Form No. 3355–926 Rev C Workman) 3100 Air Cooled Gas Utility Vehicle Model No. 07363—Serial No.
Pre–starting Checks . . . . . . . . . . . . . . . . . . . . . . . Starting Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . Driving Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping Vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . Stopping Engine . . . . . . . . . . . . . . . . . . . . . . . . . . New Vehicle Break–in . . . . . . . . . . . . . . . . . . . . . Check Interlock System . . . . . . . . . . . . . . . . . . . . Operating Characteristics . . . . . . . . .
Jump Starting Procedure . . . . . . . . . . . . . . . . . . . Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Schematic . . . . . . . . . . . . . . . . . . . . . . Electrical Schematic . . . . . . . . . . . . . . . . . . . . . . . The Toro General Commercial Products Warranty . . Safety Page 46 47 47 48 49 52 The TORO WORKMAN) meets the requirements of SAE J2258.
• 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. This is a specialized utility vehicle designed for off–road use only. its ride and handling will have a different feel than what drivers experience with passenger cars or trucks. So take time to become familiar with your WORKMAN).
• When starting the engine: – Do not pass another vehicle traveling in the same direction at intersections, blind spots, or at other dangerous locations. – Sit on operator’s seat and ensure parking brake is engaged. – 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. – Disengage PTO (if so equipped) and return hand throttle lever to OFF position (if so equipped).
• Never work under a raised bed without placing bed safety support on fully extended cylinder rod. • If major repairs are ever needed or assistance is required, contact an Authorized TORO Distributor. • Make sure all hydraulic line connectors are tight, and all hydraulic hoses and lines are in good condition before applying pressure to the system. • To be sure of optimum performance and safety, always purchase genuine TORO replacement parts and accessories.
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. 93-9442 1. Maximum tongue weight is 90 kg; maximum trailer weight is 680 kg. 93-9850 2. For information on transmission fluid, read the Operator’s Manual. 1. Do not repair or revise—read the Operator’s Manual. 93-6687 1.
93-9879 1. Stored energy hazard—read the Operator’s Manual. 106-2353 1. Electrical power 80-8040 106-2355 1. Slow to fast 2. Transmission—third high; no fast speed 93-9449 1. Read the Operator’s Manual. 2. Grease every 100 hours. 3. Add grease (9 grease points). 106-7897 1. The maximum load is 1019 kg, the vehicle weight is 795 kg, and the maximum gross vehicle weight is 1814 kg. 93-8071 1. Hot surface/burn hazard—stay a safe distance from the hot surface.
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. Battery –low charge (Liquid cooled only) 8. Temperature level (Liquid cooled only) 9. Hour meter 10. Off 11. On 110-2599 1. Warning—read the Operator’s Manual. 2. Fire hazard—stop the engine before fueling. 3.
6-2384 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 10 11. Extend hydraulics 12. Transmission—high speed 13.
106-7894 1. Engine—start 2. Ignition 3. Headlights 4. Power point 106-7767 1. Warning—read the Operator’s Manual. 2. Avoid tipping the machine. 3. Wear the seat belt. 4. Lean away from the direction the machine is tipping. 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. Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 2. No fire, open flames, or smoking. 3.
Specifications Note: Specifications and design subject to change without notice. General Specifications Type 4 wheel step through, out front operator style, two person vehicle. Certified to meet SAE J2258. Engine Kohler, 4 cycle, air cooled, 23 hp @ 3600 rpm, 41.1 cu. in. (674 cc) displacement. Mechanical fuel pump, 2 qt. oil capacity. Large capacity dual element air cleaner. Battery 12 volt with 540 cold cranking Amps @ 0 degrees F. Fuel System Gasoline tank capacity is 7 gallons.
Base Weight (Dry w/o flatbed) 1470 lbs. Rated Capacity 2,530 lbs. (includes 200 lb. operator, 200 lb. passenger and loaded attachment). Maximum. Gross Vehicle Weight Tow Capacity Ground Clearance Wheel Base Wheel Tread (center line to center line) 4,250 lbs. Tongue weight 200 lbs. Maximum trailer weight 1,500 lbs. 7” w/ no load 70” Front 46” Rear 47.7” Dimensions Overall Width Overall Length 63” 128.25” w/o bed 130.38” w/full bed 136.
Setup Note: Determine the left and right side of the machine from the normal operating position. Description Qty. ROPS frame 1 Capscrew 1/2 x 3” in. 4 Locknuts 1/2 4 Operator’s Manual (vehicle) 2 Parts Catalog 1 Use Mount ROPS (Rollover Protection System) Read before operating the machine. Note: Determine the left and right side of the machine from the normal operating position.
