Workman® MDX-D Utility Vehicle

Before starting the machine each day, perform the Each Use/Daily procedures listed in .

Tire air pressure specification: 55 to 103 kPa (8 to 22 psi)

Important: Do not exceed the maximum air pressure indicated on the sidewall of the tire.

Note: The air pressure needed in the tires is determined by the payload that you intend to carry.

1. Check the air pressure in the tires.

   Note: The air pressure in the front and rear tires should be between 55 to 103 kPa (8 to 22 psi).

   • Use lower air pressure in the tires for lighter payloads, for less soil compaction, for a smoother ride, and to minimize tire marks on the ground.

   • Use higher air pressure in the tires for carrying heavier payloads at higher speeds.

2. If necessary, adjust the air pressure in the tires by adding or removing air in the tires.

Figure 10

Perform the following guidelines to provide proper performance for the machine.

• Ensure that the brakes are burnished; refer to Burnishing the Brakes.

• Check the fluid and engine-oil levels regularly. Remain alert for signs that the machine or its components are overheating.

• After starting a cold engine, let it warm up for about 15 seconds before using the machine.

  Note: Allow more time for the engine to warm up when operating in cold temperatures.

• Vary the machine speed during operation. Avoid fast starts and quick stops.

• A break-in oil for the engine is not required. Original engine oil is the same type specified for regular oil changes.

• Refer to for any special, low-hour checks.

• Check the front suspension positioning and adjust it, if necessary; refer to Adjusting the Front Wheel Alignment.

Important: Do not attempt to push or tow the machine to get it started.

1. Sit in the operator's seat, insert the key into the key switch, press down on the brake, and rotate the key clockwise to the ON position.

   Note: If the backup alarm is installed and the gear-shift selector is in the REVERSE position, the buzzer sounds to warn the operator.

2. When the glow-plug-indicator light turns off, rotate the key clockwise to the START position.

3. When the engine starts, turn the key counterclockwise to the RUN position.

4. Disengage the parking brake.

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.

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Rotate the key switch to the OFF position and remove the key.

Use the following guidelines when loading the cargo bed and operating the machine:

• Observe the weight capacity of the machine and limit the weight of the load that you carry in the cargo bed as described in Specifications and on the gross vehicle weight tag of the machine.

  Note: The load rating is specified for machine operation on a level surface only.

• Reduce the weight of the load that you carry in the cargo bed when operating the machine on hills and rough terrain.

• Reduce the weight of the load that you carry when the materials are tall (and have a high center of gravity), such as a stack of bricks, landscaping timbers, or fertilizer bags. Distribute the load as low as possible to ensure that the load does not reduce your ability to see behind the machine when operating it.

• Keep loads centered by loading the cargo bed as follows:

  • Evenly position the weight in the cargo bed from side to side.

    Important: Tipping over is more likely to occur if the cargo bed is loaded to 1 side.

  • Evenly position the weight in the cargo bed from front to back.

    Important: Loss of steering control or the machine may tip over if you position the load behind the rear axle and the traction on the front tires is reduced.

• Use extra caution when transporting oversized loads in the cargo bed, particularly when you cannot center the weight of the oversize load to the cargo bed.

• Whenever possible, secure the load by binding it to the cargo bed so that it does not shift.

• When transporting liquids, use caution when driving the machine uphill or downhill, when suddenly changing speed or stopping, or when driving over rough surfaces.

The capacity of the cargo box is 0.37 m³ (13 ft³). The amount (volume) of material that you can place in the bed without exceeding the load ratings of the machine can vary greatly depending on the density of the material.

Refer to the following table for load volume limits with various materials:

• Use care when loading or unloading the machine into a trailer or a truck.

• Use full-width ramps for loading the machine into a trailer or a truck.

• Tie the machine down securely.

Refer to Figure 16 and Figure 17 for the tie-down locations on the machine.

Note: Load the machine on the trailer with the front of the machine facing forward. If that is not possible, secure the machine hood to the frame with a strap, or remove the hood and transport and secure it separately or the hood may blow off during transport.

Figure 16

1. Towing tongue and tie-down point (front of the machine)

Figure 17

1. Rear tie-down points

In case of an emergency, you can tow the machine for a short distance; however, this should not be a standard operating procedure.

Towing the machine is a 2-person job. If you must move the machine a considerable distance, transport it on a truck or trailer; refer to Towing a Trailer

1. Remove the drive belt from the machine; refer to Replacing the Drive Belt.

2. Affix a tow line to the tongue at the front of the machine frame (Figure 16).

3. Move the transmission to the NEUTRAL position and disengage the parking brake.

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. Overloading either the machine or the trailer can cause poor performance or damage to the brakes, axle, engine, transaxle, steering, suspension, body structure, or tires.

Always load a trailer with 60% of the cargo weight in the front of the trailer. This places approximately 10% of the gross trailer weight (GTW) on the tow hitch of the machine.

To provide adequate braking and traction, always load the cargo bed when using a trailer. Do not exceed the GTW or GVW limits.

Avoid parking a machine with a trailer on a hill. If you must park on a hill, engage the parking brake, and chock the tires of the trailer.

1. Park the machine on a level surface.

2. Shift the transmission to the NEUTRAL position.

3. Engage the parking brake.

4. Shut off the engine and remove the key.

5. Empty and raise the cargo bed.

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 18).

  

  Figure 18

  1. Front lifting point

• The lifting point at the rear of the machine is located under the axle tubes (Figure 19).

