Form No. 3419-534 Rev C Workman® GTX Electric Utility Vehicle with Extended Chassis Model No. 07043EX—Serial No. 400000000 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 Maintaining the Tires ........................................ 39 Inspecting the Steering and Suspension Components ................................................. 40 Adjusting the Front Wheel Alignment ................ 40 Checking the Transaxle-Fluid Level .................. 41 Changing the Transaxle Fluid ........................... 42 Brake Maintenance ............................................. 42 Checking the Parking Brake ............................. 42 Adjusting the Parking Brake......
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. decal115-7739 115-7739 1. Falling, crushing hazard—do not carry passengers. decal99-7345 99-7345 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.
decal131-8414 131-8414 decal131-8412 131-8412 1. Horn 2. Forward 3. Neutral 4. Reverse 5. Off 6. On 7. Turning on—1) Sit in the driver's seat; 2) Disengage the parking brake; 3) Turn the key switch to the start position; 4) Push down on the pedal. 8. Turning off—1) Release the pedal; 2) Engage the parking brake; 3) Turn the key switch to the stop position; 4) Remove the key from the key switch. 1. Warning—read the Operator's Manual. 3.
decal131-8527 131-8527 2. Eco mode 1. Performance mode decal131-8495 131-8495 1. The battery is empty. 3. The battery is charged. 2. The battery is almost charged. 4. Charger fault; refer to the charger manual for the fault codes. decal131-8551 131-8551 3. Optional lift kit (15 A) 1. Read the Operator’s Manual for fuse information. 2. Horn (30 A) 4. Main power (10 A) 200 LBS 91 KG 1500 LBS 680 KG decal131-8506 131-8506 1. Solid light—unit is prepared for operation. 137-9984 decal137-9984 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 Control Panel g034161 Figure 4 1. Light switch 7. Parking-brake lever 2. Hour meter 8. Brake pedal 3. Battery-discharge indicator 9. Accelerator pedal 4. Horn button (International models only) 10. USB power point 5. Gear-shift selector 11. Status-indicator light 6. Key switch Accelerator Pedal Brake Pedal Use the accelerator pedal (Figure 4) to vary ground speed of the machine. Pressing down the accelerator pedal starts 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 engine, 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.
Operation 2. If necessary, adjust the air pressure in the tires by adding or removing air in the tires. Before Operation Before Operation Safety General Safety • Never allow children or untrained people to operate or service the machine. Local regulations may restrict the age of the operator. The owner is responsible for training all operators and mechanics. g001055 Figure 9 • Become familiar with the safe operation of the equipment, operator controls, and safety signs.
Using the Battery System When your batteries are fully charged, the tenth bar (far right) illuminates on the battery-discharge indicator (Figure 11). g004049 Figure 10 Battery-Lifetime Table 1. Battery capacity 4. Prime battery life 2. Discharge/charge cycles 5. End of the battery life 3. Break-in period (100 to 150 cycles) After the break-in period, the battery maintains a high capacity for many cycles.
• Wear appropriate clothing, including eye If you continue to use the machine with only 2 bars remaining, bars 1 and 2 alternately flash. 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. Avoid draining your batteries down to the second bar from the left to prevent this issue.
• • • • • • • • ROPS if you will work next to drop-offs, near water, in rough terrain, or on a slope, which could result in a rollover. Contact an authorized Toro distributor for more information. uneven terrain, and near curbs, holes, and other sudden changes in terrain. Loads may shift, causing the machine to become unstable. It can take longer to stop the machine on wet surfaces than on dry surfaces.
in weight distribution may cause the machine to overturn. 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. g034019 Figure 13 1. Cargo-bed lever • Always use the prop rod to hold the bed up before working under the bed. 2. • Remove any load material from the bed before raising it. 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).
Stopping the Machine • Whenever possible, secure the load by binding it Important: When stopping the machine on • When transporting liquid in a large tank (such to the cargo bed so that it does not shift. 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. 1. Remove your foot from the accelerator pedal. 2.
After Operation Refer to the following table for load volume limits with various materials: Material Density Maximum Cargo Bed Capacity (on level ground) Gravel, dry 1522 kg/m3 (95 lb/ft3) Full Gravel, wet 1922 kg/m3 (120 lb/ft3) 3/4 Full Sand, dry 1442 kg/m3 (90 lb/ft3) Full • Do not store the machine where there is an open Sand, wet 1922 kg/m3 (120 lb/ft3) 3/4 full flame, spark, or pilot light, such as on a water heater or other appliance.
Important: If you tow the machine with the key in the ON position, the electrical system may be damaged. 2. Affix a tow line to the tongue at the front of the machine’s frame (Figure 19). 3. Disengage the parking brake. Towing a Trailer The machine is capable of pulling trailers. Tow hitches are available for the machine, contact your Authorized Toro Distributor for details. g236535 Figure 19 When hauling cargo or towing a trailer, do not overload your machine or trailer.
