Form No. 3328–381 Workman 3100 Air Cooled Gas Utility Vehicle Model No. 07214—Serial No.
New Vehicle Break–in . . . . . . . . . . . . . . . . . . . . . . Check Interlock System . . . . . . . . . . . . . . . . . . . . . Operating Characteristics . . . . . . . . . . . . . . . . . . . . Passengers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tipovers . . .
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.
• Never allow children to operate the vehicle. Never allow adults to operate it without proper instructions. Only trained and authorized persons should operate this vehicle. Make sure all operators are physically and mentally capable of operating the vehicle. Anyone who operates the vehicle should have a motor vehicle license. Safe Operating Practices Warning The WORKMAN is an off–highway vehicle only, and is not designed, equipped, or manufactured for use on public streets, roads or highways.
– Avoid sudden stops and starts. Do not go from reverse to forward or forward to reverse without first coming to a complete stop. machine. After every two years, replace the interlock switches in the safety system, whether they are working properly or not. – Do not attempt sharp turns or abrupt maneuvers or other unsafe driving actions that may cause a loss of vehicle control. While Operating • Operator and passenger should remain seated whenever the vehicle is in motion.
• If major repairs are ever needed or assistance is required, contact an Authorized TORO Distributor. Maintenance • 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. • To be sure of optimum performance and safety, always purchase genuine TORO replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous.
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. 106-6731 93-9852 1. Warning—read the Operator’s Manual. 2. Crushing hazard—install the cylinder lock.
93-9442 87-5910 1. Slow 1. Maximum tongue weight is 90 kg; maximum trailer weight is 680 kg. 2. Fast 2. For information on transmission fluid, read the Operator’s Manual. 93-6687 1. Do not step here. 87-5960 93-7814 1. Entanglement hazard, belt—stay away from moving parts. 87-6010 93-6689 1. Warning—do not carry passengers. 87-5930 93-9850 1. When adding fuel to the tank, leave 1 inch (25 mm) between the fuel and the top of the tank. 1. Do not repair or revise—read the Operator’s Manual.
3-9449 93-9899 1. Read the Operator’s Manual. 2. Grease every 100 hours. 1. Crushing hazard—install the cylinder lock. 3. Add grease (9 grease points). 93-9868 1. Crushing hazard of hand—read the Operator’s Manual. 105-4219 93-9879 1. Stored energy hazard—read the Operator’s Manual. 93-8071 1. Hot surface/burn hazard—stay a safe distance from the hot surface.
5-4215 1. Warning—avoid pinch points. 105-4214 1. Warning—the machine can tip. 2. Do not jump from a tipping machine. 3. Hold tight and brace your feet. 87-5970 4. The passenger should hold the hip restraint and hand hold. 5. Lean away from the direction the machine is tipping. 93-9862 1. Entanglement hazard, shaft—stay away from moving parts.
87-5920 87-7910 11
Specifications Note: Specifications and design subject to change without notice. General Specifications Type 4 wheel step through, out front operator style, two person vehicle. Certified to meet ANSI Specifications B56.8a–1994. Engine Kohler, 4 cycle, air cooled, 23 hp @ 3600 rpm, 41.1 cu. in. (674 cc) displacement. Mechanical fuel pump, 2 qt. oil capacity. Large capacity dual element air cleaner. Battery 12 volt with 370 cold cranking Amps @ 0 degrees F.
Base Weight (Dry w/o flatbed) 1275 lbs. Rated Capacity 2,725 lbs. (includes 200 lb. operator, 200 lb. passenger and loaded attachment). Maximum. Gross Vehicle Weight 4,000 lbs. Tongue weight 200 lbs. Maximum trailer weight 1,500 lbs. Tow Capacity Ground Clearance Wheel Base 7” w/ no load 70” Wheel Tread (center line to center line) Front 46” Rear 47.7” Dimensions Overall Width Overall Length 58” 124.
Setup Note: Determine the left and right side of the machine from the normal operating position. Description Qty. Wheel Nut 10 Wheel–Front 2 Wheel Nut 10 Wheel–Rear 2 Steering wheel 1 Foam Seal 1 Washer 1 Nut 1 Cap 1 Fenders–Front 2 Phillips screw 14 Washer 14 Locknut 10–24 14 ROPS 1 Capscrew 1/2–13 x 3” lg.
Install Wheels Install Front Fenders 1. Remove and discard fasteners securing wheels. 1. Mount a fender to each side of skirt with (7) 10–24 Phillips screws, flat washers and locknuts. 2. Mount wheels and torque nuts to 55–75 ft-lb. 1 Figure 3 1. Fender 2 1 Figure 1 1. Wheel Install ROPS 2. Wheel nut Install Steering Wheel 1. Insert each side of ROPS into mounting bracket on each side of vehicle frame, positioning ROPS as shown in figure 4. 1. Remove jam nut from steering shaft.
