FORM NO. 3318370 Hev. A OPERATOR'S () MODEL NO. 07200 — 40001 & Up MANUAL TOR, Work Mane 3200 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 is essential that you or any other operator of the machine read and understand the contents of this manual before the engine is ever started.
FOREWORD The TOR WORKMAN® 3200 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. Iris not appropriate for such use.
TABLE OF CONTENTS SAFETY INSTRUCTIONS . SAFETY AND INSTRUCTION DECALS . SPECIFICATIONS . FOREPARTS CHART SET-UP INSTRUCTIONS Install Rear Fenders install Wheels install Steering Wheel .. Install Front Fenders . Install Seat Frame install Seat Back Cushions, Manual Tube and Bed Support Install TOPS Activate and Charge Baffler 13 BEFORE OPERATING Check Crankcase Oil Fill Fuel Tank Check Cooling System .. Check Trans axle / Hydraulic Fluid . . .. Check Brake Fluid 48 Check Torque Of Whee! Nuts Or Bolts ..
A SAFETY INSTRUCTIONS The WORKMAN 3200 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.
A SAFETY INSTRUCTIONS 18. Operator and passenger should remain seated whenever the vehicle is in motion. Operator should keep both hands on steering wheel, whenever possible and passenger should use hand holds provided. Keep arms and legs within the vehicle body at all times. Never carry passengers in box or on attachments. Remember your passenger ray not be expecting you to brake or turn and may not be ready. 16. Never overload your vehicle.
A SAFETY INSTRUCTIONS 24. Make sure all hydraulic line connectors are tight, and alf hydraulic hoses and fines are in good condition before applying pressure 1o the system. 25. Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage.
A SAFETY AND INSTRUCTION DECALS ENDANGER HOT FAILURE TO COMPLY WITCH THE FOLLOWING SAFETY REQUIREMENTS P TINS MAY RESULT I PERSONAL injury DR DEA READ AND UNDERSTAND OPERATORS Manual BEFORE OPERATING THIS MACHINE. VEHICLE IS FOR OFF ROAD USE ONLY ON LEFT FRAME RAIL L0S OPERATIVES DEB EN ASTER MUY BIN CAPACITORS £N UNA {Part No. 66-6840) OPERATION SUPEREROGATORY HUTS BE STILLED AND +T0 AVOID TIP OVER: TRAINED ISP WHEATSTONE, -TREMENDOUS CAUTION QM BILLS.
A SAFETY AND INSTRUCTION DECALS WARNING . s TRANSMISSION HITCH RATING: FLUID | PARKING BRAKE MAXIMUM TONGUE || USE DETHRONE 1l WEIGHT 200 LBS. AUTOMATIC ot MAXIMUM TRANSMISSION TRAILER WEIGHT; FLUID OR ON CONSOLE 1500 LBS. EQUIVALENT (Part No. 87 ~6020) ON AXLE TUBE TIP OVER CAN (Part No. 87-6060) OCCUR IF TRUCK IS ROLL-OVER JURY OR DEATH SPEED RANGE 2 PROTECTIVE COULD RESULT : STRUCTURE e ) O MAINTAIN TIP OVER 9 OPERATOR — oW PROTECTION AND TOR TOPS ON CONSOLE CERTIFICATION: (Part No.
SPECIFICATIONS Type: 4 wheel step through, out front aerator style, two person vehicle. Verified 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. {657 cc) displacement. Forced lubrication by gear pump. 40 amp alternator with I/C regulator. 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 pairs, total set-up cannot be completed. Some parts may have already been assembled at factory. DESCRIPTION Fenders—Rear Cap screw % 3/4” Ig. Cap screw 17 Ig.
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 fail fight plates rearward and tighten cap screws and lockouts. Figure 1 1. Tail light plate 2. Frame bracket 3. Tall Hg ht mounting bracket 3. Secure rear of each tail light plate to rear of frame brackets with a x 3/4” |g. cap screw, .281" |.D, flat washer and nut, as shown in figure 1. 4.
SET—UP INSTRUCTIONS Figure 4 1. Steering Whee! 4. Washer 2. Jam Nut 8. Foam Seal 3. Cap INSTALL FRONT FENDERS (Fig. 5) 1. Mount a fender to each side of skirt with (7) 10-24 Philips 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) 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. Sade manual tube into (2) R—clamps. Figure 8 1. Cushion seat back 2. Setback bracket 3. Setback 4, Manual tube 8§, R-clamp 4. Mount cushion with seat back brackets and manual tube R—clamps to left seat back with {4} x 5/8” Ig. carriage bolts and flange lockouts. 5. Slide bed support onto storage stud (Fig. 9). Shown with seat back remove Figure 8 1.
