Part No. 08164SL (Rev. A)
Service Manual
WorkmanR MDE
Preface
The purpose of this publication is to provide the service
technician with information for troubleshooting, testing
and repair of major systems and components on the
Workman MDE.
This safety symbol means DANGER, WARNING
or CAUTION, PERSONAL SAFETY INSTRUC-
TION. When you see this symbol, carefully read
the instructions that follow. Failure to obey the
instructions may result in personal injury.
REFER TO THE OPERATOR’S MANUAL FOR OPER-
ATING, MAINTENANCE AND ADJUSTMENT IN-
STRUCTIONS. 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 avail-
able on the internet at www.Toro.com.
NOTE: A NOTE will give general information about the
correct operation, maintenance, service, testing or re-
pair of the machine.
The Toro Company reserves the right to change product
specifications or this publication without notice.
IMPORTANT: The IMPORTANT notice will give im-
portant instructions which must be followed to pre-
vent damage to systems or components on the
machine.
E The Toro Company - 2008, 2011
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Table Of Contents
Chapter 1 -- Safety
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 1 -- 2
Jacking and Other Instructions . . . . . . . . . . . . . . . 1 -- 4
Safety and Instruction Decals . . . . . . . . . . . . . . . . 1 -- 5
Chapter 2 -- Product Records and Maintenance
Product Records . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 -- 1
Equivalents and Conversions . . . . . . . . . . . . . . . . 2 -- 2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . 2 -- 3
Chapter 3 -- Electrical System
General Information . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 2
Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 3
Vehicle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 4
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 8
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 11
Component Testing . . . . . . . . . . . . . . . . . . . . . . . . 3 -- 14
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . 3 -- 28
LESTER ELECTRICAL TECHNICIAN
SERVICE GUIDE
Chapter 4 -- Transaxle and Brakes
General Information . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 4
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 4 -- 6
SPICER OFF--HIGHWAY COMPONENTS MODEL
12 (ELECTRIC) MAINTENANCE MANUAL
Chapter 5 -- Chassis
General Information . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 2
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 3
Service and Repairs . . . . . . . . . . . . . . . . . . . . . . . . 5 -- 5
Chapter 6 -- Electrical Diagrams
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . 6 -- 3
Electrical Circuit Drawings . . . . . . . . . . . . . . . . . . . 6 -- 4
Electrical Harness Drawings . . . . . . . . . . . . . . . . . 6 -- 8
Rev. A
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Chapter 1
Safety
Table of Contents
SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . 2
Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
While Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Maintenance and Service . . . . . . . . . . . . . . . . . . . . 3
JACKING AND OTHER INSTRUCTIONS . . . . . . . . . 4
Jacking Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Towing Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Transporting Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . 4
SAFETY AND INSTRUCTION DECALS . . . . . . . . . . 5
Workman MDE
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Safety
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Safety Instructions
The Workman MDE is designed and tested to offer safe
service when operated and maintained properly. Al-
though hazard control and accident prevention are par-
tially dependent upon the design and configuration of
the machine, these factors are also dependent upon the
awareness, concern and proper training of the person-
nel involved in the operation, transport, maintenance
and storage of the machine. Improper use or mainte-
nance of the machine can result in injury or death. To re-
duce the potential for injury or death, comply with the
following safety instructions.
WARNING
To reduce the potential for injury or death,
comply with the following safety instructions.
Before Operating
1. Review and understand the contents of the Opera-
tor’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 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 device or decal is defective, illegible or
damaged, repair or replace it before operating the ma-
chine. Also tighten any loose nuts, bolts or screws to en-
sure machine is in safe operating condition.
While Operating
3. Before getting off the operator seat:
WARNING
A. Stop vehicle, turn on/off switch OFF and remove
key from switch.
The Workman MDE is an off--highway vehicle
only. It is not designed, equipped or manufac-
tured for use on public streets, roads or high-
ways.
B. Apply the parking brake.
4. If vehicle is parked on incline, chock or block the
wheels after getting off the vehicle.
1. Sit on the operator seat when starting and operating
the vehicle.
2. Before starting the vehicle:
A. Make sure that the battery charger is discon-
nected from the vehicle charger receptacle.
B. Engage the parking brake.
C. Make sure accelerator pedal is not depressed.
D. Check position of forward/reverse switch and Hi/
Low speed switch.
Safety
Page 1 -- 2
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Maintenance and Service
1. Before servicing or making adjustments to the ve-
hicle, stop vehicle, turn on/off switch to OFF, engage
parking brake and remove key from the on/off switch.
10.Never use an open flame to check level or leakage
of battery electrolyte.
11.When connecting the battery charger to the vehicle,
connect the charger cord to the vehicle charger recep-
tacle before plugging the charger power cord into an
outlet. After charging the vehicle batteries, unplug the
charger power cord from theoutlet beforedisconnecting
the charger cord from the vehicle charger receptacle.
2. Make sure machine is in safe operating condition by
keeping all nuts, bolts and screws tight.
3. Do not use open pans of flammable cleaning fluids
for cleaning parts.
4. Keep battery area free of excessive grease, grass,
leaves and dirt.
12.If major repairs are ever needed or assistance is de-
sired, contact an Authorized Toro Distributor.
5. Disconnect batteries before servicing the machine.
Carefully remove one of the battery cables from the bat-
tery pack as the first step in any repair. Once a battery
cable has been removed, the electrical system on the
vehicle can be safely worked on. Take care during re-
pairs, however, to not allow tools or vehicle components
to complete the battery circuit that was opened with the
cable removal. Reattach the removed cable to the bat-
tery pack as the last step in any repair.
13.To assure optimum performance and continued
safety of the machine, use genuine Toro replacement
parts and accessories. Replacement parts and acces-
sories made by other manufacturers may result in non-
conformance with safety standards and the warranty
may be voided.
14.When raising the machine to change tires or to per-
form other service, use correct blocks, hoists and jacks.
Make sure machine is parked on a solid level surface
such as a concrete floor. Prior to raising the machine, re-
move any attachments that may interfere with the safe
and proper raising of the machine. Always chock or
block wheels. Use jack stands to support the raised ma-
chine. If the machine is not properly supported by jack
stands, the machine may move or fall, which may result
inpersonalinjury (seeJackingInstructionsintheOpera-
tor’s Manual and in this Chapter).
6. When using metal, uninsulated tools around batter-
ies, do not allow tools to contact both positive and nega-
tive battery terminals simultaneously.
7. Remove jewelry and watches before servicing elec-
trical components of the vehicle.
8. Battery acid is poisonous and can cause burns.
Avoid contact with skin, eyes and clothing. Protect your
face, eyes and clothing when working with batteries.
9. Battery gases can explode. Keep cigarettes, sparks
and flames away from the batteries. Always service,
storeandchargethevehiclebatteries ina wellventilated
area.
Workman MDE
Page 1 -- 3
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Jacking and Other Instructions
Jacking Vehicle
DANGER
POTENTIAL HAZARD
• A vehicle that is not properly supported
may become unstable.
WHAT CAN HAPPEN
• The vehicle may move or fall. Personal
injury or damage to the machine may result.
HOW TO AVOID THE HAZARD
• Make sure vehicle is parked on a solid level
surface, such as a concrete floor.
• Make sure on/off switch is OFF and key is
removed from the switch before getting off
the vehicle.
1
2
Figure 1
1. Front frame
2. Towing tongue
• Before raising the vehicle, remove any
attachments that may interfere with the safe
and proper raising of the vehicle.
• Always chock or block wheels to prevent
the vehicle from rolling.
• Make sure proper hoists and jack stands
are used to raise and support the vehicle.
Jacking Locations
1
1
2
1. Jack front of the vehicle on the front of the frame be-
hind the towing tongue (Fig. 1).
Figure 2
2. Jack rearofthevehicleundereachrearaxletube. Do
not jack vehicle below the transaxle case (Fig. 2).
1. Rear axle tube
2. Transaxle case
Towing Vehicle
IMPORTANT: Frequent or long distance towing of
the Workman MDE is not recommended.
IMPORTANT: If vehicle is towed, make sure that on/
off switch is in the OFF position and key is removed
from switch.
In case of emergency, the vehicle can be towed for a
short distance. See Operator’s Manual for towing in-
formation.
Transporting Vehicle
When moving the vehicle long distances, use a trailer or
flatbed truck. Make sure vehicle is secured to the trailer
properly. See Operator’s Manual for transport informa-
tion.
Safety
Page 1 -- 4
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Safety and Instruction Decals
Thereareseveralsafety andinstructiondecalsattached
to your Workman vehicle. If any decal becomes illegible
or damaged, install a new decal. Part numbers are listed
in the Parts Catalog. Order replacement decals from
your Authorized Toro Distributor.
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Safety
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Safety
Page 1 -- 6
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Chapter 2
Product Records and Maintenance
Table of Contents
PRODUCT RECORDS . . . . . . . . . . . . . . . . . . . . . . . . . 1
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
EQUIVALENTS AND CONVERSIONS . . . . . . . . . . . 2
Decimal and Millimeter Equivalents . . . . . . . . . . . . 2
U.S. to Metric Conversions . . . . . . . . . . . . . . . . . . . 2
TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 3
Fastener Identification . . . . . . . . . . . . . . . . . . . . . . . 3
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Inch Series) . . . . . . . . . . . . . . . 4
Standard Torque for Dry, Zinc Plated and
Steel Fasteners (Metric Fasteners) . . . . . . . . . . . 5
Other Torque Specifications . . . . . . . . . . . . . . . . . . 6
Conversion Factors . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Product Records
Insert Operator’s Manual and Parts Catalog for your
Workman vehicle at the end of this chapter. Additionally,
if any optional equipment or accessories have been
installed to your Workman, insert the Installation In-
structions, Operator’s Manuals and Parts Catalogs for
those options at the end of this chapter.
Maintenance
Maintenance procedures and recommended service in-
tervals for the Workman MDE are covered in the Opera-
tor’s Manual. Refer to that publication when performing
regular vehicle maintenance.
Workman MDE
Page 2 -- 1
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Equivalents and Conversions
0.09375
Product Records and Maintenance
Page 2 -- 2
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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 spe-
cified in this Service Manual.
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 en-
gagement, etc.
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 Ser-
vice Manual. The following factors shall be considered
when applying torque: cleanliness of the fastener, use
of a thread sealant (e.g. Loctite), degree of lubrication
on the fastener, presence of a prevailing torque feature
(e.g. Nylock nut), hardness of the surface underneath
the fastener’s head or similar condition which affects the
installation.
The standard method of verifying torque shall be per-
formed by marking a line on the fastener (head or nut)
and mating part, then back off fastener 1/4 of a turn.
Measure the torque required to tighten the fastener until
the lines match up.
Fastener Identification
Grade 1
Grade 5
Grade 8
Class 8.8
Class 10.9
Inch Series Bolts and Screws
Figure 1
Metric Bolts and Screws
Figure 2
Workman MDE
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series)
Grade 1, 5 &
8 with Thin
Height Nuts
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)
SAE Grade 8 Bolts, Screws, Studs &
Sems with Regular Height Nuts
(SAE J995 Grade 5 or Stronger Nuts)
Thread Size
in--lb
in--lb
N--cm
in--lb
15 + 2
N--cm
169 + 23
192 + 23
328 + 34
350 + 45
475 + 56
542 + 56
1130 + 113
1299 + 136
2260 + 282
2542 + 282
N--m
in--lb
23 + 3
N--cm
262 + 34
282 + 34
463 + 56
486 + 56
678 + 68
768 + 79
1582 + 169
1808 + 192
3390 + 339
3672 + 373
N--m
# 6 -- 32 UNC
# 6 -- 40 UNF
# 8 -- 32 UNC
# 8 -- 36 UNF
# 10 -- 24 UNC
# 10 -- 32 UNF
1/4 -- 20 UNC
1/4 -- 28 UNF
5/16 -- 18 UNC
5/16 -- 24 UNF
10 + 2
13 + 2
147 + 23
17 + 2
25 + 3
29 + 3
41 + 5
13 + 2
18 + 2
25 + 5
30 + 5
282 + 30
339 + 56
31 + 4
43 + 5
42 + 5
60 + 6
48 + 5
68 + 7
48 + 7
53 + 7
53 + 7
65 + 10
105 + 15
128 + 17
ft--lb
599 + 79
734 + 113
1186 + 169
1446 + 192
N--m
100 + 10
115 + 12
200 + 25
225 + 25
ft--lb
140 + 15
160 + 17
300 + 30
325 + 33
ft--lb
115 + 15
138 + 17
ft--lb
3/8 -- 16 UNC
3/8 -- 24 UNF
7/16 -- 14 UNC
7/16 -- 20 UNF
1/2 -- 13 UNC
1/2 -- 20 UNF
5/8 -- 11 UNC
5/8 -- 18 UNF
3/4 -- 10 UNC
3/4 -- 16 UNF
7/8 -- 9 UNC
16 + 2
16 + 2
22 + 3
30 + 3
41 + 4
43 + 5
58 + 7
17 + 2
18 + 2
24 + 3
35 + 4
47 + 5
50 + 6
68 + 8
27 + 3
27 + 3
37 + 4
50 + 5
68 + 7
70 + 7
95 + 9
29 + 3
29 + 3
39 + 4
55 + 6
75 + 8
77 + 8
104 + 11
142 + 15
163 + 16
285 + 28
325 + 33
508 + 52
569 + 58
813 + 81
904 + 89
30 + 3
48 + 7
65 + 9
75 + 8
102 + 11
115 + 12
203 + 20
230 + 24
359 + 37
407 + 41
583 + 61
644 + 65
105 + 11
120 + 12
210 + 21
240 + 24
375 + 38
420 + 43
600 + 60
667 + 66
32 + 4
53 + 7
72 + 9
85 + 9
65 + 10
75 + 10
93 + 12
115 + 15
140 + 20
155 + 25
88 + 12
95 + 15
140 + 20
165 + 25
225 + 25
260 + 30
119 + 16
129 + 20
190 + 27
224 + 34
305 + 34
353 + 41
150 + 15
170 + 18
265 + 27
300 + 30
430 + 45
475 + 48
7/8 -- 14 UNF
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 mini-
mum proof load specified in SAE J429. The tolerance is
approximately + 10% of the nominal torque value. Thin
height nuts include jam nuts.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Rev. A
Product Records and Maintenance
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Standard Torque for Dry, Zinc Plated and Steel Fasteners (Metric Series)
Class 8.8 Bolts, Screws and Studs with
Regular Height Nuts
Class 10.9 Bolts, Screws and Studs with
Thread Size
Regular Height Nuts
(Class 8 or Stronger Nuts)
(Class 10 or Stronger Nuts)
M5 X 0.8
M6 X 1.0
57 + 6 in--lb
96 + 10 in--lb
19 + 2 ft--lb
644 + 68 N--cm
1085 + 113 N--cm
26 + 3 N--m
78 + 8 in--lb
881 + 90 N--cm
1503 + 158 N--cm
38 + 4 N--m
133 + 14 in--lb
28 + 3 ft--lb
M8 X 1.25
M10 X 1.5
M12 X 1.75
M16 X 2.0
M20 X 2.5
38 + 4 ft--lb
52 + 5 N--m
54 + 6 ft--lb
73 + 8 N--m
66 + 7 ft--lb
90 + 10 N--m
225 + 23 N--m
440 + 45 N--m
93 + 10 ft--lb
229 + 23 ft--lb
450 + 46 ft--lb
126 + 14 N--m
310 + 31 N--m
610 + 62 N--m
166 + 17 ft--lb
325 + 33 ft--lb
NOTE: Reduce torque values listed in the table above
by 25% for lubricated fasteners. Lubricated fasteners
are defined as threads coated with a lubricant such as
engine oil or thread sealant such as Loctite.
NOTE: The nominal torque values listed above are
based on 75% of the minimum proof load specified in
SAE J1199. The tolerance is approximately + 10% of the
nominal torque value.
NOTE: Torque values may have to be reduced when
installing fasteners into threaded aluminum or brass.
The specific torque value should be determined based
on the fastener size, the aluminum or base material
strength, length of thread engagement, etc.
Workman MDE
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Other Torque Specifications
SAE Grade 8 Steel Set Screws
Wheel Bolts and Lug Nuts
Recommended Torque
Thread Size
Thread Size
Recommended Torque**
65 + 10 ft--lb 88 + 14 N--m
Square Head
140 + 20 in--lb
215 + 35 in--lb
35 + 10 ft--lb
75 + 15 ft--lb
Hex Socket
73 + 12 in--lb
145 + 20 in--lb
18 + 3 ft--lb
7/16 -- 20 UNF
Grade 5
1/4 -- 20 UNC
5/16 -- 18 UNC
3/8 -- 16 UNC
1/2 -- 13 UNC
1/2 -- 20 UNF
Grade 5
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
80 + 10 ft--lb 108 + 14 N--m
M12 X 1.25
Class 8.8
50 + 10 ft--lb
M12 X 1.5
Class 8.8
** For steel wheels and non--lubricated fasteners.
Thread Cutting Screws
(Zinc Plated Steel)
Thread Cutting Screws
(Zinc Plated Steel)
Type 1, Type 23 or Type F
Thread Threads per Inch
Size
Baseline Torque*
Thread Size
Baseline Torque*
20 + 5 in--lb
Type A Type B
No. 6 -- 32 UNC
No. 8 -- 32 UNC
No. 10 -- 24 UNC
1/4 -- 20 UNC
No. 6
No. 8
18
15
12
11
20
18
16
14
20 + 5 in--lb
30 + 5 in--lb
38 + 7 in--lb
85 + 15 in--lb
30 + 5 in--lb
38 + 7 in--lb
No. 10
No. 12
85 + 15 in--lb
110 + 20 in--lb
200 + 100 in--lb
5/16 -- 18 UNC
3/8 -- 16 UNC
*Hole size, materialstrength, materialthickness and fin-
ish must be considered when determining specific
torque values. All torque values are based on non--lubri-
cated fasteners.
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
Product Records and Maintenance
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Chapter 3
Electrical System
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Opening Battery Circuit . . . . . . . . . . . . . . . . . . . . . . 2
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . 3
VEHICLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 8
General Run Problems . . . . . . . . . . . . . . . . . . . . . . . 8
Battery Charger Operation . . . . . . . . . . . . . . . . . . . . 9
Battery Charger Problems . . . . . . . . . . . . . . . . . . . 10
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Accelerator Switch Adjustment . . . . . . . . . . . . . . . 11
Accelerator Potentiometer Adjustment
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . 28
Battery Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Battery Specifications . . . . . . . . . . . . . . . . . . . . . 28
Battery Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Battery Installation . . . . . . . . . . . . . . . . . . . . . . . . 29
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Battery Inspection and Maintenance . . . . . . . . . 30
Battery Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Traction Motor Brushes . . . . . . . . . . . . . . . . . . . . . 33
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Traction Motor Service . . . . . . . . . . . . . . . . . . . . . . 38
Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
LESTER ELECTRICAL TECHNICIAN
(Potentiometer with Short Lever) . . . . . . . . . . . . 12
Accelerator Potentiometer Adjustment
SERVICE GUIDE
(Potentiometer with Long Lever) . . . . . . . . . . 12.1
Accelerator System Calibration . . . . . . . . . . . . . . . 13
COMPONENT TESTING . . . . . . . . . . . . . . . . . . . . . . 14
On/Off Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Battery Discharge Indicator and Hour
Meter Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Vehicle Direction (Forward/Reverse) and
Headlight Switches . . . . . . . . . . . . . . . . . . . . . . . 16
Vehicle Status Light . . . . . . . . . . . . . . . . . . . . . . . . 17
Supervisor Speed Limit Switch . . . . . . . . . . . . . . . 18
Audio Alarm (Reverse) . . . . . . . . . . . . . . . . . . . . . . 18
Charger Interlock Switch . . . . . . . . . . . . . . . . . . . . 19
Main and Accessories Contactors . . . . . . . . . . . . 20
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Fusible Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Accelerator Switch . . . . . . . . . . . . . . . . . . . . . . . . . 24
Accelerator Potentiometer . . . . . . . . . . . . . . . . . . . 25
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Workman MDE
Electrical System
Rev. A
Page 3 -- 1
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General Information
The Workman MDE uses a 48 volt DC electrical system
that is an isolated circuit. The vehicle frame is not used
for any ground connections.
LED on the controller and the vehicle status light on the
dash panel will flash a fault code to assist in identifying
the problem.
The vehicle controller monitors operator and vehicle in-
puts to determine voltage to the traction motor. If a prob-
lem exists that will prevent normal vehicle operation, an
After performing any repair on electrical components on
the vehicle, make sure that wiring is routed and secured
so as to prevent abrasion or contact with moving parts.
