Form No. 3409-811 Rev G Workman® GTX Utility Vehicle Model No. 07040—Serial No. 400000000 and Up Model No. 07042—Serial No. 400000000 and Up Register at www.Toro.com.
numbers on the product. Write the numbers in the space provided. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents Fuel System Maintenance ................................... 37 Inspecting Fuel Lines and Connections............. 37 Replacing the Fuel Filter ................................... 37 Servicing the Carbon Canister .......................... 38 Electrical System Maintenance ........................... 39 Electrical System Safety ................................... 39 Servicing the Battery......................................... 39 Replacing the Fuses .........................................
Safety • Use your full attention while operating the machine. Do not engage in any activity that causes distractions; otherwise, injury or property damage may occur. 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 (Figure 2), which means Caution, Warning, or Danger—personal safety instruction.
decal120-9570 120-9570 1. Warning—stay away from moving parts; keep all guards and shields in place. decal131-8410 131-8410 1. Fire hazard—shut off the engine before fueling. decal131-8552 131-8552 1. Read the Operator's Manual for fuse information. 2. Horn (30 A) 4. Headlights (10 A) 3. Main power (15 A) 6. Optional lift kit (15 A) decal131-8463 131-8463 1. Forward 2. Neutral 5. USB power point/options (10 A) 3. Reverse decal131-8492 131-8492 1. Headlight—on 3. Raise the bed. 2.
decal131-8414 131-8414 1. Warning—read the Operator's Manual. decal131-8413 131-8413 3. Tipping hazard—drive slowly across or up slopes; take turns slowly; do not exceed speeds of 25 kph (16 mph); drive slowly when hauling cargo; drive slowly on uneven terrain. 2. Warning—receive proper training before operating the machine. 4.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure 1 2 3 4 Description Qty. Use Steering wheel Steering wheel cover Washer (1/2 inch) Dust cover 1 1 1 1 Install the steering wheel (International models only). No parts required – Check the fluid levels and tire pressure. No parts required – Burnish (break-in) the brakes.
2 4 Checking the Fluid Levels and Tire Pressure Reading the Manual and Viewing the Setup Material No Parts Required Parts needed for this procedure: Procedure 1. Check the engine-oil level before and after you first start the engine; refer to Checking the Engine-Oil Level (page 35). 2. Check the brake-fluid level before you first start the engine; refer to Checking the Brake-Fluid Level (page 50). 3.
Product Overview g033925 Figure 4 1. Hood latch 3. Steering wheel 5. Towing tongue 2. Shift lever 4. Cargo bed 6. Fuel cap 7. Cargo-bed lever g034517 Figure 5 1. Passenger handhold 3. Rear cargo-bed-accessory mount 2. Parking-brake lever 4.
Controls Control Panel g033921 Figure 6 1. Steering wheel 6. USB power point 2. Gear-shift indicator 7. Parking-brake lever 3. Gear-shift lever 4. Horn button (International models only) 8. Choke control 9. Brake pedal 5. Key switch 10. Accelerator pedal Accelerator Pedal Brake Pedal Use the accelerator pedal (Figure 6) to vary the ground speed of the machine. Pressing down the accelerator pedal starts the engine. Pressing the pedal farther increases the ground speed.
Key Switch Choke Control The key switch is located at the lower, right corner of the dash panel (Figure 6). The choke control is located on the control panel. Use the choke to help start a cold engine by pulling the choke control outward (Figure 6). After the engine starts, adjust the choke to keep the engine running smoothly. As the engine warms up, push in the choke control to the OFF position. The key switch has 3 positions: OFF, ON, and START .
Light Switch Fuel Gauge The light switch is located to the left of the steering column (Figure 10). Use the light switch to illuminate the headlights. Push the light switch up to turn on the headlights. Push the light switch down to turn off the lights. The fuel gauge (Figure 11) is located on the fuel tank in the filler cap, at the left side of the machine. The gauge displays the amount of fuel in the tank. g033954 Figure 10 1. Light switch 2.
Specifications Note: Specifications and design are subject to change without notice. Base weight 397 kg (875 lb) Rated capacity (on level ground) 544 kg (1,200 lb) total, including 90.
Performing Daily Maintenance Operation Note: Determine the left and right sides of the machine from the normal operating position. Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 24).
Adding Fuel Recommended Fuel • For best results, use only clean, fresh (less than 30 days old), unleaded gasoline with a cetane 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.
