Form No. 3359-770 Rev B Workman® 3200 & 4200 Liquid Cooled Gas Utility Vehicle Model No. 07360—Serial No. 280000001 and Up Model No. 07361—Serial No. 280000001 and Up Model No. 07361TC—Serial No. 280000001 and Up Model No. 07365—Serial No. 280000001 and Up Register at www.Toro.com.
Model No. Introduction Serial No. Warning This manual identifies potential hazards and has safety messages identified by the safety alert symbol (Figure 2), which signals a hazard that may cause serious injury or death if you do not follow the recommended precautions. CALIFORNIA Proposition 65 Warning The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
Contents Towing Vehicle................................................... 33 Trailer Towing .................................................... 33 Hydraulic Control............................................... 34 Maintenance............................................................... 36 Recommended Maintenance Schedule(s) ................ 36 Service Interval Chart......................................... 37 Heavy Duty Operation ....................................... 37 Premaintenance Procedures....
Safety 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. The TORO WORKMAN meets the requirements of 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).
• • • • • • • • passenger may not be expecting you to brake or turn and may not be ready. • 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 starting the engine: – Sit on operator’s seat and ensure parking brake is engaged. – Disengage PTO (if so equipped) and return hand throttle lever to OFF position (if so equipped).
– 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. – Keep all bystanders away. Before backing up, look to the rear and assure no one is behind the vehicle. Back up slowly. – Watch out for traffic when near or crossing roads. Always yield the right of way to pedestrians and other vehicles. This vehicle is not designed for use on streets or highways.
Sound Pressure Level Whole Body This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 88 dB(A), based on measurements of identical machines per Directive 98/37/EC and amendments. This unit does not exceed a vibration level of 0.5 m/s2 at the posterior, based on measurements of identical machines per ISO 2631 procedures. Vibration Level Hand-Arm This unit does not exceed a vibration level of 2.
93-6687 1. Do not step here. 93-9449 1. Read the Operator’s Manual. 2. Grease every 100 hours. 93-7814 1. Entanglement hazard, belt—stay away from moving parts. 3. Add grease (9 grease points). 115-2320 1. Warning—do not operate 4. Engine—preheat the vehicle on public streets, roads, or highways. 2. Headlights 5. Horn 3. Engine—oil 6. Battery 105-4215 7. Temperature level 10. Engine—run 8. Hour meter 9. Engine—stop 11. Engine—start 93-9862 1. Warning—avoid pinch points. 1.
106-2353 106-2355 1. Electrical power point 1. Slow 3. Transmission—third high; no fast speed 2. Fast 106-2377 1. Locked 2. Differential lock 3. 4. 5. 6. 7. Unlocked Hydraulic lock Engage Power take-off (PTO) Disengage 8. Warning—read the Operator’s Manual. 9. Entanglement hazard, shaft—keep bystander’s a safe distance from the vehicle. 10. Retract hydraulics 11. Extend hydraulics 12. Transmission—high speed 13. Transmission—low speed 14.
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, do not operate this machine unless you are trained, 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.
Battery Symbols Some or all of these symbols are on your battery 1. Explosion hazard 2. No fire, open flame, or smoking. 3. Caustic liquid/chemical burn hazard 4. Wear eye protection 5. Read the Operator’s Manual. 6. Keep bystanders a safe distance from the battery. 7. Wear eye protection; explosive gases can cause blindness and other injuries 8. Battery acid can cause blindness or severe burns. 9. Flush eyes immediately with water and get medical help fast. 10. Contains lead; do not discard.
106-2384 12
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 2 10 2 2 10 2 10 2 1 1 1 1 2 10 20 10 1 4 4 Rear fender Bolts, 3/8 x 1–1/4 in Locknut, 3/8 Support plate Wheel nut Front wheel Wheel nut Rear wheel Steering wheel Cap Washer Foam seal Front fender Socket hex head bolt, #10 x 3/4” in. Washer, .210 I.D. Locknut, #10 ROPS frame bolt, 1/2 x 3” in. Locknut, 1/2 1 2 3 4 5 Use Qty. Mount the rear fenders. Mount the wheels. Install the steering wheel.
