Workman® GTX EFI Utility Vehicle with Extended Chassis

Before starting the machine each day, perform the Each Use/Daily procedures listed in .

Front and rear tires air pressure specification: 165 to 207 kPa (24 to 30 psi)

Important: Do not exceed the maximum air pressure indicated on the sidewall of the tire.

Note: The air pressure needed in the tires is determined by the payload that you intend to carry.

1. Check the air pressure in the tires.

   • Use lower air pressure in the tires for lighter payloads, for less soil compaction, for a smoother ride, and to minimize tire marks on the ground.

   • Use higher air pressure in the tires for carrying heavier payloads at higher speeds.

2. If necessary, adjust the air pressure in the tires by adding or removing air in the tires.

Figure 10

Perform the following guidelines to provide proper performance for the machine.

• Ensure that the brakes are burnished; refer to Burnishing the Brakes.

• Check the fluid and engine-oil levels regularly. Remain alert for signs that the machine or its components are overheating.

• After starting a cold engine, let it warm up for about 15 seconds before using the machine.

  Note: Allow more time for the engine to warm up when operating in cold temperatures.

• Vary the machine speed during operation. Avoid fast starts and quick stops.

• A break-in oil for the engine is not required. Original engine oil is the same type specified for regular oil changes.

• Refer to for any special, low-hour checks.

• Check the front suspension positioning and adjust it, if necessary; refer to Adjusting the Front Wheel Alignment.

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 16).

   

   Figure 16

   1. Receiver
   2. “T” handle

2. Insert your accessory into the receiver until the holes align (Figure 16).

3. Secure the assembled accessory to the receiver tube using the clevis pin and hairpin cotter supplied with the accessory.

4. Tighten the “T” handle by rotating it counterclockwise (Figure 17).

   

   Figure 17

   1. “T” handle

Use the following guidelines when loading the cargo bed and operating the machine:

• 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 and on the gross vehicle weight tag of the machine.

  Note: The load rating is specified for machine operation on a level surface only.

• Reduce the weight of the load that you carry in the cargo bed when operating the machine on hills and rough terrain.

• Reduce the weight of the load that you carry when the materials are tall (and have a high center of gravity), such as a stack of bricks, landscaping timbers, or fertilizer bags. Distribute the load as low as possible to ensure that the load does not reduce your ability to see behind the machine when operating it.

• Keep loads centered by loading the cargo bed as follows:

  • Evenly position the weight in the cargo bed from side to side.

    Important: Tipping over is more likely to occur if the cargo bed is loaded to 1 side.

  • Evenly position the weight in the cargo bed from front to back.

    Important: Loss of steering control or the machine may tip over if you position the load behind the rear axle and the traction on the front tires is reduced.

• Use extra caution when transporting oversized loads in the cargo bed, particularly when you cannot center the weight of the oversize load to the cargo bed.

• Whenever possible, secure the load by binding it to the cargo bed so that it does not shift.

• When transporting liquids, use caution when driving the machine uphill or downhill, when suddenly changing speed or stopping, or when driving over rough surfaces.

The capacity of the cargo bed is 0.28 m³ (10 ft³). The amount (volume) of material that you can place in the bed without exceeding the load ratings of the machine can vary greatly depending on the density of the material.

Refer to the following table for load volume limits with various materials:

1. Sit in the operator seat, insert the key into the key switch, and rotate the key clockwise to the ON or START position.

   There are 2 modes of starting the machine:

   • Pedal Start—turn the key switch to the ON position and press down the accelerator pedal.

     Note: When you remove your foot from the accelerator pedal, the engine shuts off.

   • Key Start—turn the key switch to the START position and the engine remains on until the is turned to the OFF position.

   Note: When using key start mode, you can engage the parking brake and work away from the machine while the engine still runs and the battery holds a charge.

   Note: If you turn the key to the START position, the engine cranks until it starts. If the engine cranks for more than 10 seconds, return to the OFF position, and determine the issue (e.g., the choke controls needs to be engaged, check the air cleaner for restrictions, ensure that the fuel tank is full, the spark is bad, etc.) before starting the machine again.

   Note: When equipped with the optional backup alarm, if you move the gear-shift selector to the REVERSE position when the key switch is in the ON or START position, a buzzer sounds to warn the operator that the machine is in reverse gear.

2. Move the gear-shift selector to the desired direction of travel for the machine.

3. Disengage the parking brake.

4. Slowly step on the accelerator pedal.

   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.

Important: When stopping the machine on an incline, use the service brakes to stop the machine and engage the parking brake to hold the machine in place. Using the accelerator to stall the machine on the hill can damage the machine.

