Toro Workman GTX Service Manual
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Toro Workman GTX Service Manual

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Form No. 16224SL Rev C
Workman
GTX Gasoline
®
Original Instructions (EN)

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Summary of Contents for Toro Workman GTX

  • Page 1 Form No. 16224SL Rev C Workman GTX Gasoline ® Original Instructions (EN)
  • Page 2 THE TORO COMPANY 2020 This document and all information contained herein is the sole property of The Toro Company (and/or its affiliated companies). No intellectual property rights are granted by the delivery of this document or the disclosure of its content. This document shall not be...
  • Page 3 Reader Comments The Toro Company Technical Assistance Center maintains a continuous effort to improve the quality and usefulness of its publications. To do this effectively, we encourage user feedback. Please comment on the completeness, accuracy, organization, usability, and readability of this manual by an e-mail to servicemanuals@toro.com...
  • Page 4 NOTES...
  • Page 5 The Toro Company reserves the right to change product specifications or this publication without notice. IMPORTANT: The IMPORTANT notice will give im- portant instructions which must be followed to pre- vent damage to systems or components on the machine.
  • Page 6 This page is intentionally blank. Workman GTX Gasoline...

  • Page 7: Table Of Contents

    ....... 4 -- 7 Service and Repairs ..... . . 4 -- 10 Workman GTX Gasoline...
  • Page 8 This page is intentionally blank. Workman GTX Gasoline...
  • Page 9 ....SAFETY AND INSTRUCTION DECALS ..Workman GTX Gasoline Page 1 − 1 Safety...

  • Page 10: Safety Instructions

    Safety Instructions The Workman GTX vehicles are designed and tested to offer safe service when operated and maintained pro- perly. Although hazard control and accident prevention partially are dependent upon the design and configura- tion of the machine, these factors are also dependent...

  • Page 11: While Operating

    12.To assure optimum performance and continued er or furnace. safety of the vehicle, use genuine Toro replacement 4. To reduce potential fire hazard, keep engine area parts and accessories. Replacement parts and acces- free of excessive grease, grass, leaves and dirt.

  • Page 12: Jacking And Other Instructions

    Towing Vehicle IMPORTANT: Frequent or long distance towing of IMPORTANT: If vehicle is towed, make sure that the Workman GTX is not recommended. transaxle is in the NEUTRAL position, parking brake is released, key switch is in the OFF position, and In case of emergency, the vehicle can be towed for a key is removed from switch.

  • Page 13: Transaxle Neutral Position

    Adjust Shift Cable in the Adjustment section of Chapter 5 − Drive Train. Figure 3 1. Shift lever (in neutral) 3. Reverse position 2. Forward position Figure 4 1. Secondary clutch 3. Rear wheel 2. Primary clutch Workman GTX Gasoline Page 1 − 5 Safety...

  • Page 14: Safety And Instruction Decals

    Safety and Instruction Decals Numerous safety and instruction decals are affixed to your Workman GTX. If any decal becomes illegible or damaged, install a new decal. Part numbers are listed in the Parts Catalog. Order replacement decals from your Authorized Toro Distributor.

  • Page 15: Product Records

    Maintenance Maintenance procedures and recommended service in- tervals for your Workman are covered in the Operator’s Manual. Refer to that publication when performing regu- lar equipment maintenance. Workman GTX Page 2 − 1 Product Records and Maintenance...

  • Page 16: Equivalents And Conversions

    Equivalents and Conversions 0.09375 Product Records and Maintenance Page 2 − 2 Workman GTX...

  • Page 17: Torque Specifications

    For critical applications, as determined reduced by 25% for lubricated fasteners to achieve by Toro, either the recommended torque or a torque that the similar stress as a dry fastener. Torque values may is unique to the application is clearly identified and spe- also have to be reduced when the fastener is threaded cified in this Service Manual.

  • Page 18: Standard Torque For Dry, Zinc Plated And Steel Fasteners (Inch Series)

    The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Product Records and Maintenance Page 2 − 4 Workman GTX...

  • Page 19: Standard Torque For Dry, Zinc Plated And

    The specific torque value should be determined based on the fastener size, the aluminum or base material strength, length of thread engagement, etc. Workman GTX Page 2 − 5 Product Records and Maintenance...

  • Page 20: Other Torque Specifications

    All torque values are based on non−lubri- cated fasteners. Conversion Factors in−lb X 11.2985 = N−cm N−cm X 0.08851 = in−lb ft−lb X 1.3558 = N−m N−m X 0.7376 = ft−lb Product Records and Maintenance Page 2 − 6 Workman GTX...

  • Page 21: General Information

    ......KOHLER Command PRO CH260- CH440 Service Manual KOHLER Command PRO EFI ECH440 & ECH440LE Service Manual Workman GTX Gasoline Page 3 - 1 Gasoline Engine...

  • Page 22: General Information

    (EFI) engines. Kohler Gasoline Engine The engine that powers your Workman GTX vehicle is either a Kohler model Command Pro CH440 carbureted engine, or a ECH440 electronic fuel injected (EFI) en- gine. Verify the engine used in your vehicle before ser- vicing the vehicle.

  • Page 23: Engine Electronic Control Unit (Ecu) (Fuel Injected Engines Only)

    The cover can easily be removed by re- leasing the latches and lifting the cover from the rear frame to improve engine access. Figure 1 1. Rear frame 3. Latch (2 used) 2. Panel cover Workman GTX Gasoline Page 3 - 3 Gasoline Engine...

  • Page 24: Specifications

    Champion RC 12LC4 (or equivalent) Spark Plug Gap 0.030 in (0.76 mm) Starter/Generator 220 Amps (starting) @12VDC 41 Amps (maximum charging) @ 14.8 VDC Engine Dry Weight (approximate) 76 lb (34.5 kg) Gasoline Engine Page 3 - 4 Workman GTX Gasoline...

  • Page 25: Adjust Accelerator Cable

    Adjustments Adjust Accelerator Cable NOTE: Workman GTX vehicles use the engine gov- ernor to control engine speed. Refer to the Kohler Ser- vice Manual for additional governor information. Depressing the accelerator pedal rotates the engine mounted throttle lever which tensions the engine gover- nor spring to increase engine speed.

