Inhaltszusammenfassung zur Seite Nr. 1
Part No. 08164SL (Rev. A)
ServiceManual
R
Workman MDE
Preface
Thepurposeofthispublicationistoprovidetheservice
technician with information for troubleshooting, testing
and repair of major systems and components on the
Workman MDE.
Thissafetysymbol meansDANGER, WARNING
REFERTOTHEOPERATOR’SMANUALFOROPER-
or CAUTION, PERSONAL SAFETY INSTRUC-
ATING, MAINTENANCE AND ADJUSTMENT IN- TION.Whenyouseethissymbol,carefullyread
the instructions that follow. Failureto obeythe
STRUCTIONS. For reference, insert
Inhaltszusammenfassung zur Seite Nr. 2
This page is intentionally blank. Workman MDE
Inhaltszusammenfassung zur Seite Nr. 3
TableOfContents Chapter1 -- Safety Safety Instructions.......................... 1 -- 2 Jacking and Other Instructions ............... 1 -- 4 Safety and Instruction Decals ................ 1 -- 5 Chapter2 -- ProductRecordsand Maintenance Product Records ........................... 2 -- 1 Maintenance............................... 2 -- 1 Equivalents and Conversions ................ 2 -- 2 Torque Specifications ....................... 2 -- 3 Chapter3 -- Electrical System General Information ......
Inhaltszusammenfassung zur Seite Nr. 4
This pageis intentionally blank. Workman MDE
Inhaltszusammenfassung zur Seite Nr. 5
Chapter1 Safety TableofContents SAFETYINSTRUCTIONS ...................... 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 SAFETYAND INSTRUCTION DECALS .......... 5 Workman MDE Page1 -- 1 Safety Safety
Inhaltszusammenfassung zur Seite Nr. 6
SafetyInstructions TheWorkmanMDEisdesignedandtestedtooffersafe service when operated and maintained properly. Al- WARNING thoughhazardcontrolandaccidentpreventionarepar- tially dependent upon the design and configuration of themachine,thesefactorsarealsodependentuponthe To reduce the potential for injury or death, awareness,concernandpropertrainingoftheperson- complywiththefollowingsafetyinstructions. nel involved in the operation, transport, maintenance and storage of the machine. Improper use
Inhaltszusammenfassung zur Seite Nr. 7
MaintenanceandService 1. Before servicing or making adjustments to the ve- 10.Never use an open flame to check level or leakage hicle, stop vehicle, turn on/off switch to OFF, engage ofbattery electrolyte. parking brake and remove key from the on/offswitch. 11.Whenconnectingthebatterychargertothevehicle, 2. Makesuremachineisinsafeoperatingconditionby connectthechargercordtothevehiclechargerrecep- keeping all nuts,bolts and screws tight. tacle before plugging the charger power cord into an outlet
Inhaltszusammenfassung zur Seite Nr. 8
JackingandOtherInstructions JackingVehicle DANGER POTENTIALHAZARD • Avehiclethatisnotproperlysupported maybecomeunstable. WHATCANHAPPEN • Thevehiclemaymoveorfall.Personal injuryordamagetothemachinemayresult. HOWTOAVOIDTHEHAZARD 1 • Makesurevehicleisparkedonasolidlevel 2 surface,suchasaconcretefloor. • Makesureon/offswitchisOFFandkeyis Figure 1 removedfromtheswitchbeforegettingoff 1. Frontframe 2. Towingtongue thevehicle. • Beforeraisingthevehicle,removeany attachmentsthatmayinterferewiththesafe
Inhaltszusammenfassung zur Seite Nr. 9
SafetyandInstructionDecals Thereareseveralsafetyandinstructiondecalsattached toyourWorkmanvehicle.Ifanydecalbecomesillegible ordamaged,installanewdecal.Partnumbersarelisted in the Parts Catalog. Order replacement decals from your Authorized Toro Distributor. Workman MDE Page1 -- 5 Safety Safety
Inhaltszusammenfassung zur Seite Nr. 10
This page is intentionally blank. Safety Page1 -- 6 Workman MDE
Inhaltszusammenfassung zur Seite Nr. 11
Chapter2 ProductRecordsandMaintenance TableofContents PRODUCT RECORDS......................... 1 MAINTENANCE............................... 1 EQUIVALENTSAND CONVERSIONS ........... 2 Decimal and Millimeter Equivalents ............ 2 U.S.to Metric Conversions ................... 2 TORQUESPECIFICATIONS.................... 3 Fastener Identification ....................... 3 Standard Torque for Dry,Zinc Plated and Steel Fasteners (Inch Series) ............... 4 Standard Torque for Dry,Zinc Plated an
Inhaltszusammenfassung zur Seite Nr. 12
