Form No. 3413-372 Rev C Workman® MDX Utility Vehicle Model No. 07235—Serial No. 400000000 and Up Model No. 07235TC—Serial No. 400000000 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Fuel System Maintenance ................................... 36 Inspecting Fuel Lines and Connections............. 36 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 ...............................
Safety • Become familiar with the safe operation of 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. • • equipment, operator controls, and safety signs.
may cause the rear wheels to lock up, which impairs your control of the machine. affects the steering, braking, and stability of the machine. • Before you start the engine, ensure that the • Do not touch the engine, transmission, muffler, or transmission is in neutral, the parking brake is engaged, and you are in the operating position. muffler manifold while the engine is running, or soon after you shut off the engine, because these areas may be hot enough to cause burns.
Loading and Dumping Safety Slope Safety Note: A 2-post Rollover Protection System (ROPS) is available for this machine as an accessory. Use a ROPS if you will work next to drop-offs, near water, in rough terrain, or on a slope, which could result in a rollover. Contact an authorized Toro distributor for more information. • Do not exceed the gross vehicle weight (GVW) of the machine when operating it with a load in the cargo bed and/or towing a trailer; refer to Towing a Trailer (page 22).
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 5 Burnishing the Brakes Reading the Manual and Viewing the Setup Material No Parts Required Parts needed for this procedure: Procedure To ensure optimum performance of the brake system, burnish (break-in) the brakes before use. 1. 2. Bring the machine up to full speed, apply the brakes to rapidly stop the machine without locking up the tires. Repeat this procedure 10 times, waiting 1 minute between stops, to avoid overheating the brakes.
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 Accelerator Pedal 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.
Parking-Brake Lever Horn Button 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. TC Models Only The horn button is located at the lower, left corner of the dash panel (Figure 9). Press the horn button to sound the horn.
Hour Meter The hour meter indicates the total hours of machine operation. The hour meter (Figure 9) starts to function whenever you rotate the key switch to the ON position or if the engine is running. Engine Oil-Pressure Light 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.
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 Bed Note: Determine the left and right sides of the machine from the normal operating position. Raising the Cargo Bed WARNING CAUTION A raised bed could fall and injure persons that are working beneath it. A raised bed full of material without the proper safety support may lower unexpectedly. Working under an unsupported raised bed could injure you or others. • Always use the prop rod to hold the bed up before working under the bed.
Opening the Tailgate 1. Ensure that the cargo bed is down and latched. 2. Lift up the finger pulls at the back panel of the tailgate (Figure 14). g014860 Figure 12 1. Lever 2. Prop rod 2. 3. Detent slot Pull the prop rod into the detent slot to secure the bed (Figure 13). g024490 Figure 14 1. Tailgate flange (cargo bed) 3. Lift up (finger pull) 2. Lock flange (tailgate) 4. Rotate rearward and down 3.
Performing Daily Maintenance Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 23). Checking the Tire Pressure g024491 Service Interval: Before each use or daily Figure 15 1. Rotate the tailgate to approximately the 45° position. 3. Hinge area Front and rear tires air pressure specification: 55 to 103 kPa (8 to 22 psi) Important: Do not exceed the maximum air 2. Rotate the tailgate back and forth several times. 3.
Adding Fuel DANGER Under 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. Recommended fuel: • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).
Filling the Fuel Tank Note: While in the START position, you can engage the parking brake and work while the battery holds a charge. 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 17). Note: If you turn the key to the START position, the engine cranks until it starts.
Breaking in a New Machine Important: Tipping over is more likely to occur if the cargo bed is loaded to 1 side. Service Interval: After the first 100 hours—Perform the guidelines for breaking in a new machine. – Evenly position the weight in the cargo bed from front to back. Important: Loss of steering control or the Perform the following guidelines to provide proper performance for the machine.
Transporting the Machine Towing the Machine Use a trailer with full-width ramps to move the machine a long distance. Ensure that you secure the machine to the trailer. Refer to Figure 18 and Figure 19 for the tie-down locations 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 Note: Load the machine on the trailer with the front of the machine facing forward.
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. WARNING Failure to properly maintain the machine could result in premature failure of machine systems causing possible harm to you or bystanders. Keep the machine well maintained and in good working order as indicated in these instructions.
Maintenance Service Interval Maintenance Procedure Every 100 hours • • • • • • • • • • • • • • Grease the bearings and bushings. Change the oil filter. Change the engine oil. Replace the air filter. Replace the air filter element sooner if it dirty or damaged. 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 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.
Maintaining the Machine under Special Operating Conditions clothing, and any parts of the body away from the engine and any moving parts. Keep bystanders away from the machine. • Clean up oil and fuel spills. • Check the parking brake operation frequently. Important: If the machine is subjected to any of Adjust and service as required. the conditions listed below, perform maintenance twice as frequently: • Keep all parts in good working condition and all hardware tightened.