Operator’s Manual
The Operator’s Manual provides information 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.
Opening Battery Circuit
To prevent allowing a current path through tools used
during vehicle electrical circuit repairs, remove one of
the battery cables from the battery pack as the first step
in any repair (Fig. 1). Once a cable has been removed,
the electrical system on the vehicle can be safely
worked on. Take care during repairs, however, to not al-
low tools or vehicle components to complete the battery
circuit that was opened with the cable removal.
Reattach the removed cable to the battery pack as the
last step in any repair. Secure cable on each battery ter-
minal with lock washer and nut. Torque nuts from 115 to
125 in--lb (13.0 to 14.1 N--m).
Battery pack cable routing is shown in Figure 2.
Figure 1
1
2
Figure 2
1. Negative cable to vehicle
2. Positive cable to vehicle
Electrical System
Workman MDE
Page 3 -- 2
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Electrical Diagrams
The electrical schematic, circuit drawings and wire har-
ness drawings for the Workman MDE are located in
Chapter 6 -- Electrical Diagrams.
Workman MDE
Electrical System
Page 3 -- 3
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Vehicle Operation
The Workman MDE electrical system uses a 48 volt bat-
tery pack, an electric traction motor, a vehicle controller
and numerous other electrical components to allow ve-
hicle operation.
The vehicle controller is a sealed electronic logic device
that uses inputs from several vehicle components to
control motor speed and direction. These inputs include
several switches (on/off, forward/reverse, accelerator,
supervisor, charger), a motor temperature sensor, an
accelerator pedal potentiometer and the vehicle contac-
tor (solenoid). The controller also provides regenerative
braking to assist in slowing the vehicle. The controller
has fault detection capabilities to help identify system
problems. Battery current is available to the controller
whenever the on/off switch is ON which energizes the
main contactor. A high current fuse protects this high
current circuit.
Eight, 6 volt, deep cycle batteries that are connected in
series provide current for a 48 volt DC, high torque trac-
tion motor, the vehicle controller and vehicle accesso-
ries (headlights, horn, various optional accessories).
The batteries are discharged as the vehicle is used so
charging the batteries after using the vehicle is neces-
sary. A battery discharge indicator gauge on the dash
provides the operator with information on battery charge
level. Demands on the vehicle during use (speed, pay-
load, incline use), battery condition (age, charge level),
ambient temperature and vehicle condition will all put
constraintsonhow longavehiclecanbeusedbeforethe
batteries are discharged.
The Workman controller also provides a roll off warning
in instances when the vehicle begins to move (roll away)
after being stopped. On an incline and with the on/off
switch in the ON position, if the vehicle starts moving,
the alarm will sound warning the operator that the ve-
hicle is moving. When the vehicle goes into this roll--off
mode, regenerative braking will limit vehicle speed.
An automatic, 115 VAC (230 VAC on international mod-
els) battery charger is included with the vehicle. An inter-
lock switch on the vehicle charger receptacle prevents
the vehicle from operating when the charger cord is
plugged into the vehicle.
Vehicle accessories include headlights, horn and op-
tional electrical equipment. The accessories contactor
(solenoid) on the vehicle provides battery current to
these components when the on/off switch is ON. Fuses
provide circuit protection for these accessories.
The electric traction motor directly drives a double re-
duction transaxle with differential. Operator inputs for
forward/reverse, supervisor switch position (high or low
speed) and accelerator pedal position are used by the
controller to determine voltage to the traction motor.
The 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, the controller is
signaled to limit vehicle speed and torque until the motor
temperature reduces to a normal level.
Electrical System
Workman MDE
Page 3 -- 4
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Special Tools
Order special tools from your Toro Distributor. Some
tools may also be available from a local supplier.
Multimeter
The multimeter can test electrical components and cir-
cuits for current, resistance or voltage.
NOTE: Toro recommends the use of a DIGITAL Volt--
Ohm--Amp multimeter when testing electrical circuits.
Thehighimpedance(internalresistance) ofadigitalme-
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.
NOTE: Workman MDE vehicles use a 48 volt, DC elec-
trical system. 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 aerosol spray that
should be used on all battery and controller terminals to
reduce corrosion problems. Apply terminal protector af-
ter cable has been secured to terminal.
Toro Part Number: 107--0392
Figure 4
Dielectric Gel
Dielectric gel should be used to prevent corrosion of
connectionterminals. Toensurecompletecoatingofter-
minals, liberally apply gel to both component and wire
harness connector, plug connector to component, un-
plug connector, reapply gel to both surfaces and recon-
nect harness connector to component. Connectors
should be thoroughly packed with gel for effective re-
sults.
Toro Part Number: 107--0342
Figure 5
Workman MDE
Electrical System
Page 3 -- 5
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Battery Watering Dispenser
Use the battery watering dispenser when adding dis-
tilled water to vehicle batteries.
Toro Part Number: TOR4102
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 remove and install batteries
from the vehicle. Lift strap allows use of case loops on
battery tops as safe battery lifting points. Obtain battery
lift strap locally.
Figure 8
Electrical System
Workman MDE
Page 3 -- 6
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36/48 Volt Battery Discharge Unit
The 36/48 Volt Battery Discharge Unit is recommended
for quick and accurate load testing for the batteries on
the Workman MDE. This tool is used to determine the
capacity of the Workman battery pack and also for find-
ing a faulty battery (or batteries) in the battery pack.
Toro Part Number: TOR4106
Figure 9
Workman MDE
Electrical System
Page 3 -- 7
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Troubleshooting
CAUTION
For effective troubleshooting and repairs, there must be
a good understanding of the electrical circuits and com-
ponents used on this vehicle (see Electrical Schematic
in Chapter 6).
Remove all jewelry, especially rings and
watches, before doing any electrical trouble-
shooting or testing. Disconnect a battery cable
from the battery pack to open the battery circuit
unless a test procedure requires battery voltage.
If the vehicle has any switches by--passed, they must be
reconnected for proper vehicle operation, troubleshoot-
ing and safety.
General Run Problems
NOTE: Check vehicle status light on dash panel and
controller LED for possible faults whenever diagnosing
vehicle problems (see Controller in the Component
Testing section of this chapter).
Problem
Possible Causes
Main contactor clicks, but vehicle will not operate.
Battery charge is low.
Battery cables are loose, corroded or damaged.
Cable connection(s) at controller is/are loose or
corroded.
Cable connection(s) at traction motor is/are loose or
corroded.
Traction motor is faulty.
Controller is faulty.
Nothing happens when on/off switch is turned to ON.
Battery charge is extremely low.
Battery cables are loose, corroded or damaged.
Cable connection(s) at controller is/are loose or
corroded.
10 ampere fuse (F2) to the on/off switch is loose or
blown.
Fusible link FL2 is faulty.
Main fuse (F1) is loose or blown.
The on/off switch or circuit wiring is faulty.
Controller is faulty.
Electrical System
Workman MDE
Page 3 -- 8
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General Run Problems (Continued)
Problem
Possible Causes
Traction motor stops during operation.
Wiring to the traction motor components (e.g. main
contactor, controller, traction motor) loose, corroded or
damaged (see Electrical Schematic in Chapter 6 --
Electrical Diagrams).
Battery cables are loose, corroded or damaged.
Controller is overheated.
Traction motor is overheated.
Traction motor is faulty.
Brake or transaxle problem (see Chapter 4 -- Transaxle
and Brakes).
Vehicle runs slowly.
Supervisor speed limit switch in slow position.
Tire pressure is low (see Chapter 5 -- Chassis).
Brakes improperly adjusted (see Chapter 4 --
Transaxle and Brakes).
Battery charge is extremely low.
Controller is overheated.
Traction motor is overheated.
Vehicle movement is erratic or jerky.
Collar on throttle is loose.
Accelerator potentiometer is improperly adjusted.
Accelerator system is out of adjustment.
Battery Charger Operation
Light Status
Indicates
Green light on battery charger illuminated (not
flashing).
Batteries is fully charged. Vehicle ready to operate.
Green light on battery charger flashing.
Red light on battery charger flashing.
Slow flash (once per second): Batteries being charged
(batteries less than 80% charged). Continue charging.
Rapid flash (four times per second): Batteries being
charged (batteries more than 80% charged). Continue
charging.
Rapid flash: Charger timer shutoff has occurred after
20 hours of charging.
Slow flash: No current to charger. Check AC outlet.
Workman MDE
Electrical System
Page 3 -- 9
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Battery Charger Problems
Problem
Possible Causes
Battery charger does not turn on.
AC outlet fuse/circuit breaker blown.
AC outlet is faulty.
Vehicle wiring is loose or damaged (see electrical
schematic in Chapter 6 -- Electrical Diagrams).
Fusible link FL1 is faulty.
Vehicle charger interlock switch or circuit wiring faulty.
Vehicle charger receptacle or circuit wiring damaged.
Battery charger is faulty.
Battery charger does not turn off.
Battery charger fuse blows.
Battery charger is faulty.
NOTE: Charging new batteries or charging batteries in
cold temperatures may require extended charge time
to achieve full charge.
Vehicle battery polarity is reversed (vehicle battery
cables incorrectly attached).
Vehicle charger receptacle polarity is reversed.
Battery charger is faulty.
The AC outlet circuit breaker or fuse blows when using Overloaded AC circuit.
the battery charger.
Battery charger is faulty.
Electrical System
Workman MDE
Page 3 -- 10
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Adjustments
Accelerator Switch Adjustment
1. Position vehicle on a level surface, turn on/off switch
OFF and remove key.
2
3
1
2. With the accelerator pedal released, check that the
distance between the head of the accelerator switch
stop cap screw and the body of the switch is 5/8 inch
(15.9 mm) (Fig. 12).
6
5
3. If distance is incorrect, loosen lock nut and adjust ac-
celerator switch stop cap screw position (Fig. 11).
4
4. After adjustment, make sure that switch plunger is
not bottomed out when accelerator pedal is released.
Figure 10
1. Accelerator pedal
2. Accelerator switch
3. Plate
4. Screw (2 used)
5. Switch stop cap screw
6. Lock nut
5. Calibrate accelerator system after adjusting acceler-
ator switch (see Accelerator System Calibration in this
section).
2
3
1
Figure 11
1. Accelerator switch
2. Switch stop cap screw
3. Accelerator stop cap screw
5/8 inch
(15.9 mm)
2
1
Figure 12
1. Switch stop cap screw
2. Accelerator switch
Workman MDE
Electrical System
Page 3 -- 11
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Accelerator Potentiometer Adjustment (Potentiometer with Short Lever)
NOTE: The following adjustment procedure should be
used on vehicles thathave a potentiometer thatincludes
a short lever (Figure 14). If potentiometer has a long le-
ver, use the procedure on the following page.
5. Calibrate accelerator system after any accelerator
potentiometer adjustment (see Accelerator SystemCal-
ibration in this section).
The accelerator potentiometer is used as one of the in-
puts for the vehicle controller and is attached to the ped-
al frame under the dash (Fig. 13). A collar with roll pin on
the accelerator pedal shaft positions the accelerator po-
tentiometer lever. Potentiometers with a short lever use
a roll pin that extends approximately 1 1/2 inches (38
mm) out of the collar.
4
1
5
If the accelerator potentiometer is out of adjustment, the
diagnostic light on the dash will flash six (6) times. Addi-
tionally, if vehicle movement is erratic and jerky, poten-
tiometer adjustment and calibration of the accelerator
system should be performed.
3
2
Adjustment
Figure 13
1. Position vehicle on a level surface, turn on/off switch
OFF and remove key. Make sure that accelerator poten-
tiometer is securely attached to the pedal frame of the
machine.
1. Potentiometer
2. Accelerator pedal
3. Throttle position collar
4. Roll pin
5. Set screw (2 used)
2. Check accelerator switch adjustment and adjust if
necessary (see Accelerator Switch Adjustment in this
section).
1
3. Check movement of the potentiometer 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 potentiometer body (Fig-
ure 14).
2
3
Figure 14
1. Potentiometer lever (accelerator pedal released)
B. With the accelerator pedalfully depressed, the in-
put lever of the potentiometer should not contact the
upper stop on the potentiometer body (Figure 15).
2. Potentiometer lower stop
3. Gap of 0.050” to 0.100” (1.3 to 2.5 mm)
4. If potentiometer lever movement is incorrect, adjust
location of collar on accelerator pedal shaft:
3
2
1
A. Loosen two (2) set screws that secure throttle
position collar to throttle pedal shaft and reposition
collar to allow correct potentiometer movement.
Make sure that there is clearance between roll pin
and side of potentiometer lever to prevent binding.
B. Remove set screws one at a time from collar and
apply Loctite #242 (or equivalent) to set screw
threads. Install and tighten set screws to secure col-
lar to accelerator pedal shaft.
Figure 15
1. Potentiometer lever (accelerator pedal fully depressed)
2. Potentiometer upper stop
3. No lever contact with stop
C. Recheck potentiometer lever movement.
Electrical System
Workman MDE
Rev. A
Page 3 -- 12
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Accelerator Potentiometer Adjustment (Potentiometer with Long Lever)
NOTE: The following adjustment procedure should be
used on vehicles that have a potentiometer with a long
lever (Figure 15.1). If potentiometer has a short lever,
use the procedure on the preceding page.
1
2
The accelerator potentiometer is used as one of the in-
puts for the vehicle controller and is attached to the ped-
al frame under the dash (Fig. 15.2). A collar with roll pin
attached to the accelerator pedal shaft positions the ac-
celerator potentiometer lever. Potentiometers with a
long lever use a roll pin that extends approximately 3
inches (76 mm) out of the collar.
3
If the accelerator potentiometer is out of adjustment, the
diagnostic light on the dash will flash six (6) times. Addi-
tionally, if vehicle movement is erratic and jerky, poten-
tiometer adjustment and calibration of the accelerator
Figure 15.1
system should be performed.
1. Potentiometer
2. Lever
3. Retainer
Adjustment
1. Position vehicle on a level surface, turn on/off switch
OFF and remove key. Make sure that accelerator poten-
tiometer assembly is securely attached to the pedal
frame of the machine.
3
2. Check accelerator switch adjustment and adjust if
necessary (see Accelerator Switch Adjustment in this
section).
4
3. With the accelerator pedal released, inspect location
of roll pin on throttle position collar and potentiometer le-
ver. The roll pin should just contact the potentiometer le-
ver without rotating the lever (Figure 15.2).
1
4. If necessary, adjust location of collar on accelerator
pedal shaft so that roll pin is properly positioned:
2
5
A. Loosen two (2) set screws that secure throttle
position collar to throttle pedal shaft and reposition
collar so that roll pin on the throttle position collar just
contacts the potentiometer lever without rotating the
lever. Make sure that there is clearance between roll
pin and side of potentiometer lever to prevent bind-
ing.
Figure 15.2
1. Potentiometer
2. Collar
3. Lever
4. Roll pin
5. Accelerator pedal
B. Remove set screws one at a time from collar and
apply Loctite #242 (or equivalent) to set screw
threads. Install and tighten set screws to secure col-
lar to accelerator pedal shaft.
C. Recheck potentiometer lever movement.
5. Calibrate accelerator system after any accelerator
potentiometer adjustment (see Accelerator SystemCal-
ibration in this section).
Workman MDE
Electrical System
12.1 Rev. A
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12.2 Rev. A
Electrical System
Page 3 --
Workman MDE
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Accelerator System Calibration
The accelerator system on the Workman MDE includes
the accelerator pedal assembly, the accelerator poten-
tiometer, the accelerator switch and the controller. If any
of these components are adjusted, removed or re-
placed, the following calibration procedure should be
performed. Additionally, if vehicle movement is erratic,
jerky or if the diagnostic light on the dash is flashing six
(6) times, calibration of the accelerator system should
be performed.
1
4
1. Position vehicle on a level surface, turn on/off switch
OFF and remove key. Raise box and secure with prop
rod. Remove controller cover.
2
3
2. Check accelerator switch adjustment and adjust if
necessary (see Accelerator Switch Adjustment in this
section).
Figure 16
1. Controller
2. Gray controller lead
3. Ground post (B--)
4. Controller LED
3. Check accelerator potentiometer adjustment and
adjust if necessary (see Accelerator Potentiometer Ad-
justment in this section).
4. Using a jumper wire, connect gray controller lead to
ground post (B--) on controller (Fig. 16).
NOTE: During calibration, the vehicle status light on the
dash should flash the 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 hold pedal in position. This should
take a very smallmovement ofthe pedal. Once alarmre-
sumes, release accelerator pedal completely.
7. Depress and hold accelerator pedal fully. Alarm will
momentarily stop while controller calibration occurs.
Holdpedalfully depresseduntilalarmresumes andthen
release pedal.
8. If calibration process was successful, alarm willchirp
and diagnostic lighton the dashwillbelitcontinuous(not
flashing). If alarm continues to sound or if diagnostic
light is flashing, turn on/off switch OFF and repeat steps
5, 6 and 7.
9. Turn on/off switch OFF and remove key. Disconnect
jumper wire from gray controller lead and controller
ground post (B--).
10.Install controller cover and lower box.
11.If vehicle operation continues to be erratic after com-
pleting the accelerator system calibration procedure,
evaluate the components in the accelerator system: ac-
celerator switch, accelerator potentiometer, accelerator
pedal, circuit wiring and controller.
Workman MDE
Electrical System
Page 3 -- 13
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Component Testing
For accurate resistance and/or continuity checks, elec-
trically disconnect the component being tested from the
circuit (e.g. disconnect the harness wire connectors
from the vehicle on/off switch before doing a continuity
check on the on/off switch).
CAUTION
When testing electrical components for continu-
ity with a multimeter (ohms setting), make sure
that power to the circuit has been disconnected.
On/Off Switch
The Workman on/off switch is located on the dash panel
(Fig. 17). The switchhas two(2) positions (OFF andON)
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.
Testing
1
CAUTION
When testing the on/off switch for continuity
with a multimeter (ohms setting), make sure that
power to the circuit has been disconnected.
Figure 17
1. On/Off switch
When the on/off switch is in the OFF position, no conti-
nuity should exist between the common (center) switch
terminal and the switched (side) terminal. In the ON
position, continuity should exist between the common
(center) switch terminal and the switched (side) termi-
nal.
SWITCHED
TERMINAL
COMMON
TERMINAL
BACK OF
SWITCH
NOT USED
Figure 18
Electrical System
Workman MDE
Page 3 -- 14
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Battery Discharge Indicator and Hour Meter Gauge
The combination battery discharge indicator and hour
meter gauge is located on the dash panel (Fig. 19).
1
The battery indicator identifies state of charge of the bat-
tery pack. The battery indicator reads full (10 bars) when
the battery pack is fully charged (approximately 51
volts). As battery pack voltage decreases with vehicle
use, fewer battery indicator bars are shown.
When the battery indicator reaches 2 bars, a warning
light illuminates and a battery icon flashes on the gauge
face to identify that battery charge level is extremely low.
At this point, the batteries should be charged.
Figure 19
1. Battery discharge indicator and hour meter
If the battery indicator reaches 1 bar, the warning 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.
8
4
5
1
The hour meter registers operating time of the vehicle.
Whenever the vehicle is in motion, the hour meter
should increase one tenth every six (6) minutes of op-
eration. If the vehicle remains stationary for thirty (30)
seconds (even if the on/off switch is ON), the hour meter
BACK OF
GAUGE
quits increasing.
The back of the gauge is shown in Figure 20. A wire har-
ness connector plugs into the gauge. Terminals 1, 2 and
5 are not used on the Workman MDE. See Chapter 6 --
Electrical Diagrams for schematic and wire harness in-
formation.
Figure 20
If the battery discharge indicator or the hour meter prove
to be inaccurate, the gauge should be replaced.
Workman MDE
Electrical System
Page 3 -- 15
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Vehicle Direction (Forward/Reverse) and Headlight Switches
The vehicle direction (forward/reverse) switch (Fig. 21)
and headlight switch (Fig. 22) are located on the control
panel. These two switches have identical logic.
The vehicle direction switch is one of several inputs for
the vehicle controller and allows the direction (forward/
reverse) of the vehicle to be changed by the operator.
The headlight switch allows the headlights to be turned
on and off.
NOTE: 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.
1
Figure 21
1. Direction switch
Testing
The switch terminals for these switches are marked as
shown in Figure 23. The circuitry of the 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 switch position. Verify continuity between
switch terminals.
1
SWITCH
POSITION
NORMAL
CIRCUITS
OTHER
CIRCUITS
Figure 22
1. Headlight switch
OFF / FORWARD
ON / REVERSE
1 + 2
2 + 3
4 + 5
5 + 6
4
5
6
1
2
3
Figure 23
Electrical System
Workman MDE
Page 3 -- 16
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Vehicle Status Light
The vehicle status light is located on the control panel
(Fig. 24). During normal operation, the status light
should be continuously illuminated. A vehicle electrical
problem will be identified by a flashing status light.
