FORM NO. 3317-959 Rev. A MODEL NO. 07200 —~ 60001 & Up 5 MODEL NQ. 07202 60001 & Up s MODEL NO. 07216 — 60001 & Up WORKMANG® 3200 & 4200 Liquid Cooled Gasoline Utility Vehicle Helping you put quality into play. ™ To assure maximum safety, optimum performance, and to gain knowledge of the product, it s essential that you or any other operator of the machine read and understand the contents of this manual before the engine ls ever started.
FOREWORD The TOR 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 #f proper operation and maintenance practices are followed. This vehicle is not designed or manufactured for use on roads, streets or highways.
FOREWORD OPTIONAL SPARK ARRESTED In some places a spark arrested muffler must be used because of Local, state or federal regulations. The spark arrested available from your local Toto Distributor is approved by the United States Department of Agriculture and the United States Forest Service. When the machine 15 Used or operated on any California forest, brush or grass covered and, a properly operating spark arrested must be attached to the muffler.
A SAFETY INSTRUCTIONS The WORKMAN® was 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.
A SAFETY INSTRUCTIONS 17. When starting the engines: A. Sit on operator's seat and engage parking brake. B. Disengage PTQ (f so equipped) and return hand throttle lever to OFF position (if so equipped). C. Move shift lever o NEUTRAL and depress clutch pedal. D. Keep foot off accelerator pedal. E. Turn ignition key to START. 18. Using the machine demands attention. Failure to operate vehicle safely may result in a accident, tip over of vehicle and serious injury or death. Drive carefully.
A SAFETY INSTRUCTIONS 26. Before disconnecting or performing any work on the hydraulic system, all pressure in system must be relieved by stopping engine, cycling dump valve from raise to lower and/or lowering box and attachments. Place the remote hydraulics lever in the float position. tf box must be in raised position, secure with safety support. 27.
A SAFETY AND INSTRUCTION DECALS w— s DANGER Fuse BLOCK | F Use BLOCK [ruse BLOCK FAILURE 70 COMPLY With THE FOLLOWING SAFETY REQUIREMENTS op En HAY RESULT 1N PERSONAL INJURY GR DEATH AHEAD AND UNDERSTAND OPERATORS MANUAL BEFORE OPERATING THIS MACHINE. VEHICLE IS FOR OFF ROAD USE ONLY.
A SAFETY AND INSTRUCTION DECALS WARNING HITCH RATING TRANSMISSION At PARKING BARK! : FLUID e G BRAKE MAXIMUM TONGUE || USE DETHRONE Il WEIGHT 200 LBS. AUTOMATIC oy MAXIMUM TRANSMISSION TRAILER WEIGHT, FLUID OR ON CONSOLE 1500 LBS. EQUIVALENT (Part No. 87 ~6020) ON AXLE TUBE TI ROVER CAN (Part No., 87~6060) OCCUR IF TACK 1S i = INJURY OR DEATH O SPEED RANGE g COIL RESULT : O “ EASE GF 9 &t OVER i L.OW checkout W ON DASH ON CONSOLE (Part No. 87-5810) (Part No.
SPECIFICATIONS Type: 4 wheel step through, out front operator style, wo person vehicle. Certified to meet ANSI Specifications Engine: Mitsubishi three cylinder, liquid cooled, counterbalanced, gasoline engine. Rated at 27 hp, governed to a maximum speed of 3650 rpm by a mechanical governor. 40 cu. in. (B87 c¢) displacement. Forced lubrication by gear pump. 40 amp alternator with /G regulator. Spin—on oil filter. Air Cleaner: Heavy duty, 2-stage, remote mounted air cleaner.
LOOSE PARTS CHART Note: Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these parts, total set-up cannot be completed. Some parts may have already been assembled at factory. DESCRIPTION Qry. USE Fenders—Rear 2 Cap screw 1" Ig. 4 Flat washer .344” 1.D. 4 Lockout 4 Cap screw 17 Ig. 12 Mount rear fenders Flat washer .281" LD. 12 Lockout 12 Truss head Screw 6 Lockout 8 Wheel Nut 10 Wheel—Front 2 Wheel Nut 10 Mount wheels.
