Form No. 3355–925 Rev C Workman) 3200 & 4200 Liquid Cooled Gas Utility Vehicle Model Model Model Model No. 07360—Serial No. 260000001 and Up No. 07361—Serial No. 260000001 and Up No. 07361TC—Serial No. 260000001 and Up No. 07365—Serial No.
Warning Check Front Differential Oil . . . . . . . . . . . . . . . . . Check Torque Of Wheel Nuts . . . . . . . . . . . . . . . Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . Check Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . Check Fan Belt Tension . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre–starting Checks . . . . . . . . .
Replacing Spark Plugs . . . . . . . . . . . . . . . . . . . . . Adjusting Brake Pedal . . . . . . . . . . . . . . . . . . . . . Adjusting Clutch Pedal . . . . . . . . . . . . . . . . . . . . . Adjusting Parking Brake . . . . . . . . . . . . . . . . . . . Adjusting Shift Cables . . . . . . . . . . . . . . . . . . . . . Adjusting High–low Cable . . . . . . . . . . . . . . . . . . Adjusting Differential Lock Cable . . . . . . . . . . . . Inspect Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. • Become familiar with the controls and know how to stop the engine quickly. This is a specialized utility vehicle designed for off–road use only.
• Never overload your vehicle. Name plate (located under middle of dash) shows load limits for vehicle. Never overfill attachments or exceed the vehicle maximum GVW. – When dumping, do not let anyone stand behind vehicle and do not dump load on any one’s feet. Release tailgate latches from side of box, not from behind. • When starting the engine: – Keep all bystanders away. Before backing up, look to the rear and assure no one is behind the vehicle. Back up slowly.
Sound Pressure Level • Keep body and hands away from pin hole leaks or nozzles that eject hydraulic fluid under high pressure. Use paper or cardboard, not hands, to search for leaks. Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage. If fluid is injected into the skin it must be surgically removed within a few hours by a doctor familiar with this form of injury or gangrene may result.
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. 93-9852 1. Warning—read the Operator’s Manual. 2. Crushing hazard—install the cylinder lock. 93-8071 1. Hot surface/burn hazard—stay a safe distance from the hot surface. 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. 93-9447 1.
105-4215 93-9850 1. Warning—avoid pinch points. 1. Do not repair or revise—read the Operator’s Manual. 93-9862 93-9449 1. Read the Operator’s Manual. 2. Grease every 100 hours. 1. Entanglement hazard, shaft—stay away from moving parts. 3. Add grease (9 grease points). 106-2352 1. Warning—do not operate the vehicle on public streets, roads, or highways. 2. Preheat–glow plug (Diesel only) 3. Headlights 4. Engine—low oil pressure 5. Engine—preheat indicator (Diesel only) 6. Horn 7.
106-2353 106-2355 1. Electrical power 1. Slow to fast 2. Transmission—third high; no fast speed 106-2377 1. 2. 3. 4. 5. Locked Differential lock Unlocked Hydraulic lock Engage 6. Power take-off (PTO) 7. Disengage 8. Warning—read the Operator’s Manual. 9. Entanglement hazard, shaft—keep bystanders a safe distance from the vehicle. 10. Retract hydraulics 9 11. Extend hydraulics 12. Transmission—high speed 13.
110-2599 1. Warning—read the Operator’s Manual. 2. Fire hazard—stop the engine before fueling. 3. Tipping hazard—read the Operator’s Manual and receive training before operating the machine, use caution and drive slowly when driving on slopes, slow down and turn gradually, do not exceed 20 mph (32 kph), and drive slowly over rough terrain or when carrying a full or heavy load. 4.
106-7896 For models 07361 & 07361 TC only 1. The maximum load is 953 kg, the vehicle weight is 861 kg, and the maximum gross vehicle weight is 1814 kg. 106-7898 For model 07365 only 1. The maximum load is 953 kg, the vehicle weight is 953 kg, and the maximum gross vehicle weight is 1905 kg. 106-7888 1. Warning—the hydraulic oil pressure is 124 bar (1800 PSI). 2. Coupler A 3. Coupler B Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 2.
106-2384 12
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 SAE J2258. 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. 40 amp alternator with I/C regulator.
Tow Hitch Hitch has hole for ball or pin. Interlocks Clutch pedal must be depressed to start engine or disengage PTO, if so equipped. The hydraulic lift lever must be in the center position. Ground Speed Base Weight (Dry weight) 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 Model 07360 – 1565 lbs. Model 07361 – 1895 lbs. Model 07365 – 2030 lbs. Rated Capacity Model 07360 – 2685 lbs.