2 Install the Wheels Parts needed for this procedure: Figure 3 10 Wheel nut 2 Front wheel 10 Wheel nut 2 Rear wheel 1. Fender Procedure 3. Secure rear of each tail light bracket to rear of frame brackets with a 5/16 x 1 in. bolt, .344” I.D. flatwasher and locknut, as shown in Figure 3. 1. Remove lug nuts securing wheels to wheel brackets. Retain lug nuts. 2. Mount wheels and install lug nuts. Torque lug nuts to 45–65 ft-lb. Figure 4 1. Fender 2. Support plate 4.
3 4 Install the Steering Wheel Install the Front Fenders Parts needed for this procedure: Parts needed for this procedure: 1 Steering wheel 2 Front fender 1 Cap 10 Socket hex head bolt, #10 x 3/4” in. 1 Washer 20 Washer, .210 I.D. 1 Foam seal 10 Locknut, #10 Procedure Procedure 1. Remove the jam nut from the steering shaft. Slide the foam seal, steering wheel and washer onto steering shaft (Figure 6). 2. Secure steering wheel to shaft with jam nut and tighten it to 10-15 ft-lb. 3.
5 6 Install the ROPS Activate and Charge the Battery Parts needed for this procedure: 1 ROPS frame 4 bolt, 1/2 x 3” in. 4 Locknut, 1/2 Parts needed for this procedure: Procedure 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. Procedure 1.
Figure 10 1. Positive (+) cable Figure 9 1. Battery cover 2. Knob 6. Remove filler caps. Slowly add electrolyte to each cell until level is up to fill ring. Install filler caps. 3. Battery base Important: Do not overfill battery. Electrolyte will overflow onto other parts of the vehicle and severe corrosion and deterioration will result. 2. Remove bolt, washers and locknut securing battery hold down to battery base. Remove hold down and slide battery out of battery base. 7.
7 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. Full Bed Removal No Parts Required 6. Store cylinders in storage clips. Engage hydraulic lift lock lever on vehicle to prevent accidental extension of lift cylinders. Procedure 1. Start engine. Engage hydraulic lift lever and lower bed until cylinders are loose in slots. Release lift lever and turn off engine. 8 2.
Product Overview 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. Controls Note: Determine the left and right side of the machine from the normal operating position. Accelerator Pedal The accelerator pedal (Figure 14) 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.
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. Gear Shift Lever Fully depress clutch pedal and move shift lever (Figure 16) into desired gear selection. A diagram of the shift pattern is indicated in Figure 15. Figure 16 1. Gear shift lever 2. Parking brake 3. Hydraulic bed lift 4. Hydraulic lift lock 5. Differential lock 6.
Rotate key clockwise — START position — to engage starter motor. Release key when engine starts. The key will move automatically to the ON position. To shut engine off, rotate key counterclockwise to OFF position. • Shift only on level ground. • 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. LOW is for low speed driving. Use this range when greater than normal power or control is required.
1. Apply parking brake. 2. Turn ignition key to “ON”, but do not start engine. The oil pressure light should glow red. If light does not function, either a bulb is burned out or there is a malfunction in the system which must be repaired. Note: If engine was just turned off, it may take 1 to 2 minutes for light to come on. Fuel Gauge Figure 19 Shows amount of fuel in tank. Operates only when ignition switch is in “ON” position (Figure 18). 1. Passenger hand hold 2.
Operation Dimensions (cont'd.) Tow Capacity Ground Clearance Wheel Base Wheel Tread (center line to center line) Height Tongue weight 200 lbs. Maximum trailer weight 1,500 lbs. Note: Determine the left and right sides of the machine from the normal operating position. 7” w/ no load 70” Front 46” Rear 47.7” Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from the switch.