The vehicle status light and LED on the vehicle control-
ler should have the same condition (off, illuminated or
flashing). If the vehicle status light does not illuminate
when the on/off switch is turned ON, check the LED on
the vehicle controller to make sure it is illuminated. If the
controller LED is illuminated and the vehicle status light
is not illuminated, check the vehicle status light and cir-
cuit wiring.
1
Figure 24
1. Vehicle status light
See Controller (in this section) and your Operator’s
Manual for information on a flashing vehicle status light.
Testing
1. Make sure on/off switch is turned OFF. Remove key
from switch.
1B (--)
2. Disconnect wire harness from vehicle status light.
IMPORTANT: The vehicle status light is a 12 volt DC
component. Do not test the light using jumper wires
from the vehicle battery pack (48 VDC).
1A (+)
3. The terminals for the light are marked as shown in
Figure 25. Correctly connect 12 VDC source to the light
terminals.
Figure 25
4. Light should illuminate. Remove voltage source from
the light and reconnect wire harness. Replace status
light if needed.
Workman MDE
Electrical System
Page 3 -- 17
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Supervisor Speed Limit Switch
The supervisor speed limit switch is open in OFF posi-
tion (key vertical) and closed in ON position (key rotated
clockwise). The speed limit switch is one of several in-
puts for the vehiclecontroller andallows thespeed ofthe
vehicle to be limited.
OFF
B&C
45o
ON
A&D
B&C
Test the switch by disconnecting the wiring and connect-
ing a continuity tester across switch terminals A and D
(Fig. 26). Rotate key to ON position: there should be an
indication of continuity. Rotate key to OFF position:
there should be no continuity.
Figure 26
Audio Alarm (Reverse)
The audio alarm sounds when the direction (forward/re-
verse) switch is placed in the reverse position. The
alarm is located under the controller cover beneath the
cargo box.
2
Testing
IMPORTANT: Make sure to observe polarity on the
alarm terminals when testing. Damage to the alarm
may result from an improper connection.
IMPORTANT: The audio alarm is a 12 volt DC com-
ponent. Do not test the alarm using jumper wires
from the vehicle battery pack (48 VDC).
1
1. Make sure on/off switch is turned OFF. Remove key
fromswitch. Raisecargobox andremovecontrollercov-
er.
Figure 27
1. Controller
2. Audio alarm
2. Disconnect wire harness connectors from alarm
(Fig. 27). Using jumper wires, correctly connect 12VDC
source to the alarm terminals noting polarity shown on
alarm decal.
3. Alarm should sound. Remove voltage source from
the alarm. Reconnect alarm to the circuit or replace
alarm if needed.
Electrical System
Workman MDE
Page 3 -- 18
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Charger Interlock Switch
The charger interlock switch is located behind the char-
ger receptacle plate on the front of the seat base (Fig.
28). When the battery charger is plugged into the char-
ger receptacle, the interlock switch closes and provides
an input to the vehicle controller to inhibit vehicle opera-
tion.
NOTE: The vehicle should not operate if the charger
plug is connected to the charger receptacle.
1. Make sure vehicle on/off switch is OFF. Remove key
from switch.
1
4
2. Remove receptacle plate from front of seat base.
3. Locate charger interlock 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.
3
2
Figure 28
5. When the switch plunger is extended there should
not be continuity between the switch terminals.
1. Receptacle plate
2. Screw (4 used)
3. Charger receptacle
4. Charger interlock switch
6. When the switch plunger is depressed, there should
be continuity between the switch terminals.
1
2
7. Replace switch if needed.
7
3
8. Reconnect harness connector to switch. Install re-
ceptacle plate to front of seat base.
4
5
6
Figure 29
1. Charger interlock switch
2. Switch plate
3. Charger receptacle
4. Rivet (2 used)
5. Lock nut (2 used)
6. Socket head screw
7. Mount bracket
Workman MDE
Electrical System
Page 3 -- 19
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Main and Accessories Contactors
Two contactors (solenoids) are used on the Workman
MDE for circuit control.
4
5
1
The main contactor provides current to the vehicle con-
troller and is energized when the on/off switch is ON.
The main contactor is located under the controller cover
beneath the cargo box (Fig. 30).
2
The accessories contactor provides current to the head-
lights, horn and optional electrical accessories. The ac-
cessories contactor is energized when the on/off switch
is ON. The accessories contactor is located beneath the
dash panel.
3
6
Testing
Figure 30
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) that is due to the internal resistance of
the meter and test leads. Subtract this value from the
measured value of the component you are testing.
1. Main contactor
4. Fuse (F1)
2. Cable to controller B+
3. Wire harness connector
5. Positive battery cable
6. Isolator
1
1. Make sure on/off switch is turned OFF. Open the bat-
tery circuit by removing one of the battery cables (see
Opening Battery Circuit in the General Information sec-
tion of this chapter and Fig. 31).
2
2. Locate contactor that is to be tested. Disconnect all
vehicle harness electrical connections from contactor.
Note wire connector locations on contactor for reas-
sembly purposes.
3. Usingjumperwires, apply48VDCdirectlyacrossthe
contactor coilposts (Fig. 32). Thecontactor shouldclick.
With the contactor coil energized, resistance across the
main contact posts should be less than 1 ohm.
Figure 31
1. Negative cable to vehicle
2. Positive cable to vehicle
4
4. Remove voltage from contactor coil posts. The con-
tactor shouldclick. Withthecontactor coilnotenergized,
resistance across the main contact posts should be infi-
nite ohms.
4
2
3
5. Measure resistance across the contactor coil posts
(Fig. 32):
3
3
A. For the main contactor, the resistance should be
approximately 126 ohms.
4
4
B. For the accessories contactor, the resistance
should be approximately 200 ohms.
1
3
Figure 32
1. Main contactor
3. Main contact posts
4. Contactor coil posts
2. Accessories contactor
Electrical System
Workman MDE
Page 3 -- 20
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6. Replace contactor if necessary.
45 to 50 in--lb
(5.1 to 5.6 N--m)
7. Connect electrical connections to contactor. If main
contactor connections were removed, use Figure 33 as
a guide for reattaching cable and wire harness connec-
tions.
3
5
4
4
6
3
8. Connect battery cable that was removed from bat-
tery pack.
2
7
1
8
Figure 33
1. Main contactor
5. Wire harness connector
6. Fuse (F1)
7. Positive battery cable
8. Isolator
2. Cable to controller B+
3. Lock nut
4. Flat washer
Workman MDE
Electrical System
Page 3 -- 21
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Fuses
There are three (3) fuses in the Workman electrical sys-
tem.
Two (2) of the fuses are located beneath the steering
column (Fig. 34). These fuses supply power to the fol-
lowing:
1
The upper 10 ampere fuse (F2) supplies power to the
on/off switch and switched circuits.
The lower 10 ampere fuse (F3) supplies power to op-
tional accessories.
2
The third fuse (F1) is located under the controller cover
beneath the cargo box (Fig. 35). This fuse is rated at 355
amperes continuous and allows current flow between
the batteries and the vehicle. If this fuse has failed, ve-
hicle operation will not occur.
Figure 34
1. Fuse (F2)
2. Fuse (F3)
1
Testing
2
CAUTION
When testing fuses for continuity with a multime-
ter (ohms setting), make sure that fuse is re-
moved from circuit.
IMPORTANT: Before removing fuse F1 (355 Amp)
for testing, open the battery circuit by removing one
of the battery cables (see Opening Battery Circuit in
the General Information section of this chapter).
3
Figure 35
Make sure on/off switch is turned OFF. Remove fuse to
check continuity. The test meter should read less than
1 ohm.
1. Controller
2. Fuse (F1)
3. Main contactor
If fuse F1 was removed, torque the nuts that secure the
fuse from 45 to 50 in--lb (5.1 to 5.6 N--m).
Electrical System
Workman MDE
Page 3 -- 22
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Fusible Links
The wiring harness for the Workman includes three (3)
fusible links for circuit protection (Fig. 36).
3
1
Two (2) fusible links attach to the same main contactor
post as the main fuse. One of these fusible links (FL2)
is used for the switched power circuit. The 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.
2
5
4
If any of these fusible links should fail, the affected circuit
will not function. See Chapter 6 -- Electrical Diagrams for
schematic and wire harness information.
Figure 36
1. Main contactor
4. Fusible links FL1 & FL2
5. Fusible link FL3
2. Main fuse contactor post
3. Switched contactor post
Workman MDE
Electrical System
Page 3 -- 23
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Accelerator Switch
The accelerator switch is a four terminal, two circuit
switch that is located on the control pedal frame (Fig.
37). The Workman MDE uses only one of the switch cir-
cuits (terminals 3 and 4). When the accelerator pedal is
depressed, the switch allows a closed circuit (input) for
the controller to allow traction motor operation. When
the accelerator pedal is released, the switch provides an
open circuit (no input) for the controller to prevent trac-
tion motor operation.
2
3
1
6
5
Testing
1. Park vehicle on a level surface, turn on/off switch
OFF and remove key from switch.
4
2. Locate accelerator switch on pedal frame under
dashboard of vehicle.
Figure 37
1. Accelerator pedal
2. Accelerator switch
3. Plate
4. Screw (2 used)
5. Stop cap screw
6. Lock nut
3. Unplug wiring harness connector from accelerator
switch.
4. With the use of a multimeter (ohms setting), the
switch functions may be tested to determine whether
continuity exists between the switch terminals for both
switch positions. Verify continuity between switch termi-
nals using the following table:
1
2
6
END VIEW
3
4
PLUNGER
POSITION
NO
CONTINUITY CONTINUITY
5
IN
1 and 2
3 and 4
3 and 4
1 and 2
SIDE VIEW
OUT
6
Figure 38
5. When reconnecting wiring harness connector to
switch after testing, harness connector and switch ter-
minal area should be filled with dielectric gel (see Spe-
cial Tools) to prevent corrosion of connection terminals.
Apply gel fully to both harness connector and switch ter-
minalarea, plugharness connector intoswitchtodistrib-
ute gel, unplug harness connector, reapply gel to both
surfaces and replug harness connector into switch.
1. Terminal 1
2. Terminal 2
3. Terminal 3
4. Terminal 4
5. Switch plunger
6. Mounting tab
6. If switch replacement is needed, see Accelerator
Switch Adjustment procedure in the Adjustments sec-
tion of this chapter.
Electrical System
Workman MDE
Page 3 -- 24
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Accelerator Potentiometer
The accelerator potentiometer is attached to the pedal
frame under the dash (Fig. 39). This potentiometer is
used as one of the inputs for the vehicle controller to
command vehicle speed. The accelerator pedal posi-
tions the accelerator potentiometer lever. When the op-
erator presses or releases the accelerator pedal, the
potentiometer resistance changes. This resistance
change is used by the controller to determine current
flow to the traction motor.
4
1
Two styles of potentiometer have been used on Work-
man MDE vehicles. Vehicles with serial numbers below
310000000 have a potentiometer with a short lever (Fig.
40). This potentiometer is rotated by a roll pin that ex-
tends approximately 1 1/2 inches (38 mm) out of the col-
lar. Vehicles with serial numbers 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 earlier vehicle has been replaced,
it may have a potentiometer with a long lever.
3
2
Figure 39
1. Potentiometer
2. Accelerator pedal
3. Collar
4. Roll pin
If the accelerator potentiometer is out of adjustment, the
diagnostic light on the dash will flash six (6) times. Addi-
tionally, if vehicle movement is erratic or jerky, calibra-
tion of the accelerator system should be performed. See
Accelerator Potentiometer Adjustment and Accelerator
System Calibration in the Adjustments section of this
chapter.
1
Before suspecting a faulty potentiometer, follow adjust-
ment procedures for the accelerator switch, accelerator
potentiometer and acceleration system calibration
found in the Adjustments section of this chapter.
2
Figure 40
1. Potentiometer
2. Lever (short)
1
2
3
Figure 41
1. Potentiometer
2. Lever (long)
3. Retainer
Workman MDE
Electrical System
Rev. A
Page 3 -- 25
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Controller
The Workman controller is secured to the rear frame un-
der the controller cover beneath the cargo box (Fig. 40).
The controller uses inputs from several vehicle switches
(on/off, forward/reverse, accelerator pedal, supervisor,
charger interlock, motor temperature, accelerator po-
tentiometer) to accurately control vehicle speed, vehicle
direction (forward and reverse) and regenerative brak-
ing. An internal thermal sensor prevents overheating of
the controller.
NOTE: If the controller LED and vehicle status light are
flashing, attempt to reset the controller by turning the on/
off switch to OFF, waiting a few seconds and then turn-
ing the switch to ON. If LED and status light continue
flashing, proceed with fault code identification and nec-
essary action.
1
3
Cable connections for the controller are as follows:
Terminal B--: Negative (--) battery cable and wire
harness ground.
Terminal B+: Positive (+) cable from main contac-
tor post and wire harness fusible link (FL3).
Terminal M1: Cable to traction motor armature A2
post.
2
Terminal M2: Cable to traction motor armature A1
post.
Terminal F1: Cable to traction motor field F1 post.
Terminal F2: Cable to traction motor field F2 post.
Figure 40
1. Controller
3. Wire harness connector
When installing cables to controller, torque screws at
terminals B--, B+, M1 and M2 from 85 to 90 in--lb (9.6
to 10.2 N--m) and torque screws at terminals F1 and F2
from 55 to 60 in--lb (6.2 to 6.8 N--m) (Fig. 41). Apply
Toro battery terminal protector (see Special Tools) to
controller connections after tightening terminal screws.
2. Controller LED
UP
M 2
M 1
B +
If wire harness connector is removed from controller,
both harness connector and controller 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 harness connector into controller to distribute
gel, unplug harness connector, reapply gel to both sur-
faces and plug harness connector into controller.
85 to 90 in--lb
(9.6 to 10.2 N--m)
F 2
F 1
- B -
A LED exists on the controller to identify normal opera-
tion or faults that will prevent the vehicle from operating
correctly. The vehicle status light on the dash panel dis-
plays the same information as the LED on the controller.
See chart below for light pattern fault codes identified by
the controller LED and vehicle status light.
55 to 60 in--lb
(6.2 to 6.8 N--m)
Figure 41
Light Pattern
Cause
Necessary Action
Always on (not
flashing)
System functioning correctly. None
Always off
System inoperable.
Check for low battery voltage, faulty fuse(s), loose
battery cable connections, damaged battery cables
and/or faulty main contactor.
If batteries, cables and other electrical components are
in good condition, controller replacement may be
necessary.
Electrical System
Workman MDE
Page 3 -- 26
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1 Flash
System inoperable.
Turn on/off switch OFF, wait several seconds and turn
on/off switch ON. If controller does not reset correctly,
controller replacement may be necessary.
2 Flashes
The accelerator pedal was
depressed when on/off
switch was turned ON.
Turn on/off switch OFF, release accelerator pedal and
turn on/off switch to ON.
If controller does not reset correctly, accelerator switch
adjustment may be necessary or switch may be faulty.
3 Flashes
System inoperable.
Turn on/off switch OFF, wait several seconds and turn
on/off switch ON. If controller does not reset, check
battery pack voltage and all battery cable connections.
Also check main contactor wire and cable connections
and main contactor. NOTE: If main contactor audibly
clicks when on/off switch is turned ON, problem is most
likely a faulty wire or cable connection.
Controller replacement may be necessary.
4 Flashes
5 Flashes
Main contactor malfunction. Turn on/off switch OFF, wait several seconds and turn
on/off switch ON. If controller does not reset, inspect
main contactor (see Main and Accessories Contactors in
this section). Check main contactor wire and cable
connections.
If problem continues, contactor replacement may be
necessary.
The charger cord is plugged Turn on/off switch OFF, unplug charger cord from vehicle
into the vehicle charger
receptacle.
and turn on/off switch ON.
If controller does not reset correctly, check charger
interlock switch.
6 Flashes
7 Flashes
Accelerator control
(accelerator switch and
potentiometer) is out of
adjustment.
Adjust accelerator switch and potentiometer (see
Accelerator Switch and Accelerator Potentiometer
adjustment/calibration in the Adjustments section of this
chapter).
Battery voltage is out of
range.
Inspect and test vehicle batteries and battery cable
connections (see Battery Service in the Service and
Repairs section of this chapter).
8 Flashes
9 Flashes
The controller is overheated. The vehicle will continue to operate but at reduced
power until the controller temperature lowers.
The traction motor is
overheated (battery
Stop vehicle and allow motor to cool before continuing
operation. Traction motor high temperature switch may
discharge indicator displays be faulty.
more than 1 bar).
The battery is nearly
Charge the batteries immediately to prevent battery
damage.
discharged and the vehicle
is in the energy saving mode
(reduced speed and battery
discharge indicator displays
1 bar with red light
illuminated).
Workman MDE
Electrical System
Page 3 -- 27
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Service and Repairs
Battery Service
115 to 125 in--lb
(13.0 to 14.1 N--m)
9
11
10
12
1
115 to 125 in lb
(13.0 to 14.1 N--m)
5
4
8
6
7
5
4
3
2
RIGHT
FRONT
Figure 42
1. Battery (8 used)
5. Hex nut (2 used per battery)
6. Cable terminal boot
7. Battery cable (6 used)
8. Positive cable to vehicle
9. Cable terminal boot
10. Battery retainer (2 used)
11. Flange nut (2 used)
12. Battery cable
2. Battery rod (2 used)
3. Negative cable to vehicle
4. Lock washer (2 used per battery)
The batteries are the heart of the Workman electrical
system. With regular and proper service, battery life can
be extended. Additionally, battery and electrical compo-
nent failure can be prevented.
Battery Specifications:
Trojan model T--145 Battery (6 Volt Deep Cycle)
Weight: 72 lbs (33 kg)
Capacity: 210minutes @ 56.25 amps discharge
Electrical System
Workman MDE
Page 3 -- 28
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Battery Removal (Fig. 42)
2. Make sure the battery supports are clean and re-
painted if necessary. Make sure cables, terminals, rods
and hold down retainers are in good condition.
WARNING
POTENTIAL HAZARD:
The battery terminals, metal tools and metal ve-
hicle parts could short together.
WHAT CAN HAPPEN:
Sparks can cause battery gasses to explode.
Damaged cables could short against metal ve-
hicle parts and cause sparks.
IMPORTANT: When installing batteries into vehicle,
do not lift batteries using battery terminals as lift
points: battery damage may occur.
3. Using case loops on battery tops as lifting points, set
batteries on the battery supports with battery posts
properly orientated (Fig. 44). Make sure that battery
rods are positioned to allow installation of retainers.
4. Install two (2) battery retainers and nuts to secure
batteries to vehicle (Fig. 43). Torque nuts from 115 to
125 in--lb (13.0 to 14.1 N--m).
HOW TO AVOID THE HAZARD:
When removing or installing the batteries, do
not allow the battery terminals to short against
metal parts of the vehicle.
5. Install all but one of the battery cables used to con-
nect battery pack including the positive (red) cable and
negative (black) cable from vehicle (Figures 42 and 44).
Make sure that cables are connected to correct battery
terminal noting battery polarity. Install lock washer and
nut on each battery terminal. Torque nuts from 115 to
125 in--lb (13.0 to 14.1 N--m) to secure cables.
Do not allow metal tools or metal vehicle parts to
short between the battery terminals or battery
cables.
Always keep the battery retainers in place to
protect and secure the batteries.
IMPORTANT: Be careful to not damage terminal
posts or cable connectors when removing the bat-
tery cables.
6. Connect final battery cable to battery terminals.
Install lock washer and nut on battery terminals. Torque
nuts from 115 to 125 in--lb (13.0 to 14.1 N--m).
1. Position vehicle on a level surface, set parking
brake, turn on/off switch OFF and remove key.
7. Apply Toro battery terminal protector (see Special
Tools) to all battery posts and cable connectors to re-
duce corrosion after connections are made. Make sure
that terminal boots are positioned over all connections.
2. Raise cargo box and secure with prop rod.
3. Open the battery circuit by carefully removing one of
the battery cables (see Opening Battery Circuit in the
General Information section of this chapter).
8. Lower and secure cargo box.
4. Once initial cable has been removed from vehicle,
disconnect and remove remaining battery cables from
all battery terminals.
1
5. Remove flange nuts (item 11) and battery retainers
(item 10) used to secure batteries to vehicle (Fig. 43).
2
3
6. Make sure that all battery filler caps are on tightly.
4
IMPORTANT: When removing batteries from ve-
hicle, do not lift batteries using battery terminals as
lift points: battery damage may occur.