  • Page 26: Service And Repairs

    9. Attach spark plug wire to spark plug. 10.Secure rear frame panel cover to vehicle. Lower and secure bed. Gasoline Engine Page 3 - 6 Workman GTX Gasoline...

  • Page 27: Accelerator Control

    Accelerator Control The Workman GTX accelerator control includes an en- gine mounted throttle lever that is rotated by the acceler- FRONT ator cable to change engine speed. Disassembly (Fig. 6) 1. Park vehicle on a level surface and engage parking brake.

  • Page 28: Air Cleaner System

    9. Flange head screw (2 used) 2. Hose clamp 6. Hose clamp 10. Flange nut (2 used) 3. Intake hose 7. Air inlet hood 11. Swing arm 4. Hose clamp 8. Mounting bracket Gasoline Engine Page 3 - 8 Workman GTX Gasoline...
  • Page 29 The vacuator valve on the air cleaner cover should be positioned downward. 2. After all air cleaner components have been installed, install rear frame panel cover to vehicle. Lower and se- cure the cargo bed. Workman GTX Gasoline Page 3 - 9 Gasoline Engine...

  • Page 30: Exhaust System

    9. Flange head screw 14. Flange nut (2 used) 4. Exhaust manifold (carbureted) 10. Muffler bracket 15. Exhaust gasket 5. Exhaust manifold (EFI) 11. Flange nut (2 used) 16. Oxygen Sensor (EFI) 6. Muffler Gasoline Engine Page 3 - 10 Workman GTX Gasoline...
  • Page 31 5. On machines with electronic fuel injection (EFI) con- clean flange surface of cylinder head and exhaust mani- nect the oxygen sensor to the engine wire harness. fold. 6. Lower and secure cargo bed. Workman GTX Gasoline Page 3 - 11 Gasoline Engine...

  • Page 32: Fuel Lines And Connections

    “Click” is heard. B. Press supply hose fitting lock down to lock fitting in place (Fig. 13). 4. Connect low pressure fuel hoses to barb connectors and secure with hose clamps. Gasoline Engine Page 3 - 12 Workman GTX Gasoline...
  • Page 33 UNLOCKED LOCKED Figure 13 1. Supply hose fitting lock 2. Supply hose fitting lock (locked - down) (unlocked - up) 3. Supply hose fitting tab Workman GTX Gasoline Page 3 - 13 Gasoline Engine...

  • Page 34: Fuel Tank And Fuel Pumps

    16. Fuel filter (fuel injected engines) 6. Fuel supply hose 12. Pulse hose CAUTION Read safety precautions for handling gasoline before working on the fuel system (see Safety In- structions in Chapter 1 - Safety). Gasoline Engine Page 3 - 14 Workman GTX Gasoline...
  • Page 35 5. Loosen hose clamp and carefully disconnect fuel supply hose from the fuel tank stand pipe. 6. Add fresh fuel to tank and check for any fuel leaks. 6. Carefully disconnect vent hose from rollover valve. Workman GTX Gasoline Page 3 - 15 Gasoline Engine...

  • Page 36: Fuel Evaporative Control System

    15. Electric fuel pump 4. EVAP hose 10. EVAP hose 16. EVAP hose 5. Carbon canister 11. Orifice adapter 17. Wye fitting 6. Carbon canister bracket 12. EVAP hose (to engine) Gasoline Engine Page 3 - 16 Workman GTX Gasoline...
  • Page 37 Vapors from the canister are consumed when the engine is running which purges the canister. The fuel tank on the Workman GTX vehicle uses a non- vented fuel cap. To connect the tank to the evaporative control system, a rollover valve is positioned in the top of the tank that allows tank venting through the carbon canister.

  • Page 38: Engine

    16. Flange head screw (4 used) 34. Primary clutch 17. Flange nut (6 used) 35. Flat washer 52. Woodruff key 18. Exhaust manifold 36. Cap screw 53. Oxygen sensor (EFI engine) Gasoline Engine Page 3 - 18 Workman GTX Gasoline...

  • Page 39: Engine Removal

    C. Remove the R- clamp from the throttle bracket and secure the clamp and disconnected hoses away C. Disconnect the EVAP hose at the throttle body. from the engine. D. Disconnect the EVAP hose at the carburetor. Workman GTX Gasoline Page 3 - 19 Gasoline Engine...

  • Page 40: Engine Installation

    Figure 18. Clutches in the Service and Repairs section of Chapter 4 - Drive Train). 1. Install all removed engine parts and attachments to the engine before installing engine to vehicle. Gasoline Engine Page 3 - 20 Workman GTX Gasoline...
  • Page 41 17.Install rear frame panel cover to vehicle. Lower and C. Connect the high pressure fuel supply hose at the secure the cargo bed. carburetor (see Fuel Lines and Connections in this Chapter). Workman GTX Gasoline Page 3 - 21 Gasoline Engine...
  • Page 42 This page is intentionally blank. Gasoline Engine Page 3 - 22 Workman GTX Gasoline...
  • Page 43 ..... . Transaxle Assembly ..... . Workman GTX Gasoline Page 4 − 1 Drive Train...

  • Page 44: General Information

    Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman vehicle. Refer to the Opera- tor’s Manual for additional information when servicing the vehicle. Page 4 − 2 Workman GTX Gasoline Drive Train...

  • Page 45: Specifications

    Torque sensing with spring loaded cam Cap Screw Torque for Primary Clutch 17 to 22 ft−lb (24 to 29 N−m) Cap Screw Torque for Secondary Clutch 39 to 47 ft−lb (53 to 63 N−m) Workman GTX Gasoline Page 4 − 3 Drive Train...

  • Page 46: Drive Train Operation

    The secondary clutch responds to changes in ate at optimum efficiency. load to the rear axle, and is mounted to the transaxle in- put shaft. Page 4 − 4 Workman GTX Gasoline Drive Train...

  • Page 47: Primary Clutch Operation

    Figure 3 ramp of the fixed cam. The drive belt becomes posi- tioned closer to the outer diameter of the secondary 1. Moveable sheave 3. Spring 2. Stationary sheave clutch sheaves. Workman GTX Gasoline Page 4 − 5 Drive Train...

