Operator's Manual

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Summary of content (44 pages)

PAGE 1
! !4 )9 ! # -5 330)( %630-2) !7-0-7< "),-'0) 3 %6685) 1%;-181 6%*)7< 347-181 4)5*351%2') %2( 73 +%-2 /23:0)(+) 3* 7,) 453(8'7 -7 -6 )66)27-%0 7,%7 <38 35 %2< 37,)5 34)5%735 3* 7,) 1%',-2) 5)%( %2( 82()567%2( 7,) '327)276 3* 7,-6 1%28%0 &)*35) 7,) )2+-2) -6 )9)5 67%57)( %< 4%57-'80%5 %77)27-32 73 7,) $ ! ,-+,0-+,7)( &< 7,-6 6<1&30 ,) 6%*)7< %0)57 6<1&30 1)%26 ! # 35 = 4)5632%0 6%*)
PAGE 2
The TORO WORKMANR 3100 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. # R $, ' (!! #$"#0 1 / #$ % ('%1 ' $, '(- ,$"' *.$)) (+ & '.! -.+ !(+ ., (' ).
PAGE 3
The TORO WORKMANR 3100 meets the requirements of ANSI B56.8a-1994. Supervisors, operators and service persons should be familiar with the following standards and publications: (The material may be obtained from the address shown). D Flammable and Combustible Liquids Code: ANSI/NFPA 30 D National Fire Protection Association: ANSI/NFPA #505; Powered Industrial Trucks ADDRESS: National Fire Prevention Association Barrymarch Park Quincy, Massachusetts 02269 U.S.A D ANSI/ASME B56.
PAGE 4
. . . . . . . . . . . . . . . . . . . . 5-7 . . . . . . . 7-9 . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 . . . . . . . . . . . . . . . . . . . . . . 11 . . . . . . . . . . . . . . . . . 12-14 Install Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install Steering Wheel . . . . . . . . . . . . . . . . . . . . . 12 Install Front Fenders . . . . . . . . . . . . . . . .
PAGE 5
SAFETY INSTRUCTIONS The WORKMANR 3100 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.
PAGE 6
Never overload your vehicle. Name plate (located under dash on passenger side) shows load limits for vehicle. Never overfill attachments or exceed the vehicle maximum GVW. When dumping, do not let anyone stand behind vehicle and do not dump load on any one's feet. Release tailgate latches from side of box, not from behind. When starting the engine: Before backing up, look to the rear and assure no one is behind. Back up slowly.
PAGE 7
$ 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. If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
PAGE 8
# $( #$"% $ # $ " " " !)+, * # "$ !)+, * & " $ # " # #!" % " # '$ $ %# !)+, * # ! " $ "# % " # ## ( !" %" #!" " !)+, * # !)+, * % " " $ # # !)+, * $ ( "# #%!! "$ !)+, * # !)+, * # !)+, *
PAGE 9
# $) #$"% $ # # *,- + $ " $ ( % $ % ' $ # ( % $" " ' $ # $" # ## % %# (" %$ $ $" # ## % " !% & $ ( $% *,- + # *,- + # "$ *,- + $ #$ $$ ") & " *,- + # *,- + # *,- + " # *,- + #% "$ *,- + " # *,- +
PAGE 10
3+ . Twin molded cushions and backrests, with )"$) : Kohler, 4 cycle, air cooled, 22 hp @ 3600 rpm, 38.1 cu. in. (624 cc) displacement. Mechanical fuel pump, 2 qt. oil capacity. Large capacity dual element air cleaner. *).,*'- Foot operated accelerator, clutch and brake pedals. Hand operated shifter, differential lock, parking brake, high-low range shifter, hydraulic lift and tilt steering levers. Ignition switch, light switch, choke knob, horn button and 3rd high lockout switch.
PAGE 11
Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these parts, total setĆup cannot be completed. Some parts may have already been assembled at factory. Wheel Nut Wheel-Front Wheel Nut Wheel-Rear 10 2 10 2 Steering wheel Foam Seal Washer Nut Cap 1 1 1 1 1 Fenders-Front Phillips Screw 10-24 Washer Locknut 10-24 2 14 14 14 Seat Frame Seat Frame Bracket Carriage Bolts 3/8-16 x 3/4" lg.
PAGE 12
&$ Remove and discard fasteners securing wheels. Mount wheels and torque nuts to 45Ć55 ftĆlb. &$0-" "*!"- &$ Mount a seat frame bracket to each end of seat frame with (2) 3/8-16 x 3/4" carriage bolts and flange locknuts. Position seat frame on vehicle, aligning mounting holes in frame with holes in vehicle.
PAGE 13
(& Mount (2) seat back brackets to each seat back cushion with (4) 1/4-20 x 3/4" lg. capscrews and 1/4" flat washers. Position brackets on seat back cushions as shown in figure 5. Mount cushion with seat back brackets and manual tube R-clamps to left seat back with (4) 5/16-18 x 5/8" lg. carriage bolts and flange locknuts. Slide bed support onto storage stud (Fig. 7).
PAGE 14
SET-UP INSTRUCTIONS ACTIVATE AND CHARGE BATTERY (Fig. 9 & 10) If Battery is not filled with electrolyte or activated, it must be removed from vehicle, filled with electrolyte and charged. Bulk electrolyte with 1.260 specific gravity can be purchased from a local battery supply outlet. 4. Replace filler caps and connect a 3 to 4 amp battery charger to the battery posts. Charge the battery at a rate of 3 to 4 amperes for 4 to 8 hours. 5.
PAGE 15
! )*36) 7)6:-'-2+ 36 1%/-2+ %(.9781)287 83 8,) 1%',-2) 7834 )2+-2) 7)8 4%6/-2+ &6%/) %2( 6)13:) /)= *631 8,) 7;-8', 2= 03%( 1%8)6-%0 1978 &) 6)13:)( *631 &)( 36 38,)6 %88%',> 1)28 &)*36) ;36/-2+ 92()6 6%-7)( &)( 0;%=7 40%') 7%*)8= 7944368 32 )<8)2()( 0-*8 '=0-2()6 83 ,30( 94 &)( &)*36) ;36/-2+ 92()6 6%-7)( &)( Pour oil into fill opening until the oil level is up to the FULL" mark on the dipstick. Add the oil slowly and check the level often during this process.
PAGE 16
" ,*(<:, .(:6305, 0: -3(44()3, *(<;065 4<:; ), <:,+ >/,5 :;6905. 69 /(5+305. 0; 6 56; -033 -<,3 ;(52 >/03, ,5.05, 0: 9<5505. /6; 69 >/,5 4(*/05, 0: 05 (5 ,5*36:,+ (9,( $(769: 4(@ )<03+ <7 (5+ ), 0.50;,+ )@ ( :7(92 69 -3(4, :6<9*, 4(5@ -,,; (>(@ " ! >/03, -03305. ;/, -<,3 ;(52 ;6 79,=,5; ;/, 76::0)030;@ 6- (5 ,?736A :065 3>(@: -033 -<,3 ;(52 6<;:0+, (5+ >07, <7 (5@ :7033,+ .(:6305, ),-69, :;(9;05. ,5.05, #:, ( -<55,3 69 :76<; ;6 79,=,5; :703305. .
PAGE 17
Maximum air pressure in front and rear (23") tires is 20 psi. Optional rear (24") tires is 18 psi maximum. The air pressure needed is determined by the payload carried. The lower the air pressure, the less the compaction and tire marks are minimized. Lower pressure should not be used for heavy payloads at high speeds. Tire damage may result.
PAGE 18
$$&-&2"402 &%"- (Fig. 15) - 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. 0 /04 3)*'4 4)& 42"/3"8-& 40 4)& 2&6&23& 02 '027"2% (&"2 5/-&33 4)& 6&)*$-& *3 34"/%*/( 34*-- "."(& 40 42"/3"8-& ."9 0$$52 07/ 3)*'4*/( '20.
PAGE 19
.('+% . (# (Fig. 16) -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. 4".
PAGE 20
4''2+/) "*''- (Fig. 18) - Turns vehicle. If engine stalls or power assist fails due to a malfunction, vehicle steering will require greater effort. #%*0.'4'2 (optional-not shown) - Indicates engine RPM. Gear selection graphics indicates speed. '.04' 8&2#5-+% '6'2 (optional-not shown) Controls hydraulic flow to optional quick rear couplers. +)*4 37+4%* 052 .
PAGE 21
Release clutch pedal smoothly while depressing accelerator pedal. When vehicle gains enough speed, remove foot from accelerator pedal, fully depress clutch pedal, move gear shift lever to next gear and release clutch pedal while depressing accelerator pedal. Repeat procedure until desired speed is attained. Stop vehicle before shifting to reverse and forward. 04' Avoid long periods of engine idling.
PAGE 22
If you are not experienced at driving the vehicle, practice driving it in a safe area away from other people. Be sure you are familiar with all the vehicle's controls, particularly those used for braking, steering and transmission shifting. Learn how your vehicle handles on different surfaces. Your operating skills will improve with experience, but as in operating any vehicle, take it easy as you begin. Be sure you know how to stop quickly in an emergency.
PAGE 23
Do not downshift for braking on icy or slippery surfaces (wet grass) or while going down a hill because engine braking may cause skidding and loss of control. Shift to a lower gear before starting down a hill. The TORO WORKMAN is equipped with a roll bar, hip restraints, shoulder restraints and hand hold.
