Form No. 3437-696 Rev E Workman® MDX Utility Vehicle Model No. 07235—Serial No. 405670000 and Up Model No. 07235TC—Serial No. 405670000 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. identifies the location of the model and serial numbers on the product. Write the numbers in the space provided.
Contents Electrical System Safety ................................... 39 Servicing the Battery......................................... 39 Replacing the Fuses ......................................... 41 Maintaining the Headlights ............................... 41 Drive System Maintenance .................................. 43 Maintaining the Tires ........................................ 43 Inspecting the Steering and Suspension Components .................................................
Safety This machine has been designed in accordance with the requirements of SAE J2258 (Nov 2016). General Safety This product is capable of causing personal injury. Always follow all safety instructions to avoid serious personal injury. • Read and understand the contents of this Operator’s Manual before you start the machine. Ensure that everyone using this product knows how to use it and understands the warnings. • Use your full attention while operating the machine.
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. decal99-7345 decal115-2412 99-7345 115-2412 1. Warning—read the Operator's Manual. 1. Warning—read the Operator's Manual; no storage. 2. Warning—do not touch the hot surface. 3. Entanglement hazard, belt—stay away from moving parts; keep all guards in place. 4.
136-6313 30A 30A 15A 10A decal136-6313 136-6313 1. Read the Operator's Manual for fuse information. 2. Lift/gate (30 A) decal136-1164 5. Machine fuse (10 A) 3. Horn/power point (20 A) 136-1164 1. Do not exceed a tongue weight of 45 kg (100 lb). 4. Headlights (15 A) 2. Do not exceed a transport load of 363 kg (800 lb). decal138-3521 138-3521 1. Horn 7. Headlights 2. Warning—read the Operator's Manual. 8.
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 7. Cargo-bed lever Controls Accelerator Pedal Become familiar with all the controls before you start the engine and operate the machine. 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.
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).
Engine Oil-Pressure Light Fuel Gauge 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 32). 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.
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.
Performing Daily Maintenance Operation Note: Determine the left and right sides of the machine from the normal operating position. Service Interval: Before each use or daily Before Operation Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 23).
Adding Fuel Recommended fuel: 5. Remove the fuel-tank cap. 6. Fill the tank to about 25 mm (1 inch) below the top of tank, (bottom of the filler neck). • For best results, use only clean, fresh (less than Note: This space in the tank allows fuel to expand. Do not overfill the fuel tank.. 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method). • Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable.
During Operation During Operation Safety • General Safety • The owner/operator can prevent and is responsible • • • • • • • • • • • • • for accidents that may cause personal injury or property damage. Passengers should sit in the designated seating positions only. Do not carry passengers in the cargo bed. Keep bystanders and children out of the operating area. Wear appropriate clothing, including eye protection; long pants; substantial, slip-resistant footwear; and hearing protection.
in weight distribution may cause the machine to overturn. in rough terrain, or on a slope, which could result in a rollover. Contact an Authorized Service Dealer for more information. Slopes are a major factor related to loss-of-control and tip-over accidents, which can result in severe injury or death. Operating the Cargo Bed • Survey the site to determine which slopes are Raising the Cargo Bed safe for operating the machine and establish your own procedures and rules for operating on those slopes.
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 16). g014860 Figure 14 1. Lever 2. Prop rod 2. 3. Detent slot Pull the prop rod into the detent slot to secure the bed (Figure 15). g024490 Figure 16 1. Tailgate flange (cargo bed) 3. Lift up (finger pull) 2. Lock flange (tailgate) 4. Rotate rearward and down 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 Material Density Maximum Cargo Box Capacity (on level ground) Gravel, dry 1522 kg/m3 (95 lb/ft3) Full limit the weight of the load that you carry in the cargo bed as described in Specifications (page 13) and on the gross vehicle weight tag of the machine.
After Operation After Operation Safety General Safety • Before you leave the operating position, do the following: – Park the machine on a level surface. g033043 Figure 18 – Shift the transmission to the NEUTRAL position. 1. Towing tongue and tie-down point (front of the machine) – Engage the parking brake. – Lower the cargo bed. – Shut off the machine and remove the key. – Wait for all movement to stop • Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
Towing the Machine Towing a Trailer In case of an emergency, you can tow the machine for a short distance; however, this should not be a standard operating procedure. The machine is capable of pulling trailers. A tow hitch is available for the machine. Contact your Authorized Service Dealer for details. When hauling cargo or towing a trailer, do not overload your machine or trailer.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Maintenance Safety • If possible, do not perform maintenance while the • Do not allow untrained personnel to service the • machine. • Before you leave the operating position, do the following: – Park the machine on a level surface. • • – Shift the transmission to the NEUTRAL position. – Engage the parking brake. – Lower the cargo bed. • – Shut off the machine and remove the key.
