Toro 07200, 07202, 07216, WORKMAN 3200, WORKMAN 4200 Operator's Manual
FORM NO. 3318-342 GB Rev A
MODEL NO. 07200—60001 AND UP
MODEL NO. 07202—60001 AND UP
MODEL NO. 07216—60001 AND UP
®
WORKMAN 3200 AND 4200
To understand this product, and for safety and optimum performance, read this manual before starting
the engine. Pay special attention to SAFETY
INSTRUCTIONS highlighted by this symbol.
OPERATOR
MANUAL
UTILITY VEHICLES
It means CAUTION, WARNING or DANGER—
personal safety instruction. Failure to comply with
the instruction may result in personal injury.
© The TORO Company, 1996
Forew ord
The TORO WORKMAN®was developed to provide
an efficient, versatile, trouble free and economical
work vehicle. The latest concepts of engineering,
design and safety have been incorporated into this
machine, along with the highest quality parts and
workmanship. Excellent service will be derived if
proper operation and maintenance practices are followed. This vehicle is not designed or manufactured
for use on roads, streets or highways. It is not appropriate for such use.
You know, since you have purchased the industry
leader in maintenance excellence, that future performance and dependability are of prime importance.
TORO also is concerned about future use of the
machine and of safety to the user. Therefore, this
manual must be read by you and those involved with
®
the WORKMAN
setup, operation and maintenance procedures are followed at all times.
to make sure that safety, proper
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 4 and 5. IMPORTANT identifies special mechanical information and NOTE identifies general information worthy of special attention.
If help concerning set up, operation, maintenance or
safety is ever needed, contact your local Authorized
TORO Distributor. In addition to genuine TORO
replacement parts, the distributor also has optional
equipment for the complete line of TORO turf care
equipment. Keep your TORO all TORO. Buy genuine TORO parts and accessories.Servicing Air
Cleaner Filter
Table of Contents
Safety 3
Specifications 11
Before Operating 13
Controls 17
Operating 20
Maintenance 28
Page
2
Safety
The WORKMAN®3200 and 4200 were designed
and tested to offer safe service when operated and
maintained properly. Although hazard control
and accident prevention partially are dependent
upon the design and configuration of the machine,
these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, maintenance and
storage of the machine. Improper use or maintenance of the machine can result in injury or
death.
This is a specialized utility vehicle designed for
off-road use. its ride and handling will have a different feel than what drivers experience with passenger cars or trucks. So take time to become
familiar with your WORKMAN
attachments that adapt to the WORKMAN
covered in this manual. See the specific
Operator’s Manual provided with the attachment
for additional safety instructions. READ THESE
MANUALS.
®
. Not all of the
®
are
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 influ-
ence of drugs or alcohol.
7. Become familiar with the controls and know
how to stop the engine quickly.
8. Keep all shields, safety devices and decals in
place. If a shield, safety device or decal is malfunctioning, illegible, or damaged, repair or
replace it before operating the machine.
TO REDUCE THE POTENTIAL FOR INJURY
OR DEATH, COMPLY WITH THE FOLLOWING SAFETY INSTRUCTIONS.
SUPERVISOR’S RESPONSIBILITIES
Make sure operators are thoroughly trained and
1.
familiar with the Operator’s Manual and all
labels on the vehicle.
2. Be sure to establish your own special procedures
and work rules for unusual operating conditions
(e.g. slopes too steep for vehicle operation). Use
the 3rd High Lockout switch if high speed could
result in a safety or vehicle abuse situation.
BEFORE OPERATING
3. Operate the machine only after reading and
understanding the contents of this manual. A
replacement manual is available by sending
complete model and serial number to: The Toro
Company, 8111 Lyndale Avenue South,
Minneapolis, Minnesota 55420.
9. Always wear substantial shoes. Do not operate
machine while wearing sandals, tennis shoes or
sneakers. Do not wear loose fitting clothing or
jewelry which could get caught in moving parts
and cause personal injury.
10. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some
local safety and insurance regulations.
. Keep everyone, especially children and pets,
11
away from the areas of operation.
12. Before operating the vehicle, always check all
parts of the vehicle and any attachments. If
something is wrong, stop using vehicle. Make
sure problem is corrected before vehicle or
attachment is operated again.
13. Since gasoline is highly flammable, handle it
carefully.
A. Use an approved gasoline container.
4. Never allow children to operate the vehicle.
Never allow adults to operate it without proper
B. Do not remove cap from fuel tank when
engine is hot or running.
3
Safety
C. Do not smoke while handling gasoline.
D. Fill fuel tank outdoors and to about one inch
below top of tank (bottom of filler neck). Do
not overfill.
