FORM NO. 3318-617GB Rev A MODEL NO. 07210—60001 AND UP ® OPERATOR MANUAL WORKMAN 3100 UTILITY VEHICLES 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. It means CAUTION, WARNING or DANGER— personal safety instruction. Failure to comply with the instruction may result in personal injury.
Foreword The TORO WORKMAN® was developed to provide an efficient, versatile, trouble free and economical work vehicle. The latest concepts of engineering, design and safety have been incorporated into this machine, along with the highest quality parts and workmanship. Excellent service will be derived if proper operation and maintenance practices are followed. This vehicle is not designed or manufactured for use on roads, streets or highways. It is not appropriate for such use.
Safety The WORKMAN® was designed and tested to offer safe service when operated and maintained properly. Although hazard control and accident prevention partially are dependent upon the design and configuration of the machine, these factors are also dependent upon the awareness, concern, and proper training of the personnel involved in the operation, maintenance and storage of the machine. Improper use or maintenance of the machine can result in injury or death.
Safety D. Fill fuel tank outdoors and to about one inch below top of tank (bottom of filler neck). Do not overfill. E. Wipe up any spilled gasoline. 14. Check the safety interlock system daily for proper operation; refer to page 21. If a switch should malfunction, replace the switch before operating machine. After every two years, replace the interlock switches in the safety system, whether they are working properly or not.
Safety J. Watch out for traffic when near or crossing roads. Always yield the right of way to pedestrians and other vehicles. This vehicle is not designed for use on streets or highways. Always signal your turns or stop early enough so other persons know what you plan to do. Obey all traffic rules and regulations. K. Never operate vehicle in or near an area where there is dust or fumes in the air which are explosive.
Safety 31. If major repairs are ever needed or assistance is required, contact an Authorized TORO Distributor. Sound & Vibration Levels 32. To be sure of optimum performance and safety, always purchase genuine 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. TORO replacement parts and accessories. Replacement parts and accessories made by other manufacturers could be dangerous.
Symbol Glossary SAFETY ALERT SYMBOL GENERAL HAZARD SAFETY ALERT CRUSHING OF WHOLE BODY, APPLIED FROM ABOVE CRUSHING OF TOES OR FOOT, CRUSHING OF FINGERS OR HAND, CUTTING OF FINGERS OR HAND CUTTING OF FOOT FORCE APPLIED FROM ABOVE FORCE APPLIED FROM SIDE KEEP CHILDREN A SAFE DISTANCE FROM BATTERY STAY A SAFE DISTANCE FROM MACHINE STAY A SAFE DISTANCE FROM DRAINING STAY A SAFE DISTANCE FROM MACHINE STAY A SAFE DISTANCE FROM TANK HYDRAULIC OIL VALVE EXPLOSION FIRE OR OPEN FLAME FIRE, OPEN LIGHT & SMOK
Symbols Glossary THROWN OR FLYING OBJECTS, SEVERING OF FINGERS OR FACE EXPOSURE HAND, ENGINE FAN RIDING ON THIS MACHINE IS SHUT OFF ENGINE & REMOVE ALLOWED ONLY ON A PASS- KEY BEFORE PERFORMING ENGER SEAT & ONLY IF THE MAINTENANCE OR REPAIR WORK DRIVER'S VIEW IS NOT HINDERED MACHINE TIPPING USE CAUTION ON STEEP HILLS MACHINE TIPPING MACHINE TIPPING DO NOT JUMP FROM TIPPING MACHINE HOLD TIGHTL & BRACE FEET HOLD HIP RESTRAINT & HAND HOLD, BRACE FEET LEAN AWAY FROM TIP STAY CLEAR OF ARTICULATION RUNO
Specifications Type: 4-wheel step-through, out-front operator style, two-person vehicle. Certified to meet ANSI Specifications B56.8-1988. Engine: Kohler 4-cycle, air-cooled, 16.4 kV @ 3600 rpm, 624 cc displacement. Mechanical fuel pump, 1.9 liter oil capacity. Large capacity dual element air cleaner. Battery: 12 volt with 370 cold-cranking Amps @ –18° C (0 degrees F.) Fuel System: Fuel tank capacity is 26.5 l (7 gallons). Transmission: Rear transaxle configuration, twin axle drive.
Specifications Overall Width: 147 cm (58”) with 23 inch tires Overall Length: 316 cm (124.5” without bed) 322.3 cm (127” with full bed) 338 cm (133”) with 2/3 bed in rear mounting location Height: 190.5 cm(75”) to top of the Roll Over Protection System Ground Clearance: Wheel Base: 17.7 cm (7”) with no load 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.
