MODEL NO. 07205 — 40334 & Up FORM NO. 3316687 OPERATOR’S MANUAL 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. Pay particular attention to the SAFETY INSTRUCTIONS highlighted by this symbol— The safety alert symbol means CAUTION, WARNING or DANGER personal safety instruction.
FOREWORD The TOR WORKMAN® 3300-D 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.
TABLE OF CONTENTS CONTROLS OPERATING INSTRUCTIONS . SAFETY INSTRUCTIONS 4-6 Using Bed Safety Support 30 SAFETY AND INSTRUCTION DECALS 68 Jacking Vehicle 30 SPECIFICATIONS -9 General Air Cleaner Maintenance Practices .. 31 LOOSE PARTS CHART . 10 Servicing Dust Cup And Baffle 31 SET-UP INSTRUCTIONS . 1-13 Servicing Air Cleaner Filter .. 31 Install Rear Fenders . Inspecting Filter Element .82 Install Wheels Changing Engine Oil And Filter 32 Install Steering Wheel .. Fuel System oL 32 Install Front Fenders .
A SAFETY INSTRUCTIONS The WORKMAN® 3300-D 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 15. 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 carny passengers in box or on attachments. Remember your passenger may not be expecting you to brake or turn and may not be ready. 16. Never overload your vehicle.
A SAFETY INSTRUCTIONS MAINTENANCE 22. Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition to prevent accidental starting of the engine, 23. Never work under a raised bed without placing bed safety support on fully extended cylinder rod, 24, Make sure all hydraulic line connectors are tight, and all hydraulic hoses and lines are in good condition before applying pressure to the system.
A SAFETY AND INSTRUCTION DECALS WARNING HOT Rl S ON LEFT FRAME RAIL {Part No. 666840} OPTIONAL, FUSE BLOCK OPTIONAL FUSE BLOCK STANDARD Fuse B Lock PEN LIGHTS. 10 AN DASH 73 AMP ignition 7.5 80P UNDER DASH NEXT TO FUSE BLOCK {Part No. 87-6670) — — FAILURE 70 COMPLY WITH THE FALLOWING SAFETY REQUIREMENTS MAY RESULT (i PERSONAL INJURY R DEATH BEAD AND UNDERSTAND SUPERSATURATE MANUAL BEFORE OPERATING THIS MARINE. VEHICLE i3 FOR OFF ROAD USE ONLY, ASTER MUY BIN CAPACITORS EN UNA .
A SAFETY AND INSTRUCTION DECALS o WARNING = TIP OVER CAN OCCUR IF TRUCK 1§ IMPROPERLY OPERATED. INJURY OR DEATH COULD RESULT IN CASE OF TIPPER i DON'T JUMP . OPERATOR HOLD TIGHT AND BRACE > PASSENGER HOLD HIP RESTRAINT AND HAND HOLD, BRACE FEET 87 . 5980 LEAN AWAY ON TOPS {Part No. 87--5980) PARKING BRAKE @ ON CONSOLE {Part No. 87 -6020) TRANSMISSION HITCH RATING: FLUID MAXIMUM TONGUE USE DETHRONE 1l WEIGHT 200 LBS. AUTOMATIC MAXIMUM TRANSMISSION TRAILER WEIGHT; FLUID OR 1500 LBS.
SPECIFICATIONS Type: 4 wheal step through, out front operator style, two person vehicle. Certified to meet ANS! Specifications B56.8— 1983, Engine: Mitsubishi three cylinder, liquid cooled, counterbalanced, diesel engine. Rated at 21 hp, governed to a maximum speed of 3650 rpm by a mechanical governor. 48 cu. in. {808 cc) displacement. Forced lubrication by gear pump. 12 volt semicircle starter. 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 QTy. USE Fenders—Rear Cap screw x 3/4" Ig. Cap screw 1" ig. Flat washer .281” 1.D. Lockout Truss head Screw Lockout oo SN ®ON Mount rear fenders Wheel Nut Wheel—Front Wheel Nut Wheel—Hear o Mauritian wheels.
SET-UP INSTRUCTIONS INSTALL REAR FENDERS (fig. 1-2) 1. Loosen the lockouts and cap screws securing tail fight 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 racket 3. Tail light mounting bracket 3. Secure rear of each tail light plate to rear of frame brackets with a x 3/4” Ig. cap screw, 2817 |.D. flat washer and nut, as shown in figure 1. 4.
