Form No. 3326-210 ® Workman® 3200 & 4200 Liquid-Cooled Gas Utility Vehicle Model No. 07211TC—Serial No. 220000001 and Up Model No. 07218—Serial No.
Foreword The TORO 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. The TORO Workman® meets the requirements of ANSI B56.8a–1994.
Table of Contents Foreword Table of Contents Safety Instructions Sound Pressure Level Vibration Level Safety and Instruction Decals Page 2 3 Transporting the Vehicle Towing the Vehicle Trailer Towing Remote Hydraulic Control (Optional) Quick Coupler Operation Remote Hydraulic Control Trouble Shooting: 4 7 7 8 Specifications 10 Set-Up Instructions Loose Parts Chart Install Rear Fenders Install Wheels Install Steering Wheel Install Front Fenders Install the Roll-Over Protection System Activate and Charg
Safety Instructions The Workman® 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.
C. Do not smoke while handling fuel. B. D. Fill fuel tank outdoors and to about one inch below top of tank (bottom of filler neck). Do not overfill. E. Wipe up any spilled fuel. C. Use caution when operating vehicle on a steep slope. Normally travel straight up and down slopes. Reduce speed when making sharp turns or when turning on hillsides. Avoid turning on hillsides whenever possible. 14. Check the safety interlock system daily for proper operation; refer to page 27.
be relieved by stopping engine, cycling dump valve from raise to lower and/or lowering box and attachments. Place the remote hydraulics lever in the float position. If box must be in raised position, secure with safety support. vehicle and your head. M. If ever unsure about safe operation, STOP WORK and ask your supervisor. 19. Do not touch engine, transaxle, radiator, muffler or muffler shield while engine is running or soon after it has stopped because these areas may be hot enough to cause burns. 27.
Sound Pressure Level 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. Vibration Level Hand Arm This unit does not exceed a vibration level of 2.5 m/s2, at the hands based on measurements of identical machines per ISO 5349 procedures. Whole Body This unit does not exceed a vibration level of 0.
Safety and Instruction Decals SAFETY ALERT SYMBOL GENERAL HAZARD SAFETY ALERT CRUSHING OF WHOLE BODY, APPLIED FROM ABOVE CRUSHING OF TOES OR FOOT, CRUSHING OF FINGERS OR HAND, CUTTING OF FINGERS OR HAND CUTTING OF FOOT FORCE APPLIED FROM ABOVE FORCE APPLIED FROM SIDE KEEP CHILDREN A SAFE DISTANCE FROM BATTERY STAY A SAFE DISTANCE FROM MACHINE STAY A SAFE DISTANCE FROM DRAINING STAY A SAFE DISTANCE FROM MACHINE STAY A SAFE DISTANCE FROM TANK HYDRAULIC OIL VALVE EXPLOSION FIRE OR OPEN FLAME FIRE, OPE
THROWN OR FLYING OBJECTS, SEVERING OF FINGERS OR FACE EXPOSURE HAND, ENGINE FAN RIDING ON THIS MACHINE IS SHUT OFF ENGINE & REMOVE ALLOWED ONLY ON A PASS- KEY BEFORE PERFORMING ENGER SEAT & ONLY IF THE MAINTENANCE OR REPAIR WORK DRIVER'S VIEW IS NOT HINDERED MACHINE TIPPING USE CAUTION ON STEEP HILLS MACHINE TIPPING MACHINE TIPPING DO NOT JUMP FROM TIPPING MACHINE HOLD TIGHTL & BRACE FEET HOLD HIP RESTRAINT & HAND HOLD, BRACE FEET LEAN AWAY FROM TIP STAY CLEAR OF ARTICULATION RUNOVER/BACKOVER, VEHI
Specifications Type: 4-wheel step through, out front operator style, two-person vehicle. Certified to meet ANSI Specifications B56.8a-1994. Steering System: Power assist, 3-position tilt steering Engine: Daihatsu 23.1Kw (31 hp) three-cylinder, Tires: Front tires: 20” x 10” 10, 4-ply rating, rib tread. Rear tires: 23” x 13” 12, 6-ply rating, turf tread. wheel, 3-3⁄4 turns lock-to-lock. 17.5 to 1 ratio, 35cm (14”) diameter steering wheel.