Figure 43
1. Negative cable to vehicle
2. Positive cable to vehicle
3. Flange nut
4. Battery retainer
7. Using case loops on battery tops as lifting points, re-
move batteries from vehicle.
Battery Installation (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 rod.
Figure 44
Workman MDE
Electrical System
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Battery Charging
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.
When the vehicle is not in use, it is recommended to
keep the batteries charged by connecting the battery
charger that is included with the vehicle. The Workman
MDE charger is designed to automatically charge the
batteries fully without overcharging. Indicator lights
(green and red) and an ammeter on the charger give in-
formation about the charging operation.
4. Check the battery case for dirt and oil. Clean the bat-
tery with a solution of baking soda and water, then rinse
battery with clean water.
5. Check that the battery cover seal is not broken away.
Replace the battery if the seal is broken or leaking.
Make sure to have the battery cell plates covered with
electrolyte before charging the batteries (Fig. 45). Peri-
odically (at least every 50 operating hours) check elec-
trolyte level in the batteries and add distilled water to
ensure proper charging and the best battery perfor-
mance and life.
IMPORTANT: Make sure the area around the battery
filler caps is clean before opening the caps.
IMPORTANT: Do not add acid to the battery. Use
only distilled water to adjust the electrolyte level.
6. Check the electrolyte level in each cell. If the level is
below the tops of the plates in any cell, add just enough
distilled water to the cell to cover the plates. Replace
filler caps and charge the battery. After charging, check
electrolyte level in all cells and add distilled water until
the level is 1/8” (3 mm) below the bottom of the fill well
(Fig. 45).
Colder temperatures will increase the time needed to
fully charge the batteries. NEVER attempt to charge fro-
zen batteries. Also, if temperatures below freezing are
expected, do not add water to battery after charging as
added water could freeze and damage battery.
For additional battery charging information, see your
Operator’s Manual and the Battery Charger Operating
Instructions.
4
2
Battery Inspection and Maintenance
1/8 inch
(3 mm)
3
WARNING
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:
1
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.
Figure 45
1. Battery plates
2. Filler cap
3. Electrolyte level
4. Battery terminal
Follow all instructions and comply with all
safety messages on the electrolyte container.
1. Check for cracks in battery case caused by overly
tight or loose hold--down retainer. Replace any battery
that is cracked and/or leaking.
2. Check battery terminal posts for corrosion. Use a ter-
minal brush to clean corrosion from the battery terminal
posts.
IMPORTANT: Before cleaning the battery, make
sure the filler caps are on tightly.
Electrical System
Workman MDE
Page 3 -- 30
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Battery Testing
B. Measure the specific gravity of each cell with a
hydrometer. Fill and drain the hydrometer two to four
times before drawing a sample. At the same time,
take the temperature of the cell.
When testing batteries in the Workman MDE, it is impor-
tant to test all batteries. Proper performance of the ve-
hicle depends on all batteries being in good condition.
Testing will determine if one (or more) of the batteries
needs to be replaced.
C. Have enough electrolyte in the hydrometer to
completely support the hydrometer float. Record the
hydrometer reading and return the electrolyte to the
battery cell.
1. The preferred testing procedure is to use the Lester
Electrical 36/48 Volt Battery Discharge Unit (Model
17770). This instrument puts a known discharge load
(56.25 Amps) on the battery pack until the battery pack
reaches 42 volts. A timer incorporated into the discharg-
er measures the time needed to reach that voltage level.
Battery capacity and remaining life can be determined
from the test results. Refer to Discharge Unit Operating
Instructions for further information.
D. Repeat test for remaining battery cells.
E. Temperature correct each cell reading. For each
10oF (5.5oC) above 80oF (26.7oC) add 0.004 to the
specific gravity reading. For each 10oF (5.5oC) below
80oF (26.7oC) subtract 0.004 from the specific grav-
ity reading.
Example: Cell Temperature
100oF
Other types of battery load testers can also be used to
test the Workman batteries. Many locally available bat-
tery load testers do not, however, have any adjustment
on the load that is put on the battery. Results received
from using load testers should follow the recommenda-
tions of the load tester manufacturer.
Cell Specific Gravity Reading 1.245
ADD (20o above 80oF)
Correction to 80oF
0.008
1.253
F. The specific gravity of all battery cells should be
1.277 + 0.007. If low cell readings exist (see Fig. 46),
charge battery and take specific gravity readings
again.
2. If the Lester Battery Discharge Unit (or other load
tester) is not available, an alternate battery test can be
done using a multimeter to perform a voltage test of
each battery. Use the following procedure:
G. If specific gravity of any cells remain low after
complete charging, battery should be replaced.
A. For accurate voltage testing, allow batteries to re-
main idle (no charging, no discharging) for at least 6
hours and preferably 24 hours.
Battery Charge
Level
Specific
Gravity
Open Circuit
Voltage
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
1.277
1.258
1.238
1.217
1.195
1.172
1.148
1.124
1.098
1.073
6.37
6.31
6.25
6.19
6.12
6.05
5.98
5.91
5.83
5.75
B. Open the battery circuit by carefully removing
one of the battery cables (see Opening Battery Cir-
cuit in the General Information section of this chap-
ter). Then, disconnect both cables from battery to be
tested.
C. Measure the battery voltage with the multimeter.
Record battery voltage. 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 after charging,
consider battery replacement.
Figure 46
3. Athird option for battery testing is to performa specif-
ic gravity test of the battery electrolyte using a hydrome-
ter. Use the following procedure:
IMPORTANT: Make sure the area around the battery
fill caps is clean before removing the caps.
A. Remove battery filler caps. Do not add water prior
to testing specific gravity of battery electrolyte. If
electrolyte level is low, add distilled water and
charge battery before performing specific gravity
test.
Workman MDE
Electrical System
Page 3 -- 31
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Battery Storage
If the vehicle 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 atmosphere to
avoid quick deterioration of the charge in the batteries.
To prevent batteries from freezing, make sure they are
fully charged before storage. During the storage period,
charge the batteries at least once every three (3)
months to prevent battery damage. Before returning the
vehicle to service, make sure to fully charge the batter-
ies.
If the vehicle will be stored for any period of time, check
battery electrolyte level, adjust level if needed and then
connect battery charger to vehicle. Allow charger to re-
mainconnectedtovehicleduringstoragetopreventbat-
tery discharge and potential battery damage.
Electrical System
Workman MDE
Page 3 -- 32
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Traction Motor Brushes
The traction motor in the Workman MDE uses eight (8)
brushes. Traction motor brushes should be inspected
every 500 hours of operation or annually.
4
2
3
Inspection
1. Make sure that on/off switch is OFF. Raise and latch
cargo box to allow access to traction motor.
2. Open the battery circuit by carefully removing one of
the battery cables (see Opening Battery Circuit in the
General Information section of this chapter).
1
3. Unlatch headband of traction motor and reposition
headband to allow inspection of a brush at the top of the
motor.
Figure 47
4. If end of brush is even with the brush holder (Figs. 47
and 49), brushes should be removed from motor for in-
spection and measurement (see Traction Motor Service
in this section).
1. Brush
2. Brush holder
3. Brush spring (tensioned)
4. Brush spring (released)
5. In most instances, wear of all traction motor brushes
should be similar to wear found on the top brushes. If in-
spection of remaining brushes is needed or if brushes
require replacement, traction motor should be removed
from vehicle (see Traction Motor and Traction Motor
Service in this section).
1
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 brush (Fig. 48). If brush
surface is rough, pitted, arced or scored, additional
brush and/or motor inspection should be completed
(see Traction Motor and Traction Motor Service in this
section).
2
Figure 48
7. Visually inspect commutator surface of motor arma-
ture. If commutator surface is rough, pitted, arced or
scored, additional motor inspection should be com-
pleted (see Traction Motor and Traction Motor Service
in this section).
1. Removed brush
2. Cap screw
4
2
8. After brush inspection, make sure brush is correctly
installed in brush holder and tensioned by spring. Refit
headband to traction motor and latch headband.
1
9. Carefully connect removed battery cable to battery
terminals. Install lock washer and nut on battery termi-
nals. Torque nuts from 115 to 125 in--lb (13.0 to 14.1
N--m).
3
4
1
10.Lower and secure cargo box.
Figure 49
1. Brush holder (side view)
2. Normal brush
3. Worn brush
4. Brush shunt wire
Workman MDE
Electrical System
Page 3 -- 33
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Traction Motor
14
115 to 125 in lb
(13.0 to 14.1 N--m)
15
16
3
17
4
18
5
6
7
5
15
8
9
16
19
10
11
12
13
1
2
RIGHT
FRONT
125 to 165 in--lb
(14.2 to 18.6 N--m)
Figure 50
1. Socket head screw (6 used)
2. Flat washer (6 used)
3. Flange nut
8. Traction motor
14. Cable terminal boot
15. Hex nut
9. Fan
10. Roll pin (2 used)
11. Washer
12. Socket head screw
16. Lock washer
4. Support bracket
17. Positive battery cable
18. Cable terminal boot
19. Negative battery cable
5. Carriage screw
6. Transaxle mount plate
7. Rubber damper
13. Plastic cap (fits in rear frame)
Removal (Fig. 50)
NOTE: Label all electrical leads for assembly pur-
poses.
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from switch.
IMPORTANT: When removing wires from motor ter-
minals (A1, A2, F1 and F2), use a wrench to retain
lower nut while loosening upper nut (Fig. 52). If ter-
minal studs are allowed to turn during upper nut re-
moval, internal motor damage can occur.
2. Remove cargo box from vehicle (see Cargo Box Re-
moval in Service and Repairs section of Chapter 5 --
Chassis).
3. Open the battery circuit by carefully removing one of
the battery cables (see Opening Battery Circuit in the
General Information section of this chapter).
Electrical System
Workman MDE
Page 3 -- 34
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4. Disconnect wires from traction motor (Fig. 51):
2. Make sure that rubber damper is installed into the
motor shaft internal spline with the damper flat side to-
ward the motor (Fig. 51).
A. While retaining lower nut, remove upper nut and
wire connector from motor terminals A1, A2, F1 and
F2.
85 to 90 in--lb
(9.6 to 10.2 N--m)
55 to 60 in--lb
B. Unplug motor temperature sensor from vehicle
wire harness. Note location of cable tie that secures
temperature sensor wires to vehicle.
(6.2 to 6.8 N--m)
2
C. Position disconnected wires away from motor.
5. Remove plastic plug from rear frame to allow access
to socket head screw that retains fan to traction motor.
Remove screw and washer and then remove fan from
motor.
4
3
1
55 to 60 in--lb
(6.2 to 6.8 N--m)
CAUTION
To prevent motor damage and personal injury,
make sure that traction motor is well supported
as it is removed. Motor weighs approximately 62
pounds (28.1 kg).
Figure 51
1. Thermal switch
2. Motor shaft spline
3. Rubber damper
4. Transaxle input shaft
6. Support traction motor to prevent it from falling. Two
suggestions for traction motor support are as follows:
1
IMPORTANT: Damage to traction motor field coils
will result if eyebolt is threaded into motor housing
to far.
A. Remove silver flange head screw from top of mo-
tor and carefully install a 3/8 -- 16 eyebolt into motor
(Fig. 53). Thread 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.
2
Figure 52
1. Loosening/tightening wrench (upper nut)
2. Retaining wrench (lower nut)
B. Use lifting strap wrapped around motor housing
for support and as a lifting point for motor removal.
1
7. Remove six (6) socket head screws (item 1) and flat
washers (item 2) that secure motor to transaxle.
8. Slide motor away from transaxle to disengage motor
shaft from transaxle input shaft. Carefully lift motor from
vehicle. Take care to not damage thermal switch while
motor is removed.
9. Locate and retrieve rubber damper from motor shaft
internal spline.
2
10.If needed, remove two (2) roll pins from motor shaft.
Installation (Fig. 50)
Figure 53
1. Eyebolt
2. Jam nut
1. If removed, install two (2) roll pins into motor shaft.
Workman MDE
Electrical System
Page 3 -- 35
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3. Apply antiseize lubricant or axle grease to the
splines of the transaxle and motor shafts. Apply grease
to lip of seal in transaxle bore.
3
CAUTION
1
To prevent motor damage and personal injury,
make sure that traction motor is well sup-
ported as it is installed. Motor weighs approxi-
mately 62 pounds (28.1 kg).
2
4. Carefully lower motor into vehicle. Align motor shaft
with transaxle input shaft and slide motor to transaxle.
Take care to not damage thermal switch while installing
motor.
Figure 54
1. Transaxle
3. Transaxle mount plate
2. Screw/washer (6 used)
5. Align mounting holes of motor, transaxle and trans-
axle mount plate. Secure motor to transaxle with six (6)
socket head screws (item 1) and flat washers (item 2).
Torque screws from 125 to 165 in--lb (14.2 to 18.6
N--m).
1
2
4
5
IMPORTANT: When connecting wires to motor ter-
minals (A1, A2, F1 and F2), use a wrench to retain
lower nut while tightening upper nut (Fig. 52). If ter-
minal studs are allowed to turn during upper nut
installation, internal motor damage can occur.
3
6
Figure 55
6. Connect wires to traction motor (Fig. 51):
1. Upper nut
4. Flat washer
2. Cable connector
3. Lower nut
5. Insulating washer
6. Motor housing
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
terminals A1 and A2. While retaining lower nut,
torque upper nut on terminals A1 and A2 from 85 to
90 in--lb (9.6 to 10.2 N--m).
C. Installcorrectwire connector and nutto motor ter-
minals F1 and F2. While retaining lower nut, torque
upper nut on terminals F1 and F2 from 55 to 60 in--lb
(6.2 to 6.8 N--m).
D. Plug motor temperature sensor connector into
vehicle wire harness.
7. Position fan to traction motor and secure with socket
head screw and washer. Install plastic plug in hole in
rear frame.
8. Carefully connect removed battery cable to battery
terminals. Installlock washers and nuts on battery termi-
nals. Torque nuts from 115 to 125 in--lb (13.0 to 14.1
N--m).
9. Install cargo box to the rear frame (see Cargo Box
Installation in Service and Repairs section of Chapter 5
-- Chassis).
Electrical System
Workman MDE
Page 3 -- 36
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Workman MDE
Electrical System
Page 3 -- 37
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Traction Motor Service
1
(1
1
1
9
Figure 56
1. Frame and field assembly
2. Armature
6. Cap screw (8 used)
7. Brush (8 used)
8. High temperature sensor
9. Headband
11. Commutator end head
12. Bearing
13. Retaining ring
14. Brush spring (8 used)
15. Brush box
3. Brush lead (2 used)
4. Cap screw (2 used per brush lead)
5. Cap screw (4 used)
10. Bolt (4 used)
Disassembly (Fig. 56)
5. Remove the retaining ring and press bearing from
the commutator end head. Discard the bearing.
1. Unlatch and slide headband from traction motor.
2. Pull back the brush springs and latch them in the
open position on the spring holders. Slide brushes from
the brush holders.
CAUTION
When using compressed air for cleaning motor
components, follow all safety instructions, in-
cluding wearing eye and respiratory protection.
3. Use an arbor press or a bearing puller to remove the
armature from the commutator end head and frame and
field assembly (Fig. 57).
6. Carefully blow out any accumulated carbon dust and
dirt from the commutator end head and the frame and
field assembly using clean, oil free, compressed air.
4. Remove four (4) bolts that secure the commutator
end head to the frame and field assembly. Remove com-
mutator end head from frame and field assembly.
Electrical System
Workman MDE
Page 3 -- 38
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Brush Service
3. It is also recommended that the field be coated with
PD George 1000--70 or RanBar B--535--5S varnish for
proper insulation protection. Both recommended var-
nishes are Class H water--soluble varnishes. A similar
air--dry varnish may also be used providing it has a
Class H rating.
1. Check the brush springs for correct alignment on the
back of the brush. A brush spring that does not apply
equal pressure on the center of the brush will cause the
brushtowearunevenly.Checkforcorrectclearanceand
freedom of brush movement in the holder.
4. Screws securing the pole pieces to the frame should
be torqued from 250 to 300 in--lb (28.3 to 33.9 N--m)
(Fig. 59).
2. Replace brushes that are worn to a length of 0.620”
(16 mm). Also, replace brushes if they show signs of un-
even wear or show signs of overheating, such as discol-
ored brush shunts and brush springs.
3
3. Brushes should always be replaced in complete sets
of eight. Use identical replacement parts; do not substi-
tute brush grades as the brushes are matched to the
motor type and application to provide the best service.
Substituting brushes of the wrong grade can cause pre-
mature commutator failure and excessive brush wear.
Remove old brushes and replace with identical replace-
ment parts. Hold brush shunts in position and torque
brush screws from 18 to 22 in--lbs (2.0 to 2.5 N--m) (Fig.
59). Make sure brushes move freely in the holders and
thatshunts donotinterferewithbrush springmovement.
2
1
Figure 57
1. Motor housing
2. Puller
3. Arbor press
4. Make sure the brush box assembly is tight on the
commutator end head. Replace brush box assemblies
in the commutator end head if they are physically dam-
aged or brush holders are loose on the brush plate.
1
5. Brush springs should be checked for proper tension
using the following procedure (Fig. 58):
2
3
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 spring. When the
paper stripbegins tomovefreely, readthespringten-
sion on the scale. Brush tension for a new brush
should be 65 ounces (1820 grams) and for a worn
brush should be 40 ounces (1120 grams).
Figure 58
1. Spring scale
2. Brush spring
3. Paper
2
Frame and Field Service
1. Motors that have been disassembled for servicing
should be given a complete inspection of the frame and
field assembly. If damage to the field coils or frame is
found, replace traction motor. Individual frame and field
components are not available.
2
1
2. Accumulated carbon dust, grease and other foreign
material can produce a ground path from the field wind-
ing to the frame. The frame and field should be cleaned
with Safety--Kleen 105 washing solvent or equivalent.
After cleaning, the frame and field must be oven--dried
for one hour at 300oF (148o C) to remove any cleaning
residue.
Figure 59
1. Brush screw
2. Pole piece screw
Workman MDE
Electrical System
Page 3 -- 39
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Commutator Service
MICA
COPPER SEGMENT
1. Chuck armature on the commutator end--bearing
journal and support the drive end of armature using the
”live” center ofthe shaft. With thearmature supported on
both ends, measure the commutator runout and the bar
to bar differences with a dial gauge. Total indicated run-
out should not exceed 0.003” (0.08 mm) and not more
than 0.0005” (0.013 mm) between any two bars. If the
readings fall outside this limit, the commutator must be
turned and re--undercut.
0.040”
(1.0 mm)
GOOD UNDERCUT
MICA
MICA
COPPER SEGMENT
COPPER SEGMENT
2. If the commutator must be turned, use only high
quality cutting tools with a controlled cutting rate. Re-
move only enough copper to bring total indicated runout
and bar to bar height differences into specification.
BAD UNDERCUT
(CUT TOO WIDE)
BAD UNDERCUT
(CUT TOO NARROW)
3. The minimum commutator diameter is 2.750” (70
mm). If the commutator diameter falls below this diame-
ter after turning, the armature must be replaced.
Figure 60
4. After the commutator is turned, undercut the mica to
a uniformdepthof0.040” (1.0mm). Be carefulto only cut
the mica and not increase the slot width (Fig. 60).
Traction Motor Specifications
BRUSH LENGTH
Maximum
Minimum
1.300 in
0.620 in
33 mm
16 mm
CAUTION
BRUSH SPRING
TENSION
When using compressed air for cleaning mo-
tor components, follow all safety instructions,
including wearing eye and respiratory protec-
tion.
New Brush
Worn Brush
65 ounces
40 ounces
1820 grams
1120 grams
COMMUTATOR
New Diameter
2.920 in
2.800 in
74 mm
71 mm
5. After undercutting, use No. 00 sandpaper to lightly
remove any burrs left from the undercutting operation.
Clean commutator with dry, oil free compressed air and
recheck commutator runout.
Minimum Diame-
ter for Reslotting
Reject Diameter
2.750 in
70 mm
Armature Testing
Before an armature is reassembled into the motor, the
following tests should be performed:
NOTE: Armature is wave wound and can be short cir-
cuit tested in the following manner.
1. Check for grounded circuits by placing one test lead
of a dielectric tester on the commutator and the other
lead at the armature shaft. If the test light comes on, the
armature is grounded.
2. Check for short circuits by placing the armature on a
growler. Use a long, flat piece of metal (such as a hack-
saw blade) to locate any shorted windings.
If armature is found to be shorted, grounded or other-
wise damaged, replace the traction motor.
