Toro Workman MDX-D Service Manual Download

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Workman MDX--D

Page 6 -- 26

Chassis

8. Bleed brake system (see Bleed Brake System in this

section).

9. Install both wheels to the transaxle (see Rear

Wheels and Brakes in this section).

10.Lower machine to ground.

11. Install muffler to machine (see Exhaust System in the

Service and Repairs section of Chapter 3 -- Diesel En-

gine).

12.Lower and secure cargo box.

13.Check parking brake operation and adjust if neces-

sary (see Adjust Parking Brake in the Adjustments sec-

tion of this chapter).

Summary of Contents for Workman MDX-D

Page 1: ...anual and Parts Catalog are avail able on the internet at www Toro com The Toro Company reserves the right to change product specifications or this publication without notice This safety symbol means...

Page 2: ...Workman MDX D This page is intentionally blank...

Page 3: ...ions 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 To...

Page 4: ...Workman MDX D This page is intentionally blank...

Page 5: ...AFETY 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 Tr...

Page 6: ...t designed equipped or manufactured for use on public streets roads or highways Supervisor s Responsibilities 1 Make sure operators are thoroughly trained and fa miliar with the Operator s Manual and...

Page 7: ...ts Keep by standers 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 c...

Page 8: ...neutral Make sure proper hoists jacks and jack stands are used to raise and support the vehicle Jacking Locations 1 Jack front of the vehicle on the front of the frame and behind the towing tongue Fi...

Page 9: ...e and remove key from the ignition switch 2 Move shift lever to the neutral position Fig 3 3 Make sure transaxle is in the neutral position by ro tating the driven clutch The tires should not rotate w...

Page 10: ...ion Decals Numerous safety and instruction decals are affixed to your Workman If any decal becomes illegible or dam aged install a new decal Part numbers are listed in the Parts Catalog Order replacem...

Page 11: ...rs Metric Fasteners 5 Other Torque Specifications 6 Conversion Factors 6 Product Records Insert Operator s Manual and Parts Catalog for your Workman at the end of this chapter Additionally if any opti...

Page 12: ...0 09375 Workman MDX D Page 2 2 Product Records and Maintenance Equivalents and Conversions...

Page 13: ...ue feature hardness of the surface underneath the fastener s head or similar condition which affects the installation As noted in the following tables torque values should be reduced by 25 for lubrica...

Page 14: ...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...

Page 15: ...N m M16 X 2 0 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m NOTE Reduce torque values listed in the table above by 25 for lubricated fasten...

Page 16: ...lb Wheel Bolts and Lug Nuts Thread Size Recommended Torque 7 16 20 UNF Grade 5 65 10 ft lb 88 14 N m 1 2 20 UNF Grade 5 80 10 ft lb 108 14 N m M12 X 1 25 Class 8 8 80 10 ft lb 108 14 N m M12 X 1 5 Cl...

Page 17: ...ENERAL 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 Installa...

Page 18: ...uel with Low or Ultra Low Sulfur Content 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 Low Idle no load...

Page 19: ...plained However the cost of the test equipment and the specialized nature of some repairs may dictate that the work be done at an en gine repair facility Service and repair parts for the Kubota engine...

Page 20: ...Workman MDX D Page 3 4 Diesel Engine This page is intentionally blank...

Page 21: ...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 loos ening cable jam nuts and repos...

Page 22: ...Figure 3 1 Air cleaner assembly 2 Carriage screw 2 used 3 Air intake hose 4 Air cleaner mounting bracket 5 Air inlet hood 6 Flange nut 2 used 7 Hose clamp 2 used 8 Throttle cable 9 Shoulder bolt 10 Th...

Page 23: ...air cleaner compo nents 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 cle...

Page 24: ...l Engine Exhaust System Figure 6 1 Engine 2 Exhaust header 3 Coupler spring 2 used 4 Flange nut 4 used 5 Muffler 6 Hex nut 4 used 7 Exhaust gasket 8 Flange head screw 4 used 9 Lock washer 4 used FRONT...

Page 25: ...hly 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 fr...

