Form No. 3422-243 Rev C Workman® GTX EFI Utility Vehicle with Extended Chassis Model No. 07042EX—Serial No. 400000000 and Up Register at www.Toro.com.
Important: With your mobile device, you can scan the QR code on the serial number decal (if equipped) to access warranty, parts, and other product information. This product complies with all relevant European directives; for details, please see the separate product specific Declaration of Conformity (DOC) sheet.
Contents 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 ......................................... 41 Maintaining the Headlights ...............................
Safety 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. Failure to comply with the instruction may result in personal injury or death. This machine has been designed in accordance with the requirements of SAE J2258.
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. Hot surface/burn hazard—stay a safe distance away from 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 6 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. On 6.
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 49). 3.
Product Overview Controls Become familiar with all the controls before you start the engine and operate the machine. Note: Determine the left and right sides of the machine from the normal operating position. 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.
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.
Checking the Tire Pressure Operation Service Interval: Before each use or daily Note: Determine the left and right sides of the machine from the normal operating position. Front and rear tires air pressure specification: 165 to 207 kPa (24 to 30 psi) Before Operation Important: Do not exceed the maximum air Before Operation Safety Note: The air pressure needed in the tires is pressure indicated on the sidewall of the tire. determined by the payload that you intend to carry. 1.
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.
• A break-in oil for the engine is not required. machine. Tall grass can hide obstacles. Use care when approaching blind corners, shrubs, trees, or other objects that may obscure your vision. Original engine oil is the same type specified for regular oil changes. • Always watch out for and avoid low overhangs • Refer to Maintenance (page 24) for any special, such as tree limbs, door jambs, overhead walkways, etc. low-hour checks.
• Do not operate the machine when there is the risk Take extra care when hauling loads that shift easily (e.g., liquids, rock, sand, etc.). of lightning. • Use accessories and attachments approved by • Avoid starting, stopping, or turning the machine The Toro® Company only. on a slope, especially with a load. Stopping while 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.
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 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.
3. Disengage the parking brake. 4. Slowly step on the accelerator pedal. After Operation 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. After Operation Safety General Safety • Allow the engine to cool before storing the machine in any enclosure.
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) Note: The power steering does not function, making it difficult to steer. Towing the machine is a 2-person job.
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.
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.
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.
Pre-Maintenance Procedures parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous. Altering this machine in any manner may affect the operation of the machine, performance, durability, or its use may result in injury or death. Such use could void the product warranty of The Toro® Company. Maintenance Safety • Do not allow untrained personnel to service the • • • • • • • • • • • • • • • • • machine.
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 22 • 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.
Removing the Bench Cushion Installing 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). Slide the bench cushion onto the pins and lower the cushion (Figure 25).
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 28). Grease Type: No.
g192347 Figure 31 1. Spindle 2. Hub and rotor assembly 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). g192346 Figure 30 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 30). 6.
Installing the Hub and Rotor Greasing the Wheel Bearings 1. 1. Remove the outboard bearing and bearing race from the hub (Figure 32). Apply a light coat of the specified grease to the spindle (Figure 33). g192344 Figure 33 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. 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 34 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 36). g236567 Figure 35 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 36). Note: Avoid knocking the air filter into the side of the body. g034313 Figure 36 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 26)). 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 box and secure it with the prop rod; refer to Raising the Cargo Bed to the Service Position (page 19). Carburetor Model Spark Plug Type: Champion XC12YC 6. Change the engine oil as shown in Figure 39.
6. Install the spark plug into the cylinder head, and torque the plug to 27 N∙m (20 ft-lb). 7. Install the spark-plug wire. 8. Repeat steps 1 through 7 for the other spark plug. Fuel System Maintenance Inspecting Fuel Lines and Adjusting the High/Low Idle Connections 1. Lift the cargo bed and secure it with the prop rod. Service Interval: Every 400 hours/Yearly (whichever comes first) 2.
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 43). Clean the air filter for the carbon canister with clean, compressed air. g029685 g034099 Figure 42 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 45. Installing the Battery 1. Install the battery as shown in Figure 46. g034327 Figure 46 g034326 2. Figure 45 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 47. There are 4 fuses in the electrical system. They are located beneath the seat assembly (Figure 48). 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 49). Replacing the Bulbs CAUTION If you install a higher wattage bulb than the system is designed for, you may 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 49). 7. Connect the electrical connector for the harness to the connector of the new lamp assembly (Figure 49). 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 50). 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 51), 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 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).
Adjusting the Neutral Gear-Shift Position Note: Retain the drain plug and seal for installation in step 4. 4. Install the drain plug and seal, and torque it to 20 to 27 N∙m (15 to 20 ft-lb). 5. Fill the transaxle with the specified fluid until it runs out of the fill hole. 6. Install the fill plug and seal, and torque it to 20 to 27 N∙m (15 to 20 ft-lb). 1. Loosen the jam nuts on the gear-shift cable and adjust them as necessary (Figure 57).
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 becomes 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-lbs). 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 49). Verify that the parking brake is adjusted to the proper tension; refer to Checking the Parking Brake (page 49).
Belt Maintenance Servicing the Drive Belt Checking the Drive Belt Service Interval: After the first 8 hours Every 200 hours g002136 Figure 62 1. Brake-fluid reservoir 6. 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. Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line (Figure 62). 1. Park the machine on a level surface. 2. Engage the parking brake. 3.
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 63). 4. Remove the belt from the primary clutch (Figure 63).
Cleaning Washing the Machine Wash the machine as needed. Use water alone or with a mild detergent. You may use a rag when washing the machine; however, the hood loses some of its luster. 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.
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.
European Privacy Notice The Information Toro Collects Toro Warranty Company (Toro) respects your privacy. In order to process your warranty claim and contact you in the event of a product recall, we ask you to share certain personal information with us, either directly or through your local Toro company or dealer. The Toro warranty system is hosted on servers located within the United States where privacy law may not provide the same protection as applies in your country.
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 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).
