FORM NO. 3317962 REV. B MODEL NO. 07205 —~ 60001 & Up ’ MODEL NO. 07206 — 60001 & Up s MODEL NO. 07215 — 60001 & Up 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 consents of this manual before the engine is 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 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.
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 is used or operated on any California forest, brush or grass covered fans, a properly operating spark arrested must be attached to the muffler.
A SAFETY INSTRUCTIONS The WORKMAN® was designed and tested 1o 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 17. When starting the engine: A. Sit on operator's seat and engage parking brake. B. Disengage any attachments and return hand throttle lever to OFF position (if so equipped). C. Move shift lever to NEUTRAL and depress clutch pedal. D. Keep foot off accelerator pedal. E. Tum ignition key to ON, hold glow plug switch ON. (Maximum 30 seconds) F Turn ignition key to START, 18. Using the machine demands attention.
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. Pace the remote hydraulics lever in the float position. f box must be in raised position, secure with safety support. 27. To make sure entire machine is in good condition, keep all nuts, bolts and screws properly tightened. 28.
A SAFETY AND INSTRUCTION DECALS B DIFFERENTIAL LOCK f——— @ — OFF a0 DANGER FAILURE Y0 COMPLY WITH THE FOLLOWING SAFETY REQUIREMENTS ON CONSOLE (Part No. B-6000) optional | optional | standard FUSE BLOCK | FUSE BLOCK FUSE BLOCK. OPEN LIGHTS AMP DASH 75 AMP UNDER DASH NEXT TO FUSE BLOCK (Part No. 87-6670) WAY RESULT 1§ PERSONAL INJURY OR DEA READ AND UNDERSTAND OPERATORS HAMILL BEFORE OPERATING THIS MACHINE. VEHICLE 1S FOR OFF ROAD USE FLY.
A SAFETY AND INSTRUCTION DECALS HAND HOLD, BRACE | FEET ) 5 LEAN AWAY 875980 ON bops (Part No. 87-5980) {Part No. 87 -6010) L LT R@Ye)] ROTATING MEMBERS ON FAN SUPPORT (Part No. 80—8040) TRANSMISSION WARNING PARKING BRAKE HITCH RATING: FLUID ) MAXIMUM TONGUE || USE DETHRONE Ii ® WEIGHT 200 LBS. AUTOMATIC w1 m020 MAXIMUM TRANSMISSION TRAILER WEIGHT; FLUID OR 1500 LBS. EQUIVALENT ON AXLE TUBE TIP OVER CAN (Part No. 87-6060) R OPERATED.
SPECIFICATIONS Type: 4 wheel step through, out front operator style, wo pennon vehicle, Certified to meet ANSI Specifications Engine: Mitsubishithreecylinder, -liquid cooled; counterbalanced, diesel engine. Rated at 23 hp, governed to a maximum speed of 3650 rpm by a mechanical governor. 58 cu. in, (952 cc) displacement. Forced lubrication by gear pump. 12 volt electric 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 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" 1.D. 12 Lockout 12 Truss head Screw 6 Lockout 6 Wheel Nut 10 ‘Wheel~Front 2 Wheel Nut 10 Mount wheels.
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. Tail light mounting bracket 3. Secure rear of sate tail light plate to rear. of frame’ brackets with a x 17 Ig. cap screw, .344" 1L.D. flat washer and nut, as shown in figure 1. 4.
SET-UP INSTRUCTIONS e Figure 4 1. Steering Wheel 4, Washer 2. Jam Nut §. Foam Seal 3. Cap INSTALL FRONT FENDERS (Fig. 5) 1. Mountaineer to each side of skirt with (7) 1024 Phillips screws, fiat 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 boils and flange slackness. 2. Position seat frame on vehicle, aligning mounting hales 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. Seat back 4. Manual tube 5. 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. Shown with seat back removed Figure 9 1. Bed support 2. Storage stud INSTALL TOPS (Fig. 10) 1.
SET-UP INSTRUCTIONS Figure 11 Battery cover Knob Battery base PN 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 4 to 8 hours, 5. When battery is charged, disconnect charger from electrical outlet and battery posts. 6. Remove filler caps. Slowly add electrolyte to each cal unit elev! is up 1o fife 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 8.
BEFORE OPERATING 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 upraise fuel that may have spilled to prevent a fire hazard. A DANGER Because diesel fuel Is flammable, caution must be used when storing or handling it. Do not fill fuse tank while engine is running, hot, or when machine is in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away.
BEFORE OPERATING Figure 18 1. Front differential 2. Fill/check plug 3. Drain plug 3. Remove checklist plug and check level of oil. il should be up 1o hole. If il is low, add 10W30 oil. 4. Re—install checklist plug. CHECK TORQUE OF WHEEL NUTS A\ WARNING Failure to maintain proper tongue could result in failure or loss of wheel and may result in personal injury. Torque front and rear wheel nuts o 45-65 ft —1b after 1-4 hours of operation and again after 10 hours of operation and every 200 hours thereafter.
