Form No. 3353–797 Rev A Workman) 3200 & 4200 Liquid Cooled Gas Utility Vehicle Model Model Model Model No. 07360—Serial No. 250000701 and Up No. 07361—Serial No. 250000701 and Up No. 07361TC—Serial No. 250000701 and Up No. 07365—Serial No.
Check Front Differential Oil . . . . . . . . . . . . . . . . . Check Torque Of Wheel Nuts . . . . . . . . . . . . . . . . Check Tire Pressure . . . . . . . . . . . . . . . . . . . . . . . . Check Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . Check Fan Belt Tension . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre–starting Checks . . . . . . .
Adjusting Brake Pedal . . . . . . . . . . . . . . . . . . . . . . Adjusting Clutch Pedal . . . . . . . . . . . . . . . . . . . . . Adjusting Parking Brake . . . . . . . . . . . . . . . . . . . . Adjusting Shift Cables . . . . . . . . . . . . . . . . . . . . . . Adjusting High–low Cable . . . . . . . . . . . . . . . . . . . Adjusting Differential Lock Cable . . . . . . . . . . . . . Inspect Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inspect Tires . . . . . . . . . . . . . . . . . . . . .
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.
• Check the safety interlock system daily for proper operation. If a switch should malfunction, replace the switch before operating machine. After every two years, replace the interlock switches in the safety system, whether they are working properly or not. when handling off–center loads that cannot be centered. Keep loads balanced and secure to prevent them from shifting. – Avoid sudden stops and starts. Do not go from reverse to forward or forward to reverse without first coming to a complete stop.
• This vehicle should not be modified without the TORO Company’s authorization. Direct any inquiries to The TORO Company, Commercial Division, Vehicle Engineering Dept., 300 West 82nd St., Bloomington, Minnesota 55420–1196. USA – Block wheels if machine is on an incline. 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.
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) 7. Battery –low charge (Liquid cooled only) 8. Temperature level (Liquid cooled only) 3. Headlights 4.
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.
6-2383 1. Warning—read the Operator’s Manual. 2. Fire hazard—stop the engine before fueling. 3. Tipping hazard—do not drive the vehicle across or up a slope greater than 12 degrees, slow down and turn gradually, do not exceed 16 mph (26 kmh), 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. On model 07361TC only, engine will not crank when hydraulic lift lever is locked in the forward position. Ground Speed 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 Base Weight (Dry w/o flatbed) 1565 lbs. (2wd) 1665 lbs. (4wd) Rated Capacity 2,335 lbs.
Setup Note: Determine the left and right side of the machine from the normal operating position. Some components may already be installed. Description Qty. Capscrew 5/16–18 x 1.00” lg. 1 Flatwasher .344” I.D. 1 Locknut 5/16–18 1 Fenders–Rear 2 Capscrew 3/8–16 x 1.25” lg. 10 Flatwasher .406” I.D.
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 55–75 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 5/16–18 x 1” lg. capscrew, .
Install Front Fenders 2. Secure each side of ROPS to mounting brackets with (2) 1/2–13 x 3” lg. capscrews and locknuts. 1. Align the five fender mounting holes with the holes in each side of body (Fig. 5). Activate and Charge Battery 2. Mount a fender to each side of body with (5) #10 x 3/4” lg. capscrews, (10) flat washers and (5) #10 locknuts. Position a washer next to capscrew head and locknut.
2. Remove capscrew, washers and locknut securing battery hold down to battery base. Remove hold down and slide battery out of battery base. Warning Incorrect battery cable routing could damage the machine and cables causing sparks. Sparks can cause the battery gasses to explode, resulting in personal injury. 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.
5. Lift bed off vehicle. Caution 2 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. 6. Store cylinders in storage clips. Engage hydraulic lift lock lever on vehicle to prevent accidental extension of lift cylinders. 3 1 Re–Install Full Bed Figure 11 Note: If bed sides will be installed on flat bed, it is easier to install them before bed is installed on vehicle. 1. Spacer bracket 2.
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.
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 55–75 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 • 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. On dashboard (Fig. 26). 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. Your supervisor may want you to check other items on a daily basis, so ask what your responsibilities are.
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. Use the chart below to determine the ground speed of the vehicle at 3600 RPM. Gear Range Ratio Speed (mph) Speed (kmh) 1 L 82.83 : 1 2.9 4.7 2 L 54.52 : 1 4.5 7.2 3 L 31.56 : 1 7.7 12.5 1 H 32.31 : 1 7.6 12.2 2 H 21.27 : 1 11.5 18.5 3 H 12.31 : 1 19.8 31.9 R L 86.