E. Wipe up any spilled gasoline.
14. Check the safety interlock system daily for prop-
er operation. If a switch should malfunction,
replace the switch before operating machine.
After every two years, replace the interlock
switches in the safety system, whether they are
working properly or not.
WHILE OPERATING
WARNING: Engine exhaust contains carbon
monoxide which is an odorless, deadly poison.
Carbon monoxide is also known to the State
of California to cause birth defects. Do not
run engine indoors or in an enclosed area.
D. Keep foot off the accelerator pedal.
E. Turn ignition key to START.
18. Using the machine demands attention. Failure to
operate vehicle safely may result in a accident,
tip over of vehicle and serious injury or death.
Drive carefully. To prevent tipping or loss of
control:
A. Use extreme caution, reduce speed and
maintain a safe distance around sand traps,
ditches, creeks, ramps, any unfamiliar areas
or other hazards.
B. Watch for holes or other hidden hazards.
C. Use caution when operating vehicle on a
steep slope. Normally travel straight up and
down slopes. Reduce speed when making
sharp turns or when turning on hillsides.
Avoid turning on hillsides whenever possible.
15. Operator and passenger should remain seated
whenever the vehicle is in motion. Operator
should keep both hands on steering wheel, whenever possible and passenger should use the hand
holds provided. Keep arms and legs within the
vehicle body at all times. Never carry passengers
in box or on attachments. Remember your passenger may not be expecting you to brake or turn
and may not be ready.
16. Never overload your vehicle. Name plate (locat-
ed under dash on passenger side) shows load
limits for vehicle. Never overfill attachments or
exceed the vehicle maximum GVW.
17. When starting the engine:
A. Sit on operator’s seat and engage the parking
brake.
B. Disengage PTO (if so equipped) and return
the hand throttle lever to OFF position (if so
equipped).
C. Move shift lever to NEUTRAL and depress
clutch pedal.
D. Use extra caution when operating vehicle on
wet surfaces, at higher speeds or with a full
load. Stopping time will increase with a full
load. Shift into a lower gear before starting
up or down a hill.
E. When loading bed, distribute load evenly.
Use extra caution if the load exceeds the
dimensions of the vehicle/bed. Operate vehicle with extra caution when handling offcenter loads that cannot be centered. Keep
loads balanced and secure to prevent them
from shifting.
F. Avoid sudden stops and starts. Do not go
from reverse to forward or forward to
reverse without first coming to a complete
stop.
G. Do not attempt sharp turns or abrupt maneu-
vers or other unsafe driving actions that may
cause a loss of vehicle control.
H. When dumping, do not let anyone stand
behind vehicle and do not dump load on any
one’s feet. Release tailgate latches from side
of box, not from behind.
4
Safety
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.
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.
MAINTENANCE
22. Before servicing or making adjustments to the
machine, stop engine, set the parking brake and
remove key from ignition to prevent accidental
starting of the engine.
23. Never work under a raised bed without placing
bed safety support on fully extended cylinder
rod.
24. Make sure all hydraulic line connectors are tight,
and all hydraulic hoses and lines are in good
condition before applying pressure to the system.
25. Keep body and hands away from pin hole leaks
or nozzles that eject hydraulic fluid under high
pressure. Use paper or cardboard, not hands, to
search for leaks. Hydraulic fluid escaping under
pressure can have sufficient force to penetrate
skin and do serious damage. If fluid is injected
into the skin it must be surgically removed within a few hours by a doctor familiar with this
form of injury or gangrene may result.
19. Do not touch engine, transaxle, radiator, muffler
or muffler shield while engine is running or soon
after it has stopped because these areas may be
hot enough to cause burns.
20. If the machine ever vibrates abnormally, stop
immediately, turn engine off, wait for all motion
to stop and inspect for damage. Repair all damage before commencing operation.
21. Before getting off the seat:
A. Stop movement of the machine.
B. Lower bed.
C. Shut engine off and wait for all movement to
stop.
D. Set the parking brake.
E. Remove key from ignition.
F. Block wheels if machine is on an incline.
26. Before disconnecting or performing any work on
the hydraulic system, all pressure in system must
be relieved by stopping engine, cycling dump
valve from raise to lower and/or lowering box
and attachments. Place the remote hydraulics
lever in the float position. If box must be in
raised position, secure with safety support.
27. To make sure entire machine is in good condi-
tion, keep all nuts, bolts and screws properly
tightened.
28. To reduce potential fire hazard, keep the engine
area free of excessive grease, grass, leaves and
accumulation of dirt.