Figure 11 Battery cover Knob Hatchery has W 3. Her move filler caps from battery and slowly fill each cell until electrolyte is just above the plates. 4. Replace filler caps and connect amp battery charger to the battery posts. Charge the battery at rate amperes for 4 1o B hours. 5. When battery is charged, disconnect charger from electrical cutlet and battery posts, 8. Remove filler caps. Slowly add electrolyte to sate cell until level is up to fill ring. Install filer caps.
BEFORE OPERATING A\ 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 safely support to the down position before working under raised bed, CHECK CRANKCASE OIL Fig.
BEFORE OPERATING 2. Check coolant level. Coolant should be up fo COLD line on reserve tank, when engine is cold. 2. Remove fuel tank cap. 3. Fill tank to about one inch below fop of tank, (bottom of filler neck), DO NGT OVERFILL. Then install cap. 4. Wipe up any fuel that may have spilled o prevents fire hazard. Ab pannier Because gasoline is flammable, caution must be used when storing or handling it Do not fill fuel tank wheels engine is running, hot or when machine is In an enclosed area.
BEFORE OPERATING CHECK BRAKE FLUID (Fig. 1} The brake fluid reservoir is shipped from the factory filled with “DOT 8" brake fluid, Check level before engine is first started and every 8 hours or daily, thereafter. 1. Park machine on a level surface. 2. Fluid level should be up to FULL fine on reservoir. 3. {fluid level is low, clean area around cap, remove reservoir cap and fill to proper level. DO NOT OVERFILL. Figure 17 1. Brake fiddled reservoir 2.
CONTROLS Accelerator Pedal (Fig. 18) — The accelerator pedal gives the operator the ability to vary engine and grand speed of the vehicle, when the transmission is in gear. Depressing the pedal increases engine RPM and ground speed. Releasing pedal will decrease engine RPM and ground speed of the machine. Flower 18 Accelerator pedal Chute pedal Brake pedal $p Chute Pedal (Fig. 18) —The clutch pedal must be fully depressed io disengage clutch when starting engine or shifting transmission gears.
CONTROLS Parking Brake (Fig. 19) ~Whenever the engine is shut off, the parking brake must be engaged to prevent accidental movement of the vehicle, To engage the parking brake, pull back on lever. To disengage, push lever forward. Make sure parking brake is released before moving vehicle. if vehicle is parked on a steep grade, make sure parking brake is applied. Also, shift the Transmission into 1st gear on a uphill grade or reverse on a down hill grade, Place chocks at the down hill side of wheels.
CONTROLS 2. Turn ignition key to “ON”, but do not start engine. The charge indicator and oil pressure lights should glow. If any light does not function, either a boob is burned out or there is a malfunction in the system which must be repaired. Note: Two functions of warming light cluster are not used: glow plug and high water temperature. Hour Meter {Fig. 21) ~ Indicates the foal hoers of machine operator. The hour meter starts fo function whenever the key switch is rotated to “ON” position.
OPERATING INSTRUCTIONS PER-STARTING CHECKS Safe operation begins before taking the vehicle out for workaday. 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 or PTO (if so equipped) is disengaged. 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 yau 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 TIP OVER DON'T JUMP OPERATOR HOLD TIGHT AND BRACE FEET r.— PASSENGER HOLD HIP RESTRAINT AND HAND HOLD, BRACE FEET = LEAN AWAY 24 HILLS WARNING Tipping or rolling the vehicle ona hill will cause serious personal injury. # | engine stalls or you lose headway on a Hill, never attempt to turn vehicle around. *» Always back straight down a hill in reverse gear. * Never back down in neutral or with the clutch depressed, using only 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 handing. To avoid loss of control resulting in personal injury, folio these guidelines. Do not carry loads which exceed the load limits described on the vehicle weight label. A\ warning The bed will lower whenever the dump fever is pushed down, even when the engine is off. Turning off the engine will NOT prevent the hox from lowering.
OPERATING INSTRUCTIONS WARNING Tipping or rolling the vehicles ona hill will cause serious injury. @ The extra traction available with the differential lock nan be enough to get you into dangerous insinuation such as climbing slopes that are too spies o fum around. Be extra careful when operating with the differential dock on, especially on seaport slopes.