Before Operating CAUTION Before servicing or making adjustments to the machine, stop the engine, set the parking brake and the remove key from the switch. Any load material must be removed from the bed or other attachment before working under the raised bed. Always rotate the safety support to the down position before working under the raised bed. CHECK CRANKCASE OIL The engine is shipped with oil in the crankcase; however, the level of oil must be checked before and after the engine is first started. 4.
Before Operating every 8 hours or daily, thereafter. Capacity of the system is 7.1 l (7.5 qt). ➀ 1. Position the vehicle on a level surface. 2. Clean the area around the dipstick. 3. Unscrew the dipstick from the top of the transaxle and wipe it with a clean cloth. Figure 2 1. Fuel tank cap ➀ 4. Wipe up any fuel that may have spilled to prevent a fire hazard. CHECK THE TRANSAXLE / HYDRAULIC FLUID DANGER Because fuel is flammable, caution must be used when storing or handling it.
➁ ➀ Figure 4 1. Brake fluid reservoir 2. Full line Maximum Total Front Axle Weight (kg) Before Operating 20” FRONT TIRES 597 560 523 485 448 411 373 55 CHECK WHEEL NUT TORQUE CHECK TIRE PRESSURE Check tire pressure every 8 hours or daily. Maximum air pressure in the front tires is 1,4 kg/cm2 and 2,3 kg/cm2 in the rear (23”) tires tires. Optional rear (24”) tire pressure is 18 psi maximum. 1. The air pressure needed is determined by the payload carried. 2.
Controls Accelerator Pedal (Fig. 5)—Used to vary engine and ground speed when the transmission is in gear. Depressing the pedal increases engine RPM and ground speed. Releasing it will decrease engine RPM and ground speed. ➀ Shift Pattern R 2 1 3 IMPORTANT: Do not shift the transaxle to the reverse or forward gear unless the vehicle is standing still. Damage to the transaxle may occur. ➁ ➂ Figure 5 1. Accelerator pedal 2. Clutch pedal 3. Brake pedal Clutch Pedal (Fig.
Controls 8 additional speeds for precise speed control. 2 7 5 3 6 1 4 A. The vehicle must be completely stopped before shifting between High and Low range. B. Shift only on level ground. C. Depress the clutch pedal fully. Figure 6 1. Gear shift lever 2. Differential lock 3. Parking brake 4. High-low range shifter 5. Hydraulic lift 6. Hydraulic lift lock 7. Passenger hand hold 8. PTO lever (optional) Parking Brake (Fig.
Controls while the engine is running. If the light flickers or remains ON, stop the vehicle, turn off the engine and check the oil level. If the oil level was low, but adding oil does not cause light to go out when the engine is restarted, turn the engine off immediately and contact your local TORO distributor for assistance. Ignition Switch (Fig. 7)—The ignition switch, used to start and stop the engine, has three positions: OFF, RUN and START.
Operating PRE-STARTING CHECKS Safe operation begins before taking the vehicle out for a day’s work. You should check these items each time: 1. Check tire pressure. Note: These tires are different than car tires, they require less pressure to minimize turf compaction and damage. 2. Check all fluid levels and add the appropriate amount of Toro-specified fluids, if any are found to be low. 3. Check brake pedal operation. 4. Check to see that the lights and horn are working. 5.
Operating battery. IMPORTANT: Do not keep the front wheels turned against the right or left stops for longer than 5 seconds. The hydraulic pump may over heat, resulting in pump or steering gear damage. 6. Do not push or tow the vehicle to get it started. Damage to the drive train could result. • A break-in oil for the engine is not required. The original engine oil is the same type specified for regular oil changes. • Refer to Maintenance section for any special low hour checks.
Operating cle and not designed for use on roadways. The vehicle has special tires, low-gear ratios, a locking differential, and other features that give it extra traction. These features add to the versatility of the vehicle but they can also get you into dangerous situations. You must remember that the vehicle is not a recreation vehicle or an all-terrain vehicle. And it is definitely not meant for “stunt driving”. It is a work vehicle, not a play vehicle.
Operating cause the vehicle to lose traction and skid, or even tip over. engine braking may cause skidding and loss of control. Shift to a lower gear before starting down a hill. 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. TIPOVERS During a sharp turn at higher speeds, the inside rear wheel may lift off of the ground.
Operating vided. In case of tipover Don’t jump Tipover can occur if the truck is improperly operated. Injury or death could result. HILLS Operator: Hold tight and brace feet. 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.
Operating sure it is secured. • Mounting wheel weights to rear wheels. • Adding liquid ballast (calcium chloride) to rear tires. • Traction will increase with no passenger in front seat. LOADING AND DUMPING WARNING The bed will lower whenever the dump lever is pushed down, even when the engine is off. Turning off the engine will NOT prevent the box from lowering. