Toro 137-6946 User manual

FormNo.3417-262RevA
EngineReplacementKit
Workman®MDXUtilityVehicle
ModelNo.137-6946
InstallationInstructions
WARNING
CALIFORNIA
Proposition65Warning
ThisproductcontainsachemicalorchemicalsknowntotheStateofCalifornia
tocausecancer,birthdefects,orreproductiveharm.
Installation
LooseParts
Usethechartbelowtoverifythatallpartshavebeenshipped.
ProcedureDescriptionQty.Use
1Nopartsrequired–Preparethemachine.
2Nopartsrequired–Disconnectthebattery.
3Nopartsrequired–Removethecargobed.
4Nopartsrequired–Disconnecttheengine.
Engine1
Airintakehose1
Hoseclamp—aircleanerside1
Hoseclamp—engineside1
Aircleanerbracket1
Bolt2
Locknut2
5
Nut2
Installtheengine.
Fronttubeframe1
Rightbedspacerassembly1
Leftbedspacerassembly1
Pivotbedspacer2
Screw4
Carriagebolt2
Bolt4
6
Nut6
Installthebedspacers.
7Nopartsrequired–Installthecargobed.
8Nopartsrequired–ConnecttheBattery
©2017—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN55420
Registeratwww.Toro.com.OriginalInstructions(EN)
PrintedintheUSA
AllRightsReserved*3417-262*A

1
PreparingtheMachine
NoPartsRequired
Procedure
Note:Determinetheleftandrightsidesofthemachinefromthenormaloperatingposition.
Note:Youcanuseahoistforbetteraccessunderthemachine.
1.Parkthemachineonalevelsurface.
2.Engagetheparkingbrake.
3.Shutofftheengineandremovethekey.
4.Allowthemachinetocool.
g038494
Figure1
2
DisconnectingtheBattery
NoPartsRequired
Procedure
WARNING
Incorrectbatterycableroutingcoulddamage
themachineandcables,causingsparks.
Sparkscancausethebatterygassesto
explode,resultinginpersonalinjury.
•Alwaysdisconnectthenegative(black)
batterycablebeforedisconnectingthe
positive(red)cable.
•Alwaysconnectthepositive(red)battery
cablebeforeconnectingthenegative
(black)cable.
•Alwayskeepthebatterystrapinplaceto
protectandsecurethebattery.
WARNING
Batteryterminalsormetaltoolscouldshort
againstmetalmachinecomponents,causing
sparks.Sparkscancausethebatterygasses
toexplode,resultinginpersonalinjury.
•Whenremovingorinstallingthebattery,
donotallowthebatteryterminalstotouch
anymetalpartsofthemachine.
•Donotallowmetaltoolstoshortbetween
thebatteryterminalsandmetalpartsofthe
machine.
1.Squeezethesidesofthebatterycoverand
removethecoverfromthetopofthebattery
(Figure2).
2

g024429
Figure2
1.Positivebatteryterminal5.Batterycover
2.Positivebatterycable6.Batteryclamp
3.Negativebatterycable7.Locknut
4.Negativebatteryterminal8.Carriagebolt
2.Disconnectthenegative-batterycablefromthe
terminalofthebattery(Figure2).
3.Disconnectthepositivebatterycablefromthe
terminalofthebattery(Figure2).
3
RemovingtheCargoBed
NoPartsRequired
ForMachineswithaManualCargo
BedLift
Cargoboxweight:approximately57kg(126lb)
1.Liftthelatchleveroneithersideofthemachine,
neartheforwardcornerofthecargobed,and
fullyraisethebed(Figure3).
g014860
Figure3
1.Latchlever3.Detentslot
2.Proprod
2.Securethecargobedbypullingtheproprod
intothereardetentattheendoftheslotlocated
intheleftsideofthemachine(Figure3).
Note:Formachineswithabolt-onrod-support
bracket,pulltheproprodintothereardetentat
theendoftheslotinthebracket.
3.Attachtheliftingequipmenttothefrontandrear
ofthecargobed.
Note:Raisetheliftingequipmentatthefrontof
thebeduntilthefrontofthebedissupported.
4.Removethehairpincotterandwasherthat
securetheproprodtothebottomofthebed
(Figure4).
3