  • Page 48: Special Tools

    Special Tools Order special tools from your Toro Distributor. Primary Clutch Removal Tool This tool is required to remove the primary clutch from the tapered drive shaft of the engine. It is placed in the threaded hole of the stationary clutch sheave after the clutch holding cap screw is removed.

  • Page 49: Troubleshooting

    Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Á Workman GTX Gasoline Page 4 − 7...

  • Page 50: Service And Repairs

    FRONT Figure 7 1. Engine 4. Starter/generator pulley 7. Secondary clutch 2. Starter/generator 5. CVT drive belt 8. Vehicle swing arm 3. Starter/generator drive belt 6. Primary clutch 9. Transaxle assembly Page 4 − 8 Workman GTX Gasoline Drive Train...
  • Page 51 2. Allow engine, exhaust system and drive system to cool before working on drive system. 3. Lower and secure vehicle cargo bed (if installed). Workman GTX Gasoline Page 4 − 9 Drive Train...

  • Page 52: Primary And Secondary Clutches

    3. Raise and support vehicle cargo bed (if installed) to allow access to clutches. 4. Remove CVT drive belt from the primary and sec- ondary clutches (see CVT drive belt in this section). Page 4 − 10 Workman GTX Gasoline Drive Train...
  • Page 53 Torque screw from 17 to 22 ft−lb (24 to 29 N−m). 132 to 168 in−lb (15.0 to 18.9 N−m) Figure 10 Primary clutch Screw (4 used) Starter/generator pulley Workman GTX Gasoline Page 4 − 11 Drive Train...

  • Page 54: Primary Clutch Service

    3. Make sure that starter/generator pulley (item 2) has 9. If necessary, remove moveable sheave from station- been removed from the primary clutch (see Primary and ary sheave. Secondary Clutches in this section). Page 4 − 12 Workman GTX Gasoline Drive Train...
  • Page 55 7. Secure cover to the moveable sheave with three (3) cap screws. Torque cap screws from 132 to 168 in−lb (15.0 to 18.9 N−m). 8. Remove spider tool from stationary sheave. Workman GTX Gasoline Page 4 − 13 Drive Train...

  • Page 56: Secondary Clutch Service

    Make sure that the “X” mark cast into the stationary and moveable sheaves are aligned. Also, make sure that the retaining ring is fully seated in groove after installation. Page 4 − 14 Workman GTX Gasoline Drive Train...
  • Page 57 This page is intentionally blank. Workman GTX Gasoline Page 4 − 15 Drive Train...

  • Page 58: Transaxle Shift Cable

    C. Carefully separate shift cable from clip on swing lever (see Dash in the Service and Repairs section of arm. Chapter 6 − Chassis). It is not necessary to remove choke cable from dash. Page 4 − 16 Workman GTX Gasoline Drive Train...

  • Page 59: Installation

    If neces- sary, adjust shift cable at spanner bar so that all posi- tions engage. If necessary, additional cable adjustment can be made with jam nuts at the parking brake mount. Workman GTX Gasoline Page 4 − 17 Drive Train...
  • Page 60 3. Remove drive belt from the primary and secondary IMPORTANT: Torque tighten the fasteners based on the fastener clutches (see CVT Drive Belt in this section). grade. Make sure to use the correct torque; refer to Figure 17. Page 4 - 18 Workman GTX Gasoline Drive Train...
  • Page 61 Transaxle weighs approximate- 6. Install CVT drive belt to the primary and secondary ly 55 pounds (25 kg). clutches (see CVT Drive Belt in this section). Workman GTX Gasoline Page 4 − 19 Drive Train...
  • Page 62 9. Check that forward, neutral and reverse positions engage as shift lever is moved to each position. If neces- sary, adjust shift cable at spanner bar so that all posi- tions engage. Page 4 − 20 Workman GTX Gasoline Drive Train...
  • Page 63 This page is intentionally blank. Workman GTX Gasoline Page 4 − 21 Drive Train...

  • Page 64: Transaxle Service

    16 to 19 ft−lb (21 to 25 N−m) 40 to 45 ft−lb (54 to 61 N−m) 26 to 31 ft−lb (35 to 42 N−m) 16 to 19 ft−lb (21 to 26 N−m) Figure 19 Page 4 − 22 Workman GTX Gasoline Drive Train...

  • Page 65: Transaxle Disassembly

    Input shaft LH case RH case sealing surfaces of the cases may result. B. Using bosses on cases as pry−points, separate cases. Raise LH case leaving internal transaxle components in RH case. Workman GTX Gasoline Page 4 − 23 Drive Train...
  • Page 66 E. Replace collar or spacers if excessively worn or Figure 24 damaged. Bearing (RH case) Gear 52 Spacer (2 used) Collar Gear 51 Gear 17 Pin clutch Bearing (LH case) Center shaft Page 4 − 24 Workman GTX Gasoline Drive Train...
  • Page 67 NOTE: Bearing is press fit in axle case. Use press to remove bearing from axle case. C. Remove bearing from axle case and discard Figure 27 bearing. LH transaxle case Breather Workman GTX Gasoline Page 4 − 25 Drive Train...

  • Page 68: Transaxle Inspection

    Replace the case if ma- chined surfaces are scored or if the pinion shaft fits loosely in the bore. B. Replace pinion shaft if cracked or bent. Page 4 − 26 Workman GTX Gasoline Drive Train...

  • Page 69: Transaxle Assembly

    Gear 60 sembly. Make sure bearings are pressed fully to the Pinion shaft Bolt (6 used) Bearing (LH case) shoulders on gear 60 and the differential case. Pinion gear (2 used) Workman GTX Gasoline Page 4 − 27 Drive Train...
  • Page 70 RH case (Fig. 35). Make sure to engage pin on shift shaft into groove of Figure 35 selector shaft while installing center shaft assembly. Input shaft Differential Center shaft Counter shaft Shift shaft Page 4 − 28 Workman GTX Gasoline Drive Train...
  • Page 71 D. Insert axle shaft through axle case and bearing. Make sure that threaded end of axle shaft is inserted through bearing. Figure 37 Axle case Snap ring Axle shaft Shaft threaded end Bearing Workman GTX Gasoline Page 4 − 29 Drive Train...
  • Page 72 This page is intentionally blank. Page 4 − 30 Workman GTX Gasoline Drive Train...
  • Page 73 ......Parking Brake Alarm Switch (If Equipped) ..Reverse Alarm Switch (If Equipped) ..Workman GTX Gasoline Page 5 − 1 Electrical System...

