the screws is worn or if the threads are damaged, replace the screws.

4. Check the contact surface of the clutch weights (Fig.

10). If surface is worn or damaged, replace all three (3) clutch weights as a set.

5. Check the rollers in the spider assembly for binding or wear (Fig. 11). If binding or uneven wear is found, replace clutch assembly.

6. Check the belt contact surfaces of the movable and fixed sheaves. Remove any belt material from sheave faces with a fine abrasive pad or fine steel wool. If sheave surfaces are worn, replace clutch assembly.

Assembly (Fig. 8)

Figure 10

1. Clutch weight 2. Contact surface

Figure 11

1. Roller

2. Weight contact surface

3. Roller uneven wear

Drive Train

IMPORTANT: For proper drive clutch operation, DO NOT lubricate drive clutch components.

IMPORTANT: To maintain the balance of the clutch, all shoulder screws must be installed with their threads pointing in a clockwise direction (Fig. 12).

1. Position clutch weights to moveable sheave and slide shoulder screw into sheave and weight. Make sure that shoulder screw threads are pointing in a clockwise direction.

2. Install new lock nuts on the shoulder screws. DO NOT reuse removed lock nuts. Tighten nuts until they contact screw shoulder and then torque nuts from 40 to 50 in--lb (4.6 to 5.6 N--m).

Workman MDX--D Drive TrainPage 4 -- 13

Figure 12

1. Shoulder screw head 2. Lock nut

Driven Clutch

Driven Clutch Removal (Fig. 13)

1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. Raise and support cargo box.

2. Remove muffler from the vehicle (see Exhaust System in the Service and Repairs section of Chapter 3 -Diesel Engine).

3. Carefully remove drive belt from the driven clutch.

4. Remove cap screw and stepped washer securing the driven clutch to the input shaft of the transaxle.

5. Slide driven clutch from the transaxle input shaft.

Driven Clutch Installation (Fig. 13)

1. Coat transaxle input shaft with antiseize lubricant.

2. Position driven clutch to the input shaft. Make sure pulley side of the clutch is next to the transaxle case.

3. Secure driven clutch to the transaxle input shaft with cap screw and stepped washer. Torque cap screw from 39 to 47 ft--lb (53 to 63 N--m).

4. Install drive belt to the driven clutch.

5. Install muffler to the vehicle (see Exhaust System in the Service and Repairs section of Chapter 3 -- Diesel Engine).

6. Lower and secure cargo box.

Antiseize

Lubricant

1. Cap screw

2. Stepped washer

39 to 47 ft--lb

(53 to 63 N--m)

Figure 13

3. Driven clutch

4. Input shaft (transaxle)

Workman MDX--DPage 4 -- 14Drive Train

Driven Clutch Service

1. Use a suitable press to compress the clutch spring enough t o allow removal of the retaining ring.

2. Remove retaining ring.

3. Carefully, allow the spring to extend fully.

4. Remove outer spring retainer, spring and inner spring retainer from clutch.

5. Make note of the “X” mark cast into the fixed sheave and moveable sheave before removing the moveable sheave. These marks must be aligned during assembly for proper clutch operation.

6. Separate the clutch sheaves. Locate and retrieve thrust washer.

7. Clean and inspect driven clutch components:

A. Clean all dust and debris from clutch components. If necessary, use contact or brake cleaner to remove any oil or other lubricants from clutch components.

B. Inspect the spring and replace if damaged or fatigued.

C. Check the rollers in the fixed sheave for binding or wear. If binding or uneven wear is found, replace driven clutch assembly.

1. Fixed sheave

2. Thrust washer

3. Moveable sheave

4. Inner spring retainer

Figure 14

5. Spring

6. Outer spring retainer

7. Retaining ring

Drive Train

D. Check the contact surface of the sheaves for wear and/or fraying. If wear or damage is found, replacedrivenclutchassembly.

8. Assemble the driven clutch in the reverse order of disassembly. Make sure that the “X” mark cast into the fixed and moveable sheaves are aligned. Also, make sure that the retaining ring is fully seated in groove after installation.

Workman MDX--D Drive TrainPage 4 -- 15

Transaxle

Loctite #242

Antiseize Lubricant

Antiseize

Lubricant

39 to 47 ft--lb

(53to63N--m)

120 ft--lb

(162 N--m)

Antiseize

Lubricant

RIGHT

FRONT

1. Transaxle assembly

2. Driven clutch

3. Parking brake cable (2 used)

4. Shift cable (2 used)

5. Hardened washer (4 used)

6. Stepped washer

7. Flange nut (4 used)

8. Cap screw

9. Brake drum (2 used)

10. Cap screw (4 used)

80 to 90 ft-- lb

(109 to 122 N--m)

Figure 15

11. Cap screw (4 used)

12. Flat washer (2 used)

13. Swing arm

14. Lock nut (2 used)

15. Flat washer

16. Skid plate

17. R--clamp

18. Lock nut

19. Washer (2 used)

20. Spring washer (2 used)

21. Slotted hex nut (2 used)

22. Cotter pin (2 used)

23. Select lever

24. Wheel hub (2 used)

25. Wheel stud (5 used per hub)

26. Brake assembly (LH shown)

27. Rear brake line

28. Rear wheel assembly (2 used)

29. Lug nut (5 used per wheel)

Workman MDX--DPage 4 -- 16Drive Train

Removal ( Fig. 15)

7. Support the transaxle to prevent it from shifting.

1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch.

2. Raise and support cargo box.

3. Carefully remove drive belt from the driven clutch on transaxle.

4. Separate shift cables from transaxle:

A. Loosen jam nuts securing both shift cables to the cable bracket on the transaxle (Fig. 16).

B. Remove lock nut and flat washer that secures the select lever to the transaxle selector shaft (Fig. 17).

C. Separate select lever and shift cable assembly from the transaxle.

D. Remove cap screw (item 11 in Fig. 15) and flange nut (item 7 in Fig. 15) that secure r--clamp (item 17 in Fig. 15) to skid plate.

E. Note routing of shift cables for assembly purposes. Position select lever with attached shift cables away from transaxle assembly.

8. Remove four (4) cap screws (item 10) and flat washers (item 5) that secure the transaxle to the swing arm.

IMPORTANT: Take care to not damage the transaxle, brake hoses, electrical harness, cables or other parts while lowering the transaxle assembly from the vehicle.

9. Carefully lower transaxle assembly and remove it from the rear of the vehicle.

WARNING

Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 -- Safety.

5. Jack up both sides of the frame enough to remove rear wheels.

A. Chock the front and rear of both front tires to prevent the vehicle from moving.

B. Support both sides of the frame with appropriate jack stands positioned just in front of the transaxle tubes.

6. Remove both rear wheels and brake assemblies from the transaxle (see Rear Wheels and Brakes in the Service and Repairs section of Chapter 6 -- Chassis).

CAUTION

To prevent personal injury, make sure that transaxle is properly supported as it is removed from the machine. Transaxle weighs approxi mately 73 pounds (33 kg).

1. Select lever assembly

2. Cable jam nut location

Loctite #242

1. Transaxle assembly

2. Selector shaft

3. Select lever

Figure 16

3. Shift cable

4. Cable bracket

Figure 17

4. Flat washer

5. Lock nut

Drive Train

Workman MDX--D Drive TrainPage 4 -- 17

Installation (Fig. 15)

1. Position transaxle assembly under the vehicle swing arm.

CAUTION

To prevent personal injury, make sure that transaxle is properly supported as it is installed into the machine. Transaxle weighs approximately 73 pounds (33 kg).

IMPORTANT: Take care to not damage the transaxle, brake hoses, electrical harness, cables or other parts while raising the transaxle assembly into the vehicle.

