Toro 07213TC, 07217TC, Workman 3300-D, Workman 4300-D Operator's Manual

Download

Page 1

Form No. 3326-224

Operator’s Manual

Workman®3300-D & 4300-D

Liquid-Cooled Diesel Utility Vehicle

Model No. 07213TC—Serial No. 220000001 and Up Model No. 07217TC—Serial No. 220000001 and Up

English (GI)

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.

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 set up, operation and maintenance procedures are followed at all times. The major sections of the manual are:

1. Safety Instructions

2. Set-Up Instructions

5. Maintenance

3. Before Operating

4. Operating Instructions

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 5–7.

identifies

special mechanical information and NOTE identifies general information worthy of special attention.

The TORO Workman

meets the requirements of ANSI B56.8a–1994. Supervisors, operators and service persons should be familiar with the following standards and publications: (The material may be obtained from the address shown).

• Flammable and Combustible Liquids Code:

ANSI/NFPA 30

• National Fire Protection Association:

ANSI/NFPA # 505; Powered Industrial Trucks ADDRESS: National Fire Prevention Association, Barrymarch Park, Quincy, Massachusetts 02269 U.S.A.

• ANSI/ASME B56.8 Personal Burden Carriers

ADDRESS: American National Standards Institute, Inc. 1430 Broadway, New York, New York 10018 U.S.A.

• ANSI/UL 558; Internal Combustion Engine,

Powered Industrial Trucks ADDRESS: American National Standards Institute, Inc., 1430 Broadway, New York, New York 10018 U.S.A.

OR Underwriters Laboratories, 333 Pfingsten Road, Northbrook, Illinois 60062 U.S.A.

Optional Spark Arrester

In some places a spark arrester muffler must be used because of local, state or federal regulations. The spark arrester, available from your local Toro Distributor is approved by the United States Department of Agriculture and the United States Forest Service.

When the machine is used or operated on any California forest, brush or grass covered land, a properly operating spark arrester must be attached to the muffler. The operator is violating state law, Section 442 Public Resources Code if a spark arrester is not used.

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.

Important

The Workman®is an off-highway vehicle only, and is not designed, equipped, or manufactured for use on public streets, roads or highways.

WARNING

Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, or other reproductive harm.

WARNING

Page 3

Foreword 2 Table of Contents 3 Safety Instructions 4

Sound Pressure Level 7 Vibration Level 7

Safety and Instruction Decals 8 Specifications 10 Set-Up Instructions 12

Install Rear Fenders 13

Install Wheels 13

Install Steering Wheel 13

Install Front Fenders 14

Install the Roll-Over Protection System 14

Activate and Charge the Battery 14 Before Operating 16

Check Engine Oil 16

Fill the Fuel Tank 17

Check the Cooling System 17

Check Hydraulic Fluid 18

Check Front Differential Oil 18

Check Torque of Wheel Nuts 18

Check Tire Pressure 18

Check Brake Fluid 19 Controls 20 Operating Instructions 24

Pre-Starting Checks 24

Starting the Engine 24

Bleeding the Fuel System 24

Driving the Vehicle 25

Stopping the Vehicle 25

Stopping Engine 25

New Vehicle Break-In 25

Checking the Interlock System 26

Operating Characteristics 26

Passengers 27

Speed 27

Turning 27

Braking 27

Hills 29

Loading and Dumping 29

Using the Differential Lock 30

Four-Wheel Drive 30

Transporting the Vehicle 31

Towing the Vehicle 31

Trailer Towing 31

Remote Hydraulic Control (Optional) 32

Quick Coupler Operation 33

Remote Hydraulic Control Trouble Shooting: 33

Maintenance 34

Quick Reference Chart 35 Fluid Specifications/Change Intervals 35 Lubrication 36 Using Bed Safety Support 37 Jacking the Vehicle 38 General Air Cleaner Maintenance Practices 39 Servicing the Air Cleaner 39 Changing Engine Oil and Filter 40 Fuel System 40 Bleeding Air from Injectors 41 Removing Debris From Engine Cooling System41 Changing Engine Coolant 41 Adjusting Belts 42 Adjusting Accelerator Pedal 43 Cylinder Head Bolts 43 Changing Transaxle/Hydraulic Fluid 43 Replacing Hydraulic Filter 44 Change Front Differential Oil 44 Cleaning Hydraulic Strainer 45 Adjusting the Brake Pedal 45 Adjusting the Clutch Pedal 45 Adjusting Parking Brake 46 Adjusting Shift Cables 46 Adjusting the High-Low Cable 46 Adjusting Differential Lock Cable 47 Emergency Box Raising 47 Inspect Brakes 47 Inspect Tires 47 Front Wheel Toe-In 47 Inspect Constant Velocity Boot 48 Fuses 48 Jump Starting Procedure 48 Battery Storage 49 Battery Care 49 Hydraulic Schematic (Base Vehicle) 51 Hydraulic Schematic (Vehicle w/Remote

Hydraulic Kit) 52 Electrical Schematic (Base Vehicle) 53 Electrical Schematic (Vehicle w/Remote

Hydraulic Kit) 54 Identification And Ordering 55

Page 4

Safety Instructions

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 offroad 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

Not all of the attachments that adapt to the Workman

are covered in this manual. See the specific Operator’s Manual provided with attachment for additional safety instructions. READ THESE MANUALS.

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

Supervisor’s Responsibilities

1. 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, Bloomington, Minnesota 55420-1196.

4. Never allow children to operate the vehicle.

Never allow adults to operate it without proper instructions. Only trained and authorized persons should operate this vehicle. Make sure all operators are physically and mentally capable of operating the vehicle. Anyone who operates the vehicle should have a motor vehicle license.

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

influence 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.

11. 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 diesel fuel is highly flammable, handle it

carefully.

A. Use an approved fuel container.

B. Do not remove cap from fuel tank when

engine is hot or running.

Page 5

C. Do not smoke while handling fuel.

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 fuel.

14. Check the safety interlock system daily for proper

operation; refer to page 26. 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

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 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 (located

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

17. When starting the engine:

A. Sit on operator’s seat and engage parking

brake.

B. Disengage any attachments and return hand

throttle lever to OFF position (if so equipped).

C. Move shift lever to NEUTRAL and depress

clutch pedal.

D. Keep foot off accelerator pedal.

E. Turn ignition key to ON, hold glow plug

switch ON (Maximum 30 seconds).

F. 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.

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 off-center 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

maneuvers 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.

I. Before backing up, look to the rear and

assure no one is behind. Back up slowly.

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.

Page 6

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.

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 the bed.

C. Shut engine off and wait for all movement to

stop.

D. Set parking brake.

E. Remove key from ignition.

F. Block wheels if machine is on an incline.

Maintenance

22. Before servicing or making adjustments to the

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

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.

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 condition,

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

maintenance 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.

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:

The TORO Company Commercial Division Vehicle Engineering Dept., 300 West 82nd St. Bloomington, Minnesota 55420-1196 USA

Page 7

Sound Pressure Level

This unit has an equivalent continuous A-weighted sound pressure at the operator ear of 84 dB(A), based on measurements of identical machines per Directive 98/37/EC and amendments.

Vibration Level

Hand Arm

This unit does not exceed a vibration level of 2.5 m/s2, at the hands based on measurements of identical machines per ISO 5349 procedures.

Whole Body

This unit does not exceed a vibration level of 0.5 m/s

at the posterior based on measurements of identical machines per ISO 2631 procedures.

Page 8

Safety and Instruction Decals

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 RECTILINEAR MOTION

Page 9

THROWN OR FLYING OBJECTS, FACE EXPOSURE

MACHINE TIPPING USE CAUTION ON STEEP HILLS MACHINE TIPPING MACHINE TIPPING

SEVERING OF FINGERS OR HAND, ENGINE FAN

RIDING ON THIS MACHINE IS ALLOWED ONLY ON A PASSENGER SEAT & ONLY IF THE DRIVER'S VIEW IS NOT HINDERED

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

DO NOT JUMP FROM TIPPING MACHINE

STAY CLEAR OF ARTICULATION AREA WHILE ENGINE IS RUNNING

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

RUNOVER/BACKOVER, VEHICLE REAR POWER TAKE OFF

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

< 680 kg

< 90 kg

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

LOAD RATING, HOPPER LOAD RATING, TRAILER AND HITCH

< 1179 kg

635 kg

< 1814 kg

LOAD RATING

< 1179 kg

726 kg

< 1905 kg

LOAD RATING

< 318 kg

LOAD RATING, HOPPER

Page 10

Specifications

Type: 4-wheel step through, out front operator style,

two-person vehicle. Certified to meet ANSI Specifications B56.8a-1994.