  • Page 74: General Information

    The diagnostic connecter is secured to the left side of the swing arm under the air cleaner assembly. Electrical Drawings The electrical schematics and other electrical drawings for the Workman GTX are located in Chapter 7 − Electri- cal Drawings. Electrical System Page 5 − 2...

  • Page 75: Rear Frame Panel Cover

    The cover can easily be removed by re- leasing the latches and lifting the cover from the rear frame. Figure 1 1. Rear frame 3. Latch (2 used) 2. Panel cover Workman GTX Gasoline Page 5 − 3 Electrical System...

  • Page 76: Special Tools

    Multimeter The meter can test electrical components and circuits for current, resistance or voltage. NOTE: Toro recommends the use of a DIGITAL Volt− Ohm−Amp multimeter when testing electrical circuits. The high impedance (internal resistance) of a digital me- ter in the voltage mode will make sure that excess cur- rent is not allowed through the meter.
  • Page 77 Apply terminal protector to the connection af- ter the battery cable, ring terminal or fork terminal has been secured. Toro Part Number: 107−0392 Figure 5 Spark Tester The spark tester can be used to test magneto ignitions on gasoline engines.

  • Page 78: Troubleshooting

    15 ampere fuse to the key switch is loose or faulty. The key switch or circuit wiring is faulty. Fuse block or circuit wiring is faulty. Accelerator pedal switch is faulty. Start/run solenoid is faulty. Electrical System Page 5 − 6 Workman GTX Gasoline...

  • Page 79: General Run Problems

    Accelerator pedal switch or circuit wiring is faulty. Magneto relay or circuit wiring is faulty. An engine fault exists (fuel injected engine − EFI) Engine or fuel system is malfunctioning (see Chapter 3 − Gasoline Engine). Workman GTX Gasoline Page 5 − 7 Electrical System...

  • Page 80: Electrical System Quick Checks

    NOTE: Depending upon the condition of the battery Battery Voltage after 3 Minute Charge = 12.95 v charge and battery temperature, the battery voltage will Difference = +0.65 v increase at different rates as the battery charges. Electrical System Page 5 − 8 Workman GTX Gasoline...

  • Page 81: Component Testing

    4. Replace key switch if testing determines that the 6. After key switch testing is complete, connect wire switch is faulty. harness connector to the switch. Lower and secure front hood. Workman GTX Gasoline Page 5 − 9 Electrical System...

  • Page 82: Headlight Switch

    (see electrical schematic and wire harness drawing in Chapter 7 − Electrical Drawings). 7. After headlight switch testing is complete, connect wire harness connector to the headlight switch. Lower and secure front hood. Electrical System Page 5 − 10 Workman GTX Gasoline...

  • Page 83: Machine Fuses

    Fuse with red/white and red/black wires (10 amp) protects the switched power circuit to the engine ECU, oxygen sensor, ignition coil and fuel injector. G248194 Figure 11 1. EFI engine 3. Engine ECU 2. Engine fuse holders Workman GTX Gasoline Page 5 − 11 Electrical System...

  • Page 84: Usb Charge Port

    (−) terminal on the charge port (Fig. 13). Figure 12 1. USB charge port USB CHARGE PORT WIRE HARNESS CONNECTIONS Figure 13 1. Positive (+) terminal 2. Negative (-) terminal Electrical System Page 5 − 12 Workman GTX Gasoline...

  • Page 85: Start/Run Solenoid

    13.5 ohms. Figure 15 8. Replace start/run solenoid if testing determines that 1. Main contact post 2. Solenoid coil post it is faulty. Workman GTX Gasoline Page 5 − 13 Electrical System...

  • Page 86: Electric Fuel Pump (Fuel Injected Engines − Efi)

    Figure 17 1. Supply hose fitting lock 2. Supply hose fitting lock (locked − down) (unlocked − up) 3. Supply hose fitting tab Electrical System Page 5 − 14 Workman GTX Gasoline...
  • Page 87 Replace the fuel pump as necessary. 10.Make sure that no fuel leaks exist before returning machine to service. 11. Install rear frame panel cover and lower bed. Workman GTX Gasoline Page 5 − 15 Electrical System...

  • Page 88: Key Start Latch And Magneto/Ecu Relays

    Key Start Latch and Magneto/ECU Relays A Workman GTX vehicle uses up to three (3) identical relays that have five (5) terminals. The relays are at- tached to the dash bracket near the brake master cylin- der (Fig. 18). Two relays work together to operate the start latch cir- cuits so that the engine can be started when the key switch is rotated to the START position.
  • Page 89 9. Replace relay if testing determines that it is faulty. 10.After relay testing is complete, secure relay to vehi- cle and connect wire harness connector to relay. 11. Lower and secure hood. Workman GTX Gasoline Page 5 − 17 Electrical System...

  • Page 90: Delay Timer (Fuel Injected Engines − Efi)

    9. After timer testing is complete, install the timer and connect the wire harness. G248263 10.Lower and secure the hood. Figure 21 1. Delay timer connecter 3. Multimeter probe 2. 12 VDC power supply Electrical System Page 5 − 18 Workman GTX Gasoline...

  • Page 91: Accelerator Pedal Switch

    SIDE VIEW switch. Connectors should be thoroughly packed with gel for effective results. 7. Lower and secure hood. Figure 24 1. NO terminals 3. Switch plunger 2. NC terminals 4. Mounting tab Workman GTX Gasoline Page 5 − 19 Electrical System...

  • Page 92: Diode Assemblies

    Diode Assemblies Two (2) identical diode assemblies are included in the Workman GTX wire harness. The diode D1 is used for circuit protection from voltage spikes that can occur when the start/run solenoid is de− energized. This diode plugs into the wire harness be- neath the seat base near the battery.