Electrical System
Workman MDE
Page 3 -- 40
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Assembly (Fig. 56)
ARMATURE
ASSEMBLY
PRESS FIXTURE
MUST PRESS
AGAINST
NOTE: After the motor has been disassembled, it is
recommended that a new commutator end head bear-
ing be installed because the removed bearing may have
been damaged during disassembly. Although the bear-
ing may appear and feel good, the bearing could be ”bri-
nelled” (races or balls deformed) and may exhibit noise
and vibration problems or fail within a relatively short pe-
riod of service. When installing new bearing, always
press against the race that is absorbing the pressure or
bearing damage may occur.
OUTER RACE
BEARING AND
RETAINING RING
INSTALLED
IN END HEAD
BEARING
PRESS FIXTURE
MUST HOLD
END HEAD
MUST BE HELD
STATIONARY
INNER RACE
STATIONARY
1. After servicing the commutator and brushes, re--as-
semble the wiring in the commutator end head as origi-
nally found. Ensure the wiring does not contact metal
androtating parts. Also, makesure thatthe wiringallows
the brushes to move unrestricted in the brush holders.
Figure 61
1
2
2. Press a new bearing into the commutator end head,
pressingonthebearingouter raceonly (Fig. 61). Secure
bearing with retaining ring.
3
4
5
3. Position the commutator end head to the frame and
field assembly and secure with four (4) bolts. Torque
bolts from 120 to 140 in--lb (13.6 to 15.8 N--m).
Figure 62
1. Terminal
2. Lower nut
3. Flat washer
4. Insulating washer
5. Motor housing
4. Ensure the brushes are pushed out of the way.
5. While supporting the inner--race of the bearing in
commutator end head, carefully press the armature into
the end head and bearing assembly (Fig. 61).
2
6. Position brushes in brush holders and carefully re-
lease the brush springs allowing the brushes to contact
the commutator. Make sure brush shunts do not inter-
fere with spring movement.
1
4
7. Repair or replace the headband if damaged. Install
the headband on the motor.
3
8. Make sure that lower nuts are properly tightened on
traction motor terminals (Fig. 62 and 63). Lower nuts on
F1 and F2 terminals should be torqued from 50 to 60 in--
lb (5.7 to 6.8 N--m). Lower nuts on A1 and A2 terminals
should be torqued from 110 to 140 in--lb (12.4 to 15.8
N--m).
Figure 63
1. A2 terminal
2. F2 terminal
3. F1 terminal
4. A1 terminal
Workman MDE
Electrical System
Page 3 -- 41
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Battery Charger
1
2
12
3
11
10
4
9
5
7
8
6
Figure 64
5. Control board
6. Relay
7. Circuit breaker
8. AC cordset
1. Upper case
2. Transformer
3. Lower case
4. SCR assembly
9. DC cordset
10. Ammeter
11. Fuse
12. Diode assembly
For service of the battery charger, see the Lester Electri-
cal Technician Service Guide at the end of this chapter.
Electrical System
Workman MDE
Page 3 -- 42
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Chapter 4
Transaxle and Brakes
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 2
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 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 Cylinder Service . . . . . . . . . . . . . . . 17
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Transaxle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Transaxle Service . . . . . . . . . . . . . . . . . . . . . . . . . . 24
SPICER OFF--HIGHWAY COMPONENTS MODEL
12 (ELECTRIC) MAINTENANCE MANUAL
Workman MDE
Page 4 -- 1
Transaxle and Brakes
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General Information
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 for additional information when ser-
vicing the machine.
Page 4 -- 2
Workman MDE
Transaxle and Brakes
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Specifications
Item
Description
Transaxle
Transaxle Fluid Capacity
Transaxle Fluid
2 quarts (1.9 liters)
10W--30 Motor Oil
Brake Fluid
DOT 3
Workman MDE
Page 4 -- 3
Transaxle and Brakes
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Troubleshooting
Brakes
Problem
Possible Cause
Brake pedal goes to the floor.
Rear brake shoes are excessively worn.
Front brake pads are excessively worn.
Brake fluid level low.
Brake fluid leak at hose, caliper or wheel cylinder.
Brake master cylinder faulty.
Brake pedal is spongy.
Rear 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 contaminated.
Front wheel alignment (toe--in) is incorrect.
Rear brake shoes are distorted.
Tires on same axle are unmatched.
Brake lining is glazed or saturated.
Brakes squeal.
Rear shoe--to--shoe springs are weak or broken.
Rear brake shoes are distorted.
Brake drums and shoes are dusty.
Rear brake drums are scored or out--of--round.
Page 4 -- 4
Workman MDE
Transaxle and Brakes
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Brakes (continued)
Problem
Possible Cause
Brakes drag.
Parking brake is applied.
Rear shoe--to--shoe springs are weak or broken.
Brake pedal is binding.
Brake linings are saturated.
Rear brake drums are bent or out--of--round.
Front brake calipers or rotors are damaged.
Incorrect brake lining material.
Brake pedal is hard to push.
Wheels lock--up when braking.
Brake pedal linkage is binding.
Brake linings are contaminated, worn or damaged.
Wheel or transaxle bearings are damaged.
Rear brake shoe--to--shoe springs are weak.
Rear brake drums are grooved in the contact face with brake
shoes.
Brakes fade.
Brake drums or rotors are overheated.
Brake linings are saturated.
Vehicle surges at slow speeds and
chatters at fast speeds.
Brake drums or rotors are bent or out--of--round.
Workman MDE
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Transaxle and Brakes
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Service and Repairs
Rear Wheels and Brakes
12
125 to 140 ft--lb
(170 to 190 N--m)
2
3
6
13
1
14
7
45 to 65 ft--lb
(61 to 88 N--m)
v
26 to 30 ft--lb
(34 to 41 N--m)
4
5
8
15
11
RIGHT
10
9
FRONT
Figure 1
1. Lock nut (4 used per side)
2. Cotter pin
3. Brake assembly (LH shown)
4. Socket head screw (4 used per side)
5. Wheel stud (5 used per side)
6. Wheel hub
7. Flange nut
11. Clevis pin
12. Transaxle
13. Brake drum
14. Rear wheel assembly
15. Lug nut (5 used per side)
8. Parking brake cable
9. Retaining ring
10. Cotter pin
Page 4 -- 6
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Transaxle and Brakes
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Removal (Fig. 1)
B. Position and secure hydraulic brake line to wheel
cylinder (Fig. 3). Torque banjo bolt from 15 to 21 ft--
lb (21 to 28 N--m).
1. Park vehicle on a level surface, turn on/off switch
OFF and remove key from the on/off switch.
C. Secure parking brake cable bracket to the brake
actuator lever with clevis pin and cotter pin (Fig. 2).
WARNING
2. If wheel studs were removed from wheel hub, use
press to install wheel studs into hub. Make sure to fully
press studs into hub.
Before jacking up the vehicle, review and follow
Jacking Instructions in Operator’s Manual and
Chapter 1 -- Safety.
3. Slide wheel hub onto transaxle shaft. Install flange
nut to secure wheel hub to the transaxle shaft. Torque
nutfrom125to140ft--lb(170to190N--m). Installcotter
pin.
2. Chock wheels not being jacked up. Lift rear wheel off
thegroundusingajack andplaceappropriatejack stand
beneath the rear frame to support vehicle.
4. Slide brake drum onto wheel hub.
NOTE: To remove brake drum, it may be necessary to
loosen parking brake cable adjustment or remove park-
ing brake cable from brake actuator lever.
3
4
3. Remove five (5) lug nuts, wheel assembly and brake
drum from the wheel hub.
2
4. Remove cotter pin and flange nut that secure wheel
hub (item 7) to the transaxle shaft.
5. Remove wheel hub from transaxle.
1
6. If necessary, use press to remove wheel studs from
hub.
7. If necessary, remove brake assembly from trans-
axle:
Figure 2
1. Cotter pin
2. Clevis pin
3. Brake cable bracket
4. Brake actuator lever
A. Remove cotter pin and clevis pin securing the
parking brake cable bracket to the brake actuator le-
ver (Fig. 2).
2
1
B. Clean hydraulic brake line area of rear brake cyl-
inder to prevent contamination. Loosen and discon-
nect hydraulic brake line from wheel cylinder. Plug
brake line and position it away from wheel cylinder.
3
4
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)
15 to 21 ft--lb
(21 to 28 N--m)
IMPORTANT:The parking brake actuation levers
should be positioned above the transaxle mount.
When positioned correctly, the levers will point to-
ward the rear of the vehicle (Fig. 2).
5
Figure 3
1. Brake assembly
2. Wheel cylinder
3. Banjo washer
4. Banjo bolt
5. Brake line
1. If brake assembly was removed from axle, install
brake assembly to transaxle.
A. Secure brake assembly to the transaxle with four
(4) socket head screws and lock nuts. Torque lock
nuts from 26 to 30 ft--lb (34 to 41 N--m).
Workman MDE
Page 4 -- 7
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5. Position wheel assembly to the vehicle with valve
stem facing out and secure with five (5) lug nuts.
Burnish Brake Shoes
To provide maximum brake performance after rear
brake shoes are replaced, burnish new brake shoe lin-
ings.
6. Lower vehicle to ground. Torque lug nuts in a cross-
ing pattern from 45 to 65 ft--lb (61 to 88 N--m).
7. Bleed brakes (see Bleed Brake System in this sec-
tion).
IMPORTANT:To prevent brake overheating, do not
drive vehicle with the brakes applied.
IMPORTANT:When burnishing brake shoes, do not
allow the brakes to lock up. Also, allow brakes to
cool between stops.
CAUTION
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
1. Drive vehicle while making 6 to 7 normal stops at
about 200 ft (60 m) intervals while traveling at 10 to 15
mph (16 to 24 KPH).
2. Make several normal stops with the vehicle going in
the reverse direction.
8. Check brake operation.
Page 4 -- 8
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Workman MDE
Page 4 -- 9
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Rear Brake Service
110 to 120 in--lb
(12.4 to 13.6 N--m)
6
2
9
11
110 to 120 in--lb
(12.4 to 13.6 N--m)
10
3
7
8
11
10
5
12
1
13
7
8
110 to 120 in--lb
(12.4 to 13.6 N--m)
4
3
12
Figure 4
1. Brake backing plate
2. Washer head screw
3. Brake shoe
6. Parking brake lever (LH shown)
7. Belleville washer
8. Adjuster lever
10. Flat washer
11. Bolt
12. Shoe hold down cup and spring
13. Upper spring
4. Lower spring
9. Dust cover
5. Wheel cylinder
Disassembly (Fig. 4)
4. If required, slide parking brake lever from slot and
dust cover in backing plate.
5. If necessary, remove two (2) washer head screws
that secure wheel cylinder to backing plate. Remove
wheel cylinder from backing plate.
CAUTION
Be careful when removing springs from brake
shoes. The springs are under heavy load and
may cause personal injury.
6. If necessary, remove bolts and washers to allow ad-
juster levers to be separated from backing plate. Locate
and remove belleville washers from between adjuster
levers and backing plate.
1. Remove upper and lower springs from brake shoes.
2. Remove shoe hold down cups and springs that se-
cure the brake shoes to the backing plate.
3. Remove brake shoes from backing plate.
Page 4 -- 10
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Inspection (Fig. 4)
Assembly (Fig. 4)
1. Inspect brake drums.
IMPORTANT:Brake shoe lining surfaces must be
free of grease, oil and other foreign matter.
IMPORTANT:Brake drum machining is not re-
commended. Replace brake drums as a set to
maintain equal braking forces.
1. Apply a light film of lubricant to the following:
A. Ledges on which the brake shoes rest.
B. Pin surfaces on adjuster levers.
A. Clean drums with denatured alcohol. Check
braking surface diameter in at least three places. If
the diameter exceeds 6.320” (160.5 mm), replace
both brake drums.
C. Anchor block surface that contacts shoe webs.
D. Both surfaces of belleville washers that are posi-
tioned between adjuster levers and backing plate.
B. Replacedrumsthatarecracked, deeplygrooved,
tapered, significantly out--of--round, scored, heat
spotted or excessively rusted.
2. If removed, position lubricated belleville washer be-
tween lever adjuster and backing plate. Secure adjuster
to backing plate with washer and bolt. Torque bolt from
110 to 120 in--lb (12.4 to 13.6 N--m).
C. Minor scoring can be removed with sandpaper.
2. Inspect brake shoe linings.
3. If removed, secure wheel cylinder to backing plate
with two (2) washer head screws. Torque screws from
110 to 120 in--lb (12.4 to 13.6 N--m).
IMPORTANT:Replace brake shoes as a set (all
four shoes) to maintain equal braking forces.
A. Replace brake shoes if damaged or if lining is
worn to 1/16” (1.6 mm). Replace if lining is contami-
nated by oil, grease, or other fluids.
4. Ifremovedfrombackingplate, slideparking brakele-
ver into slot and dust cover in backing plate.
5. Position brake shoes to backing plate. Make sure
that each shoe is properly positioned at anchor block,
parking brake lever, wheel cylinder and pin on adjuster
lever. Secure shoes to backing plate with shoe hold
down cups and springs.
NOTE: Overheated springs lose their tension, and
can cause brake linings to wear out prematurely.
B. Inspect brake shoe webbing, upper and lower
springs, and shoe hold down springs for overheat-
ing. Overheatingisindicatedbyaslightbluecolor. In-
spect brake shoe webbing for deformation. Replace
parts as necessary.
CAUTION
Be careful when installing springs to brake
shoes. The springs are under heavy load and
may cause personal injury.
C. Inspect hold down pins on adjuster levers for
bends, rust and corrosion. Replace as necessary.
3. Inspect backing plate surfaces, which contact with
the brake shoes for grooves that may restrict shoe
movement. Replace plate if grooves can not be re-
moved by light sanding with emery cloth or other suit-
able abrasive. Replace plate if cracked, warped or
excessively rusted.
6. Secure brake shoes with upper and lower springs.
4. Inspect adjuster levers for deformation. Replace lev-
ers if deformation or excessive rust is found.
5. Replace parking brake cables if frayed, stretched or
kinked.
Workman MDE
Page 4 -- 11
Transaxle and Brakes
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Hydraulic Brake System
14
35
34
13
33
36
7
4
12
24
19
6
11
21
2
10
26
16
5
11
17
18
32 20
8
9
15
23
27
31
25
30
32
Loctite #242
32
28
22
29
3
37
RIGHT
1
FRONT
Figure 5
1. Brake caliper (LH)
2. Brake caliper (RH)
3. Brake rotor (2 used)
4. Front brake tube
5. Front brake hose
6. Carriage screw
7. Rear brake tube
8. Carriage screw
9. Rear brake hose bracket
10. Cap screw
14. Rear brake tube (RH)
15. Rear brake tube (LH)
16. Insulated clip (5 used)
17. Cap screw (2 used)
18. Flange nut (2 used)
19. Clevis pin
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. Washer head screw (2 used)
32. Lock nut
20. Cotter pin
21. Master cylinder
22. Union fitting
23. Rear brake tube
24. Rear brake hose
25. Hose bracket (2 used)
33. Cap screw
34. Lock nut
35. Rear brake (RH)
11. Thread forming screw (6 used)
12. Clip
13. Tee fitting
36. Rear brake (LH)
37. Wheel hub assembly (2 used)
When performing service work on the Workman MDE
hydraulic brake system, make sure to thoroughly clean
components before disassembly. Use Figure 5 as a
guide for removal and installation of hydraulic brake
components.
Page 4 -- 12
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Bleed Brake System
1. Connectasuitabletransparenthosetobleedervalve
on a wheel cylinder or caliper. Submerge other end of
hose in a glass container partially filled with clean brake
fluid.
5. Repeat steps 1 to4 for other brakecylinders andcali-
pers.
CAUTION
2. Have a second person pump brake pedal several
times, then hold pedal down firmly.
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
3. With pedal firmly depressed, open bleeder valve un-
til pedal fades to floor. Close bleeder valve before re-
leasing pedal.
6. After bleeding of brakes is completed, test vehicle to
make sure brakes are operating correctly and brake
pedal is solid.
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 in brake fluid res-
ervoir at all times.
Workman MDE
Page 4 -- 13
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Front Brake Calipers
10
2
To rear
brakes
9
8
Loctite #242
7
45 to 65 ft--lb
(61 to 88 N--m)
13
6
3
5
4
RIGHT
1
12
FRONT
11
Figure 6
1. LH brake caliper
6. Brake rotor
10. Brake master cylinder
11. Wheel assembly
12. Lug nut (5 used per wheel)
13. Front brake hose
2. RH brake caliper
7. Socket head screw (4 per rotor used)
8. Spindle (LH shown)
3. Lock washer (2 per caliper used)
4. Cap screw (2 per caliper used)
5. Wheel hub assembly
9. A--arm (LH shown)
Page 4 -- 14
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Removal (Fig. 6)
Installation (Fig. 6)
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
1. If brake pads were removed from caliper, install pads
(Fig. 7):
A. If brake pads are being replaced, it will be neces-
sary to push caliper pistons back into the caliper bore
before installing new pads.
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
B. Slide brake pads into caliper. Make sure that fric-
tion material on pads is toward brake rotor position.
C. Secure pads into caliper with two (2) pins. Make
sure that pins snap into caliper slots. Install anti--
rattle clip to caliper, pin and brake pads.
2. Chock wheels not being jacked up. Jack front wheel
off the ground and support machine with appropriate
jack stands.
2. Slide brake caliper onto brake rotor. Make sure that
rotor is between brake pads.
3. Remove front wheel from machine (see Lower
Steering and Front Wheel Removal in the the Service
and Repairs section of Chapter 5 -- Chassis).
3. Align caliper mounting holes with spindle. Secure
caliper with two (2) cap screws and lock washers.
4. Clean hydraulic brake line area of brake caliper to
prevent contamination. Loosen and disconnect brake
line from caliper. Plug brake line and position it away
from caliper.
4. Install brake hose to caliper.
5. Install front wheel assembly.
5. Remove two (2) cap screws and lock washers that
secure the brake caliper to the spindle.
6. Lower machine to ground. Torque lug nuts in a cross-
ing pattern from 45 to 65 ft--lb (61 to 88 N--m).
6. Slide brake caliper from brake rotor and remove cali-
per from machine.
7. Bleed brakes (see Bleed Brake System in this sec-
tion).
7. If necessary, remove brake pads from caliper (Fig.
7):
CAUTION
A. Remove anti--rattle clip from caliper.
After servicing the brakes, always check the
brakes in a wide open, level area that is free of
other persons and obstructions.
B. Remove pins from caliper by prying with a flat
blade screwdriver through loop in pins.
C. Slide brake pads from caliper. For assembly pur-
poses, note orientation of inner and outer pads as
the pads are not the same.
8. Check brake operation.
D. Replace the brake pads if the friction material is
worn to less than 1/32” (0.8 mm).
3
2
8. If brake rotor service is necessary, see Lower Steer-
ing and Front Wheels in the Service and Repairs section
of Chapter 5 -- Chassis.
1
Figure 7
1. Brake pad
2. Pin (2 used)
3. Anti--rattle clip
Workman MDE
Page 4 -- 15
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Brake Master Cylinder
1
4
2
5
3
6
7
RIGHT
FRONT
Figure 8
1. Master cylinder
2. Cap screw
3. Brake pedal
4. Clevis pin
5. Cotter pin
6. Flange head nut
7. Pedal frame
Removal (Fig. 8)
Installation (Fig. 8)
1. Raise and support front hood.
1. Position master cylinder to pedal frame and secure
with cap screws and flange nuts.
2. Remove cotter pin from the clevis pin that connects
master cylinder to brake pedal.
2. Remove plugs from brake lines. Install brake lines to
master cylinder.
3. Clean hydraulic brake line area of master cylinder to
prevent contamination. Remove both brake lines from
master cylinder. Cap ends of brake lines and position
them away from master cylinder.
3. Connect master cylinder to brake pedal with clevis
pin and cotter pin.
4. Lower and secure front hood.
4. Remove flange head nuts from cap screws that se-
cure master cylinder to pedal frame.
5. Bleed brakes (see Bleed Brake System in this chap-
ter). Check brake operation.
5. Pull master cylinder from machine.
Page 4 -- 16
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Brake Master Cylinder Service
Disassembly (Fig. 9)
1
2
1. Remove reservoir and flange seal. Push in on the
push rod so the stop pin can be removed.
12
3
2. Disconnect lower end of the dust cover from the
housing.
3. Push in on the push rod and remove circlip, then re-
move push rod with dust cover and clevis. Remove re-
tainer washer.
4
11
4. Remove primary piston assembly and secondary
piston assembly from cylinder housing.
