Workman® MDX Utility Vehicle

1. Lift the lever on either side of the bed and lift the bed up (Figure 12).

   

   Figure 12

   1. Lever
   2. Prop rod
   3. Detent slot

2. Pull the prop rod into the detent slot to secure the bed (Figure 13).

   

   Figure 13

   1. Detent slot
   2. Prop rod

1. Raise the cargo bed slightly by lifting up the latch lever (Figure 12).

2. Pull the prop rod out of the detent slot (Figure 13).

3. Lower the bed until it latches securely into place (Figure 13).

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).

   

   Figure 14

   1. Tailgate flange (cargo bed)
   2. Lock flange (tailgate)
   3. Lift up (finger pull)
   4. Rotate rearward and down

3. Align the lock flanges of the tailgate with the openings between the tailgate flanges of the cargo bed (Figure 14).

4. Rotate the tailgate rearward and down (Figure 14).

If you unloaded loose material such as sand, landscaping rock, or wood chips from the cargo bed of the machine, some of the material that you unloaded may have lodged in the hinge area of the tailgate. Perform the following before closing the tailgate.

1. Use your hands to remove as much of the material from the hinge area as possible.

2. Rotate the tailgate to approximately the 45° position (Figure 15).

   

   Figure 15

   1. Rotate the tailgate to approximately the 45° position.
   2. Rotate the tailgate back and forth several times.
   3. Hinge area

3. Use a short, shaking motion to rotate the tailgate back and forth several times (Figure 15).

   Note: This action helps move material away from the hinge area.

4. Lower the tailgate and check for material remaining in the hinge area.

5. Repeat steps 1 through 4 until the material is removed from the hinge area.

6. Rotate the tailgate up and forward until the lock flanges of the tailgate are flush with the tailgate pocket in the cargo bed (Figure 14).

   Note: Raise or lower the tailgate in order to align the lock flanges of the tailgate with the vertical openings between the tailgate flanges of the cargo bed.

7. Lower the tailgate until it is seated in the back of the cargo bed (Figure 14).

   Note: The lock flanges of the tailgate are fully secured by the tailgate flanges of the cargo bed.

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).

   

   Figure 17

   1. Empty
   2. Full
   3. Needle
   4. Fuel gauge
   5. Fuel-tank cap

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).

   Note: This space in the tank allows fuel to expand. Do not overfill the fuel tank..

7. Install the fuel-tank cap securely.

8. Wipe up any fuel that may have spilled.

Important: If the machine is subjected to any of the conditions listed below, perform maintenance twice as frequently:

• Desert operation

• Cold climate operation—below 10°C (50°F)

• Trailer towing

• Frequent operation in dusty conditions

• Construction work

• After extended operation in mud, sand, water, or similar dirty conditions, have your brakes inspected and cleaned as soon as possible. This prevents any abrasive material from causing excessive wear.

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

Figure 20

Important: Whenever you run the machine for routine maintenance and/or diagnostics, ensure that the rear wheels of the machine are 25 mm (1 inch) off the ground, with the rear axle supported on jack stands.

• The lifting point at the front of the machine is located at the front of the frame, behind the towing tongue (Figure 21).

  

  Figure 21

  1. Front lifting point

• The lifting point at the rear of the machine is located under the axle tubes (Figure 22).

Figure 22

1. Rear lifting points

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. With a grease gun, apply 1 or 2 pumps of grease into the grease fittings on the machine.

3. Wipe the excess grease off the machine.

The grease fittings are located at the inner end of the control arms, the tie-rod ball joint, and the outer end of the control arms (Figure 24 and Figure 25).

Figure 24

Figure 25

Grease specification: Mobilgrease XHP™-222

1. Drain the oil from the engine; refer to Draining the Engine-Oil.

2. Remove the existing oil filter (Figure 33).

3. Apply a light coat of clean oil to the gasket of the new oil filter.

4. Thread the new filter onto the filter adapter until the gasket contacts the mounting plate, then tighten the filter an additional 1/2 to 3/4 turn further (Figure 33).

