FORM NO. 3318-342 GB Rev A MODEL NO. 07200—60001 AND UP MODEL NO. 07202—60001 AND UP MODEL NO. 07216—60001 AND UP ® OPERATOR MANUAL WORKMAN 3200 AND 4200 UTILITY VEHICLES To understand this product, and for safety and optimum performance, read this manual before starting the engine. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol. It means CAUTION, WARNING or DANGER— personal safety instruction. Failure to comply with the instruction may result in personal injury.
Foreword The TORO WORKMAN® was developed to provide an efficient, versatile, trouble free and economical work vehicle. The latest concepts of engineering, design and safety have been incorporated into this machine, along with the highest quality parts and workmanship. Excellent service will be derived if proper operation and maintenance practices are followed. This vehicle is not designed or manufactured for use on roads, streets or highways. It is not appropriate for such use.
Safety The WORKMAN® 3200 and 4200 were designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
Safety C. Do not smoke while handling gasoline. D. Keep foot off the accelerator pedal. D. Fill fuel tank outdoors and to about one inch below top of tank (bottom of filler neck). Do not overfill. E. Turn ignition key to START. E. Wipe up any spilled gasoline. 14. Check the safety interlock system daily for proper operation. If a switch should malfunction, replace the switch before operating machine.
Safety I. Before backing up, look to the rear and assure no one is behind. Back up slowly. J. Watch out for traffic when near or crossing roads. Always yield the right of way to pedestrians and other vehicles. This vehicle is not designed for use on streets or highways. Always signal your turns or stop early enough so other persons know what you plan to do. Obey all traffic rules and regulations. K. Never operate vehicle in or near an area where there is dust or fumes in the air which are explosive.
Safety with a tachometer. 31. If major repairs are ever needed or assistance is required, contact an Authorized TORO Distributor. 32. To be sure of optimum performance and safety, always purchase genuine TORO replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous. Altering this vehicle in any manner may affect the vehicle’s operation, performance, durability or its use may result in injury or death.
Symbol Glossary SAFETY ALERT SYMBOL GENERAL HAZARD SAFETY ALERT CRUSHING OF WHOLE BODY, APPLIED FROM ABOVE CRUSHING OF TOES OR FOOT, CRUSHING OF FINGERS OR HAND, CUTTING OF FINGERS OR HAND CUTTING OF FOOT FORCE APPLIED FROM ABOVE FORCE APPLIED FROM SIDE KEEP CHILDREN A SAFE DISTANCE FROM BATTERY STAY A SAFE DISTANCE FROM MACHINE STAY A SAFE DISTANCE FROM DRAINING STAY A SAFE DISTANCE FROM MACHINE STAY A SAFE DISTANCE FROM TANK HYDRAULIC OIL VALVE EXPLOSION FIRE OR OPEN FLAME FIRE, OPEN LIGHT & SMOK
Symbols Glossary THROWN OR FLYING OBJECTS, SEVERING OF FINGERS OR FACE EXPOSURE HAND, ENGINE FAN RIDING ON THIS MACHINE IS SHUT OFF ENGINE & REMOVE ALLOWED ONLY ON A PASS- KEY BEFORE PERFORMING ENGER SEAT & ONLY IF THE MAINTENANCE OR REPAIR WORK DRIVER'S VIEW IS NOT HINDERED MACHINE TIPPING USE CAUTION ON STEEP HILLS MACHINE TIPPING MACHINE TIPPING DO NOT JUMP FROM TIPPING MACHINE HOLD TIGHTL & BRACE FEET HOLD HIP RESTRAINT & HAND HOLD, BRACE FEET LEAN AWAY FROM TIP STAY CLEAR OF ARTICULATION RUNO
FULL BED REMOVAL (Model 07202 only) RE-INSTALLING THE FULL BED (Model 07202 only) 1. Start the engine. Engage the hydraulic lift lever and lower the bed until the cylinders are loose in the slots. Release the lift lever and turn off the engine. 2. Remove the Iynch pins from the outer ends of the cylinder rod clevis pins (Fig. 1). Note: If bed sides will be installed on the flat bed, it is easier to install them before installing the bed on the vehicle.