Note: When adding oil, remove dipstick to allow proper venting, pour oil slowly and check the level often during this process. DO NOT OVERFILL. Important: When adding engine oil or filling oil, there must be clearance between the oil fill device and the oil fill hole in the valve cover as shown in Figure 24. This clearance is necessary to permit venting when filling, which prevents oil from overrunning into breather. Figure 21 1. Dipstick 3.
Check Cooling System Note: Never Use Methanol, Gasoline Containing Methanol, Gasoline Containing More Than 10% Ethanol, Gasoline Additives, or White Gas Because Engine Fuel System Damage Could Result. Service Interval: Before each use or daily Capacity of cooling system is approximately 4 qts. 1. Clean area around fuel tank cap. The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti–freeze. 2. Remove fuel tank cap. 1. Park machine on a level surface.
The transaxle reservoir is filled with Dexron IIl ATF. Check level before engine is first started and every 8 hours or daily, thereafter. Capacity of system is 7.5 qt. 1. Position the vehicle on a level surface. 2. Clean area around dipstick. 3. Unscrew dipstick from top of transaxle and wipe it with a clean rag. Figure 28 1. Front differential 2. Fill/check plug 3.
Every 1,000 hours/Every 2 years (whichever comes first) 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 page 45 for tensioning procedure. If correct, continue operation. 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.
Important: Do not hold front wheels turned against the right or left stops for longer than 5 seconds. 6. Do not attempt to push or tow vehicle to get it started. Damage to drive train could result. • ,If engine is hot – depress and hold the accelerator pedal about half way down while cranking engine. • If engine is flooded – fully depress accelerator pedal and hold it to the floor until the engine starts. Never pump the accelerator pedal. Stopping Vehicle 6.
1. Sit on operator’s seat and engage parking brake. Move shift lever to NEUTRAL position. The vehicle has special tires, low gear ratios, a locking differential, and other features that give it extra traction. These features add to the versatility of the vehicle but, they can also get you into dangerous situations. You must keep in mind that the vehicle is not a recreation vehicle. It is not an all terrain vehicle. And, it is definitely not meant for “stunt driving” or “horsing around”.
Passengers 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. 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.
Hills drive slowly in first gear while putting light pressure on the brake pedal. This will dry the brakes out. Do not downshift for braking on icy or slippery surfaces (wet grass) or while going down a hill because engine braking may cause skidding and loss of control. Shift to a lower gear before starting down a hill. Tipping or rolling the vehicle on a hill will cause serious personal injury. • Do not operate the vehicle on steep slopes.
• Mounting wheel weights to rear wheels. • Adding liquid ballast (calcium chloride) to rear tires. • Traction will increase with no passenger in front seat. side. This is especially true when turning if the load is on the outside of the turn. Never position heavy loads behind the rear axle. If the load is positioned so far to the rear that it is behind the rear axle, it will reduce the weight on the front wheels and this will reduce steering traction.
Transporting Vehicle For moving the vehicle long distances, a trailer should be used. Make sure the vehicle is secured to the trailer. Refer to Figure 33 and Figure 34 for location of tie down points. Tipping or rolling the vehicle on a hill will cause serious injury. • The extra traction available with the differential lock can be enough to get you into dangerous situations such as climbing slopes that are too steep to turn around.
Raise (Quick Coupler “A” Position) Several types of tow hitches are available for the Workman, depending on your application. Contact your Authorized Toro Distributor for details. This is the position which will lift the bed, rear hitch attachment or apply pressure to quick coupler ”A”. This also allows return oil from Quick coupler ”B” to flow back into the valve and then out to the reservoir. This is a momentary position and when the lever is released it spring returns to the center off position.