Setup Note: Determine the left and right side of the machine from the normal operating position. Description Qty. Rear fender 2 Capscrew, 3/8 x 1–1/4 in. 10 Locknut, 3/8 2 Support plate 2 Wheel nut 10 Front wheel 2 Wheel nut 10 Rear wheel 2 Steering wheel 1 Foam seal 1 Washer 1 Nut 1 Cap 1 Front fender 2 Socket hex head capscrew, #10 x 3/4” in. 10 Washer, .210 I.D. 20 Locknut, #10 10 ROPS frame 1 Capscrew 1/2 x 3” in.
Install Rear Fenders Install Wheels 1. Loosen the locknuts and capscrews securing tail light brackets to right and left frame brackets (Fig. 1). 1. Remove lug nuts securing wheels to wheel brackets. Retain lug nuts. 2. Pivot tail light brackets rearward and tighten capscrews and locknuts. 2. Mount wheels and install lug nuts. Torque lug nuts to 45–65 ft-lb. 1 Figure 1 1. Tail light bracket 2 1 3. Secure rear of each tail light bracket to rear of frame brackets with a 5/16 x 1 in. capscrew, .
Install Front Fenders Activate and Charge Battery 1. Align the five fender mounting holes with the holes in each side of body (Fig. 5). 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. 2. Mount a fender to each side of body with (5) #10 x 3/4 in. socket head capscrews, (10) flat washers and (5) #10 locknuts.
3. Remove filler caps from battery and slowly fill each cell until electrolyte is just above the plates. Warning 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. Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury.
4. Remove lynch pins and clevis pins securing pivot brackets to frame channels (Fig. 10). Caution 5. Lift bed off vehicle. The full bed weighs approximately 325 pounds, so do not try to install or remove it by yourself. Use an overhead hoist or get the help of two or three other people. Caution The full bed weighs approximately 325 pounds, so do not try to install or remove it by yourself. Use an overhead hoist or get the help of two or three other people. 2 6. Store cylinders in storage clips.
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 in. (25 mm) below the bottom of the filler neck. This empty space in the tank allows the fuel to expand.
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. • Allow engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning hand. • Use a rag when opening the radiator cap, and open the cap slowly to allow steam to escape. Figure 18 1. Dipstick 2. Check coolant level. Coolant should be up to COLD line on reserve tank, when engine is cold. 4.
Check Torque Of Wheel Nuts Warning Failure to maintain proper torque of the wheel nuts could result in failure or loss of wheel and may result in personal injury. 1 2 Torque the front and rear wheel nuts to 45–65 ft.-lb. after 1–4 hours of operation and again after 10 hours of operation. Torque every 200 hours thereafter. Figure 20 1. Cup holder Check Tire Pressure 2. Knob 3. Fluid level should be up to FULL line on reservoir. Check tire pressure every 8 hours or daily to assure proper levels.
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. 22) gives the operator the ability to vary engine and ground speed of the vehicle, when the transmission is in gear.
Parking Brake 2 Whenever the engine is shut off, the parking brake (Fig. 23) must be engaged to prevent accidental movement of the vehicle. To engage the parking brake, pull back on lever. To disengage, push lever forward. Make sure parking brake is released before moving vehicle. If vehicle is parked on a steep grade, make sure parking brake is applied. Also, shift the transmission into 1st gear on a uphill grade or reverse on a down hill grade. Place chocks at the down hill side of wheels.
Hour Meter Oil Pressure Warning Light Indicates the total hours of machine operation. The hour meter (Fig. 24) starts to function whenever the key switch is rotated to “ON” position or if engine is running. Light glows (Fig. 25) 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.
Passenger Hand Hold • Turn steering wheel to the left and right to check steering response. On dashboard (Fig. 26). • Check for oil leaks, loose parts and any other noticeable malfunctions. Make sure engine is off and all moving parts have stopped before checking for oil leaks, loose parts and other malfunctions. If any of the above items are not correct, notify your mechanic or check with your supervisor before taking the vehicle out for the day.
• 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. Important Always stop vehicle before shifting to reverse or forward.
One of the major causes of accidents is fatigue. Be sure to take occasional breaks. It is very important that you stay alert at all times. Caution If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. 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.
During a sharp turn at higher speeds, the inside rear wheel may lift off of the ground. This is not a flaw in the design, it happens with most four wheel vehicles including passenger cars. If this happens, you are turning too sharply for the speed at which you are traveling. Slow down! 1 Braking It is good practice to slow down before you get near an obstacle. This gives you extra time to stop or turn away. Hitting an obstacle can damage the vehicle and its contents.
Loading And Dumping accident. In the event of a tipover, the risk of serious injury or death will be reduced if the operator is using the ROPS system and follows the instructions provided. 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. Hills Do not carry loads which exceed the load limits described on the vehicle weight label.
