Form No. 3451-822 Rev A Workman® GTX Electric Utility Vehicle with Extended Chassis Model No. 07412EX—Serial No. 410500000 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. WARNING CALIFORNIA Proposition 65 Warning The power cord on this product contains lead, a chemical known to the State of California to cause birth defects or other reproductive harm. Wash hands after handling.
Contents Replacing the Fuses ......................................... 38 Maintaining the Headlights ............................... 39 Drive System Maintenance .................................. 40 Maintaining the Tires ........................................ 40 Inspecting the Steering and Suspension Components ................................................. 40 Adjusting the Front Wheel Alignment ................ 41 Checking the Transaxle-Fluid Level .................. 42 Changing the Transaxle Fluid .
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. decal99-7345 99-7345 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. Crushing hazard, cargo box—use the prop rod to support the cargo bed. decal115-7739 115-7739 decal131-8495 131-8495 1.
decal139-4610 139-4610 1. Warning—read the Operator’s Manual. decal131-8527 131-8527 2. Crushing hazard, cargo box—use the prop rod to support the cargo bed. 2. Eco mode 1. Performance mode 200 LBS 91 KG 1500 LBS 680 KG 137-9984 decal137-9984 137-9984 1. Do not exceed a tongue weight of 91 kg (200 lb). 2. Do not exceed a transport load of 680 kg (1,500 lb). decal145-2261 145-2261 1. Warning—read the Operator’s Manual. 3.
decal145-8016 145-8016 1. Read the Operator’s Manual before performing maintenance. 2. Service interval (hours) 3. Transaxle fluid decal145-2263 145-2263 1. Off 3. To start the machine: 1) Sit in the operator's position; 2) Disengage the parking brake; 3) Turn the key to the ON position; 4) Press the brake pedal. 2. On 4. To shut off the machine: 1) Release the brake pedal; 2) Engage the parking brake; 3) Turn the key to the OFF position; 4) Remove the key. decal145-2273 145-2273 1. Horn (20 A) 2.
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 water level in the batteries before you operate the machine; refer to Checking the Water Level of the Batteries (page 35). 2. Ensure that the batteries are charged; refer to Charging the Batteries (page 34). 3. Check the brake-fluid level before you operate the machine; refer to Checking the Brake-Fluid Level (page 43). 4.
Product Overview Controls Become familiar with all the controls before you start and operate the machine. Control Panel g378263 Figure 4 1. Horn switch 7. Parking-brake lever 2. Light switch 8. Status-indicator light 3. Battery-discharge indicator 9. USB power point 4. Hour meter 10. Accelerator pedal 5. Direction selector 11. Brake pedal 6. Key switch Accelerator Pedal Brake Pedal Use the accelerator pedal (Figure 4) to vary ground speed of the machine.
Parking-Brake Lever Direction Selector The parking-brake lever is located on the control panel (Figure 4). The direction selector is located to the left of the parking-brake lever. The direction selector has 3 positions: FORWARD , REVERSE, and NEUTRAL (Figure 4). Whenever you shut off the machine, engage the parking brake to prevent the machine from accidentally moving. If the machine is parked on a steep grade, ensure that you engage the parking brake.
Key Switch Status-Indicator Light Use the key switch (Figure 4), to run and shut off the machine. The status-indicator light is located to the right of the parking-brake lever on the control panel (Figure 4). The key switch has 2 positions: ON and OFF. Rotate the key clockwise to the ON position to operate the machine. When you stop the machine, rotate the key counterclockwise to the OFF position to shut off the machine. Remove the key whenever you leave the machine.
Specifications Note: Specifications and design are subject to change without notice.
Checking the Tire Pressure Operation Service Interval: Before each use or daily Note: The procedures in this section show a Front and rear tires air pressure specification: 165 to 207 kPa (24 to 30 psi) machine with a plastic cargo bed and bucket seat; for additional procedures for other attachments, refer to the Operation section (if applicable) in the Installation Instructions. Visit www.Toro.com for your instructions or scan the QR code (if applicable) on your attachment.
Understanding and Using the Battery System After the break-in period, the battery maintains a high capacity for many cycles. The number of cycles that a battery performs depends on the following: • Battery maintenance—improper maintenance severely reduces the life of the batteries. Understanding Deep-Cycle Batteries • Depth of discharge between charge cycles—the deeper the batteries are discharged on a regular basis between charges, the shorter the service life the batteries will have.
Using the Battery System If you continue to use the machine with only 2 bars remaining, bars 1 and 2 alternately flash. When your batteries are fully charged, the tenth bar (far right) illuminates on the battery-discharge indicator (Figure 11). Important: When only the second bar from the left remains on the battery-discharge indicator, the machine may enter a reduced-speed mode; this mode aids in protecting the batteries, but prolonged operation in this mode can damage the batteries and/or the machine.
