Form No. 3419-568 Rev D Workman® MDX Utility Vehicle Model No. 07235—Serial No. 401400001 and Up Model No. 07235TC—Serial No. 401400001 and Up Register at www.Toro.com.
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Contents Electrical System Safety ................................... 41 Servicing the Battery......................................... 41 Replacing the Fuses ......................................... 43 Maintaining the Headlights ............................... 43 Drive System Maintenance .................................. 45 Maintaining the Tires ........................................ 45 Inspecting the Steering and Suspension Components .................................................
Safety Improper use or maintenance by the operator or owner can result in injury. To reduce the potential for injury, comply with these safety instructions and always pay attention to the safety-alert symbol (Figure 2), which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with the instruction may result in personal injury or death. This machine has been designed in accordance with the requirements of SAE J2258.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decal115-7739 115-7739 1. Falling, crushing hazard—do not carry passengers. decal99-7345 99-7345 1. Warning—read the Operator's Manual. 2. Hot surface/burn hazard—stay a safe distance away from the hot surface. 3. Entanglement hazard, belt—stay away from moving parts; keep all guards in place. 4.
decal117-5001 117-5001 1. Warning—read the Operator's Manual. 7. Horn 2. Collision hazard—do not operate the machine on public streets, roads, or highways. 8. Hour meter 3. Falling hazard—do not carry passengers in the cargo bed. 9. Headlights 4. Falling hazard—do not allow children to operate the machine. 10. Power—Off 5. To start the motor, sit on the operator's seat, disengage the 11.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 5 Description Use Qty. Steering wheel Cover Washer (1/2 inch) 1 1 1 Install the steering wheel (TC models only). No parts required – Connect the battery (TC models only). No parts required – Check the fluid levels and tire pressure. No parts required – Burnish (break-in) the brakes.
2 Connecting the Battery TC Models Only No Parts Required g228187 Procedure Figure 5 1. Insulator boot (positive battery cable) WARNING 2. Negative battery post Incorrectly routing the battery cable could damage the machine and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 4. Slide the insulator boot over the positive terminal. Note: The insulator boot prevents a possible short-to-ground from occurring.
4 Burnishing the Brakes No Parts Required Procedure To ensure optimum performance of the brake system, burnish (break-in) the brakes before use. 1. Bring the machine up to full speed, apply the brakes to rapidly stop the machine without locking up the tires. 2. Repeat this procedure 10 times, waiting 1 minute between stops, to avoid overheating the brakes. Important: This procedure is most effective if the machine is loaded with 227 kg (500 lb).
Product Overview g033215 Figure 6 1. Hood latch 3. Cargo bed 5. Gear-shift selector 2. Parking-brake lever 4. Towing tongue 6. Fuel-tank cap Controls 7. Cargo-bed lever Control Panel Become familiar with all the controls before you start the engine and operate the machine. Note: Determine the left and right sides of the machine from the normal operating position. g033216 Figure 7 1. Steering wheel 5. Accelerator pedal 2. Cup holder 6. Parking-brake lever (center console) 3.
Accelerator Pedal Choke Control Use the accelerator pedal (Figure 7) to vary the ground speed of the machine. Pressing down the accelerator pedal starts the engine. Pressing the pedal farther increases the ground speed. Releasing the pedal slows the machine, and the engine shuts off. The choke control is located below and to the right of the operator's seat. Use the choke to help start a cold engine by pulling the choke control outward (Figure 8).
Horn Button Engine Oil-Pressure Light TC Models Only The engine oil-pressure light (Figure 9) warns you if the engine-oil pressure drops below a safe level to operate the engine. If the light comes on and remains lit, shut off the engine, and check the engine-oil level. Add oil to the engine if necessary; refer to Servicing the Engine Oil (page 34). The horn button is located at the lower, left corner of the dash panel (Figure 9). Press the horn button to sound the horn.
Fuel Gauge The fuel gauge (Figure 10) is located on the fuel tank next to the filler cap, at the left side of the machine. The gauge displays the amount of fuel in the tank. g008398 Figure 10 1. Empty 4. Fuel gauge 2. Full 5. Fuel-tank cap 3. Needle Passenger Handholds The passenger handholds are located on the right side of the dash panel and at the outside of each seat (Figure 11). g009193 Figure 11 1. Handhold—hip restraint 2.
