Form No. 3326–205 Rev B Workman) 3200 & 4200 Liquid Cooled Gas Utility Vehicle Model Model Model Model No. 07211—Serial No. 220000001 and Up No. 07211TC—Serial No. 220000001 and Up No. 07212—Serial No. 220000001 and Up No. 07218—Serial No.
Tipovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading And Dumping . . . . . . . . . . . . . . . . . . . . . Using The Differential Lock . . . . . . . . . . . . . . . . Four Wheel Drive . . . . . . . . . . . . . . . . . . . . . . . . . Transporting Vehicle . . . . . . . . . . . . . . . . . . . . . . Towing Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . Trailer Towing . . . . . . . . . . . . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. The TORO WORKMAN meets the requirements of ANSI B56.8a–1994.
• Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing or jewelry which could get caught in moving parts and cause personal injury. This is a specialized utility vehicle designed for off–road use only. its ride and handling will have a different feel than what drivers experience with passenger cars or trucks. So take time to become familiar with your WORKMAN.
• When starting the engine: – Never operate vehicle in or near an area where there is dust or fumes in the air which are explosive. The electrical and exhaust systems of the vehicle can produce sparks capable of igniting explosive materials. – Sit on operator’s seat and engage parking brake. – Disengage PTO (if so equipped) and return hand throttle lever to OFF position (if so equipped). – Always watch out for and avoid low over hangs such as tree limbs, door jambs, over head walkways, etc.
Sound Pressure Level Place the remote hydraulics lever in the float position. If box must be in raised position, secure with safety support. This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 82 dB(A), based on measurements of identical machines per Directive 98/37/EC and amendments. • To make sure entire machine is in good condition, keep all nuts, bolts and screws properly tightened.
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. ON FAN SHROUD (Part No. 98–9335) SAE 10W–30 SG, SH or SJ 93–2195 ON REAR SKIRT (Part No. 99–1216 – 2 wheel drive) (Part No. 99–1217 – 4 wheel drive) ON REAR AXLE TUBE (Part No. 93–9449) ON LEFT FRAME RAIL (Part No. 93–8071) ON SKIRT (Part No. 87–5920) ON CONSOLE (Part No. 87–6000) ON DASH (Part No.
’ ON CONSOLE (Part No. 87–6020) ON DASH (Part No. 94–5272) UNDER DASH NEXT TO FUSE BLOCK (Part No. 87–6670) ON FRONT PANEL OF BED (Part No. 92–5955) Model 07212 only ON SUPPORT TUBE UNDER BED (Part No. 92–1312) Model 07212 only ON SIDE PANELS OF BED (2) (Part No. 92–1319) Model 07212 only ’ ON SPRING CRADLE (Part No. 93–9879) ON LIFT CYLINDERS & BED SUPPORT (Part No. 93–9852) UNDER RIGHT SIDE OF DASH (Part No. 93–7142–4 wheel drive) (Part No. 87–7000–2 wheel drive) ON RADIATOR SCREEN (Part No.
ON AXLE TUBE (Part No. 93–9442) ON CONSOLE (Part No. 87–5960) ON DASH (Part No. 87–5910) ON BATTERY COVER (Part No. 93–6687) ON CONSOLE (Part No. 87–6010) ON ROPS (Part No. 105–4214) ON FAN SUPPORT (Part No. 93–7814) 9 ON ROPS (Part No. 93–9850) ON SKIRT (Part No.
Specifications Note: Specifications and design subject to change without notice. General Specifications Type Engine Air Cleaner Battery Cooling System 4 wheel step through, out front operator style, two person vehicle. Certified to meet ANSI Specifications B56.8a–1994. Daihatsu 31 hp, three cylinder, liquid cooled, counterbalanced, gasoline engine; regulated to 3650 rpm by a mechanical governor. 58.1 cu. in. (952 cc) displacement. Forced lubrication by gear pump. 40 amp alternator with I/C regulator.
Hour meter, fuel gauge, coolant temperature gauge. Warning light cluster includes engine low oil pressure and charge indicator. Tachometer optional. Gauges Lights Twin halogen headlights and single taillight. Rear stop light. Tow Hitch Hitch has hole for ball or pin. Interlocks Clutch pedal must be depressed to start engine. Forward Speeds w/23” Rear Tires High range: 7.6/11.5/19.8 mph Low range: 2.9/4.5/7.7 mph Reverse Speeds w/24” Tires High range: 7.2 mph Low range: 2.
