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Page 3 - Table Of Contents; Chapter 2 -- Product Records and Maintenance
Rev. A Workman MD/MDX Table Of Contents Chapter 1 -- Safety Safety Instructions 1 -- 2 . . . . . . . . . . . . . . . . . . . . . . . . . . Jacking and Other Instructions 1 -- 4 . . . . . . . . . . . . . . . Safety and Instruction Decals 1 -- 6 . . . . . . . . . . . . . . . . Chapter 2 -- Product Rec...
Page 5 - Chapter 1; Safety; Table of Contents; Safety
Workman MD/MDX Page 1 -- 1 Safety Chapter 1 Safety Table of Contents SAFETY INSTRUCTIONS 2 . . . . . . . . . . . . . . . . . . . . . . Supervisor’s Responsibilities 2 . . . . . . . . . . . . . . . . . Before Operating 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . While Operating 3 . . . ...
Page 6 - Supervisor’s Responsibilities
Workman MD/MDX Page 1 -- 2 Safety Safety Instructions The Workman MD and MDX series vehicles are de- signed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine...
Page 7 - While Operating
Workman MD/MDX Page 1 -- 3 Safety While Operating 1. Sit on the operator seat when starting and operating the vehicle. 2. Before starting the engine: A. Sit on operator’s seat and apply the parking brake. B. Turn ignition key to ON. C. Depress accelerator pedal to start engine and en- gage drive sys...
Page 8 - Jacking and Other Instructions; Jack Vehicle; DANGER; Transport Vehicle
Workman MD/MDX Page 1 -- 4 Safety Jacking and Other Instructions Jack Vehicle DANGER POTENTIAL HAZARD • A vehicle that is not properly supported may become unstable. WHAT CAN HAPPEN • The vehicle may move or fall. Personal injury or damage to the machine may result. HOW TO AVOID THE HAZARD • Make su...
Page 9 - Transaxle Neutral Position
Workman MD/MDX Page 1 -- 5 Safety Transaxle Neutral Position When performing routine maintenance and/or engine testing, the transaxle must be shifted into the neutral position. 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. 2. Move shift l...
Page 10 - Safety and Instruction Decals
Workman MD/MDX Page 1 -- 6 Safety Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Workman. If any decal becomes illegible or dam- aged, install a new decal. Part numbers are listed in the Parts Catalog. Order replacement decals from your Au- thorized Toro Dis...
Page 11 - Chapter 2; Product Records and Maintenance; Product
Workman MD/MDX 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 . . . ....
Page 12 - Equivalents and Conversions
0.09375 Workman MD/MDX Page 2 -- 2 Product Records and Maintenance Equivalents and Conversions
Page 13 - Torque Specifications; reduced by 25% for lubricated fasteners; Fastener Identification
Workman MD/MDX 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 ...
Page 16 - Other Torque Specifications; Conversion Factors
Workman MD/MDX 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--...
Page 17 - Chapter 3; Briggs & Stratton Gasoline Engine; Briggs
Workman MDX Page 3 -- 1 Briggs & Stratton Gasoline Engine Chapter 3 Briggs & Stratton Gasoline Engine Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3 . . . . . . . . . ....
Page 18 - General Information; Operator’s Manual
Workman MDX Page 3 -- 2 Briggs & Stratton Gasoline Engine General Information This Chapter gives information about specifications, maintenance, troubleshooting, testing and repair of the V--twin cylinder, gasoline engine used in the Workman MDX. Most repairs and adjustments require tools which a...
Page 19 - Specifications
Workman MDX Page 3 -- 3 Briggs & Stratton Gasoline Engine Specifications Item Description Make / Designation Briggs and Stratton, 4--cycle, V--Twin Cylinder, OHV, Air Cooled, Gasoline Engine -- Model 303440 Bore x Stroke 2.68” x 2.60” (68 mm x 66 mm) Total Displacement 29.3 in 3 (480 cc) Governo...
