Form No. 3359-792 Rev B Workman® 3100 Air Cooled Gas Utility Vehicle Model No. 07363—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 Using Bed Safety Support ................................... 33 Jacking Vehicle ................................................... 34 Lubrication............................................................. 34 Greasing Bearings and Bushings ......................... 34 Engine Maintenance............................................... 36 Servicing Air Cleaner.......................................... 36 Changing Engine Oil And Filter.......................... 36 Replacing Spark Plugs..............
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. illegible, or damaged, repair or replace it before operating the machine. Always wear substantial shoes. Do not operate machine while wearing sandals, tennis shoes or sneakers. Do not wear loose fitting clothing or jewelry which could get caught in moving parts and cause personal injury.
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. – Do not attempt sharp turns or abrupt maneuvers or other unsafe driving actions that may cause a loss of vehicle control. – Do not pass another vehicle traveling in the same direction at intersections, blind spots, or at other dangerous locations.
operation, performance, durability or its use may result in injury or death. Such use could void the product warranty of The Toro® Company. • This vehicle should not be modified without The Toro® Company’s authorization. Direct any inquiries to The Toro® Company, Commercial Division, Vehicle Engineering Dept., 8111 Lyndale Ave. So., Bloomington, Minnesota 55420–1196.
Safety and Instructional 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. 93-6687 1. Do not step here. 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.
106-2355 93-9449 1. Read the Operator’s Manual. 2. Grease every 100 hours. 1. Slow 3. Add grease (9 grease points). 3. Transmission—third high; no fast speed 2. Fast 93-6689 1. Warning—do not carry passengers. 106-7897 1. The maximum load is 1019 kg, the vehicle weight is 795 kg, and the maximum gross vehicle weight is 1814 kg. 105-4215 93–9868 1. Warning—avoid pinch points. 1. Crushing hazard of hand—read the Operator’s Manual. 106-2353 1. Electrical power point 110-2599 1.
6-7894 1. Engine—start 2. Ignition 3. Headlights 4. Power point 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.
93-9899 93-9899 1. Crushing hazard—install the cylinder lock. 106-7888 1. Warning—read the hydraulic oil pressure is 124 bar (1800 psi) 2. Coupler A 3. Coupler B 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 11 7. Temperature level 10. Engine—run 8. Hour meter 9. Engine—stop 11.
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.
Setup Loose Parts Use the chart below to verify that all parts have been shipped. Procedure Description 1 2 3 Use Qty. ROPS frame Bolt 1/2 x 3” in. Locknuts 1/2 1 4 4 Mount the ROPS (Rollover Protection System) No parts required – Remove the Full Bed No parts required – Re-Install the Full Bed. Media and Additional Parts Description Operator’s Manual (Vehicle) Parts Catalog Use Qty. 2 1 Note: Determine the left and right side of the machine from the normal operating position.
6. Store cylinders in storage clips. Engage hydraulic lift lock lever on vehicle to prevent accidental extension of lift cylinders. 2 Remove Full Bed 3 No Parts Required Re-Install the Full Bed Procedure No Parts Required 1. Start engine. Engage hydraulic lift lever and lower bed until cylinders are loose in slots. Release lift lever and turn off engine. Procedure 2. Remove lynch pins from outer ends of cylinder rod clevis pins (Figure 4).
Product Overview Controls Note: Determine the left and right side of the machine from the normal operating position. Accelerator Pedal The accelerator pedal (Figure 7) 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. Figure 6 1. Spacer bracket 2. Wear block 3. Carriage bolt 1.
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 9) into desired gear selection. A diagram of the shift pattern is in Figure 8. Figure 9 1. Gear shift lever 2. Parking brake 3. Hydraulic bed lift 4. Hydraulic lift lock 5. Differential lock 6.
• Shift only on level ground. 3rd High Lockout Switch • Depress clutch pedal fully. Moving switch (Figure 10) to slow position and removing key will prevent use of third gear when in the High range. Engine will shut off if shift lever is moved to third gear when in High range. Key is installed with teeth pointing downward. Push key in to turn. Key is removable in either position. • Move lever fully forward for High and fully rearward for Low.
Passenger Hand Hold On dashboard (Figure 12). Figure 12 1. Passenger hand hold 2. Storage compartment Figure 11 1. Light switch 2. Oil pressure warning light 3. Fuel gauge 4. Tachometer (Optional) 5. Horn 6. Choke Seat Adjusting Lever The seats can be adjusted fore and aft for operator comfort (Figure 13). Tachometer Optional (Figure 11). Horn Button Pressing button activates horn (Figure 11).