Specifications Note: Specifications and design are subject to change without notice. Base weight Dry 544 kg (1,200 lb) Rated capacity (on level ground) 749 kg (1,650 lb) total, including 90.7 kg (200 lb) operator and 90.
Checking the Tire Pressure Operation Service Interval: Before each use or daily Before Operation Tire air pressure specification: 55 to 103 kPa (8 to 22 psi) Before Operation Safety Important: Do not exceed the maximum air General Safety Note: The air pressure needed in the tires is pressure indicated on the sidewall of the tire. determined by the payload that you intend to carry. • Never allow children or untrained people to 1. operate or service the machine.
• Do not use gasoline containing methanol. • Do not store fuel either in the fuel tank or fuel • Check the fluid and engine-oil levels regularly. containers over the winter unless a fuel stabilizer is used. Do not add oil to gasoline. • • Filling the Fuel Tank • The fuel-tank capacity is approximately 26.5 L (7 US gallons). 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the engine and remove the key. 4. Clean the area around the fuel-tank cap (Figure 13).
• Before leaving the operating position, do the • You and your passengers should remain seated • • • • • • • • • • • • following: whenever the machine is moving. Keep your hands on the steering wheel; your passengers should use the handholds provided. Keep your arms and legs within the machine body at all times. Operate the machine only in good visibility. Watch for holes, ruts, bumps, rocks, or other hidden objects. Uneven terrain could overturn the machine. Tall grass can hide obstacles.
on level ground. If you must stop the machine, avoid sudden speed changes, which can cause the machine to tip or roll over. Do not engage the brakes suddenly when rolling rearward, as this may cause the machine to overturn. CAUTION If a load is concentrated near the back of the cargo bed when you release the latches, the bed may unexpectedly tip open, injuring you or bystanders. Loading and Dumping Safety • Center loads in the cargo bed, if possible.
Lowering the Cargo Bed Opening the Tailgate WARNING The weight of the bed may be heavy. Hands or other body parts could be crushed. 1. Ensure that the cargo bed is down and latched. 2. Lift up the finger pulls at the back panel of the tailgate (Figure 16). Keep your hands and other body parts clear when lowering the bed. 1. Raise the cargo bed slightly by lifting up the latch lever (Figure 14). 2. Pull the prop rod out of the detent slot (Figure 15). 3.
Note: When using key start mode, you can engage the parking brake and work away from the machine while the engine still runs and the battery holds a charge. Note: If you turn the key to the START position, the engine cranks until it starts. If the engine cranks for more than 10 seconds, return to the OFF position, and determine the issue (e.g., the choke controls needs to be engaged, check the air cleaner for restrictions, ensure that the fuel tank is full, the spark is bad, etc.
Loading the Cargo Bed Refer to the following table for load volume limits with various materials: Use the following guidelines when loading the cargo box and operating the machine: Material Use the following guidelines when loading the cargo bed and operating the machine: • Observe the weight capacity of the machine and limit the weight of the load that you carry in the cargo bed as described in Specifications (page 14) and on the gross vehicle weight tag of the machine.
After Operation After Operation Safety General Safety • Allow the engine to cool before storing the machine g008400 in any enclosure. Figure 19 • Do not store the machine or fuel container where 1. Rear tie-down points there is an open flame, spark, or pilot light, such as on a water heater or other appliance. • Keep all parts of the machine in good working Towing the Machine condition and all hardware tightened. • Replace all worn, damaged, or missing decals.
Towing a Trailer The machine is capable of pulling trailers. A tow hitch is available for the machine. Contact your authorized Toro distributor for details. When hauling cargo or towing a trailer, do not overload your machine or trailer. Overloading either the machine or the trailer can cause poor performance or damage to the brakes, axle, engine, transaxle, steering, suspension, body structure, or tires. Always load a trailer with 60% of the cargo weight in the front of the trailer.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Note: Download a copy of the electrical schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. Important: Refer to your engine owner’s manual for additional maintenance procedures. WARNING Failure to properly maintain the machine could result in premature failure of machine systems, causing possible harm to you or bystanders.