Page 20 - Adjustments; Adjust Throttle Cable
Workman MDX Page 3 -- 4 Briggs & Stratton Gasoline Engine Adjustments Adjust Throttle Cable NOTE: The Workman MDX is equipped with an engine governor. Refer to the Briggs & Stratton Repair Manual at the end of this chapter for governor information on these machines. Depressing the accelerato...
Page 21 - Service and Repairs; Cooling System
Workman MDX Page 3 -- 5 Briggs & Stratton Gasoline Engine Service and Repairs Cooling System To ensure proper engine cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. NOTE: Perform this maintenance procedure at the in- terval...
Page 22 - Air Cleaner
Workman MDX Page 3 -- 6 Briggs & Stratton Gasoline Engine Air Cleaner Figure 5 1. Air cleaner assembly 2. Bolt 3. Compression spring 4. Mounting band 5. Nut 6. Flange nut (2 used) 7. Cap screw (2 used) 8. Air cleaner bracket 9. Flange head screw (4 used) 10. Carburetor gasket (2 used) 11. Carbur...
Page 24 - Exhaust System
Workman MDX Page 3 -- 8 Briggs & Stratton Gasoline Engine Exhaust System Figure 7 1. Muffler 2. Swing arm 3. Cap screw (2 used) 4. Lock washer (6 used) 5. Exhaust coupler 6. Coupler spring (4 used) 7. Exhaust manifold 8. Engine tray 9. Engine 10. Screw (4 used) 6 10 9 7 5 8 3 4 2 1 FRONT RIGHT 4
Page 25 - CAUTION; The muffler and exhaust pipe may be hot. To
Workman MDX Page 3 -- 9 Briggs & Stratton Gasoline Engine Removal (Fig. 7) 1. Park machine on a level surface, stop the engine, en- gage parking brake and remove the key from the ignition switch. 2. Raise cargo box and support with prop rod. CAUTION The muffler and exhaust pipe may be hot. To av...
Page 26 - Fuel Tank
Workman MDX Page 3 -- 10 Briggs & Stratton Gasoline Engine Fuel Tank 1. Seat 2. Fuel gauge 3. Bushing 4. Gas cap 5. Fuel tank 6. Bushing 7. Stand pipe 8. Hose clamp 9. Fuel hose (to fuel filter) 10. Fuel line conduit 11. Seat base 12. Web strapping 13. Hex head flange screw (8 used) 14. Flat was...
Page 27 - Read safety precautions for handling gasoline
Workman MDX Page 3 -- 11 Briggs & Stratton Gasoline Engine Fuel Tank Removal (Fig. 10) CAUTION Read safety precautions for handling gasoline before working on the fuel system (see Safety In- structions in Chapter 1 -- Safety). 1. Remove seat base from the frame (see Seat Base Removal in the Serv...
Page 28 - Oil Filter Assembly
Workman MDX Page 3 -- 12 Briggs & Stratton Gasoline Engine Oil Filter Assembly Figure 11 1. Hose 2. Elbow fitting 3. Hose 4. Fitting 5. Oil pressure switch 6. Elbow fitting 7. Cap screw (4 used) 8. Flange nut (4 used) 9. Filter bracket 10. Oil filter 11. Oil filter adapter 12. Fitting 1 3 4 5 6 ...
Page 30 - Engine
Workman MDX Page 3 -- 14 Briggs & Stratton Gasoline Engine Engine Figure 12 1. Hose clamp 2. Fuel hose (from tank) 3. Cable bracket 4. Cable clamp 5. Cap screw 6. Threaded insert 7. Swing arm 8. Lock washer (6 used) 9. Cap screw (2 used) 10. Woodruff key 11. Lock washer 12. Nut 13. Starter V--be...
Page 35 - Chapter 4; Single Cylinder Gasoline Engine; Single
Rev. A Workman MD Single Cylinder Gasoline Engine Page 4 -- 1 Chapter 4 Single Cylinder Gasoline Engine Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 3 . . . . . . . . . . . . ....
