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Toro Workman GTX, Operator'S Manual

The Toro Workman GTX Operator's Manual is essential for providing detailed instructions and guidelines to maximize the performance and longevity of your equipment. At manualshive.com, you can easily download this manual for free, ensuring you have everything you need to operate and maintain your Toro Workman GTX with confidence.

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Contents

Safety ....................................................................... 4

Safe Operating Practices.................................... 4
Supervisor’s Responsibilities.............................. 4
Before Operating ................................................ 4
Operation............................................................ 4
Handling and Servicing Batteries ........................ 8
Maintenance....................................................... 8
Safety and Instructional Decals .......................... 9

Setup ...................................................................... 12

1 Installing the Steering Wheel (International

Models Only)................................................. 12

2 Checking the Fluid Levels and Tire

Pressure ....................................................... 12

3 Reading the Manual and Viewing the

Safety Training Material ................................ 13

Product Overview ................................................... 14

Controls ........................................................... 15
Specifications .................................................. 18
Attachments/Accessories ................................. 18

Operation ................................................................ 19

Think Safety First.............................................. 19
Operating the Cargo Box .................................. 19
Using the Rear Cargo Box Accessory

Mount............................................................ 21

Performing Pre-Starting Checks ....................... 22
Checking the Tire Pressure............................... 22
Understanding and Using the Battery

System.......................................................... 22

Stopping the Machine ....................................... 24
Parking the Machine ......................................... 24
Breaking in a New Machine .............................. 24
Loading the Cargo Box ..................................... 25
Transporting the Machine ................................. 25
Towing the Machine .......................................... 26
Towing a Trailer ................................................ 26

Maintenance ........................................................... 27

Recommended Maintenance Schedule(s) ........... 27

Daily Maintenance Checklist............................. 28

Pre-Maintenance Procedures .............................. 29

Maintaining the Machine under Special

Operating Conditions .................................... 29

Preparing to Maintain the Machine.................... 29
Lifting the Machine ........................................... 29
Accessing the Hood.......................................... 30
Raising and Lowering the Seat

Assembly ...................................................... 30

Removing the Seat Assembly ........................... 31
Installing the Seat Assembly ............................. 31

Lubrication .......................................................... 31

Greasing the Machine....................................... 31
Greasing the Front Wheel Bearings .................. 32

Electrical System Maintenance ........................... 35

Maintaining the Batteries .................................. 35
Replacing the Fuses ......................................... 39
Maintaining the Headlights ............................... 39

Drive System Maintenance .................................. 41

Maintaining the Tires ........................................ 41
Inspecting the Steering and Suspension

Components ................................................. 41

Adjusting the Front Wheel Toe-in ...................... 42
Changing the Transaxle Fluid ........................... 43

Brake Maintenance ............................................. 43

Checking the Parking Brake ............................. 43
Adjusting the Parking Brake.............................. 43
Checking the Brake-Fluid Level ........................ 44
Inspecting the Brakes ....................................... 44
Replacing the Service and Parking-Brake

Pads.............................................................. 44

Changing the Brake Fluid ................................. 45

Chassis Maintenance........................................... 45

Adjusting the Cargo-Box Latches...................... 45

Cleaning .............................................................. 46

Washing the Machine ....................................... 46

Storage ................................................................... 47

Battery Storage ................................................ 47

Troubleshooting ...................................................... 48

3

 

Summary of Contents for Workman GTX

Page 1: ...orm No 3409 828 Rev D Workman GTX Electric Utility Vehicle Model No 07041 Serial No 400000000 and Up Model No 07043 Serial No 400000000 and Up Register at www Toro com Original Instructions EN 3409 828 D ...

Page 2: ...elp finding a dealer or to register your product Whenever you need service genuine Toro parts or additional information contact an Authorized Service Dealer or Toro Customer Service and have the model and serial numbers of your product ready Figure 1 identifies the location of the model and serial numbers on the product Write the numbers in the space provided g034086 Figure 1 Bottom of Seat Assemb...