Maintenance Service Interval Maintenance Procedure Every 100 hours • • • • • • • • • • • • • • Grease the bearings and bushings. Replace the air filter. Replace the air filter element sooner if it dirty or damaged. Change the engine oil. Change the engine-oil filter. Check the spark plugs. Check the air filter for the carbon canister. Check the condition of the tires and rims. Torque the wheel-lug nuts. Inspect the steering and suspension for loose or damaged components.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Monday Tuesday Wednesday Check the brake and parking brake operation. Check the gear shift/neutral operation. Check the fuel level. Check the engine-oil level. Check the transaxle-fluid level. Inspect the air filter. Inspect the engine-cooling fins. Check for unusual engine noises. Check for unusual operating noises. Check the tire pressure. Check for fluid leaks. Check the instrument operation.
Maintaining the Machine under Special Operating Conditions Important: If the machine is subjected to any of the conditions listed below, perform maintenance twice as frequently: • • • • • • Desert operation Cold climate operation—below 10°C (50°F) Trailer towing Frequent operation in dusty conditions Construction work After extended operation in mud, sand, water, or similar dirty conditions, have your brakes inspected and cleaned as soon as possible.
Accessing the Hood Lifting the Machine Raising the Hood DANGER The machine may be unstable when using a jack. The machine could slip off the jack, injuring anyone beneath it. 1. Lift up the handle of the rubber latches on each side of the hood (Figure 22). • Do not start the machine while the machine is on a jack. • Always remove the key from the key switch before getting off the machine. • Block the tires when the machine is supported by lifting equipment.
Lubrication Greasing the Front Wheel Bearings Greasing the Machine Service Interval: Every 300 hours Service Interval: Every 100 hours/Yearly (whichever comes first)—Grease the bearings and bushings. Grease the machine more frequently when using it for heavy-duty operations. Grease specification: Mobilgrease XHP™-222 Removing the Hub and Rotor 1. Lift the front of the machine and support it with jack stands. 2. Remove the 4 lug nuts that secure the wheel to the hub (Figure 25). Grease Type: No.
g033049 Figure 28 1. Spindle 2. Hub and rotor assembly g033047 Figure 26 1. Flange-head bolts (3/8 x 3/4 inch) 3. Caliper bracket (brake assembly) 2. Spindle 4. Remove the dust cap from the hub (Figure 27). g033048 Figure 27 1. Cotter pin 4. Spindle nut 2. Spindle 5. Nut retainer 3. Tab washer 6. Dust cap 5. Remove the cotter pin and nut retainer from the spindle and spindle nut (Figure 27). 6.
Installing the Hub and Rotor Greasing the Wheel Bearings 1. 1. Remove the outboard bearing and bearing race from the hub (Figure 29). Apply a light coat of the specified grease to the spindle (Figure 30). g033050 Figure 29 g033051 Figure 30 1. Seal 4. Bearing cavity (hub) 2. Inboard bearing 5. Outboard-bearing race 1. Nut retainer 4. Outer bearing 3. Inboard-bearing race 6. Outboard bearing 2. Spindle nut 5. Hub, rotor, inner bearing, race, and seal 6. Spindle 3. Tab washer 2.
Engine Maintenance Engine Safety • Shut off the engine, remove the key, and wait for all moving parts to stop before checking the oil or adding oil to the crankcase. • Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces. Servicing the Air Filter g033054 Figure 31 1. Cotter pin Service Interval: Every 100 hours Replace the air filter element sooner if it dirty or damaged. 3. Dust cap 2. Nut retainer 9.
1. Clean the dirt ejection port located on the air-filter cover. 2. Remove the rubber outlet valve from the cover, clean the cavity, and replace the outlet valve. 3. Insert the air-filter element into air-filter housing (Figure 33). Note: Ensure that the filter is sealed properly by applying pressure to the outer rim of the filter when installing it. Do not press on the flexible center of the filter. g027733 4. Align the air-cleaner cover with the air-cleaner housing (Figure 33). 5.
Servicing the Engine Oil Service Interval: After the first 25 hours Every 100 hours (Change the oil twice as often during special operating conditions; refer to Maintaining the Machine under Special Operating Conditions (page 27). Note: Change the oil more frequently when operating conditions are extremely dusty or sandy. g002132 Note: Dispose of the used engine oil and oil filter at a Figure 35 certified recycling center. 1. Oil dipstick (loop down) Engine-Oil Specifications 6.