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 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 Many of the subjects covered in this maintenance section require raising and lowering the bed. To prevent serious injury or death, take the following precautions. 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. 4. Empty and raise the cargo bed; refer to Operating the Cargo Bed (page 17). g033043 Figure 20 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 22). 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 25). 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). g033046 Figure 25 1. Hub 3. Lug nut 2. Wheel 3.
Greasing the Wheel Bearings 1. Remove the outboard bearing and bearing race from the hub (Figure 29). g033049 Figure 28 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 29 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 29). 3.
Installing the Hub and Rotor 1. Apply a light coat of the specified grease to the spindle (Figure 30). g033054 Figure 31 1. Cotter pin 3. Dust cap 2. Nut retainer g033051 Figure 30 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 30). 3. Assemble the outboard bearing onto the spindle and seat the bearing to the outboard race (Figure 30). 4.
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 g027733 Figure 33 Service Interval: Every 100 hours Replace the air-filter element sooner if it dirty or damaged.
1. Clean the dirt ejection port located on the air-filter cover. Servicing the Engine Oil 2. Remove the rubber outlet valve from the cover, clean the cavity, and replace the outlet valve. Service Interval: After the first 25 hours 3. Every 100 hours (Change the oil twice as often during special operating conditions; refer to Maintaining the Machine under Special Operating Conditions (page 25). Insert the air-filter element into air-filter housing (Figure 33).
g002132 g009200 Figure 35 1. Oil dipstick (loop down) Figure 36 2. Fill cap (filler neck) 6. Remove the dipstick and wipe it clean (Figure 35). 7. Slide the dipstick into the dipstick tube and ensure that fully seats (Figure 35). 8. Pull the dipstick out and look at the end. 9. If the oil level is low, remove the filler cap and add the specified oil into the filler neck to raise the level up to Full mark on the dipstick. 1. Drain plug 8. engine. 11.
Adjusting the High/Low Idle Servicing the Spark Plugs Service Interval: Every 100 hours/Yearly (whichever comes first) Replace the spark plugs 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 40).
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). g024478 Figure 41 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 44). 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 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. Rear-jam nut g029659 Figure 45 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 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). 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.
4. Electrical System Maintenance Thread the knob from the gear-shift lever and tighten the knob by hand (Figure 42). Electrical System Safety • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last. • Charge the battery in an open, well-ventilated area, away from sparks and flames. Unplug the charger before connecting or disconnecting the battery.
Installing the Battery WARNING 1. Battery terminals or metal tools could short against metal machine components, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. • When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine. • Do not allow metal tools to short between the battery terminals and metal parts of the machine. 1. Align the battery to the battery tray of the machine (Figure 49).
Replacing the Fuses There are 4 fuses in the electrical system. They are located beneath the hood (Figure 50). Lift/gate (Open) 30 A Horn/power point 20 A Headlights 15 A Machine fuse 10 A g312735 Figure 51 g202997 Figure 50 1. Fuse block 1. Speed clip 4. Headlight 2. Opening in the bumper 5. Harness-electrical connector 6. Lamp assembly 3. Adjustment screw 2. Ground block 4. Maintaining the Headlights Note: Retain all parts for installation of the new headlight.
Adjusting the Headlights Use the following procedure to adjust the headlight beam position whenever a headlight assembly is replaced or removed. 1. Park the machine on a level surface with the headlights approximately 7.6 m (25 ft) from a wall (Figure 52). 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Turn the key switch to the ON position, and turn on the headlights. 4. Take note of where the headlights aim on the wall.
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 and 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 44). 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. 2. 3. Check the tire pressure to ensure that the front tires are inflated to 82 kPa (12 psi).
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. Spacers Top Speed 2 (standard) 16 mph (standard) Lower the cargo bed.
Cooling System Maintenance Brake Maintenance Cooling System Safety Service Interval: Every 100 hours Inspecting the Brakes Important: Brakes are a critical safety component • Swallowing engine coolant can cause poisoning; of the machine. Closely inspect them at the recommended service interval to ensure optimum performance and safety. keep out of reach from children and pets. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns.
4. procedure for adjusting the brake cables; refer to Adjusting the Brake Cables (page 49). 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 Rotate and route the belt over the secondary clutch (Figure 69). 7. Lower the cargo bed. Adjusting the Starter-Generator Belt Checking the Drive Belt Service Interval: After the first 8 hours Service Interval: After the first 8 hours Every 200 hours 1. 6. Every 200 hours Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key. 2. Raise the cargo bed and secure it with the prop rod. 3.
Chassis Maintenance Cleaning Adjusting the Cargo-Bed Latches Washing the Machine Service Interval: Before each use or daily—Wash the machine. 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. Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine.
Storage damaged at temperatures below 0°C (32°F). A fully charged battery maintains its charge for about 50 days at temperatures lower than 4°C (40°F). If the temperatures will be above 4°C (40°F), check the water level in the battery and charge it every 30 days. Storage Safety • Shut off the machine, remove the key, and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it. 13.
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California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Conditions and Products Covered Parts 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 2 years or 1,500 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).