Page 3: ...ded Maintenance Schedule s 27 Daily Maintenance Checklist 28 Pre Maintenance Procedures 29 Maintaining the Machine under Special Operating Conditions 29 Preparing to Maintain the Machine 29 Lifting the Machine 29 Accessing the Hood 30 Raising and Lowering the Seat Assembly 30 Removing the Seat Assembly 31 Installing the Seat Assembly 31 Lubrication 31 Greasing the Machine 31 Greasing the Front Whe...

Page 4: ...e is designed to carry only you the operator and 1 passenger in the seat provided by the manufacturer Never carry any other passengers on the machine Become familiar with the controls and know how to stop the machine quickly Never operate the machine when tired ill or under the influence of drugs or alcohol Wear substantial slip resistant shoes Do not wear loose fitting clothing tie back long hair...

Page 5: ... up slowly Watch out for traffic when near or crossing roads Always yield the right of way to pedestrians and other machines Always signal your turns or stop early enough so other persons know what you plan to do Obey all traffic rules and regulations Never operate the machine in or near an area where there is dust or fumes in the air which are explosive The electrical and exhaust systems of the m...

Page 6: ...ssure on the brake pedal This dries out the brakes Operating on Hills WARNING Operating the machine on a hill may cause tipping or rolling of the machine or the batteries may run low and you could lose headway on the hill This could result in personal injury Do not operate the machine on excessively steep slopes Do not accelerate quickly or slam the brakes when backing down a hill especially with ...

Page 7: ...or on rough terrain particularly with a load in the cargo box or when towing a trailer or both Be aware that the stability and control of the machine are reduced when the load in the cargo box is poorly distributed Carrying oversized loads in the cargo box changes the stability of the machine The steering braking and stability of the machine are affected when carrying a load where the weight of th...

Page 8: ...tal tools to short between the battery terminals and metal parts of the machine Remove all jewelry and watches before servicing the batteries Do not check a battery charge by placing a metal object across the posts This causes sparks which can cause an explosion Always keep the battery retainers in place to protect and secure the batteries Read and understand the charging instructions before charg...

Page 9: ...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 2047 115 2047 1 Warning do not touch the hot surface decal115 7739 115 7739 1 Falling crushing hazard bystanders no riders on machine decal131 8506 131 8506 1 Solid light unit is prepared for operation 2 Flashing light refer to the charger manual for the fault codes d...

Page 10: ... 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 4 Reverse 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 decal131 8411 131 8411 1 Headlight on 3 Raise the bed 2 Headlight off 4 Lower the bed 10 ...

Page 11: ...ead the Operator s Manual 3 Tipping hazard drive slowly across or up slopes take turns slowly do not exceed speeds of 25 kph 16 mph drive slowly when hauling cargo drive slowly on uneven terrain 2 Warning receive proper training before operating the machine 4 Falling hazard severing hazard of limbs do not carry passengers in the bed do not carry extra passengers in between the seats do not put you...

Page 12: ...ng position 1 Installing the Steering Wheel International Models Only Parts needed for this procedure 1 Steering wheel 1 Steering wheel cover 1 Washer 1 2 inch 1 Dust cover Procedure 1 If the cover is installed remove it from the hub of the steering wheel Figure 3 2 Remove the locknut 1 2 inch from the steering shaft Figure 3 3 Slide the steering wheel dust cover and washer 1 2 inch onto the steer...

Page 13: ... Checking the Brake Fluid Level page 44 4 Check the air pressure in the tires refer to Checking the Tire Pressure page 22 3 Reading the Manual and Viewing the Safety Training Material Parts needed for this procedure 1 Operator s Manual 1 Safety training material 1 Registration card 1 Predelivery Inspection Form 1 Certificate of Quality 2 Key 1 Charger cord Domestic Models only Procedure Read the O...

Page 14: ...34154 Figure 4 1 Hood latch 3 Cargo box 5 Battery charger 2 Steering wheel 4 Towing tongue 6 Cargo box lever g034544 Figure 5 1 Passenger handhold 3 Rear cargo box accessory mount 2 Parking brake lever 4 Trailer hitch 14 ...