Servicing the Spark Plugs Service Interval: Every 100 hours/Yearly (whichever comes first) Replace the spark plug if necessary. Type: Champion RN14YC (or equivalent) Air Gap: 0.03 inch (0.762 mm) Important: A cracked, fouled, dirty, or malfunctioning spark plug must be replaced. Do not sand-blast, scrape, or clean electrodes by using a wire brush because grit may eventually release from the plug and fall into the cylinder. The result is usually a damaged engine. g009200 Figure 36 1. Drain plug 8. 2.
Adjusting the High/Low Idle Fuel System 1. Lift the cargo bed and secure it open with the prop rod. Maintenance 2. With the machine off, fully depress the accelerator pedal and measure the gap between the leading edge of the governor bellcrank and the bracket tab. This gap should be between 0.8 to 2.0 mm (.03 to .08 inches). Inspecting Fuel Lines and Connections 3. At the throttle cable, loosen the forward jam nut and tighten the rear jam nut to increase the low idle (Figure 38).
Servicing the Carbon Canister Checking the Air Filter for the Carbon Canister Service Interval: Every 100 hours—Check the air filter for the carbon canister. Check the opening at the bottom of the air filter for the carbon canister to ensure that it is clean and free of debris and obstructions (Figure 40). g024478 Figure 41 1. Carbon-canister filter 2. Carbon canister 2. g014998 Figure 40 1.
Replacing the Carbon Canister Note: Replace the carbon canister if it is damaged, plugged, or if the machine is run without a carbon-canister filter. Note: Replace the carbon-canister filter when replacing the carbon canister. Disconnecting the Controls at the Seat Base 1. Remove the knob from the gear-shift lever (Figure 42). g029670 Figure 43 1. Cable tie 2. Parking-brake cable 6. Front of the machine 7. Clevis 3. Forward-jam nut 8. Cotter pin 4. Brake-cable bracket 9. Clevis pin 5.
2. Carefully lift the seats, seat base, and parking brake cables from the machine (Figure 44). Important: Note the routing of the parking-brake cables along the chassis as you lift the seats and seat base from the machine. g029659 Figure 45 g029628 Figure 47 1. Carbon canister 2. Carbon-canister mount (fuel tank) Replacing the Carbon Canister 1. Remove the vacuum hose from the fitting on the carbon canister marked Purge (Figure 46). 4. 3.
7. Insert the new carbon canister into the carbon-canister mount of the fuel tank with the purge and fuel tank fittings aligned rearward (Figure 47). 8. Assemble the vacuum hose onto the fitting on the carbon canister marked Purge and the fuel-tank hose to the onto the fitting marked Fuel Tank (Figure 46). 4. Installing the Seats and Seat Base 1. Lift the seats and seat base onto the machine and align brake cables to the chassis (Figure 44 and Figure 45). 2.
Disconnecting the Battery Electrical System Maintenance WARNING Incorrect battery cable routing could damage the machine and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. Electrical System Safety WARNING • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
Installing the Battery 1. Align the battery to the battery tray of the machine (Figure 49). Note: Ensure that the positive and negative posts of the battery are aligned as shown in Figure 49. 2. Secure the battery to the battery tray with the battery clamp, carriage bolt, and locknut (Figure 49). 3. Connect the battery cables; refer to Connecting the Battery (page 42). Connecting the Battery 1. Connect the positive battery cable to the terminal of the battery (Figure 49). 2.
Replacing the Fuses 1. Disconnect the battery; refer to Disconnecting the Battery (page 41). There are 4 fuses in the electrical system. They are located beneath the hood (Figure 50). 2. Open the hood. 3. Disconnect the electrical connector for the harness from the connector of the lamp assembly at the back of the headlight housing (Figure 51). Lift/gate (Open) 30 A Horn/power point 20 A Headlights 15 A Machine fuse 10 A g036872 Figure 51 1. Headlight housing g202997 2.
Adjusting the Headlights Replacing the Headlight 1. Disconnect the battery; refer to Disconnecting the Battery (page 41). 2. Open the hood; refer to Raising the Hood (page 28). 3. Use the following procedure to adjust the headlight beam position whenever a headlight assembly is replaced or removed. Disconnect the electrical connector for the harness from the connector of the lamp assembly (Figure 52). g036873 Figure 52 1. Speed clip 4. Headlight 2. Opening in the bumper 5. Lamp assembly 3.