B. Slide select lever with attached shift cables onto transaxle selector shaft.

C. Apply Loctite #242 (or equivalent) to threads of lock nut (item 18). Secure select lever assembly to the selector shaft with flat washer (item 15) and lock nut (item 18).

D. Secure both shift cables to the cable bracket with jam nuts.

E. Secure r--clamp (item 17) with shift cables to skid plate with cap screw (item 11) and flange nut (item 7).

F. Check shift cable adjustment and make necessary cable adjustments (see Shift Cable Adjustment in the Adjustments section of this chapter).

5. Install drive belt to the driven clutch.

2. Carefully raise transaxle assembly and align it with swing arm mounting points.

3. Secure the transaxle to the swing arm with four (4) cap screws (item 10) and flat washers (item 5).

4. Secure shift cables to transaxle:

A. Position select lever with attached shift cables to transaxle assembly. Use notes taken before removal to properly route cables around transaxle.

6. Install both brake assemblies and wheels to the transaxle (see Rear Wheels and Brakes in the Service and Repairs section of Chapter 6 -- Chassis). Make sure that brakes are bled and parking brake is adjusted.

7. Lower vehicle to the ground.

8. Make sure transaxle oil level is correct.

9. Lower and secure cargo box.

10.Check brakes for proper operation.

Workman MDX--DPage 4 -- 18Drive Train

This page is intentionally blank.

Drive Train

Workman MDX--D Drive TrainPage 4 -- 19

Transaxle Service

25 to 31 ft --lb

(34 to 42 N -- m)

40 to 45 ft --lb

(54 to 61 N-- m)

25 to 31 ft --lb

(34to42N--m)

Figure 18

Workman MDX--DPage 4 -- 20Drive Train

1. Case (LH)

2. Oil seal

3. Oil seal

4. Snap ring

5. Spacer

6. Selector shaft

7. Oil seal (2 used)

8. Flange bolt (4 used)

9. Oil check plug (2 used)

10. Gasket (2 used)

11. Oil drain plug (2 used)

12. Gasket (2 used)

13. Oil filler plug

14. Case (RH)

15. Axle bracket (2 used)

16. Collar (2 used)

17. Flange bolt (4 used)

18. Flange bolt (6 used)

19. Gasket

20. Input shaft

Transaxle Disassembly and Inspection

1. Disassemble case (LH and RH)

Figure 18 (Continued)

21. Bolt

22. Gasket

23. Spring

24. Ball bearing

25. Steel ball

26. Ball bearing (2 used)

27. Spacer

28. Gear 55

29. Cable bracket

30. Pin clutch

31. Center shaft

32. Gear 47

33. Collar (2 used)

34. Gear

35. Flange bolt (6 used)

36. Ball bearing

37. Ball bearing

38. Spacer (2 used)

39. Gear 34

40. Counter shaft

41. Differential case

42. Side gear (2 used)

43. Pinion gear (2 used)

44. Pinion shaft

45. Spring pin

46. Ball bearing

47. Needle bearing

48. Gear 62

49. Bolt (6 used)

50. Axle shaft (LH)

51. Axle shaft (RH)

52. Ball bearing (4 used)

53. Axle case (LH)

54. Axle case (RH)

55. Snap ring (4 used)

56. Flange nut (10 used)

57. Snap ring (2 used)

58. Shift shaft

59. Pipe knock (2 used)

1. Drain plug & gasket 2. Case (LH)

CAUTION

Make sure transaxle case is not hot prior to draining oil to prevent getting burned.

Figure 19

15 to 18 ft --lb

(21to25N--m)

A. Remove drain plug. Drain oil completely from transaxle. Replace drain plug gasket if damaged.

B. Reinstall drain plug to transaxle case. Torque plug from 15 to 18 ft--lb (21 to 25 N--m).

Drive Train

Workman MDX--D Drive TrainPage 4 -- 21

Figure 20

1. Bolt (steel ball, spring & gasket) 2. Selector shaft

C. Remove bolt near the selector shaft. Remove spring and steel ball. Replace gasket if damaged.

Figure 21

1. Input shaft 2. Oil seal

D. Wrap vinyl tape around the splined portion of the input shaft. This should protect the oil seal from being damaged.

Workman MDX--DPage 4 -- 22Drive Train

Figure 22

1. Flange bolts (3 used)

2. Axle bracket

E. Remove three (3) flange bolts securing the axle bracket and axle case to each case. Separate bracket from each axle case.

3. Axle case

Figure 23

1. Flange bolt (10 used) 2. Flange nut

F. With the input shaft side down, loosen and remove flange bolts and nuts securing the case (RH) and case (LH) together. Note location of cable bracket for assembly purposes.

Drive Train

Workman MDX--D Drive TrainPage 4 -- 23

Figure 24

1. Case (RH) 2. Governor boss

IMPORTANT: Make sure to not hit the governor boss too hard when separating the cases, the boss may get damaged. Do not pry open the two cases with a screw driver, damage may result to the sealing surfaces.

2. Remove input shaft, center shaft and differential a ssemblies.

G. Hold the case (RH) and lift up while lightly tapping the governor boss with a plastic hammer.

1. Gasket 2. Pipe knock

A. Remove gasket and pipe knocks.

Figure 25

Workman MDX--DPage 4 -- 24Drive Train

Figure 26

1. Counter shaft

2. Spacer (2 used)

B. Pull out counter shaft. Remove spacer, needle bearing, gear 34 and spacer.

3. Needle bearing

4. Gear 34

Drive Train

Figure 27

1. Counter shaft

2. Spacer (2 used)

C. Replace counter shaft if it has abnormal wear, cracks or damage.

D. Replace spacer if either one is cracked or bent.

3. Needle bearing

4. Gear 34

E. Replace needle bearing if needles are bent, do not rotate freely or do not remain in the bearing cage.

F. Replace gear 34 if worn or damaged. Cracked, broken, missing or chipped gear teeth are not acceptable.

Workman MDX--D Drive TrainPage 4 -- 25

1. Differential assembly

2. Input shaft assembly

Figure 28

3. Center shaft assembly

4. Shift shaft

IMPORTANT: Make sure to not damage the oil seal when removing the input shaft.

NOTE: If any of the assemblies can not be pulled out by

hand, hold the assembly while gently tapping the case with a plastic hammer. Make sure to tap equally around the case.

3. Remove axle case from case (RH and LH).

G. Lift up differential assembly, center shaft assembly and input shaft assembly at the same time. First, remove input shaft assembly. Then, remove center shaft assembly with the shift shaft and differential assembly.

Figure 29

1. Flange bolt

2. Axle case

A. Remove remaining two (2) flange bolts securing each axle case to the case. Remove axle case from the transaxle case.

3. Transaxle case

Workman MDX--DPage 4 -- 26Drive Train

Figure 30

1. Snap ring

2. Axle case

IMPORTANT: Do not reuse snap ring. Discard and replace ring with new one.

B. Remove snap ring from the axle case. Remove axle shaft from case.

IMPORTANT: When replacing ball bearings, both ball bearings must be replaced as a set.

4. Disassemble input shaft assembly.

3. Axle shaft

4. Ball bearing

C. Ball bearing r oller balls must be free of deformation and scoring. Ball bearing must spin freely and have minimum axial play. Replace ball bearing as necessary.

Drive Train

Figure 31

1. Ball bearing 2. Input shaft

IMPORTANT: Do not reuse ball bearings that have been removed.

Workman MDX--D Drive TrainPage 4 -- 27

A. Remove ball bearing from the input shaft with a bearing puller.

Figure 32

1. Input shaft 2. Ball bearing

B. Replace input shaft if worn or damaged. Gear teeth that are cracked, broken, chipped or missing are not acceptable.

5. Disassemble center shaft assembly .

C. Ball bearing roller balls must be free of deformation and scoring. Ball bearing must spin freely and have minimum axial play. Replace ball bearing as necessary.