Page 47 - Chapter 5; Drive Train; Drive
Rev. A Workman MD/MDX Drive Train Page 5 -- 1 Chapter 5 Drive Train Table of Contents GENERAL INFORMATION 1 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRI...
Page 49 - Drive Train Operation; Clutch System Operation
Rev. A Workman MD/MDX Drive Train Page 5 -- 3 Drive Train Operation Clutch System Operation 1. Drive clutch (engine mounted) 2. Driven clutch (transaxle mounted) 3. Moveable sheave (drive clutch) 4. Fixed sheave (drive clutch) 5. Moveable sheave (driven clutch) 6. Button 7. Ramp (fixed cam) 8. Sprin...
Page 50 - Drive Clutch Operation
Rev. A Workman MD/MDX Drive Train Page 5 -- 4 Drive Clutch Operation The operation of the drive clutch is affected by engine shaft speed. When the engine is off and not turning, the drive belt rests low within the drive clutch sheaves as the clutch sheaves are spaced apart. As the engine is started ...
Page 51 - Driven Clutch Operation
Rev. A Workman MD/MDX Drive Train Page 5 -- 5 Driven Clutch Operation The operation of the driven clutch is affected by trans- axle load. When the vehicle is stopped, the drive belt is held at the outer diameter of the driven clutch sheaves from the pressure of the spring pushing the moveable sheave...
Page 52 - Special Tools
Rev. A Workman MD/MDX Drive Train Page 5 -- 6 Special Tools Order special tools from your Toro Distributor. Drive Clutch Removal Tool (Serial Number Below 310000000) This tool is required to remove the drive clutch from the tapered drive shaft of the engine. It is placed in the threaded hole of the ...
Page 55 - Before jacking up the machine, review and follow
Workman MD/MDX Drive Train Page 5 -- 7 Adjustments Adjust Ground Speed (Workman MD) Workman MD models are equipped with a transaxle governor. Adjust ground speed using the following pro- cedure. Vehicles operating at ground speeds greater thanthe recommended speed will require furtherdistances to fu...
Page 56 - WARNING
Workman MD/MDX Drive Train Page 5 -- 8 Adjust Ground Speed (Workman MDX) Workman MDX models use an engine governor for speed control. Adjust ground speed using the following procedure. Vehicles operating at ground speeds greater thanthe recommended speed will require furtherdistances to fully stop. ...
Page 57 - Adjust Shift Cables
Workman MD/MDX Drive Train Page 5 -- 9 Adjust Shift Cables 1. Park machine on a level surface, stop engine, set parking brake and remove key from the ignition switch. Raise and support cargo box. 2. Set the shift lever into the Neutral position. Rotate driven clutch to insure transmission is in neut...
Page 58 - Drive Clutch; Drive Clutch Lubrication
Workman MD/MDX Drive Train Page 5 -- 10 Service and Repairs Drive Clutch 1. Engine (V--twin shown) 2. Starter/generator 3. Starter/generator belt 4. Starter/generator pulley 5. Cap screw (4 used) 6. Lock washer (4 used) 7. Engine starter pulley 8. Spacer 9. Drive clutch 10. Washer 11. Cap screw 12. ...
Page 66 - Driven Clutch
Rev. A Workman MD/MDX Drive Train Page 5 -- 14 Driven Clutch NOTE: The driven clutch on vehicles with serial num- bers above 310000000 is different than the clutch used on earlier vehicles. The procedure to remove or install the driven clutch is the same regardless of machine seri- al number. Driven...
Page 70 - Transaxle
Workman MD/MDX Drive Train Page 5 -- 16 Transaxle 1. Engine 2. Washer (4 used) 3. Cap screw (4 used) 4. Drive belt 5. Cap screw 6. Stepped washer 7. Driven clutch 8. Transaxle 9. Lock nut 10. Flat washer 11. Shift cable (2 used) 12. Flange nut (4 used) 13. Engine tray 14. Swing arm 15. Drive clutch ...
