Form No. 3432-231 Rev C Workman® GTX EFI Utility Vehicle with Extended Chassis Model No. 07042EX—Serial No. 403446001 and Up Register at www.Toro.com.
This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Introduction The safety-alert symbol (Figure 2) appears both in this manual and on the machine to identify important safety messages that you must follow to avoid accidents. This symbol will appear with the word Danger, Warning, or Caution. This utility vehicle is intended to be primarily used off-highway to transport people and material loads. Using this product for purposes other than its intended use could prove dangerous to you and bystanders.
Contents Fuel System Maintenance ................................... 40 Inspecting Fuel Lines and Connections............. 40 Replacing the Fuel Filter ................................... 41 Servicing the Carbon Canister .......................... 41 Electrical System Maintenance ........................... 42 Electrical System Safety ................................... 42 Servicing the Battery......................................... 42 Replacing the Fuses .........................................
Safety This machine has been designed in accordance with the requirements of SAE J2258 (Nov 2016). General Safety This product is capable of causing personal injury. Always follow all safety instructions to avoid serious personal injury. • Read and understand the contents of this Operator’s Manual before you start the machine. Ensure that everyone using this product knows how to use it and understands the warnings. • Use your full attention while operating the machine.
Safety and Instructional Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or missing. decal131-8410 131-8410 decal99-7345 99-7345 1. Fire hazard—shut off the engine before fueling. 1. Warning—read the Operator's Manual. 2. Warning—do not touch the hot surface. 3. Entanglement hazard, belt—stay away from moving parts; keep all guards in place. 4.
200 LBS 91 KG 1500 LBS 680 KG 137-9984 decal137-9984 137-9984 decal131-8463 131-8463 1. Forward 2. Neutral 1. Do not exceed a tongue weight of 91 kg (200 lb). 3. Reverse 2. Do not exceed a transport load of 680 kg (1,500 lb). decal138-3524 138-3524 1. Light—On 3. Raise the bed. 2. Light—Off 7 4. Lower the bed.
decal138-3528 138-3528 EFI Models Only 1. Read the Operator’s Manual before performing maintenance. 2. Engine intake/air filter 5. Spark plug air gap 6. Engine oil 3. Fuel filter 4. Spark plug 7. Transmission fluid 8. Brake fluid decal138-3397 138-3397 EFI Models Only 1. Horn 4. Engine—start 2. Off 5. To start the engine: 1) Sit in the operator's position; 2) Disengage the parking brake; 3) Turn the key to the engine START position; 4) Press the brake pedal. 3.
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 38). 2. Check the brake-fluid level before you first start the engine; refer to Checking the Brake-Fluid Level (page 52). 3.
Product Overview Controls Become familiar with all the controls before you start the engine and operate the machine. Control Panel g033921 Figure 4 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 CAUTION Accelerator Pedal Operating a machine with worn or incorrectly adjusted brakes can may result in personal injury.
Key Switch Choke Control The key switch is located at the lower, right corner of the dash panel (Figure 4). 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 4). 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 8). 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 9) 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 8 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. Service Interval: Before each use or daily Before Operation Before starting the machine each day, perform the Each Use/Daily procedures listed in Maintenance (page 26).
Adding Fuel Recommended Fuel Type Unleaded gasoline Minimum octane rating 87 (US) or 91 (research octane; outside the US) Ethanol No more than 10% by volume Methanol None MTBE (methyl tertiary butyl ether) Less than 15% by volume Oil Do not add to the fuel Use only clean, fresh (no more than 30 days old), fuel from a reputable source. Important: To reduce starting problems, add fuel stabilizer/conditioner to fresh fuel as directed by the fuel-stabilizer/conditioner manufacturer.
• Before you start the machine, ensure that the • A break-in oil for the engine is not required. • • transmission is in neutral, the parking brake is engaged, and you are in the operating position. Original engine oil is the same type specified for regular oil changes. Refer to Maintenance (page 26) for any special, low-hour checks. Check the front suspension positioning and adjust it, if necessary; refer to Adjusting the Front Wheel Alignment (page 47).