SET—UP INSTRUCTIONS Figure 4 1. Steering Sheet 4. Washer 2. d Jam Nut 5. Foam Seal 3. Cap INSTALL FRONT FENDERS (Fig. 5) 1. Mount fender to sate side of skirt with (7} 1024 Philips screws, flat washers and lockouts. Figure 5 1. Fender INSTALL SEAT FRAME (Fig. 6) 1. Mount a seat frame bracket to gate end of seat frame with (2) x 3/4” carriage bolts and flange lockouts, 2. Position seat frame on vehicle, aligning mounting holes in frame with holes in vehicle, 3.
SET-UP INSTRUCTIONS 3. Slide manual tube into (2) R—clamps. Figure 8 1. Cushion seat back 2. Seat back bracket 3. Setback 4. Manual tube 5. 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 removed Figure 8 1. Bed support 2. Storage stud INSTALL TOPS (Fig. 10) 1.
SET upP INSTRUCTIONS Figure 11 1. Battery cover 2. Knob 3. Battery base 3. Remove 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 a rate amperes for 410 8 hours, 5. When battery is charged, disconnect charger from electrical outlet and battery posts. 6. Remove filler caps. Slowly add electrolyte to each cell until level is up to fill ring. Install filler 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 place the safety support on extended lift cylinder to hold box up. CHECK CRANKCASE OIL. (Fig. 13-14) The engine is shipped with approximately 3.
BEFORE OPERATING 1. Clean area around fuel tank cap. 2. Remove fuel tank cap. 3. Fill tank to about one inch below top of tank, {bottom of filler neck) with diesel fuel. DO NOT OVERFILL. Then install cap. 4. Wipe up any fuel that may have spilled to prevents fire hazard. A DANGER Because diesel fuel is flammable, caution must be used when storing or handling it. Do notifier fuel tank while engine is running, hot, or when machine is in an enclosed area.
BEFORE OPERATING CHECK BRAKE FLUID (Fig. 18) The brake fluid reservoir is shipped from the factory filled with “DOT 3” 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 line on reservoir. 3. diffused level is tow, clean area around cap, remove reservoir cap and fill to proper level. DO NOT OVERFILL. Figure 18 1. Brake fluid reservoir 2. Full line CHECK TORQUE OF WHEEL NUTS A\ WARNING Failure
CONTROLS Accelerator Pedal (Fig. 19) ~ The accelerator pedal gives the operator the ability to vary engine and ground 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. Figure 19 1. Accelerator pedal 2. Clutch pedal 3. Brake pedal Clutch Pedal (Fig.
CONTROLS Parking Brake {Fig. 20} —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. i 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 Glow Plug Switch and Indicator (Fig. 21) — Use to preheat engine cylinders prior to cold engine starting procedures — cylinders are preheated automatically during warm engine start operation. For cold starting, push switch lever upward and hold while watching indicator. Indicator will glow orange when the glow plugs are activated. Length of time necessary to preheat cylinders should be determined by atmospheric temperature; refer to Starting /Stopping Engine. ignition Switch (Fig.
OPERATING INSTRUCTIONS PREDESTINING CHECKS Sate operation begins before taking the vehicle out for day's work. You should check these items sate 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 Figure 24 1. Fuel injection pump bleeder 5. Turn key in ignition switch to the ON position. Electric fuel pup will begin operation, thereby forcing air out around air bleed screw on fuel injection pump. Leave key in ON position until solid stream of fuel flows out around the screw. Tighten screw and tum key to OFF, Note: Normally, engine should start after above bleeding procedures are followed.
OPERATING INSTRUCTIONS To verify PTO interlock switch operation: 1. Sit on operator’s seat and engage parking brake. Move shift lever to NEUTRAL position. 2. Engage PTO. 3. Depress clutch pedal and rotate key clockwise o start position. 4. Engine cranks or starts, there is a malfunction in the interlock system that must be repaired before operating vehicle. OPERATING CHARACTERISTICS The vehicle is designed with safety in mind. It has four wheels for added stability.
OPERATING INSTRUCTIONS BRAKING IN CASE OF It is good practice to slow down before you get near an TIP OVER obstacle. This gives you extra time to stop or tum away. Hitting an obstacle can damage the vehicle and its contents. More important, it can injure you and your passenger. Gross vehicle weight has a major impact on your ability to stop candor turn, Heavier loads and heavier attachments make a vehicle harder to stop or turn. The heavier the load, the finger it takes to stop.
