Toro MDE - Manuals
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Manual Toro MDE
Summary
Workman MDE 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 M...
Workman MDE Page 1 -- 1 Safety Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 . . . . . . . . . . . . . . . . . . . . . . Before Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance and S...
Workman MDE Page 1 -- 2 Safety 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 ...
Workman MDE Page 1 -- 3 Safety 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. 2. Make sure machine is in safe operating condition by keeping all nuts, bolts and s...
Workman MDE Page 1 -- 4 Safety 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 su...
Workman MDE Page 1 -- 5 Safety Safety and Instruction Decals There are several safety and instruction decals attached 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 T...
Workman MDE Page 2 -- 1 Product Records and Maintenance Chapter 2 Product Records and Maintenance Table of Contents PRODUCT RECORDS 1 . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EQUIVALENTS AND CONVERSIONS 2 . . . . . ...
0.09375 Workman MDE Page 2 -- 2 Product Records and Maintenance Equivalents and Conversions
Workman MDE Page 2 -- 3 Product Records and Maintenance Torque Specifications Recommended fastener torque values are listed in the following tables. For critical applications, as determined by Toro, either the recommended torque or a torque that is unique to the application is clearly identified and...
Workman MDE Page 2 -- 6 Product Records and Maintenance Other Torque Specifications SAE Grade 8 Steel Set Screws Thread Size Recommended Torque Thread Size Square Head Hex Socket 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb 3/8 -- 16 UNC 35 + 10 ft--lb ...
Rev. A Workman MDE Page 3 -- 1 Electrical System Chapter 3 Electrical System Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Opening Battery Circuit 2 . . . . . . . . . . . . . . . . . . . . . ....
Workman MDE Page 3 -- 2 Electrical System 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. The vehicle controller monitors operator and vehicle in- puts to determine voltage to the traction ...
Workman MDE Page 3 -- 3 Electrical System Electrical Diagrams The electrical schematic, circuit drawings and wire har- ness drawings for the Workman MDE are located in Chapter 6 -- Electrical Diagrams. Electrical System
Workman MDE Page 3 -- 4 Electrical System 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. Eight, 6 volt, deep cycle batteries that are connected ...
Workman MDE Page 3 -- 5 Electrical System 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...
Workman MDE Page 3 -- 6 Electrical System 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 ...
Workman MDE Page 3 -- 7 Electrical System 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 ...
Workman MDE Page 3 -- 8 Electrical System Troubleshooting CAUTION 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....
Workman MDE Page 3 -- 9 Electrical System 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 -- Ele...
Workman MDE Page 3 -- 10 Electrical System 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...
Workman MDE Page 3 -- 11 Electrical System Adjustments Accelerator Switch Adjustment 1. Position vehicle on a level surface, turn on/off switch OFF and remove key. 2. With the accelerator pedal released, check that the distance between the head of the accelerator switch stop cap screw and the body o...
Workman MDE Page 3 -- 13 Electrical System 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...
Workman MDE Page 3 -- 15 Electrical System Battery Discharge Indicator and Hour Meter Gauge The combination battery discharge indicator and hour meter gauge is located on the dash panel (Fig. 19). The battery indicator identifies state of charge of the bat- tery pack. The battery indicator reads ful...
Workman MDE Page 3 -- 17 Electrical System 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 st...
Workman MDE Page 3 -- 18 Electrical System 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 vehicle controller and allows the speed of ...
Workman MDE Page 3 -- 19 Electrical System 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 in...
Workman MDE Page 3 -- 20 Electrical System Main and Accessories Contactors Two contactors (solenoids) are used on the Workman MDE for circuit control. 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 th...
Workman MDE Page 3 -- 22 Electrical System 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: The upper 10 ampere fuse (F2) supplies power to the on/off switch and sw...
Workman MDE Page 3 -- 23 Electrical System Fusible Links The wiring harness for the Workman includes three (3) fusible links for circuit protection (Fig. 36). 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 powe...
Workman MDE Page 3 -- 24 Electrical System 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 s...
Rev. A Workman MDE Page 3 -- 25 Electrical System 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 th...
Workman MDE Page 3 -- 26 Electrical System 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,...
Workman MDE Page 3 -- 28 Electrical System Service and Repairs Battery Service 1. Battery (8 used) 2. Battery rod (2 used) 3. Negative cable to vehicle 4. Lock washer (2 used per battery) 5. Hex nut (2 used per battery) 6. Cable terminal boot 7. Battery cable (6 used) 8. Positive cable to vehicle 9....
Workman MDE Page 3 -- 33 Electrical System 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. Inspection 1. Make sure that on/off switch is OFF. Raise and latch cargo box to allow a...