• Do not operate the machine when there is the risk going down a slope takes longer than stopping 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. of lightning. • Use accessories and attachments approved by The Toro® Company only.
Operating the Cargo Bed Raising the Cargo Bed to the Dump Position WARNING A raised bed could fall and injure persons that are working beneath it. • Always use the prop rod to hold the bed up before working under the bed. g034019 Figure 13 • Remove any load material from the bed before raising it. 1. Cargo-bed lever 2. WARNING Pull the prop rod into the dump position detent slot to secure the bed for dumping (Figure 14).
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 13). 2. Using both hands, raise the tailgate using the ridge near the top of the tailgate (Figure 15). 2. Pull prop rod into the service position detent slot to secure the bed for maintenance (Figure 14). 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 16).
Loading the Cargo Bed Material Density Maximum Cargo Bed Capacity (on level ground) Gravel, dry 1522 kg/m3 (95 lb/ft3) Full limit the weight of the load that you carry in the cargo bed as described in Specifications (page 14) and on the gross vehicle weight tag of the machine.
Starting the Engine 1. Stopping the Machine 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 • Before you leave the operating position, do the following: – Park the machine on a level surface. – Shift the transmission to the NEUTRAL position. g236535 Figure 19 – Engage the parking brake. 1. Towing tongue and tie-down point (front of the machine) – Shut off the machine and remove the key. – Wait for all movement to stop. • Allow the machine to cool before adjusting, servicing, cleaning, or storing it.
Towing the Machine In case of an emergency, you can tow the machine for a short distance; however, this should not be a standard operating procedure. WARNING Towing at excessive speeds could cause a loss of steering control, resulting in personal injury. Never tow the machine at faster than 8 km/h (5 mph). 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 (page 25) 1.
Maintenance Maintenance Safety or its use may result in injury or death. Such use could void the product warranty of The Toro® Company. • Do not allow untrained personnel to service the • • • • • • • • • • • • • • • • machine. Before you leave the operating position, do the following: – Park the machine on a level surface. – Shift the transmission to the NEUTRAL position. – Engage the parking brake. – Lower the cargo bed. – Shut off the machine and remove the key. – Wait for all movement to stop.
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 • Inspect the seat belt(s) for wear, cuts, and other damage.
WARNING Failing to properly maintain the machine could result in premature failure of machine systems, causing possible harm to you or bystanders. Keep the machine well maintained and in good working order as indicated in these instructions. CAUTION Only qualified and authorized personnel should maintain, repair, adjust, or inspect the machine. • Avoid fire hazards and have fire-protection equipment present in the work area.
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 brake-fluid 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.
Pre-Maintenance Procedures Lifting the Machine DANGER The machine may be unstable when using a jack. The machine could slip off the jack, injuring anyone beneath it. Preparing the Machine for Maintenance 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. • Do not start the machine while the machine is on a jack.
Removing the Bench Cushion 1. Push the bench cushion forward to the raised position. 2. Slide the cushion to the side, out of the pins, and lift the cushion upward (Figure 24). g034044 Figure 22 1. Rear lifting points Accessing the Hood Raising the Hood 1. Lift up the handle of the rubber latches on each side of the hood (Figure 23). g237191 Figure 24 g034045 Figure 23 2. Raise the hood. Closing the Hood 1. Gently lower the hood. 2.
Lubrication Installing the Bench Cushion Greasing the Machine Slide the bench cushion onto the pins and lower the cushion (Figure 25). 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 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.
Greasing the Front Wheel Bearings Service Interval: Every 300 hours 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 28). g033047 Figure 29 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 30). g033046 Figure 28 1. Hub 3. Lug nut 2. Wheel g192346 3.
Greasing the Wheel Bearings 1. Remove the outboard bearing and bearing race from the hub (Figure 32). g192347 Figure 31 1. Spindle 2. Hub and rotor assembly 7. Wipe clean the spindle with a rag. 8. Repeat steps 1 through 7 to the hub and rotor at the other side of the machine. g033050 Figure 32 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 32). 3.