Drive System Maintenance Maintaining the Tires Service Interval: Every 100 hours—Check the condition of the tires and rims. Every 100 hours—Torque the wheel-lug nuts. 1. Inspect the tires an rims for signs of wear and damage. Note: Operating accidents, such as hitting curbs, can damage a tire or rim and also disrupt wheel alignment, so inspect tire condition after an accident. g313199 2. Figure 53 Torque the wheel-lug nuts to 108 to 122 N∙m (80 to 90 ft-lb). 1.
Adjusting the Front Wheel Alignment Adjusting the Front Wheel Toe-in Important: Before adjusting toe-in, ensure that the camber adjustment is as close to neutral as possible; refer to Adjusting the Camber (page 46). Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the front wheel camber and toe-in. 1. Preparing to Adjust Camber or Toe-in 1. Check the tire pressure to ensure that the front tires are inflated to 82 kPa (12 psi). 2.
Checking the Transaxle-Fluid Level Service Interval: Every 100 hours Fluid Type: SAE 10W30 (API service SJ or higher) 1. 2. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key. g002109 Figure 59 Remove the bolt from the level-indicating hole (Figure 58). 1. Drain plug Note: The transaxle fluid level should be at the bottom of the level indicator hole. 3. Align a drain pan with a capacity of 2 L (2.1 qt) or more under the drain plug. 4.
10. Check the fluid level and add more fluid if the level is below the threads of the fill-plug hole (Figure 59). 5. Checking and Adjusting Neutral Pull up on each shift cable an ensure that there is a 0.76 to 1.52 mm (0.03 to 0.06 inch) between the nut/washer and the neutral bracket (Figure 62). Note: If there is a not a gap, adjust the nuts to achieve the specified gap.
g026341 Figure 64 g011947 1. Clutch spacer Figure 63 1. Cover 2. Bolts 3. Remove the spring. Add or remove spacers to adjust the top speed. Use the following table to determine the amount of spacers needed. 3. Thoroughly clean the inside of the cover and the inner components of the clutch using compressed air. 4. 4. Install the clutch cover and secure it with the 3 bolts (Figure 63) that you removed in 2.
Cooling System Maintenance Brake Maintenance Cleaning the Engine-Cooling Areas Service Interval: Every 100 hours Inspecting the Brakes Important: Brakes are a critical safety component of the machine. Closely inspect them at the recommended service interval to ensure optimum performance and safety. Service Interval: Every 100 hours Clean the cooling system twice as often during special operating conditions; refer to Maintaining the Machine under Special Operating Conditions (page 27).
4. procedure for adjusting the brake cables; refer to Adjusting the Brake Cables (page 51). parking-brake lever with a a force of 133 to 156 N (30 to 35 lbf), perform the following: Tighten the set screw and install the hand grip (Figure 65). A. Loosen the rear jam nut (Figure 66) for the threaded adjuster of the parking-brake cable 1 turn. B. Tighten the forward jam nut (Figure 66). C.
Checking the Brake-Fluid Level B. Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line (Figure 68). Note: Do not overfill the reservoir with brake fluid. Service Interval: Before each use or daily—Check the brake-fluid level. Check the brake-fluid level before you first start the engine. C. 7. Brake-fluid type: DOT 3 Install the reservoir cap (Figure 67). Close the hood. 1. Park the machine on a level surface. 2. Engage the parking brake.
Belt Maintenance Servicing the Drive Belt 5. Align the new belt over the primary clutch (Figure 69). 6. Rotate and route the belt over the secondary clutch (Figure 69). 7. Lower the cargo bed; refer to Lowering the Cargo Bed (page 19). Checking the Drive Belt Service Interval: After the first 8 hours Adjusting the Starter-Generator Belt Every 200 hours 1. 2. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key.
Chassis Maintenance Cleaning Adjusting the Cargo-Bed Latches Washing the Machine Wash the machine as needed. Use water alone or with a mild detergent. You can use a rag. If the cargo-bed latch is out of adjustment, the cargo bed vibrates up and down as you drive the machine. You can adjust the latch posts to make the latches hold the cargo bed snugly to the chassis. 1. Important: Do not use pressurized water when washing the machine.
Storage 1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key. 2. Clean the dirt and grime from the entire machine, including the outside of the cylinder-head fins of the engine and blower housing. 11. Use the electric starter to crank the engine and distribute the oil inside the cylinder. 12. Install the spark plug(s) and tighten it to recommended torque; refer to Servicing the Spark Plugs (page 35).
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The Toro Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your Toro Commercial product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