Important: If used with a hydraulic cylinder or no attachment, the On position causes the oil flow to go over a relief valve which can damage the hydraulic system. Use this position only momentarily or with a motor attached. pressure when the control lever is pushed forward or locked in the ON position. Hydraulic Control Trouble Shooting: • Difficulty in connecting or disconnecting quick couplers. Important: Check hydraulic oil level after installation of attachment.
Maintenance If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Determine the left and right side of the machine from the normal operating position. Remove the key from the ignition before you do any maintenance. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 2 hours • Torque the front and rear wheel nuts.
Maintenance Service Interval Every 800 hours Every 1,000 hours Maintenance Procedure • • • • Change the front differential oil. Change the transaxle hydraulic fluid and filter, and clean the strainer. Replace the hydraulic filter. Clean the hydraulic strainer. • Change the brake fluid. • Drain/flush the fuel tank. • Flush/replace the coolant system fluid.
Only qualified and authorized personnel shall be permitted to maintain, repair, adjust or inspect 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.
Lubrication Jacking Vehicle Greasing Bearings and Bushings A vehicle on a jack may be unstable and slip off of the jack, injuring anyone beneath it. Service Interval: Every 100 hours • Do not start the vehicle while the vehicle is on a jack. 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 45 Figure 42 Figure 46 Figure 43 Figure 44 40
Engine Maintenance Note: Cleaning of the used element is not recommended due to the possibility of damage to the filter media. General Air Cleaner Maintenance Practices 4. Inspect the new filter for shipping damage, checking the sealing end of the filter and the body. Important: Do not use a damaged element. Service Interval: Every 50 hours 5. Insert the new filter by applying pressure to the outer rim of the element to seat it in the canister.
4. Set air gap between center and side of electrodes at .040”. Install correctly gapped spark plug and tighten plug to 18–22 ft–lb. If torque wrench is not used, tighten plug firmly. 5. Install spark plug wires. Figure 49 1. Engine oil filter 4. Add oil to crankcase, refer to Check Engine Oil. Replacing Spark Plugs Service Interval: Every 400 hours Replace spark plugs to assure proper engine performance and reduce exhaust emission level. Correct spark plug to use is a Champion RC 14YC or NGK BPR 4ES.
Fuel System Maintenance Electrical System Maintenance Fuel System Fuses Fuel Lines and Connections The fuses for the machine’s electrical system are located under the center of the dash panel. Service Interval: Every 400 hours/Yearly (whichever comes first) Every 1,000 hours/Every 2 years (whichever comes first) Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections.
Jump Starting Vehicle 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. Jump starting can be dangerous. To avoid personal injury or damage to electrical components in vehicle, observe the following warnings: Battery electrolyte contains sulfuric acid which is a deadly poison and causes severe burns. • Never jump start with a voltage sources greater than 15 volts D.C.
Drive System Maintenance 1. Move shift lever to Neutral position. 2. Remove clevis pins securing shift cables to transaxle shift arms. Change Front Differential Oil Four Wheel Drive Only Service Interval: Every 800 hours 1. Position vehicle on a level surface, stop engine, engage parking brake and remove key from ignition switch. 2. Clean area around drain plug on side of differential. Place drain pan under drain plug. Figure 55 1. Shift arm (1st – Rev.) 2. Shift arm (2nd – 3rd) 3.
Figure 57 1. Front of vehicle 2. .12 ± .12 inch greater than rear of tire 2. Adjust the center–to–center distance as follows: Figure 56 1. Differential lock cable 2. Transaxle bracket 3. Center to center distance • On the right front wheel, loosen the jam nuts at both ends of the tie rod (Figure 58). 3. Spring 4. .035 ± .025 inch gap 3. Adjust jam nuts to obtain .035 ± .025 inch gap between spring hook and O.D. of hole in transaxle lever. 4. Tighten jam nuts after adjustment has been attained.