OPERATING INSTRUCTIONS TIP OVER CAN OCCUR IF TRUCK IS IMPROPERLY OPERATED. INJURY OR DEATH COULD RESULT HILLS WARNING Tipping or roofing the vehicle on a hill will cause serious personal injury. + If 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. # Never drive across a steep hill, always drive straight up or down.
OPERATING INSTRUCTIONS The vehicle has several combinations of boxes, platforms, and attachments available. These can be used in various combinations that allow for maximum capacity and versatility. The full sized box is 55 inches wide by 65 inches long and can hold up o 2000 pounds of evenly distributed cargo. Loads vary in how they are distributed. Sand spreads out evenly and quite low. Other terns, such as bricks, fertilizer or landscape timbers, stack higher in the box.
OPERATING INSTRUCTIONS 1 Figure 25 1. Eye holes in frame SR Figure 26 1. Axe tube 2. Hitch plate TRAILER TOWING The Workman 3300—D® is capable of pulling trailers and attachments of greater weight than the vehicle itself. Several types of tow hitches are available for the Workman, depending on your application. Contact your Authorized TOR Distributor for details.
QUICK REFERENCE CHART 181 WORKMAN 3300-D QUICK REFERENCE AID e CHECK/SERVICE 1, ENGINE OIL LEVEL 9. AIR CLEANER 2. ENGINE OIL DRAIN 10. FUEL PUMP &0 3, TRANSCENDENTALISM 11, BATTERY —— Ol LEVEL (DIP STICK} 12. TIRE PRESSURE MAXIMUM 20 PSI FRONT, BELTS (GOVERNOR, WATER 32951 DREAR 23" TIRE) 18 PSI REAR (24" TIRE) 1 12 PUMP, HYDRAULIC PUMP) 13. FUSES (LIGHTS 10 AMP, IGNITION 75 AMP, X 5. COOLANT LEVEL FILL DASH ACCESSORIES 7.5 AMP} 6.
LUBRICATION Figure 28 Figure 0 IMPORTANT Heavy Duty Operation If vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently.
MAINTENANCE A\ caution Only qualified and authorized personnel shall be permitted to maintain, repair, adjust or inspect the vehicle. Avoid 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 cleaning 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. 1 Figure 33 1. Front jacking point Figure 34 1, Rear jacking points GENERAL AIR CLEANER MAINTENANCE PRACTICES (Fig. 35) Inspect air cleaner and hoses periodically to maintain maximum 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 a 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 to 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 dirt are removed; refer to Inspecting Fitter Element.
MAINTENANCE 3. Clean area around filter canister mounting surface. Figure 39 1. Drain plug 2, Filter canister 4. Remove filter canister and clean mounting surface. 5. Lubricate gasket on filter canister with clean engine ail. 8. Install filter canister by hand until gasket contacts mounting surface, then rotate an additional 1/2 furn, Fuel Pump Filter Remove and replace the filter after every 400 hours operation. 1.
MAINTENANCE 3. Slowly depress accelerator pedal to full FAST position. 4. Turnkey inky switch to START position and watch fuel flow around connector. Turn key to OFF position when solid flow is observed. 5. Tighten pipe connector securely. 6. Repeat steps and 3 nozzles. REMOVING DEBRIS FROM ENGINE COOLING SYSTEM (Fig. 42) Remove debris from engine area and radiator daily, clean more frequently in dirty conditions, 1. Remove radiator cover (if so equipped). 2. Turn engine off.
MAINTENANCE 2, To adjust belt tension: A, Loosen alternator mounting bolts. B. Using a bar, rotate alternator until proper belt tension is attained, then tighten mounting bolts, Figure 43 1. Alternator bat 2. Alternator brace Fan belt (Fig. 45) 1. Check tension by depressing belt at mid span of fan and drive shaft pulleys with 22 Ibs. of force. A new belt should deflect used belt should deflect in. If deflection is incorrect, proceed to next step. If correct, continue operation. 2.
