Toro 07210, WORKMAN 3100 Operator's Manual

Page 1

FORM NO. 3318-617GB Rev A

MODEL NO. 07210—60001 AND UP

To understand this product, and for safety and optimum performance, read this manual before starting the engine. Pay special attention to SAFETY INSTRUCTIONS highlighted by this symbol.

OPERATOR

MANUAL

WORKMAN 3100

UTILITY VEHICLES

It means CAUTION, WARNING or DANGER— personal safety instruction. Failure to comply with the instruction may result in personal injury.

Page 2

Foreword

The TORO WORKMAN®was developed to provide an efficient, versatile, trouble free and economical work vehicle. The latest concepts of engineering, design and safety have been incorporated into this machine, along with the highest quality parts and workmanship. Excellent service will be derived if proper operation and maintenance practices are followed. This vehicle is not designed or manufactured for use on roads, streets or highways. It is not appropriate for such use.

You know, since you have purchased the industry leader in maintenance excellence, that future performance and dependability are of prime importance. TORO also is concerned about future use of the machine and of safety to the user. Therefore, this manual must be read by you and those involved with the WORKMAN to make sure that safety, proper setup, operation and maintenance procedures are followed at all times.

Safety, mechanical and some general information in this manual are emphasized. DANGER, WARNING and CAUTION identify safety messages. Whenever the triangle safety symbol appears, it is followed by a safety message that must be read and understood. For more details concerning safety, read the safety instructions on pages 3 –5. IMPORTANT identifies special mechanical information and NOTE identifies general information worthy of special attention.

If help concerning set up, operation, maintenance or safety is ever needed, contact your local Authorized TORO Distributor. In addition to genuine TORO replacement parts, the distributor also has optional equipment for the complete line of TORO turf care equipment. Keep your TORO all TORO. Buy genuine TORO parts and accessories.Servicing Air Cleaner Filter

Table of Contents

Safety 3

Specifications 9

Before Operating 11

Controls 15

Operating 19

Maintenance 26

Page

Page 3

Safety

The WORKMAN®was designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention 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.

This is a specialized utility vehicle designed for off-road use. 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 attachments that adapt to the WORKMAN covered in this manual. See the specific Operator’s Manual provided with the attachment for additional safety instructions. READ THESE MANUALS.

TO REDUCE THE POTENTIAL FOR INJURY OR DEATH, COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS.

. Not all of the

are

SUPERVISOR’S RESPONSIBILITIES

Make sure operators are thoroughly trained and

familiar with the Operator’s Manual and all labels on the vehicle.

2. Be sure to establish your own special procedures

and work rules for unusual operating conditions (e.g. slopes too steep for vehicle operation). Use the 3rd High Lockout switch if high speed could result in a safety or vehicle abuse situation.

BEFORE OPERATING

3. Operate the machine only after reading and

understanding the contents of this manual. A replacement manual is available by sending complete model and serial number to: The Toro Company, 8111 Lyndale Avenue South, Minneapolis, Minnesota 55420.

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.

5. This vehicle is designed to carry only you, the

operator, and one passenger in the seat provided by the manufacturer. Never carry any other passengers on the vehicle.

6. Never operate the vehicle when under the influ-

ence of drugs or alcohol.

7. Become familiar with the controls and know

how to stop the engine quickly.

8. Keep all shields, safety devices and decals in

place. If a shield, safety device or decal is malfunctioning, illegible, or damaged, repair or replace it before operating the machine.

9. 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.

10. Wearing safety glasses, safety shoes, long pants

and a helmet is advisable and required by some local safety and insurance regulations.

. Keep everyone, especially children and pets,

away from the areas of operation.

12. Before operating the vehicle, always check all

parts of the vehicle and any attachments. If something is wrong, stop using vehicle. Make sure problem is corrected before vehicle or attachment is operated again.

13. Since gasoline is highly flammable, handle it

carefully.

A. Use an approved gasoline container.

4. Never allow children to operate the vehicle.

Never allow adults to operate it without proper instructions. Only trained and authorized persons

B. Do not remove cap from fuel tank when

engine is hot or running.

C. Do not smoke while handling gasoline.

Page 4

Safety

D. Fill fuel tank outdoors and to about one inch

below top of tank (bottom of filler neck). Do not overfill.

E. Wipe up any spilled gasoline.

14. Check the safety interlock system daily for prop-

er operation; refer to page 21. 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.

WHILE OPERATING

WARNING: Engine exhaust contains carbon monoxide which is an odorless, deadly poison. Carbon monoxide is also known to the State of California to cause birth defects. Do not run engine indoors or in an enclosed area.

E. Turn ignition key to START.

18. Using the machine demands attention. Failure to

operate vehicle safely may result in a accident, tip over of vehicle and serious injury or death. Drive carefully. To prevent tipping or loss of control:

A. Use extreme caution, reduce speed and

maintain a safe distance around sand traps, ditches, creeks, ramps, any unfamiliar areas or other hazards.

B. Watch for holes or other hidden hazards.

C. Use caution when operating vehicle on a

steep slope. Normally travel straight up and down slopes. Reduce speed when making sharp turns or when turning on hillsides. Avoid turning on hillsides whenever possible.

15. Operator and passenger should remain seated

whenever the vehicle is in motion. Operator should keep both hands on steering wheel, whenever possible and passenger should use the hand holds provided. Keep arms and legs within the vehicle body at all times. Never carry passengers in box or on attachments. Remember your passenger may not be expecting you to brake or turn and may not be ready.

16. Never overload your vehicle. Name plate (locat-

ed under dash on passenger side) shows load limits for vehicle. Never overfill attachments or exceed the vehicle maximum GVW.

17. When starting the engine: A. Sit on operator’s seat and engage the parking

brake.

B. Disengage PTO (if so equipped) and return

the hand throttle lever to OFF position (if so equipped).

C. Move shift lever to NEUTRAL and depress

clutch pedal.

D. Use extra caution when operating vehicle on

wet surfaces, at higher speeds or with a full load. Stopping time will increase with a full load. Shift into a lower gear before starting up or down a hill.

E. When loading bed, distribute load evenly.

Use extra caution if the load exceeds the dimensions of the vehicle/bed. Operate vehicle with extra caution when handling offcenter loads that cannot be centered. Keep loads balanced and secure to prevent them from shifting.

F. Avoid sudden stops and starts. Do not go

from reverse to forward or forward to reverse without first coming to a complete stop.

G. Do not attempt sharp turns or abrupt maneu-

vers or other unsafe driving actions that may cause a loss of vehicle control.

H. 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.

D. Keep foot off the accelerator pedal.

I. Before backing up, look to the rear and

assure no one is behind. Back up slowly.

Page 5

Safety

J. 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. Always signal your turns or stop early enough so other persons know what you plan to do. Obey all traffic rules and regulations.

K. Never operate vehicle in or near an area

where there is dust or fumes in the air which are explosive. The electrical and exhaust systems of the vehicle can produce sparks capable of igniting explosive materials.