SERVICE INTERVAL CHART CHECK / SERVICE 8. RADIATOR SCREEN CLEAR OUT BOOR T, ENGINE O LEVEL 9, AR CLEANER 2 ENGINE OIL DRAIN 18, FUEL FILTER 3. THANKLESS/ HYDRAULIC 13, BATTERY OiL LEVEL (DIP §TOOK) 12, TIRE PRESSURE MAXIMUM 20P81 FRONT, 4, BELTS (GOVERNOR‘ WATER 32 P8I REAR (23” TIRE] 18 PSI REAR (247 TIRE) PUMP, HYDRAULIC PUMP) 13, FUSES {LIGHTS 10 AW, IGNITION 7.5 AMP, 8, COOLANT LEVEL FILL DASH ACCESSORIES 1.5 AMP) 6. FUEL {UNLEADED GAS ONLY) 1.
Figure 28 Figure 26 IMPORTANT Heavy Duty Operation it vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently, Desert operation Cold climate operation (below 32°F) Trailer or 5th wheel towing Fragment operation on dusky roads Frequent operation under maximum vehicle gross weight Construction work After extended operation in mud, sand, water or similar direly conditions, have your brakes inspected and ¢leaned and drive axle joints greased as soon as possible.
MAINTENANCE A\ caution Only qualified and authorized personnel shalt be permitted to maintain, repair, adjust or inspect the vehicle. Av old fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check level or leakage of fuel, battery electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for cloning parts. Many of the subjects covered in this maintenance section require raising and lowering the bed.
MAINTENANCE 4. When jacking up front of vehicle, always place a 2x4 block {or similar material) between jack and vehicle frame. Figure 31 1. Front jacking point Figure 32 4. Rear jacking points GENERAL AIR CLEANER MAINTENANCE PRACTICES (Fig. 33) Inspect air cleaner and hoses periodically to maintain maximums engine protection and to ensure maximum service life. 1. Check air cleaner body for dents and other damage which could possibly cause an air leak. Replace & damaged air cleaner body. 2.
MAINTENANCE Compressed Air Method IMPORTANT: Do not remove plastic fin assembly because back-blowing with compressed air removes dust from beneath fins. A, Blow compressed air from inside o the outside of dry filter element. Do not exceed 100 psi to prevent damage to the element. (Wear eye protection) B. Keep air hose nozzle at least one inch from pleated paper, and move nozzle up and down while rotating the filter element. Inspect element when dust and dit are removed; refer to Inspecting Filter Element.
MAINTENANCE 1. Remove radiator cover (if so equipped). 2. Tum engine off, Clean engine area thoroughly of all debris. 3. Remove screen cover from front of radiator, 4. Open radiator screen clean out door at lower left side of radiator and remove all debris from bottom of radiator inlet area. 5. Clean radiator thoroughly with water or compressed air. Figure 37 1. Radiator screen cover 2. Clean oul dewy CHANGING ENGINE COOLANT (rig. 38) 1. Park machine on a level surface. 2.
MAINTENANCE 2. o adjust belt tension: A, Loosen (2) alternator mounting boils. 8. Using a bar, rotate alternator until proper belt tension is attained, then frighten mounting bolts. Fan belt {Fig. 40} 1. Check tension by depressing belt al mid span of fan and drive shaft pulleys with 22 Ibs, of force. Anew helot should defect 4858 in, A used belt should deflect in. if deflection is incorrect, proceed to next step. If correct, continue operation. 2.
MAINTENANCE 4\ WARNING Engine must be running so final adjustment of the governor can be performed. To guard against possible personal injury, engage parking brake and keep hands, feet, face and other pairs of the body away from fan or other moving parts. 4. Start engine and allow it to warm up to normal operating temperature. With throttle plate held fully closed, adjust low idle stop on carburetor to obtain 1200 £ 100 rpr. &, Advance governor input lever fo increase engine speed to 3600 + 50 rpm.
MAINTENANCE b ki Figure 45 1. Hydraulic Filter 2. Gash st 4. Assure filer mounting area is clean. Screw filter on until gasket contacts mounting plate. Then tighten filter one-half turn, . Start engine and fet run for about two minuses to purge air from the system, Stop the engine and check the hydraulic oil level and for leaks, CLEANING HYDRAULIC STRAINER (Fig. 46) 1. Position the vehicle on level surface, stop engine, engage the parking brake and remove key from ignition switch. 2. Remove drain plug (Fig.
MAINTENANCE 3. Tighten jam nut after adjustment has been attained. A ok i Figure 48 Master cylinder rod dean Figure 49 1. Rake pedal 2. Civet pedal 3. Clutch pedal unstop ADJUSTING CLUTCH PEDAL (Fig. 49-50) 1. loosen jam noels securing clutch cable to bracket on bell housing. Note: Ball joint may be removed and rotated, if additional adjustment is required. 2. Disconnect return spring from clutch lever. 3. Adjust jam nuts/or ball joint unit bottom rear edge of clutch pedal is 3.75" + .
MAINTENANCE g B Figure 52 1. Parking blare lever 2 Knob 3. Setscrew ADJUSTING SHIFT CABLES (Fig. 53) 1. Move shift lever to Neutral position. 2. Remove clevis pins securing shift cables to trans axle shift arms. Figure 53 1. Shift arm (1st ~ Rev) 2. Shift arm (2nd — 3re) 3. Shift arm (High~low) 3. Loosen clevis jam nuts and adjust each clevis so cable free play is equal forward and backward relative to hole in trans axle shift arm (With transient lever free play lake up in same direction). 4.
MAINTENANCE FRONT WHEEL TOE ~IN (Fig. 5556} After every 600 operating hours or annually, check front wheel toe—in, 1. Measure center—to—center distance f(at axle height at front and rear of sleeting tires. Front measurement must be equal o the rear measurement g in.. Intercontinental Distance Figure 38 2. o adjust, loosen jam nuts at both ends of tie rod. Figure 56 1. Tie rod 3. Rotate tie rod 1o move front of tire inward or outward. 4, Tighten tie rod jam nuts when adjustment is correct.
MAINTENANCE % Figure 58 1. Positive cable 8. Connect one end of the other jumper cabin to the negative terminal of the battery in the other vehicle. The negative terminal has “NEG” on the battery cover. Do not connect the other end of the the j Jumper cable to the negative post of the discharged battery. Connect it to the engine. Do not connect the jumper cable o the fuel system, 4. Start the engine in the vehicle providing the jump start. Let it run a few minutes, then start your engine. 5.
SERVICE INTERVAL CHART Date Hour Meter Reading Service Interval Daily 100 | 150 200 250 Check Interlock System Daily Check Engine Oil Level Daily Check Trans axle Oif Level Deity Check Radiator & Coolant Daily (More often when conditions are dirty) Check Brake Fluid Level Daily Check Tire Pressure Deity Replace Hydraulic Oil Filter (initial) 10 Check Belt Tensions (initial) 10 Tighten Wheel Nuts (initial} 2 &10 Service Air Cleaner (Dust Cup & Baffle) 50 {More often when conditions are dirty) Check Battery W
OPTIONAL EQUIPMENT OPERATION REMOTE HYDRAULIC CONTROL KIT MODEL 07415 The remote hydraulic control kit supplies “rive” hydraulic power from the vehicle pump whenever the engine is running. The power can be used through the the quick couplets at the rear of the vehicle (See Hydraulic Schematic). CONTROL LEVER POSITIONS REMOTE HYDRAULICS on' @ FLOAT 809Z-Z8 Off Position: This is the normal position for the control valve when it is not being used.
OPTIONAL EQUIPMENT OPERATION When the remote hydraulic system quick couplets are connected to a remote attachment, hydraulic food flows from attachment to vehicle. if hydraulic fluid in attachment is not the same or equivalent to vehicle’s, component damage to frangible or hydraulic system may result.
OPTIONAL EQUIPMENT OPERATION POWER TAKE OFF (PTO) Model 07419 The PTO rakes power from the engine, through the trans axle and supplies it to a standard 540 RPM splines shaft at the rear of the vehicle. This power can be used for both mobile and stationary attachments. Refer to attachment Operator's Manual for APM recommendations. Figure 80 1 PTD ravel Fighter 81 1. Power Take Off (PTO) Mobile PTO Operation To operate (vehicle must not be moving when PTC is first engaged): 1. Apply parking brake. 2.
OPTIONAL EQUIPMENT OPERATION A\ DANGER An uncovered rotating spline can catch clothing and result in serious injury or death, * When an attachment is not connected to the PTQ shaft, disengage drive to the PTO by pooling back on PTO lever. # The PTO includes a shield. This shield must remain on the vehicle and be used. e Always disengage the PTO and shut off engine before attaching any attachment to the PTO shaft, 1/3 AREA COVER KIT PART NO. 875380 Use this kit when operating with the 1/3 area open.
The Toto Promise A One Year Limited Warranty The Toto Company promises to repair your model 07200 Workman 3200 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 The cost of parts, labor and transportation are included.