  • Page 93: Starter/Generator & Voltage Regulator

    2. Terminal A2 5. Terminal F2 A. Disconnect wire harness connector from starter/ 3. Terminal F1 generator terminal DF (Fig. 26). Cover the harness connector to prevent it from accidentally grounding during testing. Workman GTX Gasoline Page 5 − 21 Electrical System...
  • Page 94 1. Start/run solenoid 2. Harness wire (black) 3. Starter/gen cable (to F2) and red wire (to volt regulator) 4. Harness wire (blue) 5. Positive battery cable and red wire (to fuse blocks) Electrical System Page 5 − 22 Workman GTX Gasoline...

  • Page 95: Starter/Generator

    DF and F1. The meter reading should be approximately 3 to 6 Ohms. Figure 29 8. Measure resistance (Ohms) between each starter/ generator terminal and ground. The meter reading should be infinite (no continuity). Workman GTX Gasoline Page 5 − 23 Electrical System...

  • Page 96: Parking Brake Alarm Switch (If Equipped)

    1. Common terminal 3. NC terminal 2. NO terminal 4. Switch lever used in the parking brake alarm circuit. 7. If testing determines that alarm switch is faulty, re- place switch. Electrical System Page 5 − 24 Workman GTX Gasoline...

  • Page 97: Reverse Alarm Switch (If Equipped)

    Make sure that there is no contact be- tween the switch and the shift arm tab after adjustments are made. Workman GTX Gasoline Page 5 − 25 Electrical System...

  • Page 98: Service And Repairs

    3. Positive cable (red) 8. Battery clamp 4. Flange nut (2 used) 9. Flange nut 5. Flange screw (2 used) 10. Battery tray Electrical System Page 5 - 26 Workman GTX Gasoline...

  • Page 99: Battery Inspection And Maintenance

    9. After battery and cables are secure, apply battery the caps are on tightly. terminal protector (Toro part number 107- 0392) on bat- tery posts and cable connectors to reduce corrosion. 3. Check for signs of wetness or leakage on the top of the battery which might indicate a loose or missing filler 10.Install seat base assembly to vehicle.

  • Page 100: Battery Testing

    A. Check the voltage across the battery terminals prior to testing the battery. If the voltage is less than 12.0 VDC, recharge the battery before load testing. B. Make sure the battery terminals are free of corro- sion. Electrical System Page 5 − 28 Workman GTX Gasoline...

  • Page 101: Battery Charging

    11.5 hrs 17.3 hrs 23 hrs 6 amps 6 amps 6 amps 6 amps above 6 hrs 12 hrs 18 hrs 24 hrs 10 amps 10 amps 10 amps 10 amps Workman GTX Gasoline Page 5 − 29 Electrical System...

  • Page 102: Starter/Generator

    Cover in the General Information section of this chap- 1. Park vehicle on a level surface, stop engine, engage ter). parking brake and remove key from the key switch. Place vehicle shift lever in the NEUTRAL position. Electrical System Page 5 - 30 Workman GTX Gasoline...

  • Page 103: Installation

    B. Secure pulley to the shaft with spring washer and 40 to 49 in- lb nut. Torque nut from 17 to 22 ft- lb (24 to 29 N- m). (4.5 to 5.6 N- m) Figure 36 Workman GTX Gasoline Page 5 - 31 Electrical System...

  • Page 104: Starter/Generator Service

    2. Bearing 6. Brush kit 10. Wave washer 3. Retaining ring 7. Brush spring (4 used) 11. Commutator end head 4. Armature assembly 8. Brush box assembly 12. Rubber plug (4 used) Electrical System Page 5 − 32 Workman GTX Gasoline...

  • Page 105: Brush And Brush Spring Service

    NOTE: A troubleshooting guide for the Advanced Mo- tors and Drive starter/generator is included at the end of this chapter. Refer to this guide when diagnosing a starter/generator problem on your Workman GTX vehi- cles. Brush and Brush Spring Service 1.
  • Page 106 C. The bearings are rusted, worn, cracked or show abnormal color due to overheating. NOTE: Individual components in the frame housing are not available separately. Replace housing or complete starter/generator if damage exists in frame and field as- sembly. Electrical System Page 5 − 34 Workman GTX Gasoline...
  • Page 107 Figure 44 11. Remove brush assemblies from the brush box. Minimum brush length is 0.375 in (9.5 mm) Maximum brush length is 0.790 in (20 mm) Figure 45 Workman GTX Gasoline Page 5 − 35 Electrical System...
  • Page 108 Secure brush box to end head with two (2) screws. Torque screws from 22 to 26 in−lb (2.5 to 2.9 N−m). Figure 48 Electrical System Page 5 − 36 Workman GTX Gasoline...
  • Page 109 49 to 66 in−lb (5.6 to 7.4 N−m). Figure 50 17.Position the starter/generator on the commutator end head and support the assembly to prevent damage to the terminals in the end head. Figure 51 Workman GTX Gasoline Page 5 − 37 Electrical System...
  • Page 110 66 in−lb (5.6 to 7.4 N−m). Figure 53 22.Release brushes and center the brush springs between the wire and the edge of the brush. Make sure that brushes move freely in brush holders. Figure 54 Electrical System Page 5 − 38 Workman GTX Gasoline...

  • Page 111: Starter/Generator Specifications

    0.375 in (9.5 mm) Commutator bars Commutator original maximum diameter (new) 1.780 in (45.2 mm) Commutator minimum diameter for re−slotting 1.650 in (41.9 mm) Commutator replacement diameter 1.60 in (40.6 mm) Workman GTX Gasoline Page 5 − 39 Electrical System...
  • Page 112 This page is intentionally blank. Electrical System Page 5 − 40 Workman GTX Gasoline...
  • Page 113 ....... . Workman GTX Gasoline Page 6 - - 1...

  • Page 114: General Information

    General Information Operator’s Manual The Operator’s Manual provides information regarding the operation, general maintenance and maintenance intervals for your Workman GTX vehicle. Refer to the Operator’s Manual for additional information when ser- vicing the vehicle. Thread Forming Fasteners Numerous thread forming fasteners are used to secure Workman GTX frame components.

  • Page 115: Specifications

    Front Wheel Toe--In 0 + 0.125 inch (0 + 3 mm) Brake Fluid DOT 3 Standard Front Suspension Strut Pre--load Adjustment Position Lowest Position Standard Rear Shock Absorber Pre--load Adjustment Position Lowest Position Workman GTX Gasoline Page 6 - - 3 Chassis...