L. Always watch out for and avoid low over

hangs such as tree limbs, door jambs, over head walkways, etc. Make sure there is enough room over head to easily clear the vehicle and your head.

M. If ever unsure about safe operation, STOP

WORK and ask your supervisor.

machine, stop engine, set the parking brake and remove key from ignition to prevent accidental starting of the engine.

23. Never work under a raised bed without placing

bed safety support on fully extended cylinder rod.

24. Make sure all hydraulic line connectors are tight,

and all hydraulic hoses and lines are in good condition before applying pressure to the system.

25. 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.

19. Do not touch engine, transaxle, radiator, muffler

or muffler shield while engine is running or soon after it has stopped because these areas may be hot enough to cause burns.

20. If the machine ever vibrates abnormally, stop

immediately, turn engine off, wait for all motion to stop and inspect for damage. Repair all damage before commencing operation.

21. Before getting off the seat: A. Stop movement of the machine.

B. Lower bed.

C. Shut engine off and wait for all movement to

stop.

D. Set the parking brake.

E. Remove key from ignition.

F. Block wheels if machine is on an incline.

MAINTENANCE

26. Before disconnecting or performing any work on

the hydraulic system, all pressure in system must be relieved by stopping engine, cycling dump valve from raise to lower and/or lowering box and attachments. Place the remote hydraulics lever in the float position. If box must be in raised position, secure with safety support.

27. To make sure entire machine is in good condi-

tion, keep all nuts, bolts and screws properly tightened.

28. To reduce potential fire hazard, keep the engine

area free of excessive grease, grass, leaves and accumulation of dirt.

29. If the engine must be running to perform a main-

tenance adjustment, keep hands, feet, clothing, and any parts of the body away from the engine and any moving parts. Keep everyone away.

30. Do not overspeed engine by changing governor

settings. Maximum engine speed is 3650 rpm. To assure safety and accuracy, have an Authorized TORO Distributor check maximum engine speed with a tachometer.

22. Before servicing or making adjustments to the

Page 6

Safety

31. If major repairs are ever needed or assistance is

required, contact an Authorized TORO Distributor.

32. To be sure of optimum performance and safety,

always purchase genuine

TORO replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous. Altering this vehicle in any manner may affect the vehicle’s operation, performance, durability or its use may result in injury or death. Such use could void the product warranty of The TORO Company.

33. This vehicle should not be modified without the

TORO Company’s authorization. Direct any inquiries to:

Sound & Vibration Levels

Sound Levels

This unit has an equivalent continuous A-weighted sound pressure at the operator ear of: 78 dB(A) based on measurements of identical machines per 84/538/EEC.

Vibration Levels

This unit has a vibration level of 2.5 m/s2at the posterior, based on measurements of identical machines per ISO 2631 procedures.

This unit does not exceed a vibration level of 0.5

at the posterior based on measurements of iden-

m/s tical machines per ISO 2631 procedures.

Page 7

Symbol Glossary

SAFETY ALERT SYMBOL GENERAL HAZARD SAFETY 

STAY A SAFE DISTANCE FROM MACHINE

EXPLOSION FIRE OR OPEN FLAME FIRE, OPEN LIGHT &

CAUSTIC LIQUIDS, CHEMICAL  BURNS TO FINGERS OR HAND

ALERT

STAY A SAFE DISTANCE FROM DRAINING  TANK

DO NOT DISPOSE IN THE  GARBAGE

CRUSHING OF WHOLE BODY,  APPLIED FROM ABOVE

STAY A SAFE DISTANCE FROM MACHINE STAY A SAFE DISTANCE FROM 

SMOKING PROHIBITED

THROWN OR FLYING OBJECTS,  WHOLE BODY EXPOSURE

CRUSHING OF TOES OR FOOT,  FORCE APPLIED FROM ABOVE

EYE PROTECTION MUST BE  WORN

CRUSHING OF FINGERS OR HAND,  FORCE APPLIED FROM SIDE

HYDRAULIC OIL VALVE

CAUTION, TOXIC RISK FIRST AID FLUSH WITH WATER

25mm

FUEL TANK FILL LINE

READ OPERATOR’S MANUAL

CUTTING OF FINGERS OR HAND CUTTING OF FOOT

KEEP CHILDREN A SAFE  DISTANCE FROM BATTERY

LOCK UNLOCK

BATTERY CHARGING CONDITION

MANUAL

WHOLE BODY ENTANGLEMENT,  IMPLEMENT INPUT DRIVE LINE

ENGINE START

ENGINE STOP ENGINE LUBRI-

133 bar

PTO

HOPPER CLOSED HOPPER OPEN

HYDRAULIC PRESSURE

DO NOT OPEN OR REMOVE SAFETY  SHIELDS WHILE ENGINE IS RUNNING

CATING OIL

FAST SLOW CONTINUOUS VARIABLE, LINEAR

HYDRAULIC OIL PRESSURE  INTAKE AIR

CLOCKWISE ROTATION COUNTER CLOCKWISE 

SECURE LIFTING CYLINDER WITH  LOCKING DEVICE BEFORE GETTING  IN HAZARDOUS AREA

GLOW PLUG ENGINE INTAKE,

COMBUSTION AIR

HORN

ROTATION

HAND & ARM ENTANGLEMENT, BELT DRIVE

ON/START OFF/STOP

TRANSMISSION, 3RD HIGH GEAR

PROHIBITED ACTION OR HAZARDOUS LOCATION

DO NOT WELD DO NOT DRILL

BRAKE SYSTEMENGAGE DISENGAGE

CRUSHING OF TORSO,  FORCE APPLIED FROM  THE SIDE

HEADLIGHTS

PARKING BRAKE DIFFERENTIAL LOCK CLUTCH LIFT POINT

TRANSMISSION, LOWTRANSMISSION OIL

CRUSHING OF FINGERS OR  HAND, FORCE APPLIED FROM  ABOVE

ATTACHMENT RAISE

TRANSMISSION, HIGH

VEHICLE BED LOWER VEHICLE BED RAISE

HIGH PRESSURE SPRAY, EROSION OF FLESH

ATTACHMENT LOWER

ATTACHMENT FLOAT

< 250 kg

HOUR METER, ELAPSED 

WEIGHT

OPERATING HOURS

LIMITED RECTI- LINEAR MOTION

Page 8

Symbols Glossary

THROWN OR FLYING OBJECTS, FACE EXPOSURE

MACHINE TIPPING USE CAUTION ON STEEP HILLS MACHINE TIPPING MACHINE TIPPING

DO NOT JUMP FROM TIPPING MACHINE

STAY CLEAR OF ARTICULATION  AREA WHILE ENGINE IS RUNNING

SEVERING OF FINGERS OR  HAND, ENGINE FAN

HOLD TIGHTL & BRACE FEET LEAN AWAY FROM TIP HOLD HIP RESTRAINT & HAND 

RUNOVER/BACKOVER, VEHICLE REAR POWER TAKE OFF

RIDING ON THIS MACHINE IS  ALLOWED ONLY ON A PASS- ENGER SEAT & ONLY IF THE  DRIVER'S VIEW IS NOT HINDERED

SHUT OFF ENGINE & REMOVE  KEY BEFORE PERFORMING  MAINTENANCE OR REPAIR WORK

HOLD, BRACE FEET

(9)

GREASE LUBRICATION POINT GREASE LUBRICATION POINT

MACHINE DIRECTION OF MOVEMENT BEFORE LEAVING OPERATOR POSITION, TURN OFF IGNITION, LOCK PARKING BRAKE,

DISENGAGE PTO, REMOVE KEY FROM IGNITION.