Page 26: ...nk 1 Seat 2 Fuel tank 3 Fuel hose to fuel separator 4 Fuel hose return from engine 5 Seat base 6 Web strapping 7 Hex head flange screw 8 used 8 Flat washer 8 used 9 Parking brake support 10 Shift brac...

Page 27: ...Remove fuel tank components as needed using Fig ure 8 as a guide 8 Clean fuel tank before installing it back on vehicle Fuel Tank Installation Fig 7 1 Install all removed fuel tank components using F...

Page 28: ...12 13 14 5 18 19 20 6 7 13 20 12 12 12 23 12 23 17 14 1 2 15 16 4 23 3 CAUTION DO NOT open radiator cap or drain coolant if the engine or radiator is hot Pressurized hot coolant can escape and cause...

Page 29: ...ts 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 flang...

Page 30: ...Engine wire harness connector 6 Lock washer 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 Spa...

Page 31: ...r hose from the radiator Then re move upper radiator hose from the radiator 7 Remove air intake hose from the air cleaner and en gine intake see Air Cleaner in this section 8 Remove muffler and exhaus...

Page 32: ...sure to not damage the en gine fuel hoses electrical harness or other parts while removing the engine C Carefully move the engine assembly away from the radiator and when the engine has cleared the ra...

Page 33: ...ure the throttle cable end to injector pump speed control lever with shoulder bolt and flange nut Tighten cable nuts to se cure cable to cable mount Fig 13 Check throttle cable adjustment see Adjust T...

Page 34: ...go 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...

Page 35: ...tion 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...

Page 36: ...d 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 Sp...

Page 37: ...erator 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 addit...

Page 38: ...AD 8 Power is transferred from the 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 mounte...

Page 39: ...closer to the fixed sheave This inward movement of the sheave engages the drive belt to drive the driven clutch With increasing engine speed the moveable sheave continues to move inward which forces...

Page 40: ...ces 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 be...

Page 41: ...o 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 t...

Page 42: ...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 back shifting Drive and driven clutches are not...

Page 43: ...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 corr...

Page 44: ...Drive Train Service and Repairs Drive Clutch 1 Engine 2 Clutch adapter 3 Cap screw 5 used 4 Drive belt 5 Drive clutch 6 Flange washer 7 Cap screw Figure 7 v FRONT RIGHT 17 to 22 ft lb 23 to 29 N m Lo...

Page 45: ...e 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 eith...

Page 46: ...ust be aligned during assembly for proper clutch operation 1 Make note of the X mark cast into the cover and spi der before clutch disassembly Fig 9 These marks must be aligned during assembly for pro...

Page 47: ...s in the spider assembly for binding or wear Fig 11 If binding or uneven wear is found re place clutch assembly 6 Check the belt contact surfaces of the movable and fixed sheaves Remove any belt mater...

Page 48: ...n 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...

Page 49: ...om clutch compo nents If necessary use contact or brake cleaner to remove any oil or other lubricants from clutch com ponents B Inspect the spring and replace if damaged or fa tigued C Check the rolle...

Page 50: ...id 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 assemb...

Page 51: ...to remove rear wheels A Chock the front and rear of both front tires to pre vent the vehicle from moving B Support both sides of the frame with appropriate jack stands positioned just in front of the...

Page 52: ...y route cables around transaxle 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 assem...

Page 53: ...Workman MDX D Drive Train Page 4 19 This page is intentionally blank Drive Train...

Page 54: ...43 44 45 46 47 48 49 50 57 53 54 55 57 58 59 25 23 22 21 19 17 16 56 15 1 2 3 4 5 6 7 8 9 10 20 24 26 27 28 29 30 11 12 13 14 52 55 26 38 33 18 42 43 7 59 56 11 12 35 9 15 51 16 55 52 55 8 10 Figure...

Page 55: ...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 shaf...

Page 56: ...ector shaft Figure 20 1 2 C Remove bolt near the selector shaft Remove spring and steel ball Replace gasket if damaged 1 Input shaft 2 Oil seal Figure 21 1 2 D Wrap vinyl tape around the splined porti...