PAGE 24
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.
PAGE 25
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 to 2000 pounds of evenly distributed cargo. $!* - %.%*# +- (+2!-%*# ! +- %),(!5 )!*/ $4 - 0(% +%( 2%(( 4, .. +1!- -!(%!" 1 (1! 2$!* 4(%* !- -! $ /$! !* +" /$!%/- 1!( ./+,,%*# ,+2!- ..%./ /+ ./!!-%*# #! - * %* -! .%*# .
PAGE 26
Towing the vehicle is a two person job. Affix a tow line to holes in front frame member. Move shifter to Neutral and release parking brake. If machine must be moved a considerable distance, transport it on a truck or trailer. )- # *)/ + ,- +$(" /$&& ()- !.( -$)( ' %$(" $ $!!$ .&- $( + , !!)+- -) ,- + The Workman 3100 is capable of pulling trailers and attachments of greater weight than the vehicle itself.
PAGE 27
Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance C Check Item b MON TUES WED THURS FRI SAT SUN n Safety Interlock Operation n Service & Park Brake Operation n Clutch & Shifter Operation n Fuel Level n Engine Oil Level n Transaxle Oil Level n Brake Fluid Level n Air Filter Prefilter Inspect Engine Cooling Fins n Unusual En
PAGE 28
$%.0$ 1$04("(-& .0 , *(-& #)312,$-21 2. 2'$ , "'(-$ 12./ $-&(-$ 1$2 / 0*(-& !0 *$ -# 0$,.4$ *$7 %0., 2'$ 15(2"' -7 +. # , 2$0( + ,312 !$ 0$,.4$# %0., !$# .0 .2'$0 22 "'8 ,$-2 !$%.0$ 5.0*(-& 3-#$0 0 (1$# !$# +5 71 /+ "$ 1 %$27 13//.02 .- $62$-#$# +(%2 "7+(-#$0 2. '.+# 3/ !$# !$%.0$ 5.0*(-& 3-#$0 0 (1$# !$# When greasing drive shaft universal shaft bearing crosses, pump grease until it comes out of all 4 cups at each cross.
PAGE 29
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PAGE 30
# $# 53? 8<(30-0,+ (5+ (<;/690@,+ 7,9:655,3 :/(33 ), 7,940;;,+ ;6 4(05;(05 9,7(09 (+1<:; 69 05A :7,*; ;/, =,/0*3, =60+ -09, /(@(9+: (5+ /(=, -09, 796;,*;065 ,8<074,5; 79,:,5; 05 ;/, >692 (9,( 6 56; <:, (5 67,5 -3(4, ;6 */,*2 3,=,3 69 3,(2(., 6-<,3 )(;;,9? ,3,*;963?;, 69 *663(5; 6 56; <:, 67,5 7(5: 6- -<,3 69 -3(44()3, *3,(505. -3<0+: -69 *3,(505. 7(9;: (5? 6- ;/, :<)1,*;: *6=,9,+ 05 ;/0: 4(05;,5(5*, :,*;065 9,8<09, 9(0:05. (5+ 36>,905. ;/, ),+ #/, -6336>05.
PAGE 31
When jacking up front of vehicle, always place a 2x4 block (or similar material) between jack and vehicle frame. A. Wash foam pre-cleaner in detergent and warm water. B. Wrap foam pre-cleaner in cloth and squeeze dry. Do not wring precleaner. Allow to air dry. C. Saturate foam pre-cleaner in engine oil. Squeeze to remove excess oil. %$0-# -+*/ &!"'%*$ ,+%*/ %$0-# %$0-# -# "(#!*# !,#- #(#)#*/ #!- &!"'%*$ ,+%*/.
PAGE 32
Install new fuel filter to fuel lines with clamps previously removed. Filter to be mounted so arrow points toward carburetor. To ensure proper cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. &%/,# )%&)# *&' ", &) +'/% )%&)# *&' $&'.#, Remove oil filter. Apply a light coat of clean oil to the new filter seal before screwing it on.
PAGE 33
" #!" # " -+ " " %/) 685) )2+-2) ,%6 :%51)( 84 ',3/) -6 34)5%7-2+ '355)'70< *8)0 7%2/ -6 *800 *8)0 7%2/ '%4 9)27 -6 237 &03'/)( *8)0 *-07)5 -6 '0)%2 %2( %-5 '0)%2)5 )0)1)27 -6 '0)%2 %2( %00 '31432)276 %5) *%67)2)( 6)'85)0< &)*35) %(.867-2+ 7,) '%5&85)735 Raise bed (if so equipped) and place safety support on extended lift cylinder to hold up bed. Stop engine and engage parking brake.
