Workman® MDX 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 11

Recommended fuel:

• For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with an octane rating of 87 or higher ((R+M)/2 rating method).

• Ethanol: Gasoline with up to 10% ethanol (gasohol) or 15% MTBE (methyl tertiary butyl ether) by volume is acceptable. Ethanol and MTBE are not the same. Gasoline with 15% ethanol (E15) by volume is not approved for use. Never use gasoline that contains more than 10% ethanol by volume, such as E15 (contains 15% ethanol), E20 (contains 20% ethanol), or E85 (contains up to 85% ethanol). Using unapproved gasoline may cause performance problems and/or engine damage which may not be covered under warranty.

• Do not use gasoline containing methanol.

• Do not store fuel either in the fuel tank or fuel containers over the winter unless a fuel stabilizer is used.

• Do not add oil to gasoline.

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.

1. Sit in the operator seat, insert the key into the key switch, and rotate the key clockwise to the ON or START position.

   There are 2 modes of starting the machine:

   • Pedal Start—turn the key switch to the ON position and press down the accelerator pedal.

     Note: When you remove your foot from the accelerator pedal, the engine shuts off.

   • Key Start—turn the key switch to the START position and the engine remains on until the is turned to the OFF position.

   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.) before starting the machine again.

   Note: When equipped with the optional backup alarm, if you move the gear-shift selector to the REVERSE position when the key switch is in the ON or START position, a buzzer sounds to warn the operator that the machine is in reverse gear.

2. Move the gear-shift selector to the desired direction of travel for the machine.

3. Disengage the parking brake.

4. Slowly step on the accelerator pedal.

   Note: If the engine is cold, press and hold the accelerator pedal about half-way down, and pull the choke knob out to the ON position. Return the choke knob to the OFF position after the engine warms up.

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.

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 17 and Figure 18 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 17

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

Figure 18

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 17).

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 19).

  

  Figure 19

  1. Front lifting point

• The lifting point at the rear of the machine is located under the axle tubes (Figure 20).

Figure 20

1. Rear lifting points

Grease specification: Mobilgrease XHP™-222

Note: Service the air filter more frequently (every few hours) 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 SL or higher)

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

Viscosity: See the table below.

Figure 31

Type: Champion RN14YC (or equivalent)

Air Gap: 0.762 mm (0.03 inch)

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 34).

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

   

   Figure 34

   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 34.

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 press 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 35).

   

   Figure 35

   Bellcrank shown without accelerator pedal pressed

   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 key switch to the ON position.

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

   3. Fully press the accelerator pedal and measure the engine speed with a tachometer; the engine speed should be between 3,550 to 3,650 rpm. If it is not, shut off the engine and adjust the cable jam nuts.

      Important: Do not lower the high idle. Test using a tachometer to ensure that the high idle is between 3,550 to 3,650 rpm.

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.

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

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

4. Place a drain pan under the fuel filter.

5. Remove the clamps securing the fuel filter to the fuel lines (Figure 36).

   

   Figure 36

   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.

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 4 fuses in the electrical system. They are located beneath the hood (Figure 47).

Figure 47

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 50), 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 51).

• Steering-rack assembly tie rods

Figure 50

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

Figure 51

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 55).

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

   

   Figure 55

   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 Checking the Transaxle-Fluid Level.

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 56).

   

   Figure 56

   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 56).

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

5. Remove the drain plug by rotating it counterclockwise (Figure 56).

   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 56).

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

7. Fill the reservoir (Figure 57) 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 56).

   

   Figure 57

   1. Fluid fill

8. Install and tighten the fill plug and gasket into the fill-plug hole of the transmission (Figure 56).

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 56).

When performing routine maintenance and/or engine diagnostics, the transaxle must be shifted into NEUTRAL (Figure 58). 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 58).

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

   

   Figure 58

   1. Neutral bracket
   2. Locknuts

3. Rotate 1 of the locknuts (Figure 58) 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 59).

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

   

   Figure 59

   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.

1. Raise and latch the cargo bed.

2. Remove the 3 bolts securing the cover to the clutch, and remove the cover (Figure 60).

   Note: Retain the cover and bolts for installation.

   

   Figure 60

   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 60) that you removed in 2.

5. Lower 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 61.

   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 61

   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-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 62).

   

   Figure 62

   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 62).

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 62).

   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 62).

1. Remove the handgrip from the parking-brake lever (Figure 62).

2. Loosen the set screw (Figure 62) 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 63).

   

   Figure 63

   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 63).

5. Rotate the brake-adjustment knob (Figure 62) 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 63) for the threaded adjuster of the parking-brake cable 1 turn.

     2. Tighten the rear jam nut (Figure 63).

     3. Rotate the brake-adjustment knob (Figure 62) 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 63) for the threaded adjuster of the parking-brake cable 1 turn.

     2. Tighten the forward jam nut (Figure 63).

     3. Rotate the brake-adjustment knob (Figure 62) 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 62).

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 64).

   

   Figure 64

   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 65).

   Note: The level should be above the Minimum line.

   

   Figure 65

   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 64).

   2. Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line (Figure 65).

      Note: Do not overfill the reservoir with brake fluid.

   3. Install the reservoir cap (Figure 64).

7. Close the hood.

Contact your authorized Toro distributor.

1. Raise the cargo bed.

2. Loosen the pivot nut for the starter generator (Figure 67).

   

   Figure 67

   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 67).

5. Tighten the pivot nut by hand, and remove the pry bar (Figure 67).

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

7. Lower 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 68).

   

   Figure 68

   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 68).

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.