Page 57: ...olts securing the axle bracket and axle case to each case Separate brack et from each axle case 1 Flange bolt 10 used 2 Flange nut Figure 23 1 2 F With the input shaft side down loosen and re move fla...

Page 58: ...the cases the boss may get damaged Do not pry open the two cases with a screw driver damage may result to the seal ing surfaces G Hold the case RH and lift up while lightly tapping the governor boss w...

Page 59: ...aft 2 Spacer 2 used 3 Needle bearing 4 Gear 34 Figure 27 1 2 4 2 3 C Replace counter shaft if it has abnormal wear cracks or damage D Replace spacer if either one is cracked or bent E Replace needle b...

Page 60: ...tapping the case with a plastic hammer Make sure to tap equally around the case G Lift up differential assembly center shaft assem bly and input shaft assembly at the same time First remove input sha...

Page 61: ...T When replacing ball bearings both ball bearings must be replaced as a set C Ball bearing roller balls must be free of deforma tion and scoring Ball bearing must spin freely and have minimum axial pl...

Page 62: ...table C Ball bearing roller balls must be free of deforma tion and scoring Ball bearing must spin freely and have minimum axial play Replace ball bearing as necessary 5 Disassemble center shaft assemb...

Page 63: ...clutch collars and spacer from the input shaft C Replace gears if worn or damaged Cracked bro ken missing or chipped gear teeth are not accept able D Replace center shaft if worn or damaged Splines th...

Page 64: ...gear 62 to the dif ferential case 1 Spring pin 2 Differential case 3 Pinion shaft 4 Pinion gear Figure 36 1 2 3 4 4 NOTE The spring pin can be punched out from the hole on the opposite side of gear 62...

Page 65: ...teeth are not accept able E Ball bearing roller balls must be free of deforma tion and scoring Ball bearing must spin freely and have minimum axial play Replace ball bearing as necessary F Replace ca...

Page 66: ...n Transaxle Assembly 1 Assemble input shaft assembly 1 Ball bearing 2 Input shaft Figure 38 1 2 IMPORTANT Make sure to press ball bearing at the inner race to prevent damaging the ball bearing A Press...

Page 67: ...disul fide grease to the inside of gears 47 and 55 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 on...

Page 68: ...greased surface 4 Differential case 5 Gear 62 6 Bolt 7 Spring pin 8 Ball bearing 9 Ball bearing Figure 42 8 3 7 1 9 1 6 5 2 4 3 123 3 to 124 0 mm 4 854 to 4 882 A Apply molybdenum disulfide grease to...

Page 69: ...ntial case Figure 43 1 4 3 2 B Install side gear both pinion gears and pinion shaft into the differential case 1 Spring pin 2 Differential case 3 Pinion shaft Figure 44 1 2 3 C Align pinion shaft hole...

Page 70: ...with six 6 bolts Torque bolts in a crossing pattern from 40 to 45 ft lb 54 to 61 N m Figure 46 40 to 45 ft lb 54 to 61 N m IMPORTANT The length from the outer most side of each ball bearing must be f...

Page 71: ...the axle case 1 Axle case 2 Case 3 Flange bolt Figure 48 25 to 31 ft lb 34 to 42 N m 1 2 3 IMPORTANT Make sure to install the axle case to the proper side of the case The right side of the case takes...

Page 72: ...haft 4 Differential assembly Figure 50 1 2 3 4 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...

Page 73: ...haft 2 Pin shift shaft Figure 51 1 2 D Make sure the selector shaft fork is contacting the pin on the shift shaft 1 Spacer 2 Boss counter shaft Figure 52 1 2 E Place spacer on the counter shaft boss o...

Page 74: ...ft G Place gear 34 onto the spacer Make sure not to drop the spacer Insert needle bearing into gear In sert counter shaft with remaining spacer through the needle bearing gear 34 and into the spacer a...

Page 75: ...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 bolt...

Page 76: ...bracket 2 Bolt steel ball spring gasket Figure 57 12 to 15 ft lb 16 to 20 N m 1 2 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 qu...

