Form No. 3328–383 Rev A Workman) 3200 & 4200 Liquid Cooled Gas Utility Vehicle Model Model Model Model No. 07211—Serial No. 230000001 and Up No. 07211TC—Serial No. 230000001 and Up No. 07212—Serial No. 230000001 and Up No. 07218—Serial No.
Check Front Differential Oil . . . . . . . . . . . . . . . . . Check Torque Of Wheel Nuts . . . . . . . . . . . . . . . Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . Check Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre–starting Checks . . . . . . . . . . . . . . . . . . . . . . . Starting Engine . . . . . . . . . . . . . .
Adjusting Clutch Pedal . . . . . . . . . . . . . . . . . . . . . Adjusting Parking Brake . . . . . . . . . . . . . . . . . . . Adjusting Shift Cables . . . . . . . . . . . . . . . . . . . . . Adjusting High–low Cable . . . . . . . . . . . . . . . . . . Adjusting Differential Lock Cable . . . . . . . . . . . . Inspect Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front Wheel Toe–in . . . . . . . . . . . . . . . . . . . . .
Safe Operating Practices • 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. 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.
Maintenance Sound Pressure Level • 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. 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. • Never work under a raised bed without placing bed safety support on fully extended cylinder rod.
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.
93-9446 Model 07211TC 1. Horn 2. Engine—stop 3. On 4. Engine—start 93-9852 1. Warning—read the Operator’s Manual. 2. Crushing hazard—install the cylinder lock. 87-5920 8 5. Read the Operator’s Manual.
87-6000 87-6020 93-9443 93-9430 1. Locked 2. Differential lock 1. Parking brake 3. Unlocked 87-5910 1. Slow 2. Fast 87-6670 105-7971 1. Slow 2. Fast 93-9851 1. Headlights 2. Engine—start 9 3. Transmission—third high; no fast speed 4.
87-5960 87-5930 1. When adding fuel to the tank, leave 1 inch (25 mm) between the fuel and the top of the tank. 93-9857 1. Vehicle speed 2. Transmission—high 3. Transmission—low 93-9448 1. Warning—when adding fuel to the tank, leave 25 mm between the fuel and the top of the tank; read the Operator’s Manual. 87-6010 93-9442 1. Maximum tongue weight is 90 kg; maximum trailer weight is 680 kg. 2. For information on transmission fluid, read the Operator’s Manual. 93-9444 1. Unlocked 2. Locked 3.
93-9868 93-6687 1. Crushing hazard of hand—read the Operator’s Manual. 1. Do not step here. 93-7814 93-9879 1. Entanglement hazard, belt—stay away from moving parts. 1. Stored energy hazard—read the Operator’s Manual. 93-6689 1. Warning—do not carry passengers. 93-9449 1. Read the Operator’s Manual. 2. Grease every 100 hours. 3. Add grease (9 grease points). 93-9850 1. Do not repair or revise—read the Operator’s Manual. 105-4228 4 Wheel Drive 93-9899 1.
98-9335 1. Cutting/dismemberment hazard, fan—stay away from moving parts. 105-4219 2 Wheel Drive 93-8071 105-4215 1. Hot surface/burn hazard—stay a safe distance from the hot surface. 1. Warning—avoid pinch points.
93-6668 Model 07211TC only 1. Battery 2. Read the instructions before servicing or performing maintenance. 3. Contains lead; do not discard. 93-7276 Model 07211TC only 1. Explosion hazard—wear eye protection. 2. Caustic liquid/chemical burn hazard—to perform first aid, flush with water. 105-4214 1. Warning—the machine can tip. 2. Do not jump from a tipping machine. 3. Hold tight and brace your feet. 4. The passenger should hold the hip restraint and hand hold. 5.