29. If the engine must be running to perform a main-
tenance adjustment, keep hands, feet, clothing,
and any parts of the body away from the engine
and any moving parts. Keep everyone away.
30. Do not overspeed engine by changing governor
settings. Maximum engine speed is 3650 rpm. To
assure safety and accuracy, have an Authorized
TORO Distributor check maximum engine speed
5
Safety
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:
Sound & Vibration Levels
Sound Levels
This unit has an equivalent continuous A-weighted
sound pressure at the operator ear of: 78 dB(A)
based on measurements of identical machines per
84/538/EEC.
Vibration Levels
This unit has a vibration level of 2.5 m/s2at the posterior, based on measurements of identical machines
per ISO 2631 procedures.
This unit does not exceed a vibration level of 0.5
2
at the posterior based on measurements of iden-
m/s
tical machines per ISO 2631 procedures.
6
Symbol Glossary
SAFETY ALERT SYMBOL GENERAL HAZARD SAFETY
STAY A SAFE DISTANCE FROM MACHINE
EXPLOSION FIRE OR OPEN FLAME FIRE, OPEN LIGHT &
CAUSTIC LIQUIDS, CHEMICAL
BURNS TO FINGERS OR HAND
ALERT
STAY A SAFE DISTANCE FROM DRAINING
TANK
DO NOT DISPOSE IN THE
GARBAGE
CRUSHING OF WHOLE BODY,
APPLIED FROM ABOVE
STAY A SAFE DISTANCE FROM MACHINE STAY A SAFE DISTANCE FROM
SMOKING PROHIBITED
THROWN OR FLYING OBJECTS,
WHOLE BODY EXPOSURE
CRUSHING OF TOES OR FOOT,
FORCE APPLIED FROM ABOVE
EYE PROTECTION MUST BE
WORN
CRUSHING OF FINGERS OR HAND,
FORCE APPLIED FROM SIDE
HYDRAULIC OIL VALVE
CAUTION, TOXIC RISK FIRST AID FLUSH WITH WATER
25mm
FUEL TANK FILL LINE
READ OPERATOR’S MANUAL
CUTTING OF FINGERS OR HAND CUTTING OF FOOT
KEEP CHILDREN A SAFE
DISTANCE FROM BATTERY
LOCK UNLOCK
BATTERY CHARGING
CONDITION
MANUAL
WHOLE BODY ENTANGLEMENT,
IMPLEMENT INPUT DRIVE LINE
ENGINE START
ENGINE STOP ENGINE LUBRI-
133 bar
PTO
HOPPER CLOSED HOPPER OPEN
HYDRAULIC PRESSURE
DO NOT OPEN OR REMOVE SAFETY
SHIELDS WHILE ENGINE IS RUNNING
CATING OIL
FAST SLOW CONTINUOUS VARIABLE, LINEAR
HYDRAULIC OIL PRESSURE
INTAKE AIR
CLOCKWISE ROTATION COUNTER CLOCKWISE
SECURE LIFTING CYLINDER WITH
LOCKING DEVICE BEFORE GETTING
IN HAZARDOUS AREA
GLOW PLUG ENGINE INTAKE,
COMBUSTION AIR
HORN
ROTATION
HAND & ARM ENTANGLEMENT,
BELT DRIVE
ON/START OFF/STOP
TRANSMISSION, 3RD
HIGH GEAR
PROHIBITED ACTION OR
HAZARDOUS LOCATION
DO NOT WELD DO NOT DRILL
BRAKE SYSTEMENGAGE DISENGAGE
3H
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
L
TRANSMISSION, HIGH
VEHICLE BED LOWER VEHICLE BED RAISE
H
HIGH PRESSURE SPRAY,
EROSION OF FLESH
ATTACHMENT LOWER
ATTACHMENT FLOAT
< 250 kg
HOUR METER, ELAPSED
WEIGHT
OPERATING HOURS
LIMITED RECTI-
LINEAR MOTION
7
Symbols Glossary
THROWN OR FLYING OBJECTS,
FACE EXPOSURE
MACHINE TIPPING USE CAUTION ON STEEP HILLS MACHINE TIPPING MACHINE TIPPING
DO NOT JUMP FROM TIPPING
MACHINE
STAY CLEAR OF ARTICULATION
AREA WHILE ENGINE IS RUNNING
SEVERING OF FINGERS OR
HAND, ENGINE FAN
HOLD TIGHTL & BRACE FEET LEAN AWAY FROM TIP HOLD HIP RESTRAINT & HAND
RUNOVER/BACKOVER, VEHICLE REAR POWER TAKE OFF
RIDING ON THIS MACHINE IS
ALLOWED ONLY ON A PASS-
ENGER SEAT & ONLY IF THE
DRIVER'S VIEW IS NOT HINDERED
SHUT OFF ENGINE & REMOVE
KEY BEFORE PERFORMING
MAINTENANCE OR REPAIR WORK
HOLD, BRACE FEET
(9)
GREASE LUBRICATION POINT GREASE LUBRICATION POINT
1.