Ground Speed: Overall Width: 160cm (63”) Forward Speeds w/23” Rear Tires Overall Length: 316 cm (124.5”) w/o bed; 322cm (127”) w/full bed 337.8cm (133”) with 2⁄3 bed in rear mounting location High range: 12/18.5/31.9 kmh .(6/11.5/19.8 mph) Low range: 4.7/7.2/12.4 kmh (2.9/4.5/7.7 mph) Reverse Speeds w/24”Tires Height: 190c5cm (75”) to top of roll-over protection system High range: 11.6 kmh (7.2 mph) Low range: 4.5 kmh (2.8 mph) Ground Clearance: 17.8cm (7”) w/no load General Specifications (approx.
Set-Up Instructions 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. Fenders-Rear 2 Capscrew ⁄16-18 x 1” lg. 4 Flatwasher .344” I. D. 4 Locknut ⁄16-18 4 Capscrew 1⁄4-20 x 1” lg. 12 Flatwasher .281” I. D.
bracket, rear of fender and tail light plate together with (2) capscrews, washers and nuts, previously removed. Install Rear Fenders (Fig. 1–2) 1. 2. Loosen the locknuts and capscrews securing tail light plates to right and left frame brackets. 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 8. Loosely secure front of each fender mounting bracket to frame with a 1⁄4-20 x 1” lg. capscrew and locknut. 9.
2. Secure steering wheel to shaft with jam nut and tighten it to 14–20 Nm (10–15 ft lb.). 3. Install cap to steering wheel. system to mounting brackets with (2) 1⁄2-13 x 3” lg. capscrews and locknuts. FRONT Figure 4 1. 2. 3. 4. 5. Steering Wheel Jam Nut Cap Washer Foam Seal Figure 6 1. Roll-over protection system 2. Mounting brackets Activate and Charge the Battery (Fig. 7 & 8) Install Front Fenders (Fig. 5) 1.
2 1 1 2 2 3 Figure 8 1. Positive (+) cable 2. Hold down Figure 7 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 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. When battery is charged, disconnect charger from electrical outlet and battery posts. 6. 8.
CAUTION: The full bed weighs approximately 78 Kg, so don’t try to install or remove it by yourself. Get two or three other people to help. 6. Store cylinders in storage clips. Engage the hydraulic lift lock lever on the vehicle to prevent accidental extension of the lift cylinders. Re-install the Full Bed (Model 07212 only) Note : If the bed sides will be installed on the flat bed, it is easier to install them before the bed is installed on vehicle.
for full bed installation and front slots are for 2⁄3bed installation. Note: The engine may need to be started to extend or retract cylinders for alignment with holes. Keep fingers out! Note: The unused slot can be plugged with a capscrew and nut to prevent assembly errors. 4. Start the engine and engage the hydraulic lift lever to raise the bed. Release the lift lever and turn off the engine. Secure the raised bed with a hoist or block it to prevent it from accidentally falling. 5.
Before Operating SAE Viscosity Grades CAUTION 30 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. 10W-30 10W-40 10W-50 5W-30 ¡C —20 —10 0 10 20 30 40 Starting Temperature Range Anticipated Before Next Oil Change Figure 13 4. Check Engine Oil (Fig.
DANGER Because gasoline is flammable, caution must be used when storing or handling it. Do not fill fuel 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. DO NOT SMOKE while filling the fuel tank to prevent the possibility of an explosion. Always fill fuel tank outside and wipe up any spilled gasoline before starting engine.
Check the Cooling System (Fig. 17) 1 Capacity of cooling system is approximately 3.3 l (3.5 qts.). 3 The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Check level of coolant at beginning of each day before starting the engine. 1. 2 Park machine on a level surface. CAUTION Figure 17 1. Reserve tank 2. Cold line 3. Hot line If engine has been running, pressurized hot coolant can escape if radiator cap is removed and cause burns.