Page 77: ...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...

Page 78: ...regarding the operation general maintenance and maintenance intervals for your Workman vehicle Refer to the Opera tor s Manual for additional information when servicing the machine Electrical Drawings...

Page 79: ...me ter in the voltage mode will make sure that excess cur rent is not allowed through the meter This excess current can cause damage to circuits not designed to carry it Figure 1 Skin Over Grease Spec...

Page 80: ...icant to both component and wire harness connector plug con nector to component unplug connector reapply lubri cant to both surfaces and reconnect harness connector to component Connectors should be t...

Page 81: ...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 ha...

Page 82: ...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 Batte...

Page 83: ...se at different rates as the battery charges Make sure the shift lever is in the neutral position and the parking brake is applied Start the engine and run en gine at high idle above 3000 RPM Maintain...

Page 84: ...e positions OFF ON and START The ignition switch is located on the dash panel Fig 6 Testing The switch terminals are identified as shown in Figure 7 The circuit wiring of the ignition switch is shown...

Page 85: ...e Temperature Light If the engine coolant temperature reaches 230oF 110oC approximate the engine temperature light will come on To test the engine temperature light and circuit wiring turn ignition sw...

Page 86: ...cts the engine start circuit 3 The middle right 10 ampere fuse protects the light circuit 4 The extreme right 15 ampere fuse protects the cir cuits for engine electrical components and also dash in di...

Page 87: ...n Chapter 7 Electrical Drawings for additional circuit information Testing Make sure that ignition switch is OFF Disconnect nega tive battery cable from battery terminal and then discon nect positive...

Page 88: ...nector to hour meter Figure 13 RUNNING INDICATOR WINDOW 1 10 WHEEL WHITE W BLACK NUMBERS HOUR WHEELS BLACK W WHITE NUMBERS 1 10 HOURS 0 0 0 0 0 QUARTZ Headlight Switch The headlight switch is located...

Page 89: ...by connecting a multimeter ohms setting across the connector termi nals 4 When the switch plunger is extended brake pedal is applied there should be continuity closed between the switch terminals 5 W...

Page 90: ...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 sm...

Page 91: ...rom the measured value of the relay being testing 3 Using a multimeter ohms setting measure coil re sistance between terminals 85 and 86 Fig 20 Resist ance should be between 70 and 90 ohms 4 Connect m...

Page 92: ...ed 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 Place ignition switch in the START position...

Page 93: ...lunger 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 the e...

Page 94: ...wer coolant level in the engine and remove the over 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...

Page 95: ...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...

Page 96: ...anel should be illu minated 2 If the indicator light is not illuminated raise and sup port cargo box to gain access to engine 3 Locate oil pressure switch on engine and disconnect the wire harness con...

Page 97: ...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 conn...

Page 98: ...at vehicle shift lever is in the NEU TRAL 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 harne...

Page 99: ...rts of the ve hicle Always keep the battery retaining components secure to protect the battery Battery Specifications BCI Group Size 26 540 Amp Cranking Performance at 0o F 18oC 80 Minutes Reserve Cap...

Page 100: ...soda and water then rinse it with clean water 4 Check that the cover seal is not broken away Re place the battery if the seal is broken or leaking 5 If battery caps can be removed check the electrolyt...

Page 101: ...f the most reliable means of testing a battery as it simulates the cold cranking test A commercial bat tery load tester is required to perform this test CAUTION Follow the battery load tester manufact...

Page 102: ...se it can ex plode and cause injury Let the battery warm to 60oF 16oC before connecting to a charger Charge battery in a well ventilated place to dissi pate gases produced from charging These gases ar...

Page 103: ...10 SERVICE AND REPAIRS 11 Check Tire Pressure 11 Inspect Tires and Wheels 11 Upper Steering 12 Steering Gearbox 14 Lower Steering and Front Wheels 16 Front Shock Absorbers 19 A arms and Front Suspensi...

