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Rev. A

Workman MDE

Page 3 -- 1

Electrical System

Chapter 3

Electrical System

Table of Contents

GENERAL INFORMATION

. . . . . . . . . . . . . . . . . . . . .

Operator’s Manual

. . . . . . . . . . . . . . . . . . . . . . . . . .

Opening Battery Circuit

. . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL DIAGRAMS

. . . . . . . . . . . . . . . . . . . . . .

VEHICLE OPERATION

. . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . .

General Run Problems

. . . . . . . . . . . . . . . . . . . . . . .

Battery Charger Operation

. . . . . . . . . . . . . . . . . . . .

Battery Charger Problems

. . . . . . . . . . . . . . . . . . .

ADJUSTMENTS

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accelerator Switch Adjustment

. . . . . . . . . . . . . . .

Accelerator Potentiometer Adjustment

(Potentiometer with Short Lever)

. . . . . . . . . . . .

Accelerator Potentiometer Adjustment

(Potentiometer with Long Lever)

12.1

. . . . . . . . . .

Accelerator System Calibration

. . . . . . . . . . . . . . .

COMPONENT TESTING

. . . . . . . . . . . . . . . . . . . . . .

On/Off Switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Discharge Indicator and Hour

Meter Gauge

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Vehicle Direction (Forward/Reverse) and

Headlight Switches

. . . . . . . . . . . . . . . . . . . . . . .

Vehicle Status Light

. . . . . . . . . . . . . . . . . . . . . . . .

Supervisor Speed Limit Switch

. . . . . . . . . . . . . . .

Audio Alarm (Reverse)

. . . . . . . . . . . . . . . . . . . . . .

Charger Interlock Switch

. . . . . . . . . . . . . . . . . . . .

Main and Accessories Contactors

. . . . . . . . . . . .

Fuses

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fusible Links

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Accelerator Switch

. . . . . . . . . . . . . . . . . . . . . . . . .

Accelerator Potentiometer

. . . . . . . . . . . . . . . . . . .

Controller

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SERVICE AND REPAIRS

. . . . . . . . . . . . . . . . . . . . .

Battery Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Specifications

. . . . . . . . . . . . . . . . . . . . .

Battery Removal

. . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Installation

. . . . . . . . . . . . . . . . . . . . . . . .

Battery Charging

. . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Inspection and Maintenance

. . . . . . . . .

Battery Testing

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery Storage

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction Motor Brushes

. . . . . . . . . . . . . . . . . . . . .

Traction Motor

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Traction Motor Service

. . . . . . . . . . . . . . . . . . . . . .

Battery Charger

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

LESTER ELECTRICAL TECHNICIAN

SERVICE GUIDE

Electrical System

Содержание Workman MDE 2008

Страница 1: ...nual 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 D...

Страница 2: ...Workman MDE This page is intentionally blank...

Страница 3: ...nts 3 11 Component Testing 3 14 Service and Repairs 3 28 LESTER ELECTRICAL TECHNICIAN SERVICE GUIDE Chapter 4 Transaxle and Brakes General Information 4 2 Specifications 4 3 Troubleshooting 4 4 Servic...

Страница 4: ...Workman MDE This page is intentionally blank...

Страница 5: ...afety Table of Contents SAFETY INSTRUCTIONS 2 Before Operating 2 While Operating 2 Maintenance and Service 3 JACKING AND OTHER INSTRUCTIONS 4 Jacking Vehicle 4 Towing Vehicle 4 Transporting Vehicle 4...

Страница 6: ...op the vehicle and engine quickly Additional copies ofthe 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 devic...

Страница 7: ...ttery gases can explode Keep cigarettes sparks and flames away from the batteries Always service storeandchargethevehiclebatteries ina wellventilated area 10 Never use an open flame to check level or...

Страница 8: ...nd jack stands are used to raise and support the vehicle Jacking Locations 1 Jack front of the vehicle on the front of the frame be hind the towing tongue Fig 1 2 Jack rearofthevehicleundereachrearaxl...

Страница 9: ...ls Thereareseveralsafety andinstruction decalsattached to your Workman vehicle If any decal becomes illegible or damaged install a new decal Part numbers are listed in the Parts Catalog Order replacem...

Страница 10: ...Workman MDE Page 1 6 Safety This page is intentionally blank...

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

Страница 12: ...0 09375 Workman MDE Page 2 2 Product Records and Maintenance Equivalents and Conversions...