   Note: Do not overtighten the oil filter.

5. Fill the crankcase with the specified oil (Figure 34).

6. Start and run the engine to check for oil leaks.

7. Shut off the engine and check the oil level.

   Note: If necessary, add the specified oil into the engine until the oil level is at the Full mark on the dipstick.

Note: Change the oil more frequently when operating conditions are extremely dusty or sandy.

Note: Dispose of the used engine oil and oil filter at a certified recycling center.

Checking the Engine-Oil Level

Maintenance Service Interval	Maintenance Procedure
Before each use or daily	Check the engine-oil level.Check the engine-oil level before you start the engine.

Note: The machine is shipped with oil in the crankcase; however, check the oil level before and after you start the engine.

Engine-oil type: Detergent engine oil (API service SF, SG, SH, SJ, or higher)

Viscosity: Refer to the table below

Figure 34

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

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.

   

   Figure 35

   1. Oil dipstick (loop down)
   2. Fill cap (filler neck)

6. Remove the oil dipstick and wipe the end clean (Figure 35).

7. Slide the oil dipstick into the dipstick tube fully seating it (Figure 35).

8. Pull the dipstick out and look at the end.

9. If the oil level is low, remove the fill cap and add the specified oil into the filler neck to raise the level up to Full mark on the dipstick.

   Note: Add the oil slowly and check the oil level often during this process. Do not overfill the engine with oil.

10. Install the fill cap (Figure 35).

11. Install the oil dipstick and firmly seat it (Figure 35).

    Important: Ensure that the loop end of the oil dipstick is pointing down.

12. Lower the cargo bed.

Note: Service the air cleaner more frequently (every few hours) if operating conditions are extremely dusty or sandy.

Type: Champion RN14YC (or equivalent)

Air Gap: 0.03 inch (0.762 mm)

Important: A cracked, fouled, dirty, or malfunctioning spark plug must be replaced. Do not sand-blast, scrape, or clean electrodes by using a wire brush because grit may eventually release from the plug and fall into the cylinder. The result is usually a damaged engine.

Note: The plug should be removed and checked whenever the engine malfunctions.

1. Clean the area around the spark plug so that foreign matter cannot fall into the cylinder when you remove the spark plug.

2. Pull the wire off the terminal of the spark plug.

3. Remove the plug from the cylinder head.

4. Check the condition of the side electrode, center electrode, and center electrode insulator to ensure that there is no damage (Figure 38).

   Note: Do not use a damaged or worn spark plug. Replace it with a new spark plug of the specified type.

   

   Figure 38

   1. Side electrode
   2. Center electrode insulator
   3. Air gap (not to scale)

5. Set the air gap between the center and side of the electrodes at 0.762 mm (0.030 inch) as shown in Figure 38.

6. Install the spark plug into the cylinder head, and torque the plug to 20 N∙m (14.7 ft-lb).

7. Install the spark-plug wire.

8. Repeat steps 1 through 7 for the other spark plug.

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. At the throttle cable, loosen the forward jam nut and tighten the rear jam nut to increase the low idle (Figure 39).

   

   Figure 39

   Bellcrank shown without accelerator pedal depressed

   1. Throttle cable
   2. Jam nuts
   3. Bellcrank
   4. Bracket tab
   5. Leading edge

4. Test the high idle with a tachometer:

   1. Turn the engine on.

   2. Ensure that the shift lever is in the neutral position.

   3. Fully depress the accelerator pedal and measure the engine speed with a tachometer; the engine speed should be in the 3550 to 3650 range. If it is not, shut off the engine and adjust the cable jam nuts.

      Important: Do not lower the high idle. Test with a tachometer to ensure that the high idle is within the 3550 to 3650 range.

5. Push on the prop rod and lower the cargo bed.

Inspect the fuel lines, fittings, and clamps for signs of leaking, deterioration, damage, or loose connections.

Note: Repair any damaged or leaking fuel system component before using the machine.