Cooling System Maintenance Removing Debris From Engine Cooling System Service Interval: Before each use or daily (Clean more frequently in dirty conditions.) 1. Turn engine off. Clean engine area thoroughly of all debris. Figure 59 1. Turn buckle 2. Lift and remove radiator screen from front of radiator. Figure 60 1. Radiator screen 3. Clean radiator and screen thoroughly with compressed air. Note: Blow debris away from radiator.
If the engine has been running, the pressurized, hot coolant can escape and cause burns. • 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 63 1. Bleed screw 3. Remove radiator cap. 7. Remove coolant drain plug from engine and allow coolant to flow into drain pan.
Brake Maintenance Belt Maintenance Inspect Brakes Adjusting Belts Service Interval: Every 200 hours Service Interval: After the first 8 hours Every 200 hours Every 400 hours Visually inspect brakes for worn brake shoes after every 400 hours of operation. Alternator belt 1. Raise bed (if so equipped) and position safety support on extended lift cylinder to hold up bed. 2. Check tension by depressing belt at mid span of crankshaft and alternator pulleys with 22 lbs. of force.
Controls System Maintenance Adjusting Accelerator Pedal 1. Position vehicle on level surface, stop engine and engage the parking brake. 2. Adjust ball joint on accelerator cable (Figure 66) to allow .200”–.350” of clearance between accelerator pedal arm and top of diamond tread floor plate (Figure 67), when a 20 lb. force is applied to center of pedal. Tighten locknut. Figure 65 1. Fan belt 2. Idler pulley Note: Engine must not be running and return spring must be attached.
Note: The brake master cylinder must relieve pressure when properly adjusted. Figure 67 Figure 69 1. .200 — .350 inch Clearance 1. Accelerator pedal 2. Brake pedal 3. Clutch pedal Adjusting Brake Pedal Adjusting Clutch Pedal Service Interval: Every 200 hours (Front hood can be removed to ease adjustment.) 1. Remove cotter pin and clevis pin securing master cylinder yoke to brake pedal pivot (Figure 67).
pedal is 1.25” ±.12” from floor. If an adjustment is required, loosen switch jam nuts and adjust up or down. Figure 71 1. Clutch pedal 2. 3.75” ± .12” Note: Force is applied so the clutch release bearing lightly contacts pressure plate fingers. Figure 73 1. Clutch switch 4. Tighten the jam nuts after the adjustment has been attained. 5. Recheck the 3.75” + .12” dimension after the jam nuts have been tightened to ensure proper adjustment. Readjust, if necessary. Adjusting Parking Brake 6.
Hydraulic System Maintenance Changing Transaxle / Hydraulic Fluid Service Interval: After the first 10 hours Every 800 hours 1. Position the vehicle on a level surface, stop engine, engage the parking brake and remove key from ignition switch. 2. Remove drain plug from side of reservoir and let hydraulic fluid flow into drain pan. Reinstall and tighten plug when hydraulic fluid stops draining. Figure 75 1. Parking brake lever 2. Knob 3. Set screw 4. Tighten set screw after adjustment has been attained.
Figure 77 1. Hydraulic filter 2. Gasket Figure 78 3. Lubricate new filter gasket. 1. Hydraulic strainer 4. Assure filter mounting area is clean. Screw filter on until gasket contacts mounting plate. Then tighten filter one–half turn. 5. Reinstall strainer. 6. Reinstall hydraulic hose and 90 degree fitting to strainer in same orientation. 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. 7.
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. Never work under a raised bed without positioning safety support on a fully installed cylinder rod. Note: Two hydraulic hoses, each with a male and female quick coupler, that fit the vehicle couplers are required to perform this operation.
Storage pressure and ease the disconnection of the quick couplers. • After completing operation, remove jumper hoses and connect hydraulic hoses to both vehicles. Battery Storage 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.
Schematics Hydraulic Schematic (Rev.
Electrical Schematic (Rev.
Notes: 59
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. This warranty is applicable to all products with the exception of Aerators (refer to separate warranty statements for these products).