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 machine load and speed.

1. Stop the machine using the service brakes by pressing and holding the brake pedal.

2. Engage the parking brake by pulling the parking-brake lever toward you.

3. Rotate the key counterclockwise to the OFF position.

4. Remove the key.

• Use care when loading or unloading the machine into a trailer or a truck.

• Use full-width ramps for loading the machine into a trailer or a truck.

• Tie the machine down securely.

Refer to Figure 18 and Figure 19 for the tie-down locations on the machine.

Note: Load the machine on the trailer with the front of the machine facing forward. If that is not possible, secure the machine hood to the frame with a strap, or remove the hood and transport and secure it separately or the hood may blow off during transport.

Figure 18

1. Towing tongue and tie-down point (front of the machine)

Figure 19

1. Rear tie-down points

In case of an emergency, you can tow the machine for a short distance; however, this should not be a standard operating procedure.

Towing the machine is a 2-person job. If you must move the machine a considerable distance, transport it on a truck or trailer; refer to Towing a Trailer

1. Remove the drive belt from the machine; refer to Replacing the Drive Belt.

2. Affix a tow line to the tongue at the front of the machine frame (Figure 18).

3. Move the transmission to the NEUTRAL position and disengage the parking brake.

The machine is capable of pulling trailers. A tow hitch is available for the machine. Contact your authorized Toro distributor for details.

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, engine, transaxle, steering, suspension, body structure, or tires.

Always load a trailer with 60% of the cargo weight in the front of the trailer. This places approximately 10% of the gross trailer weight (GTW) on the tow hitch of the machine.

To provide adequate braking and traction, always load the cargo bed when using a trailer. Do not exceed the GTW or GVW limits.

Avoid parking a machine with a trailer on a hill. If you must park on a hill, engage the parking brake, and chock the tires of the trailer.

1. Park the machine on a level surface.

2. Shift the transmission to the NEUTRAL position.

3. Engage the parking brake.

4. Shut off the engine and remove the key.

5. Empty and raise the cargo bed.

Important: Whenever you run the machine for routine maintenance and/or diagnostics, ensure that the rear wheels of the machine are 25 mm (1 inch) off the ground, with the rear axle supported on jack stands.

• The lifting point at the front of the machine is located at the front of the frame, behind the towing tongue (Figure 20).

  

  Figure 20

  1. Front lifting point

• The lifting point at the rear of the machine is located under the axle tubes (Figure 21).

Figure 21

1. Rear lifting points

To raise the seat assembly, push the seat assembly forward until it rests on the steering wheel (Figure 23).

To lower the seat assembly, push the seat assembly rearward until it seats back into the original position (Figure 23).

Figure 23

1. Push the seat assembly forward to the raised position (Figure 23).

2. Slide the seat assembly to the side out of the pins, and lift the seat assembly upward (Figure 24).

   

   Figure 24

   1. Pins

Slide the seat assembly onto the pins and lower the seat assembly (Figure 25).

Figure 25

1. Pins

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 26).

   

   Figure 26

Slide the bench cushion onto the pins and lower the cushion (Figure 27).

Figure 27

Grease specification: Mobilgrease XHP™-222

1. Lift the cargo bed and secure it with the prop rod.

2. At the throttle cable housing, loosen the forward jam nut and tighten the rear jam nut to increase the low idle (Figure 41).

   

   Figure 41

   1. Throttle cable housing
   2. Jam nuts
   3. Throttle lever

3. Test the high idle with a tachometer:

   1. Ensure that the shift lever is in the NEUTRAL position.

   2. Start the engine.

   3. Fully press the accelerator pedal and measure the engine speed with a tachometer; the engine speed should be between 3,650 to 3,750 rpm. If it is not, shut off the engine and adjust the cable jam nuts.

      Important: Do not lower the high idle. Test with a tachometer to ensure that the high idle is between 3,650 to 3,750 rpm.

4. Lower and secure the cargo bed.

Inspect the fuel lines, fittings, and clamps for signs of leaking, deterioration, damage, or loose connections.

Note: Repair any damaged or leaking fuel system component before using the machine.

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Raise the bed and support it with the prop rod.

5. Disconnect the battery; refer to Disconnecting the Battery.

6. Place a clean container under the fuel filter and replace the fuel filter as shown in Figure 42.

   

   Figure 42

7. Connect the battery and lower the cargo bed; refer to Connecting the Battery.

Battery voltage: 12 V with 300 A (cold-cranking) at -18°C (0°F).

• Always keep the battery clean and fully charged.

• If the battery terminals are corroded, clean them with a solution of 4 parts water and 1 part baking soda.