1. Raise the bed and support it with the prop rod; refer to Raising the Cargo Bed.

2. Rotate the key switch to the OFF position and remove the key from the key switch.

3. Disconnect the battery; refer to Disconnecting the Battery.

4. Place a clean container under the fuel filter.

5. Remove the clamps securing the fuel filter to the fuel lines (Figure 40).

   

   Figure 40

   1. Fuel filter

6. Remove the old fuel filter from the fuel lines.

   Note: Drain the old filter and discard it at a certified recycling center.

7. Install the replacement filter to the fuel lines so that the arrow points toward the carburetor.

8. Secure the filter to the lines with the clamps the you removed in step 5.

9. Connect the battery, and lower the cargo bed; refer to Connecting the Battery and Lowering the Cargo Bed.

Battery voltage: 12 V with 300 A (cold cranking) at -18°C (0°F).

• Always keep the battery clean and fully charged.

• Always keep the battery clean and fully charged.

• If the battery terminals are corroded, clean them with a solution of 4 parts water and 1 part baking soda.

• Apply a light coating of grease to the battery terminals to prevent corrosion.

There are 4 fuses in the electrical system. They are located beneath the hood (Figure 51).

Figure 51

1. Fuse block
2. Ground block

1. Inspect the tires an rims for signs of wear and damage.

   Note: Operating accidents, such as hitting curbs, can damage a tire or rim and also disrupt wheel alignment, so inspect tire condition after an accident.

2. Torque the wheel-lug nuts to 108 to 122 N∙m (80 to 90 ft-lb).

With the steering wheel at the centered position (Figure 54), turn the steering wheel to the left or right. If you turn the steering wheel more than 13 mm (1/2 inch) to the left or right, and the tires do not turn, check the following steering and suspension components to ensure that they are not loose or damaged:

• Steering shaft to the steering-rack assembly joint

  Important: Inspect the condition and security of the pinion-shaft seal (Figure 55).

• Steering-rack assembly tie rods

Figure 54

1. Steering wheel at the centered position
2. 13 mm (1/2 inch) from the center of the steering wheel

Figure 55

1. Pinion-shaft seal

Fluid Type: SAE 10W30 (API service SJ or higher)

1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key.

2. Remove the bolt from the level-indicating hole (Figure 59).

   Note: The transaxle fluid level should be at the bottom of the level indicator hole.

   

   Figure 59

   1. Level-indicator hole

3. If the transaxle fluid is not level with the bottom of the level indicating hole, fill the reservoir with the specified fluid; refer to Changing the Transaxle Fluid.

Fluid Type: SAE 10W30 (API service SJ or higher)

Fluid Capacity: 1.4 L (1.5 US qt)

1. Park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key.

2. Wipe the area around the fill and drain plugs clean with a rag (Figure 60).

   

   Figure 60

   1. Drain plug
   2. Fill plug

3. Align a drain pan with a capacity of 2 L (2.1 qt) or more under the drain plug.

4. Remove the fill plug by rotating it counterclockwise (Figure 60).

   Note: Retain the fill plug and gasket for installation in step 8.

5. Remove the drain plug by rotating it counterclockwise (Figure 60).

   Note: Retain the drain plug and gasket for installation in step 6.

   Note: Allow the fluid to drain from the transaxle completely.

6. Install and tighten the drain plug and gasket into the drain-plug hole of the transmission (Figure 60).

   Note: Dispose of the used fluid at a certified recycling center.

7. Fill the reservoir (Figure 61) through the fill-plug hole with approximately 1.4 L (1.5 US qt) of the specified fluid or until the fluid level in the transmission is even with the bottom of the threads. (Figure 60).

   

   Figure 61

   1. Fluid fill

8. Install and tighten the fill plug and gasket into the fill-plug hole of the transmission (Figure 60).

9. Start the engine and operate the machine.

10. Check the fluid level and add more fluid if the level is below the threads of the fill-plug hole (Figure 60).

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. Set the shift lever into the NEUTRAL position.

2. Ensure that the neutral bracket is in the NEUTRAL position (level to the cable mounting bracket located below the shift bracket) by turning the driven clutch (Figure 62).