CHECK BRAKE FLUID (Fig. 19) The brake fluid reservoir is shipped from the factory filled with 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. If fluid level is low, clean area around cap, remove reservoir cap and fill to proper level. DO NOT OVERFILL. BEFORE OPERATING Figure 19 1. Brake fluid reservoir 2. Full line CONTROLS Accelerator Pedal (Fig.
CONTROLS Note: Vehicle motion plus a slight turn is requited to engage or disengage differential lock. A\ WARNING Turning with the differential lock on can resit in doss of vehicle control. Do not operate with differential lock on when making sharp turns or at high speeds. Refer to using the differential lock, page 26.
CONTROLS Horn Button (Fig. 22) — Pressing bunion activates horn. Figure 22 5. Engine low oil pressure fight 6. Charge indicator Tilt steering lever Ignition switch poppa Horn button 7. Glow plug switch Coolant temp. 8. Glow plug indicator light gauge Engine Low Oil Pressure Light (Fig. 22) — Light glows if engine oil pressure drops below a safe level while engine Is running. If light flickers or remains ON, stop vehicle, turn off engine and check oil level.
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 fow. 3. Check brake pedal operation. 4. Check to see that the lights and horn are working. 5.
Figure 25 1. Fuel injection pump bleeder 5. Turn key in ignition switch to the ON position. Electric fuel pump 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 turn key to OFF. Note: Normally, engine should start after above bleeding procedures are followed.
OPERATING INSTRUCTIONS 3. Engine cranks or starts, there is a malfunction in the interlock system that must be repaired before operating vehicle. Refer to Attachment Operator's Manual for procedure on checking attachment interlock system. 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 sifter.
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 and/or turn. Heavier loads and heavier attachments make a vehicle harder to stop or turn, The heavier the load, the longer it takes to stop.
OPERATING INSTRUCTIONS TIP OVER CAN OCCUR IF TRUCK IS IMPROPERLY OPERATED. INJURY OR DEATH COULD RESULT HILLS WARNING Tipping or rolling the vehicle on a hill will cause serious personal injury. # It engine stalls or you lose headway on a hill, never attempt to turn vehicle around. « Always back straight down a chili 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 height and weight of the load has a significant influence on tip overs. The higher a Pad is stacked, the more likely the vehicle is to tip over. You may find that 2000 pounds stacks too high for safe operation, Reducing the total weight is one way to reduce the risk of a tip over. Distributing the load as low as possible is another way to reduce the risk of a tip over.
OPERATING INSTRUCTIONS TOWING VEHICLE i case of emergency, the vehicle can be towed for a short distance. However, Toto does not recommend this as & standard procedure. A WARNING Towing at excessive speeds could cause vehicle to lose steering control, Never tow vehicle faster than 5 MPH. Towing the vehicle is a two person job. Affix stow line to holes in front frame member. Move sifter to Neutral and release parking brake. If machine must be moved a considerable distance, transport it on a truck or trailer.
MAINTENANCE CHART AND CHECKLIST Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Maintenance ail Maintenance Check For Week Check stem » MON TUES WED | THURS FRI SAT SUN » Safety Interlock Operation » Service & Park Brake Operation » Fuel Level » Accelerator Operation » Clutch & Sifter Operation » Engine Oil Level » Trans axle il Level = Cooling Stern Fluid Level » Brake Fluid Level = Air Cleaner (Dust Cup & Baffle)? » Unusual Engine
QUICK REFERENCE CHART Ax® . WORKMAN 4300-D QUICK REFERENCE AID CHECK/SERVICE 10 FUEL PUMP 1. ENGINE OIL LEVEL SHAFT 16 2. ENGINE OIL DRAIN 12 TIRE PRESSURE MAXIMUM TRANSCENDENTALIST FRONT, 18 PSI REAR (24' TIRE) OIL LEVEL DIPLOID STICK% 13. FUSES (Ll &ITS 10 AMP, IGNITION 7.5 -newsy 4 BELTS (GO ERROR TARE AMP, DASH ACCESSIBILITY) PUMP, HYDRAULIC P! UMP) 14. HYDRAULIC START 2 5. COOLANT LEVEL FILL 15. HYDRAULIC GIL FILTER 8 (75 Agreeing DIESEL FUEL ONLY) 16. BRAKE FLUID E POINTS HRS. 17.
LUBRICATION Figure 29 R Figure 30 Figure 31 Figure 34 IMPORTANT Heavy Duty Operation 1t vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently.