Inspection
10
9
8
1. Clean all metal parts with isopropyl alcohol, then
clean out and dry grooves and passageways with com-
pressed air. Make sure cylinder bore and component
pieces are thoroughly clean.
7
6
5
Figure 9
1. Reservoir
2. Flange seal
3. Stop pin
4. Secondary piston assy
5. Clevis
6. Jam nut
7. Dust cover
8. Push rod
9. Circlip
10. Retainer washer
11. Primary piston assy
12. Cylinder housing
2. Check cylinder bore, pistons andsprings 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 a film of clean brake fluid to cylinder bore and
piston assemblies.
2. Install secondary piston assembly and primary pis-
ton assembly into cylinder.
3. Install retainer washer.
4. Install push rod and secure in place with circlip.
Install lower end of dust cover to housing.
5. Push in on push rod so stop pin can be installed to
retain secondary piston assembly, then install flange
seal and reservoir.
Workman MDE
Page 4 -- 17
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Parking Brake
11
10
1
2
9
8
7
6
17
16
5
4
14
15
13
12
3
RIGHT
FRONT
Figure 10
1. Parking brake cover
2. Operator seat
3. Seat base
4. Cable equalizer bracket
5. Parking brake lever
6. Curved washer
7. Lock nut
13. Cotter pin
8. Flat washer
14. Clevis pin
9. Flange head screw (4 used)
10. Flat washer (2 used)
11. Screw (2 used)
15. Parking brake cable (2 used)
16. Parking brake support
17. Cable retaining ring (2 used)
12. Cap screw
Page 4 -- 18
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Disassembly (Fig. 10)
Assembly (Fig. 10)
1. Park machine on a level surface, stop engine and re-
move key from the ignition switch. Chock wheels to pre-
vent the machine from moving.
1. Secure brake cables to parking brake support and
cable equalizer bracket using Figure 10 as a guide.
2. Route brake cables through seat base opening tak-
ing care to not damage cables. Position parking brake
support to seat base.
2. Disconnect both parking brake cables from rear of
machine:
A. Remove cotter pin and clevis pin that secures
each parking brake cable end to brake lever.
3. Secure parking brake support to seat base with four
(4) flange head screws.
B. Remove retaining ring that secures each parking
brake cable to frame.
4. Positionbrakecablestorearbrakeassembliesusing
cable routing noted during disassembly.
C. Remove screw and flange nut that secure each
R--clamp to rear frame.
5. Secure brake cables to rear of machine:
A. Secure each R--clamp to rear frame with screw
and flange nut.
3. Note routing of brake cables for assembly purposes.
4. Remove parking brake cover from seat base.
B. Secure each parking brake cable to frame with
retaining ring.
5. Remove four (4) flange head screws that secure
parking brake support to seat base.
C. Secure each parking brake cable end to brake le-
ver with clevis pin and cotter pin.
6. Carefully remove parking brake support and brake
cables from machine. Take care to not damage brake
cables while removing them from seat base opening.
6. Check parking brake operation and adjust if neces-
sary.
7. Remove brake cables from parking brake support
and cable equalizer bracket using Figure 10 as a guide.
Workman MDE
Page 4 -- 19
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Transaxle
23
115 to 125 in--lb
(13.0 to 14.1 N--m)
2
3
4
6
5
3
7
8
9
22
10
11
20
16
15
13
45 to 65 ft--lb
(61 to 88 N--m)
14
2
1
19
21
18
12
RIGHT
17
v
FRONT
24
Figure 11
1. Socket head screw (6 used)
2. Flange nut
9. Roll pin (2 used)
10. Washer
17. Cotter pin
18. Clevis pin
19. Parking brake cable
20. Transaxle vent hose
21. Flat washer (6 used)
22. Negative battery cable
23. Positive battery cable
24. Retaining ring
3. Carriage screw (5 used)
4. Support bracket
5. Transaxle mount plate
6. Rubber damper
7. Traction motor
11. Socket head screw
12. Lug nut (5 used per wheel)
13. Wheel assembly
14. Brake drum
15. Transaxle
16. Flange head screw (4 used)
8. Fan
Page 4 -- 20
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Removal (Fig. 11)
8. Clean hydraulic brake line area of rear brake cylin-
ders to prevent contamination. Loosen and disconnect
hydraulic brake line from both wheel cylinders. Plug
brake lines and position them away from wheel cylin-
ders.
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 (see Cargo Box Re-
moval in Service and Repairs section of Chapter 5 --
Chassis).
9. Attach hoist to the transaxle and motor assembly.
Make sure lifting device is attached so it can hold the full
weight of the transaxle and traction motor.
3. Open the battery circuit by carefully removing one of
the battery cables (see Opening Battery Circuit in the
General Information section of Chapter 3 -- Electrical
System).
10.Loosen and remove two (2) flange nuts and carriage
screws that secure transaxle mount plate (item 5) to
support bracket (item 4) (Fig. 14).
NOTE: Label all electrical leads for assembly pur-
poses.
11.Remove four (4) flange head screws and flange nuts
securing the transaxle to the rear frame.
IMPORTANT: When removing cables from traction
motor terminals (A1, A2, F1 and F2), use a wrench to
retain lower nut before loosening upper nut (Fig.
12). If terminal studs are allowed to turn during up-
per nut removal, internal motor damage can occur.
12.Carefully lower transaxle and motor assembly from
the rear of the vehicle.
13.If necessary, remove traction motor from transaxle
(see Traction Motor Removal in Service and Repairs
section of Chapter 3 -- Electrical System).
4. Disconnect cables from traction motor:
A. While retaining lower nut, remove upper nut and
cable connector from motor terminals A1, A2, F1 and
F2.
1
B. Unplug motor temperature sensor from vehicle
wire harness.
C. Position disconnected cables away from motor.
2
WARNING
Figure 12
1. Loosening/tightening wrench (upper nut)
2. Retaining wrench (lower nut)
Before jacking up the vehicle, review and follow
Jacking Instructions in Operator’s Manual and in
Chapter 1 -- Safety.
5. Jack up rear of vehicle enough to remove rear
wheels.
3
4
A. Chock the front and rear of both front tires to pre-
vent the vehicle from moving.
2
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 vehicle.
1
6. Remove rear wheels from vehicle.
7. Remove cotter pins and clevis pins that secure park-
ing brake cables to brake actuator levers (Fig. 13). Posi-
tion brake cables away from transaxle assembly.
Figure 13
1. Cotter pin
2. Clevis pin
3. Brake cable bracket
4. Brake actuator lever
Workman MDE
Page 4 -- 21
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Installation (Fig. 11)
8. Carefully connect removed battery cable to battery
terminals. Installlock washers and nuts on battery termi-
nals. Torque nuts from 115 to 125 in--lb (13.0 to 14.1
N--m).
1. If removed, install traction motor to transaxle (see
Traction Motor Installation in Service and Repairs sec-
tion of Chapter 3 -- Electrical System).
9. Install cargo box to the rear frame (see Cargo Box
Installation in Service and Repairs section of Chapter 5
-- Chassis).
2. Position transaxle and motor assembly to the rear
frame. Loosely install all fasteners used to secure trans-
axle to vehicle. Tighten fasteners in the following order:
10.Check brakes for proper operation.
A. Tighten four (4) flange head screws and flange
nuts that secure transaxle to the rear frame.
B. Tighten two (2) flange nuts and carriage screws
that secure transaxle mount plate (item 5) to support
bracket (item 4).
1
2
3. Install parking brake cables to brake actuator levers
with clevis pins and cotter pins.
3
4. Position and secure hydraulic brake lines to wheel
cylinders (Fig. 3). Torque banjo bolts from 15 to 21 ft--lb
(21 to 28 N--m).
5. Position wheel assemblies to the vehicle with valve
stems facing out. Secure each wheel with five (5) lug
nuts.
Figure 14
1. Support bracket
3. Transaxle mount plate
6. Lower vehicle from jackstands. Torque lug nuts in a
crossing pattern from 45 to 65 ft--lb (61 to 88 N--m).
2. Carriage screws/nuts
7. Connect wires to traction motor (Fig. 15):
85 to 90 in--lb
(9.6 to 10.2 N--m)
55 to 60 in--lb
(6.2 to 6.8 N--m)
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 terminal studs are allowed to
turn during upper nut installation, internal motor
damage can occur.
A. Install cable connector and upper nut to motor
terminals A1 and A2. While retaining lower nut,
torque upper nut on terminals A1 and A2 from 85 to
90 in--lb (9.6 to 10.2 N--m).
B. Install cable connector and upper nut to motor
terminals F1 and F2. While retaining lower nut,
torque upper nut on terminals F1 and F2 from 55 to
60 in--lb (6.2 to 6.8 N--m).
55 to 60 in--lb
(6.2 to 6.8 N--m)
C. Plug motor temperature sensor connector into
vehicle wire harness.
Figure 15
Page 4 -- 22
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Workman MDE
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Transaxle Service
37
22
3
38
1
35
31
30
27
8
11
5
12
25
32
6
9
10
6
5
11
26
13
36
14
23
13
15
33
32
29
4
28
24
20
19
2
30
36
15
125 to 140 ft--lb
(170 to 190 N--m)
31
26
19
18
25
26 to 30 ft--lb
16
(34 to 41 N--m)
17
2
7
33
8
32
34
29
32
14
16 to 24 ft--lb
(22 to 33 N--m)
21
39
20 to 30 ft--lb
(27 to 41 N--m)
Figure 16
1. Oil seal
2. Bearing cap bolt (2 used per cap)
3. Input shaft
14. Wheel stud (5 used per hub)
15. Ball bearing (2 used)
16. Differential assembly
17. Hex screw (4 used)
18. Lock nut (4 used)
19. Bearing cap (2 used)
20. Final drive gear
21. Screw (10 used)
22. Ball bearing
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)
33. Ball bearing (2 used)
34. Gasket
35. Retaining ring
36. Flange nut (2 used)
37. O--ring
38. Ball bearing
39. Plug
4. Intermediate shaft & gear
5. Retaining ring (2 used)
6. O--ring (2 used)
7. Cover plate
8. Wheel hub (2 used)
9. Ball bearing
10. Ball bearing
23. Vent elbow
11. Endcap plug (2 used)
12. Transaxle housing
13. O--ring (2 used)
24. Plug
25. Socket head screw (4 used per brake)
26. Lock nut (4 used per brake)
NOTE: For service of the transaxle, see the Spicer Off--
Highway Components Model 12 (Electric) Maintenance
Manual at the end of this chapter.
Page 4 -- 24
Workman MDE
Transaxle and Brakes
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Chapter 5
Chassis
Table of Contents
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 1
Operator’s Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 1
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . 3
Suspension and Steering . . . . . . . . . . . . . . . . . . . . . 3
ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1
Adjust Front Wheel Camber . . . . . . . . . . . . . . . . 4.1
Adjust Front Wheel Toe--in . . . . . . . . . . . . . . . . . . 4.2
SERVICE AND REPAIRS . . . . . . . . . . . . . . . . . . . . . . 5
Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspect Tires and Wheels . . . . . . . . . . . . . . . . . . . . 5
Upper 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 Below 311000000) . . 22
Cargo Box (Serial Number Above 311000000) . 24
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 Opera-
tor’s Manual for additional information when servicing
the machine.
Rev. A
Workman MDE
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Specifications
Item
Description
8 to 22 PSI (55 to 152 kPa)
8 to 22 PSI (55 to 152 kPa)
45 to 65 ft--lb (61 to 88 N--m)
DOT 3
Front tire (22 x 9.5 -- 10, 4 ply) pressure
Rear tire (22 x 9.5 -- 10, 4 ply) pressure
Wheel lug nut torque (front and rear)
Brake Fluid
Special Tools
Order 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 that vehicle is jacked up
off the ground to allow shock spring to be at full exten-
sion before using spanner wrench.
Toro Part Number: TOR6010
Figure 1
Shock Spring Compressor
Use shock spring compressor to remove spring from
front shock absorber.
Toro Part Number: TOR6015
Figure 2
Rev. A
Chassis
Page 5 -- 2
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Troubleshooting
Suspension and Steering
Problem
Possible Cause
Front end is noisy.
Front wheel lug nuts are loose.
Front wheel bearings are loose or worn.
Front end components are loose or worn.
Steering gearbox is damaged or worn.
Rear wheel lug nuts are loose.
Rear end is noisy.
Transaxle problem (see Chapter 4 -- Transaxle and Brakes).
Front wheel lug nuts are loose.
Excessive steering play.
Front wheel bearings are loose or worn.
Steering linkage is loose or worn.
Tie rod ends are loose or worn.
Steering gearbox is damaged or worn.
Front wheel lug nuts are loose.
Front end shimmies.
Front wheel bearings are loose or worn.
Front wheel alignment (toe--in) is incorrect.
Steering linkage is loose or worn.
Tie rod ends are loose or worn.
Bushings in A--arm are worn.
Vehicle is unstable or wanders.
Tire pressure is low or uneven between tires.
Wheel lug nuts are loose.
Front wheel bearings are loose.
Front wheel alignment (toe--in) is incorrect.
Steering column bushings are worn.
Bushings in A--arm are worn.
Steering gearbox is damaged or worn.
Workman MDE
Page 5 -- 3
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Suspension and Steering (continued)
Problem
Possible Cause
Steering is hard.
Tire pressure is low 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 is low or uneven between tires.
Front wheel alignment (toe--in) is incorrect.
Steering or suspension component is bent or damaged.
Chassis
Page 5 -- 4
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Adjustments
Adjust Front Wheel Camber
1. Adjust front tire pressures to 12 PSI (82 kPa) before
checking front wheel camber.
7. Repeat steps 2 through 6 until front wheel camber on
both wheels is correct.
2. Either add weight to the driver’s seat equal to the av-
erage operator who will run the machine or have an op-
erator on the vehicle operator’s seat. The weight or
operator must remain on the seat for the duration of this
front wheel camber procedure.
8. After camber adjustment, check front wheel toe--in
(see Adjust Front Wheel Toe--in in this section).
1
3. On a level surface, roll the vehicle straight back from
6 to 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.
3
4. Make sure that the front wheels are facing straight
ahead.
5. Measure the front wheel camber on both front
wheels:
4
A. Place a 90o square on the ground with the vertical
edge touching the face of the tire (Fig. 2.1).
2
B. From the same part of the rim, measure the dis-
tance from the top and bottom of the rim to the
square. Record the two (2) measurements.
Figure 2.1
1. Front wheel
3. Top measurement
4. Bottom measurement
o
2. 90 square
C. The measurement at 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.
3
1
6. If camber measurement for either wheel is incorrect,
adjust shock absorber spring to correct camber for that
wheel:
A. Chock wheels to prevent the vehicle from mov-
ing. Use a jack to raise vehicle and allow shock ab-
sorber to extend. This will allow easier shock spring
adjustment.
2
B. Use spanner wrench (TOR6010: see Special
Tools in this chapter) to rotate shock absorber collar
which changes the length of the shock spring (Fig.
2.2). If the bottom camber measurement was too
short, rotate the collar to reduce the length of the
shock spring. If the bottom camber measurement
was too long, rotate the collar to increase the length
of the shock spring.
Figure 2.2
1. Shock absorber spring
2. Collar
3. Spring length
C. Lower vehicle to level surface.
Workman MDE
Chassis
4.1 Rev. A
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Adjust Front Wheel Toe--in
NOTE: Before adjusting front wheel toe--in, make sure
that front wheel camber is correctly adjusted (see Adjust
Front Wheel Camber in this section).
1. Adjust front tire pressures to 12 PSI (82 kPa) before
checking front wheel camber.
1
2. Either add weight to the driver’s seat equal to the av-
erage operator who will run the machine or have an op-
erator on the vehicle operator’s seat. The weight or
operator must remain on the seat for the duration of this
front wheel camber procedure.
2
3
3. On a level surface, roll the vehicle straight back from
6 to 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.
Figure 2.3
1. Tire center line (back)
2. Tire center line (front)
3. Axle center line
4. Make sure that the front wheels are facing straight
ahead.
5. Measure distance between the front tires at axle
height at both the front and rear of the tires (Fig. 2.3).
Front wheel toe--in should be from 0 to 1/4 inch (0 to 6
mm).
2
6. Ifthefrontwheeltoe--inis incorrect, adjustasfollows:
1
A. Loosen jam nuts at both ends of tie rods
(Fig. 2.4).
B. Rotate both tie rods to move front of tire inward or
outward.
1
Figure 2.4
C. Tighten tie rod jam nuts when toe--in adjustment
is correct.
1. Jam nut
2. Tie rod
7. Ensure that there is full steering travel in both direc-
tions.
4.2 Rev. A
Chassis
Page 5 --
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Service and Repairs
Check Tire Pressure
The tire pressure range for front and rear tires is 8 to 22
PSI (55 to 152 kPa). The tire pressure needed is deter-
mined by the payload carried.
Higher pressures should be used for heavier payloads
at higher speeds. Do not exceed the maximum tire pres-
sure.
Lower air pressure will provide less compaction, a
smoother ride and fewer tire marks. Lower pressure
shouldnotbeusedfor heavy payloads athigher speeds.
Inspect Tires and Wheels
Operating accidents, such as hitting curbs, can damage
a tire or rim and also disrupt wheel alignment, so inspect
wheel condition (tire and rim) and wheel alignment (toe--
in) after any accident.
If desired, tires can be moved from one position of the
vehicle to another to extend tread life (e.g. front tires to
rear and rear tires to front). All tires are the same size.
Check wheels to ensure they are mounted securely.
Torque wheel lug nuts (front and rear) from 45 to 65 ft-lb
(61 to 88 N--m).
Workman MDE
Page 5 -- 5
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Upper Steering
18 to 22 ft--lb
(25 to 29 N--m)
1
RIGHT
2
16
FRONT
11
3
175 to 225 in lb
(20 to 25 N--m)
Antiseize
lubricant
13
10
12
10
15
5
14
8
Loctite #242
7
9
4
7
6
Antiseize
lubricant
Figure 1
1. Hex nut
7. Lock washer (6 used)
8. Steering shaft
9. Cap screw (4 used)
10. Bearing (2 used)
11. Carriage bolt (4 used)
12. Steering column
13. Dust cover
2. Flat washer
3. Steering wheel
4. Flange nut (4 used)
5. Steering box assembly
6. Cap screw
14. Collar
15. Set screw
16. Steering wheel cover
Disassembly (Fig. 1)
3. Carefully remove steering wheel cover from the
steering wheel. Remove nut and flat washer securing
the steering wheel to the steering shaft. Pull steering
wheel from the shaft.
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
2. Raise front hood to gain access to the steering com-
ponents.
4. Remove cap screw and lock washer securing the
lower steering shaft knuckle to the steering gearbox in-
put shaft. Pull knuckle from the gearbox shaft.
Chassis
Page 5 -- 6
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5. Support steering column to prevent it from falling.
Remove four (4) flange nuts and carriage screws secur-
ing the steering column to the mounting plate on the
frame.
5. Position knuckle of the lower steering shaft onto the
gearbox input shaft. Secure knuckle to the steering
gearbox shaft with cap screw and lock washer.
6. Make sure that collar (item 14) is just below steering
column. If necessary, re--position collar on steering
shaft. Apply Loctite #242 (or equivalent) to collar set
screw and secure collar with set screw.
6. Remove dust cover (item 13) from the steering shaft.
Replacecover ifdamaged. Slidesteering shaftoutofthe
steering column.
7. Disconnect both tie rods from the Pitman arm on the
steering gearbox (see Lower Steering and Front Wheel
Removal in this section).
7. Place dust cover onto the steering shaft.
8. Connect both tie rods to the Pitman arm on the steer-
ing gearbox (see Lower Steering and Front Wheel
Installation in this section).
8. Remove four (4) cap screws and lock washers that
secure the steering gearbox to the tower plate on the
front frame. Remove gearbox from the tower plate.
NOTE: Apply antiseize lubricant to the steering shaft
taper before installing the steering wheel.
Assembly (Fig. 1)
9. Position front tires straight ahead. Slide steering
wheel onto the steering shaft so that the leg of the “Y”
formed by the wheel struts is directed towards the oper-
ator platform.
1. Position steering gearbox to the tower plate of the
front frame with the Pitman arm facing down and to the
rear. The gearbox shaft must be to the left side of the
tower.
10.Secure steering wheel to shaft with flat washer and
nut. Torque nut from 18 to 22 ft--lb (25 to 29 N--m).
Install steering wheel cover to wheel.
2. Secure steering gearbox to the tower plate with four
(4) cap screws and lock washers. Torque screws from
175 to 225 in--lb (20 to 25 N--m).
11.Lower front hood.
3. Make sure that collar (item 14) is positioned on steer-
ing shaft. Insert steering shaft up through the steering
column.