Note: If automatic tail gate release has been installed on bed, make sure front dump link rod has been placed on inside of left side clevis pin before Iynch pin is installed. 6. Once cylinder installation has been completed, the bed safety support can be used to prevent accidental lowering of the bed. Refer to Using The Bed Safety Support. Figure 3 1. Spacer bracket 2. Wear block 1. Assure lift cylinders are fully retracted.
Specifications Type: 4-wheel step-through, out-front operator style, two-person vehicle. Certified to meet ANSI Specifications B56.8-1988. Engine: Mitsubishi three-cylinder, liquid-cooled, counterbalanced, gasoline engine. Rated at 20 kW (27 hp), governed to a maximum speed of 3650 rpm by a mechanical governor.657 cc (40 cu. in.) displacement. Forced lubrication by gear pump. 40-amp alternator with I/C regulator. Spin-on oil filter. Air Cleaner: Heavy-duty, 2-stage, remote mounted air cleaner.
Specifications (7.6/11.5/19.8 mph) Low range: 4.7/9.2/12.4 kmh (2.9/5.7/7.7 mph) Reverse Speeds with 58 cm (24”) Tires— High range: 11.6 kmh (7.2 mph) Low range: 4.5 kmh (2.8 mph) General Specifications: Base Weight: Dry w/o flatbed 522.5 kg (1400 lbs.) Rated Capacity: 970 kg*(2,600 lbs). *includes 74.6 (200 lb.) operator and 74.6 (200 lb.) passenger and loaded attachment. Maximum Gross Vehicle Weight: 1,493 kg (4,000 lbs.) 2-wheel drive 1,568 kg (4,200 lbs.) 4 wheel drive Tow Capacity Tongue weight 74.
Before Operating CHECK THE CRANKCASE OIL process. DO NOT OVERFILL. The engine is shipped with oil in the crankcase; however, the level of oil must be checked before and after the engine is first started. IMPORTANT: Check the level of oil every 8 operating hours or daily. Change the oil and filter initially after the first 50 hours of operation, thereafter, change the oil and filter every 100 hours. However, change the oil more frequently when the engine is operated in extremely dusty or dirty conditions.
Before Operating SYSTEM DAMAGE COULD RESULT. 4. Wipe up any fuel that may have spilled to prevent a fire hazard. 1. Clean the area around the fuel tank cap. CHECK THE COOLING SYSTEM CAUTION ➀ If the engine has been running, pressurized hot coolant can escape if radiator cap is removed and cause burns. Allow the engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning hand. Figure 5 Capacity of the cooling system is approximately 3.8 liters (4 qts.). 1.
Before Operating 4. Install the reserve tank cap. CHECK THE TRANSAXLE / HYDRAULIC FLUID The transaxle reservoir is filled with Dexron II ATF. Check the level before the engine is first started and every 8 hours or daily, thereafter. Capacity of the system is 7.1 l (7.5 qt). 1. Position the vehicle on a level surface. 2. Clean the area around the dipstick. Figure 8 1. Front differential 2. Fill plug 3. Drain plug 3. Unscrew the dipstick from the top of the transaxle and wipe it with a clean cloth. 1.
3. If the fluid level is low, clean the area around cap, remove the reservoir cap and fill to proper level. DO NOT OVERFILL. Maximum Total Front Axle Weight (kg) Before Operating 20” FRONT TIRES 597 560 523 485 448 411 373 55 69 83 97 110 124 138 152 Tire pressure (Nm) Check tire pressure every 8 hours or daily. Maximum air pressure in the front tires is 1,4 kg/cm2 and 1,3 kg/cm3 in the rear (24”) tires tires. Optional rear (23”) tire pressure is 2,3 kg/cm2 maximum. 1.
Controls Accelerator Pedal (Fig. 10)—Used to vary engine and ground speed when the transmission is in gear. Depressing the pedal increases engine RPM and ground speed. Releasing it will decrease engine RPM and ground speed. ➀ Shift Pattern R IMPORTANT: Do not shift the transaxle to the reverse or forward gear unless the vehicle is standing still. Damage to the transaxle may occur. 1 ➁ 2 3 ➂ CAUTION Figure 10 1. Accelerator pedal 2. Clutch pedal 3. Brake pedal Clutch Pedal (Fig.
