Form No. 3411-880 Rev B Workman® MDX-D Utility Vehicle Model No. 07236—Serial No. 400000000 and Up Model No. 07236TC—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 Electrical System Maintenance ........................... 37 Servicing the Battery......................................... 37 Replacing the Fuses ......................................... 39 Maintaining the Headlights ............................... 39 Drive System Maintenance .................................. 41 Maintaining the Tires ........................................ 41 Inspecting the Steering and Suspension Components .................................................
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. operator, and 1 passenger in the seat provided by the manufacturer.
• Never remove the fuel cap or add fuel with the • • • • • • engine running. Allow engine to cool before refueling. Never refuel the machine indoors. 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.
• Turning while traveling up or down hills can be • Gross Vehicle Weight (GVW) has a major impact dangerous. If you have to turn while on a hill, do it slowly and cautiously. Never make sharp or fast turns. on your ability to stop and/or turn. Heavy loads and attachments make the machine harder to stop or turn. The heavier the load, the longer it takes to stop. • Heavy loads affect stability.
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. decal121-9775 121-9775 1. Warning—read the Operator’s Manual and receive training before operating the machine. 4. Tipping hazard—drive slowly on or across inclines; take turns slowly; do not exceed speeds of 31 kph (19 mph); drive slowly when hauling a load or when driving on uneven terrain. 2.
decal99-7345 99-7345 decal106-6755 1. Warning—read the Operator's Manual. 106-6755 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. 1. Engine coolant under pressure. 3. Warning—do not touch the hot surface. 2. Explosion hazard—read the Operator's Manual. 4. Warning—read the Operator's Manual.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description Use Qty. 1 Steering wheel Cover Washer (1/2 inch) 1 1 1 Install the steering wheel (Model 07236TC only). 2 No parts required – Connect the battery (Model 07236TC only). 3 No parts required – Check the fluid levels and tire air pressure.
2 Connecting the Battery (Model 07236TC 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 Parts Catalog 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 13 7.
Accelerator Pedal Controls 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). Brake Pedal Use the brake pedal to stop or slow the machine (Figure 7). CAUTION Operating a machine with worn or incorrectly adjusted brakes can may result in personal injury.
Gear-Shift Selector starts to function whenever you turn the key switch to the ON position or if the engine is running. The gear-shift selector is located between the seats and below the parking-brake lever. The gear-shift selector has 3 positions: FORWARD , REVERSE, and NEUTRAL (Figure 6). Battery Light The battery light is located to the right of the steering column and above the oil light (Figure 8).
Passenger Handholds START . Rotate the key clockwise to the ON position to activate the glow plugs. When the glow-plug-indicator light turns off, rotate the key clockwise to the START position. When the engine starts, turn the key counterclockwise to the RUN position. The passenger handholds are located on the right side of the dash panel and at the outside of each seat (Figure 10). To shut off the engine, rotate the key counterclockwise to the OFF position.
Specifications Note: Specifications and design are subject to change without notice. Base weight Dry 590 kg (1,300 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 tail gate (Figure 14). g014860 Figure 12 1. Lever 2. Prop rod 2. 3. Detent slot Pull the prop rod into the detent slot, securing the box (Figure 13). g024490 Figure 14 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 15 1. Rotate the tailgate to approximately the 45° position.
2. Raise the cargo box; refer to Raising the Cargo Box (page 18). 3. Use a rag to clean around the oil dipstick (Figure 19) so that dirt cannot fall into the dipstick tube and damage the engine. g002136 Figure 17 1. Brake-fluid reservoir 4. 2. Minimum line If the fluid level is low, preform the following: A. Clean the area around the reservoir cap and remove the cap (Figure 16). B. Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line (Figure 17).
Checking the Tire Pressure 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. Service Interval: Before each use or daily Tire Air Pressure Range: 55 to 103 kPa (8 to 22 psi) Important: Do not exceed the maximum air pressure indicated on the sidewall of the tire. • 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 causing 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 20). • Always place fuel containers on the ground away from your machine before filling.
Stopping the Machine Important: When stopping the machine on an incline, use the service brakes to stop the machine and engage the parking brake to hold the machine in place. Using the accelerator to stall the machine on the hill can damage the machine. 1. Remove your foot from the accelerator pedal. 2. Slowly press the brake pedal to apply the service brakes until the machine comes to a complete stop. Note: The stopping distance may vary depending on the machine load and speed. Parking the Machine 1.
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 17) 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 21 and Figure 22 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 unusual engine noises. Check unusual operating noises. Check the clutch operation. Check the tire pressure.
Pre-Maintenance Procedures Important: Whenever the engine is run for routine maintenance and/or engine diagnostics, the rear wheels of the machine should be 25 mm (1 inch) off the ground, with the rear axle supported on jack stands. Maintaining the Machine under Special Operating Conditions • The lifting point at the front of the machine is at the front of the frame behind the towing tongue (Figure 23).
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 25). 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 28). g033047 Figure 29 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 30). g033046 Figure 28 1. Hub 3. Lug nut 2. Wheel 3.
Greasing the Wheel Bearings 1. Remove the outboard bearing and bearing race from the hub (Figure 32). g033049 Figure 31 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 32 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 32). 3.
Installing the Hub and Rotor 1. Apply a light coat of the specified grease to the spindle (Figure 33). g033054 Figure 34 1. Cotter pin 3. Dust cap 2. Nut retainer g033051 Figure 33 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 33). 3. Assemble the outboard bearing onto the spindle and seat the bearing to the outboard race (Figure 33). 4.