Engine: Daihatsu three-cylinder, liquid-cooled,

counterbalanced, diesel engine. Rated at 19.8 kW (26.5 hp), governed to a maximum speed of 3650 rpm by a mechanical governor. 58 cu. in. (952 cc) displacement. Forced lubrication by gear pump. 12volt electric starter. Spin-on oil filter.

Air Cleaner: Heavy-duty, 2-stage, remote mounted air

cleaner.

Battery: 12 volt with 650 cold cranking amps @ –17.8

degrees C.

Cooling System: Mid mounted radiator with

removable screen and lower clean out access. Cooling system capacity is approximately 3.8 l (4 qts.) of 50/50 mixture of ethylene glycol anti-freeze.

Fuel System: Fuel tank capacity is 26.5 liter

(7 gallons). 12-volt electric (transistor type) fuel pump with replaceable filter. Replaceable fuel filter/water separator with 3-micron filtration.

Transmission: Rear transaxle configuration, twin axle

drive. 3-speed synchromesh, H-shift pattern with highlow range providing 6 forward and 2 reverse speeds. Manual engage differential lock. 4-wheel drive output shaft (4-wd only).

Clutch: 17cm (6.7”) clutch and pressure plate.

Front Differential: (4-wd only) 5.0 to 1 ratio.

Center Differential: (4-wd only) Bi-directional

overrunning clutch.

Frame: Welded, high strength steel channels and

tubes.

Front Suspension: Independent “A” frame control

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

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-

⁄4 turns lock-to-lock. 17.5 to 1 ratio, 35cm

(14”) diameter steering wheel.

Tires: Front tires: 20” x 10” 10, 4-ply rating, rib tread.

Rear tires: 23” x 13” 12, 6-ply rating, turf tread.

Brakes: 4-wheel hydraulic, dual safety circuit self-

adjusting drum: 17.7cm (7”) diameter front and

20.3cm (8”) diameter rear (2-wd) 20.3 cm (8”) diameter front and rear (4-wd). Hand-actuated parking brake actuates rear brake shoes.

Roll-over protection system: 2-post roll-over

protection structure with shoulder restraint.

Hydraulics: 4.25 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 (8 quart) total capacity. Spin-on, 10-micron hydraulic oil filter. 100mesh strainer in transaxle. The optional, remote hydraulic control kit supplies “live” hydraulic power from the vehicle pump whenever the engine is running.

Seat: Bucket seats 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, glow plug switch, horn button and 3rd high-lockout switch.

Gauges: Hour meter, fuel gauge, coolant temperature

gauge. Warning light cluster includes engine low oil pressure, charge indicator and glow indicator. Tachometer optional.

Lights: Twin halogen headlights and single taillight.

Rear stop light.

Tow Hitch: Hitch has hole for ball or pin.

Interlocks: Clutch pedal must be depressed to start

engine.

Ground Speed:

Page 11

Forward Speeds w/23” Rear Tires

High range: 12/18.5/31.9 kmh .(6/11.5/19.8 mph) Low range: 4.7/7.2/12.4 kmh (2.9/4.5/7.7 mph)

Reverse Speeds w/24”Tires

High range: 11.6 kmh (7.2 mph) Low range: 4.5 kmh (2.8 mph)

General Specifications (approx.):

Base Weight: Dry w/o flatbed 522.5 kg (1400lbs) (2wd); 597kg (1600 lbs.)(4-wd)

Rated Capacity: *970.42kg ( 2,600 lbs.) * includes 75 kg. operator and 75 kg. passenger and loaded attachment.

Maximum. Gross Vehicle Weight: 1493kg (4,000 lbs). (2wd); 1568 kg (4,200 lbs.) (4-wd)

Tow Capacity: Tongue weight 75 kg (200 lbs.) Maximum trailer weight 560 kg (1,500 lbs.)

Overall Width: 160cm (63”)

Overall Length: 316 cm (124.5”) w/o bed; 322cm

(127”) w/full bed 337.8cm (133”) with

⁄3 bed in rear

mounting location

Height: 190.5cm (75”) to top of roll-over protection system

Ground Clearance: 17.8cm (7”) w/no load

Wheel Base: 177.8cm (70”)

Wheel Tread: (center line to center line)

116.8 cm (46”); Front 121cm (47.7”)

Rear Specifications and design subject to change without notice.

Page 12

Set-Up Instructions

Loose Parts Chart

Note: Use this chart as a checklist to assure all parts necessary for assembly have been received. Without these parts, total set up cannot be completed. Some parts may have already been assembled at factory.

DESCRIPTION QTY. USE

Fenders-Rear 2

Capscrew 5⁄16-18 x 1” lg. 4

Flatwasher .344” I. D. 4

Locknut 5⁄16-18 4

Capscrew 1⁄4-20 x 1” lg. 12 Mount rear fenders

Flatwasher .281” I. D. 12

Locknut 1⁄4-20 12

Trusshead Screw 6

Locknut 3⁄8-16 6

Wheel Nut 10

Wheel—Front 2

Wheel Nut 10 Mount wheels.

Wheel—Rear 2

Steering wheel 1

Foam Seal 1

Washer 1 Install steering wheel

Nut 1

Cap 1

Fenders-Front 2

Phillips Screw 10-24 14 Install front fenders

Washer 14

Locknut 10-24 14

Roll-Over Protection System 1

Capscrew 1⁄2-13 x 3” lg. 4 Mount Roll-Over Protection System

Locknuts 1⁄2-13 4

Operator’s Manual (Vehicle) 2 Read before operating machine.

Parts Catalog 1

Registration Card 1 Fill out and return to Toro

Page 13

Install Rear Fenders (Fig. 1–2)

1. Loosen the locknuts and capscrews securing tail

light plates to right and left frame brackets.

2. Pivot tail light plates rearward and tighten

capscrews and locknuts.

Figure 1

1. Tail light plate

2. Frame bracket

3. Tail light mounting bracket

3. Secure rear of each tail light plate to rear of frame

brackets with a

⁄16-18 x 1” lg. capscrew, .344” I.

D. flatwasher and nut, as shown in figure 1.

4. On left side, remove (2) capscrews, washers and

nuts securing tail light mounting bracket to tail light plate.

Figure 2

1. Fender

2. Fender mounting bracket

5. Position a fender over each tail light plate,

aligning mounting holes.

6. On left side, loosely secure tail light mounting

bracket, rear of fender and tail light plate together with (2) capscrews, washers and nuts, previously removed.

7. On right side, secure rear of fender to tail light

plate with (2)

⁄4-20 x 1” lg. capscrews, .281” I. D.

flatwashers and nuts

8. Loosely secure front of each fender mounting

bracket to frame with a

⁄4-20 x 1” lg. capscrew

and locknut.

9. Loosely secure side of each fender to frame (3)

3/8-16 x 1” lg. truss head screws and locknuts.

Note: Capscrews securing fronts of fenders to mounting brackets may have to be loosened to align all mounting holes.

10. Tighten all fasteners.

Install Wheels (Fig. 3)

1. Remove and discard fasteners securing wheels.

2. Mount wheels and torque nuts to 61–75 Nm

(45–55 ft lb.).

Figure 3

1. Wheel

2. Wheel Nut

Install Steering Wheel (Fig. 4)

1. Remove jam nut from steering shaft. Slide foam

seal, steering wheel and washer onto steering shaft.

Page 14

2. Secure steering wheel to shaft with jam nut and

tighten it to 14–20 Nm (10–15 ft lb.).

3. Install cap to steering wheel.

Figure 4

1. Steering Wheel

2. Jam Nut

3. Cap

4. Washer

5. Foam Seal

Install Front Fenders (Fig. 5)

1. Mount a fender to each side of skirt with (7) 10-

24 Phillips screws, flat washers and locknuts.

Figure 5

1. Fender

Install the Roll-Over Protection System (Fig. 6)

1. Insert each side of the system into the mounting

bracket on each side of the vehicle frame, positioning the protection system as shown in figure 6.