EquivalentsandConversions 0.09375 ProductRecordsandMaintenance Page2 -- 2 Workman MDE
Inhaltszusammenfassung zur Seite Nr. 13
TorqueSpecifications Recommendedfastenertorquevaluesarelistedinthe Asnotedinthefollowingtables,torquevaluesshouldbe followingtables.Forcriticalapplications,asdetermined reduced by 25% for lubricated fasteners to achieve byToro,eithertherecommendedtorqueoratorquethat thesimilarstressasadryfastener.Torquevaluesmay isuniquetotheapplicationisclearlyidentifiedandspe- alsohavetobereducedwhenthefasteneristhreaded cified in this Service Manual. into aluminum or brass. The specific torque value shouldbed
Inhaltszusammenfassung zur Seite Nr. 14
Standard Torque for Dry, Zinc Plated and Steel Fasteners (Inch Series) Grade 1, 5 & SAE Grade 1 Bolts, Screws, Studs & SAE Grade 5 Bolts, Screws, Studs & SAE Grade 8 Bolts, Screws, Studs & Thread Size 8withThin Sems with Regular Height Nuts Sems with Regular Height Nuts Sems with Regular Height Nuts Height Nuts (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 2 or Stronger Nuts) (SAE J995 Grade 5 or Stronger Nuts) in--lb in--lb N--cm in--lb N--cm in--lb N--cm # 6 -- 32 UNC 15 + 2 169 + 23 23
Inhaltszusammenfassung zur Seite Nr. 15
StandardTorqueforDry,ZincPlatedandSteelFasteners(MetricSeries) Class8.8Bolts,ScrewsandStudswith Class10.9Bolts,ScrewsandStudswith T Thread hreadS Size ize R Regular egularH Height eightN Nuts uts R Regular egularH Height eightN Nuts uts (Class8orStrongerNuts) (Class10orStrongerNuts) M5 X 0.8 57 +6in--lb 644 + 68 N--cm 78 +8in--lb 881 +90N--cm M6 X 1.0 96 + 10 in--lb 1085 + 113 N--cm 133 +14 in--lb 1503 + 158 N--cm M8 X1.25 19 +2ft--lb 26 +3N--m 28 +3ft--lb 38 +4N--m M10 X1.5 38 +4ft--lb 52 +5N--
Inhaltszusammenfassung zur Seite Nr. 16
OtherTorqueSpecifications SAEGrade8SteelSetScrews WheelBoltsandLugNuts RecommendedTorque ThreadSize RecommendedTorque** Thread ThreadS Size ize SquareHead HexSocket 7/16 -- 20 UNF 65 + 10 ft--lb 88 +14N--m Grade 5 1/4 -- 20 UNC 140 + 20 in--lb 73 + 12 in--lb 1/2 -- 20 UNF 80 + 10 ft--lb 108 + 14 N--m 5/16 -- 18 UNC 215 + 35 in--lb 145 + 20 in--lb Grade 5 3/8 -- 16 UNC 35 + 10 ft--lb 18 +3ft--lb M12 X1.25 80 + 10 ft--lb 108 + 14 N--m Class 8.8 1/2 -- 13 UNC 75 + 15 ft--lb 50 + 10 ft--lb M12 X1.5
Inhaltszusammenfassung zur Seite Nr. 17
Chapter 3 Electrical System Table of Contents GENERAL INFORMATION ..................... 2 SERVICEAND REPAIRS ..................... 28 Operator’s Manual .......................... 2 Battery Service ............................ 28 Opening Battery Circuit ...................... 2 Battery Specifications ..................... 28 ELECTRICAL DIAGRAMS...................... 3 Battery Removal.......................... 29 VEHICLEOPERATION ........................ 4 Battery Installation ....................
Inhaltszusammenfassung zur Seite Nr. 18
GeneralInformation TheWorkmanMDEusesa48voltDCelectricalsystem LEDonthecontrollerandthevehiclestatuslightonthe thatisanisolatedcircuit.Thevehicleframeisnotused dashpanelwillflashafaultcodetoassistinidentifying for any ground connections. the problem. Thevehiclecontrollermonitorsoperatorandvehiclein- Afterperforminganyrepaironelectricalcomponentson putstodeterminevoltagetothetractionmotor.Ifaprob- thevehicle,makesurethatwiringisroutedandsecured lemexiststhatwillpreventnormalvehicleoperation,an soa
Inhaltszusammenfassung zur Seite Nr. 19
ElectricalDiagrams Theelectricalschematic,circuitdrawingsandwirehar- ness drawings for the Workman MDE are located in Chapter 6 -- Electrical Diagrams. Workman MDE ElectricalSystem Page3 -- 3 Electrical System
Inhaltszusammenfassung zur Seite Nr. 20
VehicleOperation TheWorkmanMDEelectricalsystemusesa48voltbat- Thevehiclecontrollerisasealedelectroniclogicdevice terypack,anelectrictractionmotor,avehiclecontroller that uses inputs from several vehicle components to andnumerousotherelectricalcomponentstoallowve- controlmotorspeedanddirection.Theseinputsinclude hicle operation. several switches (on/off, forward/reverse, accelerator, supervisor, charger), a motor temperature sensor, an Eight,6volt,deepcyclebatteriesthatareconnectedin acceleratorp