Setup Note: Determine the left and right side of the machine from the normal operating position. Description Qty. Fenders–Rear 2 Capscrew 5/16–18 x 1” lg. 4 Flatwasher .344” I.D. 4 Locknut 5/16–18 4 Capscrew 1/4–20 x 1” lg. 12 Flatwasher .281” I.D.
Install Rear Fenders 6. On left side, loosely secure tail light mounting bracket, rear of fender and tail light plate together with (2) capscrews, washers and nuts, previously removed. 1. Loosen the locknuts and capscrews securing tail light plates to right and left frame brackets (Fig. 1). 7. On right side, secure rear of fender to tail light plate with (2) 1/4–20 x 1” lg. capscrews, .281” I.D. flatwashers and nuts 2. Pivot tail light plates rearward and tighten capscrews and locknuts. 8.
4 3 1 5 2 1 Figure 4 1. Steering wheel 2. Jam nut 3. Cap 2 4. Washer 5. Foam seal FRONT Figure 6 1. ROPS Install Front Fenders 1. Mount a fender to each side of skirt with (7) 10–24 Phillips screws, flat washers and locknuts. 2. Mounting bracket Activate and Charge Battery 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.
1. Loosen knobs securing battery cover to battery base and slide cover off. 2. Remove capscrew, washers and locknut securing battery hold down to battery base. Remove hold down and slide battery out of battery base. 2 1 2 2 1 Figure 8 1. Positive (+) cable 6. Remove filler caps. Slowly add electrolyte to each cell until level is up to fill ring. Install filler caps. 3 Important Do not overfill battery.
Full Bed Removal 3 1 1. Start engine. Engage hydraulic lift lever and lower bed until cylinders are loose in slots. Release lift lever and turn off engine. 2. Remove lynch pins from outer ends of cylinder rod clevis pins (Fig. 9). 5 4 1 6 2 5 Figure 10 1. Left rear corner of bed 2. Vehicle frame channel 3. Pivot plate 4 2 3 4. Clevis pin 5. Lynch pin Note: Make sure spacer brackets and wear blocks (Fig. 11) are installed or radiator cover may be damaged. Figure 9 1. Bed mounting plate 2.
3. With bed lowered, secure each cylinder rod end, to appropriate slots in bed mounting plates with clevis pin and lynch pin. Insert clevis pin from outside of bed with lynch pin toward outside (Fig. 10). Rear slots are for full bed installation and front slots are for 2/3 bed installation. Note: Engine may need to be started to extend or retract cylinders for alignment with holes. Keep fingers out! Note: Unused slot can be plugged with a capscrew and nut to prevent assembly errors. 4.
Before Operating 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. Figure 13 4. If oil level is low, remove filler cap and add enough oil to raise level to FULL mark on dipstick. Check Crankcase Oil The engine is shipped with approximately 3.
Danger Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full. Add fuel to the fuel tank until the level is 1/4 to 1/2 in. (6 to 13 mm) below the bottom of the filler neck.
Caution If the engine has been running, the pressurized, hot coolant can escape and cause burns. 1 • Do not open the radiator cap when the engine is running. • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. 2. Check coolant level. Coolant should be up to COLD line on reserve tank, when engine is cold. Figure 18 1. Dipstick 2. 4. Screw dipstick into transaxle and make sure it is seated fully. Unscrew dipstick and check fluid level.
Maximum Total Front Axle Weight (lb.) Check Torque Of Wheel Nuts Warning (thousands) Failure to maintain proper torque of the wheel nuts could result in failure or loss of wheel and may result in personal injury. Torque the front and rear wheel nuts to 45–65 ft.-lb. (61–88 NVm) after 1–4 hours of operation and again after 10 hours of operation. Torque every 200 hours thereafter. Check Tire Pressure 20” FRONT TIRES 1.6 1.5 1.4 1.3 1.2 1.
Check Brake Fluid 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. If fluid level is low, clean area around cap, remove reservoir cap and fill to proper level. DO NOT OVERFILL. 1 2 Figure 20 1. Brake fluid reservoir 22 2.