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. WARNING Failure 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.
Daily Maintenance Checklist Duplicate this page for routine use. Maintenance Check Item For the week of: Monday Tuesday Wednesday Thursday Friday Saturday Sunday Check brake and parking brake operation. Check gear shift/neutral operation. Check the water level of the batteries. Check brake-fluid level. Check unusual operating noises. Check tire pressure. Check fluid leaks. Check instrument operation. Check accelerator operation. Lubricate all grease fittings. Touch up any damaged paint.
Pre-Maintenance Procedures • Never interfere with the intended function of a safety device or reduce the protection provided by a safety device. Check their proper operation regularly. • If major repairs are ever necessary or assistance Maintenance Safety is required, contact an authorized Toro distributor. • Do not allow untrained personnel to service the • To ensure optimum performance and safety, machine. always purchase genuine Toro replacement parts and accessories.
Accessing the Hood Raising the Hood 1. Lift up the handle of the rubber latches on each side of the hood (Figure 23). g034043 Figure 21 1. Front lifting point • The lifting point at the rear of the machine is located under the axle tubes (Figure 22). g034407 Figure 22 g034045 Figure 23 1. Rear lifting points 2. Raise the hood. Closing the Hood 27 1. Gently lower the hood. 2. Secure the hood by aligning the rubber latches onto the latch anchors on each side of the hood (Figure 23).
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.
Electrical System Maintenance Electrical System Safety WARNING CALIFORNIA Proposition 65 Warning Battery posts, terminals, and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and reproductive harm. Wash hands after handling. g192345 Figure 34 1. Cotter pin 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). 11.
• • • • • • • Maintaining the Batteries – Do not use an open flame to check the level or leakage of battery electrolyte. – Wear proper eye, hand, and face protection. – Do not lean over the batteries at any time. – Avoid breathing in battery fumes. – Fill the batteries where clean water is always available for flushing the skin. – If you get electrolyte on your skin or eyes, flush the affected area for 20 minutes with clean water. Remove affected clothing. Seek medical attention immediately.
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 35 for information on the meanings of the varying colors of the charger-status light. Checking the Water Level of the Batteries Charger-Status Light Table Service Interval: Before each use or daily Charger-Status Light Color Solid/Flashing Green Solid Charging complete Green Flashing Short flash—less than 80% charge Long flash—greater than 80% charge Amber Red Flashing Flashing 1.
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.
Replacing the Fuses Connecting the Batteries 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 38). 3. Connect the main negative-battery cable (black) between the bank of batteries and the machine (Figure 38). 4. Torque the nuts securing all of the battery cables until the retainer securely grips the battery. 5. Coat the battery terminals with Toro battery-terminal protector.
Maintaining the Headlights with the slots in the headlight housing (Figure 40). 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 40). 7. Connect the electrical connector for the harness to the connector of the new lamp assembly (Figure 40). 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 41). 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 42), 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 40). 1. Service Interval: Every 100 hours—Check the transaxle-fluid level. Measure the distance between both of the front tires at the axle height at both the front and rear of the front tires (Figure 45). 1. Park the machine on a level surface. 2. Engage the parking brake. 3.
Brake Maintenance Changing the Transaxle Fluid Checking the Parking Brake Service Interval: Every 100 hours—Check the transaxle for leaks. 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 42).
8. Verify that the parking brake is adjusted to the proper tension; refer to Checking the Parking Brake (page 42). 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 Toro Service Dealer for assistance. Checking the Brake-Fluid Level g002136 Figure 51 1. Brake-fluid reservoir Service Interval: Before each use or daily Check the brake-fluid level before the motor is first used. 4. Brake Fluid Type: DOT 3 1.
Replacing the Service and Parking-Brake Pads Chassis Maintenance Adjusting the Cargo-Bed Latches Service Interval: Every 400 hours Contact your authorized Authorized Toro Service Dealer to inspect and possibly replace the service and parking-brake pads. 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. Changing the Brake Fluid 1.
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 will lose some of its luster. Important: Pressurized water is not recommended when washing the machine. It may damage the electrical system, loosen important decals, or wash away necessary grease at friction points.
Battery Storage Storage 1. Park the machine on a level surface, engage the parking brake, shut off the machine, and remove the key. 2. Clean dirt and grime from the entire machine, including the outside of the motor housing. 3. Inspect the brakes; refer to Inspecting the Brakes (page 43). 4. Grease the machine; refer to Greasing the Machine (page 29). 5. Check the tire pressure; refer to Checking the Tire Pressure (page 14). 6. Check and tighten all bolts, nuts, and screws.
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 Toro 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.
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 Toro Service Dealer.
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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.