Check Front Differential Oil 1. The air pressure needed is determined by the payload carried. Four-Wheel Drive Model Only (Fig. 19) 2. 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. 3. Higher pressures should be used for heavier payloads at higher speeds. Do not exceed the maximum pressure.
Maximum Total Axle Weight (lb.) (thousands) 23” FRONT TIRES Tire Pressure (p.s.i. Check Brake Fluid (Fig. 20) 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.
Controls Accelerator Pedal (Fig. 21)—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.
B. 4 1 5 2 Shift only on level ground. 6 C. Depress clutch pedal fully. D. Move lever fully forward for High and fully rearward for Low. HIGH is for higher speed driving on level, dry surfaces with light loads. 3 7 LOW is for low speed driving. Use this range when greater than normal power or control is required. For example, steep grades, difficult terrain, heavy loads, slow speed but high engine speed (spraying). Figure 22 1. 2. 3. 4. 5. 6. 7.
immediately and contact your local TORO distributor for assistance. 3 2 Important Do not operate vehicle until repair is complete. Failure to observe this precaution may result in damage to the engine. Ignition Switch (Fig. 23)—The ignition switch, used to start and stop the engine, has three positions: OFF, ON /Preheat and START. Rotate key clockwise— START position—to engage starter motor. Release key when engine starts. The key will move automatically to the ON position.
to start the engine. Operating Instructions B. Pre-Starting Checks C. If the engine is flooded—fully depress the accelerator pedal and hold it to the floor until the engine starts. Never pump the accelerator pedal. Safe operation begins before taking the vehicle out for a day’s work. You should check these items each time: 1. Check tire pressure. 5. Note: These tires are different than car tires, they require less pressure to minimize turf compaction and damage. 2.
Stopping the Vehicle CAUTION To stop machine, remove foot from accelerator pedal, depress clutch pedal, then depress brake pedal. The interlock switches are for the operator’s protection, so do not bypass them. Check operation of the switches daily to assure interlock system is operating. If a switch is malfunctioning replace it before operating. Regardless whether switches are operating properly or not, replace them every two years to assure maximum safety.
You and your passenger should remain seated at all times, keeping arms and legs inside the vehicle. The operator should keep both hands on steering wheel, whenever possible and passenger should use hand holds provided. vehicle. Children should not be allowed to operate the vehicle. Anyone who operates the vehicle should have a motor vehicle license. If you are not experienced at driving the vehicle, practice driving it in a safe area away from other people.
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. The braking characteristics also change with no bed or attachment on the vehicle. Fast stops may cause the rear wheels to lock up before the front wheels lock up, which may affect the control of the vehicle. It is a good idea to decrease vehicle speed with no bed or attachment.
and without a load, tip overs are more likely if you turn on a hill. IN CASE OF TIPOVER, DON’T JUMP Slow down and shift into a lower gear before starting up or down a hill. If you have to turn while on a hill, do it as slowly and cautiously as possible. Never make sharp or fast turns on a hill. WARNING • Tipping or rolling 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.
• • another way to reduce the risk of a tip over. Adding liquid ballast (calcium chloride) to the rear tires. 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. Traction will increase with no passenger in the front seat. Loading and Dumping Never position heavy loads behind the rear axle.
does not replace the safe operation, already discussed concerning steep hills and heavy loads. Transporting the Vehicle For moving the vehicle long distances, a trailer should The differential lock causes the rear wheels to spin at the same speed. When using differential lock your ability to make sharp turns is somewhat restricted and may scuff the turf. Use the differential lock only when needed, at slower speeds and only in first or second gear.
Remote Hydraulic Control (Optional) 1 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 quick couplers at the rear of the vehicle. 2 Figure 27 Control Lever Positions 1. Axle tube 2. Hitch plate REMOTE HYDRAULICS Trailer Towing The Workman® is capable of pulling trailers and attachments of greater weight than the vehicle itself.
Note: If hydraulic motor is used, it may see 6900 kPa (1000 psi) back pressure. Important If used with a hydraulic cylinder or no attachment, the Raise or On position causes the oil flow to go over a relief valve which can damage the hydraulic system. Additionally this condition does not allow return flow to supply the power steering circuit, which makes steering more difficult. Use these positions only momentarily or with a motor attached.
Remote Hydraulic Control Trouble Shooting: CAUTIOIN Use caution when moving lever to the float position because it will allow rear implement to lower unimpeded. A. Difficulty in connecting or disconnecting quick couplers. Pressure not relieved (Quick coupler under pressure). Important Check hydraulic oil level after installation of attachment. Check operation of attachment by cycling attachment several times to purge air from system, then recheck hydraulic oil level.
Maintenance Maintenance Chart and Checklist Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications Maintenance Check Item Daily Maintenance Check For Week Of _________________ MON TUES ✓ Safety Interlock Operation ✓ Service & Park Brake Operation ✓ Fuel Level ✓ Accelerator Operation ✓ Clutch & Shifter Operation ✓ Engine Oil Level ✓ Transaxle Oil Level ✓ Cooling System Fluid Level1 ✓ Brake Fluid Level ✓ Air Cleaner2 ✓ Unusual Engine Noi
Quick Reference Chart 4-Wheel Drive Chart Shown 1. 2. 3. 4. 5. 6. 7. 8. 8.1. 9. 10. 11. 12. 13. 14. 15. 16. Engine oil level Engine oil drain Transaxle/hydraulic oil level (dip stick) Belts (Governor, water pump, hydraulic pump) Coolant level fill Fuel (unleaded fuel only) Grease points (34) 100 hours Radiator screen Ratiator cleanout door Air cleaner Fuel pump Battery Tire pressure—maximum 20 psi front; 18 psi rear (24” tire) Fuses (lights–10 amp; ignition–7.5 amp; dash assessories–7.
Lubrication Greasing Bearings And Bushings (Fig. 28–34) WARNING Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition 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. The vehicle has grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease.
Important Heavy-Duty Operation If vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently.
WARNING Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition switch. Any load material must be removed from bed or other attachment before working under raised bed. Al ways place the safety support on extended lift cylinder to hold box up. After maintenance is completed, remove safety support, slide it onto storage stud and lower bed. 1. Raise bed until lift cylinders are fully extended. 2.
1 Figure 37 1. Front jacking point Figure 39 1. Air cleaner latches 2. Dust cup 3. Filter 1 1 2. Gently slide filter out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body. General Air Cleaner Maintenance Practices (Fig. 39) 3. Inspect filter and discard if damaged. Do not wash or reuse a damaged filter.
5. Inspect new filter for shipping damage. Check sealing end of filter. Do not install a damaged filter. 6. Insert new filter properly into air cleaner body. Make sure filter is sealed properly by applying pressure to outer rim of filter when installing. Do not press on flexible center of filter. 7. 4. Fuel System (Fig. 42) Fuel Lines and Connections Check lines and connections every 600 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections.
2. Lift and remove radiator screen from front of radiator. 5. Clean radiator and screen thoroughly with compressed air. 4. Remove reserve tank cap. 1 1 Figure 45 1. Reserve tank cap 5. Open coolant drain cock at bootom of radiator and allow coolant to flow into a drain pan. When coolant stops flowing, close the drain cock. 6. Open bleed screw on top of water pump (Fig. 43). Figure 43 1. Radiator screen Changing Engine Coolant (Fig. 44) 1. Park machine on a level surface. 2.
and tighten nut. 11. Stop the engine. Recheck the level and replenish, if required. 1 Adjusting Belts (Fig. 47–48) Check condition and tension of all belts after first day of operation and every 200 operating hours thereafter. Raise bed (if so equipped) and place safety support on extended lift cylinder to hold up bed. 2 Alternator Belt (Fig. 47) 1. 2. Check tension by depressing belt at mid span of crankshaft and alternator pulleys with 30 Nm (22 lbs.) of force. A new belt should deflect 7–12 mm (0.