• Apply a light coating of grease to the battery terminals to prevent corrosion.

Disconnecting the Battery

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.

• Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.

• Always reconnect the positive (red) battery cable before reconnecting the negative (black) cable.

• Always keep the battery strap in place to protect and secure the battery.

Warning

Battery terminals or metal tools could short against metal machine components, causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.

• When removing or installing the battery, do not allow the battery terminals to touch any metal parts of the machine.

• Do not allow metal tools to short between the battery terminals and metal parts of the machine.

Disconnect the battery as shown in Figure 44.

Figure 44

Connecting the Battery

Connect the battery as shown in Figure 47.

Figure 47

There are 5 fuses in the electrical system; the other slots are open for options. They are located beneath the seat assembly (Figure 48).

Figure 48

1. Fuse block

1. Inspect the tires and rims for signs of wear and damage.

   Note: Operating accidents, such as hitting curbs, can damage a tire or rim and also disrupt wheel alignment, so inspect tire condition after an accident.

2. Torque the wheel lug nuts to 108 to 122 N∙m (80 to 90 ft-lb).

With the steering wheel at the centered position (Figure 51), 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 to the steering-rack assembly joint

  Important: Inspect the condition and security of the pinion-shaft seal (Figure 52).

• Steering-rack assembly tie rods

Figure 51

1. Steering wheel at the centered position
2. 13 mm (1/2 inch) from the center of the steering wheel

Figure 52

1. Pinion-shaft seal

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).

   Note: The fluid level should be even with the bottom of the fill plug.

   

   Figure 56

   1. Drain plug
   2. Fill plug

5. If the fluid level is low, remove the fill plug and add the specified fluid until it runs out of the hole (Figure 56).

6. Replace the fill plug and torque it to 20 to 27 N∙m (15 to 20 ft-lb).

Fluid Type: SAE 80W-90 (API MT-1) or SAE 80W-90 (API GL-5)

Fluid Capacity: 1.6 L (1.7 US qt)

1. Align a drain pan under the drain plug (Figure 56).

2. Remove the fill plug and the seal (Figure 56).

   Note: Retain the fill plug and seal for installation in step 6.

3. Remove the drain plug and the seal, and allow the fluid to drain completely (Figure 56).

   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).

When performing routine maintenance and/or engine diagnostics, shift the transaxle into NEUTRAL. The machine has a NEUTRAL position on the gear-shift selector, which controls the neutral in the transaxle. Perform the following steps to ensure that the neutral shift lever operates the transaxle neutral correctly:

1. Set the gear-shift selector to the NEUTRAL position.

2. Rotate the secondary clutch (Figure 63) to see if it spins freely in the NEUTRAL position.

3. Set the gear-shift selector to the FORWARD position.

4. Rotate the secondary clutch (Figure 63) to see if it rotates the rear wheels.

5. Set the gear-shift selector to the REVERSE position.

6. Rotate the secondary clutch (Figure 63) to see if it rotates the rear wheels.

7. If any of these tests fail, proceed to Adjusting the Neutral Gear-Shift Position.

1. Loosen the jam nuts on the gear-shift cable and adjust them as necessary (Figure 57).

   

   Figure 57

   1. Shift lever
   2. Spanner bar
   3. Gear-shift cable
   4. Jam nuts

2. Test the gear-shift position by rotating the gear-shift selector to the 3 different positions and check to see if the shift lever (Figure 57) shifts properly when shifting the gears; refer to Gear-Shift Lever and Gear-Shift Indicator.

3. Verify that all of the positions are working correctly by repeating the steps in Checking the Neutral Gear-Shift Position.

1. Raise and latch the cargo bed.

2. Remove the 3 bolts securing the cover to the clutch, and remove the cover (Figure 58).

   Note: Retain the cover and bolts for installation.

   

   Figure 58

   1. Cover
   2. Bolts

3. Thoroughly clean the inside of the cover and the inner components of the clutch using compressed air.

4. Install the clutch cover and secure it with the 3 bolts (Figure 58) that you removed in 2.

5. Lower the cargo bed.

1. Raise and latch the cargo bed; refer to Raising the Cargo Bed to the Service Position.

2. Remove the bolts securing the primary clutch cover as shown in Figure 59.

   Important: Use caution when removing the clutch cover; the spring is under compression.

   Important: Take note of the X orientation on the clutch covers and clutch assemblies for later installation.

