FORM NO. 3325-605 MODEL NO. 07220 - 210000001 & Up OPERATOR'S MANUAL WORKMAN 3210 Liquid Cooled Gas Heavy Industry Vehicle To ensure maximum safety, optimum performance, and to gain knowledge of the product, it is essential that you or any other operator of the machine read and understand the contents of this manual before the engine is ever started.
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. WARNING The WORKMAN is an off-highway vehicle only, and is not designed, equipped, or manufactured for use on public streets, roads or highways.
FOREWORD The TORO WORKMAN meets the requirements of ANSI B56.8a-1994 and SAE J2258. Supervisors, operators and service persons should be familiar with the following standards and publications: (The material may be obtained from the address shown). Flammable and Combustible Liquids Code: ANSI/NFPA 30 National Fire Protection Association: ANSI/NFPA #505; Powered Industrial Trucks ADDRESS: National Fire Prevention Association Barrymarch Park Quincy, Massachusetts 02269 U.S.A ANSI/ASME B56.
TABLE OF CONTENTS SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 5-7 SAFETY AND INSTRUCTION DECALS . . . . . 8-10 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LOOSE PARTS CHART . . . . . . . . . . . . . . . . . . . . . . . 12 SET-UP INSTRUCTIONS . . . . . . . . . . . . . . . . 13-15 Install Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install Steering Wheel . . . . . . . . . . . . . . . . . . . . . 13 Install Front Fenders . . . . . . . . . . . . .
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.
SAFETY INSTRUCTIONS 17. When starting the engine: A. Sit on operator's seat and engage parking brake. B. Disengage any attachments and return hand throttle lever to OFF position (if so equipped). C. Move shift lever to NEUTRAL and depress clutch pedal. D. Keep foot off accelerator pedal. E. Turn ignition key to ON, then to START. 18. Using the machine demands attention. Failure to operate vehicle safely may result in a accident, tip over of vehicle and serious injury or death. Drive carefully.
SAFETY INSTRUCTIONS 26. Before disconnecting or performing any work on the hydraulic system, all pressure in system must be relieved by stopping engine. 27. To make sure entire machine is in good condition, keep all nuts, bolts and screws properly tightened. 28. To reduce potential fire hazard, keep the engine area free of excessive grease, grass, leaves and accumulation of dirt. 29.
SAFETY AND INSTRUCTION DECALS The following safety and instruction decals are installed on the machine. If any become damaged or illegible, replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your Authorized TORO Distributor. ON REAR SKIRT (Part No. 99-1125) ON DASH (Part No. 87-8520 ON REAR AXLE TUBE (Part No. 87-9080) 8 ON FAN SHROUD (Part No.
SAFETY AND INSTRUCTION DECALS ' UNDER DASH NEXT TO FUSE BLOCK (Part No. 87-6670) ON SKIRT (Part No. 87-5920) WARNING THIS ARM IS SPRING LOADED! SEE OPERATORS MANUAL FOR DISASSEMBLY PROCEDURE ON SPRING CRADLE (Part No. 44-0760) DO NOT STEP ON BATTERY COVER (Part No. 36-3400) ON DASH (Part No. 94-5272) ON LEFT FRAME RAIL (Part No. 66-6840) ON FAN SUPPORT (Part No. 80-8040) UNDER RIGHT SIDE OF DASH (Part No.
SAFETY AND INSTRUCTION DECALS HITCH RATING: MAXIMUM TONGUE WEIGHT 200 LBS. MAXIMUM TRAILER WEIGHT; 1500 LBS. TRANSMISSION FLUID USE DEXRON IIl AUTOMATIC TRANSMISSION FLUID OR EQUIVALENT ON AXLE TUBE (Part No. 87-6060) IN FRONT OF RADIATOR (Part No. 87-9420) ON CONSOLE (Part No. 87-6020) ON SKIRT (Part No. 87-5930) ON ROPS (Part No. 87-5980) 10 ON ROPS (Part No.