Replacing Hydraulic Filter (Fig. 51) 1 Initially, replace the hydraulic filter after 10 operating hours; thereafter, replace the filter every 800 hours.Use the Toro replacement filter (Part No. 54-0110). 2 Important Use of any other filter may void the warranty on some components. Figure 49 1. Accelerator cable 2. Ball joint Changing Transaxle/Hydraulic Fluid (Fig. 50) 1. Position vehicle on a level surface, stop engine, engage parking brake and remove key from ignition switch. 2.
differential. Place drain pan under drain plug. Figure 53 1. Hydraulic strainer 4. Remove strainer and clean by back flushing with a clean degreaser. Allow to air dry before reinstalling. 5. Reinstall strainer. 6. Reinstall hydraulic line and fitting to strainer. 7. Reinstall and tighten drain plug. 8. Fill reservoir with approximately 7.1 l (7.5 qt.) of Dexron III ATF. Refer to Check Hydraulic Fluid, p 20. Figure 52 1. Front differential 2. Fill/check plug 3. Drain plug 3.
1 Figure 54 Important : a cracked fouled, dirty or otherwise malfunctioning spark plug must be replaced. Do not sand blast, scrape, or clean electrodes by using a wire bursh because grit may eventually release from the plug and fall into the cylinder. The result is usually a damaged engine. 4. 5. Figure 55 1. Link rod ball joint 3. Set the air gap between the center and side of the electrods at 0.81mm. Install a correctly gapped spark plug and tighten the plug to 20–27 Nm (1520 ft. lb).
1 3 1 4 2 Figure 58 1. Clutch switch Figure 57 1. 2. 3. 4. Clutch cable Jam nuts Return spring Ball joint Adjusting Parking Brake (Fig. 59) Check adjustment every 200 hours. Note: Ball joint may be removed and rotated if additional adjustment is required. 2. Disconnect return spring from clutch lever. 3. Adjust jam nuts and/or ball joint until bottom rear edge of clutch pedal is 9.5 cm ± 3mm (3.75” ± 0.12”) from top of floor plate diamond pattern, when a 4-lb. force is applied to pedal. 1.
Adjusting the High-Low Cable (Fig. 60) 2 Check adjustment every 200 hours. 1. Remove clevis pin securing High-Low cable to transaxle. 2. Loosen clevis jam nut and adjust clevis so clevis hole aligns with hole in transaxle bracket. 3. Reinstall clevis pin and tighten jam nut after adjustment has been attained. 1 3 0.89mm ±0.64mm 2 Figure 61 1. Differential lock cable 2. Transaxle bracket 3. Spring 3 1 3. While pulling back on spring, adjust jam nuts to obtain 0.89mm ± 0.64mm ( 0.035” ± .
Fuses (Fig. 64) 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 Figure 62 1. Center-to-center distance 2. — 10A 7.5A 7.5A To adjust, loosen jam nuts at both ends of tie rod. 1 1 Figure 64 1. Fuse block Figure 63 Jump Starting Procedure 1. Tie rod 3. 4. Rotate tie rod to move front of tire inward or outward. WARNING Tighten tie rod jam nuts when adjustment is correct. Jump starting can be dangerous.
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. 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. 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.
Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Check battery fluid level Every Check batterycable connections 50 hours Check air cleaner Maintenance Interval& Service Every 100 hours Every 200 hours Every 400 hours Every 800 hours Lubricate all grease fittings Inspect the condition and wear of the tires Check front differential oil level (4WD) ‡Change engine oil and filter Inspect cooling system hoses Check governor oil level ✝Check cable adjustments Check alter
Hydraulic Schematic (Base Vehicle) 53
Hydraulic Schematic (Vehicle w/Remote Hydraulic Kit) (MODEL 07211 TC Only) 54
Electrical Schematic (Base Vehicle) 55
Electrical Schematic (Vehicle w/Remote Hydraulic Kit) (MODEL 07211 TC Only) 56
Identification And Ordering Model and Serial Numbers The Workman® 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. Note: Do not order by reference number if a parts catalog is being used; use the part number.
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