Figure 19

1. Rear lifting points

Grease specification: Mobilgrease XHP™-222

Note: Service the air filter more frequently if operating conditions are extremely dusty or sandy.

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.

Engine-Oil Specifications

Oil Type: Detergent oil (API service CH-4, CI-4, CJ-4, or higher)

Crankcase Capacity: 1.4 L (1.5 US qt) when the filter is changed

Viscosity: See the table below.

Figure 29

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.

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

3. Place a drain pan under the fuel filter.

4. Unscrew the fuel filter from the bracket (Figure 32).

   

   Figure 32

   1. Fuel filter

5. Install the replacement filter by turning it until the filter contacts the top of the bracket, then tighten it an additional 3/4 of a turn.

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

• 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 7 fuses in the electrical system. They are located beneath the hood (Figure 34).

Figure 34

1. Fuse block
2. Ground block

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.

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 37), 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 38).

• Steering-rack assembly tie rods

Figure 37

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

Figure 38

1. Pinion-shaft seal

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

1. Park the machine on a level surface, shift the transmission to the NEUTRAL position, engage the parking brake, shut off the engine, and remove the key.

2. Remove the bolt from the level-indicating hole (Figure 42).

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

   

   Figure 42

   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, shift the transmission to the NEUTRAL position, 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 43).

   

   Figure 43

   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 43).

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

5. Remove the drain plug by rotating it counterclockwise (Figure 43).

   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 43).

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

7. Fill the reservoir (Figure 44) 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 43).

   

   Figure 44

   1. Fluid fill

8. Install and tighten the fill plug and gasket into the fill-plug hole of the transmission (Figure 43).

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 43).

When performing routine maintenance and/or engine diagnostics, the transaxle must be shifted into NEUTRAL (Figure 45). 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. Shift the transmission to 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 45).

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

   

   Figure 45

   1. Neutral bracket
   2. Locknuts

3. Rotate 1 of the locknuts (Figure 45) 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 46).

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

   

   Figure 46

   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)

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

Clutch operation should be monitored daily for proper shifting. If shifting is sticky or sluggish, or the clutch does not return completely to neutral when idling, the clutch requires a simple cleaning.

Note: Focus debris removal in and around moving parts.

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

2. Raise and secure the cargo bed.

3. Remove dirt and mud buildup on the clutch with water and dry the clutch immediately with compressed air to remove excess water and debris.

   Note: Remaining debris may be removed using a fast-drying contact cleaner.

Note: Operating the machine with a dirty clutch can increase wear to internal components.

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

2. Raise and secure the cargo bed.

3. Remove the 6 flange-head bolts securing the clutch cover.

4. Set aside the cover, spacer, and spring (Figure 47).

   

   Figure 47

   1. Clutch shaft
   2. Spring
   3. Spacer
   4. Clutch cover
   5. Flange-head bolt

5. Remove dirt and mud buildup with water and dry immediately with compressed air to remove excess water and debris.

6. Remove any remaining debris using a fast-drying contact cleaner or brake cleaner.

   Note: Remove the debris in and around moving parts.

7. If debris or buildup exists around the belt or along the clutch shaft, use a fine abrasive pad or a similar product to remove it.

8. Install the spring, clutch cover, and flange-head bolts.

9. Torque the bolts to 12 to 13.5 N∙m (105 to 120 in-lb).

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 49).

   

   Figure 49

   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 49).

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 49).

   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 49).

1. Remove the handgrip from the parking-brake lever (Figure 49).

2. Loosen the set screw (Figure 49) 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 50).

   

   Figure 50

   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 50).

5. Rotate the brake-adjustment knob (Figure 49) 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 50) for the threaded adjuster of the parking-brake cable 1 turn.

     2. Tighten the rear jam nut (Figure 50).

     3. Rotate the brake-adjustment knob (Figure 49) 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 50) for the threaded adjuster of the parking-brake cable 1 turn.

     2. Tighten the forward jam nut (Figure 50).

     3. Rotate the brake-adjustment knob (Figure 49) 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 49).

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 51).

   

   Figure 51

   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 52).

   Note: The level should be above the Minimum line.

   

   Figure 52

   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 51).

   2. Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line (Figure 52).

      Note: Do not overfill the reservoir with brake fluid.

   3. Install the reservoir cap (Figure 51).

7. Close the hood.

Contact your authorized Toro distributor.

Note: Check the belt-pull bumper only when troubleshooting vibration, performing a rebuild, or experiencing an engine-mount failure.

The belt-pull bumper (Figure 54) should maintain a gap of 2.2 mm (0.09 inches).

If the bumper is too close to the engine bracket, the belt causes excessive vibration; if the bumper is too far from the engine bracket, the belt causes harmful engine stress.

To adjust the gap, loosen the 3 flanged-head bolts securing the bracket to the frame and slide the bracket the appropriate distance.

Once the gap is correct, tighten the 3 flanged-head bolts.

Figure 54

1. Engine bracket
2. Bumper
3. Bracket
4. Flanged-head bolt

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 55).

   

   Figure 55

   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 55).

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 using water alone or with a mild detergent. You may use a rag when washing the machine.

Important: Do not use brackish or reclaimed water to clean the machine.

Important: Do not use power-washing equipment to wash the machine. Power-washing equipment may damage the electrical system, loosen important decals, or wash away necessary grease at friction points. Avoid excessive use of water near the control panel, engine, and battery.

Important: Do not wash the machine with the engine running. Washing the machine with the engine running may result in internal engine damage.