Figure 33

1. Ball bearing 2. Ball bearing

IMPORTANT: Do not reuse ball bearings that have been removed.

A. Remove ball bearings from the center shaft assembly. Discard removed bearings.

Workman MDX--DPage 4 -- 28Drive Train

Figure 34

1. Gear 55

2. Gear 47

3. Gear (small)

4. Ball bearing

5. Ball bearing

B. Remove gears, pin clutch, collars and spacer from the input shaft.

C. Replace gears if worn or damaged. Cracked, broken, missing or chipped gear teeth are not acceptable.

6. Pin clutch

7. Center shaft

8. Collar (2 used)

9. Spacer

D. Replace center shaft if worn or damaged. Splines that are cracked, broken, chipped or missing are not acceptable.

E. Replace pin clutch if cracked or bent.

F. Replace collars or spacer if excessively worn or damaged. Replace both collars as a set.

Drive Train

Workman MDX--D Drive TrainPage 4 -- 29

6. Disassemble differential case assembly.

1. Bolt (6 used)

2. Gear 62

A. Remove six (6) bolts securing gear 62 to the differential c ase.

Figure 35

3. Differential case

Figure 36

1. Spring pin

2. Differential case

NOTE: The spring pin can be punched out from the hole

on the opposite side of gear 62.

B. Remove spring pin from the differential case. Discard pin and replace it with new spring pin.

3. Pinion shaft

4. Pinion gear

C. Remove pinion shaft and gears from the case. Separate gears from shaft.

Workman MDX--DPage 4 -- 30Drive Train

Figure 37

1. Side gear (2 used)

2. Pinion gear (2 used)

3. Gear 34

4. Ball bearing

D. Replace gears if worn or damaged. Cracked, broken, missing or chipped gear teeth are not acceptable.

E. Ball bearing roller balls must be free of deformation and scoring. Ball bearing must spin freely and have minimum axial play. Replace ball bearing as necessary.

5. Differential case

6. Pinion shaft

7. Spring pin

8. Bolt (6 used)

F. Replace case if machined areas where the side and pinion gears mesh are scored or if the pinion shaft fits loosely in its bore.

G. Replacepinionshaftifcrackedorbent.

H. Replace oil seal if cracked, nicked or distorted such that it would not hold a proper seal.

Drive Train

Workman MDX--D Drive TrainPage 4 -- 31

Transaxle Assembly

1. Assemble input shaft assembly.

Figure 38

1. Ball bearing 2. Input shaft

IMPORTANT: Make sure to press ball bearing at the inner race to prevent damaging the ball bearing.

A. Press ball bearing onto the input shaft.

Workman MDX--DPage 4 -- 32Drive Train

2. Assemble the center shaft assembly.

5.386” to 5.398”

(136.8 to 137.1 mm)

Figure 39

1. Pin clutch

2. Center shaft

3. Gear 47

4. Gear 55

5. Collar

NOTE: Before assembling, apply molybdenum disul-

fide grease to the inside of gears 47 and 55.

6. Gear (small)

7. Bearing

8. Bearing

9. Spacer

A. Slide pin clutch onto the centershaft. Install gears 47 and 55 onto shaft noting correct orientation of gears. Slide collars, small gear and spacer onto the center shaft.

Drive Train

Figure 40

1. Ball bearing 2. Ball bearing

B. Press ball bearings onto the center shaft using a bearing press.

Workman MDX--D Drive TrainPage 4 -- 33

C. Make sure distance from one ball bearing outer edge to the other ball bearing outer edge is 5.386” to

5.398” (136.8 to 137.1 mm) (Fig. 39).

D. The center shaft should appear as above when assembled.

3. Assemble differential assembly.

Figure 41

4.854” to 4.882”

(123.3 to 124.0 mm)

Figure 42

1. Pinion gear (greased surface)

2. Pinion shaft

3. Side gear (greased surface)

4. Differential case

5. Gear 62

A. Apply molybdenum disulfide grease to the inside of both pinion gears where they contact the pinion shaft. Apply molybdenum disulfide grease to the outside of both side gears where they contact the differential case and gear 62.

6. Bolt

7. Spring pin

8. Ball bearing

9. Ball bearing

Workman MDX--DPage 4 -- 34Drive Train

Figure 43

1. Side gear

2. Pinion gear

B. Install side gear, both pinion gears and pinion shaft into the differential case.

3. Pinion shaft

4. Differential case

Figure 44

1. Spring pin

2. Differential case

C. Align pinion shaft hole and install new spring pin through the differential case and pinion shaft.

3. Pinion shaft

Drive Train

Workman MDX--D Drive TrainPage 4 -- 35

Figure 45

1. Side gear

2. Pinion gear

3. Gear 62

4. Differential case

D. Install remaining side gear to the pinion gears. E. Secure gear 62 to the differential case with six (6)

bolts. Torque bolts in a crossing pattern from 40 to 45

ft--lb (54 to 61 N--m).

40 to 45 ft--lb

(54to61N--m)

Figure 46

IMPORTANT: The length from the outer most side of each ball bearing must be from 4.854” to 4.882” (123.3 to 124.0 mm) (Fig. 42).

F. If ball bearings were removed, press new ball bearings onto differential case and gear 62.

G. The differential assembly should appear as above when assembled.

Workman MDX--DPage 4 -- 36Drive Train

4. Installaxlecasetocase(RHandLH).

Figure 47

1. Axle shaft

2. Snap ring

IMPORTANT: Do not reuse snap ring. Replace snap ring with new one.

25 to 31 ft --lb

(34to42N--m)

3. Ball bearing

A. Insert axle shaft with snap rings, collar and ball bearings into the axle case. Install snap ring to the axle case.

Drive Train

Figure 48

1. Axle case

2. Case

3. Flange bolt

IMPORTANT: Make sure to install the axle case to the proper side of the case. The right side of the case takes the short axle case, and the left side takes the long axle case.

IMPORTANT: Make sure to not damage the oil seal when installing the axle case to the case.

Workman MDX--D Drive TrainPage 4 -- 37

B. Install axle case to the case. Secure each axle case to the case with flange bolts. Torque bolts from 25 to 31 ft--lb (34 to 42 N--m).

5. Install input shaft, center shaft and differential assemblies to the case.

Figure 49

1. Shift shaft 2. Clutch groove

A. Insert fork of the shift shaft to the clutch groove of the center shaft assembly.

Figure 50

1. Center shaft assembly

2. Shift shaft

B. Replace oil seals for the input and selector shafts on the case (LH) if cracked, nicked or distorted such that they would not hold a proper seal.

IMPORTANT: Make sure to not damage the oil seal when installing the input shaft.

3. Input shaft

4. Differential assembly

C. Install center shaft assembly with shift shaft and differential assembly. Then, install input shaft assembly. Lower differential assembly, center shaft assembly and input shaft assembly into the case at the same time.

Workman MDX--DPage 4 -- 38Drive Train

Figure 51

1. Fork (selector shaft) 2. Pin (shift shaft)

D. Make sure the selector shaft fork is contacting the pinontheshiftshaft.

Drive Train

Figure 52

1. Spacer 2. Boss (counter shaft)

E. Place spacer on the counter shaft boss of the case (LH) so the oil groove faces up.

Workman MDX--D Drive TrainPage 4 -- 39

1. Gear 34

2. Counter shaft

Figure 53

3. Spacer

F. Apply molybdenum disulfide grease to the inside of gear 34 and the contact surface between the case and the counter shaft.

6. Assemble case (LH and RH).

G. Place gear 34 onto the spacer. Make sure not to drop the spacer. Insert needle bearing into gear. Insert counter shaft with remaining spacer through the needle bearing, gear 34 and into the spacer and case.