Specifications Operation Note: Specifications and design are subject to change without notice. Note: Determine the left and right sides of the machine from the normal operating position. Dimensions Overall Width 63” Overall Length 128.25” w/o bed 130.38” w/full bed 136.38” w/2/3 bed in rear mounting location Base Weight (Dry w/o flatbed) Rated Capacity Maximum.
Figure 14 1. Dipstick 2. Filler Cap Figure 15 3. The engine uses any high-quality detergent oil having the American Petroleum Institute -API“service classification” SH, SJ or higher. Oil viscosity – weight – is selected according to anticipated ambient temperature. 1. Note clearance Important: Check level of oil every 8 operating hours or daily. Change oil and filter initially after the first 50 hours of operation, thereafter, change oil and filter every 150 hours.
2. Clean area around dipstick (Figure 17). 3. Unscrew dipstick from top of transaxle and wipe it with a clean rag. Under certain conditions, gasoline 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.
2. The lower the air pressure, the less the compaction and tire marks are minimized. Lower pressure should not be used for heavy payloads at high speeds. Tire damage may result. 3. Higher pressures should be used for heavier payloads at higher speeds. Do not exceed the maximum pressure. Check Brake Fluid Service Interval: Before each use or daily Figure 19 Every 1,000 hours/Every 2 years (whichever comes first) 1.
Note: Avoid long periods of engine idling. and all moving parts have stopped before checking for oil leaks, loose parts and other malfunctions. Use the chart below to determine the ground speed of the vehicle at 3600 RPM. 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. Starting Engine 1.
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. • Vary vehicle speeds during operation. Avoid excessive idling. Avoid fast starts and quick stops. • A break–in oil for the 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.
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. Read the label on the medicine or check with your doctor or pharmacist if you are unsure about a certain medication. One of the most important rules to follow is to go slower in unfamiliar areas. It is surprising how much damage and injury common things can cause.
including passenger cars. If this happens, you are turning too sharply for the speed at which you are traveling. Slow down! vehicle, to stay alert and to avoid actions or conditions which could result in a accident. In the event of a tip over, the risk of serious injury or death will be reduced if the operator is using the ROPS system and seat belts and is following the instructions provided. Braking It is good practice to slow down before you get near an obstacle.
Note: The Workman has excellent hill climbing ability. The differential lock will increase this ability. Hill climbing traction can also be increased by adding weight to the rear of the vehicle in one of the following ways: the more likely the vehicle is to tip over. You may find that 2000 pounds stacks too high for safe operation. Reducing the total weight is one way to reduce the risk of a tip over. Distributing the load as low as possible is another way to reduce the risk of a tip over.
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. Be extra careful when operating with the differential lock on, especially on steeper slopes. Figure 22 1.
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 The hydraulic control supplies “live” hydraulic power from the vehicle pump whenever the engine is running. The power can be used through the quick couplers at the rear of the vehicle.
– Fittings loose. – Fitting missing o–ring. Hydraulic fluid escaping under pressure can have sufficient force to penetrate skin and do serious damage. Care must be used when connecting or disconnecting hydraulic quick couplers. Stop engine, apply parking brake, lower attachment and place remote hydraulic valve in float detent position to relieve hydraulic pressure before connecting or disconnecting quick couplers. • Attachment does not function. – Quick couplers not fully engaged.
Maintenance 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. Recommended Maintenance Schedule(s) Maintenance Service Interval Maintenance Procedure After the first 2 hours • Torque the front and rear wheel nuts. After the first 8 hours • Check the condition and tension of the pump drive belt.
Maintenance Service Interval Every 800 hours Every 1,000 hours Yearly Maintenance Procedure • • • • Replace the spark plugs. 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. • Complete all yearly maintenance procedures specified in the Engine Operator’s Manual.
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 34 Figure 31 Figure 32 Figure 33 35
Engine Maintenance 4. Reinstall element with pre–cleaner, breather seal, inner cover, wing nut, air cleaner cover, O–ring and knob. 5. Tighten knob 1/2 to 1 turn after knob contacts cover. Do not overtighten. Servicing Air Cleaner Service Interval: Every 50 hours (Every 25 hours if operating conditions are extremely dusty or sandy) Changing Engine Oil And Filter Every 50 hours Service Interval: After the first 50 hours Every 100 hours 1.