SPECIFICATIONS Type: 4 wheel step through, out front operator style, ROPS: 2 post roll over protection structure with two person vehicle. Certified to meet ANSI Specifications B56.8a-1994. Engine: Mitsubishi 27 hp, three cylinder, liquid cooled, counterbalanced, gasoline engine; regulated to a maximum of 23 hp at 3650 rpm by a mechanical governor. 40 cu. in. (657 cc) displacement. Forced lubrication by gear pump. 40 amp alternator with I/C regulator. Spin-on oil filter.
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 12 QTY. USE Wheel Nut Wheel-Front Wheel Nut Wheel-Rear 10 2 10 2 Steering wheel Foam Seal Washer Nut Cap 1 1 1 1 1 Fenders-Front Phillips Screw 10-24 Washer Locknut 10-24 2 14 14 14 Seat Frame Seat Frame Bracket Carriage Bolts 3/8-16 x 3/4" lg.
SET-UP INSTRUCTIONS INSTALL WHEELS (Fig. 1) 1. Remove and discard fasteners securing wheels. 2. Mount wheels and torque nuts to 45 55 ft lb. 1 1 2 Figure 3 1. Fender Figure 1 INSTALL SEAT FRAME (Fig. 4) 1. Wheel 2. Wheel Nut 1. Mount a seat frame bracket to each end of seat frame with (2) 3/8-16 x 3/4" carriage bolts and flange locknuts. INSTALL STEERING WHEEL (Fig. 2) 1. Remove jam nut from steering shaft. Slide foam seal, steering wheel and washer onto steering shaft. 2.
SET-UP INSTRUCTIONS INSTALL SEAT MANUAL TUBE BACK CUSHIONS, AND BED SUPPORT 2. Secure each side of ROPS to mounting brackets with (2) 1/2-13 x 3" lg. capscrews and locknuts. (Fig. 5 - 6) 1. Mount (2) seat back brackets to each seat back cushion with (4) 1/4-20 x 3/4" lg. capscrews and 1/4" flat washers. Position brackets on seat back cushions as shown in figure 5. 1 1 2 FRONT 2 Figure 7 1. ROPS 2. Mounting brackets Figure 5 1. Cushion seat back 2. Seat back bracket ACTIVATE AND CHARGE BATTERY 2.
SET-UP INSTRUCTIONS CAUTION Electrolyte gases are explosive and can cause serious injury to eyes, lungs and skin. Wear safety goggles and rubber gloves when working with electrolyte or battery. Charge the battery in a well venti lated place so gasses produced while charging can dissipate. Since the gases are explosive, keep open flames and electrical spark away from the battery; do not smoke. Nausea may result if the gases are inhaled.
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 attach ment before working under raised bed. Always place the safety support on extended lift cylin der to hold box up. CHECK CRANKCASE OIL (Fig.
BEFORE OPERATING 3. Fill tank to about one inch below top of tank, (bottom of filler neck). DO NOT OVERFILL. Then install cap. 4. Wipe up any fuel that may have spilled to prevent a fire hazard. 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.
BEFORE OPERATING CHECK TORQUE OF WHEEL NUTS WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury. Torque front and rear wheel nuts to 45 65 ft -lb after 1 4 hours of opera tion and again after 10 hours of operation and every 200 hours thereafter. IMPORTANT: When replacing vehicle tires, only use replacements approved for the Workman. Use of tires not approved may cause turf damage or accelerated drive train damage. CHECK BRAKE FLUID (Fig.
CONTROLS Accelerator Pedal (Fig. 15) - The accelerator pedal gives the operator the ability to vary engine and ground speed of the vehicle, when the transmission is in gear. Depressing the pedal increases engine RPM and ground speed. Releasing pedal will decrease engine RPM and ground speed of the machine. 1 IMPORTANT: Do not shift the transaxle to the reverse or forward gear unless the vehicle is standing still. Damage to transaxle may occur.
CONTROLS Horn Button (Fig. 17) - Pressing button activates horn. 5 1 To check operation of warning lights: 1. Apply parking brake. 6 4 3 1. Tilt steering lever 2. Ignition switch 3. Horn button 2 Figure 17 4. Coolant temp. gauge 5. Engine low oil pressure light 6. Charge indicator Engine Low Oil Pressure Light (Fig. 17) - The light glows and the engine will shut down if the oil pressure drops below safe levels. Turn the key off and check the oil level.
OPERATING INSTRUCTIONS 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. 1. Check tire condition. 3. Move gear shift lever to 1st gear. 4. Release clutch pedal smoothly while depressing accelerator pedal. 5.
OPERATING INSTRUCTIONS A break-in oil for engine is not required. Original engine oil is the same type specified for regular oil changes. Refer to Maintenance section of Operator's Manual for any special low hour checks. CHECK INTERLOCK SYSTEM The purpose of the interlock system is to prevent the engine from cranking or starting unless the clutch pedal is depressed. CAUTION The interlock switches are for the opera tor's protection, so do not bypass them.
OPERATING INSTRUCTIONS SPEED Speed is one of the most important variables leading to accidents. Driving too fast for the conditions can cause you to lose control and have an accident. Speed can also make a minor accident worse. Driving head-on into a tree at slow speed can cause injury and damage, but, driving into a tree at high speed can destroy the vehicle and kill you and your passenger. Never drive too fast for the conditions. If there is any doubt about how fast to drive, slow down.
OPERATING INSTRUCTIONS HILLS 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. Always back straight down a hill in reverse gear. Never back down in neutral or with the clutch depressed, using only the brakes. Never drive across a steep hill, always drive straight up or down. Avoid turning on a hill Don't drop the clutch" or slam on the brakes.
OPERATING INSTRUCTIONS Do not carry loads which exceed the load limits described on the vehicle weight label. The vehicle has several combinations of boxes, platforms, and attachments available. These can be used in various combinations that allow for maximum capacity and versatility. The full sized box is 55 inches wide by 65 inches long and can hold up to 2000 pounds of evenly distributed cargo. Loads vary in how they are distributed. Sand spreads out evenly and quite low.
OPERATING INSTRUCTIONS TRAILER TOWING The Workman is capable of pulling trailers and attachments of greater weight than the vehicle itself. Several types of tow hitches are available for the Workman, depending on your application. Contact your Authorized TORO Distributor for details. 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.
MAINTENANCE CHART AND CHECKLIST Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance MON TUES WED THURS FRI SAT SUN Check Item 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 Cl
QUICK REFERENCE CHART LUBRICATION WARNING Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition switch. Any load ma terial must be removed from bed or other at tachment before working under raised bed. Al ways place the safety support on extended lift cylinder to hold box up. 1. Wipe grease fitting clean so foreign matter cannot be forced into the bearing or bushing. 2. Pump grease into the bearing or bushing. 3. Wipe off excess grease.
LUBRICATION Figure 25 Figure 23 Figure 26 Figure 24 IMPORTANT Heavy Duty Operation If vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently.
MAINTENANCE CAUTION Only qualified and authorized personnel shall be permitted to maintain, repair, adjust or in spect the vehicle. Avoid fire hazards and have fire protection equipment present in the work area. Do not use an open flame to check level or leakage of fuel, battery electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for cleaning parts. Many of the subjects covered in this maintenance section require raising and lowering the bed.
SERVICING AIR CLEANER MAINTENANCE 1. Release latches securing air cleaner cover to air cleaner body. Separate cover from body. Clean inside of air cleaner cover. 2. Remove drain plug and let oil flow into drain pan. When oil stops, install drain plug. 2. Gently slide primary filter (Fig. 29) out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body. Do not remove safety filter. 3. Inspect primary filter and discard if damaged.
MAINTENANCE 4. Open coolant drain cock at bottom of radiator and allow coolant to flow into drain pan. When coolant stops, close drain cock. 1 5. Remove coolant drain plug from engine and allow coolant to flow into drain pan. When coolant stops, install drain plug. 6. Slowly fill radiator with a 50/50 mixture of water and permanent ethylene glycol anti-freeze. Install radiator cap. Figure 32 7. Slowly fill reserve tank until level reaches COLD line. DO NOT OVERFILL. Install reserve tank cap. 5.