   

   Figure 59

   1. Clutch spacer

3. Remove the spring.

4. Add or remove spacers to adjust the top speed. Use the following table to determine the amount of spacers needed.

   Spacers	Top Speed
   2 (standard)	16 mph (standard)
   3	12 mph
   4	9 mph
   5	6 mph
   6	4 mph

   Important: Do not operate the machine without at least 2 clutch spacers in place.

5. Install the spring and clutch cover.

   Important: Ensure that the X is placed back in the original location.

6. Torque the bolts to 179 to 228 N∙m (132 to 168 in-lb).

Important: Operating the engine with a blocked rotating screen, dirty or plugged cooling fins, or cooling shrouds removed causes engine damage due to overheating.

Important: Never clean the engine with a pressure washer because water could contaminate the fuel system.

Clean the inlet, cooling fins, and external surfaces of the engine.

Note: Clean the engine cooling components more often under extremely dusty and dirty conditions.

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.

1. Ensure that the parking brake is disengaged.

2. Using jack stands, lift the rear of the machine; refer to Lifting the Machine.

3. Using 2 wrenches, hold the adjusting post on the caliper in place with 1 wrench, and loosen the jam nut 1/4 turn with the other wrench (Figure 60).

   

   Figure 60

   1. Adjusting post
   2. Jam nut
   3. Caliper

4. While holding the adjusting post and the jam nut in place, turn the adjusting post in to tighten (Figure 60).

   Note: Perform this step until you feel drag on the wheel.

5. While holding the adjusting post and the jam nut in place, back off 1/4 turn (Figure 60).

6. While holding the adjusting post and the jam nut in place, tighten the jam nut (Figure 60).

7. Perform steps 1 through 6 to the other side.

8. Verify that the parking brake is adjusted to the proper tension; refer to Checking the Parking Brake.

   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 distributor for assistance.

Brake Fluid Type: DOT 3

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Shut off the engine and remove the key.

4. Raise the hood to gain access to the master-brake cylinder and reservoir (Figure 61).

   

   Figure 61

   1. Filler neck (reservoir)
   2. Reservoir cap
   3. DOT 3 brake fluid

5. Look at the outline of the fluid level at the side of the reservoir (Figure 62).

   Note: The level should be above the Minimum line.

   

   Figure 62

   1. Brake-fluid reservoir
   2. Minimum line

6. If the fluid level is low, perform the following:

   1. Clean the area around the reservoir cap and remove the cap (Figure 61).

   2. Add DOT 3 brake fluid to the reservoir until the fluid level is above the Minimum line (Figure 62).

      Note: Do not overfill the reservoir with brake fluid.

   3. Install the reservoir cap (Figure 61).

7. Close the hood of the machine.

Important: Brakes are a critical safety component of the machine. Closely inspect them at the recommended service interval to ensure optimum performance and safety.

• Inspect the brake lining for wear or damage. If the lining (brake pad) thickness is less than 1.6 mm (1/16 inch), replace the brake lining.

• Inspect the backing plate and other components for signs of excessive wear or deformation. Replace any deformed components.

• Check the brake-fluid level; refer to Checking the Brake-Fluid Level.

Contact your authorized Toro distributor to inspect and possibly replace the service and parking-brake pads.

Contact your authorized Toro distributor.

1. Raise the cargo bed; refer to Raising the Cargo Bed to the Dump Position.

2. Loosen the pivot nut for the starter generator (Figure 63).

3. Align a pry bar between the engine mount and starter.

4. Apply downward pressure to the pry bar to rotate the starter down in the slot until the belt tension only allows 6 mm (1/4 inch) belt deflection with 44 N∙m (10 ft-lb) of force (Figure 63).

5. Tighten the pivot nut hand tight, and remove the pry bar (Figure 63).

6. Torque the pivot nut to 88 to 115 N∙m (65 to 85 ft-lb).

7. Lower the cargo bed.

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. Verify that the cargo bed is latching.

   Note: If the cargo bed does not latch, the bed-latch striker is likely too low. If the cargo bed latches, but vibrates up and down as you drive, the bed-latch striker is likely too high.

2. Raise the cargo bed; Raising the Cargo Bed to the Dump Position.

3. Loosen the 2 bolts on the bed-latch striker and move the striker up or down, depending on if the striker is too high or too low (Figure 64).

   

   Figure 64

   1. Bolts
   2. Bed-latch striker

4. Tighten the 2 bolts on the bed-latch striker (Figure 64).

5. Verify that the adjustment is correct by latching the cargo bed several times.

Wash the machine as needed using water alone or with a mild detergent. You may use a rag when washing the machine.

Important: Do not use brackish or reclaimed water to clean the machine.

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.

Important: Do not wash the machine with the engine running. Washing the machine with the engine running may result in internal engine damage.