Fuel System Maintenance 1. Clean area around spark plugs so foreign matter cannot fall into cylinder when spark plug is removed. 2. Pull spark plug wires off spark plugs and remove plugs from cylinder head. Fuel System 3. Check condition of side electrode, center electrode, and center electrode insulator to assure there is no damage. Fuel Lines and Connections Important: A cracked, fouled, dirty or otherwise malfunctioning spark plug must be replaced.
Jump Starting Vehicle Electrical System Maintenance Jump starting can be dangerous. To avoid personal injury or damage to electrical components in vehicle, observe the following warnings: Fuses The fuses for the machine’s electrical system are located under the center of the dash panel (Figure 39 & Figure 40). • Never jump start with a voltage sources greater than 15 volts D.C. This will damage the electrical system. • Never attempt to jump start a discharged battery that is frozen.
soda solution. Flush the top surface with water after cleaning. Do not remove the fill cap while cleaning. 3. Battery cables must be tight on terminals to provide good electrical contact. 4. If corrosion occurs at terminals, remove battery cover, disconnect cables, negative (–) cable first and scrape clamps and terminals separately. Reconnect cables, positive (+) cable first and coat terminals with petroleum jelly. 5.
Adjusting Differential Lock Cable Drive System Maintenance Service Interval: Every 200 hours Adjusting Shift Cables 1. Move differential lock lever to Off position. Service Interval: After the first 10 hours 2. Loosen jam nuts securing differential lock cable to bracket on transaxle (Figure 43). Every 200 hours 1. Move shift lever to Neutral position. 2. Remove clevis pins securing shift cables to transaxle shift arms (Figure 42). Figure 43 1. Differential lock cable 2. Transaxle bracket 3.
• Tighten tie rod and turnbuckle jam nuts when the adjustment is correct. • 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 Figure 44 1. Front of vehicle 2. .12 ± .12 inch greater than rear of tire 3. Center to center distance 2. Adjust the center–to–center distance as follows: • On the right front wheel, loosen the jam nuts at both ends of the tie rod (Figure 45).
Cooling System Maintenance Brake Maintenance Removing Debris From Engine Cooling System Service Interval: Every 200 hours Service Interval: Every 100 hours (Clean more frequently in dirty conditions.) Adjusting Parking Brake To ensure proper cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. Service Interval: Every 200 hours Inspect Brakes Every 400 hours 1. Remove rubber grip from parking brake lever (Figure 47).
Adjusting Brake Pedal Belt Maintenance 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 49). Adjusting Belt Service Interval: After the first 8 hours Every 200 hours Raise bed and position safety support on extended lift cylinder to hold up bed. 1. Check tension by depressing belt at mid span of crankshaft and pump pulleys with 22 lbs. of force. A new belt should deflect .48–.
Controls System Maintenance 5. Stop engine. 6. Adjust ball joint on accelerator cable and/or cable jam nuts while throttle lever is against high idle stop to allow .100”–.250” of clearance between accelerator pedal arm and top of diamond tread floor plate, when a 25 lb. force is applied to center of pedal (Figure 53). Tighten locknut. Adjusting Accelerator Service Interval: Every 200 hours 1. Position vehicle on level surface, stop engine and engage the parking brake. 2.
Note: The clutch free play should never be less than .75”. 2. Disconnect the return spring from the clutch lever. 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 (Figure 55). 7. Recheck the clutch safety switch adjustment (Figure 57). The engine must not crank unless clutch pedal is 1.25” ±.12” from floor.
Hydraulic System Maintenance Changing Transaxle / Hydraulic Fluid Service Interval: 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 (Figure 58). Reinstall and tighten plug when hydraulic fluid stops draining. Figure 59 1. Hydraulic filter 2. Gasket 3. Lubricate new filter gasket. 4. Assure filter mounting area is clean.
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.
pressure and ease the disconnection of the quick couplers. • After completing operation, remove jumper hoses and connect hydraulic hoses to both vehicles. Important: Check hydraulic fluid levels, in both vehicles, before resuming operation. Figure 62 1. Disconnected hoses 2. Jumper hoses • 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 (Figure 63). Cap unused fittings. Figure 63 1.
Storage 9. Remove the spark plugs and check their condition; refer to Changing Spark Plugs. 1. Position the machine on a level surface, set the parking brake, stop the engine, and remove the ignition key. 10. With the spark plugs removed from the engine, pour two tablespoons of engine oil into the spark plug hole. 2. Clean dirt and grime from the entire machine, including the outside of the engine’s cylinder head fins and blower housing. 11.
Schematics Hydraulic Schematic (Rev.
Electrical Schematic (Rev.
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).