93-9525 Model 07211TC only 93-9084 Model 07211TC only 1. Lift point 2. Tie-down point 93-9866 Model 07211TC only 1. Float 2. Read the Operator’s Manual. 3. On 4. A-coupler, lower the attachment, or clockwise flow direction 5. Raise the attachment, counterclockwise flow direction, or B-coupler 93-9089 Model 07211TC only 1. Warning—the hydraulic oil pressure is 133 bar. 2. Coupler A 3. Coupler B 94-1224 Model 07211TC only 1.
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 maximum by a mechanical governor. 58.1 cu. in. (952 cc) displacement. Forced lubrication by gear pump.
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/24” 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: 2.8 mph Ground Speed Base Weight (Dry w/o flatbed) 1400 lbs. (2wd) 1600 lbs. (4wd) Rated Capacity 2,600 lbs. (includes 200 lb. operator, 200 lb. passenger and loaded attachment).
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. (Model 07211TC only) 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 1. Loosen the locknuts and capscrews securing tail light plates to right and left frame brackets (Fig. 1). 2.
3. Install cap to steering wheel. 4 5 3 1 2 1 2 Figure 4 1. Steering wheel 2. Jam nut 3. Cap FRONT 4. Washer 5. Foam seal Figure 6 1. ROPS Install Front Fenders 2. Mounting bracket (Model 07211TC only) Activate and Charge Battery 1. Mount a fender to each side of skirt with (7) 10–24 Phillips screws, flat washers and locknuts. If battery is not filled with electrolyte or activated, it must be removed from vehicle, filled with electrolyte and charged. Bulk electrolyte with 1.
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 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 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.
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 27 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 Starting Engine On dashboard (Fig. 25). 1. Sit on operator’s seat and engage parking brake. 2. Disengage PTO (if so equipped) and return hand throttle lever to OFF position (if so equipped). 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.
Stopping Vehicle 3. If engine cranks or starts, there is a malfunction in the interlock system that must be repaired before operating vehicle. To stop machine, remove foot from accelerator pedal, depress clutch pedal, then depress brake pedal. Caution Stopping Engine If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. To stop engine, rotate ignition key to OFF and engage parking brake.
When using heavy attachments (more than 1000 pounds), such as sprayers, top dressers, or spreaders, etc., operating speeds should be restricted by moving 3rd high lockout switch to slow– – position. operating any vehicle, take it easy as you begin. Be sure you know how to stop quickly in an emergency. If you need help, ask your supervisor for assistance. Many factors contribute to accidents. You have control over several of the most important.
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.
Hills Loading And Dumping The weight and position of the cargo and passenger can change the vehicle center of gravity and vehicle handling. To avoid loss of control resulting in personal injury, follow these guidelines. Warning Tipping or rolling the vehicle on a hill will cause serious personal injury. Do not carry loads which exceed the load limits described on the vehicle weight label. • If engine stalls or you lose headway on a hill, never attempt to turn vehicle around.
back, the front wheels can even come off of the ground when going over bumps or up a hill. This will result in a loss of steering and may lead to the vehicle tipping over. Warning As a general rule, position the weight of the load evenly from front to rear and evenly from side to side. Tipping or rolling the vehicle on a hill will cause serious injury. If a load is not secured, or you are transporting a liquid in a large container such as a sprayer, it can shift.
Transporting Vehicle For moving the vehicle long distances, a trailer should be used. Make sure the vehicle is secured to the trailer. Refer to Figures 26 and 27 for location of tie down points. Towing Vehicle 1 In case of emergency, the vehicle can be towed for a short distance. However, Toro does not recommend this as a standard procedure. 2 Figure 27 1. Axle tube Warning Towing at excessive speeds could cause vehicle to lose steering control. Never tow vehicle faster than 5 MPH. 2.
Remote Hydraulic Control On Position 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 the quick couplers at the rear of the vehicle. This position is similar to Raise (quick coupler ”B” position). It also directs oil to quick coupler ”B” except that the lever is held in this position by a detent notch in the control panel. This allows oil to flow continuously to equipment that uses a hydraulic motor.