Page 71 - When removing engine tray, make sure hoist can
Workman MD/MDX Drive Train Page 5 -- 17 6. On Workman MD, remove governor and cable brackets from the transaxle as follows (Fig. 23). A. Scribe mark across governor bracket and gover- nor shaft to help installation. Loosen both set screws securing the bracket to the shaft. B. Remove both lock nuts s...
Page 74 - Transaxle Service
Workman MD/MDX Drive Train Page 5 -- 20 Transaxle Service 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 57 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 69 70 71 72 73 74 75 76 1 2 3 4 5 6 7 8 9 10 16 1718 19 20 21 22 23 24 25 26 27 28 29 30 11 12 13 14 15 52 55 70 19 26 38 33 65 65 ...
Page 75 - Transaxle Disassembly and Inspection; Make sure transaxle case is not hot prior to drain-
Workman MD/MDX Drive Train Page 5 -- 21 1. Case (LH) 2. Oil seal 3. Oil seal 4. Snap ring 5. Spacer 6. Selector shaft 7. Oil seal (2 used) 8. Flange bolt (4 used) 9. Oil check plug (2 used) 10. Gasket (2 used) 11. Oil drain plug (2 used) 12. Gasket (2 used) 13. Oil filler plug 14. Case (RH) 15. Oil ...
Page 80 - IMPORTANT: Make sure not to damage the oil seal
Workman MD/MDX Drive Train Page 5 -- 26 1. Differential assembly 2. Input shaft assembly 3. Center shaft assembly 4. Shift shaft Figure 36 1 3 2 4 IMPORTANT: Make sure not to damage the oil seal when removing the input shaft. NOTE: If any of the assemblies can not be pulled out by hand, hold the ass...
Page 82 - IMPORTANT: Make sure to not damage the screw
Workman MD/MDX Drive Train Page 5 -- 28 1. Ball bearing 2. Input shaft Figure 40 1 2 IMPORTANT: Do not reuse ball bearings that have been removed. B. Remove ball bearing from the input shaft with a bearing puller. 1. Governor plate assembly 2. Governor base Figure 41 1 2 IMPORTANT: Make sure to not ...
Page 98 - IMPORTANT: Make sure to not damage the oil seal
Workman MD/MDX Drive Train Page 5 -- 44 6. Install input shaft, center shaft and differential as- semblies to the case. 1. Shift shaft 2. Clutch groove Figure 69 1 2 A. Insert fork of the shift shaft to the clutch groove of the center shaft assembly. 1. Center shaft assembly 2. Shift shaft 3. Input ...
Page 103 - Chapter 6; Electrical System; Electrical System
Workman MD/MDX Page 6 -- 1 Electrical System Chapter 6 Electrical System Table of Contents GENERAL INFORMATION 2 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 2 . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SCHEMATICS 2 . . . . . . . . . . . . . . . . . . . SPECIAL TOO...
Page 104 - Electrical Schematics
Workman MD/MDX Page 6 -- 2 Electrical System 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 th...
Page 105 - Multimeter
Workman MD/MDX Page 6 -- 3 Electrical System Special Tools Order special tools from your Toro Distributor. Some tools may also be available from a local supplier. Multimeter The meter can test electrical components and circuits for current, resistance or voltage. NOTE: Toro recommends the use of a D...
Page 106 - Battery Hydrometer
Workman MD/MDX Page 6 -- 4 Electrical System Battery Hydrometer Use the Battery Hydrometer when measuring specific gravity of battery electrolyte. Obtain this tool locally. Figure 4
Page 107 - Starting Problems
Workman MD/MDX Page 6 -- 5 Electrical System Troubleshooting CAUTION Remove all jewelry, especially rings and watches, before doing any electrical trouble- shooting or testing. Disconnect the battery cables unless the test requires battery voltage. For effective troubleshooting and repairs, you must...