2. Secure each side of the roll-over protection

system to mounting brackets with (2)

⁄2-13 x 3”

lg. capscrews and locknuts.

Figure 6

1. Roll-over protection system

2. Mounting brackets

Activate and Charge the Battery (Fig. 7 & 8)

If the battery is not filled with electrolyte or activated, it must be removed from vehicle, filled with electrolyte and charged. Bulk electrolyte with 1.260 specific gravity can be purchased from a local battery supply outlet.

1. Loosen knobs securing battery cover to battery

base and slide cover off.

2. Remove capscrew, washers and locknut securing

battery hold down to battery base. Remove hold

FRONT

Electrolyte gases are explosive and can cause serious injury to eyes, lungs and skin. Wear safety goggles and rubber gloves when working with electrolyte or battery. Charge the battery in a well-ventilated place so gasses produced while charging can dissipate. Since the gases are explosive, keep open flames and electrical spark away from the battery; do not smoke. Nausea may result if the gases are inhaled. Unplug charger from electrical outlet be fore connecting to or disconnecting charger leads from battery posts.

CAUTION

Page 15

down and slide battery out of battery base.

Figure 7

1. Battery cover

2. Knob

3. Battery base

3. Remove filler caps from battery and slowly fill

each cell until electrolyte is just above the plates.

4. Replace filler caps and connect a 3- to 4-amp

battery charger to the battery posts. Charge the battery at a rate of 3 to 4 amperes for 4 to 8 hours.

5. When battery is charged, disconnect charger from

electrical outlet and battery posts.

6. Remove filler caps. Slowly add electrolyte to

each cell until level is up to fill ring. Install filler caps.

Do not overfill battery. Electrolyte will overflow onto other parts of the vehicle and severe corrosion and deterioration will result.

7. Slide battery into battery base so battery terminals

are toward the rear of the vehicle.

Figure 8

1. Positive (+) cable

2. Hold down

8. Install the positive cable (red) to the positive (+)

terminal and the negative cable (black) to the negative (–) terminal of the battery and secure with capscrews and nuts. Slide the rubber boot over the positive terminal to prevent possible short-out from occurring.

9. Install battery hold down and secure to base with

capscrew, washers and locknut.

10. Reinstall battery cover to battery base and tighten

knobs.

Important

Connecting cables to the wrong post could result in personal injury and/or damage to the electrical system. Make sure battery or cables do not interfere or rub on any moving or hot parts.

WARNING

Page 16

Before Operating

Check Engine Oil (Fig. 9–11)

The engine is shipped with approximately 3.3 l (3.5 qts.) (w/filter) of oil in the crankcase; however, level of oil must be checked before and after the engine is first started.

1. Position machine on a level surface.

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

Insert dipstick into tube and make sure it is seated fully. Remove dipstick and check level of oil.

Figure 9

1. Dipstick

3. The engine uses any high quality 10W30

detergent oil having the American Petroleum Institute API “service classification” CF or better.

4. If oil level is low, remove filler cap and add

enough oil to raise level to FULL mark on dipstick.

Figure 10

1. Filler cap

Note: When adding oil, remove dipstick to allow proper venting, pour oil slowly and check the level often during this process. DO NOT OVERFILL.

When adding engine oil or filling oil, there must be clearance between the oil fill device and the oil fill hole in the valve cover as shown in figure

11. This clearance is necessary to permit venting when filling, which prevents oil from overrunning into breather.

Figure 11

1. Note Clearance

5. Install the dipstick firmly in place.

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 100 hours. However, change oil more frequently when engine is operated in extremely dusty or dirty conditions.

Important

Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from the switch. Any load material must be removed from bed or other attachment before working under raised bed. Always place the safety support on extended lift cylinder to hold box up.

CAUTION

Page 17

Note: After filling or changing oil, start and run the engine at idle for 30 seconds. Shut engine off. Wait 30 seconds and check oil level. Add enough oil to raise level to FULL mark on dipstick.

Fill the Fuel Tank (Fig. 12)

Fuel tank capacity is approximately 26.5 l (7 gallons).

The engine runs on No. 2-D or 1-D automotive type diesel fuel with a minimum cetane rating of 40.

Note: Higher cetane rated fuel may be required if machine is to be used at high altitude and low atmospheric temperatures.

Figure 12

1. Fuel tank cap

1. Clean area around fuel tank cap.

2. Remove fuel tank cap.

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

(bottom of filler neck) with diesel fuel. DO NOT OVERFILL. Then install cap.

4. Wipe up any fuel that may have spilled to prevent

a fire hazard.

Check the Cooling System (Fig. 13)

Capacity of cooling system is approximately 3.8 l (4 qts.).

The cooling system is filled with a 50/50 solution of water and permanent ethylene glycol anti-freeze. Check level of coolant at beginning of each day before starting the engine.

1. Park machine on a level surface.

2. Check coolant level. Coolant should be up to

COLD line on reserve tank, when engine is cold.

3. If coolant is low, remove reserve tank cap and add

a 50/50 mixture of water and permanent ethylene glycol anti-freeze. DO NOT OVERFILL.

If engine has been running, pressurized hot coolant can escape if radiator cap is removed and cause burns. Allow engine to cool at least 15 minutes or until the radiator cap is cool enough to touch without burning hand.

CAUTION

Because diesel fuel is flammable, caution must be used when storing or handling it. Do not fill fuel tank while engine is running, hot, or when 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 fuel tank outside and wipe up any spilled diesel fuel before starting engine. Use a funnel or spout to prevent spilling diesel fuel and fill tank to about 1 inch (25 mm) below the filler neck. Store diesel fuel in a clean, safety approved container and keep the cap in place on the container Keep diesel fuel in a cool, well ventilated place; never in an en closed area such as a hot storage shed. To as sure volatility and to prevent contamination, do not buy more than a 6 month supply.

DANGER

Page 18

4. Install reserve tank cap.

Figure 13

1. Reserve tank

2. Cold line

3. Hot line

Check Hydraulic Fluid (Fig. 14)

The transaxle reservoir is filled with Dextron III ATF. Check level before engine is first started and every 8 hours or daily, thereafter. Capacity of system is 7.1 l (7.5 qts.).

1. Position the vehicle on a level surface.

2. Clean area around dipstick.

3. Unscrew dipstick from top of transaxle and wipe

it with a clean cloth.

Figure 14

1. Dip stick

4. Screw dipstick into transaxle and make sure it is

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

Check Front Differential Oil

Four-Wheel Drive Model Only (Fig. 15)

The differential is filled with 10W30 oil. Check level of oil every 100 hours or monthly. Capacity of system is 0.9 l (1 qt.).

1. Position the vehicle on a level surface.

2. Clean area around fill/check plug on side of

differential.

Figure 15

1. Front differential

2. Fill/check plug

3. Drain plug

3. Remove fill/check plug and check level of oil. Oil

should be up to hole. If oil is low, add 10W30 oil.

4. Re-install fill/check plug.

Check Torque of Wheel Nuts

Check Tire Pressure

Check tire pressure every 8 hours or daily to assure proper levels.

Maximum air pressure in front tires is 138 kPa (20 psi) and rear tires is 124 kPa (18 psi).

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 (45–65 ft-lb) after 1 to 4 hours of operation and again after 10 hours of operation and every 200 hours thereafter.

WARNING

Page 19

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.

When replacing vehicle tires, only

use replacements approved for the Workman

. Use of tires not approved may cause turf damage or accelerated drive train damage.

Check Brake Fluid (Fig. 16)

The brake fluid reservoir is shipped from the factory filled with “DOT 3” brake fluid. Check level before engine is first started and every 8 hours or daily, thereafter.

1. Park machine on a level surface.

2. Fluid level should be up to FULL line on

reservoir.

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

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

Figure 16

1. Brake fluid reservoir

2. Full line

Maximum Total Axle Weight (lb.)

(thousands)

23” FRONT TIRES

Tire Pressure (p.s.i.)

Maximum Total Axle Weight (lb.)

(thousands)

20” FRONT TIRES

Tire Pressure (p.s.i.)

Important

Page 20

Controls

Accelerator Pedal (Fig. 17)—The accelerator pedal 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 17

1. Accelerator pedal

2. Clutch pedal

3. Brake pedal

Clutch Pedal (Fig. 17)—The clutch pedal must be fully depressed to disengage clutch when starting engine or shifting transmission gears. Release pedal smoothly when transmission is in gear to prevent unnecessary wear on transmission and other related parts.