Remote Hydraulic Control Trouble Shooting: 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. Attachment cylinder will slightly affect transaxle oil level. Operation of vehicle with low oil level can damage pump, remote hydraulics, power steering and vehicle transaxle. • Difficulty in connecting or disconnecting quick couplers.
Maintenance Note: Determine the left and right side of the machine from the normal operating position. Service Interval Chart 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. If machine is operated under normal conditions, lubricate all bearings and bushings after every 100 hours of operation.
Figure 32 Figure 29 Figure 33 Figure 30 Figure 34 Figure 31 41
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.
2 ÎÎ ÎÎ 1 Figure 40 1. Engine oil drain plug 1 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 cover 2. 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. 3. Clean radiator and screen thoroughly with compressed air. Note: Blow debris away from radiator. 1 Changing Engine Coolant 1. Park machine on a level surface. 2. Raise bed (if so equipped) and place safety support on extended lift cylinder to hold up bed. Caution If the engine has been running, the pressurized, hot coolant can escape and cause burns. Figure 42 • Do not open the radiator cap when the engine is running.
10. Start engine and operate until warm. Tighten water pump bleed screw when water appears at the bleed screw. 1 11. Stop engine. Recheck level and replenish, if required. Adjusting Belts 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. Alternator belt 1.
2. To adjust belt tension: • Loosen idler pulley mounting nut, move pulley to increase tension and tighten nut. 1 2 1 2 Figure 49 1. Accelerator cable 2. Ball joint Figure 48 1. Fan belt 2. Idler pulley Adjusting Accelerator Pedal 1. Position vehicle on level surface, stop engine and engage the parking brake. .200–.350” clearance 2. Adjust ball joint on accelerator cable (Fig. 49) to allow .200”–.350” of clearance between accelerator pedal arm and top of diamond tread floor plate, when a 20 lb.
4. Assure filter mounting area is clean. Screw filter on until gasket contacts mounting plate. Then tighten filter one–half turn. 5. Start engine and let run for about two minutes to purge air from the system. Stop the engine and check the hydraulic oil level and for leaks. 1 Change Front Differential Oil 2 Front Wheel Drive Only Figure 51 1. Hydraulic reservoir Change front differential oil every 800 hours. 2. Drain plug 1.
2. Remove drain plug (Fig. 53) from side of reservoir and let hydraulic fluid flow into drain pan. 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 brush because grit may eventually release from the plug and fall into the cylinder. The result is usually a damaged engine. 3. Note orientation of hydraulic hose and 90 fitting connected to strainer on side of reservoir.
Note: The clutch free play should never be less than .75”. 6. Tighten jam nuts after adjustment has been attained. 7. Recheck clutch safety switch adjustment (Fig. 59). 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. 3 2 1 1 Figure 57 1. Brake pedal 2. Clutch pedal 3. Clutch pedal upstop Figure 59 Adjusting Clutch Pedal 1. Clutch switch Check adjustment every 200 hours. 1.
Adjusting Shift Cables 2. Loosen jam nuts securing differential lock cable to bracket on transaxle. Check adjustment every 200 hours. 1. Move shift lever to Neutral position. 2 2. Remove clevis pins securing shift cables to transaxle shift arms. 2 1 1 3 3 .035” + .025" Figure 62 Figure 61 1. Shift arm (1st – Rev.) 2. Shift arm (2nd – 3rd) 1. Differential lock cable 2. Transaxle bracket 3. Shift arm (High–low) 3.
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 Center–to–center Distance –– 10A 7.5A 7.5A Figure 63 2. To adjust, loosen jam nuts at both ends of tie rod. 1 1 Figure 65 1. Fuse block Figure 64 1. Tie rod Jump Starting Procedure 3. Rotate tie rod to move front of tire inward or outward. Warning 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 (Base Vehicle) 56
Hydraulic Schematic (Vehicle w/ Remote Hydraulic Kit) (Model 07211 TC Only) 57
Electrical Schematic (Base Vehicle) 58
Electrical Schematic (Vehicle w/ Remote Hydraulic Kit) (Model 07211 TC Only) 59
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.