Page 108 - General Run Problems; Problem
Workman MD/MDX Page 6 -- 6 Electrical System General Run Problems Problem Possible Causes Battery does not charge. Wiring to the charging circuit components is loose, corroded or damaged (see Wiring Schematics in Chapter 8 -- Electrical Diagrams). Voltage regulator and/or starter/generator is faulty...
Page 109 - Electrical System Quick Checks; Battery Test; Voltage Measured; Charging System Test; At least 0.50 volt over initial battery voltage.
Workman MD/MDX Page 6 -- 7 Electrical System Electrical System Quick Checks Battery Test Use a multimeter to measure the voltage between the battery terminals. Set the multimeter to the DC volts setting. The battery should be at a temperature of 60 o to 100 o F. The ignition key should be off and al...
Page 110 - Component Testing; When testing electrical components for continu-; Ignition Switch; Testing
Workman MD/MDX Page 6 -- 8 Electrical System Component Testing For accurate resistance and/or continuity checks, elec- trically disconnect the component being tested from the circuit (e.g. unplug the ignition switch connector before doing a continuity check on the switch). NOTE: See the Briggs and S...
Page 111 - Hour Meter; Headlight Switch
Workman MD/MDX Page 6 -- 9 Electrical System Hour Meter Testing IMPORTANT: Make sure to observe polarity on the hour meter terminals when testing. Damage to the meter may result from an improper connection. 1. Unplug wire harness connector from hour meter. 2. Connect positive (+) terminal of a 12 VD...
Page 113 - Fuse Block; less than 1 ohm
Workman MD/MDX Page 6 -- 11 Electrical System Fuse Block The fuse block is located beneath the dash panel. Fusescan be removed to check continuity. The test meter should read less than 1 ohm . Fuses protect circuits as follows (Fig. 10): 1. The extreme left fuse protects the optional accesso- ry cir...
Page 114 - Accelerator Switch
Workman MD/MDX Page 6 -- 12 Electrical System Accelerator Switch The accelerator switch is a four (4) terminal, two (2) cir- cuit switch. The switch is attached to the pedal support (Fig. 11). When the accelerator pedal is pushed, the switch allows current flow to the start/run solenoid, hour meter ...
Page 117 - Diode Assembly
Workman MD/MDX Page 6 -- 15 Electrical System Diode Assembly The diode D1 (Fig. 17) is used to protect the ignition switch from voltage spikes that can occur when the start- er solenoid is de--energized. The diode plugs into the wiring harness. Testing The diode can be tested using a digital multime...
Page 122 - Starter/Generator Service; WIRING DIAGRAM
Workman MD/MDX Page 6 -- 20 Electrical System Starter/Generator Service 1. Yoke 2. Armature kit 3. Ball bearing 4. Bearing retainer 5. Ball bearing 6. Spacer 7. Through bolt & flat washer 8. Brush cover 9. Screw, lock washer & flat washer 10. Spring washer 11. Hex nut 12. Woodruff key 13. Sc...
Page 127 - Battery Service
Workman MD/MDX Page 6 -- 25 Electrical System Battery Service The battery is the heart of the electrical system. With regular and proper service, battery life can be extended. Additionally, battery and electrical component failure can be prevented. WARNING POTENTIAL HAZARD: Either the battery termin...
Page 131 - Chapter 7; Chassis; Chassis
Workman MD/MDX Page 7 -- 1 Chassis Chapter 7 Chassis Table of Contents GENERAL INFORMATION 1 . . . . . . . . . . . . . . . . . . . . . Operator’s Manual 1 . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFICATIONS 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIAL TOOLS 2 . ...