Controls 8 additional speeds for precise speed control. 2 7 5 3 6 1 4 A. The vehicle must be completely stopped before shifting between High and Low range. B. Shift only on level ground. C. Depress the clutch pedal fully. Figure 11 1. Gear shift lever 2. Differential lock 3. Parking brake 4. High-low range shifter 5. Hydraulic lift 6. Hydraulic lift lock 7. Passenger hand hold 8. PTO lever (optional) Parking Brake (Fig.
Controls Coolant Temperature Gauge (Fig. 12)—Registers coolant temperature in the engine. Operates only when the ignition switch is in the On position. Engine Low Oil Pressure Light (Fig. 12)—This light glows if engine oil pressure drops below a safe level while the engine is running. If the light flickers or remains ON, stop the vehicle, turn off the engine and check the oil level.
Operating PRE-STARTING CHECKS Safe operation begins before taking the vehicle out for a day’s work. You should check these items each time: 1. Check tire pressure. Note: These tires are different than car tires, they require less pressure to minimize turf compaction and damage. 2. Check all fluid levels and add the appropriate amount of Toro-specified fluids, if any are found to be low. 3. Check brake pedal operation. 4. Check to see that the lights and horn are working. 5.
Operating battery. IMPORTANT: Do not keep the front wheels turned against the right or left stops for longer than 5 seconds. The hydraulic pump may over heat, resulting in pump or steering gear damage. 6. Do not push or tow the vehicle to get it started. Damage to the drive train could result. STOPPING THE VEHICLE To stop the machine, remove your foot from the accelerator pedal, depress the clutch pedal, then depress the brake pedal.
Operating OPERATING CHARACTERISTICS The vehicle is designed with safety in mind. It has four wheels for added stability. It uses familiar automotive style controls, including the steering wheel, brake pedal, clutch pedal, accelerator pedal, and gear shifter. It is important to remember, however, that this vehicle is not a passenger car. It is a work vehicle and not designed for use on roadways.
Operating such as sprayers, top dressers, or spreaders, etc., operating speeds should be restricted by moving 3rd high lockout switch to slow position. TURNING Turning is another important variable leading to accidents. Turning too sharply for the conditions can cause the vehicle to lose traction and skid, or even tip over. Wet, sandy and slippery surfaces make turning more difficult and risky. The faster you are going, the worse this situation becomes so, slow down before turning.
Operating In case of tipover Don’t jump Tipover can occur if the truck is improperly operated. Injury or death could result. HILLS WARNING Operator: Hold tight and brace feet. Passenger: Hold hip restraint and hand hold, brace feet Lean away Tipping or rolling the vehicle on a hill will cause serious personal injury. • If the engine stalls or you lose headway on a hill, never attempt to turn the vehicle around. • Always back straight down a hill in reverse gear.
Operating make sharp or fast turns on a hill. If you stall or begin to lose headway while climbing a steep hill, quickly apply the brakes, shift to neutral, restart the engine and shift to reverse. At idle speed, engine and transaxle drag will aid the brakes in controlling the vehicle on the hill and help you back down the hill more safely. Reduce the weight of the load if it is a steep hill or if the load has high center of gravity. Remember, loads can shift. Secure them.
Operating This shifting happens most often while turning, going up or down hills, suddenly changing speeds or while driving over rough surfaces. Shifting loads can lead to tip overs. Always secure loads so that they do not shift. Never dump the load while the vehicle is sideways on the hill. Heavy loads increase stopping distance and reduce your ability to turn quickly without tipping over. The rear cargo space is intended for load carrying purposes only, not for passengers.
Operating When hauling cargo or towing a trailer (attachment), do not overload your vehicle or trailer. Overloading can cause poor performance or damage to the brakes, axle, engine, transaxle, steering, suspension, body structure or tires. Important: To reduce potential for drive line damage, use low range.