Page 15: ... pedal starts the machine Pressing the pedal farther increases ground speed Releasing the pedal slows the machine and the machine shuts off The maximum forward speed in performance mode is 26 km h 16 mph as shown in Figure 9 The maximum forward speed in economy mode is 19 km h 12 mph as shown in Figure 9 Brake Pedal Use the brake pedal to stop or slow the machine Figure 6 CAUTION Operating a machi...

Page 16: ...Light Switch The light switch is located to the left of the steering column Figure 6 Use the light switch to illuminate the headlights Push the light switch upward to turn on the headlights or push downward to turn off the lights Battery Discharge Indicator The battery discharge indicator is located to the left of the steering column Figure 6 The battery discharge indicator indicates the remaining...

Page 17: ...ervisor speed limit switch 2 Economy position Status Indicator Light The status indicator light is located to the right of the parking brake lever on the control panel Figure 6 When the machine is turned on the green status indicator light illuminates either solid or blinking If the light is solid this indicates that the machine is ready for normal operation If the light is blinking there is an is...

Page 18: ...ht 127 5 cm 50 2 inches Ground clearance 21 6 cm 8 5 inches at the front with no load or operator 14 cm 5 5 inch at the rear with no load or operator Wheel base 220 cm 86 6 inches Wheel tread center line to center line 119 cm 47 inches in the front 119 cm 47 inches in the rear Cargo box length 102 cm 40 inches inside 114 3 cm 45 inches outside Cargo box width 98 cm 38 5 inches inside 107 3 cm 42 3...

Page 19: ...box Remove any load material from the box before raising it WARNING Driving the machine with the cargo box raised may cause the machine to tip or roll easier The box structure may become damaged if you operate the machine with the box raised Operate the machine only when the cargo box is down After emptying the cargo box lower it CAUTION If a load is concentrated near the back of the cargo box whe...

Page 20: ...body parts could be crushed Keep hands and other body parts clear when lowering the box 1 Raise the cargo box slightly by lifting up on the latch lever Figure 11 2 Pull the prop rod out of the detent slot Figure 12 3 Lower the box until it latches securely Opening the Tailgate 1 Ensure that the cargo box is down and latched 2 Using both hands raise the tailgate using the ridge near the top of the ...

Page 21: ... Note This action helps move material away from the hinge area 4 Lower the tailgate and check for material remaining in the hinge area 5 Repeat steps 1 through 4 until the material is removed from the hinge area 6 Rotate the tailgate up and lift the tailgate into the notches in the cargo box Using the Rear Cargo Box Accessory Mount Use the rear cargo box accessory mount to attach accessories to th...

Page 22: ... the tires for lighter payloads for less the soil compaction for a smoother the ride and to minimize tire marks in the ground Use higher air pressure in the tires for carrying heavier payloads at higher speeds 2 If needed adjust the air pressure in the tires by adding or removing air in the tires Understanding and Using the Battery System Understanding Deep Cycle Batteries The machine contains 8 d...

Page 23: ...electrolyte level After fully charging the batteries fill the batteries with distilled or deionized water refer to Checking the Water Level of the Batteries page 36 and Adding Distilled or Deionized Water to the Batteries page 37 Important Fully charge the batteries before adding the water to the batteries While charging the electrolyte increases in volume and filling a low battery before fully ch...

Page 24: ...e 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 Slowly press the brake pedal to apply the service brakes until the machine comes to a complete stop Note The stopping distance may vary depending on the...

Page 25: ...ter the wight of the oversize load to the cargo box Whenever possible secure the load by binding it to the cargo box so it does not shift When transporting liquid in a large tank such as a sprayer tank use caution when driving the machine up hill or down hill when suddenly changing speed or stopping or when driving over tough surfaces The capacity of the cargo box is 0 28 m3 10 ft3 The amount volu...