Page 132 - Spanner Wrench
Page 7 -- 2 Workman MD/MDX Chassis Specifications Item Description Front Tire (Workman MD and MDX) (22 x 9.5 -- 10, 2 ply) Pressure Range 8 to 22 PSI (56 to 151 kPa) Rear Tire (Workman MD) (22 x 9.5 -- 10, 2 ply) Pressure Range 8 to 22 PSI (56 to 151 kPa) Rear Tire (Workman MDX) (24 x 12 -- 10, 2 pl...
Page 133 - Troubleshooting; Suspension and Steering
Workman MD/MDX Page 7 -- 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 shocks are loose or worn. Front end components (e.g. tie--rod, spindle, A--arm) are loose or worn. Steer...
Page 134 - Brakes
Workman MD/MDX Page 7 -- 4 Chassis Suspension and Steering (continued) Problem Possible Cause Front end shimmies. Front wheel lug nuts are loose. Front wheel bearings are loose or worn. Steering linkage is loose or worn. Tie rod ends are loose or worn. Front wheel alignment (toe--in) is incorrect. R...
Page 136 - Adjust Parking Brake
Workman MD/MDX Page 7 -- 6 Chassis Adjustments Adjust Parking Brake 1. Pry the rubber cover off of the parking brake. 2. Loosen the set screw securing the knob to the park- ing brake lever (Fig. 1). 3. Rotate the knob until a force from 30 to 40 lb. (133 to 177 N) is required to actuate the lever. 4...
Page 137 - Adjust Front Wheel Camber
Workman MD/MDX Page 7 -- 7 Chassis 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 operator’s seat. ...
Page 139 - Check Tire Pressure; Lower; Inspect Tires and Wheels
Workman MD/MDX Page 7 -- 9 Chassis Service and Repairs Check Tire Pressure See Specifications for tire pressure range for front and rear tires. The air pressure needed is determined by the payload carried. Lower air pressure will provide less compac- tion, a smoother ride and fewer tire marks. Lower...
Page 140 - Upper Steering
Workman MD/MDX Page 7 -- 10 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 cov...
Page 142 - Steering Gearbox
Workman MD/MDX Page 7 -- 12 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...
Page 144 - Lower Steering and Front Wheels
Workman MD/MDX Page 7 -- 14 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 washe...
Page 147 - Front Shock Absorbers
Workman MD/MDX Page 7 -- 17 Chassis Front Shock Absorbers Shock Removal (Fig. 13) 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 check...
Page 150 - Frame Pivot Yoke
Workman MD/MDX Page 7 -- 20 Chassis Frame Pivot Yoke 1. Flange nut (4 used) 2. Shock absorber (2 used) 3. Cap screw (4 used) 4. Rubber bumper 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-...
Page 152 - Swing Arm
Workman MD/MDX Page 7 -- 22 Chassis Swing Arm 1. Flange nut (4 used) 2. Hitch 3. Flange head screw (4 used) 4. Bushing (2 used) 5. Rear frame 6. Retaining ring (2 used) 7. Washer head screw (2 used) 8. R--clamp (2 used) 9. Rear shock assembly (2 used) 10. Cap screw (2 used) 11. Rubber bumper (2 used...
Page 156 - Parking Brake
Workman MD/MDX Page 7 -- 26 Chassis 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. Cotter pin ...
Page 158 - Rear Wheels and Brakes
Workman MD/MDX Page 7 -- 28 Chassis Rear Wheels and Brakes 1. Wheel assembly 2. Lug nut (5 used per hub) 3. Castle nut 4. Brake drum 5. Socket head screw (4 used per brake) 6. Brake assembly (LH shown) 7. Clevis pin 8. Cotter pin 9. Cotter pin 10. Flange lock nut (4 used per brake) 11. Transaxle 12....
Page 160 - Rear Brake Service; Be careful when removing springs from brake
Workman MD/MDX Page 7 -- 30 Chassis 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 spring 13. Upp...
Page 162 - Front Brake Calipers
Workman MD/MDX Page 7 -- 32 Chassis 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. Brake mas...