Breaking in a New Machine During Operation Service Interval: After the first 100 hours—Perform the guidelines for breaking in a new machine. During Operation Safety Perform the following guidelines to provide proper performance for the machine. General Safety • The owner/operator can prevent and is responsible • Ensure that the brakes are burnished; refer to 3 Burnishing the Brakes (page 8). • • Check the fluid and engine-oil levels regularly.
• If you have a load in the cargo bed, ensure that roll over if a wheel goes over the edge or if the edge gives way. you do not exceed the capacity of the machine by having too many passengers. • When using the machine on public roads, follow • Passengers should sit in the designated seating all traffic regulations and use any additional accessories that may be required by law, such as lights, turn signals, slow-moving vehicle (SMV) signs, and others as required. positions only.
on level ground. If you must stop the machine, avoid sudden speed changes, which can cause the machine to tip or roll over. Do not engage the brakes suddenly when rolling rearward, as this may cause the machine to overturn. CAUTION If a load is concentrated near the back of the cargo bed when you release the latches, the bed may unexpectedly tip open, injuring you or bystanders. Loading and Dumping Safety • Center loads in the cargo bed, if possible.
Opening the Tailgate Raising the Cargo Bed to the Service Position 1. Ensure that the cargo bed is down and latched. 1. Pull the lever on left, inside of the cargo bed toward you and lift the cargo bed up (Figure 15). 2. Using both hands, raise the tailgate using the ridge near the top of the tailgate (Figure 17). 2. Pull prop rod into the service position detent slot to secure the bed for maintenance (Figure 16). 3.
Closing the Tailgate Using the Rear Cargo Bed Accessory Mount 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 steps 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 18).
Loading the Cargo Bed Refer to the following table for load volume limits with various materials: Use the following guidelines when loading the cargo bed and operating the machine: Material Density Maximum Cargo Bed Capacity (on level ground) • 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 (page 13) and on the gross vehicle weight tag of the machine.
Stopping the Machine Starting the Engine 1. Sit in the operator seat, insert the key into the key switch, and rotate the key clockwise to the ON or START position. 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.
After Operation After Operation Safety General Safety • Allow the engine to cool before storing the machine in any enclosure. • Do not store the machine or fuel container where there is an open flame, spark, or pilot light, such as on a water heater or other appliance. g236535 Figure 21 • Keep all parts of the machine in good working 1. Towing tongue and tie-down point (front of the machine) condition and all hardware tightened. • Replace all worn, damaged, or missing decals.
Maintenance Note: Determine the left and right sides of the machine from the normal operating position. Note: Download a copy of the electrical schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page. Important: Refer to your engine owner’s manual for additional maintenance procedures. WARNING Failure to properly maintain the machine could result in premature failure of machine systems, causing possible harm to you or bystanders.
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 for unusual engine noises. Check for unusual operating noises. Check the tire pressure. Check for fluid leaks.
Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 5 hours • Change the engine oil. After the first 8 hours • Check the condition of the drive belt. • Check the tension of the starter-generator belt. After the first 50 hours • Check the air filter for the carbon canister. After the first 100 hours • Perform the guidelines for breaking in a new machine. Before each use or daily • • • • Check Check Check Check the tire pressure.
Pre-Maintenance Procedures could void the product warranty of The Toro® Company. Pre-Maintenance Safety Maintenance Safety Before adjusting, cleaning, repairing, or leaving the machine, do the following: • Do not allow untrained personnel to service the machine. • Before servicing or making any adjustments to the machine, park the machine on a level surface, engage the parking brake, shut off the engine, and remove the key to prevent accidental starting of the machine. 1.
Lifting the Machine DANGER The machine may be unstable when using a jack. The machine could slip off the jack, injuring anyone beneath it. • Do not start the machine while the machine is on a jack. • Always remove the key from the key switch before getting off the machine. g034044 Figure 24 • Block the tires when the machine is supported by lifting equipment. 1. Rear lifting points • Use jack stands to support the machine once you have lifted it.
Raising and Lowering the Seat Assembly To raise the seat assembly, push the seat assembly forward until it rests on the steering wheel (Figure 26). To lower the seat assembly, push the seat assembly rearward until it seats back into the original position (Figure 26). g190187 Figure 27 1. Pins Installing the Seat Assembly Slide the seat assembly onto the pins and lower the seat assembly (Figure 28). g190066 Figure 26 Removing the Seat Assembly 1.