Figure 54

1. Case (sealing surface) 2. Pipe knock

A. Make sure gasket sealing surfaces of both cases are clean. Install gasket to case.

B. Install both pipe knocks to the c ase (LH).

Workman MDX--DPage 4 -- 40Drive Train

Figure 55

1. Cable bracket 2. Flange bolt

15 to 18 ft--lb

(21 to 25 N--m)

NOTE: Keep the gasket sealing surfaces of the cases

as horizontal to each other as possible. If the sealing surfaces do not join to each other, tap the case lightly with a plastic hammer.

C. Install case (RH) so each shaft fits properly into the case.

D. Position cable bracket to transaxle cases.

E. Secure case (RH) to case (LH) with flange bolts and nuts. Torque bolts from 15 to 18 ft--lb (21 to 25

N--m).

25 to 31 ft--lb

(34to42N--m)

Drive Train

Figure 56

1. Axle bracket 2. Flange bolt

F. Position axle bracket to each axle case. Secure axle bracket to each axle case with flange bolts. Torque bolts from 25 to 31 ft--lb (34 to 42 N--m).

Workman MDX--D Drive TrainPage 4 -- 41

12 to 15 ft--lb

(16 to 20 N--m)

Figure 57

1. Cable bracket 2. Bolt (steel ball, spring & gasket)

G. Install steel ball, spring, gasket and bolt. Torque bolt from 12 to 15 ft--lb (16 to 20 N--m).

H. Fill transaxle with 1.5 quarts (1.4 liters) of new SAE 10W--30 motor oil.

Workman MDX--DPage 4 -- 42Drive Train

Chapter 5

Electrical System

GENERAL INFORMATION 2.....................

Operator’s Manual 2..........................

Electrical Drawings 2..........................

SPECIAL TOOLS 3.............................

TROUBLESHOOTING 5.........................

Starting Problems 5...........................

General Run Problems 6......................

ELECTRICAL SYSTEM QUICK CHECKS 7........

Battery Test 7................................

Charging System Test 7.......................

Glow Plug Test 7.............................

COMPONENT TESTING 8.......................

Ignition Switch 8..............................

Indicator Lights 9.............................

Fuse Blocks 10...............................

Fusible Links 11...............................

Hour Meter 12................................

Headlight Switch 12...........................

Brake Switch 13..............................

Main Power and Glow Relays 14................

Start Relay 15................................

Glow Plug Controller 16.......................

Engine Run Solenoid 17.......................

Over Temperature Switch 18...................

Fuel Pump 19................................

Oil Pressure Switch 20........................

Backup Alarm (Optional Kit) 21.................

BackupSwitch(OptionalKit) 22................

SERVICE AND REPAIRS 23.....................

Battery Service 23............................

Battery Removal 23..........................

Battery Inspection and Maintenance 24........

Battery Installation 24........................

Battery Testing 25...........................

Battery Charging 26.........................

Battery Storage 26..........................

Electrical

System

Workman MDX--D Electrical SystemPage 5 -- 1

General Information

Operator’s Manual

The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Operator’s Manual for additional information when servicing the machine.

Electrical Drawings

The electrical schematic and other electrical drawings for the Workman MDX--D are located in Chapter 7 -Electrical Drawings.

Electrical System

Page 5 -- 2

Workman MDX--D

Special Tools

Order special tools from your Toro Distributor. Some tools may also be available from a local supplier.

Multimeter

The meter can test electrical components and circuits for current, resistance or voltage.

NOTE: Toro recommends the use of a DIGITAL Volt-Ohm--Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital 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.

Figure 1

Skin--Over Grease

Special non--conductive grease which forms a light protective skin which helps waterproof electrical switches and contacts.

Toro Part Number: TOR50547

Battery Terminal Protector

Aerosol spray that should be used on battery terminals to reduce corrosion problems. Apply terminal protector after the battery cable has been secured to the battery terminal.

Toro Part Number: 107--0392

Figure 2

Electrical

System

Workman MDX--D Electrical SystemPage 5 -- 3

Figure 3

Dielectric Lubricant/Sealant

Dielectric lubricant should be used to prevent corrosion of non--sealed connection terminals. To ensure complete coating of terminals, liberally apply lubricant to both component and wire harness connector, plug connector to component, unplug connector, reapply lubricant to both surfaces and reconnect harness connector to component. Connectors should be thoroughly packed with lubricant for effective results.

Toro Part Number: 107--0342

Battery Hydrometer

Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally.

Figure 4

Figure 5

Electrical System

Page 5 -- 4

Workman MDX--D

Troubleshooting

For effective troubleshooting and repairs, you must

CAUTION

Remove all jewelry, especially rings and watches, before doing any electrical troubleshooting or testing. Disconnect the battery cables unless the test requires battery voltage.

Starting Problems

Problem Possible Causes

Starter solenoid clicks, but starter will not crank. Battery is discharged.

have a good understanding of the electrical circuits and components used on this vehicle (see electrical drawings in Chapter 7 -- Electrical Drawings).

If the vehicle has any interlock switches by--passed, they must be reconnected for proper troubleshooting and safety.

Battery cables are loose or corroded.

Battery ground to frame is loose or corroded.

Wiring at starter is faulty.

Starter solenoid is faulty.

Starter is faulty and causing an incomplete circuit for the starter solenoid.

Nothing happens when start attempt is made. Brake pedal is not depressed.

Battery is discharged.

In--line primary fuse (10 ampere) is loose or faulty.

Battery cables are loose or corroded.

Battery ground to frame is loose or corroded.

Wiring to the start circuit components is loose, corroded or damaged (see electrical drawings in Chapter 7 -- Electrical Drawings).

Brake pedal switch is out of adjustment or faulty.

Start relay or circuit wiring is faulty.

The ignition switch or circuit wiring is faulty.

Fuseblockisfaulty.

Fusible link harness at the engine starter motor has faulty link(s) so battery power is not available to vehicle electrical system.

Electrical

System

Starter solenoid or circuit wiring is faulty.

Workman MDX--D Electrical SystemPage 5 -- 5

Starting Problems (Continued)

Problem Possible Causes

Engine cranks, but does not start. Fuel tank is empty.

Wiring to start circuits is loose, corroded or damaged (see electrical drawings in Chapter 7 -- Electrical Drawings).

Engine or fuel system is malfunctioning (see Chapter 3

-- Diesel Engine).

15 ampere fuse in fuse block is faulty.

Fuel pump or circuit wiring is faulty.

Glow plugs, glow relay or glow plug controller are faulty.

Wire harness fusible link to run solenoid pull coil is faulty.

Engine and fuel may be too cold.

Run solenoid is faulty.

General Run Problems

Problem Possible Causes

Battery does not charge. Wiring to the charging circuit components is loose,

corroded or damaged (see electrical drawings in Chapter 7 -- Electrical Drawings).

Alternator or circuit wiring is faulty.

Battery is faulty.

Engine stops during operation. Wiring to the run circuit components became broken or

disconnected (see electrical drawings in Chapter 7 -Electrical Drawings).

Engine or fuel system is malfunctioning (see Chapter 3

-- Diesel Engine).

Electrical System

Page 5 -- 6

Workman MDX--D

Electrical System Quick Checks

Battery Test

Use a multimeter to measure the voltage between the battery terminals.

Set the multimeter to the DC volts setting. The battery should be at a temperature of 60 C). The ignition key should be off and all accessories turned off. Connect the positive (+) meter lead to the positive battery post and the negative (--) meter lead to the negative battery post.

NOTE: This test provides a relative condition of the battery. Load testing of the battery will provide additional and more accurate information.

to 100oF(16oto 38

Charging System Test

This is a simple test used to determine if a charging system is functioning. It will tell you if the charging system has an output, but not its capacity.

Remove battery cover to gain access to battery. Use a digital multimeter set to DC volts. Connect the positive (+) multimeter lead to the positive battery post and the negative (--) multimeter lead to the negative battery post. Keep the test leads connected to t he battery posts and record the battery voltage.