Страница 13: ...e e g Nylock nut 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 l...

Страница 14: ...2 22 3 30 3 41 4 43 5 58 7 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...

Страница 15: ...10 N m 93 10 ft lb 126 14 N m M16 X 2 0 166 17 ft lb 225 23 N m 229 23 ft lb 310 31 N m M20 X 2 5 325 33 ft lb 440 45 N m 450 46 ft lb 610 62 N m NOTE Reduce torque values listed in the table above by...

Страница 16: ...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 Class...

Страница 17: ...OMPONENT TESTING 14 On Off Switch 14 Battery Discharge Indicator and Hour Meter Gauge 15 Vehicle Direction Forward Reverse and Headlight Switches 16 Vehicle Status Light 17 Supervisor Speed Limit Swit...

Страница 18: ...operation general maintenance and maintenance intervals for your Workman vehicle Refer to the Opera tor s Manual for additional information when servicing the machine Opening Battery Circuit To preven...

Страница 19: ...an MDE Page 3 3 Electrical System Electrical Diagrams The electrical schematic circuit drawings and wire har ness drawings for the Workman MDE are located in Chapter 6 Electrical Diagrams Electrical S...

Страница 20: ...The traction motor is cooled with an external fan Addi tionally the motor is protected from overheating by a thermal switch in the motor housing If unsafe motor temperature is sensed by the switch th...

Страница 21: ...m If multimeter is not of the auto range type make sure to properly set multimeter range before per forming any voltage test Figure 3 Battery Terminal Protector Battery Terminal Protector is an aeroso...

Страница 22: ...4102 Figure 6 Battery Hydrometer Use the battery hydrometer when measuring specific gravity of battery electrolyte Obtain hydrometer locally Figure 7 Battery Lift Strap Use the battery lift strap to r...

Страница 23: ...ischarge Unit is recommended for quick and accurate load testing for the batteries on the Workman MDE This tool is used to determine the capacity of the Workman battery pack and also for find ing a fa...

Страница 24: ...tus light on dash panel and controller LED for possible faults whenever diagnosing vehicle problems see Controller in the Component Testing section of this chapter Problem Possible Causes Main contact...

Страница 25: ...nsaxle and Brakes Battery charge is extremely low Controller is overheated Traction motor is overheated Vehicle movement is erratic or jerky Collar on throttle is loose Accelerator potentiometer is im...

Страница 26: ...charger receptacle or circuit wiring damaged Battery charger is faulty Battery charger does not turn off Battery charger is faulty NOTE Charging new batteries or charging batteries in cold temperatur...

Страница 27: ...ust ac celerator switch stop cap screw position Fig 11 4 After adjustment make sure that switch plunger is not bottomed out when accelerator pedal is released 5 Calibrate accelerator system after adju...

Страница 28: ...otentiometer lever A With the accelerator pedal released the roll pin on the throttle position collar should keep the poten tiometer lever from 0 050 to 0 100 1 3 to 2 5 mm from the lower stop on the...

Страница 29: ...me of the machine 2 Check accelerator switch adjustment and adjust if necessary see Accelerator Switch Adjustment in this section 3 With the accelerator pedal released inspect location of roll pin on...

Страница 30: ...Workman MDE Electrical System Page 3 This page is intentionally blank Rev A 12 2...

Страница 31: ...e same as the controller LED 5 Turn on off switch ON The alarm should sound and the controller LED should flash six 6 times 6 Slowly depress accelerator pedal until the alarm mo mentarily stops and ho...

Страница 32: ...ash panel Fig 17 The switch has two 2 positions OFF and ON and three 3 switch terminals Only two of the terminals are used on the Workman MDE The switch terminals are positioned as shown in Figure 18...

Страница 33: ...rning light begins flashing and the vehicle will go into an energy saving mode vehicle speed will be reduced to 3 MPH At this point the batteries should be charged to prevent serious battery damage Th...

Страница 34: ...TE The headlight system on the Workman MDE consists of two 2 24 volt lamps connected in series If one lamp is burned out or disconnected neither lamp will illuminate Testing The switch terminals for t...

Страница 35: ...ated and the vehicle status light is not illuminated check the vehicle status light and cir cuit wiring See Controller in this section and your Operator s Manual for information on a flashing vehicle...