  • Page 116: Special Tools

    Special Tools Order special tools from your Toro Distributor. Spanner Wrench Use spanner wrench to rotate collar on front suspension strut and rear shock absorber. Collar rotation may be necessary to accommodate installed accessories or heavier vehicle loads. Make sure that vehicle is jacked up off the ground to allow spring to be at full extension before using spanner wrench.
  • Page 117 3. Place bridge onto installed threaded rod making sure that the bridge extends across both rear frame tubes. 4. Secure bridge in place with second flange nut from tool kit. Do not over--tighten flange nut. Toro Part Number: TOR6040 Figure 5 1. Bridge 2. Leg (RH shown) Figure 6 1.

  • Page 118: Troubleshooting

    Front wheel alignment (toe--in) is incorrect. Bushings in spindle or A--arm are loose or worn. Rubber shock insert in front suspension strut is loose or worn. Steering rack assembly is damaged or worn. Chassis Page 6 - - 6 Workman GTX Gasoline...

  • Page 119: Brakes

    Brake pads are excessively worn. Brake master cylinder is faulty. Brake pedal is spongy. Air is trapped in brake lines. Transaxle bearings are loose or damaged. Brake master cylinder is faulty. Workman GTX Gasoline Page 6 - - 7 Chassis...
  • Page 120 Air is trapped in brake lines. Excessive moisture in brake fluid. Brake pads are saturated. Vehicle surges at slow speeds and Brake rotors are bent or damaged. chatters at fast speeds. Chassis Page 6 - - 8 Workman GTX Gasoline...

  • Page 121: Adjustments

    2. Parking brake cable 5. Parking brake lever 3. Parking brake rod 7. After securing parking brake adjustment, make sure that rear wheel still rotates with little evidence of brake drag. Workman GTX Gasoline Page 6 - - 9 Chassis...

  • Page 122: Adjust Front Wheel Toe--In

    There should be no contact between any machine compon- ents as the wheels are moved from lock to lock. Adjust if necessary. Chassis Page 6 - - 10 Workman GTX Gasoline...

  • Page 123: Service And Repairs

    Inspect Torque wheel lug nuts in a crossing pattern from 75 to tire and rim condition after any accident. 95 ft-lb (102 to 128 N- -m). Workman GTX Gasoline Page 6 - - 11 Chassis...

  • Page 124: Front Wheels And Hubs

    Before jacking up the vehicle, review and follow caliper assembly with attached brake line from brake ro- Jacking Instructions in Chapter 1 - - Safety. tor and support caliper away from the front wheel hub. Chassis Page 6 - - 12 Workman GTX Gasoline...
  • Page 125 130 in-lb (14.7 N--m) to set the bearings. Then, 1. Wheel hub 3. Inner bearing cup 2. Outer bearing cup 4. Wheel stud (4 used) loosen the nut until the hub has endplay. Workman GTX Gasoline Page 6 - - 13 Chassis...

  • Page 126: Rear Wheels And Hubs

    16. Socket head screw (4 per rotor) 5. Socket head screw (2 per caliper) 11. Slotted hex nut 17. Wheel stud (4 per hub) 6. Parking brake cable (2 used) 12. Thrust washer Chassis Page 6 - - 14 Workman GTX Gasoline...
  • Page 127 IMPORTANT: Do not get antiseize lubricant onto brake rotor or brake pads. 3. Apply a light coating of antiseize lubricant to both the transaxle shaft and splines in wheel hub bore. Workman GTX Gasoline Page 6 - - 15 Chassis...

  • Page 128: Front Brake Calipers

    6. Socket head screw (4 per rotor) 10. Bleed screw 3. Socket head screw (2 per caliper) 7. Spindle (RH shown) 11. Washer head screw 4. Wheel hub assembly (2 used) 8. Front brake line Chassis Page 6 - - 16 Workman GTX Gasoline...
  • Page 129 (2) socket head screws. Torque screws 2. Repeat this procedure 10 times. To avoid overheat- from 35 to 40 ft- -lb (48 to 54 N- -m). ing the brakes, wait 1 minute between each stop. Workman GTX Gasoline Page 6 - - 17 Chassis...

  • Page 130: Front Brake Caliper Service

    4. Caliper bracket 7. Piston (2 used) 2. Caliper body 5. Square seal (2 used) 8. Brake pad (2 used) 6. Dust seal (used) 3. O- -ring (4 used) 9. Caliper anvil Chassis Page 6 - - 18 Workman GTX Gasoline...
  • Page 131 Replace brake pistons or complete brake caliper assembly if necessary. 3. Check that pins on caliper bracket are not worn, cor- roded or damaged. Wear on the pins will prevent smooth brake operation. Workman GTX Gasoline Page 6 - - 19 Chassis...

  • Page 132: Rear Brake Calipers

    D. Position disconnected parking brake cable away vehicle with appropriate jack stands beneath the frame. from brake caliper. 3. Remove rear wheel from machine (see Rear Wheels and Hubs in this section). Chassis Page 6 - - 20 Workman GTX Gasoline...
  • Page 133 2. Repeat this procedure 10 times. To avoid overheat- A. Make sure that parking brake is not applied. ing the brakes, wait 1 minute between each stop. B. Insert brake cable end into parking brake lever. Workman GTX Gasoline Page 6 - - 21 Chassis...

  • Page 134: Rear Brake Caliper Service

    NOTE: Replacement parts for the rear caliper assem- bly are limited to the brake pad assembly and bleed screw. If any other caliper components are damaged or worn, replace the caliper assembly. Chassis Page 6 - - 22 Workman GTX Gasoline...
  • Page 135 (2) caliper slide pins. Make sure that the slide pins are inserted through the center of the anti--rattle springs. Tighten pins from 30 to 35 ft- -lb (41 to 47 N- -m). Workman GTX Gasoline Page 6 - - 23 Chassis...

  • Page 136: Parking Brake Cables And Lever Assembly

    10. Parking brake cable (2 used) NOTE: The parking brake assembly includes the dash mounted parking brake lever, two (2) identical brake ca- bles and parking brake actuators in the rear brake calipers. Chassis Page 6 - - 24 Workman GTX Gasoline...
  • Page 137 1. Parking brake cable 4. Parking brake lever brake calipers and the parking brake lever assembly. 2. Cable conduit 5. Lock nut 3. Cable end 6. Parking brake rod Workman GTX Gasoline Page 6 - - 25 Chassis...