Page 26: ...Disengage the parking brake Towing a Trailer The machine is capable of pulling trailers When hauling cargo or towing a trailer do not overload your machine or trailer Overloading either the machine or the trailer can cause poor performance or damage to the brakes axle motor transaxle steering suspension body structure or tires Always load a trailer with 60 of the cargo weight in the front of the t...

Page 27: ...the day Check the tire pressure Charge the batteries Check the water level of the batteries Check the brake fluid level Every 25 hours Clean the batteries Check the water level of the batteries and add distilled or deionized water to the batteries if necessary Every 100 hours Grease the bearings and bushings Check the condition of the tires and rims Torque the wheel lug nuts Inspect the steering a...

Page 28: ...heck accelerator operation Lubricate all grease fittings Touch up damaged paint WARNING A raised cargo box can fall and injure persons that are underneath it You must raise the cargo box to perform some routine maintenance Always use the prop rod to hold the cargo box up before working under it Remove any load material from the cargo box before working under it CAUTION If you leave the key in the ...

Page 29: ...he key Lifting the Machine DANGER The machine may be unstable when using a jack It 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 Block the tires when the machine is supported by lifting equipment Use jack stands to support the machine once you have lifted the it Imp...

Page 30: ...he chassis 2 Secure the hood by aligning the rubber latches onto the latch anchors at each side of the hood Figure 24 Raising and Lowering the Seat Assembly To raise the seat assembly push the seat assembly forward until it rests on the steering wheel Figure 25 To lower the seat assembly push the seat assembly rearward until it seats back into the original position Figure 25 g190066 Figure 25 30 ...

Page 31: ...ours 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 With a grease gun apply 1 or 2 pumps of grease into the grease fittings on the machine 3 Wipe the excess grease...

Page 32: ...ake assembly to the spindle and separate the brake from the spindle Figure 31 Note Support the brake assembly before proceeding to the next step g033047 Figure 31 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 32 g192346 Figure 32 1 Cotter pin 4 Spindle nut 2 Spindle 5 Nut retainer 3 Tab washer 6 Dust cap 5 Remove the cotter ...

Page 33: ... clean the seal and check for wear and damage Note Do not use cleaning solvent to clean the seal Replace the seal if it is worn or damaged 4 Clean the bearings and races and check these parts for wear and damage Note Replace all worn or damaged parts Ensure that the bearings and races are clean and dry 5 Clean the cavity of the hub of all grease dirt and debris Figure 34 6 Pack the bearings with t...

Page 34: ...to a maximum torque of 226 N cm 20 in lb on the nut g192345 Figure 36 1 Cotter pin 3 Dust cap 2 Nut retainer 9 Install the cotter pin and bend each legs around the retainer Figure 36 10 Install the dust cap onto the hub Figure 36 11 Repeat steps 1 through 10 for the hub and rotor at the other side of the machine Installing the Brakes and Wheels 1 Clean the 2 flange head bolts 3 8 x 3 4 inch and ap...

Page 35: ...nd clamps should have a bright metallic shine 4 Apply a light coating of Toro battery terminal protector Charging the Batteries Service Interval Before each use or daily The charger for this machine is located inside the machine under the operator s seat For maximum battery life charge the batteries whenever you are not using the machine Depending on how discharged the batteries are and the ambien...

Page 36: ...et 6 Disconnect the charger from the machine Refer to the following table and Figure 37 for information on the meanings of the varying colors of the charger status light Charger Status Light Table Charger Status Light Color Solid Flashing Meaning Green Solid Charging complete Green Flashing Short flash less than 80 charge Long flash greater than 80 charge Amber Flashing Reduced power mode low AC v...

Page 37: ...ater hand pump to the water fill port Figure 39 g034255 Figure 39 1 Water fill port 3 Water hand pump 2 Hand pump connector 5 Pump water into the water into batteries until all of the eyelets on top of the batteries are black indicating that they are filled with water Important Do not overfill the battery Electrolyte will overflow onto other parts of the machine and severe corrosion and deteriorat...