Operation Caution Note: Determine the left and right side of the machine from the normal operating position. Worn or misadjusted brakes may result in personal injury. If brake pedal travels to within 1–1/2” of the vehicle floor board, the brakes must be adjusted or repaired. Controls Accelerator Pedal Gear Shift Lever The accelerator pedal (Fig. 21) gives the operator the ability to vary engine and ground speed of the vehicle, when the transmission is in gear.
4 1 2 High–Low Range Shifter 5 Adds three additional speeds for precise speed control (Fig. 22). 6 3 • Vehicle must be completely stopped before shifting between High and Low range. • Shift only on level ground. 7 • Depress clutch pedal fully. • Move lever fully forward for High and fully rearward for Low. HIGH is for higher speed driving on level, dry surfaces with light loads. Figure 22 1. 2. 3. 4. Gear shift lever Differential lock Parking brake High–low range shifter5 5.
Coolant Temperature Gauge Hour Meter Registers coolant temperature in engine. Operates only when ignition switch is in On position (Fig. 23). Indicates the total hours of machine operation. The hour meter (Fig. 24) starts to function whenever the key switch is rotated to “ON” position. Engine Low Oil Pressure Light Light Switch Light glows (Fig. 23) if engine oil pressure drops below a safe level while engine is running.
Passenger Hand Hold 2. Disengage PTO (if so equipped) and return hand throttle lever to OFF position (if so equipped). On dashboard (Fig. 25). 3. Move shift lever to NEUTRAL position and depress clutch pedal. 4. Keep foot off accelerator pedal. • In extremely cold weather (below 0 degrees F) – fully depress and release the accelerator pedal several times before trying to start engine. • ,If engine is hot – depress and hold the accelerator pedal about half way down while cranking engine.
Stopping Engine To verify clutch interlock switch operation: 1. Sit on operator’s seat and engage parking brake. Move shift lever to NEUTRAL position. To stop engine, rotate ignition key to OFF and engage parking brake. Remove key from switch to prevent accidental starting. 2. Without depressing clutch pedal, rotate key clockwise to start position. New Vehicle Break–in 3. If engine cranks or starts, there is a malfunction in the interlock system that must be repaired before operating vehicle.
Turning Never operate the vehicle, or any equipment, if you are under the influence of alcohol or other drugs. Even prescription drugs and cold medicines can cause drowsiness. Read the label on the medicine or check with your doctor or pharmacist if you are unsure about a certain medication. Turning is another important variable leading to accidents. Turning too sharply for the conditions can cause the vehicle to lose traction and skid, or even tip over.
Tipovers The TORO WORKMAN is equipped with a roll bar, hip restraints, shoulder restraints and hand hold. The ROPS system used on the vehicle will reduce the risk of serious or fatal injury in the unlikely event of a tipover, although the system cannot protect the operator from all possible injuries. Replace a damaged ROPS, do not repair or revise. Any alteration of ROPS must be approved by manufacturer.
Note: The Workman has excellent hill climbing ability. The differential lock will increase this ability. Hill climbing traction can also be increased by adding weight to the rear of the vehicle in one of the following ways: • Adding weight to inside of box, making sure it is secured. • Mounting wheel weights to rear wheels. • Adding liquid ballast (calcium chloride) to rear tires. • Traction will increase with no passenger in front seat.
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. Warning Tipping or rolling the vehicle on a hill will cause serious injury. If the load is positioned toward one of the sides, it will make the vehicle much more likely to tip over on that side. This is especially true when turning if the load is on the outside of the turn.
Towing Vehicle When equipped with a tow hitch bolted onto rear axle tube, your Workman can tow trailers or attachments with a Gross Trailer Weight (GTW) up to 1500 lbs. Always load a trailer with 60% of the cargo weight in the front of the trailer. This places approximately 10% (200 lbs. max.) of the Gross Trailer Weight (GTW) on the tow hitch of the vehicle. In case of emergency, the vehicle can be towed for a short distance. However, Toro does not recommend this as a standard procedure.
Float Position the power steering circuit. In this position the work ports of the control valve are blocked and any load will be held by the check valves in both directions. This valve position allows oil to flow in and out of the work ports and is connected to the inlet and outlet ports at the same time. This allows for attachments as the rear hitch to ”float” up and down. The same pressure is applied to both quick couplers due to back pressure from the steering circuit.