Do not ride clutch pedal during operation. Clutch pedal must be fully out or 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. 17)—The brake pedal is used to apply service brakes to stop or slow vehicle.

Gear Shift Lever (Fig. 18)—Fully depress clutch pedal and move shift lever into desired gear selection. A diagram of the shift pattern is indicated below.

R = reverse 1 = First gear 2 = Second gear 3 = Third gear

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

Differential Lock (Fig. 18)—Allows rear axle to be locked for increased traction. Differential lock may be engaged with vehicle in motion. Move lever forward and to the right to engage lock.

Note: Vehicle motion plus a slight turn is required to engage or disengage differential lock.

Important

Shift Pattern

Important

Worn or misadjusted brakes may result in personal injury. If brake pedal travels to within 1-

⁄2” of the vehicle floor board, the brakes must be adjusted or repaired.

CAUTION

Down shifting from too high a speed can cause the rear wheels to skid resulting in loss of vehicle control as well as clutch and/or transmission damage. Shift smoothly to avoid grinding gears.

CAUTION

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, page 30.

WARNING

Page 21

Figure 18

1. Gear shift lever

2. Differential lock

3. Parking brake

4. High-low range shifter

5. Hydraulic lift

6. Hydraulic lift lock

Parking Brake (Fig. 18)—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 lever. To disengage, push lever forward. Make sure parking brake is released before moving vehicle. If vehicle is parked on a steep grade, make sure parking brake is applied. Also, shift the transmission into 1st gear on a uphill grade or reverse on a down hill grade. Place chocks at the down hill side of wheels.

Hydraulic Lift (Fig. 18)—Raises and lowers bed. Move rearward to raise, forward to lower.

When lowering bed, hold lever in forward position for 1 or 2 seconds after bed contacts frame to secure it in lowered position.

Do not hold the hydraulic lift in either the raise or lower position, for more than 5 seconds, once the cylinders have reached the end of their travel. The hydraulic pump may over heat, resulting in pump damage.

Hydraulic Lift Lock (Fig. 18)—Locks lift lever so

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

Passenger Hand Hold (Fig. 18)—Left side of passenger seat.

High-Low Range Shifter (Fig. 18)—Adds three additional speeds for precise speed control.

A. Vehicle must be completely stopped before

shifting between High and Low range.

B. Shift only on level ground.

C. Depress clutch pedal fully.

D. Move lever fully forward for High and fully

rearward for Low.

HIGH is for higher speed driving on level, dry surfaces with light loads.

LOW is for low speed driving. Use this range when greater than normal power or control is required. 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. 19)—Lever on right side of console allows steering wheel to be adjusted for operator comfort.

Coolant Temperature Gauge (Fig. 19)—Registers coolant temperature in engine. Operates only when ignition switch is in On position.

Horn Button (Fig. 19)—Pressing button activates horn.

Important

When raising or lowering bed or implement, hydraulic oil will bypass over a relief valve when cylinders reach the end of their travel, stopping power assist to steering gear and increasing steering effort. Release lift levers to NEUTRAL immediately after bed or implement is raised or lowered, to regain assist to power steering.

CAUTION

Page 22

Figure 19

1. Tilt steering lever

2. Ignition switch

3. Horn button

4. Coolant temp. gauge

5. Engine low oil pressure light

6. Charge indicator

7. Glow plug switch

8. Glow plug indicator light

Engine Low-Oil Pressure Light (Fig. 19)—Light glows if engine oil pressure drops below a safe level while engine is running. If light flickers or remains ON, stop vehicle, turn off engine and check oil level. If oil level was low, but adding oil does not cause light to go out when engine is restarted, turn engine off immediately and contact your local TORO distributor for assistance.

Do not operate vehicle until repair is complete. Failure to observe this precaution may result in damage to the engine.

Glow Plug Switch and Indicator (Fig. 19)—Use to preheat engine cylinders prior to cold engine starting procedures—cylinders are preheated automatically during warm engine start operation. For cold starting, push switch lever upward and hold while watching indicator. Indicator will glow orange when the glow plugs are activated. Length of time necessary to preheat cylinders should be determined by atmospheric temperature; refer to Starting /Stopping Engine, p. 24.

Ignition Switch (Fig. 19)—The ignition switch, used to start and stop the engine, has three positions: OFF, ON /Preheat and START. Rotate key clockwise— START position—to engage starter motor. Release key when engine starts. The key will move automatically to the ON position. To shut engine off, rotate key counterclockwise to OFF position.

Charge Indicator (Fig. 19)—Illuminates when battery is being discharged. If light illuminates during operation, stop vehicle, turn off engine and check for possible causes, such as alternator belt.

If alternator belt is loose or broken, do not operate vehicle until adjustment or repair is complete. Failure to observe this precaution may result in damage to the engine.

To check operation of warning lights:

1. Apply parking brake.

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

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

Note: High water temperature function on warning light cluster is not used.

Hour Meter (Fig. 20)—Indicates the total hours of machine operation. The hour meter starts to function whenever the key switch is rotated to “ON” position.

Light Switch (Fig. 20)—Toggle switch to activate headlights. Push to turn lights “ON”.

3rd High-Lockout Switch (Fig. 20)—Moving switch 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.

Figure 20

1. Light switch

2. Hour meter

3. Fuel gauge

4. 3rd High-lockout switch

5. Steering wheel

Important

Page 23

Fuel Gauge (Fig. 20)—Shows amount of fuel in tank. Operates only when ignition switch is in “ON” position.

Steering Wheel (Fig. 20)—Turns vehicle. If engine stalls or power assist fails due to a malfunction, vehicle steering will require greater effort.

Passenger Hand Hold (Fig. 21)—On dashboard.

Figure 21

1. Passenger hand hold

2. Tachometer (Optional)

Tachometer—Optional (Fig. 21)—Indicates engine RPM. Gear selection graphics indicates speed.

Remote Hydraulic Lever (optional-not shown)— Controls hydraulic flow to optional quick rear couplers.

Page 24

Operating Instructions

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 working.

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

steering response.

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

The fuel system must be bled if any of the

following situations have occurred.

A. Initial start up of a new machine.

B. Engine has ceased running due to lack of fuel.

C. Maintenance has been performed upon fuel

system components; i.e., filter replaced, separator serviced, etc.

Refer to Bleeding the Fuel System.

1. Sit on operator’s seat and engage parking brake.

2. Disengage PTO (if so equipped) and return hand

throttle lever to OFF position (if so equipped).

3. Move shift lever to NEUTRAL position and

depress clutch pedal.

4. Keep foot off accelerator pedal.

5. When temperature is below 15° C (60° F), push

glow plug switch upward to ON position (Fig. 19) and hold for suggested interval.

Note: Do not exceed 30 seconds of continuous use or glow plug may burn out prematurely.

Note: Refer to chart indicating approximate preheat time suggested in various temperature ranges.

5. Insert key into ignition switch and rotate it

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

Note: Do not run starter motor more than 20 seconds at a time or premature starter failure may result. If engine fails to start after 20 seconds, turn key to OFF position, recheck controls and procedures, wait 10 additional seconds and repeat starter operation.

Bleeding the Fuel System

1. Loosen air bleed screw on top of fuel filter/water

separator (Fig. 22).

Temperature Preheat time (sec)

Above 5° C (41° F) 10

+ 5° C (41° F) to –5° C (23° F) 20

Below –5° C (23° F) 30

Important

Page 25

Figure 22

1. Fuel filter/water separator

2. Air bleeder screw

3. Turn key in ignition switch to the ON position.

Electric fuel pump will begin operation, thereby forcing air out around air bleed screw. Leave key in ON position until solid stream of fuel flows out around screw. Tighten screw and turn key to OFF.

4. Open the air bleed screw on the fuel injection

pump (Fig. 23) with a 10 mm wrench.

Figure 23

1. Fuel injection pump bleeder

5. Turn key in ignition switch to the ON position.

Electric fuel pump will begin operation, thereby forcing air out around air bleed screw on fuel injection pump. Leave key in ON position until solid stream of fuel flows out around the screw. Tighten screw and turn key to OFF.