635 kg

BEFORE LEAVING OPERATOR POSITION, TURN OFF IGNITION AND REMOVE KEY.

< 11 79 kg

635 kg

< 181 4 kg

LOAD RATING

LOAD RATING, HOPPER LOAD RATING, TRAILER AND HITCH

< 11 79 kg

726 kg

< 1 905 kg

LOAD RATING

< 680 kg

< 318 kg

LOAD RATING, HOPPER

< 90 kg

Page 9

Specifications

Type: 4-wheel step-through, out-front operator style, two-person vehicle. Certified to meet ANSI Specifications B56.8-1988.

Engine: Kohler 4-cycle, air-cooled, 16.4 kV @ 3600 rpm, 624 cc displacement. Mechanical fuel pump,

1.9 liter oil capacity. Large capacity dual element air

cleaner.

Battery: 12 volt with 370 cold-cranking Amps @ –18° C (0 degrees F.)

Fuel System: Fuel tank capacity is 26.5 l (7 gallons).

Transmission: Rear transaxle configuration, twin axle drive. 3-speed synchromesh, H-shift pattern with high-low range providing 6 forward and 2 reverse speeds. Manual engage differential lock.

Clutch: 17 cm (6.7 inch) clutch and pressure plate. Frame: Welded, high-strength steel channels and

tubes. Front Suspension: Independent “A” frame control

arm, dual coil springs and dual shock absorbers with anti-sway bar.

Roll Over Protection System: 2-post roll over protection structure with shoulder restraint.

Hydraulics: 4 gpm pressure balanced gear pump provides hydraulic flow for power steering, lift and optional remote hydraulics. Lift control valve and dual cylinders for lifting dump box. Transaxle is used for reservoir for hydraulic system. 7.6 l capacity. Spin-on 25-micron hydraulic oil filter. 100 mesh strainer in transaxle.

Seat: Twin molded cushions and backrests, with shoulder and hip restraints.

Controls: Foot-operated accelerator, clutch and brake pedals. Hand -operated shifter, differential lock, parking brake, high-low range shifter, hydraulic lift and tilt steering levers. Ignition switch, light switch, horn button, and 3rd high lockout switch.

Gauges: Hour meter, warning light and fuel gauge. Tachometer optional.

Lights: Twin halogen headlights and single taillight. Rear stop light.

Interlocks: Clutch pedal must be depressed to start engine.

Rear Suspension: DeDion axle (weight carrying axle is independent of transaxle), leaf spring and dual shock absorbers.

Steering System: Power assist, 3-position tilt steering wheel, 3-3/4 turns lock-to-lock. 17.5 to 1 ratio,

34.3 cm (13.5 inch) diameter steering wheel.

Tires:

Front tires: 50.8 x 25.4 cm (20” x 10”)-10, 4-ply rating, rib tread.

Rear tires: 58.4 x 26.7 cm (23” x 10.5”)-12, 6-ply rating, turf tread.

Optional rear tires: 61 x 38 cm (24" x 13") x 12, 4ply rating, turf tread.

Brakes: 4-wheel hydraulic, dual safety circuit selfadjusting drum: 17.8 (7”) diameter front, 20.3 (8”) diameter rear. Hand-actuated parking brake actuates rear brake shoes.

Ground Speed:

Forward Speeds with 58 cm (23”) Tires-

High range: 11,7/21.9/37 kmh (7.3/13.6/23

mph)

Low range: 4.5/8.5/14.5 kmh (2.8/5.3/9 mph)

Reverse Speeds with 58 cm (23”) Tires-

High range: 11.1 kmh (6.9 mph) Low range: 4.3 kmh (2.7 mph)

General Specifications (approx.):

Base Weight:Dry w/o flatbed 475.9 kg (1275 lbs.)

Rated Capacity: 1117 kg*(2,725 lbs). *includes 74.6 (200 lb.) operator and 74.6 (200 lb.) passenger and loaded attachment.

Maximum. Gross Vehicle Weight:1,493 kg (4,000 lbs.)

Tow Capacity

Tongue weight 74.6 kg (200 lbs.) Maximum trailer weight 560 kg (1,500 lbs.)

Page 10

Specifications

Overall Width: 147 cm (58”) with 23 inch tires

Overall Length: 316 cm (124.5” without bed)

322.3 cm (127” with full bed)

338 cm (133”) with 2/3 bed in rear mounting

location

Height: 190.5 cm(75”) to top of the Roll Over

Protection System

Ground Clearance: 17.7 cm (7”) with no load

Wheel Base: 177.8 cm (70”)

Wheel Tread: (center line to center line) Front 116.8 cm (46”) Rear 121.6 (47.7”) (w 23” Rear Tire)

Specifications and design subject to change without notice.

Page 11

Before Operating

CAUTION

Before servicing or making adjustments to the machine, stop the engine, set the parking brake and the remove key from the switch. Any load material must be removed from the bed or other attachment before working under the raised bed. Always rotate the safety support to the down position before working under the raised bed.

CHECK CRANKCASE OIL

4. Pour oil into the fill opening until the oil level is

up to the “FULL” mark on the dipstick. Add the oil slowly and check the level often during this process. DO NOT OVERFILL.

IMPORTANT: Check the level of oil every 8 operating hours or daily. Change the oil and filter initially after the first 5 hours of operation, thereafter, change the oil and filter every 50 hours. However, change the oil more frequently when the engine is operated in extremely dusty or dirty conditions.

The engine is shipped with oil in the crankcase; however, the level of oil must be checked before and after the engine is first started.

1. Position the machine on a level surface.

2. Remove the dipstick and wipe it with a clean rag.

Insert the dipstick into tube and make sure it is seated fully. Remove the dipstick and check the level of oil. If the oil level is low, remove the filler cap and add enough oil to raise the level to the FULL mark on the dipstick.

Figure 1

1. Dipstick 2. Filler cap

3. Gasoline engines use any high-quality detergent

oil having the American Petroleum Institute— API—“service classification” SG or SG/CD. Seethe viscosity chart for recommended weight to use.

5. Install the dipstick firmly in place.

FILL FUEL TANK

Fuel tank capacity is approximately 32 l.

Gasoline Models:

THE TORO COMPANY STRONGLY RECOMMENDS THE USE OF FRESH, CLEAN, UNLEADED REGULAR GRADE GASOLINE IN TORO GASOLINE POWERED PRODUCTS. UNLEADED GASOLINE BURNS CLEANER, EXTENDS ENGINE LIFE, AND PROMOTES GOOD STARTING BY REDUCING THE BUILDUP OF COMBUSTION CHAMBER DEPOSITS. LEADED GASOLINE CAN BE USED IF UNLEADED IS NOT AVAILABLE. MINIMUM OCTANE RATING OF 87.