MAINTENANCE A\ caution Only qualified and authorized personnel sail 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 dowering 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 37 1. Front jacking point Figure 38 1. Bear jacking points GENERAL. AIR CLEANER MAINTENANCE PRACTICES (Fig. 39) inspect air cleaner and hoses periodically to maintain maximum engine protection and 1o ensure maximum service life. 1. Check air cleaner body for dines 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 fitter element. Do not exceed 100 psi to prevent damage io 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 Filter Element.
MAINTENANCE 3. Clean area around filter canister mounting surface. Figure 43 1. Drain plug 2. Filter canister 4. Remove filter canister and clean mounting surface. 5. Lubricate gasket on filter canister with clean engine oil. 6. Install filter canister by hand until gasket contacts mourning surface, then rotate an additional 1/2 turn. 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. Tum key in key 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. 46) Remove debris from engine area and radiator daily, clean more frequently in dirty conditions. 1. Remove radiator cover. 2. Turn engine off. Clean engine area thoroughly of all debris. 3.
MAINTENANCE 2. TTo adjust belt tension: A. Loosen alternator mounting obits. B. Using a bar, rotate alternator unfit proper belt tension is attained, then tighten mounting bolts. Figure 48 1. Alternator bet 2. Alternator brace Fan belt (Fig. 49) 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 in. A used belt should deflect deflection is Incorrect, process to next step. if correct, continue operation. 2.
MAINTENANCE CHANGING TRANS AXLE / HYDRAULIC FLUID (Fig. 51) Change . Transient hydraulic fluid, filtered_ clean strainer every 800 hours. 1. Position the vehicle on 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 i ATF. Refer to Checking Hydraulic Fluid, 4.
MAINTENANCE 2. Remove drain plug (Fig. 51} from side of reservoir and let hydraulic fluid flow into drain pan. 3. Remove hydraulic line and fitting connected to strainer on side of reservoir. 4. Remove strainer and clean by back flushing with a clean greaser. Ali ow fo air dry before reinstalling. Figure 54 1. Hydraulic strainer 5. Reinstall strainer. 6. Reinstall hydraulic ine and fitting to strainer. 7. Reinstall and tighten drain plug. 8. Fill reservoir with approximately 7.5 at. of Dethrone il ATF.
MAINTENANCE 2. Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in transpire bracket. Figure 58 1. Clutch switch ADJUSTING PARKING BRAKE (Fig. 59) Check adjustment every 200 hours. 1. Loosen set screw securing knob to parking brake fever. 2. Rotate knob until a force of 3545 Ibs. for 2 wd models and 4555 Ibs. for 4 wd models is required to actuate lever. 3. Tighten set screw after adjustment has been attained. Figure 59 1. Parking brake lever 2 Knob 3.
MAINTENANCE 3. While pulling back on spring, adjust jam nuts to obtain 085" +.025" gap between spring hook and O.D. of hole in transient lever. 4. Tighten jam nuts after adjustment has been attained and recheck. EMERGENCY BOX RAISING (without starting engine) The box can be raised in an emergency by cranking starter and holding Sift lever. Run starter for 15 seconds then wait 60 seconds before engaging starter again. \f engine will not crank, the load and box {attachment) must be removed 1o service engine o
MAINTENANCE JUMP STARTING PROCEDURE A\ warning Jump starting can be dangerous. To avoid personal injury or damage to electrical components in vehicle, observe the following warnings: * Never jump start with a voltage sources greater than 15 vomits 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.
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval & Service Check Battery Fluid Level Check Battery Cable Connections Check Dust Cup/Baffle Every 50hrs 100hrs Lubricate All Grease Fittings inspect Condition and Wear of Tires Change Engine Oil and Filter inspect Cooling System Hoses Check Cable Adjustments Check Alternator and Fan Belts Service Air Filter Check Front Axle GV Boot Joint (4WD) Check Engine RPM (idle and full throttle) Torque Wheel Lug Nut
ELECTRICAL SCHEMATIC s ] SR “Iwi 201 | e oLg House § i BR SIR Ne raiser wem METE VG 44
IDENTIFICATION AND ORDERING MODEL AND SERIAL NUMBERS The WORKMAN® has two identification numbers: a medal 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, Note: Do not order by reference number i a parts catalog is being used; use the part number.
California Emission Control Warranty Statement A Two Year Limited Warranty Your Warranty Rights and Obligations The California Air Resources Board and Toto are pleased to explain the emission control system warranty on your 1995 and later utility, lawn and garden equipment engine. In California, new utility, lawn and garden equipment engines must be designed, built and equipped to meet the State’s stringent anti-smog standards.
Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the effect of “repair or replace as necessary” shall be warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement point for that part.
The Toto Promise A One Year Limited Warranty The Toto 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 The cost of parks, labor and transportation are included.