Form No. 3406-473 Rev E Workman® MDX Utility Vehicle Model No. 07235—Serial No. 316000001 and Up Model No. 07235TC—Serial No. 316000001 and Up Register at www.Toro.com.
on the product. Write the numbers in the space provided. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Replacing the Fuel Filter ................................... 36 Servicing the Carbon Canister .......................... 36 Electrical System Maintenance ........................... 40 Servicing the Battery......................................... 40 Replacing the Fuses ......................................... 42 Maintaining the Headlights ............................... 42 Drive System Maintenance .................................. 44 Maintaining the Tires ......................................
Before Operating Safety • This machine is designed to carry only you, the 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, which means Caution, Warning, or Danger—personal safety instruction. Failure to comply with the instruction may result in personal injury or death. • The machine meets the requirements of SAE J2258.
• Never store the machine or fuel container where • • • there is an open flame, spark, or pilot light, such as on a water heater or on other appliances. Remove equipment from the truck or trailer and refuel it on the ground. If this is not possible, then refuel such equipment with a portable container rather than from a fuel-dispenser nozzle. If fuel is spilled on clothing, change clothing immediately. Never overfill the fuel tank. Replace the fuel cap and tighten it securely.
• Turning while traveling up or down hills can be and attachments make the machine harder to stop or turn. The heavier the load, the longer it takes to stop. dangerous. If you have to turn while on a hill, do it slowly and cautiously. Never make sharp or fast turns. • Decrease the speed of the machine if the • Heavy loads affect stability. Reduce the weight of cargo box has been removed and there is no attachment installed on the machine.
Operating on Rough Terrain • The rear cargo space is intended for load carrying Reduce the ground speed of the machine and load carried in the machine when operating on rough terrain, uneven ground, and near curbs, holes, and other sudden changes in terrain. Loads may shift, causing the machine to become unstable. • WARNING Maintenance Sudden changes in terrain may cause abrupt steering wheel movement, possibly resulting in hand and arm injuries.
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. 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.
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. Crushing hazard, cargo box—use the prop rod to support the cargo bed. decal99-7952 99-7952 3. Neutral 4. Forward 1. Choke 2. Reverse decal115-2412 decal112-3325 115-2412 112-3325 1. Warning—read the Operator's Manual; no storage. 4. Headlights (15 A) 1.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. Steering wheel Steering wheel cover Locknut (1/2 inch) Washer (1/2 inch) Dust cover 1 1 1 1 1 Install the steering wheel (Model 07235TC only). No parts required – Connect the battery (Model 07235TC only). No parts required – Check the fluid levels and tire pressure.
2 Connecting the Battery (Model 07235TC Only) No Parts Required g033852 Procedure Figure 5 1. Insulator boot (positive-battery cable) WARNING 2. Negative-battery post Incorrect battery-cable routing could damage the machine and cables, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 4. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. Slide the insulator boot over the positive terminal.
4 5 Reading the Manual and Burnishing the Brakes Viewing the Safety Training No Parts Required Material Procedure Parts needed for this procedure: 1 Operator's Manual 1 Engine owner’s manual 1 Safety training material 1 Registration card 1 Predelivery Inspection Form 1 Certificate of Quality 2 Key To ensure optimum performance of the brake system, burnish (break-in) the brakes before use. 1.
Product Overview g033215 Figure 6 1. Hood latch 3. Cargo box 5. Gear-shift selector 2. Parking-brake handle 4. Towing tongue 6. Fuel cap Controls 7. Cargo-box lever Accelerator Pedal Use the accelerator pedal (Figure 7) to vary ground speed of the machine. Pressing down the accelerator pedal starts the engine. Pressing the pedal farther increases ground speed. Releasing the pedal slows the machine, and the engine shuts off. Note: The maximum forward speed is 26 km/h (16 mph).
Parking-Brake Lever The parking-brake lever is located between the seats (Figure 6 and Figure 7). Whenever you shut off the engine, engage the parking brake to prevent the machine from accidentally moving. To engage the parking brake, pull up the parking-brake lever. To disengage the parking brake, push the lever down. Choke Control 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).
Key Switch Passenger Handholds The key switch (Figure 9), is used to run and shut off the engine, and has 2 positions: ON and OFF. Rotate the key clockwise to the ON position to run the engine to operate the machine. When the machine is stopped, rotate the key counterclockwise to the OFF position to shut off the engine. Remove the key from the key switch when you leave the machine. The passenger handholds are located on the right side of the dash panel and at the outside of each seat (Figure 11).