Install ROPS 5 1 1. Insert each side of ROPS into mounting bracket on each side of vehicle frame, positioning ROPS as shown in figure 1. 6 Note: The ROPS cover plate mounting bolts may have to be loosened to insert the ROPS into the mounting brackets 2. Secure each side of ROPS to mounting brackets with (2) 1/2–13 x 3” lg. capscrews and locknuts. 4 1 2 3 Figure 2 1. Bed mounting plate 2. Cylinder rod end 3. Clevis pin 3 2 6. Store cylinders in storage clips.
Note: Carriage bolt heads are to be positioned inside the machine. 1. Assure lift cylinders are fully retracted. 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 3 1 Figure 4 1. Spacer bracket 2. Wear block 3. Carriage bolt 2. Carefully set bed onto vehicle frame aligning rear bed pivot plate holes with holes in rear frame channel and install (2) clevis pins and lynch pins (Fig.
Before Operating Note: SAE 10W40 and straight weight oils (SAE 30, etc.) are not recommended in Kohler engines due to problems with pump–up of hydraulic lifters with those oils. Either synthetic or mineral based oils may be used, but oil drain intervals should be the same (per recommendations Caution 4. Pour oil into fill opening until the oil level is up to the “FULL” mark on the dipstick.
1. Position the vehicle on a level surface. 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. 2. Clean area around dipstick. 3. Unscrew dipstick from top of transaxle and wipe it with a clean rag. 1. Clean area around fuel tank cap. 2. Remove fuel tank cap. Danger 1 Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive.
Check Brake Fluid Check Pump Belt Tension 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. Check belt for wear, cracking or improper tension. Check tension by depressing belt at mid span of crankshaft and pump pulleys with 22 lbs. of force. A new belt should deflect .48–.58 in. A used belt should deflect .55–.65 in.
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. 11) gives the operator the ability to vary engine and ground speed of the vehicle, when the transmission is in gear.
High–Low Range Shifter Caution Adds three additional speeds for precise speed control (Fig. 12). Turning with the differential lock on can result in loss of vehicle control. Do not operate with differential lock on when making sharp turns or at high speeds. Refer to using the differential lock. 2 • Vehicle must be completely stopped before shifting between High and Low range. • Shift only on level ground. • Depress clutch pedal fully. 4 • Move lever fully forward for High and fully rearward for Low.
Hour Meter 4 Indicates the total hours of machine operation. The hour meter (Fig. 13) starts to function whenever the key switch is rotated to “ON” position or if engine is running. 3 2 1 3rd High Lockout Switch Moving switch (Fig. 13) 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.
1 2 Figure 15 1. Passenger hand hold 2. Storage compartment Seat Adjusting Lever The seats can be adjusted fore and aft for operator comfort (Fig. 16). 1 Figure 16 1.
Pre–starting Checks Driving Vehicle Safe operation begins before taking the vehicle out for a day’s work. You should check these items each time: 1. Release parking brake. 2. Fully depress clutch pedal. • Check tire pressure. 3. Move gear shift lever to 1st gear. Note: These tires are different than car tires, they require less pressure to minimize turf compaction and damage. 4. Release clutch pedal smoothly while depressing accelerator pedal.
New Vehicle Break–in 4. If engine cranks or starts, there is a malfunction in the interlock system that must be repaired before operating vehicle. Your Workman is ready for work. To provide proper performance and long vehicle life, follow these guidelines for the first 100 operating hours. Caution • Check the fluid and engine oil levels regularly and be alert for indications of overheating in any component of the vehicle.
Many factors contribute to accidents. You have control over several of the most important. Your actions, such as driving too fast for conditions, braking too fast, turning too sharp, and combinations of these, are frequent cause of accidents. 1 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. Never operate the vehicle, or any equipment, if you are under the influence of alcohol or other drugs.
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 follows the instructions provided. 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.
Loading And Dumping 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. 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. As a general rule, position the weight of the load evenly from front to rear and evenly from side to side.
Transporting Vehicle Several types of tow hitches are available for the Workman, depending on your application. Contact your Authorized TORO Distributor for details. For moving the vehicle long distances, a trailer should be used. Make sure the vehicle is secured to the trailer. Refer to Figures 19 and 20 for location of tie down points. When equipped with a tow hitch bolted onto rear axle tube, your Workman can tow trailers or attachments with a Gross Trailer Weight (GTW) up to 1500 lbs.