MAINTENANCE CHANGING TRANS AXLE / HYDRAULIC FLUID (Fig. 47) Change Transient hydraulic fluid, filter and clean strainer every 600 hours. 1. Position the vehicle on a level surface, stop engine, engage the parking brake and remove key from ignition switch. 2. Remove drain plug from side of reservoir and let hydraulic fluid flow into drain pan. Reinstall and tighten plug when hydraulic fluid stops draining. 3. Fill reservoir with approximately 7.5 gt. of Dethrone |t ATF. Refer to Checking Hydraulic Fluid. 4.
MAINTENANCE ADJUSTING BRAKE PEDAL (Fig. 50~51) 1. Loosen jam nut on master cylinder rod. 2. Rotate rod until gap between brake pedal and up stop is 5 Figure 50 1. Master cylinder rod 2. Jam nut 3. Tighten jam nut after adjustment has been attained. Figure 51 1, Brake pedal 2. Church pedal 3. Clutch pedal up stop ADJUSTING CLUTCH PEDAL (Fig. 51-52) 1. Loosen jam nuts securing clutch cable to bracket on bell housing. Note: Ball joint may be removed and rotated if additional adjustment is required.
MAINE Figure 54 Parking brake lever Knob Set screw ADJUSTING SHIFT CABLES (Fig. 55) 1. Move shift lever to Neutral position. 2. Remove clevis pins securing shift cables to transient shift arms. Figure 55 1. Shift arm {tst ~ Rev.) 2. Shift am (2nd 3rd) 3. Shirt 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 trans axle lever free play taken up in same direction). 4.
MAINTENANCE FRONT WHEEL TOE~IN (Fig. 57-58) Afire every 600 operating hours or annually, check front wheel toe~in, 1. Measure distance (at axis height} at front and rear of steering tires. Front measurement must be equal to the rear measurement £1/81in.. * Distance Figure 57 2. To adjust, loosen jam nuts at both ends of tie rod. Figure 58 1. Tie rod 3. Rotate tie rod to move front of tire inward or outward, 4. Tighten tie rod jam nuts when adjustment is correct.
MAINTENANCE Figure 60 1. Positive cable 3. Connect one end of the other jumper cable 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 jumper cable to the negative post of the discharged battery. Connect it to the engine. Do not connect the jumper cable fo the fuel system. 4. Start the engine in the vehicle providing the jump start, Let it rut a few minutes, then start your engine. 6.
SERVICE INTERVAL CHART Date Hour Meter Reading Service Interval Daily 10 50 100 150 200 250 Check interlock System Daily Check Engine Oil Level Daily Check Trans axle Oil Level Daily Check Radiator & Coolant Daily {More often when conditions are dirty) Check Brake Fluid Level Daily Check Tire Pressure Daily Replace Hydraulic Oil Filter (initial) 10 Check Belt Tensions (initial) 10 Check Cable Adjustments (initial) 10 Tighten Wheel Nuts (initial) 2510 Service Air Cleaner (Dust Cup & Ba file) | 50 (More often
HYDRAULIC SCHEMATICS {Base Vehicle) oo vase BB | = Ba ens s B e Fret ATTEND e O] mam Tl e {Vehicle w/ Optional Remote Hydraulic Kit) e e SRR casework [2.
OPTIONAL EQUIPMENT OPERATION REMOTE HYDRAULIC CONTROL KIT MODEL 07415 The remote hydraulic control kit supplies “live” 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 &roar 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 fluid flows from attachment to vehicle. if hydraulic fluid in attachment is not the same or equivalent to vehicle's, component damage to trans axle or hydraulic system may resit.
OPTIONAL EQUIPMENT OPERATION ® Move stop knob upward until it contacts control fever. Tighten knob. « Check to assure proper RPM is attained. To disengage. move control fever to OFF position. POWER TAKE OFF (PTO) Model 07419 The PTO takes 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 RPM recommendations. ol Figure 62 .
OPTIONAL EQUIPMENT OPERATION A\ DANGER An uncovered rotating spline can catch clothing and result in serious injury or death. e When an attachment is not connected to the PTO shaft, disengage drive to the PTO by pulling back on PTO lever. & The PTO includes a shield. This shield must remain on the vehicle and be used. * Always disengage the PTO and shut off engine before attaching any attachment 1o 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 Torah Company promises fo repair your model 07208 Workman 3300~ D vehicle if defective in materials or workmanship. The following time periods from the date of purchase apply {special warranty germs, 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. recommended: 1.