NOTE:NEVER USE METHANOL, GASO-

LINE CONTAINING METHANOL, GASOLINE CONTAINING MORE THAN 10% ETHANOL, GASOLINE ADDITIVES, OR WHITE GAS BECAUSE ENGINE FUEL SYSTEM DAMAGE COULD RESULT.

1. Clean the area around the fuel tank cap.

2. Remove the fuel tank cap.

A. Above –20° C—Use 10W-30 or 10W-40.

B. Below 0° C—Use SAE 5W-20 or SW-30.

3. Fill the tank to about one inch below top of the

tank, (bottom of the filler neck). DO NOT OVERFILL. Then install the cap.

Page 12

Before Operating

every 8 hours or daily, thereafter. Capacity of the system is 7.1 l (7.5 qt).

➀

Figure 2

1. Fuel tank cap

4. Wipe up any fuel that may have spilled to pre-

vent a fire hazard.

CHECK THE TRANSAXLE / HYDRA ULIC FLUID

DANGER

Because fuel is flammable, caution must be used when storing or handling it. Do not fill the fuel tank while the engine is running, hot or when the machine is in an enclosed area. Vapors may build up and be ignited by a spark or flame source many feet away. DO NOT SMOKE while filling the fuel tank to prevent the possibility of an explosion. Always fill the fuel tank outside and wipe up any spilled fuel before starting the engine. Use a funnel or spout to prevent spilling, and fill the tank no higher than 2.5 cm (one inch) below top of the tank, (bottom of the filler neck). DO NOT OVER FILL.

Store fuel in a clean safety approved container and keep the cap on the container. Keep fuel in a cool, well-ventilated place; never in an enclosed area such as a hot storage shed. To assure volatility, do not buy more than a 30-day supply of gasoline, or a 6-month supply of diesel fuel.

1. Position the vehicle on a level surface.

2. Clean the area around the dipstick.

3. Unscrew the dipstick from the top of the

transaxle and wipe it with a clean cloth.

➀

Figure 3

1. Dipstick

4. Screw the dipstick into the transaxle and make

sure it is seated fully. Unscrew the dipstick and check fluid level. Fluid should be up to the top of flat portion of the dipstick. If the level is low, add enough fluid to achieve the proper level.

CHECK BRAKE FLUID

The brake fluid reservoir is shipped from the factory filled with brake fluid. Check the level before the engine is first started and every 8 hours or daily, thereafter.

1. Park the machine on a level surface.

2. Fluid level should be up to the FULL line on

reservoir.

Since many children like the smell of gasoline, keep it out of their reach because the fumes are explosive and dangerous to inhale.

The transaxle reservoir is filled with Dexron II ATF. Check the level before the engine is first started and

3. If the fluid level is low, clean the area around

cap, remove the reservoir cap and fill to proper level. DO NOT OVERFILL.

Page 13

597

560

Before Operating

20” FRONT TIRES

➁

➀

Figure 4

1. Brake fluid reservoir

2. Full line

CHECK WHEEL NUT T ORQUE

WARNING

Failure to maintain proper torque could result in failure or loss of wheel and may result in personal injury. Torque front and rear wheel nuts to 61–88 Nm after 1–4 hours of operation and again after 10 hours of operation and every 200 hours thereafter.

CHECK TIRE PRESSURE

Check tire pressure every 8 hours or daily.

Maximum air pressure in the front tires is 1,4 kg/cm and 2,3 kg/cm2 in the rear (23”) tires tires. Optional rear (24”) tire pressure is 18 psi maximum.

1. The air pressure needed is determined by the payload carried.

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. Use the following charts to determine correct tire pressures for tire size and payload of vehicle.

523

485

448

411 373

Maximum Total Front Axle Weight (kg)

Tire pressure (Nm)

9783110 124

138 152

23” REAR TIRES (Standard)

970 933 896 858 821 784 709 672 635 560 523 485 448 411

373

Maximum Total Rear Axle Weight (kg)

6955 9783 110 124138152

TIRE PRESSURE (Nm)

165179193207 221

24” EXTRA WIDE REAR TIRES

970 933

896 858 821

784 709

672 635

635

Maximum Total Rear Axle Weight (kg)

TIRE PRESSURE (Nm)

9783 110 124 138

Page 14

Controls

Accelerator Pedal (Fig. 5)—Used to vary engine and ground speed when the transmission is in gear. Depressing the pedal increases engine RPM and ground speed. Releasing it will decrease engine RPM and ground speed.

➀

➁

Figure 5

1. Accelerator pedal

2. Clutch pedal

3. Brake pedal

Clutch Pedal (Fig. 5)—The clutch pedal must be fully depressed to disengage the clutch when starting the engine or shifting transmission gears. Release the pedal smoothly when the transmission is in gear to prevent unnecessary wear on the transmission and other related parts.

➂

Shift Pattern

IMPORTANT: Do not shift the transaxle to the reverse or forward gear unless the vehicle is standing still. Damage to the transaxle may occur.

CAUTION

Down shifting from too high a speed can cause the rear wheels to skid and can result in loss of vehicle control. Shift smoothly to avoid grinding gears..

Differential Lock (Fig. 6)—Allows rear axle to be locked for increased traction. Differential lock may be engaged with vehicle in motion. Move the lever forward and to the right to engage the lock.

IMPORTANT: Do not ride the clutch pedal during operation. The clutch pedal must be fully out or the clutch will slip causing friction and wear. Never hold the vehicle stopped on a hill using the clutch pedal. Damage to the clutch may occur.

Brake Pedal (Fig. 5)—The brake pedal is used to

apply service brakes to stop or slow vehicle.

CAUTION

Worn or misadjusted brakes may result in personal injury. If the brake pedal travels to within 2.5 cm of the vehicle floor board, the brakes must be adjusted or repaired.

Gear Shift Lever (Fig. 6)—Fully depress the clutch

pedal and move shift lever into desired gear selection. A diagram of the shift pattern is indicated below.

WARNING

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.

Note: Vehicle motion plus a slight turn is

required to engage or disengage the differential lock.

Choke (Fig. 6)—To start a cold engine, close the carburetor choke by pulling the choke control upward to the ON position. After the engine starts, regulate the choke to keep the engine running

smoothly. As soon as possible, open the choke by pushing it downward to the OFF position. A warm engine requires little or no choking.

Page 15

Controls

Figure 6

1. Gear shift lever

2. Differential lock

3. Parking brake

4. High-low range shifter

5. Hydraulic lift

6. Hydraulic lift lock

7. Passenger hand hold

8. PTO lever (optional)

Parking Brake (Fig. 6)—Whenever the engine is shut off, the parking brake must be engaged to prevent accidental movement of the vehicle. To engage the parking brake, pull back on the lever. To disengage, push lever forward. Make sure the parking brake is released before moving the vehicle. If the vehicle is parked on a steep grade, make sure the parking brake is applied. Also, shift the transmission into 1st gear on an uphill grade or into reverse on a down hill grade. Place chocks at the down hill side of wheels.

additional speeds for precise speed control.