Workman MDE Page 3 -- 34 Electrical System Traction Motor 1. Socket head screw (6 used) 2. Flat washer (6 used) 3. Flange nut 4. Support bracket 5. Carriage screw 6. Transaxle mount plate 7. Rubber damper 8. Traction motor 9. Fan 10. Roll pin (2 used) 11. Washer 12. Socket head screw 13. Plastic cap...
Workman MDE Page 3 -- 38 Electrical System Traction Motor Service 1. Frame and field assembly 2. Armature 3. Brush lead (2 used) 4. Cap screw (2 used per brush lead) 5. Cap screw (4 used) 6. Cap screw (8 used) 7. Brush (8 used) 8. High temperature sensor 9. Headband 10. Bolt (4 used) 11. Commutator ...
Workman MDE Page 3 -- 42 Electrical System Battery Charger 1. Upper case 2. Transformer 3. Lower case 4. SCR assembly 5. Control board 6. Relay 7. Circuit breaker 8. AC cordset 9. DC cordset 10. Ammeter 11. Fuse 12. Diode assembly Figure 64 3 4 5 8 6 7 9 1 2 10 11 12 For service of the battery charg...
Workman MDE Transaxle and Brakes Page 4 -- 1 Chapter 4 Transaxle and Brakes Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . ....
Workman MDE Transaxle and Brakes Page 4 -- 3 Specifications Item Description Transaxle Transaxle Fluid Capacity 2 quarts (1.9 liters) Transaxle Fluid 10W--30 Motor Oil Brake Fluid DOT 3 Tr ansaxle and Brakes
Workman MDE Transaxle and Brakes Page 4 -- 4 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 fa...
Workman MDE Transaxle and Brakes Page 4 -- 6 Service and Repairs Rear Wheels and Brakes 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 8. Parking brake cable 9. Retaining ring ...
Workman MDE Transaxle and Brakes Page 4 -- 10 Rear Brake Service 1. Brake backing plate 2. Washer head screw 3. Brake shoe 4. Lower spring 5. Wheel cylinder 6. Parking brake lever (LH shown) 7. Belleville washer 8. Adjuster lever 9. Dust cover 10. Flat washer 11. Bolt 12. Shoe hold down cup and spri...
Workman MDE Transaxle and Brakes Page 4 -- 12 Hydraulic Brake System 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 11. Thread forming screw (6...
Workman MDE Transaxle and Brakes Page 4 -- 13 Bleed Brake System 1. Connect a suitable transparent hose to bleeder valve on a wheel cylinder or caliper. Submerge other end of hose in a glass container partially filled with clean brake fluid. 2. Have a second person pump brake pedal several times, th...
Workman MDE Transaxle and Brakes Page 4 -- 14 Front Brake Calipers 1. LH brake caliper 2. RH brake caliper 3. Lock washer (2 per caliper used) 4. Cap screw (2 per caliper used) 5. Wheel hub assembly 6. Brake rotor 7. Socket head screw (4 per rotor used) 8. Spindle (LH shown) 9. A--arm (LH shown) 10....
Workman MDE Transaxle and Brakes Page 4 -- 15 Removal (Fig. 6) 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. WARNING Before jacking up the machine, review and follow Jacking Instructions in Chapter 1 -- Safety. 2. Chock wheels not being j...
Workman MDE Transaxle and Brakes Page 4 -- 16 Brake Master Cylinder 1. Master cylinder 2. Cap screw 3. Brake pedal 4. Clevis pin 5. Cotter pin 6. Flange head nut 7. Pedal frame Figure 8 7 3 5 6 2 1 4 FRONT RIGHT Removal (Fig. 8) 1. Raise and support front hood. 2. Remove cotter pin from the clevis p...
Workman MDE Transaxle and Brakes Page 4 -- 17 Brake Master Cylinder Service Disassembly (Fig. 9) 1. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 2. Disconnect lower end of the dust cover from the housing. 3. Push in on the push rod and remove circlip, the...
Workman MDE Transaxle and Brakes Page 4 -- 18 Parking Brake 1. Parking brake cover 2. Operator seat 3. Seat base 4. Cable equalizer bracket 5. Parking brake lever 6. Curved washer 7. Lock nut 8. Flat washer 9. Flange head screw (4 used) 10. Flat washer (2 used) 11. Screw (2 used) 12. Cap screw 13. C...
Workman MDE Transaxle and Brakes Page 4 -- 24 Transaxle Service 1. Oil seal 2. Bearing cap bolt (2 used per cap) 3. Input shaft 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 11. Endcap plug (2 use...
Workman MDE Page 5 -- 1 Chassis Chapter 5 Chassis Table of Contents GENERAL INFORMATION 1 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 2 . . ....