MACHINE DIRECTION OF MOVEMENT BEFORE LEAVING OPERATOR POSITION, TURN OFF IGNITION, LOCK PARKING BRAKE,
DISENGAGE PTO, REMOVE KEY FROM IGNITION.
2.
635 kg
BEFORE LEAVING OPERATOR POSITION,
TURN OFF IGNITION AND REMOVE KEY.
< 11 79 kg
635 kg
< 181 4 kg
LOAD RATING
LOAD RATING, HOPPER LOAD RATING, TRAILER AND HITCH
< 11 79 kg
726 kg
< 1 905 kg
LOAD RATING
3.
< 680 kg
< 318 kg
LOAD RATING, HOPPER
4.
< 90 kg
8
FULL BED REMO VAL (Model
07202 only)
RE-INSTALLING THE FULL BED
(Model 07202 only)
1. Start the engine. Engage the hydraulic lift lever
and lower the bed until the cylinders are loose in
the slots. Release the lift lever and turn off the
engine.
2. Remove the Iynch pins from the outer ends of
the cylinder rod clevis pins (Fig. 1).
Note: If bed sides will be installed on the flat
bed, it is easier to install them before
installing the bed on the vehicle.
Note: Assure the rear pivot plates are bolted to
the bed frame/channel so that the lower
end angles to the rear (Fig. 2).
1. Bed mounting plate 4.
Figure 1
Lynch pin
2. Cylinder rod end 5. Rear slots (Full bed)
3. Clevis pin 6. Front slots (2/3 bed)
3. Remove the clevis pins securing the cylinder rod
ends to the bed mounting plates by pushing the
pins toward the inside (Fig. 2).
4. Remove the Iynch pins and clevis pins securing
the pivot brackets to the frame channels (Fig. 2).
5. Lift the bed off the vehicle.
CAUTION: The full bed weighs approximately
210 pounds, so do not try to install or remove it
by yourself. Get the help of two or three other
people.
6. Store the cylinders in the storage clips. Engage
the hydraulic lift lock lever on the vehicle to prevent accidental extension of the lift cylinders.
1. Left rear corner of bed
Figure 2
2. Vehicle frame channel
3. Pivot plate
4. Clevis pin
5. Lynch pin
Note: Make sure spacer brackets and wear
blocks (Fig. 3) are installed or the radiator cover may be damaged.
9
Note: If automatic tail gate release has been
installed on bed, make sure front dump
link rod has been placed on inside of left
side clevis pin before Iynch pin is
installed.
6. Once cylinder installation has been completed,
the bed safety support can be used to prevent
accidental lowering of the bed. Refer to Using
The Bed Safety Support.
1. Spacer bracket
2. Wear block
Figure 3
1. Assure lift cylinders are fully retracted.
CAUTION: The full bed weighs approximately
210 pounds, so do not try to install or remove it
by yourself. Get the help of two or three other
people.
2. Carefully set bed onto vehicle frame aligning
rear bed pivot plate holes with holes in rear
frame channel and install (2) clevis pins and
Iynch pins (Fig. 3).
3. With bed lowered, secure each cylinder rod end,
to appropriate slots in bed mounting plates with
clevis pin and Iynch pin. Insert clevis pin from
outside of bed with Iynch pin toward outside
(Fig. 1). Rear slots are for full bed installation
and front slots are for 2/3 bed installation.
Note: Engine may need to be started to extend
or retract cylinders for alignment with
holes. Keep fingers out!
Note: Unused slot can be plugged with a cap-
screw and nut to prevent assembly
errors.
4. Start engine and engage hydraulic lift lever to
raise bed. Release lift lever and turn off engine.
Secure raised bed with a hoist or block it to prevent it from accidentally falling.
5. Install Iynch pins to inside ends of clevis pins.
10
Specifications
Type: 4-wheel step-through, out-front operator style,
two-person vehicle. Certified to meet ANSI
Specifications B56.8-1988.