Страница 36: ...he direction forward re verse switch is placed in the reverse position The alarm is located under the controller cover beneath the cargo box Testing IMPORTANT Make sure to observe polarity on the alar...

Страница 37: ...terlock switch on rear of receptacle plate Disconnect harness connector from the switch 4 Check the continuity of the switch by connecting a multimeter ohms setting across the connector termi nals 5 W...

Страница 38: ...battery cables see Opening Battery Circuit in the General Information sec tion of this chapter and Fig 31 2 Locate contactor that is to be tested Disconnect all vehicle harness electrical connections...

Страница 39: ...oved use Figure 33 as a guide for reattaching cable and wire harness connec tions 8 Connect battery cable that was removed from bat tery pack 1 Main contactor 2 Cable to controller B 3 Lock nut 4 Flat...

Страница 40: ...w between the batteries and the vehicle If this fuse has failed ve hicle operation will not occur Testing CAUTION When testing fuses for continuity with a multime ter ohms setting make sure that fuse...

Страница 41: ...other fusible link FL1 protects the charger circuit The third fusible link FL3 is attached to the controller B terminal This link provides protection for the charge indicator hour meter gauge If any o...

Страница 42: ...e whether continuity exists between the switch terminals for both switch positions Verify continuity between switch termi nals using the following table PLUNGER POSITION CONTINUITY NO CONTINUITY IN 1...

Страница 43: ...above 310000000 have a potentiometer with a long lever Fig 41 This po tentiometer is rotated by a roll pin that extends approxi mately 3 inches 76 mm out of the collar If a potentiometer on an earlie...

Страница 44: ...ller socket should be filled with dielectric gel to prevent corrosion of connec tion terminals and potential controller damage Apply gel fully to both harness connector and controller sock et plug har...

Страница 45: ...or wire and cable connections If problem continues contactor replacement may be necessary 5 Flashes The charger cord is plugged into the vehicle charger receptacle Turn on off switch OFF unplug charge...

Страница 46: ...ttery retainer 2 used 11 Flange nut 2 used 12 Battery cable Figure 42 1 2 3 4 5 10 11 8 6 9 7 5 4 12 115 to 125 in lb 13 0 to 14 1 N m 115 to 125 in lb FRONT RIGHT 13 0 to 14 1 N m The batteries are t...

Страница 47: ...ation Fig 42 IMPORTANT To prevent possible electrical prob lems install only fully charged batteries 1 Make sure vehicle on off switch and all accessories are OFF Raise cargo box and secure with prop...

Страница 48: ...ing 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 Follow all instructions and comply with...

Страница 49: ...ltage The measured voltage will determine battery state of charge D If voltage readings below 70 charged see Fig 46 exist charge battery and take voltage measure ments again If voltage remains low aft...

Страница 50: ...e will be stored for more than 30 days and the battery charger cannotbeusedforsomereason charge the batteries fully Either store batteries on a shelf or in the vehicle Store the batteries in a cool at...

Страница 51: ...raction Motor and Traction Motor Service in this section 6 If vehicle is often operated in severely dirty environ ments brush should be removed from motor to allow in spection of mating surface of bru...

Страница 52: ...0 to 14 1 N m 19 125 to 165 in lb 14 2 to 18 6 N m Removal Fig 50 1 Park vehicle on a level surface turn on off switch OFF set parking brake and remove key from switch 2 Remove cargo box from vehicle...

Страница 53: ...eyebolt into motor approximately four 4 turns taking care to not bottom eyebolt into internal field coils Secure eyebolt with jam nut Use eyebolt for support and as a lifting point for motor re moval...

Страница 54: ...can occur 6 Connect wires to traction motor Fig 51 A Make sure that fasteners and cable connectors are properly positioned on motor terminals Fig 55 B Install correct cable connector and nut to motor...

Страница 55: ...Workman MDE Page 3 37 Electrical System This page is intentionally blank Electrical System...

Страница 56: ...tch them in the open position on the spring holders Slide brushes from the brush holders 3 Use an arbor press or a bearing puller to remove the armature from the commutator end head and frame and fiel...

Страница 57: ...following procedure Fig 58 A Place paper strip between brush face and com mutator Hook spring scale as shown B Pull spring scale on a line directly opposite the line of force exerted by the brush spr...

Страница 58: ...tions including wearing eye and respiratory protec tion 5 After undercutting use No 00 sandpaper to lightly remove any burrs left from the undercutting operation Clean commutator with dry oil free com...