A. The vehicle must be completely stopped before

shifting between High and Low range.

B. Shift only on level ground.

C. Depress the clutch pedal fully.

D. Move the 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. For example, steep grades, difficult terrain, heavy loads, slow speed but high engine speed (spraying).

NOTE:There is a location between HIGH and LOW in which the transaxle is in neither range. This should not be used as a neutral position because the vehicle could move unexpectedly if the HIGH-LOW shifter is bumped and the gear shift lever is in gear.

Tilt Steering Lever (Fig. 7)—Lever on right side of the console lets you adjust the steering wheel for your comfort.

Hydraulic Lift (Fig. 6)—Raises and lowers bed. Move rearward to raise, forward to lower.

IMPORTANT: When lowering the bed, hold the lever in the forward position for 1 or 2 seconds after the bed contacts the frame to secure it in the lowered position. Do not hold the hydraulic lift in either the raise or lower position for more than 5 seconds after the cylinders have reached the end of their travel. The hydraulic pump may overheat, resulting in pump damage.

Hydraulic Lift Lock (Fig. 6)—Locks the lift lever

so the hydraulic cylinders do not operate when vehicle is not equipped with a bed.

Passenger Hand Hold (Fig. 6)—On the left side of the passenger seat.

High-Low Range Shifter (Fig. 6)—Adds three

1. Tilt steering lever

Figure 7

2. Ignition switch

3. Horn button

4. Oil pressure warning light

Horn Button (Fig. 7)—Pressing this button activates the horn.

Engine Low Oil Pressure Light (Fig. 7)—This light glows if engine oil pressure drops below a safe level

Page 16

Controls

while the engine is running. If the light flickers or remains ON, stop the vehicle, turn off the engine and check the oil level. If the oil level was low, but adding oil does not cause light to go out when the engine is restarted, turn the engine off immediately and contact your local TORO distributor for assistance.

➁

➂

Ignition Switch (Fig. 7)—The ignition switch, used to start and stop the engine, has three positions: OFF, RUN and START. Turn the key clockwise—START position—to engage the starter motor. Release the key when the engine starts. The key will move automatically to the ON position. To shut the engine off, turn the key counterclockwise to OFF.

To check warning light operation:

1. Apply the parking brake.

2. Turn the ignition key to “ON”, but do not start

the engine. The oil pressure light should glow. If the light does not function, either a bulb is burned out or there is a malfunction in the system which must be repaired.

Hour Meter (Fig. 8)—Indicates the total hours of machine operation. The hour meter starts to function whenever the key switch is turned to the “ON” position.

➄

➃

Figure 8

1. Light switch

2. Hour meter

3. Fuel gauge

4. 3rd High lockout switch

5. Steering wheel

Steering Wheel (Fig. 8)—Turns the vehicle. If the

engine stalls or the power assist fails, vehicle steer-

ing will require greater effort.

Tachometer (optional-not shown)—Indicates engine

RPM. Gear selection graphics indicate speed.

Remote Hydraulic Lever (optional-not shown)—

Controls hydraulic flow to optional quick rear cou-

plers.

➀

Light Switch (Fig. 8)—Toggle this switch to activate the headlights. Push to turn lights “ON”.

Fuel Gauge (Fig. 8)—Shows the amount of fuel in the tank. Operates only when the ignition switch is in the “ON” position.

3rd High Lockout Switch (Fig. 8)—Moving this switch to the slow position and removing the key will prevent use of third gear when in the High range. The engine will shut off if the shift lever is moved to third gear when in the High range. Install the key with its teeth pointing downward. Push the key in to turn it. The key is removable in either position.

Page 17

Operating

PRE-STARTING CHECKS

Safe operation begins before taking the vehicle out for a day’s work. You should check these items each time:

1. Check tire pressure. Note: These tires are different than car tires,

they require less pressure to minimize turf compaction and damage.

2. Check all fluid levels and add the appropriate amount of Toro-specified fluids, if any are found to be low.

3. Check brake pedal operation.

4. Check to see that the lights and horn are work-

ing.

5. Turn the steering wheel to the left and right to check steering response.

A. In extremely cold weather (below 18° C)—

fully depress and release the accelerator pedal several times before trying to start the engine.

B. If the engine is hot—depress and hold the

accelerator pedal about half way down while cranking the engine.

C. If the engine is flooded—fully depress the

accelerator pedal and hold it to the floor until the engine starts. Never pump the accelerator pedal.

5. Insert the key into the ignition switch and turn it

clockwise to start the engine. Release the key when the engine starts.

IMPORTANT: To prevent overheating the starter motor, do not engage the starter longer than 10 seconds. After 10 seconds of continuous cranking, wait 60 seconds before engaging the starter motor again.

6. 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. Your supervisor may want you to check other items on a daily basis, so ask what your responsibilities are.

STARTING THE ENGINE

1. Sit on the seat and engage the parking brake.

2. Disengage the PTO (Power Take Off—if so

equipped) and return the hand throttle lever to the OFF position (if so equipped).

3. Move the shift lever to NEUTRAL and depress the clutch pedal.

4. Keep your foot off the accelerator pedal.

DRIVING THE VEHICLE

1. Release the parking brake.

2. Fully depress the clutch pedal.

3. Move the gear shift lever to 1st gear.

4. Release the clutch pedal smoothly while depress-

ing the accelerator pedal.

5. When the vehicle gains enough speed, remove

your foot from the accelerator pedal, fully depress the clutch pedal, move gear shift lever to the next gear and release the clutch pedal while depressing the accelerator pedal. Repeat this procedure until desired speed is attained. Stop the vehicle before shifting to reverse and forward.

Note: Avoid long periods of engine idling.

Note: Leaving the ignition switch in the “ON”

position for long periods of time without running the engine will discharge the

Page 18

Operating

battery.

IMPORTANT: Do not keep the front wheels turned against the right or left stops for longer than 5 seconds. The hydraulic pump may over heat, resulting in pump or steering gear damage.

6. Do not push or tow the vehicle to get it started.

Damage to the drive train could result.

STOPPING THE VEHICLE

To stop the machine, remove your foot from the accelerator pedal, depress the clutch pedal, then depress the brake pedal.

STOPPING THE ENGINE

To stop the engine, turn the ignition key to OFF and engage the parking brake. Remove the key from the switch to prevent accidental starting.

NEW VEHICLE BREAK-IN

Your Workman®is ready for work. To provide top performance and long vehicle life, follow these guidelines for the first 100 operating hours.

• A break-in oil for the engine is not required. The original engine oil is the same type specified for regular oil changes.

• Refer to Maintenance section for any special low hour checks.