SET-UP INSTRUCTIONS INSTALL REAR FENDERS (Fig. 1 -2) 1. Loosen the lockouts and cap screws securing tail light plates to right and left frame brackets. 2. Pivot tail light plates rearward and tighten cap screws and lockouts, Figure 1 1. Tail light plate 2. Frame bracket 3. Tami light mounting bracket 3. Secure rear of each tail light plate to rear of frame brackets with a x 17 ig. cap screw, .281" |.D. flat washer and nut, as shown in figure 1. 4.
SET-UP INSTRUCTIONS Figure 4 1. Steering Wheel 4. Washer 2. Jam Nut 5. Foam Seal 3. Cap INSTALL FRONT FENDERS (Fig. 5) 1. Mount a fender ta each side of skirt with (7) 10-24 Phillips screws, flat washers and lockouts. Figure 5 1. Fender INSTALL SEAT FRAME (Fig. 6) 1. Mount a seat frame bracket to each end of seat frame with {2) 3/816 x 3/4” carriage bolts and flange knockouts. 2. Position seat frame on vehicle, aligning mounting holes in frame with holes in vehicle. 3.
SET-UP INSTRUCTIONS 2. Mount cushion with seat back brackets to right side of seat back with (4) x 5/8" Ig. carriage bolts and flange lockouts. 3. Slide manual tube into (2) R—clamps. Figure 8 1. Cushion seat back 2. Seat back bracket 3. Seat back 4, Manual tube 8. R-clamp 4. Mount cushion with seat back brackets and manual tube R—clamps to left seat back with (4} {1618 x 5/8” Ig. carriage bolts and flange lockouts. 5. Slide bed support onto storage stud (Fig. 9).
SET UP INSTRUCTIONS Figure i1 Battery cover Knots Battery base PR 3. Remove filler caps from battery and slowly fill each cell unit electrolysis is just above the plates. 4. Replace filler caps and comment amp battery charger to the battery poss. Charge the battery arbitrate of 310 4 amperes for 4 1o 8 hours, Figure 12 1. Positive cable 2. Hood down 5. When battery is charged, disconnected charger from electrical outlet and battery posts. 6. Remove filler caps.
SET—UP INSTRUCTIONS 6. Store cylinders in storage clips. Engage hydraulic lift lock [ever on vehicle to prevent accidental extension of lift cylinders. RE—INSTALL FULL BED {Model 07202 only) NOTE: if bed sides will be installed on flat bed, it is easier to install them before bed is installed on vehicle NOTE: Assure rear pivot plates are bolted to the bed frame/channel so that lower end angles to the rear (Fig. 14). Figure 14 1. Left rear corner of bed 4. Clevis pin 2. Vehicle frame channel 5. Lynch gin 3.
BEFORE OPERATING 4h caution Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from the switch, Any load material must be removed from bed or other attachment before working under raised bed. Always rotate safety support to the down position before working under raised bed, CHECK CRANKCASE OIL (Frig.
BEFORE OPERATING 2. Remove fuel tank cap. 3. Fill tank to about one inch below top of tank, (bottom of filer neck). DO WOT OVERFILL. Then install cap. 4. Wipe up any fuse that may have spilled to prevents fire hazard. &b p Anger Because gasoline is flammable, caution must be used when storing or handling It Do not fill fuel tank while engine is running, hot or when machine Is In an enclosed are. Vapors may bulls up and be ignited by a spark or flame source many feet away.
BEFORE OPERATING Figure 20 1. Front differentiate 2. Checklist plug 3. Drain pig 3. Remove fill/check plug and check level of oil. Ol should be up 1o hole. If oil is low, add 10W30 oil. 4. Re-install fill/check plug. CHECK TORQUE OF WHEEL NUTS A\ WARNING Failure to maintain proper torque could result in failure or loss of whee! and may result in personal injury. Torque front and rear wheel nuts to 45-85 ft —Ib after 1-4 hours of operation and again after 10 hours of operation and very 200 hours thereafter.