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.
Operation Operating the Cargo Box Note: Determine the left and right sides of the machine from the normal operating position. Raising the Cargo Box WARNING Think Safety First A raised box could fall and injure persons that are working beneath it. Carefully read all safety instructions and symbols in the safety section. Knowing this information could help you or bystanders avoid injury. • Always use the prop rod to hold the box up before working under the box.
Opening the Tailgate 1. Ensure that the cargo box is down and latched. 2. Lift up the finger pulls at the back panel of the tailgate (Figure 15). g014860 Figure 13 1. Lever 2. Prop rod 2. 3. Detent slot Pull the prop rod into the detent slot, securing the box (Figure 14). g024490 Figure 15 1. Tailgate flange (cargo box) 3. Lift up (finger pull) 2. Lock flange (tailgate) 4. Rotate rearward and down 3.
• Check the brake pedal operation. • Check to see that the lights are working. • Turn the steering wheel to the left and right to check steering response. • Check for oil leaks, loose parts, and any other noticeable malfunctions. Note: Shut off the engine and allow all moving parts to stop before checking for oil leaks, loose parts, and other wear and damage. g024491 Figure 16 1. Rotate the tailgate to approximately the 45° position.
g002136 Figure 18 1. Brake-fluid reservoir 4. g002134 2. Minimum line Figure 19 If the fluid level is low, preform the following: A. Clean the area around the reservoir cap and remove the cap (Figure 17). B. Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line (Figure 18). Note: Do not overfill the reservoir with 1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key from the key switch. 2.
Important: Make sure that the loop end of the oil dipstick is pointing down. 10. DANGER In certain conditions, fuel is extremely flammable and highly explosive. A fire or explosion from fuel can burn you and others and can damage property. Lower the cargo box; refer to Lowering the Cargo Box (page 18). Checking the Tire Pressure • Fill the fuel tank outdoors, in an open area, when the engine is cold. Wipe up any fuel that spills.
Filling the Fuel Tank DANGER The fuel-tank capacity is approximately 26.5 L (7 US gallons). In certain conditions during fueling, static electricity can be released and cause a spark, which can ignite the fuel vapors. A fire or explosion from fuel can burn you and others and can damage property. 1. Shut off the engine and engage the parking brake. 2. Clean the area around the fuel-tank cap (Figure 21). • Always place fuel containers on the ground away from your machine before filling.
4. • Refer to the Maintenance (page 26) for any special Slowly step on the accelerator pedal. low hour checks. Note: If the engine is cold, press and hold the • Check the front suspension positioning and adjust accelerator pedal about half-way down, and pull the choke knob out to the ON position. Return the choke knob to the OFF position after the engine warms up. it if necessary; refer to Adjusting the Front Wheel Toe-in and Camber (page 45).
Loading the Cargo Box See the table below for load volume limits with various materials: Use the following guidelines when loading the cargo box and operating the machine: Material Density Maximum Cargo Box Capacity (on level ground) • Observe the weight capacity of the machine and limit the weight of the load that you carry in the cargo box as described in Specifications (page 16) and on the gross vehicle weight tag of the machine.
Transporting the Machine Towing the Machine Use a trailer with full-width ramps to move the machine a long distance. Make sure that the machine is securely bound to the trailer. Refer to Figure 22 and Figure 23 for the location of the tie-down points on the machine. In case of an emergency, you can tow the machine for a short distance. However, this should not be a standard operating procedure. WARNING Towing at excessive speeds could cause a loss of steering control, resulting in personal injury.
Maintenance Note: Download a copy of the electrical schematic by visiting www.Toro.com and search your machine from the Manuals link. Note: Determine the left and right sides of the machine from the normal operating position. Important: Refer to your engine owner's manual for additional maintenance procedures. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 8 hours • Check the condition of the drive belt.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Monday Tuesday Wednesday Thursday Friday Saturday Sunday 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.
Pre-Maintenance Procedures Lifting the Machine DANGER The machine may be unstable when using a jack. It could slip off the jack, injuring anyone beneath it. Maintaining the Machine under Special Operating Conditions • Do not start the engine while the machine is on a jack. • Always remove the key from the key switch before getting off the machine. If the machine is subjected to any of the conditions listed below, maintenance should be performed twice as frequently.