Activate and Charge Battery 2. Remove capscrew, washers and locknut securing battery hold down to battery base. Remove hold down and slide battery out of battery base. 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. 3. Remove filler caps from battery and slowly fill each cell until electrolyte is just above the plates. 4.
3. Remove clevis pins securing cylinder rod ends to bed mounting plates by pushing pins towards inside (Fig. 8). Warning 4. Remove lynch pins and clevis pins securing pivot brackets to frame channels (Fig. 8). Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 5. Lift bed off vehicle. Caution • Always disconnect the negative (black) battery cable before disconnecting the positive (red) cable.
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. 8). Rear slots are for full bed installation and front slots are for 2/3 bed installation. 2 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.
4. Pour oil into fill opening until the oil level is up to the “FULL” mark on the dipstick. Before Operating Note: When adding oil, remove dipstick to allow proper venting, pour oil slowly and check the level often during this process. DO NOT OVERFILL. 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.
2. Remove fuel tank cap. 3. Unscrew dipstick from top of transaxle and wipe it with a clean rag. 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. 1 • 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.
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 55–75 ft.-lb. 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 1.1 1 8 10 12 14 14.7 16 18 20 Tire Pressure (p.s.i.
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. 15) gives the operator the ability to vary engine and ground speed of the vehicle, when the transmission is in gear.
Choke Hydraulic Lift Lock To start a cold engine, close carburetor choke (Fig. 16) by pulling choke control upward to ON position. After engine starts, regulate choke to keep engine running smoothly. As soon as possible, open the choke by pushing it downward to the OFF position. A warm engine requires little or no choking. Locks lift lever so hydraulic cylinders do not operate when vehicle is not equipped with a bed (Fig. 16).
Oil Pressure Warning Light Light glows (Fig. 17) 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. If oil level was low, but adding oil does not cause light to go out when engine is restarted, turn engine off immediately and contact your local TORO distributor for assistance. 3 2 5 4 To check operation of warning lights: 1 1. Apply parking brake. Figure 18 2.
Pre–starting Checks Driving Vehicle Safe operation begins before taking the vehicle out for a day’s work. You should check these items each time: 1. Release parking brake. 2. Fully depress clutch pedal. • Check tire pressure. 3. Move gear shift lever to 1st gear. Note: These tires are different than car tires, they require less pressure to minimize turf compaction and damage. 4. Release clutch pedal smoothly while depressing accelerator pedal.
• To assure optimum performance of the brake system, burnish (break–in) the brakes before use. To burnish brakes: Operate the vehicle at full speed for 3 minutes, apply the brakes for 30 seconds while driving in 1st gear. Repeat these steps 20 to 30 times. To verify the brakes are completely burnished remove a rear tire and inspect the brake drum for residue. The residue color should be light grey to almost white color. pedal, accelerator pedal, and gear shift.
Passengers 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. Whenever you have a passenger riding in the vehicle make sure he or she is holding on securely. Drive slower and turn less sharply because your passenger does not know what you are going to do next and may not be prepared for turning, stopping, accelerating, and bumps.
The best way to prevent accidents involving utility vehicles is through continuous supervision and training of operators and paying constant attention to the area in which vehicle is being operated. The best way for operators to prevent serious injury or death to themselves or others, is to familiarize themselves with the proper operation of the utility vehicle, to stay alert and to avoid actions or conditions which could result in a accident.
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. 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: If the load is positioned toward one of the sides, it will make the vehicle much more likely to tip over on that side.
Towing Vehicle Warning In case of emergency, the vehicle can be towed for a short distance. However, Toro does not recommend this as a standard procedure. Tipping or rolling the vehicle on a hill will cause serious injury. • The extra traction available with the differential lock can be enough to get you into dangerous situations such as climbing slopes that are too steep to turn around. Be extra careful when operating with the differential lock on, especially on steeper slopes.
Maintenance Note: Determine the left and right side of the machine from the normal operating position.
Lubrication The vehicle has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If machine is operated under normal conditions, lubricate all bearings and bushings after every 100 hours of operation. More frequent lubrication is required if used for heavy duty vehicle operations. The grease fitting locations and quantities are: Tie rod ends (4) (Fig. 22), Front ball joints (4) (Fig. 22), Rear drive shafts (18) (Fig. 23), Pedal Pivots (4) (Fig.