Lower (Quick Coupler “B” Position) Important Check hydraulic oil level after installation of attachment. Check operation of attachment by cycling attachment several times to purge air from system, then recheck hydraulic oil level. Attachment cylinder will slightly affect transaxle oil level. Operation of vehicle with low oil level can damage pump, remote hydraulics, power steering and vehicle transaxle. This position will lower the bed, rear hitch attachment or apply pressure to quick coupler ”B”.
Hydraulic Control Trouble Shooting: • Difficulty in connecting or disconnecting quick couplers. • Pressure not relieved (Quick coupler under pressure). • Power steering hard. • Hydraulic oil level low. • Hydraulic oil hot. • Pump not operating. • Hydraulic leaks. • Fittings loose. • Fitting missing o–ring. • Attachment does not function. • Quick couplers not fully engaged. • Quick couplers are interchanged. • Squealing noise.
Maintenance Note: Determine the left and right side of the machine from the normal operating position. Service Interval Chart Lubrication 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 25 Figure 23 Figure 26 Figure 24 33
Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure Check cable adjustments Check pump drive belt tension Torque wheel lug nuts Replace transaxle filter After first 10 hours • • • • After first 50 hours • Replace engine oil and filter Every 50 hours • Check the battery fluid level. • Check the battery cable connections.
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 brake fluid level Check the air filter/prefilter Inspect engine cooling fins Check for any unusual engine noises. Check for any unusual operating 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. 28). 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.
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 filter and additional 1/2 turn. DO NOT OVER–TIGHTEN. Inspect paper element every 50 hours of operation and replace if dirty or damaged. Change paper element every 200 hours. Do not wash paper element or do not clean with compressed air as damage will occur. 1 2 3 4 1 2 5 Figure 32 6 1. Engine oil drain plug 7 2. Engine oil filter 4.
Adjusting Choke 4. Remove clamps securing fuel filter to fuel lines. 5. Install new fuel filter to fuel lines with clamps previously removed. Filter must be mounted so arrow points toward carburetor. 1. Raise bed and place safety support on extended lift cylinder to hold up bed. Stop engine and engage parking brake. 2. Loosen cable clamp screw securing cable to engine. Removing Debris From Engine 3. Push choke knob in to OFF position.
Adjusting Accelerator pedal arm and top of diamond tread floor plate, when a 25 lb. force is applied to center of pedal. Tighten locknut. Check adjustment every 200 hours. 1. Position vehicle on level surface, stop engine and engage the parking brake. 2. With return spring installed, hold engine governor arm toward operator’s side of vehicle and adjust low idle stop to obtain a .01” – .05” gap between O.D. of hole in throttle lever and inside of governor spring hook. .100–.
Important Use only hydraulic fluids specified. Other fluids could cause system damage. 1 Replacing Hydraulic Filter Initially, replace the hydraulic filter after 10 operating hours, thereafter, replace filter every 800 hours. Important Use of any other filter may void the warranty on some components. 1. Position vehicle on a level surface, stop engine, engage the parking brake and remove key from ignition switch. 2. Clean area around filter mounting area. Place drain pan under filter and remove filter.
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. 44). 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 44 1 2 1.
7. Recheck the clutch safety switch adjustment (Fig. 46). 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 48 1. Parking brake lever 2. Knob Figure 46 3. Set screw 1. Clutch switch Adjusting Shift Cables Adjusting Parking Brake Check adjustment every 200 hours. Check adjustment every 200 hours. 1. Move shift lever to Neutral position. 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 Important The vehicles hydraulic system uses Dexron IIl ATF. To avoid system contamination, make sure vehicle used to jump hydraulic system uses an equivalent fluid. • On both vehicles, disconnect the two quick coupler hoses from the hoses secured to the coupler bracket (Fig. 54). 1 1 Figure 53 1.
1 Figure 56 1. Jumper hoses Figure 58 • Keep all bystanders away from the vehicles. • Start second vehicle and move lift lever to the raise position which will raise the disabled box. Jump Starting Procedure • Move the hydraulic lift lever to the neutral position and engage the lift lever lock. Warning • Install the bed safety support onto the extended lift cylinder. Refer to Using the Bed Safety Support. Jump starting can be dangerous.
Battery Care 1. Battery electrolyte level must be properly maintained and the top of the battery kept clean. lf the machine 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. Danger 1 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.
Hydraulic Schematic 48
Electrical Schematic 49
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.