  • Page 138: Brake Master Cylinder

    4. Brake pedal 7. Flange head screw (2 used) 2. Hair pin 5. Pedal mount 8. Front brake line 3. Clevis pin 6. Flange nut (2 used) 9. Rear brake line Chassis Page 6 - - 26 Workman GTX Gasoline...
  • Page 139 5. Lower and secure front hood. CAUTION After servicing brake system components, al- ways check the brakes in a wide open, level area that is free of other persons and obstructions. 6. Check brake operation. Workman GTX Gasoline Page 6 - - 27 Chassis...

  • Page 140: Brake Master Cylinder Service

    Install lower end of dust cover to housing. 5. Push in on push rod so stop pin can be installed to retain secondary piston assembly, then install flange seal and reservoir. Chassis Page 6 - - 28 Workman GTX Gasoline...

  • Page 141: Bleed Brake System

    7. After bleeding of brakes is completed, test vehicle to Figure 27 make sure brakes are operating correctly and brake 1. Rear caliper (RH shown) 2. Bleeder valve pedal is firm when applying brakes. Workman GTX Gasoline Page 6 - - 29 Chassis...

  • Page 142: Steering Assembly

    4. Use suitable puller to remove steering wheel from 8. Support steering column to prevent it from falling. steering shaft. Remove four (4) flange nuts and carriage bolts securing the steering column to the mounting plate on the frame. Chassis Page 6 - - 30 Workman GTX Gasoline...
  • Page 143 (see Front Suspension in this sec- 1. Shift lever 3. Extension spring tion). 2. Detent arm 9. Make sure that front wheels are centered by the steering rack before securing the steering wheel. Workman GTX Gasoline Page 6 - - 31 Chassis...

  • Page 144: Steering Rack Assembly Service

    NOTE: Check parts catalog to identify individual com- ponents that are available for the steering rack assem- bly on your Workman GTX vehicle. Depending on wear or damage that exists with the steering rack, replace- ment of the complete steering rack assembly might be necessary.
  • Page 145 Rotate input shaft to extend rack shaft in opposite direction and apply general purpose grease to exposed teeth on rack. Figure 32 1. Input shaft 2. Input shaft seal Workman GTX Gasoline Page 6 - - 33 Chassis...

  • Page 146: Shift Lever Assembly

    19. Shifter shaft 5. Shift cable 13. Lock nut 20. Knob 6. Extension spring 14. Shift arm 21. Flange nut 7. Detent arm 15. Slotted roll pin 22. Shift decal 8. Bearing Chassis Page 6 - - 34 Workman GTX Gasoline...
  • Page 147 2. Carefully position and secure dash to vehicle (see Dash in this section). Figure 34 1. Shift lever 3. Extension spring 3. Lower and secure front hood. 2. Detent arm Workman GTX Gasoline Page 6 - - 35 Chassis...

  • Page 148: Front Suspension

    Before jacking up the vehicle, review and follow 2. Raise hood to allow access to suspension compo- Jacking Instructions in Chapter 1 - - Safety. nents from above. Chassis Page 6 - - 36 Workman GTX Gasoline...
  • Page 149 Use an arbor press to fully install the bush- ings into the spindle or A--arm. D. Install sleeves into spindle or A--arm. NOTE: On Workman GTX vehicles, suspension strut assembly should be set to lowest pre--load setting. Assembly (Fig. 35)

  • Page 150: Rear Suspension

    Before jacking up the vehicle, review and follow 2. Raise and support cargo bed for access to rear sus- Jacking Instructions in Chapter 1 - - Safety. pension components from above. Chassis Page 6 - - 38 Workman GTX Gasoline...
  • Page 151 1. Rear frame 4. Flange head screw 2. Swing arm 5. Lock nut NOTE: On Workman GTX vehicles, rear shocks should 3. Shock absorber be set to lowest pre--load setting. NOTE: Use spanner wrench TOR6010 (see Special Tools in this chapter) if rear shock spring pre--load re- quires adjustment.

  • Page 152: Swing Arm Mount Assembly

    5. Isolator (upper portion) 8. Rear suspension mount 2. Swing arm 6. Isolator (lower portion) 9. Cap screw (2 used) 3. Cap screw 7. Snubbing washer 10. Flange nut (2 used) 4. Upper plate Chassis Page 6 - - 40 Workman GTX Gasoline...
  • Page 153 7. If necessary, remove two (2) cap screws, washers 6. Lower and secure cargo bed. and flange nuts that secure the rear suspension mount to the front frame. Remove mount from front frame. Workman GTX Gasoline Page 6 - - 41 Chassis...

  • Page 154: Seat Base

    22. Flange head screw (2 used) 7. Screw with washer (2 used) 15. Washer head screw (5 used) 23. Flange nut (2 used) 8. Seat base assembly 16. Screw (12 used) Chassis Page 6 - - 42 Workman GTX Gasoline...
  • Page 155 (10.2 to 12.4 N- -m) Figure 43 1. Seat base 4. Flat washer (8 used) 2. Seat (2 used) 5. Retainer (2 used) 3. Cap screw (8 used) 6. Screw (4 used) Workman GTX Gasoline Page 6 - - 43 Chassis...

  • Page 156: Dash

    4. Screw (2 used) 10. LH dash bracket 15. Side dash bracket (2 used) 5. Washer head screw (10 used) 11. Dash angle bracket 16. Flange nut (2 used) 6. Foot board cover Chassis Page 6 - - 44 Workman GTX Gasoline...
  • Page 157 5. Connect wire harness connectors to all switches and from vehicle, disconnect choke cable from engine and power ports on dash. remove it from dash. 6. Lower and secure front hood. Workman GTX Gasoline Page 6 - - 45 Chassis...

  • Page 158: Front Fenders, Hood And Bumper

    16. Flange nut (4 used) 24. Flange nut (4 used) 8. Clevis pin (2 used) 17. Washer head screw (2 used) 25. Flat washer (2 used) 9. Spring pin (2 used) Chassis Page 6 - - 46 Workman GTX Gasoline...
  • Page 159 2. Remove front fenders, hood or front bumper using 1. Install removed body components using Figure 45 Figure 45 as a guide. as a guide. During assembly, use fastener torque speci- fications that are identified in Figure 45. Workman GTX Gasoline Page 6 - - 47 Chassis...