NOTE: When starting the engine, the battery voltage will drop and then should increase once the engine is running.

NOTE: Depending upon the condition of the battery charge and battery temperature, the battery voltage will increase at different rates as the battery charges.

Voltage Measured

12.68 V (or higher) Fully charged (100%)

Make sure the shift lever is in the neutral position and the parking brake is applied. Start the engine and run engine at high idle (above 3000 RPM). Maintain engine speed to allow the battery to charge for at least three (3) minutes. Record the battery voltage.

After running the engine for at least three (3) minutes, battery voltage should be at least 0.50 volt higher than initial battery voltage.

An example of a charging system that is functioning:

At least 0.50 volt over initial battery voltage.

Initial Battery Voltage = 12.30 v

Battery Voltage after 3 Minute Charge = 12.95 v

Difference =+0.65v

12.45 V 75% charged

12.24 V 50% charged

12.06 V 25% charged

11.89 V 0% charged

Battery Charge Level

Electrical

System

Glow Plug Test

This is a fast, simple test that can help to determine the integrity and operation of your Workman MDX--D glow plug system. The test should be run anytime hard starting (cold engine) is encountered on a diesel engine equipped with a glow plug system.

Use a digital multimeter and/or inductive Ammeter (AC/ DC Current Transducer). Properly connect the ammeter to the digital multimeter (refer to manufacturers’ instructions) and set the multimeter to the correct scale. With the ignition switch in the OFF position, place the

Workman MDX--D Electrical SystemPage 5 -- 7

ammeter pickup around the main glow plug power supply wire and read the meter prior to activating the glow plug system. Adjust the meter t o read zero (if applicable). Activate the glow plug system by turning the ignition switch to ON and record the multimeter results.

The Workman MDX--D glow plug system should have a reading of approximately nine (9) amps per glow plug (18 amps total). If low current reading is observed, one (or more) of the glow plugs is faulty.

Component Testing

For accurate resistance and/or continuity checks, electrically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check on the switch).

NOTE: See the Kubota Workshop Manual, Diesel Engine, SM--E3B Series for engine component testing information.

Ignition Switch

The ignition (key) switch has three positions (OFF, ON andSTART).Theignitionswitchislocatedonthedash panel (Fig. 6).

Testing

The switch terminals are identified as shown in Figure

7. The circuit wiring of the ignition switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be t ested to determine whether continuity exists between the various switch terminals for each switch position. Disconnect wire harness connector from key switch and verify continuity between switch terminals in the different switch positions.

POSITION

OFF NONE

ON B+C+F, D+E

STAR T A+B+C

CIRCUITS

CAUTION

When testing electrical components for continuity with a multimeter (ohms setting), make sure that power to the circuit has been disconnected.

Figure 6

1. Dash panel 2. Ignition switch

RUN

OFF

START

After testing is completed, connect wire harness connector to ignition switch.

Electrical System

Page 5 -- 8

FRONT VIEW

Figure 7

REAR VIEW

Workman MDX--D

Indicator Lights

Charge Indicator Light

The charge indicator light should come on when the ignition switch is in the ON position with the engine not running. Also, it should illuminate with an improperly operating charging circuit while the engine is running.

Engine Oil Pressure Light

The engine oil pressure light should come on when the ignition switch is in the ON position with the engine not running. Also, it should illuminate with the engine running if the engine oil pressure drops to an unsafe level.

IMPORTANT: If the oil pressure indicator light is illuminated with the engine running, shut off the engine immediately.

To test the oil pressure light and circuit wiring, ground the wire attached to oil pressure switch located on the engine near the oil filter. Turn ignition switch to the ON position; the engine oil pressure light should come on indicating correct operation of the indicator light and circuit wiring.

Engine Temperature Light

If the engine coolant temperature reaches 230

C) (approximate), the engine temperature light will

(110

come on.

To test the engine t emperature light and circuit wiring, turn ignition switch to the ON position and ground the wire attached to over temperature switch located on the engine water pump housing (see Over Temperature Switch in this section). The engine temperature light should illuminate while the wire is grounded.

Glow Plug Indicator Light

Figure 8

1. Charge Indicator

2. Engine oil pressure

3. Engine temperature

4. Glow plug indicator

1B (--)

1A (+)

System

Electrical

2A (+)2B (--)

The glow plug light should come on when the ignition switch is placed in the ON position prior to placing the ignition switch in START. The light should stay lit for approximately six (6) seconds while the ignition switch is left in the ON position.

Testing Indicator Lights

1. Apply 12 VDC to indicator light terminals 1A and 2A (Fig. 9).

2. Ground indicator light terminals 1B and 2B (Fig. 9).

3. Both indicator lights should illuminate.

Workman MDX--D Electrical SystemPage 5 -- 9

1. Charge indicator

2. Engine oil pressure

3. Engine temperature

Figure 9

4. Glow plug indicator

5. Indicator light front

6. Indicator light back

Fuse Blocks

The fuse block on Workman MDX--D vehicles is located beneath the dash panel.

In addition to the fuses in the fuse block, an in--line 10 amp fuse is included in the wire harness. This fuse protects the ignition switch circuits and also provides protection for the optional brake and signal light kit. The in-- line fuse resides in a fuse holder under the dash panel near the fuse blocks (Fig. 11).

Fuse Identification and Function

Use F igure 10 to identify each individual fuse in the fuse block.

The upper row of fuses protect circuits as follows:

1. The extreme left 10 ampere fuse protects the power point circuit. This fuse also protects the circuit for the optional backup alarm (if equipped).

2. The middle left 10 ampere fuse protects the engine start circuit.

3. The middle right 10 ampere fuse protects the light circuit.

1. Fuse blocks

2. Fuse decal

Figure 10

3. Upper fuses

4. Lower fuses

4. The extreme right 15 ampere fuse protects the circuits for engine electrical components and also dash indicators (hour meter and indicator lights).

The lower row of fuses protect circuits as follows:

1. The extreme left fuse position is not used.

2. Themiddleleft15amperefuseprotectsthecircuitfor the optional cargo box lift.

3. The middle right 15 ampere fuse protects the circuit for the optional rear lift kit.

4. The extreme right 30 ampere fuse protects the circuit for the horn (if equipped).

Fuse Testing

Make sure that ignition switch is OFF and key is removed from switch. Remove fuses from the fuse block for testing. A fuse in usable condition should have continuity between the fuse terminals. A faulty fuse will not have continuity between the fuse terminals.

Figure 11

1. In--line fuse 2. Fuse block

Electrical System

Page 5 -- 10

Workman MDX--D

Fusible Links

The Workman MDX--D uses four (4) fusible links for circuit protection. Three (3) of these fusible links are included in a wire harness that connects the starter B+ terminal to the vehicle wire harness (Fig. 12). The remaining fusible link is included in the engine wire harness and connects the starter G terminal to the engine run solenoid pull coil. If any of these links should fail, current to the protected circuit will cease. Refer to the electrical schematic and wire harness drawings in Chapter 7 -- Electrical Drawings for additional circuit information.

Testing

Make sure that ignition switch is OFF. Disconnect negative battery cable from battery terminal and then disconnect positive cable from battery (see Battery Service in the Service and Repairs section of this chapter). Locate and unplug fusible link connector. Use a multimeter to make sure that continuity exists between the fusible link terminals. If a fusible link is open, replace the link.

After testing is complete, make sure that fusible link is securely attached to engine component and wire harness. Connect positive battery cable to battery terminal first and then connect negative cable to battery.

FUSIBLE LINK

FUSIBLE LINK FUSIBLE LINK

Figure 12

Electrical

System

Workman MDX--D Electrical SystemPage 5 -- 11

Hour Meter

Testing

IMPORTANT: Make sure to observe polarity on the hour meter terminals when testing. Damage to the meter may result from an improper connection.