During Operation when approaching blind corners, shrubs, trees, or other objects that may obscure your vision. • Do not drive the machine near drop-offs, ditches, During Operation Safety or embankments. The machine could suddenly roll over if a wheel goes over the edge or if the edge gives way. General Safety • Always watch out for and avoid low overhangs • The owner/operator can prevent and is responsible such as tree limbs, door jambs, overhead walkways, etc.
Loading and Dumping Safety • Passengers should sit in the designated seating • • positions only. Do not allow passengers to sit in the cargo bed. You and your passengers should remain seated whenever the machine is in motion. The additional machine length results in a larger turn radius, so allow more space to maneuver the machine. • Do not exceed the gross vehicle weight (GVW) • • Slope Safety • Note: A 2-post Rollover Protection System (ROPS) is available for this machine as an accessory.
1. Raising the Cargo Bed to the Service Position Pull the lever on left, inside of the cargo bed toward you and lift the cargo bed up (Figure 13). 1. Pull the lever on left, inside of the cargo bed toward you and lift the cargo bed up (Figure 13). 2. Pull prop rod into the service position detent slot to secure the bed for maintenance (Figure 14). Lowering the Cargo Bed WARNING The weight of the bed may be heavy. Hands or other body parts could be crushed.
Opening the Tailgate Closing the Tailgate 1. Ensure that the cargo bed is down and latched. 2. Using both hands, raise the tailgate using the ridge near the top of the tailgate (Figure 15). 3. Lower the tailgate until it is flush with the bottom of the cargo bed (Figure 15). 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.
Using the Rear Cargo Bed Accessory Mount Stopping the Machine 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 overheat the motor or drain the batteries. Use the rear cargo bed accessory mount to attach accessories to the rear of the machine. Capacity: 45 kg (100 lb) 1. Loosen the “T” handle by rotating it clockwise (Figure 17). 1.
After Operation • Whenever possible, secure the load by binding it to the cargo bed so that it does not shift. • When transporting liquids, use caution when After Operation Safety driving the machine uphill or downhill, when suddenly changing speed or stopping, or when driving over rough surfaces. General Safety The capacity of the cargo bed is 0.28 m3 (10 ft3).
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). g236535 Figure 19 1. Towing tongue and tie-down point (front of the machine) Towing the machine is a 2-person job.
Maintenance Note: The procedures in this section show a machine with a plastic cargo bed and bucket seat; for additional procedures for other attachments, refer to the Maintenance section (if applicable) in the Installation Instructions. Visit www.Toro.com for your instructions or scan the QR code (if applicable) on your attachment. • To ensure that the entire machine is in good condition, keep all hardware properly tightened.
Maintenance Service Interval Maintenance Procedure Every 300 hours • Grease the front wheel bearings. Every 400 hours • Replace the service and parking-brake pads. Every 800 hours • Change the transaxle fluid. Every 1,000 hours • Change the brake fluid. Note: Download a free copy of the electrical schematic by visiting www.Toro.com and searching for your machine from the Manuals link on the home page.
Maintaining the Machine under Special Operating Conditions Important: If the machine is subjected to any of the conditions listed below, perform maintenance twice as frequently: • Desert operation • Cold climate operation—below 10°C (50°F) • Trailer towing • Frequent operation in dusty conditions • Construction work • After extended operation in mud, sand, water, or similar dirty conditions, do the following: – Have your brakes inspected and cleaned as soon as possible.
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. g034407 Figure 22 • Always remove the key from the key switch before getting off the machine. 1. Rear lifting points • Block the tires when the machine is supported by lifting equipment. Accessing the Hood • 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 24). To lower the seat assembly, push the seat assembly rearward until it seats back into the original position (Figure 24). g190187 Figure 25 1. Pins Installing a Bucket Seat Slide the seat assembly onto the pins and lower the seat assembly (Figure 26). g190066 Figure 24 Removing a Bucket Seat 1.
Lubrication 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 29). g237191 Figure 27 Installing a Bench Cushion Slide the bench cushion onto the pins and lower the cushion (Figure 28). g033046 Figure 29 1. Hub 3. Lug nut 2. Wheel 3.
g192347 Figure 32 1. Spindle 2. Hub and rotor assembly g033047 Figure 30 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 31). g192346 Figure 31 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 31). 6.
Installing the Hub and Rotor Greasing the Wheel Bearings 1. 1. Remove the outboard bearing and bearing race from the hub (Figure 33). Apply a light coat of the specified grease to the spindle (Figure 34). g192344 Figure 34 g033050 Figure 33 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 33). 3. Wipe clean the seal and check for wear and damage. 1.