Note: Normally, engine should start after above bleeding procedures are followed. However, if engine does not start, air may be trapped between injection pump and injectors; refer to Bleeding Air from Injectors, p. 41

Driving the Vehicle

1. Release parking brake.

2. Fully depress clutch pedal.

3. Move gear shift lever to 1st gear.

4. Release clutch pedal smoothly while depressing

accelerator pedal.

5. When vehicle gains enough speed, remove foot

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

Note: Avoid long periods of engine idling.

Note: Leaving ignition switch in “ON” position

for long periods of time without running engine will discharge battery.

Do not hold 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 attempt to push or tow vehicle to get it

started. Damage to drive train could result.

Stopping the Vehicle

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

Stopping Engine

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

New Vehicle Break-In

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

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

Important

Page 26

component 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 hard braking situations for the first several hours of new vehicle brake-in operation. New brake linings may not be at optimum performance until several hours of use has caused the brakes to become burnished (broke-in). However, a specific brake burnish procedure may be followed to allow optimum performance right away.

•To burnish brakes: Operate the vehicle at full speed for 3 minutes, apply the brakes for 30 seconds while engaging the accelerator pedal. Repeat these steps 20 to 30 times. To verify the brakes are completely burnished remove a rear tire and inspect the brake drum for residue. The residue color should be light grey to almost white color.

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

•Abreak-in oil for engine is not required. Original engine oil is the same type specified for regular oil changes.

• Refer to Maintenance section of the operator’s manual for any special low-hour checks.

Checking the Interlock System

The purpose of the interlock system is to prevent the engine from cranking or starting unless the clutch pedal is depressed.

To verify clutch interlock switch operation:

1. Sit on operator’s seat and engage parking brake.

Move shift lever to NEUTRAL position.

2. Without depressing clutch pedal, rotate key

clockwise to start position.

3. If engine cranks or starts, there is a malfunction

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

Refer to the attachment operator’s manual for the procedure on checking the attachment interlock system.

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 vehicle and is designed for off road use only.

The vehicle has special tires, low gear ratios, a locking differential, and other features that give it extra traction. These features add to the versatility of the vehicle but, they can also get you into dangerous situations. You must keep in mind that the vehicle is not a recreation vehicle. It is not an all terrain vehicle. And, it is definitely not meant for “stunt driving” or “horsing around”. It is a work vehicle, not a play vehicle. Children should not be allowed 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.

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

CAUTION

The Workman®is an off-highway vehicle only, and is not designed, equipped, or manufactured for use on public streets, roads or highways.

WARNING

Page 27

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.

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. 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.

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 are going 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 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.

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 373 kg), such as sprayers, top dressers, or spreaders, etc., operating speeds should be restricted by moving 3rd high lockout switch to the slow position.

Turning

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

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.

Page 28

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 out.

Do not downshift for braking on icy or slippery surfaces (wet grass) or while going down a hill because engine braking may cause skidding and loss of control. Shift to a lower gear before starting down a hill.

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 provided.

Tipovers

The TORO Workman®is equipped with a roll bar, hip restraints, shoulder restraints and hand hold. The rollover 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.

IN CASE OF TIPOVER,

DON’T JUMP

OPERATOR—HOLD

TIGHT AND BRACE FEET

LEAN AWAY

PASSENGER—HOLD HIP RESTRAINT

AND HAND HOLD, BRACE FEET

Page 29

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.

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 Workman

has excellent hill climbing

ability. The differential lock will increase this ability.

Loading and Dumping

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 that exceed the load limits described on the vehicle weight label.

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 140 cm

TIPOVER CAN OCCUR IF TRUCK IS IMPROPERLY OPERATED. INJURY OR DEATH COULD RESULT!

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

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

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 ex tended 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.

WARNING

Page 30

wide by 165 cm long and can hold up to 746 kg of evenly distributed cargo.

Loads vary in how they are distributed. Sand spreads out evenly and quite low. Other items, such 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 746 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 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 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.

Four-Wheel Drive

Four-Wheel Drive Model Only

The “Automatic on Demand” four-wheel drive feature, on this vehicle, does not require operator activation. The front wheel drive is not engaged (no power delivered to front wheels) until the rear wheels begin to lose traction. The bi-directional clutch senses the rear wheels slipping, engages the front wheel drive and delivers power to the front wheels. The four-wheel drive system continues to deliver power to the front wheels until the rear wheels have enough traction to move the vehicle without slipping. Once this occurs, the system stops delivering power to the front wheels and the handling characteristics become similar to that of a two-wheel drive vehicle. The four-wheel drive system functions in both forward and reverse, however, when turning the rear wheels will slip slightly more before power is delivered to the front

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.

• 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 that could cause vehicle to skid (Refer to section on Using the Differential Lock, p. 30). Use the differential lock only at slower speeds.

WARNING

Page 31

wheels.

Transporting the Vehicle

For moving the vehicle long distances, a trailer should be used. Make sure the vehicle is secured to the trailer. Refer to Figures 24 and 25 for location of tie down points.

Towing the Vehicle

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 holes in front frame member. Move shifter to Neutral and release parking brake. If machine must be moved a considerable distance, transport it on a truck or trailer.

Note: The power steering will not function, making it difficult (increase effort) to steer.

Figure 24

1. Eye holes in frame

Figure 25

1. Axle tube

2. Hitch plate

Trailer Towing

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

Several types of tow hitches are available for the Workman

, depending on your application. Contact

your Authorized TORO Distributor for details.

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 560 kg Always load a trailer with 60% of the cargo weight in the front of the trailer. This places approximately 10% (75 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 560 kg, use either a chassis mounted draw bar hitch (rated for 1306 kg lb. GTW) or 5th wheel kit with brakes. Trailer brakes are required whenever a trailer over 560 kg GTW is towed behind a Workman

vehicle.

When hauling cargo or towing a trailer (attachment),

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

The extra traction available with the four wheel drive feature can be enough to get you into dangerous situations such as climbing slopes that are too steep to turn around. Be careful when operating, especially on steeper slopes.

WARNING

Towing at excessive speeds could cause vehicle to lose steering control. Never tow vehicle faster than 5 mph.

WARNING

Page 32

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.

To reduce potential for drive-line

damage, use low range.

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.

Remote Hydraulic Control (Optional)

The remote hydraulic control kit 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.

Control Lever Positions

1. FLOAT

2. ON

3. OFF

Off Position: This is the normal position for the control valve when it is not being used. This position allows the oil leaving the dump valve to flow through the remote hydraulic valve to the power steering circuit. In this position the work ports of the control valve are blocked and any load will be held by the check valves in both directions.

Raise (Quick Coupler “B” Position): This is the position that will lift the rear hitch attachment or apply pressure to quick coupler “B”. This also allows return oil from quick coupler “A” to flow back into the valve and then out to the power steering circuit. This is a momentary position and when the lever is released it spring returns to the center off position.

Use double acting cylinders only. Using a single acting cylinder does not allow return flow of hydraulic oil and makes steering more difficult. Using a single acting cylinder can lower oil level in transaxle and cause damage to hydraulic pump and transaxle.

On Position: This position is similar to Raise (quick coupler “B” position). It also directs oil to quick coupler “ B” except that the lever is held in this position by a detent notch in the control panel. This allows oil to flow continuously to equipment that uses a hydraulic motor. This position must only be used on attachments with a hydraulic motor attached.

Note: If hydraulic motor is used, it may see 6900 kPa (1000 psi) back pressure.

If used with a hydraulic cylinder or no attachment, the Raise or On position causes the oil flow to go over a relief valve which can damage the hydraulic system. Additionally this condition does not allow return flow to supply the power steering circuit, which makes steering more difficult. Use these positions only momentarily or with a motor attached.

Lower (Quick Coupler “A” Position): This position will lower the rear hitch attachment or apply pressure to quick coupler “A”. This also allows return oil from quick coupler “B” to flow back into the valve and then out to the power steering circuit. This is a momentary position and when the lever is released it spring returns to the center off position. Momentarily holding and then releasing the control lever in this position will provide flow to quick coupler “A” which provides power down on the rear hitch. When released, it will hold the down pressure on the hitch.

If used with a hydraulic cylinder, holding the control lever in the lower position causes the oil flow to go over a relief valve which can damage the hydraulic system.