1. Unplug wire harness connector from hour meter.

2. Connect positive (+) terminal of a 12 VDC source to the positive terminal of the hour meter.

3. Connect negative (--) terminal of the voltage source to the other terminal of the hour meter.

4. The hour meter should move 1/10 of an hour in six (6) minutes.

5. Disconnect voltage source from the hour meter. Reconnect wire harness connector to hour meter.

Headlight Switch

The headlight switch is located on the dash panel (Fig.

14). This rocker switch allows the headlights to b e turned on and off.

QUARTZ

00000

HOURS

1/10 WHEEL: WHITE W/BLACK NUMBERS HOUR WHEELS: BLACK W/WHITE NUMBERS

RUNNING: INDICATOR WINDOW

Figure 13

Testing

The switch terminals are marked as shown in Figure 15. The circuitry of the headlight switch is shown in the chart below. With the use of a multimeter (ohms setting), the switch functions may be tested to determine whether continuity exists between the various terminals for each position. Verify continuity between switch terminals.

SWITCH

POSITION

NORMAL

CIRCUITS

OTHER

CIRCUITS

ON 2+3 5+6

OFF 1+2 4+5

Figure 14

1. Dash panel 2. Headlight switch

BACK OF SWITCH

Figure 15

Electrical System

Page 5 -- 12

Workman MDX--D

Brake Switch

The brake switch is a normally closed switch that opens when the brake pedal is not applied. When the brake pedal is applied, the brake pedal moves away from the switch plunger to allow the switch to be in its normally closed state. The brake switch is attached to the pedal support frame under the dash panel (Fig. 16).

Testing

1. Park vehicle on a level surface, stop engine, apply parking brake and remove key from ignition switch.

2. Locate brake switch for testing. Disconnect vehicle wire harness electrical connector from the brake switch.

3. Check the continuity of the switch by connecting a multimeter (ohms setting) across the connector terminals.

4. When the switch plunger is extended (brake pedal is applied), there should be continuity (closed) between the switch terminals.

5. When the switch p lunger is depressed (brake pedal is not applied), there should not be continuity (open) between the switch terminals.

6. Replace brake switch if testing determines that it is faulty. When installing switch, make sure that the brake pedal does not bottom switch when the pedal is released.

7. If the brake switch tests correctly and a circuit problem still exists, check wire harness (see Electrical Schematic and Circuit Drawings in Chapter 7 -- Electrical Drawings).

Figure 16

1. Brake pedal assembly 2. Brake switch

System

Electrical

8. When switch testing is completed, connect switch connector to vehicle wire harness.

Workman MDX--D Electrical SystemPage 5 -- 13

Main Power and Glow Relays

The Workman MDX--D main and glow relays are attached to the front of the dash bracket and can be accessed by raising the hood (Fig. 17). The vehicle wire harness is attached to the main and glow relays with four (4) wire connectors. Relays can be identified by a tag on thewireharness.

The main power relay is used to provide current to the fuse blocks. When the ignition switch is in the ON or START position, the main power relay is energized.

The glow relay is used to provide current to the engine glow plugs when the relay is energized by the glow plug controller.

Testing

1. Park vehicle on a level surface, stop engine, apply parking brake and remove key from ignition switch. Open and support hood to access relays.

2. Make sure ignition switch is in the OFF position. Disconnect wire harness electrical connector from relay that is to be tested. Remove relay from dash bracket for easier testing.

NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually

0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from the measured value of the relay being testing.

3. Verify coil resistance between terminals 85 and 86 with a multimeter (ohms setting). Resistance should be approximately 72 ohms.

4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC to terminal 85. The relay should make and break continuity between terminals 30 and 87 as +12 VDC is applied and removed from terminal 85.

Figure 17

1. Main power relay 2. Glow relay

85 86

86 87

85 30

Figure 18

5. Disconnect voltage and leads from the relay terminals. Replace relay if testing determines that it is faulty.

6. Secure relay to dash bracket and connect wire harness electrical connector to relay after testing is completed.

7. Close and secure hood.

Electrical System

Page 5 -- 14

Workman MDX--D

Start Relay

The Workman MDX--D start relay provides electrical current to the engine starter solenoid when energized. The relay is energized when the ignition switch is in the START position and the brake pedal is depressed (brake switch closed). The start relay is attached to the front of the dash bracket and can be accessed by raising the hood (Fig. 19). The vehicle wire harness is attached to the start relay with a five (5) wire connector. The relay canbeidentifiedbyatagonthewireharness.

Testing

1. Park vehicle on a level surface, stop engine, apply parking brake and remove key from ignition switch. Open and support hood to access start relay.

2. Locate start relay and disconnect the machine wire harness connector from the relay. Remove relay from from dash bracket for easier testing.

NOTE: Prior to taking small resistance readings with a digital multimeter, short the meter test leads together. The meter will display a small resistance value (usually

0.5 ohms or less). This resistance is due to the internal resistance of the meter and test leads. Subtract this value from the measured value of the relay being testing.

3. Using a multimeter (ohms setting), measure coil resistance between terminals 85 and 86 (Fig. 20). Resistance should be between 70 and 90 ohms.

4. Connect multimeter (ohms setting) leads to relay terminals 30 and 87. Ground terminal 86 and apply +12 VDC t o terminal 85. The relay terminals 30 and 87 should have continuity as +12 VDC is applied to terminal

85. The relay terminals 30 and 87 should not have continuity as +12 VDC is removed from terminal 85.

Figure 19

1. Start relay 2. Wire harness

868587A 87

Figure 20

1. Coil terminal

2. Common terminal

3. Normally closed term.

4. Normally open term.

System

Electrical

5. Disconnect voltage from terminal 85 and multimeter lead from terminal 87.

6. Connect multimeter (ohms setting) leads to relay terminals 30 and 87A. With terminal 86 grounded, apply +12 VDC to terminal 85. The relay terminals 30 and 87A should not have continuity as +12 VDC is applied to terminal 85. The relay terminals 30 and 87A should have continuity as +12 VDC is removed from terminal 85.

7. When relay testing is completed, disconnect voltage and multimeter leads from the relay terminals. Replace relay if testing determines that it is faulty.

8. Secure relay to machine and connect machine wire harness connector to relay.

9. Lower and secure hood.

Workman MDX--D Electrical SystemPage 5 -- 15

Glow Plug Controller

The glow plug controller is attached to the front of the dash bracket and can be accessed by raising the hood (Fig. 21).

NOTE: When troubleshooting the glow controller, refer to electrical drawings in Chapter 7 -- Electrical Drawings.

Glow Plug Controller Operation

1. When the ignition switch is initially placed in the ON position, the glow plug controller energizes the glow plugs for six (6) seconds. The console glow plug indicator light will also be illuminated for six (6) seconds.

2. When the ignition switch is turned to the START position, the glow plugs will energize as long as the switch is held in START. The console glow plug indicator light will not be illuminated.

3. When the ignition switch is released from the START to the ON position, the glow plugs will de--energize and the console glow plug indicator light will remain off.

Glow Plug Controller Checks

1. Make sure there is electrical power from the battery.

5. If any of the conditions in Step 3 are not met or electrical power to controller terminal 1 exists and any of the other conditions in Step 4 are not met:

A. Verify continuity of the circuitry from the battery to the glow relay and glow plugs (see Chapter 7 -- Electrical Drawings).

B. Verify continuity of the circuitry from the battery to ignition switch, glow plug controller, glow plug indicator light, glow relay and ground (see Chapter 7 -Electrical Drawings).

C. Repair or replace components as necessary.

6. After testing is completed, connect wire harness electrical connector to the engine run solenoid.

2. Disconnect the wire harness electrical connector from the engine run solenoid to prevent the engine from starting (see Engine Run Solenoid in this section).