Installing the Hub and Rotor 1. Apply a light coat of the specified grease to the spindle (Figure 33). g192345 Figure 34 g192344 1. Cotter pin Figure 33 1. Nut retainer 4. Outer bearing 2. Spindle nut 5. Hub, rotor, inner bearing, race, and seal 6. Spindle 3. Tab washer 3. Dust cap 2. Nut retainer 9. Install the cotter pin and bend each legs around the retainer (Figure 34). 10. Install the dust cap onto the hub (Figure 34).
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. Servicing the Air Cleaner Servicing the Air-Cleaner Cover Service Interval: Every 50 hours—Remove the air-cleaner cover and clean out the debris. Do not remove the air-cleaner element.
Replacing the Air-Cleaner Element Service Interval: Every 50 hours—Under special operating conditions (refer to Maintaining the Machine under Special Operating Conditions)—replace the air-cleaner element. Replace the air-cleaner element sooner if dirty or damaged. Every 100 hours—Under normal operating conditions—replace the air-cleaner element. Replace the air-cleaner element sooner if dirty or damaged.
Servicing the Engine Oil Engine-Oil Specifications Crankcase Capacity: 1.0 L (1.1 US qt) Oil Type: API service class SJ or higher detergent oil Viscosity: See the table below. g192771 g034082 Figure 38 Figure 37 Checking the Engine-Oil Level Service Interval: Before each use or daily Note: The machine is shipped with oil in the crankcase; however, check the oil before and after you start the engine.
Changing the Engine Oil Servicing the Spark Plug Service Interval: After the first 5 hours—Change the engine oil. Checking and Replacing the Spark Plug Every 50 hours—Under special operating conditions (refer to Maintaining the Machine under Special Operating Conditions)—change the engine oil. Service Interval: Every 100 hours/Yearly (whichever comes first) Replace the spark plug if necessary. Every 100 hours—Under normal operating conditions—change the engine oil.
7. Install the spark-plug wire. 8. Repeat steps 1 through 7 for the other spark plug. Fuel System Maintenance Adjusting the High/Low Idle Inspecting Fuel Lines and 1. Lift the cargo bed and secure it with the prop rod. Connections 2. At the throttle cable housing, loosen the forward jam nut and tighten the rear jam nut to increase the low idle (Figure 41).
Replacing the Fuel Filter Servicing the Carbon Canister Service Interval: Every 400 hours/Yearly (whichever comes first) 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 bed and support it with the prop rod. 5. Disconnect the battery; refer to Disconnecting the Battery (page 42). 6. Place a clean container under the fuel filter and replace the fuel filter as shown in Figure 42.
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 • Disconnect the battery before repairing the machine. Disconnect the negative terminal first and the positive last. Connect the positive terminal first and the negative last.
Removing the Battery 1. Disconnect the battery cables; refer to Disconnecting the Battery (page 42). 2. Remove the battery as shown in Figure 45. Installing the Battery 1. Install the battery as shown in Figure 46. g034327 Figure 46 g034326 2. Figure 45 43 Connect the battery cables; refer to Connecting the Battery (page 44).
Connecting the Battery Replacing the Fuses Connect the battery as shown in Figure 47. There are 5 fuses in the electrical system; the other slots are open for options. They are located beneath the seat assembly (Figure 48). Horn 30 A Main power 15 A Headlights 10 A USB power point/options 10 A Fuel 10 A Optional lift kit—open 15 A g034315 Figure 47 Charging the Battery WARNING Charging the battery produces gasses that can explode.
Maintaining the Headlights 7. Secure the headlight assembly with the speed clips that you removed in step 4. Replacing the Headlight 8. Connect the electrical connector for the harness to the connector of the lamp assembly (Figure 49). 9. Adjust the headlights to direct the beams to the desired position, refer to Adjusting the Headlights (page 45). Specification: See your Parts Catalog. 1. Disconnect the battery; refer to Disconnecting the Battery (page 42). 2. Open the hood. 3.
Drive System Maintenance Inspecting the Steering and Suspension Components Maintaining the Tires Service Interval: Every 100 hours—Inspect the steering and suspension for loose or damaged components. Service Interval: Every 100 hours—Check the condition of the tires and rims. Inspect the tires and rims for signs of wear and damage. With the steering wheel at the centered position (Figure 51), turn the steering wheel to the left or right.