Float Position: This valve position allows oil to flow in and out of the work ports and is connected to the inlet and outlet ports at the same time. This allows for attachments as the rear hitch to “ float” up and down. The same pressure is applied to both quick couplers due to back pressure from the steering circuit.

Important

REMOTE HYDRAULICS

Important

Page 33

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.

Quick Coupler Operation

CONNECTION

Clean dirt from quick couplers before connecting. Dirty couplers can introduce contamination to hydraulic system.

Insert hose nipple into coupler until it snaps into position.

Note: When attaching remote hydraulic cylinders to the quick couplers, determine which side of the remote cylinder requires pressure, then attach that hose to quick coupler “B”. Only connect double acting cylinders (two hoses).

DISCONNECTION

Pull hose firmly from coupler

Clean and install dust plug and dust covers to quick coupler ends when not in use.

Remote Hydraulic Control Trouble Shooting:

A. Difficulty in connecting or disconnecting quick

couplers.

Pressure not relieved (Quick coupler under pressure).

Engine running. Remote hydraulic valve not placed in float.

B. Power steering hard. Remote valve not in neutral

or float position. Remote hydraulic valve linkage out of adjustment.

Hydraulic oil level low.

Hydraulic oil hot.

C. Hydraulic leaks. Fittings loose. Fitting missing o-

ring.

D. Attachment does not function. Quick couplers not

fully engaged. Quick couplers are interchanged.

E. Squealing noise. Remote valve left in ON detent

position causing hydraulic oil to flow over relief valve.

Important

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 be fore connecting or disconnecting quick couplers.

CAUTION

Use caution when moving lever to the float position because it will allow rear implement to lower unimpeded.

CAUTIOIN

Page 34

Maintenance Check Item Daily Maintenance Check For Week Of _________________

MON TUES WED THURS FRI SAT SUN

✓ Safety Interlock Operation

✓ Service & Park Brake Operation

✓ Fuel Level

✓ Accelerator Operation

✓ Clutch & Shifter Operation

✓ Engine Oil Level

✓ Transaxle Oil Level

✓ Cooling System Fluid Level

✓ Brake Fluid Level

✓ Air Cleaner

✓ Unusual Engine Noises

✓ Unusual Operating Noises

✓ Tire Pressure

✓ Radiator Screen/Clean out Door

✓ Hydraulic Hoses for Damage

✓ Fluid Leaks

✓ Instrument Operation

Lubricate All Grease Fittings

Touch–up Damaged Paint

Maintenance

Maintenance Chart and Checklist

Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator’s Manual for fluid specifications

1= Inspect at Overflow Tank

2= More often when conditions are dirty

3= Immediately after every washing, regardless of the interval listed.

Page 35

Quick Reference Chart

4-Wheel Drive Chart Shown

See operator’s manual for initial changes

Fluid Type

Capacity Change Intervals

Filter Part

No.

Liter Quart Fluid Filter

Engine Oil

SAE 10W-

30 CD

3.7 3.9 100 hours 100 hours 67-4330 A

Trans/Hydraulic Oil

Dextron III

ATF

7.1 7.5 800 hours 800 hours 54-0110 C

Air Cleaner Clean every 50 hours 200 hours 33-1300 B

Fuel > 0° C No. 2 D 26.5 7 gal. — 400 hours 83-8300 E

Fuel Pump — — — — 400 hours 43-2550 D

Coolant 50/50 Ethylene Glycol/Water

— 4.3 4.5 1200 hours — —

Strainer — — Clean 800 hours 87-3990

Differential Oil

SAE 10W-

30 CD

.95 1 800 hours — —

1. Engine oil level

2. Engine oil drain

3. Transaxle/hydraulic oil level (dip stick)

4. Belts (Governor, water pump, hydraulic pump)

5. Coolant level fill

6. Fuel (Diesel fuel only)

7. Grease points (37) 100 hours

8. Radiator screen

8.1. Ratiator cleanout door

9. Air cleaner

10. Fuel pump

11.Battery

12. Tire pressure—maximum 20 psi front; 18 psi rear (24” tire)

13. Fuses (lights–10 amp; ignition–7.5 amp; dash assessories–7.5 amp)

14. Hydraulic strainer

15. Hydraulic oil filter

16. Brake fluid

17. Water separator

18. Differential fill/check

19. 4-WD shaft

Fluid Specifications/Change Intervals

Page 36

Lubrication

Greasing Bearings And Bushings (Fig. 26–32)

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.

The grease fitting locations and quantities are: Tie rod ends (4) (Fig. 26), Front ball joints (4) (Fig. 26), Rear drive shafts (18) (Fig. 27) Front pivot bushings (2) (Fig. 28); Mid drive shaft -4 wd only (3) (Fig. 29); Pedal Pivots (4) (Fig. 30); Steering shaft (1) (Fig. 31) and Accelerator Arm (1) (Fig. 32).

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

1. Wipe 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 26

Figure 27

Figure 28

Important

Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition switch. Any load material must be removed from bed or other attachment before working under raised bed. Always place the safety support on extended lift cylinder to hold box up.

WARNING

Page 37

Figure 29

Figure 30

Figure 31

Figure 32

Heavy-Duty Operation

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

• Desert operation

• Cold climate operation (below 0° C)

•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.

Using Bed Safety Support (Fig. 33 & 34)

Many of the subjects covered in this maintenance section require raising and lowering the bed. The following precautions must be taken or serious injury or death could result.

Important

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.

CAUTION

Page 38

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

1. Raise bed until lift cylinders are fully extended.

2. Remove bed support from storage brackets on

back of the roll-over protection panel (Fig. 33).

Figure 33

1. Bed support

3. Push bed support onto cylinder rod, making sure

support end tabs rest on end of cylinder barrel and on cylinder rod end (Fig. 34).

Figure 34

1. Bed support

2. Cylinder barrel

3. Bed

4. To store bed support, remove bed support from cylinder and insert into brackets on back of the roll-over protection system.

5. Always install or remove bed support from outside of bed.

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

Jacking the Vehicle (Fig. 35 & 36)

1. Do not start engine while vehicle is on jack, because engine vibration or wheel movement could cause vehicle to slip off jack.

2. Do not work under vehicle without jack stands supporting it. The vehicle could slip off jack, injuring any one beneath it.

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 5 x 10 cm (2” x 4”) block (or similar material) between jack and vehicle frame.

Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition switch. Any load material must be removed from bed or other attachment before working under raised bed. Al ways place the safety support on extended lift cylinder to hold box up.

WARNING

Page 39

Figure 35

1. Front jacking point

Figure 36

1. Rear jacking points

General Air Cleaner Maintenance Practices (Fig. 37)

Inspect air cleaner and hoses periodically to maintain maximum engine protection and to ensure maximum service life.

1. Check air cleaner body for damage that could

possibly cause an air leak. Replace a damaged air cleaner body.

2. Clean the air cleaner filter every 50 hours and

change every 200 hours (more frequently in extreme dusty or dirty conditions).

Servicing the Air Cleaner

1. Release latches securing air cleaner cover to air

cleaner body. Separate cover from body. Clean inside of air cleaner cover.

Figure 37

1. Air cleaner latches

2. Dust cup

3. Filter

2. Gently slide filter out of air cleaner body to reduce the amount of dust dislodged. Avoid knocking filter against air cleaner body.

3. Inspect filter and discard if damaged. Do not wash or reuse a damaged filter. Clean the filter as follows:

Washing Method

A. Prepare a solution of filter cleaner and water

and soak filter element about 15 minutes. Refer to directions on filter cleaner carton for complete information.

B. After soaking filter for 15 minutes, rinse it

with clear water. Maximum water pressure must not exceed 276 kPa (40 psi) to prevent damage to the filter element. Rinse filter from clean side to dirty to side.

C. Dry filter element using warm, flowing air

71°C (160° F) max), or allow element to airdry. Do not use a light bulb to dry the filter element because damage could result.

Compressed Air Method

A. Blow compressed air from inside to the

outside of dry filter element. Do not exceed 689 kPa (100 psi) to prevent damage to the element.

B. Keep air hose nozzle at least 5cm (2”) from

filter and move nozzle up and down while rotating the filter element. Inspect for holes and tears by looking through the filter toward a bright light.

Page 40

5. Inspect new filter for shipping damage. Check

sealing end of filter. Do not install a damaged filter.