Страница 59: ...assembly and secure with four 4 bolts Torque bolts from 120 to 140 in lb 13 6 to 15 8 N m 4 Ensure the brushes are pushed out of the way 5 While supporting the inner race of the bearing in commutator...

Страница 60: ...3 Lower case 4 SCR assembly 5 Control board 6 Relay 7 Circuit breaker 8 AC cordset 9 DC cordset 10 Ammeter 11 Fuse 12 Diode assembly Figure 64 3 4 5 8 6 7 9 1 2 10 11 12 For service of the battery cha...

Страница 61: ...SHOOTING 4 Brakes 4 SERVICE AND REPAIRS 6 Rear Wheels and Brakes 6 Rear Brake Service 10 Hydraulic Brake System 12 Bleed Brake System 13 Front Brake Calipers 14 Brake Master Cylinder 16 Brake Master C...

Страница 62: ...rmation Operator s Manual The Operator s Manual provides information regarding the operation general maintenance and maintenance intervals for your Workman MDE vehicle Refer to the Operator s Manual f...

Страница 63: ...Workman MDE Transaxle and Brakes Page 4 3 Specifications Item Description Transaxle Transaxle Fluid Capacity 2 quarts 1 9 liters Transaxle Fluid 10W 30 Motor Oil Brake Fluid DOT 3 Transaxle and Brakes...

Страница 64: ...ear brake drums are excessively worn or damaged Rear brake shoes are not burnished Air in brake lines Brakes pull to either side Tire pressure is incorrect or uneven between tires Brake linings are co...

Страница 65: ...dal is hard to push Incorrect brake lining material Brake pedal linkage is binding Wheels lock up when braking Brake linings are contaminated worn or damaged Wheel or transaxle bearings are damaged Re...

Страница 66: ...crew 4 used per side 5 Wheel stud 5 used per side 6 Wheel hub 7 Flange nut 8 Parking brake cable 9 Retaining ring 10 Cotter pin 11 Clevis pin 12 Transaxle 13 Brake drum 14 Rear wheel assembly 15 Lug n...

Страница 67: ...sition it away from wheel cylinder C Remove four 4 socket head screws and lock nuts securing the brake assembly to the transaxle Remove brake assembly from the transaxle Installation Fig 1 IMPORTANT T...

Страница 68: ...free of other persons and obstructions 8 Check brake operation Burnish Brake Shoes To provide maximum brake performance after rear brake shoes are replaced burnish new brake shoe lin ings IMPORTANT T...

Страница 69: ...Workman MDE Transaxle and Brakes Page 4 9 This page is intentionally blank Transaxle and Brakes...

Страница 70: ...areful 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...

Страница 71: ...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 deformation or...

Страница 72: ...23 Rear brake tube 24 Rear brake hose 25 Hose bracket 2 used 26 Tube clamp 2 used 27 R Clamp 28 Cap screw 2 per caliper used 29 Lock washer 2 per caliper used 30 Socket head screw 4 per rotor used 31...

Страница 73: ...es to floor Close bleeder valve before re leasing pedal 4 Repeat procedure until a continuous flow of brake fluid with no air bubbles is released from bleeder valve Make sure fluid level is maintained...

Страница 74: ...4 Cap screw 2 per caliper used 5 Wheel hub assembly 6 Brake rotor 7 Socket head screw 4 per rotor used 8 Spindle LH shown 9 A arm LH shown 10 Brake master cylinder 11 Wheel assembly 12 Lug nut 5 used...

Страница 75: ...ds are not the same D Replace the brake pads if the friction material is worn to less than 1 32 0 8 mm 8 If brake rotor service is necessary see Lower Steer ing and Front Wheels in the Service and Rep...

Страница 76: ...tamination Remove both brake lines from master cylinder Cap ends of brake lines and position them away from master cylinder 4 Remove flange head nuts from cap screws that se cure master cylinder to pe...

Страница 77: ...y clean 2 Check cylinder bore pistons and springs for damage or excessive wear Replace brake cylinder assembly if signs of pitting scoring or cracks are evident in cylinder bore Assembly Fig 9 1 Apply...

Страница 78: ...racket 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...

Страница 79: ...m machine Take care to not damage brake cables while removing them from seat base opening 7 Remove brake cables from parking brake support and cable equalizer bracket using Figure 10 as a guide Assemb...