Page 163 - After servicing brake system components, al-
Workman MD/MDX Page 7 -- 33 Chassis Disassembly (Fig. 21) 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 jacked...
Page 164 - Front Brake Caliper Service
Workman MD/MDX Page 7 -- 34 Chassis Front Brake Caliper Service Disassembly (Fig. 22) 1. If caliper is equipped with anti--rattle clip, remove clip from caliper, pins and brake pads. 2. Remove pins from caliper by prying with a flat blade screwdriver through loop in pins. 3. Slide brake pads from ca...
Page 166 - Brake Master Cylinder
Workman MD/MDX Page 7 -- 36 Chassis 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 8. Front brake line 9. Rear brake line 10. Accelerator pedal Figure 23 7 3 5 6 2 1 4 FRONT RIGHT 8 9 10
Page 168 - Brake Master Cylinder Service; Inspection; Use eye protection such as goggles when using
Workman MD/MDX Page 7 -- 38 Chassis Brake Master Cylinder Service Disassembly (Fig. 24) 1. Thoroughly clean outside of master cylinder before disassembly. 2. Remove reservoir and flange seal. Push in on the push rod so the stop pin can be removed. 3. Disconnect lower end of the dust cover from the h...
Page 169 - Bleed Brake System
Workman MD/MDX Page 7 -- 39 Chassis Bleed Brake System IMPORTANT: To prevent contamination of the brake system, make sure to clean components before dis- assembly. 1. Connect a suitable transparent hose to bleeder valve on rear wheel brake cylinder or front brake caliper. Sub- merge other end of hos...
Page 170 - Seat Base
Workman MD/MDX Page 7 -- 40 Chassis Seat Base 1. Seat (2 used) 2. Seat bracket (2 used) 3. Cap screw (8 used) 4. Seat base 5. Shift cable (2 used) 6. Choke cable 7. Shift bracket 8. Short screw (4 used) 9. Long screw (4 used) 10. Fuel tank 11. Web strapping 12. Flange head screw (12 used) 13. Flat w...
Page 172 - Front Hood
Workman MD/MDX Page 7 -- 42 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...
Page 179 - Chapter 8; Electrical Drawings; Electrical Drawings
Rev. A Workman MD/MDX Electrical Drawings Page 8 -- 1 Chapter 8 Electrical Drawings Table of Contents ELECTRICAL SCHEMATICS Workman MD 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Workman MDX 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT DIAGRAMS Start Circ...
Page 183 - Start Circuits
Page 8 -- 5 F3 F4 F2 F1 10A 20A 15A 30A AUTO RESETTING Start Circuits Power Current Control CurrentIndication Current (Workman MDX Schematic Shown) (ENERGIZED)
Page 184 - Run Circuits
Page 8 -- 6 Run Circuits Power Current Control CurrentIndication Current (Workman MDX Schematic Shown) F3 F4 F2 F1 10A 20A 15A 30A AUTO RESETTING (ENERGIZED)
Page 185 - Main Electrical Harness Drawing; Workman MD and MDX
Rev. A Page 8 -- 7 Main Electrical Harness Drawing Workman MD and MDX (Serial Number Below 280999999)
Page 186 - Main Electrical Harness Wiring Diagram
Rev. A Page 8 -- 8 Main Electrical Harness Wiring Diagram Workman MD and MDX G R EEN GR AY VI O LET BL U E BL AC K RE D/B LA C K WH IT E BL AC K WH IT E WH IT E/ BL AC K BLACK YELLOW PINK VI O LET YELLOW VIOLET BLUE BLUE BLACK YELLOW BLACK BROWN BLUE BL AC K BL AC K BL U E BL U E BL AC K YEL LO W BL...
Page 191 - Engine Electrical Harness
Rev. A Page 8 -- 13 Engine Electrical Harness Workman MD WHITE/BLUE BROWN BLACK GREEN BROWN/WHITE BR O W N