Remote Hydraulic Control Trouble Shooting: • Difficulty in connecting or disconnecting quick couplers. • Pressure not relieved (Quick coupler under pressure). • Engine running. • Remote hydraulic valve not placed in float. • Power steering hard. • Remote valve not in neutral or float position. • Remote hydraulic valve linkage out of adjustment. • Hydraulic oil level low. • Hydraulic oil hot. • Hydraulic leaks. • Fittings loose. • Fitting missing o–ring. • Attachment does not function.
Maintenance Note: Determine the left and right side of the machine from the normal operating position. Service Interval Chart SAE 10W–30 SG, SH or SJ 93–2195 2 Wheel Drive Shown Greasing Bearings And Bushings 2. Pump grease into the bearing or bushing. 3. Wipe off excess grease. The vehicle has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
Figure 32 Figure 29 Figure 33 Figure 30 Figure 34 Figure 31 36
Maintenance Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 10 hours • Check cable adjustments • Torque wheel lug nuts • Replace transaxle filter After first 50 hours • Replace the engine oil and filter. Every 50 hours • Check the battery fluid level. • Check the battery cable connections. • Service the air cleaner.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Check the safety interlock operation. Check service and park brake operation. Check the fuel level. Check the accelerator operation Check the clutch and shifter operation Check the engine oil level. Check the transaxle oil level. Check the cooling system fluid level1 Check the brake fluid level Check the air cleaner2 Check for any unusual engine noises.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance. Heavy Duty Operation Warning Important If the vehicle is subjected to any of the conditions listed below, maintenance should be performed twice as frequently: Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition switch.
3. The jacking point at the front of the vehicle is under the front center frame support and at the rear it is under the axle tube. 3. Push bed support onto cylinder rod, making sure support end tabs rest on end of cylinder barrel and on cylinder rod end (Fig. 36). 4. When jacking up front of vehicle, always place a 2x4 block (or similar material) between jack and vehicle frame. 1 3 1 Figure 37 1. Front jacking point 2 Figure 36 1. Bed support 2. Cylinder barrel 3. Bed 1 4.
3 ÎÎÎ ÎÎÎ 1 1 Figure 40 1. Engine oil drain plug 2 3. Remove oil filter. Apply a light coat of clean oil to the new filter seal before screwing it on. Screw filter on until gasket contacts mounting plate, then tighten 1/2 to 2/3 of a turn. DO NOT OVER–TIGHTEN. Figure 39 1. Air cleaner latches 2. Dust cup 3. Filter 2. Gently slide filter out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body. 3. Inspect filter and discard if damaged.
4. Remove clamps securing fuel filters to fuel lines. 1 1 Figure 43 Figure 42 1. Radiator screen 1. Fuel filter 5. Install new fuel filters to fuel lines with clamps previously removed. Filters to be mounted so arrow points toward carburetor. Changing Engine Coolant Removing Debris From Engine Cooling System 2. Raise bed (if so equipped) and place safety support on extended lift cylinder to hold up bed. 1. Park machine on a level surface.
1 1 Figure 44 1. Radiator cap Figure 46 4. Remove reserve tank cap. 1. Bleed screw 7. Remove coolant drain plug from engine and allow coolant to flow into drain pan. When coolant stops, install drain plug. 1 8. Slowly fill radiator with a 50/50 mixture of water and permanent ethylene glycol anti–freeze. Install radiator cap. 9. Slowly fill reserve tank until level reaches COLD line. DO NOT OVERFILL. Install reserve tank cap. 10. Start engine and operate until warm.
Adjusting Belts 1 Check condition and tension of all belts after first day of operation and every 200 operating hours thereafter. Raise bed (if so equipped) and position safety support on extended lift cylinder to hold up bed. 2 Alternator belt 1. Check tension by depressing belt at mid span of crankshaft and alternator pulleys with 22 lbs. of force. A new belt should deflect .3–.5 in. A used belt should deflect .4–.55 in. If deflection is incorrect, proceed to next step. If correct, continue operation.
Changing Transaxle / Hydraulic Fluid Change Transaxle hydraulic fluid, filter and clean strainer every 800 hours. 1. Position the vehicle on a level surface, stop engine, engage the parking brake and remove key from ignition switch. 1 2 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. Figure 51 1. Hydraulic filter 2. Gasket 4. Assure filter mounting area is clean.