Engine: Mitsubishi three-cylinder, liquid-cooled,
counterbalanced, gasoline engine. Rated at 20 kW
(27 hp), governed to a maximum speed of 3650 rpm
by a mechanical governor.657 cc (40 cu. in.) displacement. Forced lubrication by gear pump. 40-amp
alternator with I/C regulator. Spin-on oil filter.
Air Cleaner: Heavy-duty, 2-stage, remote mounted
air cleaner.
Battery: 12 volt with 370 cold-cranking Amps @
–18° C (0 degrees F.)
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 l (7 gallons). 12-volt, electric fuel pump.
Transmission: Rear transaxle configuration, twin
axle drive. 3-speed synchromesh, H-shift pattern
with high-low range providing 6 forward and 2
reverse speeds. Manual engage differential lock. 4Wheel drive output shaft (4-wheel drive model only).
Clutch: 19 cm (7.5 inch) clutch and pressure plate.
Front Differential: (4-Wheel-drive only) 5.0 to 1
ratio.
Center Differential: (4-Wheel drive only) Bi-direc-
tional overrunning clutch.
Frame: Welded, high-strength steel channels and
tubes.
Tires:
Front tires: 50.8 x 25.4 cm (20” x 10”)-10, 4-ply rating, rib tread.
Rear tires: 61 x 38 cm (24" x 13") x 12, 4-ply rating,
turf tread.
Optional rear tires: 58.4 x 26.7 cm (23” x 10.5”)-12,
6-ply rating, turf tread.
Brakes: 4-wheel hydraulic, dual safety circuit selfadjusting drum: 17.8 (7”) diameter front, 20.3 (8”)
diameter rear. Hand-actuated parking brake actuates
rear brake shoes.
Roll Over Protection System: 2-post roll over protection structure with shoulder restraint.
Hydraulics: 4 gpm pressure balanced gear pump
provides hydraulic flow for power steering, lift and
optional remote hydraulics. Lift control valve and
dual cylinders for lifting dump box. Transaxle is
used for reservoir for hydraulic system. 7.6 l (8
quart) total capacity. Spin-on 25-micron hydraulic oil
filter. 100 mesh strainer in transaxle.
Seat: Twin molded cushions and backrests, with
shoulder and hip restraints.
Controls: Foot-operated accelerator, clutch and
brake pedals. Hand-operated shifter, differential lock,
parking brake, high–low range shifter, hydraulic lift
and tilt steering levers. Ignition switch, light switch,
horn button, glow plug switch (diesel models only),
and 3rd high lockout switch.
Gauges: Hour meter, fuel gauge, coolant temperature gauge. Warning light cluster includes engine low
oil pressure, charge indicator and on diesel models
only, a glow plug indicator. Tachometer optional.
Front Suspension: Independent “A” frame control
arm, dual 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, 3-3/4 turns lock-to-lock. 17.5 to 1 ratio,
35.5 cm (14 inch) diameter steering wheel.
Lights: Twin halogen headlights and single taillight.
Rear stop light.
Interlocks: Clutch pedal must be depressed to start
engine. PTO must be disengaged (if so equipped) to
start engine.
Ground Speed:
Forward Speeds with 58 cm (24”) Tires—
High range: 12.2/18.5/31.9 kmh
11
Specifications
(7.6/11.5/19.8 mph)
Low range: 4.7/9.2/12.4 kmh (2.9/5.7/7.7 mph)
Reverse Speeds with 58 cm (24”) Tires—
High range: 11.6 kmh (7.2 mph)
Low range: 4.5 kmh (2.8 mph)
General Specifications:
Base Weight: Dry w/o flatbed 522.5 kg (1400 lbs.)
Rated Capacity: 970 kg*(2,600 lbs).
*includes 74.6 (200 lb.) operator and 74.6 (200 lb.)
passenger and loaded attachment.
Maximum Gross Vehicle Weight: 1,493 kg (4,000
lbs.) 2-wheel drive
1,568 kg (4,200 lbs.) 4 wheel drive
Tow Capacity
Tongue weight 74.6 kg (200 lbs.)
Maximum trailer weight 560 kg (1,500 lbs.)
Overall Width: 160 cm (63”)
Overall Length: 316 cm (124.5” without bed)
322.3 cm (127” with full bed)
338 cm (133”) with 2/3 bed in rear
mounting location
Height: 190 cm (75”) to top of the Roll Over
Protection System
Ground Clearance: 17.7 cm (7”) with no load
Wheel Base: 177.8 cm (70”)
Wheel Tread: (center line to center line)
Front 116.8 cm (46”)
Rear 121.6 (47.7”) (w 23” Rear Tire)
Specifications and design subject to change without notice.
12
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