Maintenance Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 5 hours • Replace the engine oil and filter. After first 10 hours • • • • Check cable adjustments Check pump drive belt tension Torque wheel lug nuts Replace transaxle filter Every 50 hours • • • • Check the battery fluid level. Check the battery cable connections.
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 brake fluid level Check the air filter/prefilter Inspect engine cooling fins Check for any unusual engine noises. Check for any unusual operating 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. Push bed support onto cylinder rod, making sure support end tabs rest on end of cylinder barrel and on cylinder rod end (Fig. 28). 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. 4. When jacking up front of vehicle, always place a 2x4 block (or similar material) between jack and vehicle frame. 1 3 1 Figure 29 1. Front jacking point 2 Figure 28 1. Bed support 2. Cylinder barrel 3. Bed 1 1 4.
Inspect paper element every 25 hours of operation and replace if dirty or damaged. Change paper element every 200 hours. Do not wash paper element or do not clean with compressed air as damage will occur. 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 filter and additional 1/2 turn. DO NOT OVER–TIGHTEN. 1 2 3 4 1 2 5 Figure 32 6 1. Engine oil drain plug 7 2. Engine oil filter 4.
Adjusting Choke 4. Remove clamps securing fuel filter to fuel lines. 5. Install new fuel filter to fuel lines with clamps previously removed. Filter to be mounted so arrow points toward carburetor. 1. Raise bed and place safety support on extended lift cylinder to hold up bed. Stop engine and engage parking brake. 2. Loosen cable clamp screw securing cable to engine. Removing Debris From Engine 3. Push choke knob down to OFF position.
Adjusting Accelerator pedal arm and top of diamond tread floor plate, when a 25 lb. force is applied to center of pedal. Tighten locknut. 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” – .05” gap between O.D. of hole in throttle lever and inside of governor spring hook. .200–.
Important Use only hydraulic fluids specified. Other fluids could cause system damage. 1 Replacing Transaxle Filter Initially, replace the hydraulic filter after 10 operating hours, thereafter, replace filter every 800 hours. Use the Toro replacement filter (Part No. 54–0110). Important Use of any other filter may void the warranty on some components. 1. Position vehicle on a level surface, stop engine, engage the parking brake and remove key from ignition switch. Figure 40 2.
5. Verify that rear edge of clutch pedal is 5.5” + .12” from top of floor plate diamond pattern. If dimension is not attained, adjust clutch pedal upstop. 3 Note: The clutch free play should never be less than .75”. 6. Tighten jam nuts after adjustment has been attained. 2 7. Recheck clutch safety switch adjustment (Fig. 44). Engine must not crank unless clutch pedal is 1.25” ±.12” from floor. If an adjustment is required, loosen switch jam nuts and adjust up or down. 1 Figure 42 1. Brake pedal 2.
2. Remove clevis pins securing shift cables to transaxle shift arms. 2 2 1 1 3 3 Figure 46 1. Shift arm (1st – Rev.) 2. Shift arm (2nd – 3rd) .035” + .025" 3. Shift arm (High–low) Figure 47 1. Differential lock cable 2. Transaxle bracket 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). 3. Spring 3. Adjust jam nuts to obtain .035” ± .
FUSES OPEN LIGHTS & HORN DASH IGNITION –– 15 A 25 A 10 A Center–to–center Distance Figure 48 2. To adjust, loosen jam nuts at both ends of tie rod. 1 1 Figure 50 1. Fuse block Jump Starting Procedure Figure 49 Warning 1. Tie rod Jump starting can be dangerous. To avoid personal injury or damage to electrical components in vehicle, observe the following warnings: 3. Rotate tie rod to move front of tire inward or outward. 4. Tighten tie rod jam nuts when adjustment is correct.
2. Connect a jumper cable between the positive posts of the two batteries. The positive post may be identified by a “+” sign on top of battery cover. the machine. Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery. To prevent battery from freezing, make sure it is fully charged. The specific gravity of a fully charged battery is 1.250. Battery Care 1. Battery electrolyte level must be properly maintained and the top of the battery kept clean.
Hydraulic Schematic 45
BROWN YELLOW BLACK 46 R/BK R/W BROWN BLACK BLACK BLACK TAIL/BRAKE LIGHT RED R/W BLACK BROWN BLACK WHT/BK BLACK GRAY 7.5 AMP FUSE R/BK R/W HEADLIGHTS BLACK RUN START WHT/BK WHT/BK BLACK BLUE/WHT WHT/BK WHT/BK GRAY WHITE ACCESSORIES PINK LTS/HORN ORANGE DASH A X RED IGNITION B ELEC.
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.