Accessing the Hood Lubrication Raising the hood Greasing the Machine 1. Lift up the handle of the rubber latches at each side of the hood (Figure 26). 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 Type: No. 2 lithium grease 1. Use a rag to wipe the grease fitting clean so that foreign matter cannot be forced into the bearing or bushing. 2.
Greasing the Front Wheel Bearings Service Interval: Every 300 hours 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 29). g033047 Figure 30 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 31). g033046 Figure 29 1. Hub 3. Lug nut 2. Wheel 3.
Greasing the Wheel Bearings 1. Remove the outboard bearing and bearing race from the hub (Figure 33). g033049 Figure 32 1. Spindle 2. Hub and rotor assembly 7. Wipe clean the spindle with a rag. 8. Repeat steps 1 through 7 to the hub and rotor at the other side of the machine. g033050 Figure 33 1. Seal 4. Bearing cavity (hub) 2. Inboard bearing 5. Outboard-bearing race 3. Inboard-bearing race 6. Outboard bearing 2. Remove the seal, inboard bearing from the hub (Figure 33). 3.
Installing the Hub and Rotor 1. Apply a light coat of the specified grease to the spindle (Figure 34). g033054 Figure 35 1. Cotter pin 3. Dust cap 2. Nut retainer g033051 Figure 34 1. Nut retainer 4. Outer bearing 2. Spindle nut 5. Hub, rotor, inner bearing, race, and seal 6. Spindle 3. Tab washer 2. Assemble the hub and rotor onto the spindle with the rotor inboard (Figure 34). 3. Assemble the outboard bearing onto the spindle and seat the bearing to the outboard race (Figure 34). 4.
Engine Maintenance Servicing the Air Filter Service Interval: Every 100 hours Replace the air filter element sooner if it dirty or damaged. Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy. g027733 Checking the Air Filter 1. 2. Figure 37 Raise the cargo box and secure it with the prop rod. 1. Air-filter housing 3. Air-filter cover 2. Air-filter element 4.
1. Clean the dirt ejection port located on the air-filter cover. 2. 3. 2. Remove the rubber outlet valve from the cover, clean the cavity, and replace the outlet valve. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key from the key switch. 3. Insert the air-filter element into air-filter housing (Figure 37). Raise the cargo box and secure it with the prop rod; refer to Raising the Cargo Box (page 17). 4.
10. Important: A cracked, fouled, dirty, or Insert the dip stick fully into the dipstick tube, remove the dipstick, and check the oil level (Figure 40). 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. Note: If necessary, add the specified oil into the engine until the oil level is at the Full mark on the dipstick. 11.
Fuel System Maintenance Servicing the Carbon Canister Inspecting Fuel Lines and Connections Checking the Air Filter for the Carbon Canister Service Interval: Every 100 hours—Check the air filter for the carbon canister. Service Interval: Every 400 hours/Yearly (whichever comes first) 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 43).
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 45). g024478 Figure 44 1. Carbon-canister filter 2. Carbon canister 2. 3. Hose 4.
2. Carefully lift the seats, seat base, and parking brake cables from the machine (Figure 47). Important: Note the routing of the parking-brake cables along the chassis as you lift the seats and seat base from the machine. g029670 Figure 46 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. Rear-jam nut g029659 Figure 48 10. Brake-actuating lever Replacing the Carbon Canister 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 50). 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 49). Installing the Seats and Seat Base 1. Lift the seats and seat base onto the machine and align brake cables to the chassis (Figure 47 and Figure 48). 2.
4. Electrical System Maintenance Thread the knob from the gear-shift lever and tighten the knob by hand (Figure 45). Servicing the Battery Battery voltage: 12 V with 300 A (cold cranking) at -18°C (0°F). WARNING CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling.
Disconnecting the Battery 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. • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable. • Always connect the positive (red) battery cable before connecting the negative (black) cable. • Always keep the battery strap in place to protect and secure the battery.
Replacing the Fuses Installing the Battery 1. Align the battery to the battery tray of the machine (Figure 52). There are 3 fuses in the electrical system. They are located beneath the hood (Figure 53). Note: Ensure that the positive and negative posts of the battery are aligned as shown in Figure 52. 2. 3. Secure the battery to the battery tray with the battery clamp, carriage bolt, and locknut (Figure 52).
1. Disconnect the battery; refer to Disconnecting the Battery (page 41). 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 54). Replacing the Headlight 1. Disconnect the battery; refer to Disconnecting the Battery (page 41). 2. Open the hood; refer to Closing the Hood (page 29). 3. Disconnect the electrical connector for the harness from the connector of the lamp assembly (Figure 55).