Maintenance Daily Maintenance Procedures Check the following items daily • Safety Interlock operation • Service & park brake operation • Fuel level • Accelerator operation • Clutch & shifter operation • Engine oil level • Transaxle oil level • Cooling system fluid level • Brake fluid level • Air cleaner (dust cup & baffle) • Unusual engine noises • Tire pressure • Radiator screen/cleanout door • Hydraulic hoses for damage • Fluid leaks • Instrument operation • Lubricate all
Maintenance Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Check battery fluid level/ cable connections Maintenance Interval& Service Every 50 hours Every 100 hours Every 200 hours Every 400 hours Every 800 hours Lubricate all grease fittings Inspect the condition and wear of the tires Check front differential oil level (4-wheel drive) ‡Change engine oil and filter Inspect cooling system hoses Check governor oil level ✝Check cable adjustments ✝Check alternator
Maintenance Check/Service 1. 2. 3. 4. Engine oil level Engine oil drain Transaxle/Hydraulic oil level (dipstick) Belts (Governor, water pump hydraulic pump) 5. Coolant level fill 8.1 9. 10. 11. Radiator screen cleanout door Air filter Fuel filter Battery 12. 6. Fuel(Unleaded gas only) 13. 7. Grease points (34) 100 hours 8. Radiator screen 14. 15. 16.
Maintenance GREASING BEARINGS AND BUSHINGS WARNING Before servicing or making adjustments to the machine, stop the engine, set the parking brake and remove key from the ignition switch. Any load material must be removed from bed or other attachment before working under raised bed. Never work under a raised bed without positioning safety support on a fully installed cylinder rod. Always rotate the safety support to the down position before working under the raised bed.
Maintenance Figure 19 Figure 21 Figure 20 Figure 22 IMPORTANT • Construction work • After extended operation in mud, sand, water or similar dirty conditions, have your brakes inspected and cleaned and drive axle joints greased as soon as possible. This will prevent any abrasive material from causing excessive wear. • Under frequent heavy duty operating conditions, lubricate all grease fittings and inspect air cleaner daily to prevent excessive wear.
Maintenance CAUTION Only qualified and authorized personnel shall be permitted to maintain, repair, adjust or inspect the vehicle. 5. Always install or remove bed support from outside of bed. 6. Do not try to lower bed with bed safety support on cylinder. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check the level or leakage of fuel, battery electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts.
Maintenance rear it is under the axle tube. 4. When jacking up front of the vehicle, always place a 50 x 100mm block (or similar material) between the jack and vehicle frame. Locations For Selected Maintenance Procedures ➀ Figure 25 1. Front jacking point Figure 27 1. Dust Cup & Baffle 2. Filter Element 3. Air Cleaner Body ➀ ➀ ➀ Figure 26 1. Rear jacking points Figure 28 1. Engine Oil Drain Plug ➀ Figure 29 1.
Maintenance ➀ ➁ ➀ ➂ Figure 33 Figure 30 1. Governor belt 2. Alternator belt 1. Fuel Filter 3. Idler pulley ➀ ➀ ➁ ➁ Figure 31 1. Radiator screen cover 2. Clean out door Figure 34 1. Fan belt ➁ ➀ 2. Idler pulley CHECKING THE OIL LEVEL IN THE GOVERNOR Check the oil level in the governor after every 600 hours of operation. 1. Position the vehicle on level surface, stop the engine and engage the parking brake. Figure 32 1. Radiator cap 2.
Maintenance When the oil is at point of overflowing from the check plug hole, install the check plug and fill plug. ➃ ➄ ➀ ➂ ➀ ➅ ➁ Figure 37 1. Hydraulic Filter 2. Gasket ➁ Figure 35 1. Governor 2. Check plug 3. Fill plug 4. Governor output lever 5. Surge screw 6. Locknut CHANGING THE TRANSAXLE/ HYDRAULIC FLUID Change the transaxle hydraulic fluid, filter and clean the strainer every 800 hours. Figure 38 1. Front differential 2. Fill plug 3. Drain plug ➀ ➁ Figure 36 1. Hydraulic Reservoir 2.
Maintenance 3. Rotate tie rod to move front of tire inward or outward. 4. Tighten tie rod jam nuts when adjustment is correct. EMERGENCY BOX RAISING (without starting the engine) Figure 40 FRONT WHEEL TOE-IN After every 600 operating hours or annually, check front wheel toe-in. 1. Measure center-to-center distance (at axle height) at front and rear of steering tires. Front measurement must be equal to the rear measurement 3mm.
Maintenance be identified by a “+” sign on top of battery cover. WARNING Jump starting can be dangerous. To avoid personal injury or damage to electrical components in the vehicle, observe the following warnings: • • Never jump start with a voltage sources greater than 15 volts D.C. This will damage the electrical system. Never attempt to jump start a discharged battery that is frozen. It could rupture or explode during jump starting. • Observe all battery warnings while jump starting your vehicle.