Page 104: ...ifications Item Description Front Tire 22 x 9 5 10 4 ply Pressure Range 8 to 22 PSI 55 to 151 kPa Rear Tire 24 x 12 10 2 ply Pressure Range 8 to 22 PSI 55 to 151 kPa Wheel Lug Nut Torque 80 to 90 ft l...

Page 105: ...erator 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 addit...

Page 106: ...which changes the length of the shock spring to affect front wheel camber Make sure that vehicle is jacked up off the ground to allow shock spring to be at full exten sion before using spanner wrench...

Page 107: ...se Clutch or transaxle problem see Chapter 4 Drive Train Excessive steering play Front wheel lug nuts are loose Front wheel bearings are loose or worn Steering linkage is loose or worn Tie rod ends ar...

Page 108: ...nment toe in is incorrect Steering gearbox is damaged or worn Vehicle pulls to one side when not braking Tire pressure is low or uneven between tires Front wheel alignment toe in is incorrect Steering...

Page 109: ...ke is applied or incorrectly adjusted Rear brake shoe to shoe spring s is are weak or broken Brake pedal is binding Parking brake cable is binding Rear brake linings or front brake pads are saturated...

Page 110: ...parking brake 2 Loosen the set screw securing the knob to the park ing brake lever Fig 3 3 Rotate the knob until a force from 30 to 35 lb 133 to 156 N is required to actuate the lever 4 Tighten the se...

Page 111: ...ttom of the rim should be 0 090 2 3 mm larger than the top measure ment This measurement allows for a camber of 0 1 2 degree D Repeat measurement procedure for other front wheel 6 If camber measuremen...

Page 112: ...10 feet 2 to 3 meters and then straight forward to the original starting position This will allow the suspen sion to settle into the normal operating position 4 Make sure that the front wheels are fac...

Page 113: ...er pres sure should not be used for heavy payloads at higher speeds Higher pressures should be used for heavier payloads at higher speeds Do not exceed the maximum tire pres sure Inspect Tires and Whe...

Page 114: ...4 4 13 8 7 5 9 12 7 6 2 1 16 15 Loctite 242 175 to 225 in lb 20 to 25 N m Antiseize Lubricant Disassembly Fig 8 1 Park machine on a level surface stop engine set parking brake and remove key from the...

Page 115: ...steering shaft up through the steering column 4 Secure steering column to the mounting plate on the frame with four 4 carriage screws and flange nuts NOTE Apply antiseize lubricant to the steering gea...

Page 116: ...rew with patch lock 10 Ball bearing 11 Input shaft spacer 12 Flat washer 13 Flange head screw with patch lock 14 Lube fitting 15 Steering housing cover 16 Steering housing 17 Pinion gear 18 Oil seal 1...

Page 117: ...ng over Insert spacer and press new bearing into housing 2 If seals were removed press new seals into housing Seal lips should be facing up 3 Place flat washer item 5 onto shaft of the Pitman arm item...

Page 118: ...nut 5 used per wheel 19 Cap screw 2 used per A arm 20 Cotter pin 21 Wheel stud 5 used per hub 22 Socket head screw 4 used per rotor 23 Brake caliper LH shown 24 Flange screw 2 used per caliper 25 Grea...

Page 119: ...amaged parts C If necessary remove wheel studs and brake rotor from wheel hub 9 Remove spindle Fig 13 A Remove cotter pin and castle nut securing tie rod ball joint to the spindle Separate ball joint...

Page 120: ...be toward the inner bear ing C Lubricate the inside of the new seal and press it into the wheel hub D If brake rotor was removed position rotor to hub with chamfered edge toward hub Secure rotor to hu...

Page 121: ...prevent it from moving after the shock is removed 4 Remove lock nuts cap screws and flat washer that secure shock to frame and a arm Remove shock ab sorber from vehicle NOTE Use spanner wrench TOR6010...

Page 122: ...shock 8 LH A arm 9 Brake rotor 10 Wheel hub assembly 11 Tab washer 12 RH A arm 13 Jam nut 14 Front frame 15 Nut retainer 16 Dust cap 17 Wheel assembly 18 Lug nut 5 used per wheel 19 Cap screw 2 used p...