12.Check front wheel alignment and adjust if necessary.
13.Make sure that front wheels move fully in both direc-
tions without contacting any front end components.
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 gear-
box input shaft before installing to steering shaft
knuckle.
Workman MDE
Page 5 -- 7
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Steering Gearbox
27 to 33 ft--lb
(37 to 44 N--m)
9
90 to 110 in--lb
(10.2 to 12.4 N--m)
8
3
6
2
18
15
17
10
16
7
14
1
4
6
11
10
12
175 to 225 in--lb
(20 to 25 N--m)
5
13
19
Matchmark before disassembly
Figure 2
8. Stepped washer
1. Gasket
14. Lube fitting
2. Hex washer head screw (3 used)
3. Seal
9. Flange head screw with patch lock
10. Ball bearing
15. Steering housing cover
16. Steering housing
17. Pinion gear
4. Sector gear
11. Input shaft spacer
5. Flat washer
12. Flat washer
13. Flange head screw with patch lock
18. Oil seal
6. Ball bearing
19. Pitman arm
7. Output shaft spacer
Chassis
Page 5 -- 8
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Disassembly (Fig. 2)
2. If seals were removed, press new seals into housing.
Seal lips should be facing up.
IMPORTANT:Do not reuse flange head screw with
patch lock after it has been removed.
3. Place flat washer (item 5) onto shaft of the Pitman
arm (item 19). Insert shaft into steering housing.
1. Remove flange head screw with patch lock (item 9)
and stepped washer (item 8) from Pitman arm. Discard
flange head screw.
IMPORTANT:The position of the Pitman arm and
sector gear is critical during gearbox assembly. If ei-
ther or both of these parts is replaced, make sure
their alignment matches the matchmark position of
the original gear and arm.
2. Remove flange head screw with patch lock (item 13)
and flat washer (item 12) from pinion gear shaft. Discard
flange head screw.
4. Position sector gear (item 4) onto the spline of the
Pitman arm shaft.
3. Remove three (3) hex washer head screws (item 2)
securing the housing cover and gasket to the steering
housing. Remove cover and gasket from the housing.
Replace gasket if damaged.
IMPORTANT:Make sure sector gear is centered to
the pinion gear.
4. Inspect gears. Sector and pinion gear teeth must be
free of damage that prevents them of free movement.
5. Insert pinion gear (item 17) into the small bearing in
the steering housing.
5. Remove pinion gear (item 17) from the housing.
6. Fill steering housing with number 2 general purpose
grease. Make sure all gear teeth on the sector and pin-
ion gears are covered with grease.
IMPORTANT:Matchmark pitman arm shaft and sec-
tor gear. Their position is critical during reassembly.
7. Place gasket and steering housing cover onto the
housing. Secure cover to housing with three (3) hex
washer head screws (item 2). Torque screws from 90 to
110 in--lb (10.2 to 12.4 N--m).
6. Separate Pitman arm (item 19) from the sector gear
(item 4) and steering housing and remove from the
housing.
7. Inspect bearings. Bearings must spin smoothly and
be free of damage. Press bearings and spacer out of
housing if necessary.
IMPORTANT:Flange head screws with patch lock
(items 9 and 13) should be replaced whenever they
are removed.
8. Inspect seals. Seals must be free of rips and tears.
Replace seals if necessary.
8. Secure stepped washer and flange head screw with
patch lock (item 9) to the Pitman arm (item 8). Make sure
to position stepped washer as shown in Figure 2. Torque
screw from 27 to 33 ft--lb (37 to 44 N--m).
Assembly (Fig. 2)
IMPORTANT:Always replace ball bearings as a set.
1. If ball bearings were removed:
9. Secure flat washer (item 12) and flange head screw
with patch lock (item 13) to the pinion gear shaft. Torque
screw from 175 to 225 in--lb (20 to 25 N--m).
A. Press new bearing into housing from the inside
first.
10.After assembly is completed, make sure that pitman
arm rotates freely from stop to stop without binding.
B. Turn housing over. Insert spacer and press new
bearing into housing.
Workman MDE
Page 5 -- 9
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Lower Steering and Front Wheels
20 to 25 ft--lb
(28 to 33 N--m)
12
14
7
4
3
19
6
See text for
tightening procedure
1
7
6
5
2
8
9
32
31
6
10
17
16
25
24
15
13
11
30
29
22
45 to 55 ft--lb
(62 to 74 N--m)
28
27
21
23
20
26
Loctite #242
RIGHT
FRONT
45 to 65 ft--lb
(62 to 88 N--m)
18
Figure 3
1. Steering gearbox pitman arm
2. Shock absorber (2 used)
3. Cotter pin
12. RH A--arm
23. Brake caliper (LH shown)
24. Lock washer (2 used per caliper)
25. Cap screw (2 used per caliper)
26. Grease fitting
27. Ball joint (LH threads)
28. Jam nut (LH threads
29. Tie rod tube
30. Jam nut (RH threads)
31. Ball joint (RH threads)
32. Spindle (LH shown)
13. Jam nut
14. Front frame
15. Nut retainer
16. Dust cap
4. Slotted hex nut
5. Flat washer
6. Lock nut (3 used per side)
7. Cap screw (2 used per shock)
8. LH A--arm
17. Wheel assembly
18. Lug nut (5 used per wheel)
19. Cap screw (2 used per A--arm)
20. Cotter pin
9. Brake rotor
10. Wheel hub assembly
11. Tab washer
21. Wheel stud (5 used per hub)
22. Socket head screw (4 used per rotor)
Chassis
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Removal (Fig. 3)
6
4
5
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition.
3
7
WARNING
2
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
8
2. Chock wheels not being jacked up. Jack front wheel
off the ground and support vehicle with appropriate jack
stand beneath the frame.
9
Loctite #242
1
Figure 4
3. Remove lug nuts and pull wheel assembly from ma-
chine.
1. Outer bearing cone
2. Outer bearing cup
3. Wheel hub
6. Inner bearing cone
7. Seal
8. Socket screw (4 used)
9. Wheel stud (5 used)
4. Brake rotor
4. Remove brake caliper from spindle (see Front Brake
Caliper inthis section). Positioncaliper away fromwheel
hub and spindle.
5. Inner bearing cup
5. Carefully pry dust cap from wheel hub.
1
6. Remove cotter pin and nut retainer from spindle.
2
7. Remove jam nut that secures wheel hub to spindle.
Slide wheel hub with bearings and brake rotor from
spindle.
75 to 100 ft--lb
(102 to 135 N--m)
8. Disassemble the wheel hub (Fig. 4):
A. Pull the seal out of the wheel hub.
3
B. Remove bearings from both sides of the wheel
hub. Clean bearings in solvent. Make sure bearings
are in good operating condition. Clean the inside of
the wheel hub. Check the bearing cups for wear, pit-
ting or other noticeable damage. Replace worn or
damaged parts.
4
5
6
Figure 5
C. If necessary, remove wheel studs and brake rotor
from wheel hub.
1. Cap screw
2. Brake hose clip
3. A--arm (LH shown)
4. Kingpin sleeve
5. Thrust washer
6. Lock nut
9. Remove spindle (Fig. 5):
Installation (Fig. 3)
A. Remove cotter pin and castle nut securing tie rod
ball joint to the spindle. Separate ball joint from the
spindle. Remove tie rod from steering gearbox pit-
man arm if necessary.
1. Install spindle as follows (Fig. 5):
A. Make sure king pin sleeve is positioned into the
pivot hub of the A--arm. Sleeve must extend through
the bottom of the hub.
B. Remove lock nut and cap screw securing the
spindle to the A--arm. Separate spindle from A--arm.
B. Place thrust washer onto the bottom of the king
pin sleeve. Then place spindle over the A--arm hub,
king pin sleeve and thrust washer.
C. Locate and remove thrust washer from bottom of
kingpin sleeve in A--arm and brake hose clip from top
of A--arm. Remove kingpin sleeve from A--arm if nec-
essary.
NOTE: Make sure cap screw is inserted down
through the spindle and A--arm hub.
Workman MDE
Page 5 -- 11
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C. Install brake hose clip onto cap screw. Secure
spindle to A--arm hub with cap screw and lock nut.
Torque fasteners from 75 to 100 ft--lb (102 to 135
N--m).
4. Slide wheel hub assembly onto spindle. Install outer
bearing, tab washer and jam nut onto spindle.
5. Rotate the wheel by hand and tighten the jam nut
from 75 to 100 in-lb (8.5 to 11.3 N--m) to set the bear-
ings. Then, loosen the nut until the hub has end play.
2. Install tie rod:
A. Position tie rod assembly to spindle and pitman
arm so that tie rod groove (LH threads) is orientated
toward the left side of the machine (Fig. 6).
6. Again, rotate the wheel by hand and tighten the jam
nut from 15 to 20 in-lb (1.7 to 2.3 N--m).
7. Position nut retainer over jam nut and install cotter
pin through spindle shaft hole. Install dust cap to hub.
B. Insert tie rod ball joints down through the spindle
and up through the Pitman arm. Secure with castle
nuts.
8. Install brake caliper to spindle (see Front Brake Cali-
per in this section).
C. Torque castle nuts from 20 to 25 ft--lb (28 to 33
N--m) to secure ball joint while aligning castle nut slot
with hole in ball joint stud. If necessary to align holes,
castle nut torque may be slightly more than specifi-
cation. Install cotter pin.
9. Install wheel assembly with valve stem facing out.
10.Lower machine to ground.
11.Torque wheel lug nuts in a crossing pattern from 45
to 65 ft--lb (62 to 88 N--m).
3. Assemble wheel hub (Fig. 4):
12.Lubricate tie rod ball joints and king pin.
13.Align steering and toe--in.
A. If bearing cups were removed from the wheel
hub, press inner and outer cups into the hub until
they seat against the hub shoulder.
14.Make sure that front wheels move fully in both direc-
tions without contacting any front end components.
B. Pack both bearings with grease. Install inner
bearingintothecuponinboardsideofthewheelhub.
IMPORTANT: The wheel hub seal must be
pressed in so it is flush with the end of the hub.
The lip of the seal must be toward the inner bear-
ing.
2
3
1
TIE ROD TUBE
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. Apply Loctite #242
(or equivalent) to socket head screws and secure ro-
tor to hub.
Figure 6
1. Tie rod groove
2. LH threads
3. RH threads
Chassis
Page 5 -- 12
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Front Shock Absorbers
Shock Removal (Fig. 9)
IMPORTANT: Any adjustment to the shock spring
preload will affect the front wheel camber (see Ad-
just Front Wheel Camber in the Adjustments sec-
tion of this chapter). Do not make shock spring
adjustment without checking front wheel camber.
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition.
3
WARNING
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
2
2. Chock wheels not being jacked up. Jack front wheel
off the ground and support vehicle with appropriate jack
stand beneath the frame.
2
5
1
4
3. Support a--arm to prevent it from moving after the
shock is removed.
3
4. Remove lock nuts, cap screws and flat washer that
secure shock to frame and a--arm. Remove shock ab-
sorber from vehicle.
Figure 9
1. Shock absorber
2. Cap screw
3. Lock nut
4. A--arm (LH shown)
5. Flat washer
NOTE: Use spanner wrench TOR6010 (see Special
Tools in this chapter) if spring preload requires adjust-
ment. If the spring is to be removed from the shock ab-
sorber, shock spring compressor tool TOR6015 (see
Special Tools in this chapter) can be used.
Shock Installation (Fig. 9)
1. Position shock absorber to frame and a--arm brack-
ets.
2. Secure shock absorber to vehicle.
A. Slide upper cap screw through frame mounting
holes and upper shock eye.
B. Slide lower cap screw through flat washer, lower
shock eye and a--arm mounting hole.
C. Secure cap screws with lock nuts.
3. Lower vehicle to ground.
Rev. A
Workman MDE
Page 5 -- 13
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A--arms and Front Suspension
20 to 25 ft--lb
(28 to 33 N--m)
12
14
7
4
3
19
6
1
7
See text for
6
5
tightening procedure
8
2
36
34
31
30
6
35
25
24
9
10
17
15
16
13
11
29
32
45 to 55 ft--lb
(62 to 74 N--m)
28
27
22
33
37
21
26
23
20
Loctite #242
RIGHT
FRONT
75 to 100 ft--lb
(102 to 135 N--m)
45 to 65 ft--lb
(62 to 88 N--m)
18
Figure 7
1. Steering gearbox pitman arm
2. Shock absorber (2 used)
3. Cotter pin
4. Slotted hex nut
5. Flat washer
6. Lock nut (3 used per side)
7. Cap screw (2 used per 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
26. Grease fitting
27. Ball joint (LH threads)
28. Jam nut (LH threads
29. Tie rod
17. Wheel assembly
18. Lug 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 screw (4 used per rotor)
23. Brake caliper (LH shown)
24. Lock washer (2 used per caliper)
25. Cap screw (2 used per caliper)
30. Jam nut (RH threads)
31. Ball joint (RH threads)
32. Kingpin sleeve
33. Thrust washer
34. Spindle (LH shown)
35. Brake hose clip
36. Cap screw
37. Lock nut
Chassis
Page 5 -- 14
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A--arm Removal (Fig. 7)
3. Position A--arm to the frame. Secure A--arm to the
frame with cap screws (item 19) and lock nuts (item 6).
Insert front screw from front of machine and rear screw
from rear of machine. Do not fully tighten nuts.
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the on/off
switch.
4. Position lower end of shock absorber to A--arm and
insert cap screw (item 7) with flat washer (item 5) from
rear of shock. Secure with lock nut (item 6).
WARNING
5. Fully tighten lock nuts (item 6) to secure A--arm to
machine frame.
Before jacking up the machine, review and follow
Jacking Instructions in Chapter 1 -- Safety.
6. Install spindle and front wheel to the A--arm (see
Lower Steering and Front Wheel Installation in this sec-
tion).
2. Chock wheels not being jacked up. Jack front wheel
off the ground and support vehicle with appropriate jack
stand beneath the frame.
7. Lower machine to ground. Make sure that wheel lug
nuts are properly torqued in a crossing pattern from 45
to 65 ft--lb (62 to 88 N--m).
3. Remove front wheel and spindle from A--arm (see
Lower Steering and Front Wheel Removal in this sec-
tion).
8. Lubricate tie rod ball joints and king pin.
9. Align steering and toe--in.
4. Remove cap screw (item 7), flat washer (item 5) and
lock nut(item6) that securelower endof shock absorber
to A--arm.
10.Make sure that front wheels move fully in both direc-
tions without contacting any front end components.
5. Support A--arm to prevent it from falling.
6. Remove both cap screws (item 19) and lock nuts
(item 6) that secure A--arm to frame. Pull A--arm from
frame.
2
7. If necessary, remove flange bushings and straight
bushings from A--arm bores (Fig. 8).
8. If necessary, remove cap screw and lock nut that se-
cure upper end of shock absorber to frame. Remove
shock absorber.
3
A--arm Installation (Fig. 7)
1. If bushings were removed from A--arm, press new
bushings fully into bore of A--arm (Fig. 8).
1
2. If shock absorber was removed from frame, position
shock to frame, insert cap screw from front of machine
and secure with lock nut.
Figure 8
1. A--arm
2. Flange bushing
3. Straight bushing
Workman MDE
Page 5 -- 15
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Frame Pivot Yoke
RIGHT
21
4
FRONT
15
1
10
17
16
18
22
3
11
20
13
240 to 290 ft--lb
(326 to 393 N--m)
12
7
14
19
6
7
6
19
5
2
8
6
9
Figure 9
1. Flange nut (4 used)
9. Grease fitting (1 used per arm)
10. Screw
16. Flange head screw (4 used)
17. Flat washer (4 used)
18. Hardened washer
19. Cap screw (2 used per arm)
20. Ground cable
21. Rear frame
22. Parking brake cable (LH shown)
2. Shock absorber (2 used)
3. Cap screw (4 used)
4. Plug
11. Cap screw
12. RH A--arm
13. Lock washer
14. Front frame
15. Pivot yoke
5. Flat washer
6. Lock nut (4 used per side)
7. Cap screw (2 used per shock)
8. LH A--arm
Chassis
Page 5 -- 16
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Pivot Yoke Removal (Fig. 9 and 10)
Pivot Yoke Installation (Fig. 9 and 10)
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the on/off
switch.
WARNING
2. Open the battery circuit by carefully removing one of
the battery cables (see Opening Battery Circuit in the
General Information section of Chapter 3 -- Electrical
System).
Support pivot yoke while installing it to the front
frame to prevent dropping and causing serious
injury and damage to the machine.
1. Position pivot yoke to the front frame so the diamond
pattern faces up. Secure yoke to front frame with four (4)
flange head screws and flanged lock nuts. Tighten lower
two (2) fasteners first, then tighten upper two (2) fasten-
ers.
3. Remove cargo box from the rear frame (see Cargo
Box Removal in this section).
4. Remove seat base from the front frame (see Seat
Base Removal in this section).
2. Secure pivot yoke to the front frame tab with cap
screw and hardened washer. Torque cap screw from
240 to 290 ft--lb (326 to 393 N--m).
WARNING
3. Secure pivot yoke to the rear frame with four (4) cap
screws and flat washers.
Make sure all tires are chocked to prevent the
machine frommoving. Before removingthepivot
yoke, make sure front and rear frames are
supported with jack stands. Support both the
front and back of each frame.
4. Install seat base to the front frame (see Seat Base
Installation in this section).
5. Install cargo box to the rear frame (see Cargo Box
Installation in this section).
5. Remove four (4) cap screws and flat washers secur-
ing the pivot yoke to the rear frame.
6. Reconnect removed battery cable to battery termi-
nals. Install lock washer and nut on battery terminals.
Torque nuts from 115 to 125 in--lb (13 to 14.1 N--m).
6. Remove cap screw and hardened washer securing
the pivot yoke to the front frame tab.
3
2
WARNING
2
Support pivot yoke while removing it from the
front frame to prevent dropping and causing
serious injury and damage to the machine.
1
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.
4
6
5
Figure 10
1. Pivot yoke
4. Flange lock nut
5. Front frame
2. Cap screw & flat washer
3. Rear frame
6. Diamond pattern
Workman MDE
Page 5 -- 17
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Seat Base
26
24
25
RIGHT
35
23
36
27
28
29
FRONT
30
19
31
32
18
20
33
34
17
16
1
15
14
2
13
3
5
12
21
22
4
6
7
8
9
10
11
10
Figure 11
1. Seat
13. Screw (4 used)
25. Cotter pin
2. Seat bracket
14. Washer head screw (4 used)
15. Charger receptacle plate
16. Charger receptacle
17. Socket mount bracket
18. Charger interlock switch
19. Pop rivet (2 used)
26. Parking brake cover
27. Screw (2 used)
28. Flat washer (2 used)
29. Retaining ring (2 used)
30. Parking brake support
31. Clevis pin
3. Rubber receptacle
4. Rivet
5. Cap screw (4 used per seat)
6. Screw
7. Holding post
8. Seat base
20. Lock nut (2 used)
32. Cap screw
9. Seat base tray
10. Flange head screw (8 used)
11. Flat washer (4 used)
12. Front frame
21. Charger wire harness
22. Socket head screw (2 used)
23. Lock nut
33. Flange head screw (4 used)
34. Brake cable equilizer
35. Curved washer
24. Flat washer
36. Parking brake lever
Chassis
Page 5 -- 18
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Removal (Fig. 11)
1
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the on/off
switch.
2. Open the battery circuit by carefully removing one of
the battery cables (see Opening Battery Circuit in the
General Information section of Chapter 3 -- Electrical
System).
2
3. Remove seats from seat base.
4. Remove four (4) screws (item 12) that secure recep-
tacleplatetofrontofseatbase. Unplugcharger wirehar-
ness from vehicle wire harness and remove receptacle
plate assembly from vehicle.
Figure 12
1. Negative cable to vehicle
2. Positive cable to vehicle
5. Remove parking brake assembly from seat base
(see Parking Brake in the Service and Repairs section
of Chapter 4 -- Transaxle and Brakes).
6. Remove eight (8) flange head screws (item 10) that
secure seat base to vehicle. Locate and retrieve flat
washers (item 11) from screws that secure front of seat
base.
7. Carefully 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 head screws (item 10) through
holes in front frame and into rear seat base threaded in-
serts. Install four (4) flange head screws (item 10) and
flat washers (item 11) through holes in front frame and
into front seat base threaded inserts.
3. Starting at the middle of the vehicle, tighten flange
head screws to secure seat base to vehicle.
4. Install parking brake assembly to seat base (see
Parking Brake in the Service and Repairs section of
Chapter 4 -- Transaxle and Brakes).