CHECKING THE INTERLOCK SYSTEM

CAUTION

The interlock switches are for the operator’s protection, so do not bypass them. Check operation of the switches daily to assure the system is operating. If a switch is malfunctioning replace it before operating. Regardless of whether switches are operating properly, replace them every two years to assure maximum safety. Also, do not rely entirely on safety switches—use common sense!

The interlock system prevents the engine from cranking or starting unless the clutch pedal is depressed or PTO (if so equipped) is disengaged.

To verify PTO interlock switch operation:

1. Sit on operator’s seat and engage the parking brake. Move the shift lever to NEUTRAL.

• Check the fluid and engine oil levels regularly and be alert for indications of overheating in any part of the vehicle.

• After starting a cold engine, let it warm up for about 15 seconds before shifting into gear.

• Avoid racing the engine.

• Avoid situations requiring hard stops, especially when hauling heavy loads or pulling a trailer. It is necessary to fully break-in a new set of brake linings to achieve full braking performance. Follow this guideline whenever new linings are installed.

• Vary vehicle speeds during operation. Avoid excessive idling. Avoid fast starts and quick stops.

2. Engage the PTO.

3. Depress the clutch pedal and turn the key clock-

wise to the start position.

4. If the engine cranks or starts, there is a malfunc-

tion in the interlock system that must be repaired before operating the vehicle.

OPERATING CHARACTERISTICS

The vehicle is designed with safety in mind. It has four wheels for added stability. It uses familiar automotive style controls, including the steering wheel, brake pedal, clutch pedal, accelerator pedal, and gear shifter. It is important to remember, however, that this vehicle is not a passenger car. It is a work vehi-

Page 19

Operating

cle and not designed for use on roadways.

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 remember that the vehicle is not a recreation vehicle or an all-terrain vehicle. And it is definitely not meant for “stunt driving”. It is a work vehicle, not a play vehicle. Do not allow children should to operate the vehicle. Anyone who operates the vehicle should have a motor vehicle license.

If you are not experienced at driving the vehicle, practice driving it in a safe area away from other people. Be sure you are familiar with all the vehicle’s controls, particularly those used for braking, steering and transmission shifting. Learn how your vehicle handles on different surfaces. Your operating skills will improve with experience, but as in operating any vehicle, take it easy as you begin. Be sure you know how to stop quickly in an emergency. If you need help, ask your supervisor for assistance.

Avoid driving when it is dark, especially in unfamiliar areas. If you must drive when it is dark, be sure to drive cautiously, use the head lights, and even consider adding additional lights.

PASSENGERS

Whenever you have a passenger riding in the vehicle make sure he or she is holding on securely. Drive slower and turn less sharply because your passenger does not know what you intend to do next and may not be prepared for turning, stopping, accelerating, and bumps.

You and your passenger should remain seated at all times, keeping arms and legs inside the vehicle. The operator should keep both hands on steering wheel, whenever possible and passenger should use the hand holds provided.

There should never be passengers in the dump box or on any attachments. The vehicle is meant to have one driver and only one passenger-no more.

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 causes of accidents.

One of the major causes of accidents is fatigue. Be sure to take occasional breaks. It is 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. 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. Tree branches, fences, wires, other vehicles, tree stumps, ditches, sand traps, streams, and other things found in most parks and golf courses can be hazardous to the operator and passenger.

SPEED

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. 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.

Never drive too fast for the conditions. If there is any doubt about how fast to drive, slow down.

When using heavy attachments (more than 500 kg), such as sprayers, top dressers, or spreaders, etc., operating speeds should be restricted by moving 3rd high lockout switch to slow position.

TURNING

Turning is another important variable leading to accidents. Turning too sharply for the conditions can

Page 20

Operating

cause the vehicle to lose traction and skid, or even tip over.

Wet, sandy and slippery surfaces make turning more difficult and risky. The faster you are going, the worse this situation becomes so, slow down before turning.

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!

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. More important, it can injure you and your passenger.

engine braking may cause skidding and loss of control. Shift to a lower gear before starting down a hill.

TIPO VERS

WARNING

Tipping or rolling the vehicle on a hill will cause serious personal injury.

• If the engine stalls or you lose headway on a hill, never attempt to turn the vehicle around.

• Always back straight down a hill in reverse gear.

• Never back down in neutral or with the clutch depressed, using only the brakes.

• Never drive across a steep hill, always drive straight up or down.

• Avoid turning on a hill

• Don’t “drop the clutch” or slam on the brakes. Sudden speed change can initiate tipover.

Gross vehicle weight has a major impact on your ability to stop and/or turn. Heavier loads and heavier attachments make a vehicle harder to stop or turn. The heavier the load, the longer it takes to stop.

The braking characteristics also change with no bed or attachment on the vehicle. Fast stops may cause the rear wheels to lock up before the front wheels lock up, which may affect the control of the vehicle. It is a good idea to decrease vehicle speed with no bed or attachment.

Turf and pavement are much slipperier when they are wet. It can take 2 to 4 times as long to stop on wet surfaces as on dry surfaces.

If you drive through standing water deep enough to get the brakes wet, they will not work well until they are dry. After driving through water, you should test the brakes to make 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.

Do not downshift for braking on icy or slippery surfaces (wet grass) or while going down a hill because

The TORO WORKMAN®is equipped with a roll bar, hip restraints, shoulder restraints and hand hold. The Roll Over Protection System used on the vehicle will reduce the risk of serious or fatal injury in the unlikely event of a tipover, although the system cannot protect the operator from all possible injuries.

Replace a damaged Roll Over Protection System; do not repair or revise. Any alteration of Roll Over Protection System must be approved by manufacturer.

The best way to prevent accidents involving utility vehicles is through continuous supervision and training of operators and paying constant attention to the area in which vehicle is being operated.

The best way for operators to prevent serious injury or death to themselves or others, is to familiarize themselves with the proper operation of the utility 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 Roll-Over Protection System and follows the instructions pro-

Page 21

vided.

In case of tipover

Don’t jump

Operator: Hold tight and brace feet.

Operating

Tipover can occur if the truck is impr operly operated. Injury or death could result.

HILLS

Use extra care when on hills. Never go on hills that are extremely steep. Stopping while going down a hill will take longer than on level ground. Turning while going up or down a hill is more dangerous than turning on the level. Turns while going down hill, especially with the brakes on, 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.

Passenger: Hold hip restraint and

hand hold, brace feet

Lean away

Slow down and shift into a lower gear before starting up or down a hill. If you have to turn while on a hill, do it as slowly and cautiously as possible. Never make sharp or fast turns on a hill.

If you stall or begin to lose headway while climbing a steep hill, quickly apply the brakes, shift to neutral, restart the engine and shift to reverse. At idle speed, engine and transaxle drag will aid the brakes in controlling the vehicle on the hill and help you back down the hill more safely.

Reduce the weight of the load if it is a steep hill or if the load has high center of gravity. Remember, loads can shift. Secure them.

Note: The Workmen

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:

have excellent hill climbing

• Adding weight to inside of box, making

Page 22

Operating

sure it is secured.

• Mounting wheel weights to rear wheels.