  • Page 160: Cargo Bed

    10. Lock nut (2 used) 3. Flange head screw 7. LH cargo bed support 11. Prop rod bracket 4. Bed latch striker (2 used) 8. Flange head screw (6 used) 12. Prop rod U- -bracket Chassis Page 6 - - 48 Workman GTX Gasoline...
  • Page 161 Strikers can be raised or lowered to latch bed. Figure 48 1. Tailgate lanyard 3. Tailgate 2. Shoulder screw (2 used) 4. Cargo bed Workman GTX Gasoline Page 6 - - 49 Chassis...
  • Page 162 This page is intentionally blank. Chassis Page 6 - - 50 Workman GTX Gasoline...
  • Page 163 Wire Harness -- Parking Brake Alarm ..Wire Harness -- EU Tail Light Kit ... . . Workman GTX Gasoline Page 7 - - 1 Electrical Drawings...

  • Page 164: Electrical Drawing Designations

    WHITE Y or YE YELLOW Numerous harness wires used on Workman GTX vehicles include a line with an alternate color. These wires are identified with the wire color and line color with either a / or _ separating the color abbreviations listed above (e.g.

  • Page 165: Electrical Schematic

    122--0226 REV. A Workman GTX Gasoline Models 07042 and 07152 (carbureted engine) Machine serial number below 401400000 Electrical Schematic All relays and solenoids are shown as de- - energized. All ground wires are black. Page 7 - - 3...

  • Page 166: Electrical Schematic (Carbureted Engine)

    122--1144 REV. A Workman GTX Gasoline (carbureted engine) Machine serial number 401400001 to 403448000 Electrical Schematic All relays and solenoids are shown as de- - energized. All ground wires are black. Page 7 - - 4...

  • Page 167: Electrical Schematic (Carbureted Engine)

    122--1470 Rev. A Workman GTX Gasoline (carbureted engine) Electrical Schematic (Serial Numbers Above 403448001) (All relays and solenoids are shown as de--energized) Page 7 - - 5...

  • Page 168: Machine Serial Numbers Below 403446000

    122--1029 REV. B Workman GTX Gasoline (EFI engine) Machine Serial Numbers Below 403446000 Electrical Schematic All relays and solenoids are shown as de- - energized. All ground wires are black. Page 7 - - 6...
  • Page 169 122--1472 Rev. A Workman GTX Gasoline (EFI engine) Electrical Schematic (Serial Numbers Above 403446001) (All relays and solenoids are shown as de--energized) Page 7 - - 7...

  • Page 170: Start Circuit (Key Switch In Start Position) (Fuel Injected Models Shown)

    122--1029 REV. B Start Circuit (Key Switch in START Position) (fuel injected engine models shown) Power Current Control Current Indication Current Page 7 - - 8...

  • Page 171: Run Circuit (Engine Started With Key Switch) (Fuel Injected Models Shown)

    122--1029 REV. B Run Circuit (Engine Started With Key Switch) (fuel injected models shown) Power Current Control Current Indication Current Page 7 - - 9...

  • Page 172: Run Circuit (Engine Started With Accelerator Pedal) (Fuel Injected Models Shown)

    122--1029 REV. B Run Circuit (Engine Started With Accelerator Pedal) (fuel injected models shown) Power Current Control Current Indication Current Page 7 - - 10...

  • Page 173: Machine Serial Number Below 401400000

    122--0225 REV.D Workman GTX Gasoline Models 07042 and 07152 (carbureted engine) Machine serial number below 401400000 Wire Harness Drawing - - Main Page 7 - - 11...
  • Page 174 122--0225 REV.D Workman GTX Gasoline Models 07042 and 07152 (carbureted engine) Machine serial number below 401400000 Wire Harness Diagram - - Main Page 7 - - 12...
  • Page 175 122--1143 REV. B Workman GTX Gasoline (Carbureted engine) Machine serial numbers 401400001 to 403448000 Wire Harness Drawing - - Main Page 7 - - 13...
  • Page 176 122--1143 REV. B Workman GTX Gasoline (carbureted engine) Machine serial numbers 401400001 to 403448000 Wire Harness Diagram - - Main Page 7 - - 14...
  • Page 177 122--1471 Rev. D Workman GTX Gasoline (carbureted engine) Wire Harness Diagram - - Main (Serial Numbers Above 403448001) Page 7 - - 15...
  • Page 178 122--1471 Rev. D Workman GTX Gasoline (carbureted engine) Wire Harness Diagram - - Main (Serial Numbers Above 403448001) Page 7 - - 16...
  • Page 179 122--1030 REV. B Workman GTX Gasoline (EFI Engine) Machine serial numbers below 403446000 Wire Harness Drawing - - Main Page 7 - - 17...
  • Page 180 122--1030 REV. B Workman GTX Gasoline (EFI engine) Machine serial numbers below 403446000 Wire Harness Diagram - - Main Page 7 - - 18...
  • Page 181 122--1473 Rev. C Workman GTX Gasoline (EFI engine) Wire Harness Diagram - - Main (Serial Numbers Above 403446001) Page 7 - - 19...
  • Page 182 122--1473 Rev. C Workman GTX Gasoline (EFI engine) Wire Harness Diagram - - Main (Serial Numbers Above 403446001) Page 7 - - 20...
  • Page 183 122--0730 REV. D Workman GTX Wire Harness Drawing and Diagram - - Cab Model 07142 Page 7 - - 21...
  • Page 184 122--0818 REV. A Workman GTX Wire Harness Drawing and Diagram - - Light Kit (Cab) Page 7 - - 22...
  • Page 185 122--0785 REV. A Workman GTX Wire Harness Drawing and Diagram - - Light Kit (No Cab) Page 7 - - 23...
  • Page 186 122--0739 REV. D Workman GTX Gasoline Wire Harness Drawing and Diagram - - Parking Brake Alarm Page 7 - - 24...
  • Page 187 122--3995 REV. A Workman GTX Wire Harness Drawing and Diagram - - EU Tail Light Kit Page 7 - - 25...

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