Adjusting the Front Wheel Alignment Adjusting the Front Wheel Toe-in Important: Before adjusting toe-in, ensure that the camber adjustment is as close to neutral as possible; refer to Adjusting the Camber (page 47). Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the front wheel camber and toe-in. Preparing to Adjust Camber or Toe-in 1. Check the tire pressure to ensure that the front tires are inflated to 82 kPa (12 psi). 2.
Checking the Transaxle-Fluid Level Changing the Transaxle Fluid Service Interval: Every 100 hours Service Interval: Every 800 hours/Yearly (whichever comes first) Fluid Type: SAE 80W-90 (API MT-1) or SAE 80W-90 (API GL-5) 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the engine and remove the key. 4. Remove the fill plug on the transaxle (Figure 56). Fluid Type: SAE 80W-90 (API MT-1) or SAE 80W-90 (API GL-5) Fluid Capacity: 1.6 L (1.7 US qt) 1.
Adjusting the Neutral Gear-Shift Position Checking the Neutral Gear-Shift Position 1. Service Interval: Every 100 hours When performing routine maintenance and/or engine diagnostics, shift the transaxle 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 Reducing the Top Speed CAUTION Service Interval: Every 400 hours/Yearly (whichever comes first) The dust in the clutch will become airborne and could damage your eyes or you could inhale it, causing breathing difficulties. CAUTION Wear safety goggles and a dust mask or other eye and respiratory protection when performing this procedure. The dust in the clutch will become airborne and could damage your eyes or you could inhale it, causing breathing difficulties.
Cooling System Maintenance 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). Cooling System Safety • Swallowing engine coolant can cause poisoning; keep out of reach from children and pets. • Discharge of hot, pressurized coolant or touching a hot radiator and surrounding parts can cause severe burns. – Always allow the engine to cool at least 15 minutes before removing the radiator cap.
Brake Maintenance 8. Checking the Parking Brake 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 52). Verify that the parking brake is adjusted to the proper tension; refer to Checking the Parking Brake (page 52).
Replacing the Service and Parking-Brake Pads Service Interval: Every 400 hours Contact your authorized Toro distributor to inspect and possibly replace the service and parking-brake pads. Changing the Brake Fluid g002136 Service Interval: Every 1,000 hours Figure 62 1. Brake-fluid reservoir 6. Contact your authorized Toro distributor. 2. Minimum line If the fluid level is low, perform the following: A. Clean the area around the reservoir cap and remove the cap (Figure 61). B.
Belt Maintenance Replacing the Drive Belt Servicing the Drive Belt 1. Raise the cargo bed; refer to Raising the Cargo Bed to the Dump Position (page 19). 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 63). 4. Checking the Drive Belt Service Interval: After the first 8 hours Every 200 hours 1. Park the machine on a level surface.
Chassis Maintenance Cleaning Adjusting the Cargo-Bed Latches Washing the Machine Service Interval: Before each use or daily—Wash the machine. 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. Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine.
Storage D. Start the engine again and run it until it stops. Storage Safety E. Choke the engine. F. Start and run the engine until it does not start again. • Shut off the machine, remove the key, and wait for all movement to stop before you leave the operator’s position. Allow the machine to cool before adjusting, servicing, cleaning, or storing it. • 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.
Notes:
California Proposition 65 Warning Information What is this warning? You may see a product for sale that has a warning label like the following: WARNING: Cancer and Reproductive Harm—www.p65Warnings.ca.gov. What is Prop 65? Prop 65 applies to any company operating in California, selling products in California, or manufacturing products that may be sold in or brought into California.
EEA/UK Privacy Notice Toro’s Use of Your Personal Information The Toro Company (“Toro”) respects your privacy. When you purchase our products, we may collect certain personal information about you, either directly from you or through your local Toro company or dealer.
The Toro Warranty Two-Year or 1,500 Hours Limited Warranty Conditions and Products Covered Parts 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 2 years or 1,500 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).