Страница 80: ...et head screw 12 Lug nut 5 used per wheel 13 Wheel assembly 14 Brake drum 15 Transaxle 16 Flange head screw 4 used 17 Cotter pin 18 Clevis pin 19 Parking brake cable 20 Transaxle vent hose 21 Flat was...

Страница 81: ...to pre vent the vehicle from moving B Support both sides of the rear frame with jack stands positioned just in front of the axle tubes This will allow the transaxle to be removed fromthe rear of the v...

Страница 82: ...N m 7 Connect wires to traction motor Fig 15 IMPORTANT When connecting cables to motor terminals A1 A2 F1 and F2 use a back up wrench to retain lower nut before tightening up per nut Fig 12 If termina...

Страница 83: ...Workman MDE Transaxle and Brakes Page 4 23 This page is intentionally blank Transaxle and Brakes...

Страница 84: ...ocket head screw 4 used per brake 26 Lock nut 4 used per brake 27 LH brake assembly 28 RH brake assembly 29 Oil seal 2 used 30 Axle shaft 2 used 31 Cotter pin 2 used 32 Bearing retaining ring 4 used 3...

Страница 85: ...per Steering 6 Steering Gearbox 8 Lower Steering and Front Wheels 10 Front Shock Absorbers 13 A arms and Front Suspension 14 Frame Pivot Yoke 16 Seat Base 18 Front Hood 20 Cargo Box Serial Number Belo...

Страница 86: ...der special tools from your Toro Distributor Spanner Wrench Use spanner wrench to rotate front shock absorber col lar which changes the length of the shock spring toaffect front wheel camber Make sure...

Страница 87: ...rings are loose or worn Steering linkage is loose or worn Tie rod ends are loose or worn Steering gearbox is damaged or worn Front end shimmies Front wheel lug nuts are loose Front wheel bearings are...

Страница 88: ...or uneven between tires Front wheel alignment toe in is incorrect Steering linkage is binding or damaged Steering gearbox is damaged or worn Vehicle pulls to one side when not braking Tire pressure i...

Страница 89: ...the bottom 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 mea...

Страница 90: ...o 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 f...

Страница 91: ...d for heavier payloads at higher speeds Do not exceed the maximum tire pres sure Inspect Tires and Wheels Operating accidents such as hitting curbs can damage a tire or rim and also disrupt wheel alig...

Страница 92: ...29 N m 3 10 10 11 14 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 Disassembly Fig 1 1 Park machine on a level surface stop engine set parking brake and remove key from the i...

Страница 93: ...ame with four 4 carriage screws and flange nuts NOTE Apply antiseize lubricant to the steering gear box input shaft before installing to steering shaft knuckle 5 Position knuckle of the lower steering...

Страница 94: ...w 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 19...

Страница 95: ...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 19 Insert shaft into steering housing IMPOR...

Страница 96: ...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 Lock washer 2 used per caliper 25 Cap screw 2 used per caliper...

Страница 97: ...r damaged parts C If necessary remove wheel studs and brake rotor from wheel hub 9 Remove spindle Fig 5 A Remove cotter pin and castle nut securing tie rod ball joint to the spindle Separate ball join...

Страница 98: ...ub The lip of the seal must 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 t...

Страница 99: ...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...

Страница 100: ...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...

Страница 101: ...r A arm Installation Fig 7 1 If bushings were removed from A arm press new bushings fully into bore of A arm Fig 8 2 If shock absorber was removed from frame position shock to frame insert cap screw f...

Страница 102: ...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 Hardened washer 19 Cap screw 2 u...

Страница 103: ...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 9 and 10 WARNING Suppor...

Страница 104: ...cket mount bracket 18 Charger interlock switch 19 Pop rivet 2 used 20 Lock nut 2 used 21 Charger wire harness 22 Socket head screw 2 used 23 Lock nut 24 Flat washer 25 Cotter pin 26 Parking brake cove...

Страница 105: ...fully lift seat base from vehicle Installation Fig 11 1 Position seat base to the vehicle NOTE Do not tighten fasteners securing the seat base until all fasteners are in place 2 Install four 4 flange...

Страница 106: ...in 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 25...

Страница 107: ...al System 3 Remove hood using Figure 13 as a guide Installation Fig 13 NOTE Do not tighten fasteners securing the hood until all fasteners are in place 1 Install hood using Figure 13 as a guide During...