CHECK BRAKE FLUID (Fig. 21) The brake fluid reservoir is shipped from the factory filled with "DOT 3 brake fluid. Check level before engine is first stated and every B hours or daily, thereafter. 1. Park machine on a level surface. 2. Fluid level should be up to FULL line on reservoir, 3. I fluid level is low, clean area around cap, remove reservoir cap and filo to proper level. DO NOT OVERFILL. BEFORE OPERATING Figure 21 1. Brake fluid reservoir 2. Full line CONTROLS Accelerator Pedal (Fig.
CONTROLS Differential Lock (Fig. 23) — Allows rear axle to be locked for increased traction. Differential Jock may be engaged with vehicle in motion. Move lever forward and to the right to engage lock. Note: Vehicle motion plus a slight turn is required to engage or disengage differential lock. Ab warning Turning with the differential lock on can result in doss of vehicle control, Do not operate with differential Inc on when making sharp turns or at high speeds.
CONTROLS Engine Low Ol Pressure Light (Fig. 24} Light glows if engine oil pressure drops below a safe level while engine is running. It light flickers or remains ON, slop vehicle, turn off engine and check oil level, If oil level was low, but adding oil does not cause light 10 go out when engine is restarted, tum engine off immediately and contact your local TOR distributor for assistance.
OPERATING INSTRUCTIONS PER-STARTING CHECKS Safe operation begins before taking the vehicle out for 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 Toto 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 INSTRUCTIONS CHECK INTERLOCK SYSTEM The purpose of the interlock system is to prevent the engine from cranking or starting unless the clutch pedal is depressed. A\ caution The interlock switches are for the operator's protection, so do not bypass them. Check operation of the switches daily to assure interlock system is operating. if a switch is malfunctioning replace it before operating.
OPERATING INSTRUCTIONS SPEED Speed is one of the most important variables leading to accidents. Driving too fast for the conditions can cause you to lose control and have an accident. Speed can also make a minor accident worse. Driving head—on into a tree at slow speed can cause injury and damage, but, driving into a tree at high speed can destroy the vehicle and kill you and your passenger. Never drive too fast for the conditions.
OPERATING INSTRUCTIONS IN CASE OF HILLS TIP OVER WARNING Tipping or rolling the vehicle o a hilt will cause serious personal injury. = if engine stales or you lose headway on a hill, never attempt to turn vehicle around. DON'T JUMP o Always back straight down a hill in reverse gear. * Never back down in neutral or with the clutch depressed, using only the brakes. #» Never drive across a steep hill, always drive straight up or down. * Avoid turning on a hill * Don’t “drop the clutch® or slam on the brakes.
OPERATING INSTRUCTIONS LOADING AND DUMPING The weight and position of the cargo and passenger can change the vehicle center of gravity and vehicle handling. To avoid toss of control resulting in personal injury, follow these guidelines. Do not carry loads which exceed the load limits described on the vehicle weight label. WARNING The bed will lower whenever the dump ever Is pushed down, even when the engine is off. Turning off the engine will NOT prevent the box from lowering.
OPERATING INSTRUCTIONS A WARNING Tipping of roiling the vehicle on a bill will cause serious injury, @ The extra traction available with the differential lock can be enough to get you into dangerous situations such as climbing slopes that are too steep to turn around. Be exile careful when operating with the differential lock on, especially on steeper slopes.
OPERATING INSTRUCTIONS When equipped with a tow hitch bottled onto rear axis tube, your Workman can tow trailers or attachments with a Gross Trailer Weight (GTW) up to 1500 ibs. Always load a trailer with 80% of the cargo weight in the front of the trailer. This places approximately 10% (200 ibs. max.) of the Gross Trailer Weight (GTW) on the tow hitch of the vehicle.