Passengers Warning Whenever you have a passenger riding in the vehicle make sure he or she is wearing the seat belt and 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 WORKMAN is an off–highway vehicle only, and is not designed, equipped, or manufactured for use on public streets, roads or highways.
Speed sure they work properly. If they do not, drive slowly in first gear while putting light pressure on the brake pedal. This will dry the brakes out. 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.
and, turning up hill while traversing a hill are particularly dangerous. Even at a slow speed and without a load, tip overs are more likely if you turn on a hill. Warning When lowering the box it is possible for you or others to get their hands or other body parts in the wrong spot and have them crushed. Take extra care that no one will get hurt. Also, do not dump on anyone’s feet. It may seem funny but, it can be dangerous. Slow down and shift into a lower gear before starting up or down a hill.
Using The Differential Lock system functions in both froward and reverse, however, when turning the the rear wheels will slip slightly more before power is delivered to the front wheels. The differential lock increases the vehicle’s traction by locking the rear wheels so one wheel will not spin out. This can help when you have heavy loads to haul on wet turf or slippery areas, going up hills and on sandy surfaces.
Hydraulic Control The hydraulic control 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. 1 Figure 30 Control Lever Positions 1. Eye holes in frame Off Position This is the normal position for the control valve when it is not being used. In this position the work ports of the control valve are blocked and any load will be held by the check valves in both directions.
Disconnection 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. Note: With both the vehicles turned off, move the lift lever back and forth to remove the system pressure and ease the disconnection of the 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 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.
Servicing Air Cleaner 2. Remove drain plug and let oil flow into drain pan. When oil stops, install drain plug. 1. Pull latch outward and rotate air cleaner cover counter–clockwise. Separate cover from body. Clean inside of air cleaner cover. 2 ÎÎ ÎÎ ÎÎ 1 Figure 44 1. Engine oil drain plug 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.
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 Change Front Differential Oil 2 Front Wheel Drive Only Figure 55 1. Hydraulic reservoir Change front differential oil every 800 hours. 2. Drain plug 1.
2. Remove drain plug (Fig. 57) 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.
3. Adjust jam nuts/or ball joint until bottom rear edge of clutch pedal is 3.75” + .12” from top of floor plate diamond pattern, when an 4 lb. force is applied to pedal. 3. Loosen jam nuts securing yoke to master cylinder shaft (Fig. 60). 4. Adjust yoke until its holes align with hole in brake pedal pivot. Secure yoke to pedal pivot with clevis pin and cotter pin. Note: Force is applied so release bearing lightly contacts pressure plate fingers. 4. Reconnect return spring to clutch lever. 5.
3. Lift up on clutch pedal (Fig. 61) until it contacts frame. 4. Tighten set screw after adjustment has been attained. 4. Adjust clutch cable until ball joint end is aligned with hole in clutch pedal pivot. Insert rod end into pivot hole. 5. Install rubber grip onto parking brake lever. 5. While holding clutch pedal against frame, tighten jam nuts securing cable to frame bracket. Adjusting Shift Cables Check adjustment every 200 hours. 6. Secure rod end to pedal pivot with nut previously removed. 1.
Front of Vehicle 2. Loosen jam nuts securing differential lock cable to bracket on transaxle. .25 $ .12“ Greater than rear of tire 2 1 Center–to–center Distance Figure 69 3 2. To adjust, loosen jam nuts at both ends of tie rod. .035” + .025” Figure 68 1. Differential lock cable 2. Transaxle bracket 3. Spring 1 3. Adjust jam nuts to obtain .035” ± .025” gap between spring hook and O.D. of hole in transaxle lever. Figure 70 4. Tighten jam nuts after adjustment has been attained. 1.
• On the disabled vehicle, connect the two jumper hoses to the hoses that were disconnected (Fig. 72). Cap unused fittings. Starter Method • Crank starter while holding lift lever in the raise position. Run starter for 15 seconds then wait 60 seconds before engaging starter again. • If engine will not crank, the load and box (attachment) must be removed to service engine or transaxle.
Jump Starting Procedure Important Check hydraulic fluid levels, in both vehicles, before resuming operation. Warning Fuses Jump starting can be dangerous. To avoid personal injury or damage to electrical components in vehicle, observe the following warnings: The fuses for the machine’s electrical system are located under the center of the dash panel. • Never jump start with a voltage sources greater than 15 volts D.C. This will damage the electrical system.
Battery Storage 5. Check the electrolyte level every 50 operating hours or, if machine is in storage, every 30 days. If the machine will be stored for more than 30 days, remove the battery and charge it fully. Either store it on the shelf or on the machine. Leave the cables disconnected if stored on 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.
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.