6. Insert new filter properly into air cleaner body.

Make sure filter is sealed properly by applying pressure to outer rim of filter when installing. Do not press on flexible center of filter.

7. Reinstall cover and secure latches.

Changing Engine Oil and Filter (Fig. 38 & 39)

Change oil and filter initially after the first 50 hours of operation, thereafter, change oil and filter every 100 hours.

1. Raise bed (if so equipped) and place safety

support on extended lift cylinder to hold up bed.

2. Remove drain plug and let oil flow into drain pan.

When oil stops, install drain plug.

Figure 38

1. Engine Oil Drain Plug

Figure 39

1. Engine Oil Filter

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

⁄2 to 2⁄3 of a turn. DO NOT OVER-

TIGHTEN.

4. Add oil to crankcase, refer to Check Engine Oil,

p. 16.

Fuel System (Fig. 40)

Fuel Lines and Connections

Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections.

Fuel Filter/Water Separator

Drain water or other contaminants from fuel filter/water separator daily by loosening drain plug (Fig. 40) on filter canister. Tighten plug after draining. Replace filter canister after every 400 hours of operation.

1. Raise bed (if so equipped) and place safety support on extended lift cylinder to hold up bed.

2. Fuel filter/water separator is mounted on inner side of right frame rail.

Figure 40

1. Drain plug

2. Filter canister

3. Clean area around filter canister mounting surface.

4. Remove filter canister and clean mounting surface.

5. Lubricate gasket on filter canister with clean engine oil.

6. Install filter canister by hand until gasket contacts mounting surface, then rotate an additional

⁄

2 turn.

Page 41

Bleeding Air from Injectors (Fig. 41)

Note: This procedure should be used only if fuel system has been purged of air through normal priming procedures and engine still will not start; refer to Bleeding the Fuel System, p 24.

1. Raise bed (if so equipped) and place safety

support on extended lift cylinder to hold up bed.

2. Loosen the pipe connection to the No. 1 nozzle

and holder assembly (Fig. 41).

Figure 41

1. Fuel injectors (3)

3. Slowly depress accelerator pedal to full FAST

position.

4. Turn key in key switch to START position and

watch fuel flow around connector. Turn key to OFF position when solid flow is observed.

5. Tighten pipe connector securely.

6. Repeat steps 1–4 on No. 2 and 3 nozzles.

Removing Debris From Engine Cooling System (Fig. 42)

Remove debris from engine area and radiator daily, clean more frequently in dirty conditions.

1. Remove radiator cover.

2. Turn engine off. Clean engine area thoroughly of

all debris.

3. Remove screen cover from front of radiator.

4. Open radiator screen clean out door at lower left

side of radiator and remove all debris from bottom of radiator inlet area.

5. Clean radiator thoroughly with water or compressed air.

Figure 42

1. Radiator screen cover

2. Clean out door

Changing Engine Coolant (Fig. 43)

1. Park machine on a level surface.

2. Raise the bed (if so equipped) and place safety

support on extended lift cylinder to hold up the bed.

3. Remove radiator and reserve tank caps.

CAUTION

Page 42

Figure 43

1. Radiator cap

2. Reserve tank cap

4. Open the coolant drain cock at bottom of the

radiator and allow coolant to flow into drain pan. When coolant stops, close drain cock.

5. Open bleed screw on top of water pump (Fig. 44).

Figure 44

1. Bleed screw

6. Remove coolant drain plug from engine and

allow coolant to flow into drain pan. When coolant stops, install drain plug.

7. Slowly fill radiator with a 50/50 mixture of water

and permanent ethylene glycol anti-freeze. Install radiator cap.

8. Slowly fill reserve tank until level reaches COLD

line. DO NOT OVERFILL. Install reserve tank cap.

9. Start engine and operate until warm. Tighten

water pump bleed screw when water appears at the bleed screw.

10. Stop engine. Recheck level and replenish, if

required.

Adjusting Belts (Fig. 45–46)

Check condition and tension of all belts after first day of operation and every 200 operating hours thereafter. Raise bed (if so equipped) and place safety support on extended lift cylinder to hold up bed.

Alternator Belt (Fig. 45)

1. Check tension by depressing belt at mid span of crankshaft and alternator pulleys with 30 Nm (22 lbs.) of force. A new belt should deflect 7–12 mm (0.3–0.5 in). A used belt should deflect 10–14mm (0.4–0.55 in.). If deflection is incorrect, proceed to next step. If correct, continue operation.

2. To adjust belt tension:

Loosen alternator mounting bolts. Using a bar, rotate alternator until proper belt tension is attained, then tighten mounting bolts.

Figure 45

1. Alternator belt

2. Alternator brace

Fan Belt (Fig. 46)

1. Check tension by depressing belt at mid span of fan and drive shaft pulleys with 10 Kg (22 lbs.) of force. A new belt should deflect 12–14mm (0.48–0.58 in.). A used belt should deflect 14–16mm (0.55–0.65 in.). If deflection is incorrect, proceed to next step. If correct, continue operation.

2. To adjust belt tension, loosen idler pulley mounting nut, move pulley to increase tension and tighten nut.

Page 43

Figure 46

1. Fan belt

2. Idler pulley

Adjusting Accelerator Pedal (Fig. 47)

If engine throttle lever does not contact high idle stop when accelerator pedal is fully depressed, an adjustment to the accelerator cable is required. Check adjustment every 200 operating hours.

1. Position vehicle on level surface, stop engine and

engage the parking brake.

Note: Engine must not be running and return spring must be attached.

2. Adjust ball joint on accelerator cable to allow

2.5–6.3mm (0.100”–0.250”) clearance between accelerator pedal and top of diamond tread floor plate, when a 11kg (25 lb. force) is applied to center of pedal. Tighten locknut.

Figure 47

1. Accelerator cable

2. Ball joint

3. Locknut

3. Maximum high idle speed 3650 rpm. High idle

stop should not be adjusted.

Cylinder Head Bolts

Re-torque initially after 50 operating hours and check every 1000 operating hours or annually thereafter.

Engine Valve Clearance

Adjust initially at 50 operating hours and check every 600 operating hours or annually thereafter.

Changing Transaxle/Hydraulic Fluid (Fig. 48)

Change Transaxle hydraulic fluid, filter and clean strainer every 800 hours.

1. Position the vehicle on a level surface, stop engine, engage the parking brake and remove key from ignition switch.

2. Remove drain plug from side of reservoir and let hydraulic fluid flow into drain pan. Reinstall and tighten plug when hydraulic fluid stops draining.

3. Fill reservoir with approximately 7.1 l (7.5 qt.) of Dexron III ATF. Refer to Check Hydraulic Fluid, p 18.

4. Start engine and operate to fill hydraulic system. Recheck oil level and replenish, if required.

Use only hydraulic fluids specified.

Other fluids could cause system damage.

Important

Engine must be running so final adjustment can be performed. To guard against possible personal injury, engage parking brake and keep hands, feet, face and other parts of the body away from fan or other moving parts.

WARNING

Page 44

Figure 48

1. Hydraulic Reservoir

2. Drain plug

Replacing Hydraulic Filter (Fig. 49)

Use the Toro replacement filter (Part No. 54-0110).

Use of any other filter may void the

warranty on some components.

1. Position vehicle on a level surface, stop engine,

engage parking brake and remove key from ignition switch.

2. Clean area around filter mounting area. Place

drain pan under filter and remove filter.

Figure 49

1. Hydraulic Filter

2. Gasket

3. Lubricate new filter gasket.

4. Assure filter mounting area is clean. Screw filter

on until gasket contacts mounting plate. Then tighten filter one-half turn.

5. Start engine and let run for about two minutes to

purge air from the system. Stop the engine and check the hydraulic oil level and for leaks.

Change Front Differential Oil

Front-Wheel Drive Models Only (Fig. 50)

Change front differential oil every 800 hours.

1. Position vehicle on a level surface, stop engine, engage parking brake and remove key from ignition switch.

2. Clean area around drain plug on side of differential. Place drain pan under drain plug.

Figure 50

1. Front differential

2. Fill/check plug

3. Drain plug

3. Remove drain plug and let oil flow into drain pan. Reinstall and tighten plug when oil stops draining.

4. Clean area around fill/check plug on side of differential.

5. Remove fill/check plug and add 10W30 oil until oil is up to hole.

6. Re-install fill/check plug.

Important

Page 45

Cleaning Hydraulic Strainer (Fig. 51)

1. Position the vehicle on a level surface, stop

engine, engage the parking brake and remove key from ignition switch.