   Note: The machine should not roll back and forth. If it does, manually move the neutral bracket to the NEUTRAL position.

   

   Figure 62

   1. Neutral bracket
   2. Locknuts

3. Rotate 1 of the locknuts (Figure 62) 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.

   Note: You must hold the threaded shaft below the bracket when adjusting the locknut position on top.

4. Rotate the other locknut to achieve a 0.76 to 1.52 mm (0.03 to 0.06 inch) gap between the bottom of the nut/washer and the neutral bracket.

5. 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 63).

   Note: If there is a not a gap, adjust the nuts to achieve the specified gap.

   

   Figure 63

   1. Neutral bracket
   2. Pull up
   3. Cable boot
   4. 0.76 to 1.52 mm (0.03 to 0.06 inch) gap
   5. Wrong—adjust the to achieve a gap of 0.76 to 1.52 mm (0.03 to 0.06 inch) inch

6. Start the engine and shift into FORWARD, REVERSE, and NEUTRAL several times to ensure that the neutral bracket is operating properly.

1. Raise and latch the cargo bed; refer to Raising the Cargo Bed.

2. Remove the 3 bolts securing the cover to the clutch, and remove the cover (Figure 64).

   Note: Retain the cover and bolts for installation.

   

   Figure 64

   1. Cover
   2. Bolts

3. Thoroughly clean the inside of the cover and the inner components of the clutch using compressed air.

4. Install the clutch cover and secure it with the 3 bolts (Figure 64) that you removed in 2.

5. Lower the cargo bed; refer to Lowering the Cargo Bed.

1. Raise and latch the cargo bed; refer to Raising the Cargo Bed.

2. Remove the bolts securing the primary clutch cover as shown in Figure 65.

   Important: Use caution when removing the clutch cover; the spring is under compression.

   Important: Take note of the X orientation on the clutch covers and clutch assemblies for later installation.

   

   Figure 65

   1. Clutch spacer

3. Remove the spring.

4. Add or remove spacers to adjust the top speed. Use the following table to determine the amount of spacers needed.

   Spacers	Top Speed
   2 (standard)	16 mph (standard)
   3	12 mph
   4	9 mph
   5	6 mph
   6	4 mph

   Important: Do not operate the machine without at least 2 clutch spacers in place.

5. Install the spring and clutch cover.

   Important: Ensure that the X is placed back in the original location.

6. Torque the bolts to 179 to 228 N–m (132 to 168 in-lbs).

Important: Operating the engine with a blocked rotating screen, dirty or plugged cooling fins, or with the cooling shrouds removed, causes engine damage due to overheating.

Important: Never clean the engine with a pressure washer because water could contaminate the fuel system.

Clean the rotating screen, cooling fins, and external surfaces of the engine.

Note: Clean the engine cooling components more often under extremely dusty and dirty conditions.

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 lining (brake pad) thickness is less than 1.6 mm (1/16 inch), replace the brake lining.

• Inspect the backing plate and other components for signs of excessive wear or deformation. Replace any deformed components.

• Check the brake-fluid level; refer to Checking the Brake-Fluid Level.

1. Remove the handgrip from the parking-brake lever (Figure 66).

   

   Figure 66

   1. Handgrip
   2. Brake-adjustment knob
   3. Set screw
   4. Parking-brake lever

2. Loosen the set screw securing the brake-adjustment knob to the parking-brake lever (Figure 66).

3. Rotate the brake-adjustment knob until you reach a force of 133 to 156 N (30 to 35 lbf) to engage the parking-brake lever (Figure 66).

   Note: If you rotated the brake-adjustment knob the full travel of the adjuster, and cannot attain the force of 133 to 156 N (30 to 35 lbf) required to engage the parking-brake lever, perform the procedure for adjusting the brake cables; refer to Adjusting the Brake Cables.

4. Tighten the set screw and install the hand grip (Figure 66).

1. Remove the handgrip from the parking-brake lever (Figure 66).

2. Loosen the set screw (Figure 66) securing the brake-adjustment knob to the parking-brake lever, disengage the parking brake, and loosen the brake-adjustment knob.