Page 123: ...nd straight bushings from A arm bores Fig 16 A arm Installation Fig 15 1 If bushings were removed from A arm press new bushings fully into bore of A arm Fig 16 2 Position A arm to the frame Secure A a...

Page 124: ...p screw 2 used per shock 8 LH A arm 9 Grease fitting 1 used per arm 10 Screw 11 Cap screw 12 RH A arm 13 Lock washer 14 Front frame 15 Pivot yoke 16 Flange head screw 4 used 17 Flat washer 4 used 18 H...

Page 125: ...o the machine 7 Remove four 4 flange head screws and flanged lock nuts securing the pivot yoke to the front frame Re move pivot yoke from the machine Pivot Yoke Installation Fig 17 and 19 WARNING Supp...

Page 126: ...Hardened washer 4 used 4 Rear shock assembly 2 used 5 Cap screw 2 used 6 Lock nut 4 used 7 Thrust washer 4 used 8 Cap screw 2 used 9 Swing arm 10 Rear frame 11 Cap screw 2 used 12 Lock nut 2 used Figu...

Page 127: ...ers to swing arm 9 Support swing arm to prevent it from falling 10 Remove cap screws thrust washers and lock nuts that secure swing arm pivots to machine frame IMPORTANT Take care to not damage the en...

Page 128: ...Rear Wheels and Brakes in this section 10 Lower machine to ground 11 Install muffler to machine see Exhaust System in the Service and Repairs section of Chapter 3 Diesel En gine 12 Lower and secure ca...

Page 129: ...Workman MDX D Page 6 27 Chassis This page is intentionally blank Chassis...

Page 130: ...cket 5 Parking brake lever 6 Curved washer 7 Lock nut 8 Flat washer 9 Flange head screw 4 used 10 Flat washer 2 used 11 Screw 2 used 12 Cap screw 13 Cotter pin 14 Clevis pin 15 Parking brake cable 2 u...

Page 131: ...igure 22 as a guide 7 Note routing of brake cables for assembly purposes 8 Remove brake cables from machine Assembly Fig 22 1 Secure brake cables to parking brake support and cable equalizer bracket u...

Page 132: ...ch WARNING Before jacking up the machine review and follow Jacking Instructions in Chapter 1 Safety 2 Chock wheels not being jacked up Lift rear wheel off the ground using a jack and support vehicle w...

Page 133: ...shaft Castle nut torque should not exceed 200 ft lb 271 N m 7 Secure castle nut to transaxle shaft with cotter pin 8 Slide brake drum onto wheel hub 9 Position wheel assembly to the machine with valv...

Page 134: ...l when removing springs from brake shoes The springs are under heavy load and may cause personal injury 1 Remove upper and lower springs from brake shoes 2 Remove shoe hold down cups and springs that...

Page 135: ...not be re moved by light sanding with emery cloth or other suit able abrasive Replace plate if cracked warped or excessively rusted 4 Inspect adjuster levers for deformation Replace lev ers if deform...

Page 136: ...pin 9 Cap screw 2 used 10 Flange nut 2 used 11 Flange screw 2 used 12 Flange screw 2 per caliper 13 Banjo bolt 2 used 14 Banjo washer 4 used 15 Socket head screw 4 per rotor 16 Wheel hub assembly Figu...

Page 137: ...wo 2 flange head screws that secure the brake caliper to the spindle 6 Slide brake caliper from brake rotor and remove cali per from machine Assembly Fig 27 1 Slide brake caliper onto brake rotor Make...

Page 138: ...aliper Service 1 Bolt 2 used 2 Caliper body 3 O ring 4 used 4 Caliper bracket 5 Square seal 2 used 6 Piston 2 used 7 Brake pad 2 used 8 Caliper anvil Figure 28 2 3 6 8 1 5 7 4 37 to 44 N m 27 to 33 ft...

Page 139: ...ce brake pistons or complete brake caliper assembly if necessary 3 Check that pins on caliper bracket are not worn or damaged Wear on the pins will prevent smooth brake operation Assembly Fig 28 1 If...