Four Wheel Drive 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. Four Wheel Drive Only As a general rule, position the weight of the load evenly from front to rear and evenly from side to side. The “Automatic on Demand” four wheel drive feature, on this vehicle does not require operator activation.
Note: The power steering will not function, making it difficult (increase effort) to steer. When towing 5th wheel attachments, like a fairway aerator, always install the ”wheely bar”(included with the 5th wheel kit) to prevent the front wheels from lifting off the ground if the towed attachments movement is suddenly impaired. Hydraulic Control 1 The hydraulic control supplies “live” hydraulic power from the vehicle pump whenever the engine is running.
then out to the reservoir. This is a momentary position and when the lever is released it spring returns to the center off position. Momentarily holding and then releasing the control lever in this position will provide flow to quick coupler ”B” which provides power down on the rear hitch. When released, it will hold the down pressure on the hitch.
Maintenance Note: Determine the left and right side of the machine from the normal operating position. Service Interval Chart Greasing Bearings And Bushings 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.
Figure 37 Figure 34 Figure 38 Figure 35 Figure 36 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.
2. Do not work under vehicle without jack stands supporting it. The vehicle could slip off jack, injuring any one beneath it. 3. Push bed support onto cylinder rod, making sure support end tabs rest on end of cylinder barrel and on cylinder rod end (Fig. 40). 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.
2. Remove drain plug and let oil flow into drain pan. When oil stops, install drain plug. 2 ÎÎ ÎÎ 1 1 Figure 44 1. Engine oil drain plug Figure 43 1. Air cleaner cover 2. Filter 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. 2.
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 46 • Do not open the radiator cap when the engine is running.
11. Stop engine. Recheck level and replenish, if required. 1 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. 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.
2. To adjust belt tension: • Loosen idler pulley mounting nut, move pulley to increase tension and tighten nut. 1 2 1 2 Figure 53 1. Accelerator cable 2. Ball joint Figure 52 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. 53) 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 Cleaning Hydraulic Strainer 2 Clean hydraulic strainer every 800 hours. 1. Position the vehicle on a level surface, stop engine, engage the parking brake and remove key from ignition switch. Figure 55 1. Hydraulic reservoir 2.
1. Position vehicle on a level surface, stop engine, engage parking brake and remove key from ignition switch. 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. 2. Clean area around drain plug on side of differential. Place drain pan under drain plug. 1 .032” Figure 59 2 3 4.
3. Adjust the jam nuts/or ball joint until the back rear edge of the clutch pedal is 3.75” + .12” from the top of the floor plate diamond pattern, when an 4 lb. force is applied to the pedal (Fig. 63). 4. Adjust yoke until its holes align with hole in brake pedal pivot. Secure yoke to pedal pivot with clevis pin and cotter pin. 5. Tighten jam nuts securing yoke to master cylinder shaft. Note: The brake master cylinder must relieve pressure when properly adjusted. 1 3.75 + .12” Figure 63 1 2 1.
7. Recheck the clutch safety switch adjustment (Fig. 65). The 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 3 2 1 Figure 67 1. Parking brake lever 2. Knob Figure 65 3. Set screw 1. Clutch switch 4. Tighten set screw after adjustment has been attained. 5. Install rubber grip onto parking brake lever. Adjusting Parking Brake Check adjustment every 200 hours. Adjusting Shift Cables 1.
Adjusting High–low Cable Inspect Tires Check adjustment every 200 hours. 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. 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. Front Wheel Toe 3.
• Check to make sure the tires turn an equal amount to the right and to the left. If the tires do not turn equally, refer to the Workman Service Manual for the adjustment procedure Note: Two hydraulic hoses, each with a male and female quick coupler, that fit the vehicle couplers are required to perform this operation. • Back another vehicle up to the rear of the disabled vehicle. Important The vehicles hydraulic system uses Dexron IIl ATF.
• On the other vehicle, connect the two hoses to the coupler still in the coupler bracket (Connect the top hose to the top coupler and the bottom hose to the bottom coupler. Cap unused fittings. 1 Figure 76 1. Fuses 1 Figure 75 1. Jumper hoses • Keep all bystanders away from the vehicles. • Start second vehicle and move lift lever to the raise position which will raise the disabled box. • Move the hydraulic lift lever to the neutral position and engage the lift lever lock.
1. Loosen knobs securing battery cover to battery base and slide cover off. Danger 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. Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Do not drink electrolyte and avoid contact with skin, eyes or clothing. Wear safety glasses to shield your eyes and rubber gloves to protect your hands.
Hydraulic Schematic 53
Electrical Schematic 54
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 Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