Preparing the Machine for Maintenance 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the engine and remove the key. g038494 Figure 20 Lifting the Machine DANGER The machine may be unstable when using a jack. The machine could slip off the jack, injuring anyone beneath it. • Do not start the machine while the machine is on a jack. g033043 • Always remove the key from the key switch before getting off the machine. Figure 21 1.
Accessing the Hood Lubrication Raising the Hood Greasing the Machine 1. Lift up the handle of the rubber latches on each side of the hood (Figure 23). 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 26). g033047 Figure 27 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 28). g033046 Figure 26 1. Hub 3. Lug nut 2. Wheel 3.
Greasing the Wheel Bearings 1. Remove the outboard bearing and bearing race from the hub (Figure 30). g033049 Figure 29 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 30 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 30). 3.
Installing the Hub and Rotor 1. Apply a light coat of the specified grease to the spindle (Figure 31). g033054 Figure 32 1. Cotter pin 3. Dust cap 2. Nut retainer g033051 Figure 31 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 31). 3. Assemble the outboard bearing onto the spindle and seat the bearing to the outboard race (Figure 31). 4.
Engine Maintenance 6. Align a drain pan with a 1.8 L (1.9 qt) capacity under the drain plug (Figure 33). Changing the Engine-Oil Filter Service Interval: After the first 25 hours Every 100 hours/Yearly (whichever comes first) Change the oil twice as often during special operating conditions; refer to Maintaining the Machine under Special Operating Conditions (page 26). g009200 1. Drain the oil from the engine; refer to Draining the Engine-Oil (page 32). 2. Remove the existing oil filter (Figure 33).
2. Engage the parking brake. Note: If the light does not function, either a bulb 3. Shut off the engine and remove the key. is burned out, or there is a malfunction in the system that you must repair. 4. Raise the cargo bed. 5. Use a rag to clean the area around the oil dipstick and fill cap (Figure 35) so that dirt cannot fall into the dipstick tube or oil-filler neck and damage the engine.
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 37). 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 37). 5.
Adjusting the High/Low Idle Servicing the Spark Plugs Service Interval: Every 100 hours/Yearly (whichever comes first) Replace the spark plug if necessary. 1. Lift the cargo bed and secure it open with the prop rod. 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). 3.
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 41).
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 43). g024478 Figure 42 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 45). 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 44 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 46 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 48). 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 47). Installing the Seats and Seat Base 1. Lift the seats and seat base onto the machine and align brake cables to the chassis (Figure 45 and Figure 46). 2.
4. Electrical System Maintenance Thread the knob from the gear-shift lever and tighten the knob by hand (Figure 43). 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 50). There are 4 fuses in the electrical system. They are located beneath the hood (Figure 51). Note: Ensure that the positive and negative posts of the battery are aligned as shown in Figure 50. 2. 3. Secure the battery to the battery tray with the battery clamp, carriage bolt, and locknut (Figure 50).
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 52). 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. Disconnect the electrical connector for the harness from the connector of the lamp assembly (Figure 53).
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 53) 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 54), turn the steering wheel to the left or right.
g033219 g033218 Figure 58 Figure 56 1. Shock-absorber spring 1. Tie rod 3. Spring length 2. Jam nut 2. Collar 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 45). 1. Measure the distance between both of the front tires at the axle height at both the front and rear of the front tires (Figure 57). 3. Rotate both tie rods to move the front of the tire inward or outward. 4.
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. 1. Fluid fill Wipe the area around the fill and drain plugs clean with a rag (Figure 60). 8. Install and tighten the fill plug and gasket into the fill-plug hole of the transmission (Figure 60). 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 62). The machine has a NEUTRAL position on the shift lever, which controls the neutral in the transaxle. Perform the following steps to ensure that the neutral shift lever operates the transaxle neutral correctly: 1.
g026341 Figure 65 g011947 1. Clutch spacer Figure 64 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 64) that you removed in 2.
Cooling System Maintenance Brake Maintenance Cleaning the Engine-Cooling Areas Service Interval: Every 100 hours Inspecting the Brakes Brakes are a critical safety component of the machine. As with all safety components, they should be closely inspected at regular intervals to ensure optimum performance and safety. • Inspect the brake shoes and pads for wear or damage. If the lining (brake pad) thickness is less than 1.6 mm (1/16 inch), the brake shoes should be replaced.
D. required to engage the parking-brake lever, perform the procedure for adjusting the brake cables; refer to Adjusting the Brake Cables (page 51). 4. Repeat steps A through C up to 2 more times to attain the parking brake force between 133 to 156 N∙m (30 to 35 ft-lb). • 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∙m (30 to 35 ft-lb); perform the following: Tighten the set screw and install the hand grip (Figure 66).
Checking the Brake-Fluid Level B. Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line (Figure 69). 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 68). 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 70). 6. Rotate and route the belt over the secondary clutch (Figure 70). 7. Lower the cargo bed; refer to Lowering the Cargo Bed (page 17). 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. 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. 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).