3. Place ignition s witch in the ON position. Verifythe following while in the ON position:

A. Glow plug indicator light is illuminated.

B. Glow relay is energized.

C. Glow plugs are energized.

D. Glow plug indicator light goes out and glow plugs de--energize after approximately six (6) seconds.

4. PlaceignitionswitchintheSTARTposition.Verify thefollowingwhileintheSTARTposition:

A. Glow plug indicator light is not illuminated.

B. Glow relay is energized.

C. Glow plugs are energized.

D. Electrical power exists at terminal 1 of the glow plug controller.

NOTE: If there is no electrical power at terminal 1 of the glow plug controller, verify continuity of the circuitry from the ignition switch to the controller and perform Step 4 again (see Chapter 7 -- Electrical Drawings).

Electrical System

Page 5 -- 16

Figure 21

1. Glow plug controller 2. Wire harness

VIOLET

ORANGE

PINK

CONTROLLER

CONNECTIONS

START

LAMP

+12V

TEMP (not used)

GLOW

GROUND

GRAY

BLACK

Figure 22

1. Controller top view 2. Controller end view

Workman MDX--D

Engine Run Solenoid

The engine run solenoid used on Workman MDX--D vehicles must be energized for the diesel engine to run. The run solenoid is mounted totheinjectionpumponthe engine (Fig. 23). The run solenoid is energized when the ignition switch is in either the ON or START position.

The engine run solenoid includes two (2) coils for operation: the pull coil and the hold coil. When the ignition switch is turned to START, the fuel solenoid pull coil is energized and the solenoid plunger retracts. Once the plunger is retracted, the hold coil will keep it retracted for continued engine operation. When the solenoid is de-energized, the plunger extends to shut off fuel supply to theenginecausingtheenginetostoprunning.

NOTE: A fusible link in the engine wire harness protects the engine run solenoid pull coil circuit. If this link should fail, the run solenoid will not function and the engine will not run. Refer to electrical drawings in Chapter 7 -- Electrical Drawings when troubleshooting the run solenoid.

NOTE: See Kubota Workshop Manual, Diesel Engine, SM--E3B Series for information regarding engine run solenoid testing procedure.

Figure 23

1. Engine assembly 2. Engine run solenoid

Electrical

System

Workman MDX--D Electrical SystemPage 5 -- 17

Over Temperature Switch

The over temperature switch is located on the engine thermostat housing near the alternator (Fig. 24). If the engine coolant temperature reaches 230 (approximate), the over temperature switch closes which causes the dash panel engine temperature light to come on. The over temperature switch has a gray wire connected to it.

Switch Testing

F(110oC)

CAUTION

Make sure engine is cool before removing the temperature switch.

1. Park vehicle on a level surface, stop engine, apply parking brake and remove key from ignition switch. Raise and support cargo box to allow access to engine.

2. Lower coolant level in the engine and remove the over temperature switch.

Figure 24

1. Thermostat housing 2. Temperature switch

3. Put switch in a container of oil with a thermometer and slowly heat the oil (Fig. 25).

CAUTION

Handle the hot oil with extreme care to prevent personal injury or fire.

4. Check continuity of the switch with a multimeter (ohms setting). The over temperature switch is normally open and should close between 225

C).

113

5. Replace switch if necessary.

6. After testing, install over temperature switch to the engine housing.

A. Clean threads of housing and switch thoroughly. Apply thread sealant to the threads of the switch.

B. Thread temperature switch into the housing and tighten.

to 235oF(107oto

Figure 25

C. Connect wire harness connector to over temperature switch.

7. Fill engine cooling system. Lower and secure cargo bed.

Electrical System

Page 5 -- 18

Workman MDX--D

Fuel Pump

The MDX--D fuel pump is secured in a cavity in the top of the fuel tank (Fig. 26). Electrical current is available for the fuel pump when the ignition switch is in either the ON or START position.

IMPORTANT: When testing fuel pump, make sure that pump is not operated without fuel.

DANGER

Because diesel fuel is flammable, use caution when handling it. Do not smoke while testing the fuel pump. Do not test fuel pump while engine is hot. Make sure that there is adequate ventilation when testing. Always wipe up any spilled fuel before starting the engine.

Fuel Pump Capacity Test

1. Park vehicle on a level surface, stop engine, apply parking brake and remove key from ignition switch. Raise and support cargo box.

2. Disconnect wire harness electrical connector from the engine run solenoid to prevent the engine from starting (see Engine Run Solenoid in this section).

3. Disconnect fuel hose (fuel pump discharge) from the fuel/water separator inlet fitting (Fig. 27).

9. Install fuel hose to the fuel/water separator. Make sure to secure fuel hos e with hose clamp.

10.Connect wire harness electrical connector to the engine run solenoid.

11. Bleed the fuel system.

12.Lower and secure cargo box.

Figure 26

1. Fuel tank

2. Fuel pump

3. Fuel hose to filter

4. Make sure fuel hoses attached to the fuel pump and fuel tank suction tube screen are free of obstructions.

5. Place disconnected fuel hose into a large, graduated cylinder sufficient enough to collect 1 quart (0.95 liter).

IMPORTANT: When testing the fuel pump, DO NOT turn ignition switch to START.

6. Collect fuel in the graduated cylinder by turning ignition switch to the ON position. Allow pump to run for fifteen (15) seconds, then turn ignition switch to OFF.

7. Fuel collected in the graduated cylinder should be approximately 16 fl oz (475 ml) after fifteen (15) s econds.

8. Replace fuel pump if testing determines that it is faulty. Remove seat base to access fuel pump (see Seat Base in the Service and Repairs section of Chapter 6 -Chassis).

Figure 27

1. Fuel/water separator 2. Pump discharge hose

Fuel Pump Specifications

Pump Capacity

Pressure 7PSI(48.3kPa)

Current Draw 2.0 amp

64 fl oz/min (1.9 l/min)

Electrical

System

Workman MDX--D Electrical SystemPage 5 -- 19

Oil Pressure Switch

The engine oil pressure switch is located on the engine near the oil filter (Fig. 28). The oil pressure switch is a normally closed switch that opens with pressure.

The oil pressure switch should open at approximately 8

PSI (0.56 kg/cm

Switch Testing

NOTE: Refer to Kubota Workshop Manual, Diesel En-

gine, SM--E3B Series for information regarding engine lubrication system and testing.

1. Turn the ignition switch to the ON position. The oil pressure indicator light on the dash panel should b e illuminated.

2. If the indicator light is not illuminated, raise and support cargo box to gain access to engine.

3. Locate oil pressure switch on engine and disconnect the wire harness connector from the switch.

4. With the ignition switch in the ON position, ground the disconnected wire to the engine block.

5. If the indicator light comes on, the oil pressure switch is faulty. Replace oil pressure switch.

6. If the indicator light does not come on after step 5, check the oil pressure indicator light and circuit wiring (see Indicator Lights in this section).

Figure 28

1. Oil filter 2. Oil pressure switch

7. After testing is completed, connect the wire harness connector to the oil pressure switch. Lower and secure cargo box.

Electrical System

Page 5 -- 20

Workman MDX--D

Backup Alarm (Optional Kit)

When the shift lever is placed in the reverse position, the backup alarm should sound. The alarm is attached beneath the cargo box to a bracket on the right side of the frame.

Alarm Testing

1. Park vehicle on a level surface, stop engine, apply parking brake and remove key from ignition switch. Make sure that vehicle shift lever is in the NEUTRAL position.

2. Raise and support cargo box to allow access to backup alarm.

IMPORTANT: Make sure to observe polarity on the alarm terminals when testing. Damage to the alarm may result from an improper connection.

3. Disconnect wire harness connector from backup alarm. Correctly connect 12VDC source to the terminals (Fig. 29). Alarm should sound.