MAINTENANCE Fan belt (Fig. 35) 1. Check tension by depressing belt at mid span of fan and drive shaft pulleys with 22 lbs. of force. A new belt should deflect .48-.58 in. A used belt should deflect .55-.65 in. If deflection is incorrect, proceed to next step. If correct, continue operation. 4. Remove check plug from governor. Oil level must be up to bottom of hole. If oil level is low, remove oil fill plug and add same oil that is being used in engine.
MAINTENANCE IMPORTANT: Use only hydraulic fluids specified. Other fluids could cause system damage. 3. Remove hydraulic line and fitting connected to strainer on side of reservoir. 4. Remove strainer and clean by back flushing with a clean degreaser. Allow to air dry before reinstalling. 1 1 2 Figure 38 1. Hydraulic Reservoir 2. Drain plug REPLACING HYDRAULIC FILTER (Fig. 39) Figure 40 1. Hydraulic strainer Use the Toro replacement filter (Part No. 54-0110 ). 5. Reinstall strainer.
MAINTENANCE 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. 4. Set air gap between center and side of electrodes at .040". Install correctly gapped spark plug and tighten plug to 15-20 ft-lb. If torque wrench is not used, tighten plug firmly. 5. Install spark plug wires.
MAINTENANCE ADJUSTING PARKING BRAKE (Fig. 46) Check adjustment every 200 hours. 1. Loosen set screw securing knob to parking brake lever. 2. Rotate knob until a force of 35-45 lbs. for 2 wd models and 45-55 lbs. for 4 wd models is required to actuate lever. Center-to-center Distance 3. Tighten set screw after adjustment has been attained. Figure 47 2 2. To adjust, loosen jam nuts at both ends of tie rod. 1 1 3 Figure 46 1. Parking brake lever 2 Knob 3.
JUMP STARTING PROCEDURE MAINTENANCE WARNING Jump starting can be dangerous. To avoid personal injury or damage to electrical com ponents in vehicle, observe the following warnings: Never jump start with a voltage sources greater than 15 volts D.C. This will dam age the electrical system. Never attempt to jump start a discharged battery that is frozen. It could rupture or explode during jump starting. Observe all battery warnings while jump starting your vehicle.
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Check Battery Fluid Level Check Battery Cable Connections Clean Air Cleaner Maintenance Interval & Service Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800hrs Lubricate All Grease Fittings Inspect Condition and Wear of Tires Check Front Differential Oil Level (4WD) Change Engine Oil and Filter Inspect Cooling System Hoses Check Governor Oil Level Check Cable Adjustments Check Alternator, Governor and Fan
HYDRAULIC SCHEMATIC HYDRAULIC PUMP DISPLACEMENT SPEED 3 .388 IN /REV OR OPERATING SPEED .625 OF ENGINE SPEED INTERNAL 1000 PSI RELIEF VALVE POWER ASSISTED STEERING GEAR PITMAN OUTPUT SHAFT WORM SCREW IN TANK SUCTION STRAINER 100 MESH RETURN FILTER 10 MICRON WITH 25 PSI BYPASS VALVE TRANSAXLE RESERVOIR MANUAL INPUT FROM STEERING WHEEL T-3016-1 TORO.99.
"C" CARB FUEL PUMP + - COIL DIODE 86-7470 BLUE BLACK BLACK BLACK BLACK RED BLUE BLACK BU/R WHT/BK BLACK WHITE R/BK WHT/BK BLACK BLACK DISTRIBUTOR "B" R/W R/GN RED S R PINK "E" PINK HI-LO LOCKOUT SWITCH 2-3 LOCKOUT SWITCH R/W ALTERNATOR L B STARTER R B 30 87 87A R/BK Y/BK YEL/BK R/GN W/BK BLUE R/W "L" 86 "D" BLACK R/GN RED BU/W GREEN OFF = CLOSED PTO (OPT) TIME DELAY 15 SEC.
NOTES 41
NOTES 42
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.
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.