Engine Maintenance • If the air-filter element is clean, install the Servicing the Air Filter • If the air-filter element is damaged, replace filter element, refer to Installing the Air Filter (page 35). the filter element; refer to Replacing the Air Filter (page 35). Service Interval: Every 100 hours Replace the air-filter element sooner if it dirty or damaged. Note: Service the air filter more frequently (every few hours) if operating conditions are extremely dusty or sandy.
Replacing the Air Filter 1. Remove the air-filter element; refer to steps 1 through 5 in Checking the Air Filter (page 34). 2. Inspect the new filter for shipping damage. Servicing the Engine Oil Note: Change the oil and oil filter more frequently when operating conditions are extremely dusty or sandy. Note: Check the sealing end of the filter. Oil Type: Detergent oil (API service CH-4, CI-4, CJ-4, or higher) Important: Do not install a damaged filter. 3.
9. 10. Pour oil into the fill opening until the oil level is up to the Full mark on the dipstick. Add the oil slowly and check the level often during this process. Note: Do not overfill the engine with oil. 11. Install the oil-fill cap and dipstick firmly in place. Changing the Engine-Oil Filter Service Interval: After the first 50 hours Every 150 hours/Yearly (whichever comes first) Change the oil twice as often during special operating conditions. 1.
Fuel System Maintenance Electrical System Maintenance Inspecting Fuel Lines and Connections Servicing the Battery Battery voltage: 12 V with 300 A (cold cranking) at -18°C (0°F). Service Interval: Every 400 hours/Yearly (whichever comes first) WARNING Inspect the fuel lines, fittings, and clamps for signs of leaking, deterioration, damage, or loose connections.
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 40). There are 7 fuses in the electrical system. They are located beneath the hood (Figure 41). Note: Ensure that the positive and negative posts of the battery are aligned as shown in Figure 40. 2. 3. Secure the battery to the battery tray with the battery clamp, carriage bolt, and locknut (Figure 40). Connect the battery cables; refer to Connecting the Battery (page 39).
Replacing the Headlight CAUTION The bulbs become extremely hot when in operation. Handling a hot bulb can cause severe burns and personal injury. Always allow enough time to for the bulbs to cool before replacing them. Use care whenever handling the bulbs. 1. Disconnect the battery; refer to Disconnecting the Battery (page 38). 2. Open the hood; refer to Closing the Hood (page 30). 3. Disconnect the electrical connector for the harness from the connector of the lamp assembly (Figure 43).
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 43) 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 44), turn the steering wheel to the left or right.
g033219 g033218 Figure 48 Figure 46 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 47). 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 10W-30 (API service SJ or higher) Fluid Capacity: 1.4 L (1.5 US qt) 1. 2. Park the machine on a level surface, shut off the engine, engage the parking brake, 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 50). 8. Install and tighten the fill plug and gasket into the fill-plug hole of the transmission (Figure 50). 9.
g002094 Figure 53 1. Neutral bracket 4. 0.76 to 1.52 mm (0.03 to 0.06 inch) gap 2. Pull up 5. Wrong—adjust the to achieve a gap of 0.76 to 1.52 mm (0.03 to 0.06 inch) inch g002093 Figure 52 1. Neutral bracket 3. 2. Locknuts 3. Cable boot Rotate one of the locknuts (Figure 52) to achieve a 0.762 to 1.524 mm (0.030 to 0.060 inch) gap between the bottom of the nut/washer and the neutral bracket. 6.
Maintaining the Primary-Drive Clutch Cooling System Maintenance Service Interval: Every 200 hours—Clean the primary-drive clutch (more often in dusty or dirty conditions). Cleaning the Engine-Cooling Areas Note: Operating the machine with a dirty clutch can increase wear to internal components. 1. Shut off the engine, engage the parking brake, and remove the key from the key switch. 2. Raise and latch the cargo box. 3. Remove the 6 flange-head bolts securing the clutch cover. 4.
Brake Maintenance Changing the Radiator Coolant Service Interval: Every 1,000 hours/Every 2 years (whichever comes first) Inspecting the Brakes Service Interval: Every 100 hours CAUTION 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. The following inspections should be done every 100 hours: • Inspect the brake lining for wear or damage.
• If you cannot adjust the brake-adjustment required to set the parking-brake lever, perform the procedure for adjusting the brake cables; refer to Adjusting the Brake Cables (page 48). 4. 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 56). A. Loosen the rear-jam nut (Figure 57) for the threaded adjuster of the parking-brake cable 1 turn. B.
Belt Maintenance Replacing the Drive Belt Servicing the Drive Belt New belts must be broken in before they shift properly. A belt breaks in within the first 2 hours of normal operation. Checking the Drive Belt 1. Raise the cargo box; refer to Raising the Cargo Box (page 18). 2. Shift the transmission to the NEUTRAL position, shut off the engine, engage the parking brake, and remove the key from the key switch.. 3. Rotate and route the belt over the secondary clutch (Figure 58). 4.
Chassis Maintenance Adjusting the Cargo-Box Latches 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. 1. Loosen the locknut on the end of the latch post (Figure 60). g017511 Figure 59 1. Engine bracket 3. Bracket 2. Bumper 4. Flange-head bolt g002181 Figure 60 1. Latch 3. Latch post 2. Locknut 50 2.
Cleaning Storage Washing the Machine Wash the machine as needed. Use water alone or with a mild detergent. You can use a rag. 1. Park the machine on a level surface, shut off the engine, engage the parking brake, and remove the key from the key switch. 2. Clean dirt and grime from the entire machine, including the outside of the engine cylinder-head fins and blower housing. Important: Pressurized water is not recommended when washing the machine.
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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).