4. Remove voltage source from the alarm. Replace alarm if testing determines that it is faulty. Connect wire harness connector to alarm.

1. Alarm top view

2. Alarm bottom view

Figure 29

3. Positive (+) terminal

4. Negative (--) terminal

5. Lower and secure cargo box.

Electrical

System

Workman MDX--D Electrical SystemPage 5 -- 21

Backup Switch (Optional Kit)

The optional backup switch is a four (4) terminal, two (2) circuit switch that is used to energize the backup alarm when the shift lever is in the reverse position. The normally open switch circuit is used while the normally closed switch circuit is not used. If equipped, this switch is attached to the shift bracket in the seat base (Fig. 30).

Switch Testing

1. Position vehicle on a level surface, set parking brake, turn ignition switch OFF and remove key from switch. Make sure that vehicle shift lever is in the NEUTRAL position.

2. Remove four (4) screws and carefully slide shift bracket assembly from front of seat base to gain access to backup switch.

3. Unplug vehicle wire harness connector from backup switch.

4. With the use of a multimeter (ohms setting), check that the normally open switch contacts (Fig. 31) do not have continuity when the switch plunger is extended. The contacts should have continuity when the switch plunger is fully depressed.

5. When testing is complete, connect wire harness connector to backup switch. Slide shift bracket into seat base and secure with four (4) screws.

Figure 30

1. Seat base

2. Screw (4 used)

3. Shifter plate

4. Backup switch

Figure 31

1. Backup switch 2. Normally open contact

Electrical System

Page 5 -- 22

Workman MDX--D

Service and Repairs

NOTE: For information on engine electrical compon-

ents, see the Kubota Workshop Manual, Diesel Engine, SM--E3B Series.

Battery Service

The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure canbeprevented.

WARNING

POTENTIAL HAZARD:

Either the battery terminals or metal tools could

short against metal vehicle components.

WHAT CAN HAPPEN:

Sparks can cause the battery gasses to explode. Damaged cables could short against metal ve-

hicle components and cause sparks.

HOW TO AVOID THE HAZARD:

When removing or installing the battery, do not

allow the battery terminals to touch any metal parts of the vehicle.

Always DISCONNECT the negative (black) bat-

tery cable before disconnecting the positive (red) cable.

Always CONNECT the positive (red) battery

cable before connecting the negative (black) cable.

Do not allow metal tools to short between the

battery terminals and metal parts of the vehicle.

Always keep the battery retaining components

secure to protect the battery.

2. Remove battery cover.

3. Disconnect negative (black) cable from battery first to prevent short circuiting the battery, other components or operator’s hands. Then disconnect positive ( red) cable.

4. Remove battery retainer that secures battery to battery tray.

5. Make sure that battery filler caps are on tightly.

6. Remove battery from chassis to a service area. This will minimize possible battery damage and allow better access for battery inspection and service.

FRONT

Electrical

System

Battery Specifications

BCI Group Size 26

540 Amp Cranking Performance at 0 80 Minutes Reserve Capacity at 80

F(--18oC)

F(27oC)

Electrolyte Specific Gravity

Fully charged: 1.265 corrected to 80

F(27oC)

Discharged: less than 1.240

Battery Removal (Fig. 32)

IMPORTANT: Be careful to not damage terminal posts or cable connectors when removing the battery cables.

1. Position vehicle on a level surface, set parking brake, turn ignition switch OFF and remove key.

Workman MDX--D Electrical SystemPage 5 -- 23

Figure 32

1. Battery tray

2. Carriage screw (4 used)

3. Flange nut (4 used)

4. Battery cover

5. Carriage screw

6. Battery

7. Positive cable (red)

8. Negative cable (black)

9. Battery retainer

10. Flange nut

Battery Inspection and Maintenance

WARNING

CAP TUBES

FILLER CAPS

POTENTIAL HAZARD:

Battery electrolyte contains sulfuric acid which

is a deadly poison and it causes severe burns.

WHAT CAN HAPPEN:

If you carelessly drink electrolyte you could die

or if it gets onto your skin you will be burned.

HOW TO AVOID THE HAZARD:

Do not drink electrolyte and avoid contact with

skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.

Fill the battery where clean water is always

available for flushing the skin. Always RECONNECT the positive (red) battery cable before reconnecting the negative (black) cable.

Follow all instructions and comply with all safe-

ty messages on the electrolyte container.

1. Check for cracks caused by overly tight or loose hold down rod. Replace battery if cracked and leaking.

2. Check battery terminal posts for corrosion. Use a terminal brush or steel wool to clean corrosion from the battery terminal posts.

IMPORTANT: Before cleaning the battery, tape or block the vent holes to the filler caps and make sure the caps are on tightly.

3. Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler cap, overcharging, loose terminal post or overfilling. Also, check the battery case for dirt and oil. Clean the battery with a solution of baking soda and water, then rinse it with clean water.

CORRECT

ELECTROLYTE

LEVEL

COVER

SEAL

Figure 33

Battery Installation (Fig. 32)

IMPORTANT: To prevent possible electrical problems, install only a fully charged battery.

1. Make sure the ignition switch and all accessories are off.

2. Make sure the battery tray is clean and repainted if necessary.

3. Make sure battery cables, battery connections and the battery hold down components are in good condition.

4. Set battery on the battery base with its posts toward the right side of the vehicle.

5. Secure positive cable (red) to positive battery post .

6. Secure battery with retainer and fasteners.

7. Connect a digital multimeter (set to amps) between the negative battery post and the negative cable (black) connector. The reading should be less than 0.1 amp. If the reading is 0.1 amp or more, the vehicle’s electrical system should be tested and repaired.

4. Check that the cover seal is not broken away. Replace the battery if the seal is broken or leaking.

5. If battery caps can be removed, check the electrolyte level in each cell. If the level is below the tops of the plates in any cell, fill all cells with distilled water to the bottom of the cap tubes (or fill line). Charge at 15 to 25 amps for 15 minutes to allow sufficient mixing of the electrolyte.

Electrical System

Page 5 -- 24

8. Secure negative cable (black) to negative battery post with flange screw and flange nut.

9. Apply battery terminal protector (see Special Tools in this chapter) on battery posts and cable connectors to reduce corrosion after connections are made.

10.Install battery cover.

Workman MDX--D

Toro MDX-D User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Preface

Table Of Contents

Table of Contents

Safety Instructions

Supervisor’s Responsibilities

Before Operating

While Operating

Maintenance and Service

Jacking and Other Instructions

Jack Vehicle

Transport Vehicle

Tow Vehicle

Transaxle Neutral Position

Safety and Instruction Decals

Table of Contents

Product Records

Maintenance

Equivalents and Conversions

Torque Specifications

Fastener Identification

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)

Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)

Other Torque Specifications

Conversion Factors

Table of Contents

Specifications

General Information

Operator’s Manual

Adjustments

Adjust Throttle Cable

Service and Repairs

Air Cleaner

Exhaust System

Fuel Tank

Radiator

Engine

Engine Clutch Adapter

Table of Contents

Specifications

General Information

Operator’s Manual

Drive Train Operation

Clutch System Operation

Drive Clutch Operation

Driven Clutch Operation

Special Tools

Troubleshooting

Clutch

Adjustments

Adjust Shift Cables

Service and Repairs

Drive Clutch

Drive Clutch Service

Driven Clutch

Driven Clutch Service

Transaxle

Transaxle Service

Transaxle Disassembly and Inspection

Transaxle Assembly

Table of Contents

General Information

Operator’s Manual

Electrical Drawings

Special Tools

Troubleshooting

Starting Problems

General Run Problems

Electrical System Quick Checks

Battery Test

Charging System Test

Glow Plug Test

Component Testing

Ignition Switch

Indicator Lights

Fuse Blocks

Fusible Links