3. At the bottom of the machine, loosen the rear jam nut for the threaded adjuster of the parking-brake cable 4 turns (Figure 67).

   

   Figure 67

   1. Forward jam nut
   2. Rear jam nut
   3. Brake-cable bracket
   4. Threaded adjuster (parking-brake cable)
   5. Front of the machine

4. Tighten the forward jam nut (Figure 67).

5. Rotate the brake-adjustment knob (Figure 66) until a force of 133 to 156 N (30 to 35 lbf) is required to engage the parking-brake lever.

   • If you cannot adjust the brake-adjustment knob by loosening it and engage the parking-brake lever with a force of 133 to 156 N (30 to 35 lbf), perform the following:

     1. Loosen the forward jam nut (Figure 67) for the threaded adjuster of the parking-brake cable 1 turn.

     2. Tighten the rear jam nut (Figure 67).

     3. Rotate the brake-adjustment knob (Figure 66) until a force of 133 to 156 N (30 to 35 lbf) is required to engage the parking-brake lever.

     4. Repeat steps 1 through 3 up to 2 more times to attain the parking brake force between 133 to 156 N (30 to 35 lbf).

   • 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:

     1. Loosen the rear jam nut (Figure 67) for the threaded adjuster of the parking-brake cable 1 turn.

     2. Tighten the forward jam nut (Figure 67).

     3. Rotate the brake-adjustment knob (Figure 66) until a force of 133 to 156 N (30 to 35 lbf) is required to engage the parking-brake lever.

     4. Repeat steps 1 through 3 up to 3 more times to attain the parking brake force between 133 to 156 N (30 to 35 lbf).

     Note: If you cannot adjust the parking-brake cable enough to get the brake-adjustment knob within its adjustment range, check the brake pads for excessive wear.

   • Tighten the set screw and install the handgrip (Figure 66).

Brake-fluid type: DOT 3

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Raise the hood to access to the master brake cylinder and reservoir (Figure 68).

   

   Figure 68

   1. Filler neck (reservoir)
   2. Reservoir cap
   3. DOT 3 brake fluid

5. Look at the outline of the fluid level at the side of the reservoir (Figure 69).

   Note: The level should be above the Minimum line.

   

   Figure 69

   1. Brake-fluid reservoir
   2. Minimum line

6. If the fluid level is low, preform the following:

   1. Clean the area around the reservoir cap and remove the cap (Figure 68).

   2. 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.

   3. Install the reservoir cap (Figure 68).

7. Close the hood.

Contact your authorized Toro distributor.

1. Raise the cargo bed; refer to Raising the Cargo Bed.

2. Loosen the pivot nut for the starter generator (Figure 71).

   

   Figure 71

   1. Primary drive clutch housing
   2. Drive belt
   3. Generator-pivot bracket
   4. Pivot nut
   5. Starter generator
   6. Starter-generator belt

3. Align a pry bar between the engine mount and starter.

4. Apply downward pressure to the pry bar to rotate the starter down in the slot until the belt tension only allows 6 mm (1/4 inch) belt deflection with 44 N∙m (10 ft-lb) of force (Figure 71).

5. Tighten the pivot nut by hand, and remove the pry bar (Figure 71).

6. Torque the pivot nut to 88 to 115 N∙m (65 to 85 ft-lb).

7. Lower the cargo bed; refer to Lowering the Cargo Bed.

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. Loosen the locknut on the end of the latch post (Figure 72).

   

   Figure 72

   1. Latch
   2. Locknut
   3. Latch post

2. Rotate the latch post clockwise until it is snug against the hook portion of the latch (Figure 72).

3. Torque the locknut to 19.7 to 25.4 N∙m (175 to 225 in-lb).

4. Repeat this steps 1 through 3 for the latch on the other side of the machine.

Wash the machine as needed. Use water alone or with a mild detergent. You can use a rag.

Important: Do not use pressurized water 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.