Lubrication Greasing the Front Wheel Bearings Greasing the Machine Service Interval: Every 300 hours 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 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 31). Grease Type: No.
g192347 Figure 34 1. Spindle 2. Hub and rotor assembly g033047 Figure 32 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 33). g192346 Figure 33 1. Cotter pin 4. Spindle nut 2. Spindle 5. Nut retainer 3. Tab washer 6. Dust cap 5. Remove the cotter pin and nut retainer from the spindle and spindle nut (Figure 33). 6.
Installing the Hub and Rotor Greasing the Wheel Bearings 1. 1. Remove the outboard bearing and bearing race from the hub (Figure 35). Apply a light coat of the specified grease to the spindle (Figure 36). g192344 Figure 36 g033050 Figure 35 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 35). 3. Wipe clean the seal and check for wear and damage. 1.
Engine Maintenance Engine Safety • Shut off the engine, remove the key, and wait for all moving parts to stop before checking the oil or adding oil to the crankcase. • Keep your hands, feet, face, clothing, and other body parts away from the muffler and other hot surfaces. g192345 Figure 37 1. Cotter pin Servicing the Air Cleaner 3. Dust cap Service Interval: Every 100 hours Replace the air-filter element sooner if dirty or damaged. 2. Nut retainer 9.
4. Install the air-cleaner cover with the side indicated as “UP” facing upward and secure the latches (Figure 39). g236567 Figure 38 Servicing the Air Filter Service Interval: Every 100 hours (more frequently in extreme dusty or dirty conditions). 1. Gently slide the air filter out of the air-cleaner body (Figure 39). Note: Avoid knocking the air filter into the side of the body. g034313 Figure 39 Important: Do not attempt to clean the air filter. 2.
Servicing the Engine Oil Service Interval: After the first 5 hours Every 100 hours (Change the oil twice as often during special operating conditions; refer to Maintaining the Machine under Special Operating Conditions (page 25)). 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 Crankcase Capacity: 1.0 L (1.
Changing the Engine Oil Servicing the Spark Plug 1. Start the machine and let the engine run for a few minutes. 2. Park the machine on a level surface. 3. Engage the parking brake. 4. Shut off the engine and remove the key. 5. Raise the cargo bed and secure it with the prop rod; refer to Raising the Cargo Bed to the Service Position (page 19). 6. Checking and Replacing the Spark Plug Service Interval: Every 100 hours/Yearly (whichever comes first) Replace the spark plug if necessary.
7. Install the spark-plug wire. 8. Repeat steps 1 through 7 for the other spark plug. Fuel System Maintenance Adjusting the High Idle 1. Lift the cargo bed and secure it with the prop rod. 2. At the throttle cable housing, loosen the forward jam nut and tighten the rear jam nut to increase the idle speed (Figure 44).
Servicing the Carbon Canister Checking the Air Filter for the Carbon Canister Service Interval: After the first 50 hours Every 200 hours Check the opening at the bottom of the air filter for the carbon canister to ensure that it is clean and free of debris and obstructions (Figure 46). Clean the air filter for the carbon canister with clean, compressed air. g029685 g034099 Figure 45 7.
Disconnecting the Battery Electrical System Maintenance 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. Electrical System Safety WARNING • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
Removing the Battery 1. Disconnect the battery cables; refer to Disconnecting the Battery (page 39). 2. Remove the battery as shown in Figure 48. Installing the Battery 1. Install the battery as shown in Figure 49. g034327 Figure 49 g034326 2. Figure 48 40 Connect the battery cables; refer to Connecting the Battery (page 41).
Connecting the Battery Replacing the Fuses Connect the battery as shown in Figure 50. There are 4 fuses in the electrical system. They are located beneath the seat assembly (Figure 51). Note: If you install the optional lift kit, you will receive another fuse block to install next to the fuse block installed currently.
Maintaining the Headlights with the slots in the headlight housing (Figure 52). Replacing the Bulbs CAUTION If you install a higher wattage bulb than the system is designed for, you may damage the 12 V power supply, or at a minimum, blow the fuse. Always use the specified Toro LED bulb to prevent this issue. 6. Secure lamp assembly by turning it 1/4 turn clockwise (Figure 52). 7. Connect the electrical connector for the harness to the connector of the new lamp assembly (Figure 52). 8.