LUBRICATION IMPORTANT: When greasing drive shaft universal ey shaft bearing crosses, pump grease until it comes out e of all 4 cups at each Cross. 1. Wipe grease fitting clean so foreign matter cannot be forced into the bearing or bushing. 2. Pump grease into the bearing or bushing. 3. Wipe off excess grease.
Check proper section of Operator's Manual for fluid specifications MAINTENANCE CHART AND CHECKLIST Daily Maintenance: (duplicate this page for routine use} Maintenance Check stem » Daily Maintenance Check For Week Of MON TUES WED THURS FRI SAT SUN Safety Interlock Operation Service & Park Brake Operation Fuel Tevet Accelerator Operation Clutch & Sifter Operation Engine Oil Level Trans axle Ol Level N ASSYRIAN Cooling System Fluid Level Brake Fluid Level Alr Cleaner (Dust Cup & Baffle)2 Unusual Engine Noises
MAINTENANCE IMPORTANT » Desert operation Cold climate operation {(below 32°F) Trailer or 5th wheel towing Frequent operation on dusty roads * s e Construction work from causing excessive wear. daily to prevent excessive wear. Heavy Duty Operation If vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently.
MAINTENANCE 4. To store bed support, remove bed support from cylinder and insert on stud on top of back rest support channel. 5. Always install or remove bed support from outside of bed. 8. Do not try to lower bed with bed safety support on cylinder. Figure 36 1. Bed support 2. Cylinder barrel 3. Bed JACKING VEHICLE (Fig. not start engine while vehicle is on jack, because engine vibration or wheel movement could cause vehicles 1o slip off jack. 2. Do not work under vehicle without jack stands supporting it.
MAINTENANCE SERVICING AIR CLEANER FILTER Service the air cleaner filer every 200 hours or more frequently in extreme dusty or direly conditions by washing or using compressed air. Replace the element. after every four cleanings (800 hours) or annually, whichever comes first. 1. Remove and service dust cup; refer to Servicing Dust Cup and Braille. 2. Remove wing nut w/gasket and slide filter element out of air cleaner body. 3. Clean the element by washing it in a solution of filter cleaner (Toto Part No. 27.
MAINTENANCE Fuel Filter Replace filter canister after every 600 hours of operation. i, Raise bed (f so equipped) and place safety support on extended lift cylinder to hold up bed. 2. Place a clan container under fuel filter, 3. Loosen R—clamp securing filler 1o frame. 4. Remove clamps securing dust filter to fuel lines. Figure 42 1. Fuel Fitter 8. Install new fuel filter o fuel lines with clamps previously removed, Filter to be mounted so arrow points toward carburetor.
MAINTENANCE Governor helot {Fig. 45) 1. Check tension by depressing belt at mid span of governor and crankshaft pulleys with 22 ibs. of force. A new belt should deflect .52~ .62 in. A used belt should deflect in. if deflection is incorrect, proceed to next step. If correct, continue operation. 2. To adjust belt tension: A, Loosen idler pulley mounting nut, move pulley to increase tension and tighten nul. G Figure 45 Governor belt Alternator belt tiler pulls @ Alternator belt (Fig. 45) 1.
MAINTENANCE 2. Rotate governor input lever clockwise to put a light tension load on the governor spring. Hold carburetor throttle against wide open throttle stop and adjust the ball joint on throttle rod to allow the ball joint socket to trace! past the carburetor throttle stud by .200” +.031" (Fig. 48}. Tighten lockouts on throttle rod. Ball joints must move freely through full gravel, Note: Governor input lever must nat contact high idle screw during this settling.
MAI NTE s Figure 50 1. Hydraulic Reservoir 2. Drain plug 3. Fill reservoir with approximately 7.5 gt. of Dethrone i ATE Refer to Checking Hydraulic Fluid. 4, Start engine and operate to fill hydraulic system. Recheck olf level and replenish, if required, IMPORTANT. Use only hydraulic fluids specified. Other fluids could cause system damages. REPLACING HYDRAULIC FILTER (Fig. 51) Initially, replace the hydraulic filter after 10 operating hours, thereafter, replace filter every 800 hours.