Page 140: ...assis Brake Master Cylinder 1 Brake master cylinder 2 Cap screw 2 used 3 Brake pedal 4 Clevis pin 5 Cotter pin 6 Flange head nut 2 used 7 Pedal frame 8 Front brake line 9 Rear brake line Figure 29 FRO...

Page 141: ...from master cylinder 4 Remove two 2 flange head nuts and cap screws that secure master cylinder to pedal frame 5 Remove master cylinder from machine Installation Fig 29 1 Position master cylinder to...

Page 142: ...eways with com pressed air Make sure cylinder bore and component pieces are thoroughly clean 2 Check cylinder bore pistons and springs for damage or excessive wear Replace brake cylinder assembly if s...

Page 143: ...brake fluid with no air bubbles is released from bleeder valve Make sure fluid level is maintained in brake fluid res ervoir at all times 5 When brake bleeding is completed torque caliper bleed valve...

Page 144: ...Flat washer 8 used 14 Shift plate 15 Rubber receptacle 2 used 16 Holding post 2 used 17 Screw 2 used 18 Rivet 2 used 19 Shifter decal 20 Parking brake support 21 Cap screw 22 Curved washer 23 Lock nu...

Page 145: ...tion Fig 33 IMPORTANT Make sure shift bracket shift cables and fuel tank do not catch on the seat base during installation 1 Carefully lower seat base to the vehicle frame NOTE Do not tighten fastener...

Page 146: ...g pin 2 used 17 Headlight bracket 18 Flange head screw 2 used 19 Washer head screw 20 used 20 Washer head screw 4 used 21 Flange nut 2 used 22 Rubber latch 2 used 23 Catch 2 used 24 Flat washer 4 used...

Page 147: ...and remove key from the ignition 2 Remove hood using Figure 35 as a guide Installation Fig 35 NOTE Do not tighten fasteners securing the hood until all fasteners are in place 1 Install hood using Figu...

Page 148: ...2 Handle 3 Latch pin 2 used 4 Lock nut 2 used 5 Carriage screw 4 used 6 Pivot bracket 7 Pivot bushing 2 used 8 Screw 4 used 9 Carriage screw 4 used 10 Flange nut 4 used 11 Prop rod 12 Flange nut 6 use...

Page 149: ...identified in Figure 36 B When installing tailgate latches use torque spe cifications identified in Figure 37 C Adjust latch pin item 3 in Figure 36 so that cargo box is tight to frame when latched 1...

Page 150: ...Workman MDX D Page 6 48 Chassis This page is intentionally blank...

Page 151: ...Chapter 7 Electrical Drawings Table of Contents ELECTRICAL SCHEMATIC 3 CIRCUIT DIAGRAMS Glow Plug Circuits 4 Start Circuits 5 Run Circuits 6 ELECTRICAL HARNESS DRAWINGS Main Electrical Harness 8 Engin...

Page 152: ...Page 7 2 Workman MDX D Electrical Drawings This page is intentionally blank...

Page 153: ...Page 7 3 Electrical Schematic Workman MDX D Relays are shown as de energized...

Page 154: ...Page 7 4 Glow Plug Circuits Power Current Control Current Indication Current...

Page 155: ...Page 7 5 Start Circuits Power Current Control Current Indication Current...

Page 156: ...Page 7 6 Run Circuits Power Current Control Current Indication Current...

Page 157: ...Page 7 7 This page is intentionally blank...

Page 158: ...Page 7 8 Main Electrical Harness Workman MDX D Wiring Drawing...

Page 159: ...ORANGE ORANGE BLACK BLACK BLUE PINK ORANGE BLACK BLACK GREEN YELLOW TAN BLUE BLUE WHITE YELLOW RED BLACK YELLOW WHITE YELLOW RED BLACK BLACK YELLOW BLUE YELLOW YELLOW BLACK YELLOW BLACK WHITE YELLOW B...

Page 160: ...Page 7 10 Engine Electrical Harness Workman MDX D BROWN BLACK FUSIBLE LINK RED BLUE WHITE BLUE...

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