2. Remove drain plug (Fig. 48) from side of

reservoir and let hydraulic fluid flow into drain pan.

3. Remove hydraulic line and fitting connected to

strainer on side of reservoir.

Figure 51

1. Hydraulic strainer

4. Remove strainer and clean by back flushing with

a clean degreaser. Allow to air dry before reinstalling.

5. Reinstall strainer.

6. Reinstall hydraulic line and fitting to strainer.

7. Reinstall and tighten drain plug.

8. Fill reservoir with approximately 7.1 l (7.5 qt.) of

Dexron III ATF. Refer to Check Hydraulic Fluid, p 18.

Adjusting the Brake Pedal (Fig. 52–53)

Check adjustment every 200 hours.

1. Loosen jam nut on link rod ball joint.

2. Rotate rod until gap between brake pedal and up

stop is 0,5mm—2mm (0.020–0.080”).

Figure 52

1. Link rod ball joint

3. Tighten jam nut after adjustment has been attained.

Figure 53

1. Brake pedal

2. Clutch pedal

3. Clutch pedal up stop

Adjusting the Clutch Pedal (Fig. 53–54)

Check adjustment every 200 hours.

1. Loosen jam nuts securing clutch cable to bracket on bell housing.

Note: Ball joint may be removed and rotated if additional adjustment is required.

2. Disconnect return spring from clutch lever.

3. Adjust jam nuts and/or ball joint until bottom rear

edge of clutch pedal is 9.5 cm ± 3mm (3.75” ±

0.12”) from top of floor plate diamond pattern, when a 4-lb. force is applied to pedal.

Note: Force is applied so release bearing lightly contacts pressure plate fingers.

Page 46

4. Reconnect return spring to clutch lever.

5. Verify that rear edge of clutch pedal is 14 cm ±

3mm (5.5” ± 0.12”) from the top of the floor plate diamond pattern. If dimension is not attained, adjust clutch pedal up stop.

Note: Clutch free play should never be less than

1.9 cm (0.75”).

6. Tighten jam nuts after adjustment has been

attained.

7. Recheck clutch safety switch adjustment (Fig.

55). Engine must not crank unless clutch pedal is

2.9cm ± 6mm (1.25” ± .25”) from floor. If an adjustment is required, loosen switch jam nuts and adjust up or down.

Figure 54

1. Clutch cable

2. Jam nuts

3. Return spring

4. Ball joint

Figure 55

1. Clutch switch

Adjusting Parking Brake (Fig. 56)

Check adjustment every 200 hours.

1. Loosen the set screw securing knob to parking

brake lever.

2. Rotate knob until a force of 47–61 Nm (35–45 lbs.) for 2-wd models and 61–75 Nm (45–55 lbs.) for 4-wd models is required to actuate lever.

3. Tighten set screw after adjustment has been attained.

Figure 56

1. Parking brake lever 2 Knob

3. Set screw

Adjusting Shift Cables (Fig. 57)

Check adjustment every 200 hours.

1. Move shift lever to Neutral position.

2. Remove clevis pins securing shift cables to

transaxle shift arms.

3. Loosen clevis jam nuts and adjust each clevis so cable free play is equal forward and backward relative to hole in transaxle shift arm (With transaxle lever free play taken up in same direction).

4. Reinstall clevis pins and tighten jam nuts after adjustments have been attained.

Adjusting the High-Low Cable (Fig. 57)

Check adjustment every 200 hours.

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.

3. Reinstall clevis pin and tighten jam nut after adjustment has been attained.

Page 47

Figure 57

1. Shift arm (1st—Rev.)

2. Shift arm (2nd—3rd)

3. Shift arm (High—low)

Adjusting Differential Lock Cable (Fig. 58)

Check adjustment every 200 hours.

1. Move differential lock lever to Off position.

2. Loosen jam nuts securing differential lock cable

to bracket on transaxle.

Figure 58

1. Differential lock cable

2. Transaxle bracket

3. Spring

3. While pulling back on spring, adjust jam nuts to

obtain 0.89mm ± 0.64mm ( 0.035” ± .025”) gap between spring hook and O. D. of hole in transaxle lever.

4. Tighten jam nuts after adjustment has been attained and recheck.

Emergency Box Raising (without starting the engine)

The box can be raised in an emergency by cranking the starter and holding the lift lever. Run starter for 15 seconds then wait 60 seconds before engaging starter again.

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

Inspect Brakes

Visually inspect brakes for worn brake shoes after every 600 hours of operation.

Inspect Tires

Check tire condition at least every 100 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.

Front Wheel Toe-In (Fig. 59–60)

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 (

⁄8 in.).

Figure 59

1. Center-to-center distance

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

0.89mm ±0.64mm

Page 48

Figure 60

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.

Inspect Constant Velocity Boot

Four-Wheel Drive Models Only

After every 200 operating hours, inspect constant velocity boot for cracks, holes or a loose clamp.

Fuses (Fig. 61)

There are 3 fuses in the machine’s electrical system. They are located under right side of dash panel.

FUSES

OPEN — LIGHTS & HORN 10A DASH 7.5A IGNITION 7.5A

Figure 61

1. Fuse block

Jump Starting Procedure

1. Loosen knobs securing battery cover to battery base and slide cover off.

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.

Figure 62

1. Positive (+) cable

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

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

• Never jump start with a voltage sources greater than 15 volts D. C. This will dam age 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.

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

WARNING

Page 49

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 tighten

knobs.

Battery Storage

If the machine will be stored for more than 30 days, remove the battery and charge it fully. Either store it on the shelf or on the machine. Leave the cables disconnected if stored on the machine. Store the battery in a cool atmosphere to avoid quick deterioration of the charge in the battery. To prevent battery from freezing, make sure it is fully charged. The specific gravity of a fully charged battery is 1.250.

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.

2. Keep top of battery clean by washing periodically

with a brush dipped in ammonia or bicarbonate of 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. Check the electrolyte level every 50 operating

hours or, if machine is in storage, every 30 days.

6. Maintain cell level with distilled or demineralized

water. Do not fill cells above the bottom of the fill ring inside each cell.

Wear safety goggles and rubber gloves when working with electrolyte. Charge the battery in a well-ventilated place so gasses produced while charging can dissipate. Since the gases are explosive, keep open flames and electrical spark away from the battery; do not smoke. Nausea may result if the gases are inhaled. Unplug charger from electrical outlet before connecting to or disconnecting charger leads from battery posts.

CAUTION

Page 50

Maintenance Procedure Maintenance Interval& Service

‡ Initial break in at 10 hours

✝ Initial break in at 50 hours

✝Replace the transaxle filter

Change the transaxle oil Clean the transaxle strainer Change the front differential oil (4-wheel drive) Pack the front wheel bearings

Maintenance Schedule

Replace all interlock switches Flush the cooling the cooling system and replace fluid Drain and flush the fuel tank Change the brake fluid

Check front wheel alignment Inspect service and parking brakes Inspect fuel lines Replace electric fuel pump filter ‡Torque cylinder head and adjust valves

✝Check cable adjustments ✝Check alternator and fan belts

Service the air filter Check front axle boot joint (4-wheel drive) Check engine RPM (idle and full throttle) ✝Torque the wheel lug nuts

Lubricate all grease fittings Inspect the condition and wear of the tires Check front differential oil level (4WD) ‡Change engine oil and filter Inspect cooling system hoses

Check battery fluid level/

cable connections

‡Check dust cup/baffle

Every

400

hours

Every

800

hours

Every

200

hours

Every

100

hours

Every 50

hours

Minimum Recommended Maintenance Intervals

Annual Recommendations

Items are recommended every 1200 hours

or 2 years, whichever occurs first.

Page 51

Hydraulic Schematic (Base Vehicle)

Page 52

Hydraulic Schematic (Vehicle w/Remote Hydraulic Kit) (MODELS 07205 TC and 07215 TC Only)

Page 53

Electrical Schematic (Base Vehicle)

Page 54

Electrical Schematic (Vehicle w/Remote Hydraulic Kit) (MODELS 07205 TC and 07215 TC Only)

Page 55

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.

Note: Do not order by reference number if a parts catalog is being used; use the part number.

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.