MAINTENANCE Figure 53 4. Hydraulic strainer 5. Reinstall strainer, 6. F Reinstall hydraulic hose and 90° filling 1o strainer in same teleportation, 7. Reinstall and tighten drain plug. 8. Fill reservoir with approximately 7.5 gt. of Dethrone §i ATF. Refer to Checking Hydraulic Fluid. REPLACING SPARK PLUGS (Fig. 59) Replace spark plugs after every 800 operating hours to assure proper engine performance and reduce exhaust emission level.
MAINTENANCE ADJUSTING CLUTCH PEDAL (Fig. 57-58) Check adjustment every 200 hours. 1. Loosen jam news securing clutch cable to bracket on bell housing. Mete: Ball joint may be removed and rotated, i additional adjustment is required, 2. Disconnect return spring from clutch lever. 3. Adjust jam nuts/or ball joint until bottom rear edge of clutch pedal is 3.75” -+ 12" from top of floor plate diamond pastern, when an 4 Ib. force is applied to pedal.
MAINTENANCE 2. Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in trans axle bracket. 3. Reinstall clevis pin and tighten jam nut after adjustment has been attained. ADJUSTING DIFFERENTIAL LOCK CABLE {Fig. 61) Check adjustment every 200 hours. 1. Move differential lock lever to Off position. 2. Loosen jam noels securing differential lock cable to bracket on transient. 0387 £.028” Figure 81 Differential lock cable Transsexual bracket Spring e 3. Adjust jam nuts fo obtain .035" + .
FUSES (Fig. 84} There are 3 fuses in the machine’s electrical system. They are located under right side of dash panel. FUSES OPEN e LIGHTS & HORN 10A DAG 7.54 IGNITION 758 Figure 64 1. Fuse block JUMP STARTING PROCEDURE Ah warning Jump starting can be dangerous. To avoid personal in fury or damage to electrical components in vehicle, ch serve the following warnings: ® Never jump start with a collage sources grater than 15 volts D.C. This will damage the electrical system.
MAINTENANCE 4, If corrosion occurs at terminals,remove battery cover, disconnect cables, negative cable first and scrape clamps and terminals separately. Reconnect cables, positive cable first and coat terminals with petroleum jelly. 5. Check the electrolyte level every 50 operating hours or, if machine is in storage, every 30 days. 6. Maintain cell level with distilled or decriminalized water. Do not file cells above the bottom of the file ring inside each cell.
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Check Battery Fluid Level Check Battery Cable Connections Check Dust Cup & Baffle Very Every Every Eve 800hrs 1ODrr\yrs 200hrs | 400hrs Lubricate All Grease Fittings inspect Condition and Wear of Tires 4 Change Engine Oil and Filter inspect Cooling System Hoses Check Governor Ol Level Check Front Differential Oll Level {(4WD) + Check Cable Adjustments 1 Check Governor Adjustments Service Air F
ELECTRICAL SCHEMATIC SR RIB FUSIBLE LINK STARTER Sweeten O g ALTERNATOR g s 5ES BLACK Blag K ot .
IDENTIFICATION AND ORDERING MODEL AND SERIAL NUMBERS The WORKMAN® has two identification numbers: a model number and a serial number. These numbers are stamped into a plate located on the right frame member under dash. In any correspondence conceding the unit, supply the model and serial numbers to ensure correct information and replacement parts are obtained.
The Toto Promise A One Year Limited Warranty The Tore Company promises to repair your Workman vehicle if defective in materials or workmanship. The following time periods from the date of purchase apply (special warranty terms, on certain components, may be offered through The Toto Company by the component manufacturers): Commercial Products .. 1 Year The cost of parts, favor and transportation are included.