Adjusting the Headlights Drive System Maintenance Use the following procedure to adjust the headlight beam position whenever a headlight assembly is replaced or removed. 1. Turn the key switch to the ON position, and turn on the headlights. 2. At the back of the headlight assembly, rotate adjustment screws (Figure 55) to pivot the headlight assembly and align the position of the cast beam. Maintaining the Tires Service Interval: Every 100 hours—Check the condition of the tires and rims.
Inspecting the Steering and Suspension Components Service Interval: Every 100 hours—Inspect the steering and suspension for loose or damaged components. With the steering wheel at the centered position (Figure 56), turn the steering wheel to the left or right.
g033219 g033218 Figure 60 Figure 58 1. Shock-absorber spring 1. Tie rod 3. Spring length 2. Jam nut 2. Collar 2. 3. On a level surface, roll the machine straight back 2 to 3 m (6 to 10 ft) and then straight forward to the original starting position. Measure the distance between both of the front tires at the axle height at both the front and rear of the front tires (Figure 59). 5. Rotate both tie rods to move the front of the tire inward or outward. 6.
Changing the Transaxle Fluid Service Interval: Every 800 hours/Yearly (whichever comes first) Fluid Type: SAE 10W30 (API service SJ or higher) Fluid Capacity: 1.4 L (1.5 US qt) 1. 2. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key from the key switch. 1. Fluid fill Wipe the area around the fill and drain plugs clean with a rag (Figure 62). 8. Install and tighten the fill plug and gasket into the fill-plug hole of the transmission (Figure 62). 9.
Checking and Adjusting Neutral Note: If there is a not a gap, adjust the nuts to achieve the specified gap. Service Interval: Every 100 hours When performing routine maintenance and/or engine diagnostics, the transaxle must be shifted into NEUTRAL (Figure 64). The machine has a NEUTRAL position on the shift lever, which controls the neutral in the transaxle. The following steps should be taken to make sure that the neutral shift lever operates the transaxle neutral correctly: 1.
Maintaining the Primary-Drive Clutch Cooling System Maintenance Service Interval: Every 400 hours/Yearly (whichever comes first) Cleaning the Engine-Cooling Areas CAUTION The dust in the clutch will become airborne and could damage your eyes or you could inhale it, causing breathing difficulties. 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 28).
Brake Maintenance procedure for adjusting the brake cables; refer to Adjusting the Brake Cables (page 50). 4. Inspecting the Brakes Tighten the set screw and install the hand grip (Figure 67). Service Interval: Every 100 hours Adjusting the Brake Cables Important: Brakes are a critical safety component of the machine. Closely inspect them at the recommended service interval to ensure optimum performance and safety. • Inspect the brake lining for wear or damage. If the 1.
Belt Maintenance • If you cannot adjust the brake-adjustment knob by tightening it and engage the parking-brake lever with a a force of 133 to 156 N (30 to 35 lbf), perform the following: A. Servicing the Drive Belt Loosen the rear jam nut (Figure 68) for the threaded adjuster of the parking-brake cable 1 turn. B. Tighten the forward jam nut (Figure 68). C. Rotate the brake-adjustment knob (Figure 67) until a force of 133 to 156 N (30 to 35 lbf) is required to engage the parking-brake lever. D.
6. Rotate and route the belt over the secondary clutch (Figure 69). 7. Lower the cargo box; refer to Lowering the Cargo Box (page 18). Chassis Maintenance Adjusting the Cargo-Box Latches Adjusting the Starter-Generator Belt If the cargo-box latch is out of adjustment, the cargo box vibrates up and down as you drive the machine. You can adjust the latch posts to make the latches hold the cargo box snugly to the chassis. Service Interval: After the first 8 hours Every 200 hours 1. 1.
Cleaning Washing the Machine Wash the machine as needed. Use water alone or with a mild detergent. You can use a rag. Important: Pressurized water is not recommended when washing the machine. It may damage the electrical system, loosen important decals, or wash away necessary grease at friction points. Avoid excessive use of water, especially near the control panel, engine, and battery.
Storage 1. 2. Choke the engine. F. Start and run the engine until it does not start again. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key from the key switch. 9. Clean the dirt and grime from the entire machine, including the outside of the cylinder-head fins of the engine and blower housing. 10. With the spark plugs removed from the engine, pour 2 tablespoons of engine oil into each spark plug hole. 11.
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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).