Electrical System Maintenance Electrical System Safety • Disconnect the battery before repairing the • g192345 Figure 35 1. Cotter pin 3. Dust cap 2. Nut retainer 9. Battery Safety Install the cotter pin and bend each legs around the retainer (Figure 35). 10. Install the dust cap onto the hub (Figure 35). 11. Repeat steps 1 through 10 for the hub and rotor at the other side of the machine. • To reduce the potential for fire, keep the batteries • • Installing the Brakes and Wheels 1.
Maintaining the Batteries • Electrolyte is poisonous. – Do not drink the electrolyte. Raise the seat assembly and raise the cargo bed before maintaining the batteries; refer to Raising and Lowering the Seat Assembly (page 28) and Raising the Cargo Bed to the Dump Position (page 18). – If electrolyte has been swallowed, have them drink large quantities of water immediately to dilute the electrolyte, if possible. – Do not attempt to make them vomit.
Cleaning the Batteries electrolyte to overflow and leak out of the vent. Service Interval: Every 25 hours 1. Ensure that all the battery caps are tight. 2. Use a paper towel to clean the batteries. 3. If the battery terminals are corroded, clean them with a solution of 4 parts water and 1 part baking soda. Also, clean the posts and cable clamps with a post and clamp cleaner. 3. Note: Ensure that the charger-voltage setting matches the voltage at the power outlet being used.
Refer to the following table and Figure 36 for information on the meanings of the varying colors of the charger-status light.
Important: Use only clean, distilled or deionized water to fill the batteries. Using tap water may damage and reduce the life of the batteries. 1. Park the machine on a level surface, engage the parking brake, shut off the machine, remove the key, and raise cargo bed; Raising the Cargo Bed to the Dump Position (page 18). 2. Charge the batteries until a full charge is achieved; refer to Charging the Batteries (page 34). 3.
6. Connecting the Batteries Connect the batteries together as shown in Figure 39 with the battery-interconnect cables that you removed in step 1. 1. Ensure that the battery terminals are clean and free of oxidation. 2. Connect the main positive-battery cable (red) between the bank of batteries and the machine (Figure 39). 3. Connect the main negative-battery cable (black) between the bank of batteries and the machine (Figure 39). 4.
Replacing the Fuses 48 V Fuses There are 6 fuses in the electrical system; the other slots are open for options. Horn 20 A Electric relay 20 A The 12 V and 48 V fuses are located under the seat assembly behind a battery on the right side of the machine (Figure 40). Optional lift kit—open 15 A Electric power 10 A 12 V Fuses g378264 Figure 40 1. 48 V fuse block 2.
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 41). 9. Adjust the headlights to direct the beams to the desired position, refer to Adjusting the Headlights (page 39). 1. Disconnect the batteries; refer to Disconnecting the Batteries (page 36). 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 43), 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 41). Service Interval: Every 100 hours/Yearly (whichever comes first)—Check the front wheel camber and toe-in. 1. 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—Check the transaxle-fluid level. Service Interval: Every 100 hours—Check the transaxle for leaks. Every 800 hours/Yearly (whichever comes first)—Change the transaxle fluid. 1. Park the machine on a level surface. 2. Engage the parking brake. 3. Shut off the motor and remove the key. Fluid Type: SAE 10W-30 (API service SJ or higher) 4. Remove the fill plug on the transaxle (Figure 48).
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 43). Verify that the parking brake is adjusted to the proper tension; refer to Checking the Parking Brake (page 43).
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 52 1. Brake-fluid reservoir 4. 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 51). B.
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 2. Important: If the machine cannot be plugged in during storage, fully charge the batteries at least once a month. The batteries self-discharge over long periods of time, which may damage the batteries to the point of being unusable, even if the batteries are new. Storage Safety • 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.
Troubleshooting Machine-Status Light Flash Pattern Problem Possible Cause Corrective Action The machine-status light is always illuminated. 1. The system is functioning properly. 1. None The machine-status light flashed 1 time. 1. There is a controller-configuration fault. 1. Contact your Authorized Service Dealer. The machine-status light flashed 2 times. 1. The parking brake is engaged while in FORWARD or REVERSE position. 1. Disengage the parking brake. 2. A drive-switch fault occurred. 2.
Problem The machine-status light flashed 11 times. Possible Cause Corrective Action 1. A motor-encoder fault occurred. 1. Check the motor-encoder (speed sensor) wiring. 2. Exceeded the maximum motor speed. 2. Turn the key switch to the OFF position, wait a few seconds, turn the key switch to the ON position, and check for normal operation. The machine-status light flashed 12 times. 1. A controller-configuration fault occurred. 1. Contact your Authorized Service Dealer.
Notes:
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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.
The Toro Warranty Electric Workman A 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. Where a warrantable condition exists, we will repair the Product at no cost to you including diagnostics, labor, parts, and transportation.