Страница 108: ...Flange head screw 6 used 18 Box brace 3 used 19 Flange head screw 5 per brace 20 LH pivot bracket 21 Flange head screw 2 per bracket 22 Flange head screw 2 used 23 Prop rod bracket 24 Flat washer 25...

Страница 109: ...0 and 30 to the rear frame 3 Release latch rod item 33 from the latch pins item 26 Remove cargo box from the frame Disassemble cargo box as necessary using Figure 18 as a guide Installation Fig 18 1 A...

Страница 110: ...ng 2 used 8 Screw 4 used 9 Carriage screw 4 used 10 Flange nut 4 used 11 Prop rod 12 Flange nut 6 used 13 Latch pin 2 used 14 Tension spring 2 used 15 Carriage screw 2 used 16 Prop rod bracket 17 Latc...

Страница 111: ...using Figures 19 and 20 as gui des A When installing cargo box use torque specifica tions identified in Figure 19 B Adjust latch pin item 13 in Figure 19 so that car go box is tight to frame when latc...

Страница 112: ...Workman MDE Page 5 26 Chassis This page is intentionally blank Rev A...

Страница 113: ...tch Turned On 4 Run Circuit Forward 5 Battery Charging Circuit 6 ELECTRICAL HARNESS DRAWINGS Electrical Harness Drawing Serial Number Below 310000000 8 Electrical Harness Wiring Diagram Serial Number...

Страница 114: ...Workman MDE Electrical Diagrams Page 6 2 This page is intentionally blank...

Страница 115: ...V ACCELERATOR PEDAL SWITCH 1 BN ACCELERATOR POT BU W GY BU W BU NC NC NC IGNITION SWITCH 7 BACKUP ALARM 4 HI LOW 1 48 VDC INPUT F2 10 A CONTROLLER MILLIPAK 3 B 6 OR 4 GA 10 GA 4 GA W 355 A 5 2 3 6 4 1...

Страница 116: ...VDC INPUT F2 10 A CONTROLLER MILLIPAK 3 B 6 OR 4 GA 10 GA 4 GA W 355 A 5 2 3 6 4 1 BK BACKUP ALARM MOTOR TEMP SENSOR ACCESSORIES W BK HOUR METER INDICATOR FUSE FIELD F1 A2 ARMATURE Y GN HEADLIGHTS 24V...

Страница 117: ...VDC INPUT F2 10 A CONTROLLER MILLIPAK 3 B 6 OR 4 GA 10 GA 4 GA W 355 A 5 2 3 6 4 1 BK BACKUP ALARM MOTOR TEMP SENSOR ACCESSORIES W BK HOUR METER INDICATOR FUSE FIELD F1 A2 ARMATURE Y GN HEADLIGHTS 24V...

Страница 118: ...Rev A Page 6 7 This page is intentionally blank...

Страница 119: ...Rev A Page 6 8 Electrical Harness Drawing Serial Number Below 310000000 Workman MDE...

Страница 120: ...WHITE BLUE BLACK BLUE WHITE FUSIBLE LINK FUSIBLE LINK RED WHITE BLACK WHITE BLUE WHITE WHITE BLACK ORANGE BLUE WHITE BROWN WHITE VIOLET BLACK TAN GRAY BLACK BLUE YELLOW BLACK RED WHITE BLACK RED BLACK...

Страница 121: ...Rev A Page 6 10 Electrical Harness Drawing Serial Number Above 310000000 Workman MDE...

Страница 122: ...RANGE RED WHITE ORANGE BLUE BLACK BLACK ORANGE PINK ORANGE BLACK BROWN YELLOW PINK RED WHITE BLACK BLUE WHITE FUSIBLE LINK FUSIBLE LINK WHITE BLUE WHITE ORANGE BLUE WHITE VIOLET BLACK RED BLACK BROWN...

Страница 123: ...Rev A Page 6 12 This page is intentionally blank...

Страница 124: ...NPUT F2 10 A CONTROLLER MILLIPAK 3 B 6 OR 4 GA 10 GA 4 GA W 355 A 5 2 3 6 4 1 BK BACKUP ALARM MOTOR TEMP SENSOR ACCESSORIES W BK HOUR METER INDICATOR FUSE FIELD F1 A2 ARMATURE Y GN HEADLIGHTS 24V HORN...

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Страница 126: ...Rev A Page 6 8 Electrical Harness Drawing Serial Number Below 310000000 Workman MDE...

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