Drive System Maintenance Note: Ensure the adjustment posts are lined up with the holes in the mounting bracket behind the bumper. 7. Secure the headlight assembly with the speed clips that you removed in step 4. 8. Connect the electrical connector for the harness to the connector of the lamp assembly (Figure 53). 9. Maintaining the Tires Service Interval: Every 100 hours—Check the condition of the tires and rims.
Inspecting the Steering and Adjusting the Front Wheel Alignment Suspension Components Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the front wheel camber and toe-in. Service Interval: Every 100 hours—Inspect the steering and suspension for loose or damaged components. With the steering wheel at the centered position (Figure 54), turn the steering wheel to the left or right.
Adjusting the Front Wheel Toe-in Checking the Transaxle-Fluid Level Important: Before adjusting toe-in, ensure that the camber adjustment is as close to neutral as possible; refer to Adjusting the Camber (page 44). 1. Service Interval: Every 100 hours Measure the distance between both of the front tires at the axle height at both the front and rear of the front tires (Figure 57). Fluid Type: SAE 80W-90 (API MT-1) or SAE 80W-90 (API GL-5) 1. Park the machine on a level surface. 2.
Changing the Transaxle Fluid Checking the Neutral Gear-Shift Position Service Interval: Every 800 hours/Yearly (whichever comes first) Service Interval: Every 100 hours When performing routine maintenance and/or engine diagnostics, the transaxle must be shifted into NEUTRAL. The machine has a NEUTRAL position on the gear-shift selector, which controls the neutral in the transaxle.
Maintaining the Primary Drive Clutch Adjusting the Neutral Gear-Shift Position 1. Loosen the jam nuts on the gear-shift cable and adjust them as necessary (Figure 60). Service Interval: Every 400 hours/Yearly (whichever comes first) CAUTION The dust in the clutch will become airborne and could damage your eyes or you could inhale it, causing breathing difficulties. Wear safety goggles and a dust mask or other eye and respiratory protection when performing this procedure. 1.
Reducing the Top Speed Important: Ensure that the X is placed back in the original location. 6. CAUTION The dust in the clutch will become airborne and could damage your eyes or you could inhale it, causing breathing difficulties. Wear safety goggles and a dust mask or other eye and respiratory protection when performing this procedure. 1. Raise and latch the cargo bed; refer to Raising the Cargo Bed to the Service Position (page 19). 2.
Brake Maintenance Cooling System Maintenance Checking the Parking Brake Cooling System Safety 1. Engage the parking brake by pulling the parking-brake lever toward you, until you feel tension. 2. If you do not feel tension when pulling the parking-brake toward you within 11.4 to 16.5 cm (4-1/2 to 6-1/2 inches) from the “P” symbol on the dash, then you need to adjust the parking brake; refer to Adjusting the Parking Brake (page 49).
8. Verify that the parking brake is adjusted to the proper tension; refer to Checking the Parking Brake (page 49). Note: If you cannot adjust the parking brake to the required tension, the brake pads may be worn and need to be replace. Contact your Authorized Service Dealer for assistance. Checking the Brake-Fluid Level g002136 Figure 65 1. Brake-fluid reservoir Service Interval: Before each use or daily Check the brake-fluid level before the motor is first used. 6. Brake Fluid Type: DOT 3 2.
Belt Maintenance Inspecting the Brakes Service Interval: Every 100 hours Servicing the Drive Belt 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: Checking the Drive Belt Service Interval: After the first 8 hours • Inspect the brake lining for wear or damage.
Replacing the Drive Belt 1. Raise the cargo bed; refer to Raising the Cargo Bed to the Dump Position (page 18). 2. Shift the transmission into the NEUTRAL position, engage the parking brake, rotate the key switch to the OFF position, and remove the key. 3. Rotate and route the belt over the secondary clutch (Figure 66). 4. Remove the belt from the primary clutch (Figure 66).
Cleaning Washing the Machine The machine should be washed as needed. Use water alone or with a mild detergent. A rag may be used when washing 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.
Storage B. Run the engine to distribute conditioned fuel through the fuel system (5 minutes). Storage Safety C. Shut off the engine, allow the engine to cool, and drain the fuel tank. • Let the engine cool before storing the machine. • Do not store the machine or fuel near flames or Note: Dispose of fuel properly. Recycle as according to local codes. drain the fuel indoors. Storing the Machine D. Start the engine again and run it until it stops. E. Choke the engine. F.
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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).