Replacing Spark Plugs 3. Remove drain plug and let oil flow into drain pan. Reinstall and tighten plug when oil stops draining. Replace spark plugs after every 400 operating hours to assure proper engine performance and reduce exhaust emission level. 4. Clean area around fill/check plug on side of differential. 5. Remove fill/check plug and add 10W30 oil until oil is up to hole. Correct spark plug to use is a Champion RC 14YC or NGK BPR 4ES. 6. Re–install fill/check plug. Recommended air gap is .032”.
Adjusting Brake Pedal Check adjustment every 200 hours. 1. Loosen jam nut on link rod ball joint. 2. Rotate rod until gap between brake pedal and up stop is .020–.080”. 3. Tighten jam nut after adjustment has been attained. 3 4 1 2 Figure 57 1 1. Clutch cable 2. Jam nuts 3. return spring 4. Ball joint Note: Ball joint may be removed and rotated, if additional adjustment is required. 2. Disconnect return spring from clutch lever. 3.
Adjusting Parking Brake 3. Loosen clevis jam nuts and adjust each clevis so cable free play is equal forward and backward relative to hole in transaxle shift arm (With transaxle lever free play taken up in same direction). Check adjustment every 200 hours. 1. Loosen set screw securing knob to parking brake lever. 4. Reinstall clevis pins and tighten jam nuts after adjustments have been attained. 2. Rotate knob until a force of 35–45 lbs. for 2 wheel drive or 45–55 lbs.
3. Adjust jam nuts to obtain .035” ± .025” gap between spring hook and O.D. of hole in transaxle lever. 4. Tighten jam nuts after adjustment has been attained. Inspect Brakes Visually inspect brakes for worn brake shoes after every 600 hours of operation. 1 Inspect Tires Check tire condition at least every 200 hours of operation. Operating accidents, such as hitting curbs, can damage a tire or rim and also disrupt wheel alignment, so inspect tire condition after an accident. Figure 63 1.
Fuses There are 3 fuses in the machine’s electrical system. They are located under right side of dash panel. FUSES OPEN LIGHTS & HORN DASH IGNITION –– 10A 7.5A 7.5A 1 Figure 65 1. Positive (+) cable 1 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.
Battery Care 2. Keep top of battery clean by washing periodically with a brush dipped in ammonia or bicarbonate of soda solution. Flush the top surface with water after cleaning. Do not remove the fill cap while cleaning. 1. Battery electrolyte level must be properly maintained and the top of the battery kept clean. lf the machine is stored in a location where temperatures are extremely high, the battery will run down more rapidly than if the machine is stored in a location where temperatures are cool.
Hydraulic Schematic (Base Vehicle) 52
Hydraulic Schematic 10 (Vehicle w/ Remote Hydraulic Kit) (Model 07211 TC Only) 53
CARB FUEL PUMP + – COIL YEL/BK R B S R HI–LO LOCKOUT SWITCH 2–3 LOCKOUT SWITCH R/W ALTERNATOR L B PINK 30 87 87A FUSIBLE LINK PINK RED STARTER R/W R/W BLACK BLACK BLACK BLACK RED BLUE BLUE R/W 10 GA R/BK PINK BLUE 85 86 PINK RED RED TAIL/BRAKE LIGHT BLACK BROWN FUEL SENDER BU/WHT OFF = CLOSED PTO (OPT) CLUTCH SWITCH TEMP SENDER GRN/BK BN/WHT GRAY OIL PRESSURE (OPEN WHEN RUNNING) 7.
WHITE R/BK WHT/BK DIODE 86–7470 CARB R/W S 30 HI–LO LOCKOUT SWITCH PINK BLUE 85 87A 86 87 2–3 LOCKOUT SWITCH R/W ALTERNATOR R L B PINK FUSIBLE LINK R/W 10 GA STARTER R B RED R/W R/W BLACK BLACK BLACK BLACK RED BLUE BLACK BU/R FUEL WHT/BK PUMP BLACK COIL + – BLACK BLACK DISTRIBUTOR BLUE YEL/BK YEL/BK + PINK WHT/BK BLUE – RED TAIL/BRAKE LIGHT WHT/BK BROWN RED BU/WHT TEMP SENDER GRN/BK BN/WHT GRAY 7.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