g025013
Figure4
1.Washer4.Bedhole
2.Hairpin5.Proprod
3.Slot(frame)
5.Slidetheproprodforwardtoremoveitfromthe
bracketontheframe(Figure4).
Note:Retainthehardwareforcargobed
installation.
6.Lowerthefrontofthebed.
7.Removethe4anged-headbolts(3/8x1inch)
thatsecurethehingebracketsofthecargobed
totherearframechannelofthemachine(Figure
5).
Note:Retainthehardwareforcargobed
installation.
g226636
Figure5
1.Rearframechannel3.Hingebracket
2.Flanged-headbolt(3/8x
1inch)
8.Liftthelatchleveroneithersideofthemachine,
neartheforwardcornerofthecargobed(Figure
3).
9.Liftthecargobedupandoffthemachine(Figure
6).
g226635
Figure6
4

ForMachineswithanElectric
CargoBedLift
1.Removethehex-headbolt(1/2x5-1/2inches)
andlocknut(1/2inch)fromtheinboardand
outboardliftbrackets(Figure7).
Note:Retainthehardwareforcargobed
installation.
2.Removethehairpincotterfromtheclevispin
(3-1/2inches),andremovetheclevispin(3-1/2
inches)fromtheliftactuatorrod(Figure7).
Note:Retainthehardwareforcargobed
installation.
g226666
Figure7
1.Locknut(1/2inch)4.Liftactuatorrod
2.Hex-headbolt(1/2x5-1/2
inches)
5.Clevispin(3-1/2inches)
3.Hairpincotter
3.Removethe4anged-headbolts(3/8x1inch)
thatsecurethehingebracketsofthecargobed
totherearframechannelofthemachine(Figure
5).
Note:Retainthehardwareforcargobed
installation.
4.Liftthecargobedupandoffthemachine(Figure
6).
5

4
DisconnectingtheEngine
NoPartsRequired
Procedure
RefertoFigure8andFigure9forthisprocedure.
Important:Topreventcontaminantsfrom
enteringthefuelsystemandengine,ensurethat
allhosesandengineopeningsarecoveredor
pluggedafterdisconnecting.
Note:Keepanypartsremovedinthisprocedurefor
laterinstallationunlessotherwisestated.
1.Draintheoilfromtheenginebeforeremoving
theengine;refertoyourOperator’sManual.
2.Disconnectthechokeandthrottlecablesfrom
theengine,butdonotremovethemfromthe
cablebrackets.
3.Disconnecttheairintakehosefromtheair
cleaner.
DANGER
Incertainconditions,fuelisextremely
ammableandhighlyexplosive.Are
orexplosionfromfuelcanburnyouand
othersandcandamageproperty.
•Neverllthefueltankinsidean
enclosedtrailer.
•Neversmokewhenhandlingfuel,
andstayawayfromanopenameor
wherefuelfumesmaybeignitedby
aspark.
•Storefuelinanapprovedcontainer
andkeepitoutofthereachofchildren.
Neverbuymorethana30-daysupply
offuel.
DANGER
Incertainconditionsduringfueling,
staticelectricitycanbereleasedand
causeaspark,whichcanignitethefuel
vapors.Areorexplosionfromfuelcan
burnyouandothersandcandamage
property.
•Alwaysplacefuelcontainersonthe
groundawayfromyourmachine
beforelling.
•Donotllfuelcontainersinsidea
machineoronatruckortrailerbed
becauseinteriorcarpetsorplastic
truckbedlinersmayinsulatethe
containerandslowthelossofany
staticcharge.
WARNING
Fuelisharmfulorfatalifswallowed.
Long-termexposuretovaporscancause
seriousinjuryandillness.
•Avoidprolongedbreathingofvapors.
•Keepyourfaceawayfromthenozzle
andfueltankopening.
•Keepfuelawayfromyoureyesand
skin.
4.Disconnectthefuelinlethosefromthefuel
pump;clampthehosesothatfueldoesnotleak.
5.Removetheexhaustmanifoldfromtheengine.
6.Unthreadthe2oilhosesfromtheirttingsinthe
engine.
7.Disconnectthewireharnessterminalfromthe
frontsideoftheengine.
6