Page 38: ... the bank of batteries and the machine Figure 40 3 Connect the main negative battery cable black between the bank of batteries and the machine Figure 40 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 6 Ensure that the rubber boots on each battery cable are securely seated over the ...

Page 39: ...event this issue CAUTION The bulbs become extremely hot when in operation Handling a hot bulb can cause severe burns and personal injury Always allow enough time for the bulbs to cool before replacing them Use care whenever handling the bulb Specification See your Parts Catalog 1 Disconnect the batteries refer to Disconnecting the Batteries page 37 2 Open the hood refer to Accessing the Hood page ...

Page 40: ...ew headlight 5 Remove the headlight assembly by moving it forward through the opening in the front bumper Figure 43 6 Install the new headlight through the opening in the bumper Figure 43 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 conn...

Page 41: ... 100 hours Inspect the steering and suspension for loose or damaged components With the steering wheel at the centered position Figure 44 turn the steering wheel to the left or right If you turn the steering wheel more than 13 mm 1 2 inch to the left or right and the tires do not turn check the following steering and suspension components to ensure that they are not loose or damaged Steering shaft...

Page 42: ...he desired position by performing the following procedure 1 Using Toro Tool No 6010 rotate the collar on the shock absorber to change the spring pre load Figure 46 Note This is easier to do if the front of the machine is jacked up so that the front wheels are off the ground g192355 Figure 46 1 Shock absorber spring 2 Collar 2 On a level surface roll the machine straight back 2 to 3 m 6 to 10 ft an...

Page 43: ... 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 Adjusting the Parking Brake 1 Ensure that the parking brake is disengaged 2 Using jack stands lift t...

Page 44: ...orm the following A Clean the area around the reservoir cap and remove the cap Figure 51 B Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line Figure 52 Note Do not overfill the reservoir with brake fluid C Install the reservoir cap Figure 51 5 Close the hood of the machine Inspecting the Brakes Service Interval Every 100 hours Brakes are a critical safety compon...

Page 45: ... is latching Note If the cargo box does not latch the box latch striker is likely too low If the cargo box latches but vibrates up and down as you drive the box latch striker is likely too high 2 Raise the cargo box Raising the Cargo Box to the Dump Position page 19 3 Loosen the 2 bolts on the box latch striker and move the striker up or down depending on if the striker is too high or too low Figu...

Page 46: ...he 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 Avoid excessive use of water especially near the control panel motor motor controller charger back of the dashboard and batteries 46 ...

Page 47: ...r 8 Store the machine in a clean dry garage or storage area 9 Remove the key and put it in a safe place out of the reach of children 10 Cover the machine to protect it and keep it clean Battery Storage 1 Charge the batteries fully before placing the machine into storage refer to Charging the Batteries page 35 Plug the charger into a wall outlet while the machine and batteries are in storage Leave ...

Page 48: ...e key switch to the OFF position wait a few seconds turn the key switch to the ON position and check for normal operation 1 The throttle is pressed while starting the machine 1 Release the pedal 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 6 times 2 There is a wire that is not makin...

Page 49: ...ine status light flashed 12 times 1 A controller configuration fault occurred 1 Contact your Authorized Toro Service Dealer The machine status light flashed 13 times 1 An internal software fault occurred 1 Contact your Authorized Toro Service Dealer The machine status light flashed 14 times 1 A communication fault occurred 1 Contact your Authorized Toro Service Dealer The machine status light is n...

Page 50: ...Notes ...

Page 51: ...f these activities We will not sell your personal information to any other company We reserve the right to disclose personal information in order to comply with applicable laws and with requests by the appropriate authorities to operate our systems properly or for our own protection or that of other users Retention of your Personal Information We will keep your personal information as long as we n...

Page 52: ... to be outside influence include but are not limited to weather storage practices contamination use of unapproved lubricants additives chemicals etc Normal wear and tear items Normal wear and tear includes but is not limited to damage to seats due to wear or abrasion worn painted surfaces scratched decals or windows etc Parts Parts scheduled for replacement as required maintenance are warranted fo...

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