Workman MDE Page 5 -- 2 Chassis Specifications Item Description Front tire (22 x 9.5 -- 10, 4 ply) pressure 8 to 22 PSI (55 to 152 kPa) Rear tire (22 x 9.5 -- 10, 4 ply) pressure 8 to 22 PSI (55 to 152 kPa) Wheel lug nut torque (front and rear) 45 to 65 ft--lb (61 to 88 N--m) Brake Fluid DOT 3 Speci...
Workman MDE Page 5 -- 3 Chassis 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 end is noisy. Rear wheel lug nu...
Rev. A 4.1 Workman MDE Chassis Page 5 -- Adjustments Adjust Front Wheel Camber 1. Adjust front tire pressures to 12 PSI (82 kPa) before checking front wheel camber. 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...
Workman MDE Page 5 -- 5 Chassis 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. Lower air pressure will provide less compaction, a smoother ride and fewer tire ma...
Workman MDE Page 5 -- 6 Chassis Upper Steering 1. Hex nut 2. Flat washer 3. Steering wheel 4. Flange nut (4 used) 5. Steering box assembly 6. Cap screw 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 1...
Workman MDE Page 5 -- 8 Chassis Steering Gearbox 1. Gasket 2. Hex washer head screw (3 used) 3. Seal 4. Sector gear 5. Flat washer 6. Ball bearing 7. Output shaft spacer 8. Stepped washer 9. Flange head screw with patch lock 10. Ball bearing 11. Input shaft spacer 12. Flat washer 13. Flange head scr...
Workman MDE Page 5 -- 10 Chassis Lower Steering and Front Wheels 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 1...
Workman MDE Page 5 -- 13 Chassis 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 ...
Workman MDE Page 5 -- 16 Chassis Frame Pivot Yoke 1. Flange nut (4 used) 2. Shock absorber (2 used) 3. Cap screw (4 used) 4. Plug 5. Flat washer 6. Lock nut (4 used per side) 7. Cap screw (2 used per shock) 8. LH A--arm 9. Grease fitting (1 used per arm) 10. Screw 11. Cap screw 12. RH A--arm 13. Loc...
Workman MDE Page 5 -- 18 Chassis Seat Base 1. Seat 2. Seat bracket 3. Rubber receptacle 4. Rivet 5. Cap screw (4 used per seat) 6. Screw 7. Holding post 8. Seat base 9. Seat base tray 10. Flange head screw (8 used) 11. Flat washer (4 used) 12. Front frame 13. Screw (4 used) 14. Washer head screw (4 ...
Workman MDE Page 5 -- 20 Chassis Front Hood 1. Fender (LH shown) 2. Lock nut (4 used) 3. Flat washer (2 used) 4. Front bumper 5. Headlight (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) 12. Washer he...
Workman MDE Electrical Diagrams Page 6 -- 1 Chapter 6 Electrical Diagrams Table of Contents ELECTRICAL SCHEMATIC Electrical Schematic 3 . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL CIRCUIT DRAWINGS On/Off Switch Turned On 4 . . . . . . . . . . . . . . . . . . . . . Run Circuit (Forwa...
Page 6 -- 3 Electrical Schematic Workman MDE Contactors shown de-- energized RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 1 2 4 5 F2 F1 FL1 FL2 F1 FRONT HORN SWITCH W HORN SWITCH HOOK UP R (PEDAL NOT PUSHED IN) (+) 4 HR ENABLE 3 SETUP + 2 SENSE A 1 CW 7 FET OUT8 (-- ) 6 IGN + 5 SENSE B T VIO/BK Y P...
Page 6 -- 4 RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 1 2 4 5 F2 F1 FL1 FL2 F1 FRONT W SWITCH HOOK UP R (PEDAL NOT PUSHED IN) CW T VIO/BK Y PK OR NC NC NC OR R/W OFF 11 PROGRAMMING 9 DIAGNOSTIC LIGHT 8 MAIN CONTACTOR 5 CHARGER 2 FOR/REV F3 10 A SEVCON B+ 10 GA R A1 ARMATURE MAIN 48V BATT ARRAY A...
Rev. A Page 6 -- 8 Electrical Harness Drawing Serial Number Below 310000000 Workman MDE
Page 6 -- 6 RUN 15 14 M1 M2 FL3 BU B BK BK BK 4 Y W 16 13 1 2 4 5 F2 F1 FL1 FL2 F1 FRONT W SWITCH HOOK UP R (PEDAL NOT PUSHED IN) CW T VIO/BK Y PK OR NC NC NC OR R/W OFF 11 PROGRAMMING 9 DIAGNOSTIC LIGHT 8 MAIN CONTACTOR 5 CHARGER 2 FOR/REV F3 10 A SEVCON B+ 10 GA R A1 ARMATURE MAIN 48V BATT ARRAY A...
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