g226804
Figure8
1.Throttlecable10.Oilinhose19.Clutchassembly28.Clutchscrew
2.Enginenut11.Oilouthose20.Exhaustmanifold29.Enginetray
3.Cablebracketscrew12.Straighttting(engine)21.Manifoldscrew30.Mount
4.Cableclamp13.Elbowtting(engine)22.Couplerspring31.Mountwasher
5.Threadedinsert14.Cablebracket(throttle)23.Assemblynut32.Mountscrew
6.Cablebracket(choke)15.Lockwasher24.Oillterassembly33.Internallockwasher
7.Spring16.Capscrew25.Assemblyscrew34.Enginebolt
8.Studball17.Starterbelt26.Filterbracket35.Mountnut
9.Springkeeper18.Drivebelt27.Flangewasher
7

g226803
Figure9
1.Intakehose6.Air-cleanerbracket11.Cablebracket(choke)16.Engine
2.Hoseclamp7.Screw12.Spring17.Air-intakehose
3.Aircleaner8.Cable-bracketscrew13.Studball18.Locknut
4.Mountingbracket9.Cableclamp14.Springkeeper
5.Nut10.Threadedinsert15.Hoseclamp(engineside)
5
InstallingtheEngine
Partsneededforthisprocedure:
1Engine
1Airintakehose
1Hoseclamp—aircleanerside
1Hoseclamp—engineside
1Aircleanerbracket
2Bolt
2Locknut
2Nut
Procedure
RefertoFigure8andFigure9forthisprocedure.
1.Installtheoilhosettingsintothesideofthe
engine.
Note:Installtheelbowedttingintothelower
oriceandinstallthestraightttingtotheupper
orice.
2.Installtheaircleanertotheaircleanerbracket.
3.Installtheaircleanerbrackettotheengine,and
installtheairintakehosewiththeprovidedhose
clamps.
4.Attachashortsectionofchainbetween2lift
pointsontheengineandconnectthehoistto
thecenterofthechain.
5.Slowlylowertheengineintothemachinewith
onepersonoperatingthehoistandanother
guidingtheengineintotheframe.
Note:Thecrankshaftshouldbefacingtheright
sideofthemachinewheninstalled.
6.Threadtheballstudandspringkeeperintothe
engineandattachthespring.
7.Installthechokeandthrottlecablesandcable
bracketstotheengine.
8.Alignthestarterbeltwiththeenginepulleys.
9.Applymedium-strengththread-locking
compound(suchasBlueLoctite®242)tothe
clutchscrewandinstalltheclutchassemblyto
theenginecrankshaft.
10.Alignthedrivebeltwiththeclutchassembly.
11.Installtheexhaustmanifoldtotheengineand
connectittotheexhaustpipewiththecoupler
springs.
8

12.Installthe4angenutsand4capscrews
securingtheenginetotheenginetray.
13.Threadthe2oilhosesintotheirttingsinthe
engine.
Note:Threadthestraighthoseendtothe
elbowedttingontheengineandthreadthe
elbowedhoseendontothestraighthosetting.
14.Connectthegroundwiretothefrontsideofthe
engine.
15.Connectthefuelinlethosetothefuelpump.
16.Connecttheairintakehosetotheaircleaner
andtheengineusinghoseclamps.
17.Filltheenginewithoil;refertoyourOperator’s
Manual.
6
InstallingtheBedSpacers
Partsneededforthisprocedure:
1Fronttubeframe
1Rightbedspacerassembly
1Leftbedspacerassembly
2Pivotbedspacer
4Screw
2Carriagebolt
4Bolt
6Nut
Procedure
1.Removethehingebracketassemblyfromthe
bottomofthedetachedcargobed.
2.Alignthepivotbedspacersdirectlyabovethe
pivotbushings,andinstallthehingebracket
assemblytothecargobedusingthelongscrews
(Figure10).
g227144
Figure10
Undersideofcargobedshown
1.Washers3.Pivotbushingandbracket
assembly
2.Pivotbedspacer4.Longscrews
3.Placethefronttubeframeushwiththeforward
edgeofthebedframeassembly.
9