5. Connect charger wire harness to vehicle wire har-
ness. Secure receptacle plate to seat base with four (4)
screws (item 12).
6. Install seats to vehicle.
7. Connect removed battery cable to battery terminals.
Install lock washer and nut on battery terminals. Torque
nuts from 115 to 125 in--lb (13.0 to 14.1 N--m).
Workman MDE
Page 5 -- 19
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Front Hood
32
7
7 to 13 in--lb
(0.8 to 1.4 N--m)
2
24
23
20
22
28
7 to 13 in--lb
(0.8 to 1.4 N--m)
11
16
15
12
19
27
12
14
3
8
9
1
29
17
25
12
30
26
RIGHT
18
6
21
4
5
FRONT
10
31
13
Figure 13
1. Fender (LH shown)
2. Lock nut (4 used)
3. Flat washer (2 used)
4. Front bumper
12. Washer head screw (8 used)
13. Carriage screw (2 used)
14. Lock nut (2 used)
23. Catch (2 used)
24. Flat washer (4 used)
25. Flange head screw (10 used)
26. Clip (3 used per headlight)
27. Flat washer (2 used)
28. Retainer (2 used)
15. Pivot pin (2 used)
5. Headlight (2 used)
16. Spring pin (2 used)
6. Washer (3 used per headlight)
7. Hood
8. Fender well (LH shown)
9. Cap screw (2 used)
10. Hood pivot keeper (2 used)
11. Screw (6 used)
17. Headlight bracket
18. Flange head screw (2 used)
29. Flange nut (2 used)
30. Tinnerman nut (10 used)
31. Headlight bulb (24V) (2 used)
32. Foam seal
19. Washer head screw (20 used)
20. Washer head screw (4 used)
21. Flange nut (2 used)
22. Rubber latch (2 used)
Chassis
Page 5 -- 20
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Removal (Fig. 13)
1
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the on/off
switch.
2. Open the battery circuit by carefully removing one of
the battery cables (see Opening Battery Circuit in the
General Information section of Chapter 3 -- Electrical
System).
2
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.
Figure 14
1. Negative cable to vehicle
2. Positive cable to vehicle
1. Install hood using Figure 13 as a guide. During as-
sembly, use fastener torque specifications that are iden-
tified in Figure 13.
2. Reconnect removed battery cable to battery termi-
nals. Install lock washer and nut on battery terminals.
Torque nuts from 115 to 125 in--lb (13.0 to 14.1 N--m).
Workman MDE
Page 5 -- 21
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Cargo Box (Serial Number Below 311000000)
5
35 to 55 in--lb
(4 to 6.2 N--m)
6
3
7
8
4
10
11
2
9
1
12
13
35 to 55 in--lb
(4 to 6.2 N--m)
17
14
15
16
15
100 to 200 in--lb
(11.3 to 22.6 N--m)
33
32
31
18
30
19
20
21
22
29
23
24
RIGHT
FRONT
25
26
27
28
Figure 18
1. Cargo box
12. Screw (2 per bracket)
13. Spring
23. Prop rod bracket
24. Flat washer
2. Striker plate (2 used)
3. Screw (3 per striker plate)
4. Tailgate channel
5. RH latch rod
14. Flat washer
25. Push nut
15. Flange head screw (2 per bracket)
16. Pivot bracket (2 used)
17. 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)
26. Latch pin (2 used)
27. Lock nut (2 used)
28. Carriage screw (2 used)
29. Rear frame
6. RH latch bracket
7. Grip knob
8. Tailgate
9. LH latch rod
10. Screw (2 per bracket)
11. LH latch bracket
30. RH pivot bracket
31. Flange head screw (4 used)
32. Tension spring
33. Latch rod
Rev. A
Chassis
Page 5 -- 22
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Removal (Fig. 18)
Installation (Fig. 18)
1. Park vehicle on a level surface, turn on/off switch
OFF, set parking brake and remove key from the on/off
switch.
1. Assemble cargo box using Figure 18 as a guide.
2. Position cargo box to the frame locking the latch rod
(item 33) to the latch pins (item 26).
2. Remove two (2) flange head screws (item 21) that
secure RH and LH pivot brackets (items 20 and 30) to
the rear frame.
3. Secure both pivot brackets (items 20 and 30) to the
rear frame with flange head screws (item 21).
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.
Rev. A
Workman MDE
Page 5 -- 23
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Cargo Box (Serial Number Above 311000000)
15
5
9
1
14
2
200 to 210 in--lb
(22.6 to 23.7 N--m)
12
17
11
16
6
200 to 210 in--lb
(22.6 to 23.7 N--m)
12
7
10
8
RIGHT
FRONT
200 to 210 in--lb
(22.6 to 23.7 N--m)
3
4
13
Figure 19
7. Pivot bushing (2 used)
8. Screw (4 used)
1. Cargo box
13. Latch pin (2 used)
14. Tension spring (2 used)
15. Carriage screw (2 used)
16. Prop rod bracket
2. Handle
3. Carriage screw (2 used)
4. Lock nut (2 used)
5. Carriage screw (4 used)
6. Pivot bracket
9. Carriage screw (4 used)
10. Flange nut (4 used)
11. Prop rod
17. Latch assembly
12. Flange nut (6 used)
Rev. A
Chassis
Page 5 -- 24
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Removal (Fig. 19)
4
1. Park machine on a level surface, stop engine, set
parking brake and remove key from the ignition switch.
3
6
5
2. Disassemble cargo box as necessary using Figures
19 and 20 as guides.
2
12
Installation (Fig. 19)
1
1. Assemble cargo box using Figures 19 and 20 as gui-
des.
11
10
7
9
6
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 latched.
8
6
Figure 20
1. Cargo box
7. LH latch rod
8. Retainer (2 used)
2. Inner tailgate
3. Outer tailgate
4. RH latch rod
5. Latch handle
9. Striker mount (2 used)
10. Strike latch (2 used)
11. Screw (4 used)
6. Screw (24 used)
12. Screw (4 used)
Rev. A
Workman MDE
Page 5 -- 25
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Rev. A
Chassis
Page 5 -- 26
Workman MDE
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Chapter 6
Electrical Diagrams
Table of Contents
ELECTRICAL SCHEMATIC
Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 3
ELECTRICAL CIRCUIT DRAWINGS
On/Off Switch 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 Below 310000000) . . . . . . . . . . . . . . . . . 9
Electrical Harness Drawing (Serial Number
Above 310000000) . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical Harness Wiring Diagram (Serial
Number Above 310000000) . . . . . . . . . . . . . . . . 11
Workman MDE
Page 6 -- 1
Rev. A
Electrical Diagrams
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Page 6 -- 2
Workman MDE
Electrical Diagrams
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F3 10 A
BU
PK
FUSE
HOLDERS
IGNITION--SWITCH
OFF RUN
F2 10 A
R
ACCESSORIES
CONTACTOR
(SOLENOID)
HORN
W
BK
OR
HORN SWITCH
BATT. CHG.
HOOK UP
R/W
R
FL1
HEADLIGHTS, 24V
GN
Y
Y
1
3
4
6
INTERLOCK
CHARGER
SWITCH
(CHARGER
PLUGGED IN)
STATE OF CHARGE
FL2
2
5
INDICATOR
OR
LIGHT SWITCH
BU
A
OR
HOUR METER
BK
2
1
3
4
6
F1
355 A
BU/W
5
BK
FL3
B
BU
A
FORWARD/REVERSE
(IN FORWARD)
BK
B
OPTIONS
FRONT
3 (NC)
2 (NO)
1 48 VDC INPUT
2 FOR/REV
4
1
1
2
3
4
5
6
OR
PROGRAMMER
PORT
MAIN
PK
ACCELERATOR PEDAL SWITCH
(PEDAL NOT PUSHED IN)
CONTACTOR
(SOLENOID)
OPTIONS
REAR
3 ACCELERATOR PEDAL
4 HI/LOW
B+
BU
4 GA
HI / LOW SPEED SWITCH
(IN OFF (HI) POSITION)
Y
M2
F1
5 CHARGER
NC
10 GA
VIO/BK
BU/W
48V BATT ARRAY
6V x 8
6 HIGH TEMP/LOW BATTERY
7 BACKUP ALARM
8 MAIN CONTACTOR
9 DIAGNOSTIC LIGHT
10 ACCELERATOR POT
11 PROGRAMMING
12 12 VDC OUTPUT (100 mA)
13
BK
(DEEP CYCLE)
MOTOR TEMP SENSOR
(180 C)
W/BK
FIELD F1
FIELD F2
A1 ARMATURE
DRIVE MOTOR
DIAGNOSTIC LED
GN
T
A2 ARMATURE
STATE OF CHARGE
INDICATOR
BACKUP ALARM
HORN
(--)
CW
NC
10 GA
4 GA
ACCELERATOR POT
+ 12V
W
F2
M1
B--
BK
BN
SENSE A
SETUP +
1
2
5 SENSE B
6 IGN +
(+)
NC
NC
NC
NC
HR ENABLE
(+)
3
4
7 FET OUT
8 (--)
14
MILLIPAK
GY
SEVCON
CONTROLLER
W
15
16
HOUR METER
BK
PROGRAMMING
SPLICE
Workman MDE
Electrical Schematic
Contactors shown de-energized
Page 6 -- 3
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F3 10 A
BU
PK
FUSE
HOLDERS
IGNITION--SWITCH
OFF RUN
F2 10 A
R
ACCESSORIES
CONTACTOR
HORN
(SOLENOID)
(ENERGIZED)
(IN RUN)
R/W
W
BK
OR
HORN SWITCH
BATT. CHG.
HOOK UP
R
FL1
HEADLIGHTS, 24V
GN
Y
Y
1
3
4
6
FL2
INTERLOCK
CHARGER
SWITCH
(CHARGER NOT
PLUGGED IN)
STATE OF CHARGE
2
5
INDICATOR
OR
LIGHT SWITCH
BU
A
OR
HOUR METER
BK
2
1
3
4
6
F1
355 A
BU/W
5
BK
FL3
BU
A
B
FORWARD/REVERSE
(IN FORWARD)
OPTIONS
FRONT
3 (NC)
2 (NO)
1 48 VDC INPUT
2 FOR/REV
4
1
1
2
3
4
5
6
OR
BK
B
PROGRAMMER
PORT
MAIN
PK
ACCELERATOR PEDAL SWITCH
(PEDAL NOT PUSHED IN)
CONTACTOR
(SOLENOID)
(ENERGIZED)
OPTIONS
REAR
3 ACCELERATOR PEDAL
4 HI/LOW
B+
BU
4 GA
HI / LOW SPEED SWITCH
(IN OFF (HI) POSITION)
Y
M2
F1
5 CHARGER
NC
10 GA
VIO/BK
BU/W
48V BATT ARRAY
6V x 8
6 HIGH TEMP/LOW BATTERY
7 BACKUP ALARM
8 MAIN CONTACTOR
9 DIAGNOSTIC LIGHT
10 ACCELERATOR POT
11 PROGRAMMING
12 12 VDC OUTPUT (100 mA)
13
BK
(DEEP CYCLE)
MOTOR TEMP SENSOR
(180 C)
FIELD F1
FIELD F2
A1 ARMATURE
W/BK
DIAGNOSTIC LED
DRIVE MOTOR
A2 ARMATURE
GN
T
BACKUP ALARM
HORN
(--)
CW
NC
10 GA
4 GA
ACCELERATOR POT
+ 12V
W
F2
M1
B--
BK
BN
(+)
NC
NC
NC
NC
14
MILLIPAK
GY
SEVCON
W
15
16
CONTROLLER
BK
PROGRAMMING
SPLICE
Workman MDE
On/Off Switch Turned On
Power Current
Control Current
Indication Current
Page 6 -- 4
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F3 10 A
BU
PK
FUSE
HOLDERS
IGNITION--SWITCH
OFF RUN
F2 10 A
R
ACCESSORIES
CONTACTOR
(SOLENOID)
HORN
(ENERGIZED)
(IN RUN)
R/W
W
BK
OR
HORN SWITCH
BATT. CHG.
HOOK UP
R
FL1
HEADLIGHTS, 24V
GN
Y
Y
1
3
4
6
FL2
INTERLOCK
CHARGER
SWITCH
(CHARGER NOT
PLUGGED IN)
STATE OF CHARGE
2
5
INDICATOR
OR
LIGHT SWITCH
BU
A
OR
HOUR METER
BK
2
1
3
4
6
F1
355 A
BU/W
5
BK
FL3
B
FORWARD/REVERSE
(IN FORWARD)
BU
A
OPTIONS
FRONT
3 (NC)
2 (NO)
1 48 VDC INPUT
2 FOR/REV
4
1
1
2
3
4
5
6
OR
BK
B
PROGRAMMER
PORT
MAIN
PK
ACCELERATOR PEDAL SWITCH
(PEDAL PUSHED IN)
CONTACTOR
(SOLENOID)
(ENERGIZED)
3 ACCELERATOR PEDAL
4 HI/LOW
B+
M2
F1
BU
OPTIONS
REAR
4 GA
HI / LOW SPEED SWITCH
(IN OFF (HI) POSITION)
Y
5 CHARGER
NC
10 GA
VIO/BK
BU/W
48V BATT ARRAY
6V x 8
6 HIGH TEMP/LOW BATTERY
7 BACKUP ALARM
8 MAIN CONTACTOR
9 DIAGNOSTIC LIGHT
10 ACCELERATOR POT
BK
(DEEP CYCLE)
MOTOR TEMP SENSOR
(180 C)
W/BK
A1 ARMATURE
FIELD F1
FIELD F2
DIAGNOSTIC LED
DRIVE MOTOR
A2 ARMATURE
GN
T
BACKUP ALARM
HORN
(--)
11 PROGRAMMING
CW
NC
ACCELERATOR POT
10 GA
4 GA
+ 12V
W
12 12 VDC OUTPUT (100 mA)
13
F2
BK
BN
(+)
NC
NC
NC
NC
M1
B--
14
MILLIPAK
GY
SEVCON
W
15
16
CONTROLLER
BK
PROGRAMMING
SPLICE
Workman MDE
Run Circuit (Forward)
Power Current
Control Current
Indication Current
Page 6 -- 5
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Page 6 -- 7
Rev. A
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Workman MDE
Serial Number Below 310000000
Electrical Harness Drawing
Page 6 -- 8
Rev. A
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PINK
RED/WHITE
ORANGE
ORANGE
RED
WHITE
ORANGE
RED/WHITE
BLACK
BLUE
BLUE/WHITE
BLACK
BROWN
WHITE/BLACK
BLUE/WHITE
ORANGE
YELLOW
BLUE
PINK
BLACK
BLACK
YELLOW
VIOLET/BLACK
WHITE
BLUE/WHITE
BROWN
GREEN
BLACK
TAN
TAN
TAN
GRAY
BLACK
BLUE
BLACK
BLUE
BLUE
RED/WHITE
BLACK
BLUE
ORANGE
ORANGE
GREEN
BLUE
ORANGE
Workman MDE
Serial Number Below 310000000
Electrical Harness
Wiring Diagram
Page 6 -- 9
Rev. A
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Workman MDE
Serial Number Above 310000000
Electrical Harness Drawing
Page 6 -- 10
Rev. A
Download from Www.Somanuals.com. All Manuals Search And Download.
PINK
RED/WHITE
ORANGE
ORANGE
RED
WHITE
ORANGE
RED/WHITE
BLACK
BLUE/WHITE
BLUE
BLACK
BROWN
WHITE/BLACK
BLUE/WHITE
BLACK
BLUE
YELLOW
BLUE
ORANGE
PINK
PINK
YELLOW
VIOLET/BLACK
WHITE
BLUE/WHITE
BROWN
BLACK
GREEN
TAN
BLACK
TAN
TAN
GRAY
BLACK
BLUE
BLACK
BLUE
BLUE
BLACK
RED/WHITE
BLUE
ORANGE
BLACK
ORANGE
GREEN
VIOLET
GRAY
BLUE
ORANGE
WHITE/BLACK
GREEN
Workman MDE
Serial Number Above 310000000
Electrical Harness
Wiring Diagram
Page 6 -- 11
Rev. A
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Page 6 -- 12
Rev. A
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F3 10 A
BU
PK
FUSE
HOLDERS
IGNITION--SWITCH
OFF RUN
F2 10 A
R
ACCESSORIES
CONTACTOR
HORN
(SOLENOID)
(NOT ENERGIZED)
(OFF)
R/W
W
BK
OR
HORN SWITCH
BATT. CHG.
HOOK UP
R
FL1
HEADLIGHTS, 24V
GN
Y
Y
1
3
4
6
INTERLOCK
CHARGER
SWITCH
STATE OF CHARGE
FL2
2
5
INDICATOR
OR
(CHARGER
PLUGGED IN)
LIGHT SWITCH
BU
A
OR
HOUR METER
BK
2
1
3
4
6
F1
355 A
BU/W
5
BK
FL3
B
FORWARD/REVERSE
(IN FORWARD)
BU
A
OPTIONS
FRONT
3 (NC)
2 (NO)
1 48 VDC INPUT
2 FOR/REV
4
1
1
2
3
4
5
6
OR
PROGRAMMER
PORT
BK
B
MAIN
PK
ACCELERATOR PEDAL SWITCH
(PEDAL NOT PUSHED IN)
CONTACTOR
3 ACCELERATOR PEDAL
4 HI/LOW
B+
(SOLENOID)
BU
OPTIONS
REAR
(NOT ENERGIZED)
4 GA
HI / LOW SPEED SWITCH
(IN OFF (HI) POSITION)
Y
M2
F1
5 CHARGER
NC
10 GA
VIO/BK
BU/W
48V BATT ARRAY
6V x 8
(DEEP CYCLE)
(CHARGING)
6 HIGH TEMP/LOW BATTERY
7 BACKUP ALARM
8 MAIN CONTACTOR
9 DIAGNOSTIC LIGHT
10 ACCELERATOR POT
11 PROGRAMMING
BK
MOTOR TEMP SENSOR
(180 C)
W/BK
FIELD F1
FIELD F2
A1 ARMATURE
DRIVE MOTOR
A2 ARMATURE
DIAGNOSTIC LED
GN
T
BACKUP ALARM
HORN
(--)
CW
NC
ACCELERATOR POT
10 GA
4 GA
+ 12V
W
12 12 VDC OUTPUT (100 mA)
13
F2
M1
B--
BK
BN
(+)
NC
NC
NC
NC
14
MILLIPAK
SEVCON
GY
W
15
16
CONTROLLER
BK
PROGRAMMING
SPLICE
Workman MDE
Battery Charging Circuit
Power Current
Control Current
Indication Current
Page 6 -- 6
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Page 6 -- 7
Rev. A
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Workman MDE
Serial Number Below 310000000
Electrical Harness Drawing
Page 6 -- 8
Rev. A
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PINK
RED/WHITE
ORANGE
ORANGE
RED
WHITE
ORANGE
RED/WHITE
BLACK
BLUE
BLUE/WHITE
BLACK
BROWN
WHITE/BLACK
BLUE/WHITE
ORANGE
YELLOW
BLUE
PINK
BLACK
BLACK
YELLOW
VIOLET/BLACK
WHITE
BLUE/WHITE
BROWN
GREEN
BLACK
TAN
TAN
TAN
GRAY
BLACK
BLUE
BLACK
BLUE
BLUE
RED/WHITE
BLACK
BLUE
ORANGE
ORANGE
GREEN
BLUE
ORANGE
Workman MDE
Serial Number Below 310000000
Electrical Harness
Wiring Diagram
Page 6 -- 9
Rev. A
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Workman MDE
Serial Number Above 310000000
Electrical Harness Drawing
Page 6 -- 10
Rev. A
Download from Www.Somanuals.com. All Manuals Search And Download.
PINK
RED/WHITE
ORANGE
ORANGE
RED
WHITE
ORANGE
RED/WHITE
BLACK
BLUE/WHITE
BLUE
BLACK
BROWN
WHITE/BLACK
BLUE/WHITE
BLACK
BLUE
YELLOW
BLUE
ORANGE
PINK
PINK
YELLOW
VIOLET/BLACK
WHITE
BLUE/WHITE
BROWN
BLACK
GREEN
TAN
BLACK
TAN
TAN
GRAY
BLACK
BLUE
BLACK
BLUE
BLUE
BLACK
RED/WHITE
BLUE
ORANGE
BLACK
ORANGE
GREEN
VIOLET
GRAY
BLUE
ORANGE
WHITE/BLACK
GREEN
Workman MDE
Serial Number Above 310000000
Electrical Harness
Wiring Diagram
Page 6 -- 11
Rev. A
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Page 6 -- 12
Rev. A
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