• Adding liquid ballast (calcium chloride) to rear tires.

• Traction will increase with no passenger in front seat.

LO ADING AND DUMPING

WARNING

The bed will lower whenever the dump lever is pushed down, even when the engine is off. Turning off the engine will NOT prevent the box from lowering. Always place the safety support on extended lift cylinder to hold box up if you are not going to lower it right away.

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.

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.

Do not carry loads which exceed the load limits described on the vehicle weight label.

as bricks, fertilizer or landscape timbers, stack higher in the box.

The height and weight of the load has a significant influence on tip overs. The higher a load is stacked, the more likely the vehicle is to tip over. You may find that 900 kg 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.

If the load is positioned toward one of the sides, it will make the vehicle much more likely to tip over on that 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. With the load all the way to the 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.

As a general rule, position the weight of the load evenly from front to rear and evenly from side to side.

If a load is not secured, or you are transporting a liquid in a large container such as a sprayer, it can shift. This shifting happens most often while turning, going up or down hills, suddenly changing speeds or while driving over rough surfaces. Shifting loads can lead to tip overs. Always secure loads so that they do not shift. Never dump the load while the vehicle is sideways on the hill.

Heavy loads increase stopping distance and reduce your ability to turn quickly without tipping over.

The vehicle has several combinations of boxes, platforms, and attachments available. These can be used in various combinations that allow for maximum capacity and versatility. The full-sized box is 1.4m wide by 1.64 m long and can hold up to 900 kg of evenly distributed cargo.

Loads vary in how they are distributed. Sand spreads out evenly and quite low. Other items, such

The rear cargo space is intended for load carrying purposes only, not for passengers.

USING THE DIFFERENTIAL LOCK

The differential lock increases the vehicle’s traction by locking the rear wheels so one wheel will not spin

Page 23

Operating

out. This can help when you have heavy loads to haul on wet turf or slippery areas, going up hills and on sandy surfaces.

It is important to remember however, that this extra traction is only for temporary limited use. Its use does not replace the safe operation, already discussed concerning steep hills and heavy loads.

The differential lock causes the rear wheels to spin at the same speed. When using differential lock your ability to make sharp turns is somewhat restricted and may scuff the turf. Use the differential lock only when needed, at slower speeds and only in first or second gear.

WARNING

Tipping or rolling the vehicle on a hill will cause serious injury.

In case of emergency, the vehicle can be towed for a short distance. However, Toro does not recommend this as a standard procedure.

Towing the vehicle is a two-person job. Affix a tow line to the holes in the front frame member. Move the shifter to Neutral and release the parking brake. If the machine must be moved a considerable distance, transport it on a truck or trailer.

Note: The power steering will not function, mak-

ing it difficult (increase effort) to steer.

➀

• 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.

• If the differential lock is on when making a sharp turn at a higher speed and inside rear wheel lifts off the ground, there may be a loss of control which could cause the vehicle to skid (Refer to Differential Lock Operation). Use the differential lock only at slower speeds.

TRANSPORTING THE VEHICLE

For moving the vehicle long distances, a trailer should be used. Make sure the vehicle is secured to the trailer.

1. Eye holes in frame

➀

1. Axle tube

2. Hitch plate location (optional)

Figure 9

➁

Figure 10

TRAILER T O WING

The Workman®is capable of pulling trailers and attachments of greater weight than the vehicle itself.

TOWING THE VEHICLE

WARNING

Towing at excessive speeds could cause the vehicle to lose steering control. Never tow the vehicle faster than 8 km/h.

Several types of tow hitches are available for the

Workman your Authorized TORO Distributor for details.

When equipped with a tow hitch bolted onto rear axle tube, your Workman ments with a Gross Trailer Weight (GTW) up to 680

, depending on your application. Contact

can tow trailers or attach-

Page 24

Operating

kg. Always load a trailer with 60% of the cargo weight in the front of the trailer. This places approximately 10% (90 kg max.) of the Gross Trailer Weight (GTW) on the tow hitch of the vehicle.

When towing either standard tongue or 5th wheel trailers having a Gross Trailer Weight (GTW) in excess of 900 kg, use either a chassis mounted draw bar hitch (rated for 1590 kg. GTW) or the 5th wheel kit with the brakes. Trailer brakes are required whenever a trailer over 900 kg. GTW is towed behind a Workman vehicle.

When hauling cargo or towing a trailer (attachment), do not overload your vehicle or trailer. Overloading can cause poor performance or damage to the brakes, axle, engine, transaxle, steering, suspension, body structure or tires.

Important: To reduce potential for drive line damage, use low range.

When towing 5th wheel attachments, like a fairway aerator, always install the 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.

Page 25

Maintenance

Daily Maintenance Procedures

Check the following items daily

• Safety interlock operation

• Service & park brake operation

• Clutch and shifter operation

• Fuel level

• Engine oil level

• Transaxle oil level

• Brake fluid level

• Air filter prefilter

• Inspect engine cooling fins

• Unusual engine noises

• Tire pressure

• Hydraulic hoses for damage

• Fluid leaks

• Instrument operation

• Lubricate all grease fittings (also immediately after every washing)

• Touch-up damaged paint

Page 26

Maintenance

WORKMAN 3100 QUICK REFERENCE AID

Check/Service

1. Engine oil level 10. Tire pressure—maximum 1,4 kg/cm

2. Engine oil drain front 1,3 kg/cm2rear (24" tire)

3. Transaxle/Hydraulic oil level (dipstick) 11. Fuses (Lights 10 A, ignition 7,5 A, dash accessories 7,5 A)

4. Belt (Hydraulic pump) 12. Hydraulic strainer

5. Fuel (unleaded fuel only) 13. Hydraulic oil filter

6. Grease points (33) 100 hours 14. Brake fluid

7. Air filter

8. Fuel filter

9. Battery

Fluid Type Capacity

Engine Oil 10°C-40°C SAE 10W 30 CD 1.9 l 50 hours 50 hours

Transmission/Hydraulic Oil

Air Cleaner

Fuel/Fuel Filter Unleaded

Dextron II ATF 7.1 l 800 hour 800 hours 54-0110

Clean Every 25 hours 200 hours 4708303

26.5 l 400 hours 18-520

Change Intervals

Fluid Filter

Filter Part No.

1205001

Strainer — — Clean 800 hours 87-3990

FOR HEAVY DUTY OPERATION, MAINTENANCE SHOULD BE PERFORMED TWICE AS FREQUENTLY

Page 27

Maintenance

Maintenance Schedule

Minimum Recommended Maintenance Intervals

Maintenance Procedure Maintenance Interval& Service

Check battery fluid level Check battery cable connections Lubricate engine prefilter ✝Change engine oil and filter

Lubricate all grease fittings Remove engine shrouds, clean fins Inspect the condition and wear of tires Inspect cooling system hoses

‡Check cable adjustments ‡Check pump drive belt tension Replace the air filter Check engine RPM (idle and full throttle) ‡Torque the wheel lug nuts

Check front wheel alignment Inspect service and parking brakes Inspect fuel lines Replace the fuel filter

‡Replace the transaxle filter Change the transaxle oil Clean the transaxle strainer Pack the front wheel bearings Replace the spark plugs

Every 50

hours

Every

100

hours

Every

200

hours

Every

400

hours

Every

800

hours

✝ Initial break in at 5 hours ‡ Initial break in at 50 hours

Replace all interlock switches Drain and flush the fuel tank Change the brake fluid

Annual Recommendations

Items are recommended every 1200 hours

or 2 years, whichever occurs first.