PAGE 34
MAINTENANCE 4. Set air gap between center and side of electrodes at .040". Install correctly gapped spark plug and tighten plug to 18-22 ft-lb. If torque wrench is not used, tighten plug firmly. 5. Install spark plug wires. ADJUSTING ACCELERATOR (Fig. 37) Check adjustment every 200 hours. 1. Position vehicle on level surface, stop engine and engage the parking brake. 2. With return spring installed, hold engine governor arm toward operator's side of vehicle and adjust low idle stop to obtain a .01" - .
PAGE 35
! Reinstall strainer. Reinstall hydraulic hose and 90_ fitting to strainer in same orientation. Reinstall and tighten drain plug. Fill reservoir with approximately 7.5 qt. of Dexron II ATF. Refer to Checking Hydraulic Fluid. " ! +) Check adjustment every 200 hours. +)52( 6'2$5.+& +.4(2 $3-(4 Loosen jam nut on link rod ball joint. Assure filter mounting area is clean. Screw filter on until gasket contacts mounting plate.
PAGE 36
'% Check adjustment every 200 hours. Loosen jam nuts securing clutch cable to bracket on bell housing. Disconnect return spring from clutch lever. Adjust jam nuts until bottom rear edge of clutch pedal is 3.75" + .12" from top of floor plate diamond pattern, when an 4 lb. force is applied to pedal. ,0$ Force is applied so release bearing lightly contacts pressure plate fingers. '%1.
PAGE 37
# Reinstall clevis pins and tighten jam nuts after adjustments have been attained. $"# % ., Check adjustment every 200 hours. Remove clevis pin securing High-Low cable to transaxle. Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in transaxle bracket. Reinstall clevis pin and tighten jam nut after adjustment has been attained. ± .,85* .++*5*27.&0 03(/ (&'0* #5&26&;0* '5&(/*7 "45.
PAGE 38
MAINTENANCE 2. To adjust, loosen jam nuts at both ends of tie rod. 3. Rotate tie rod outward. JUMP STARTING PROCEDURE to move front of tire inward or WARNING Jump starting can be dangerous. To avoid personal injury or damage to electrical comĆ ponents in vehicle, observe the following warnings: 1 Figure 49 1. Tie rod 4. Tighten tie rod jam nuts when adjustment is correct. EMERGENCY BOX RAISING (without starting engine) The box can be raised in an emergency by cranking starter and holding lift lever.
PAGE 39
Start the engine in the vehicle providing the jump start. Let it run a few minutes, then start your engine. Battery cables must be tight on terminals to provide good electrical contact. Remove the negative jumper cable first from your engine, then the battery in the other vehicle. If corrosion occurs at terminals,remove battery cover, disconnect cables, negative (-) cable first and scrape clamps and terminals separately.
PAGE 40
! Check Battery Fluid Level Check Battery Cable Connections Lubricate Engine Prefilter { Change Engine Oil and Filter ! ! Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800hrs Lubricate All Grease Fittings Remove Engine Shrouds, Clean Fins Inspect Condition and Wear of Tires } Check Cable Adjustments } Check Pump Drive Belt Tension Replace Air Filter Check Engine RPM (idle and full throttle)
PAGE 41
PAGE 42
YELLOW BROWN BLACK BLACK R/BK R/W BROWN BLACK BLACK BLACK TAIL/BRAKE LIGHT RED R/W BLACK BROWN BLACK WHT/BK BLACK R/W BLACK BLACK HEADLIGHTS R/BK R/W WHT/BK WHT/BK B A X RUN START BLACK BLUE/WHT WHT/BK WHT/BK RED BLACK GRAY RED ORANGE ELEC.
PAGE 43
The WORKMANR 3100 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 concerning the unit, supply the model and serial numbers to ensure correct information and replacement parts are obtained. Do not order by reference number if a parts catalog is being used; use the part number.
PAGE 44
)& /2/ /--&2$*", 2/%5$43 7/ !&"2 *-*4&% "22".49 )& /2/ /-0".9 7"22".43 9/52 /2 .&7&2 /2/ /--&2$*", 2/%5$4 : 2/%5$4 052$)"3&% "'4&2 ".5"29 4/ #& '2&& '2/- %&'&$43 *. -"4&2*",3 /2 7/2+-".3)*0 '/2 4)& 0&2*/% /' 4*-& ,*34&% #&,/7 )&2& " 7"22".4"#,& $/.%*4*/. &8*343 /2/ 7*,, 2&0"*2 4)& 2/%5$4 "4 ./ $/34 4/ 9/5 *.$,5%*.( %*"(./3*3 ,"#/2 0"243 ".% 42".30/24"4*/. )*3 7"22".49 #&(*.3 /. 4)& %"4& 4)& 2/%5$4 *3 %&,*6&2&% 4/ 4)& /2*(*.", 2&4"*, 052$)"3&2 "22".49 52"4*/.