4.Connecttherightbedspacerassemblytothe
fronttubeframewithaboltandtothebedframe
assemblywithacarriageboltasshowninFigure
11.
g227145
Figure11
1.Fronttubeframe2.Rightbedspacer
assembly
Important:Moveanycomponentsthat
arebehindtheframeinthepathofthedrill
beforedrilling.
5.Ontherightsideofthemachine,detachthe
solenoidbracketandmoveitoutofthepathof
thedrill(Figure12).
6.Drillaholeinthebedframeassemblyusingthe
mountingtabofthesidebedspacerassemblies
asatemplateandsecuretheframeassembly
withashortboltandanut(Figure12).
g227146
Figure12
1.Nut3.Solenoidbracketbolts
2.Rightbedspacer
assemblymountingtab
4.Shortbolt
7.Repeatthesestepsontheothersideofthe
machine.
10

7
InstallingtheCargoBed
NoPartsRequired
ForMachineswithaManualCargo
BedLift
1.Rotatethecargobedsothatthehinge-bracket
assemblyandproprodarefacingdownward
(Figure13).
2.Usingliftingequipmentatthefrontandrear
ofthecargobed,raisethecargobed,and
alignitovertheframeofthemachinewiththe
hinge-bracketassemblyfacingrearward(Figure
13).
g226677
Figure13
3.Adjusttheheightandpositionofthelifting
equipmentsothattheshortlegoftheproprod
isalignedwiththedetentslotattheendofthe
proprodslotintheleftframechannelorprop
rodbracket(Figure13).
Note:Youwillhavetoanglethecargobedwith
theliftingequipmentinordertoaligntheprop
rodtothedetentslot.
4.Rotatetheproprodforwardandinserttheshort
legoftherodthroughthedetentslot(Figure13
andFigure14).
5.Movethecargobedandproprodrearwarduntil
thehinge-bracketassemblyalignsovertherear
framechannel(Figure14).
g026402
Figure14
1.Detentslot2.Proprod
6.Carefullylowerthecargobeduntiltheholesin
thehingebracketsalignwiththemountingholes
forthecargobedintherearframechannel
(Figure15).
7.Securethehingebracketstotherearframe
channelusingthepreviouslyremoved4
anged-headbolts(3/8x1inch)asshownin
Figure15.
8.Torquethe4anged-headboltsto37to45N∙m
(27to33ft-lb).
g226636
Figure15
1.Rearframechannel3.Hingebracket
2.Flanged-headbolt(3/8x
1inch)
11

ForMachineswithanElectric
CargoBedLift
1.Rotatethecargobedsothatthehinge-bracket
assemblyandproprodarefacingdownward
(Figure13).
2.Usingliftingequipmentatthefrontandrear
ofthecargobed,raisethecargobed,and
alignitovertheframeofthemachinewiththe
hinge-bracketassemblyfacingrearward(Figure
13).
3.Securetheliftactuatorrodtotheinboardand
outboardliftbracketsusingthepreviously
removedhex-headbolt(1/2x5-1/2inches),
locknut(1/2inch),clevispin(3-1/2inches),and
hairpincotter(Figure16).
g226666
Figure16
1.Locknut(1/2inch)4.Liftactuatorrod
2.Hex-headbolt(1/2x5-1/2
inches)
5.Clevispin(3-1/2inches)
3.Hairpincotter
4.Securethehingebracketstotherearframe
channelusingthepreviouslyremoved4
anged-headbolts(3/8x1inch)asshownin
Figure15.
5.Torquethe4anged-headboltsto37to45N∙m
(27to33ft-lb).
8
ConnectingtheBattery
NoPartsRequired
Procedure
1.Connectthepositivebatterycabletotheterminal
ofthebattery(Figure2).
2.Connectthenegativebatterycabletothe
terminalofthebattery(Figure2).
3.Installthebatterycoverontothetopofthe
battery(Figure2).
12