Page 28

Maintenance

GREASING BEARINGS AND BUSHINGS

The vehicle has (33) grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the 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.

The grease fitting locations and quantities are: Tie rod ends (4) (Fig. 11), Front ball joints (4) (Fig. 11), Rear drive shafts (6) (Fig. 12), Steering shaft (1) (Fig. 13), Front pivot bushings (2) (Fig. 14) and Pedal pivots (4) (Fig. 15).

IMPORTANT: When greasing drive shaft universal shaft bearing crosses, pump grease until it comes out of all 4 cups at each cross.

Figure 12

1. Wipe the grease fitting clean so foreign matter

cannot be forced into the bearing or bushing.

2. Pump grease into the bearing or bushing.

3. Wipe off excess grease.

Figure 13

Figure 14

Figure 11

Figure 15

Page 29

Maintenance

IMPORTANT

Heavy Duty Operation

If the vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently.

• Desert operation

• Cold climate operation (below 32° F)

• Trailer or 5th wheel towing

• Frequent operation on dusty roads

• Frequent operation under maximum vehicle gross weight

• Construction work

• After extended operation in mud, sand, water or similar dirty conditions, have your brakes inspected and cleaned and drive axle joints greased as soon as possible. This will prevent any abrasive material from causing excessive wear.

• Under frequent heavy duty operating conditions, lubricate all grease fittings and inspect air cleaner daily to prevent excessive wear.

2. Remove the bed support from storage stud on

CAUTION

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 the level or leakage of fuel, battery electrolyte or coolant. Do not use open pans of fuel or flammable cleaning fluids for

Many maintenance procedures require raising and lowering the bed. The following precautions must be taken or serious injury or death could result.

top of the back rest support channel on the Workman (Fig. 16).

WARNING

Before servicing or making adjustments to the machine, stop the engine, set the parking brake and remove key from the ignition 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. Always rotate the safety support to the down position before working under the raised bed.

After maintenance is completed, remove the safety support, slide it onto storage stud and lower the bed.

USING THE BED SAFETY SUPPORT

1. Raise the bed until the lift cylinders are fully

extended.

3. Push the bed support onto the cylinder rod, mak-

ing sure support end tabs rest on the end of the cylinder barrel and on cylinder rod end (Fig. 17).

4. To store the bed support, remove bed support

from cylinder and insert on stud on top of back rest support channel.

Page 30

Maintenance

5. Always install or remove bed support from out-

side of bed.

6. Do not try to lower bed with bed safety support

on cylinder.

Figure 16

1. Bed support 2. Storage stud

rear it is under the axle tube.

4. When jacking up front of the vehicle, always

place a 50 x 100mm block (or similar material) between the jack and vehicle frame.

➀

Figure 18

1. Front jacking point

1. Bed support 3. Bed

Figure 17

2. Cylinder barrel

JA CKING THE VEHICLE

1. Do not start the engine while the vehicle is on

jack, because engine vibration or wheel movement could cause the vehicle to slip off jack.

2. Do not work under the vehicle without jack

stands supporting it. The vehicle could slip off jack, injuring any one beneath it.

➀

Figure 19

1. Rear jacking points

Locations For Selected Maintenance Procedures

Figure 20

1. Air cleaner cover

➀

3. The jacking point at the front of the vehicle is

under the front center frame support and at the

Page 31

Maintenance

1. Pre-cleaner

2. Paper element

1. Engine oil drain plug

2. Engine oil filter

Figure 21

Figure 22

1. Pump belt

Figure 24

Figure 25

CHANGING THE TRANSAXLE/ HYDRA ULIC FLUID

Change the transaxle hydraulic fluid, filter and clean the strainer every 600 hours.

➀

1. Fuel filter

➀

➁

Figure 23

Figure 26

1. Hydraulic reservoir

2. Drain plug

Page 32

Maintenance

➁

➀

Center-to-Center Distance

Figure 29

1. Hydraulic filter

Figure 27

2. Gasket

Figure 28

1. Hydraulic strainer

FRONT WHEEL TOE-IN

2. To adjust, loosen jam nuts at both ends of tie

rod.

➀

Figure 30

1. Tie rod

3. Rotate tie rod to move front of tire inward or

outward.

4. Tighten tie rod jam nuts when adjustment is

correct.

After every 600 operating hours or annually, check front wheel toe-in.

1. Measure center-to-center distance (at axle

height) at front and rear of steering tires. Front measurement must be equal to the rear measurement 3mm.

EMERGENCY BO X RAISING (without starting the engine)

The box can be raised in an emergency by cranking starter and holding lift lever. Run starter for 10 seconds then wait 60 seconds before engaging starter again.

If the engine will not crank, the load and box (attachment) must be removed to service the engine or transaxle.

FUSES

There are three fuses in the machine’s electrical sys-

Page 33

Maintenance

tem. They are located under right side of dash panel.

FUSES OPEN — LIGHTS & HORN 10A IGNITION

7.5A DASH

7.5A

➀

Figure 31

1. Fuse block

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.

➀

Figure 32

1. Positive (+) cable

JUMP STARTING PROCEDURE

WARNING

Jump starting can be dangerous. To avoid personal injury or damage to electrical components in the vehicle, observe the following warnings:

• 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. It could rupture or explode during jump starting.

• Observe all battery warnings while jump starting your vehicle.

• Be sure your vehicle is not touching the jump start vehicle.

3. Connect one end of the other jumper cable to the

negative terminal of the battery in the other vehicle. The negative terminal has “NEG” on the battery cover. Do not connect the other end of the jumper cable to the negative post of the discharged battery. Connect it to the engine. Do not connect the jumper cable to the fuel system.

4. Start the engine in the vehicle providing the

jump start. Let it run a few minutes, then start your engine.

5. Remove the negative jumper cable first from

your engine, then the battery in the other vehicle.

6. Reinstall battery cover to battery base and tight-

en knobs.

• Connecting cables to the wrong post could result in personal injury and/or damage to the electrical system.

1. Loosen knobs securing battery cover to battery

base and slide cover off.

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Maintenance

IDENTIFICATION AND ORDERING

MODEL AND SERIAL NUMBERS

The WORKMAN®has two identification numbers: a model number and a serial number. These numbers are stamped into a plate located on the right frame member under dash. In any correspondence concerning the unit, supply the model and serial numbers to ensure correct information and replacement parts are obtained.

To order replacement parts from an authorized TORO Distributor, supply the following information:

1. Model and serial numbers.

2. Part number, description, and quantity of parts

desired.

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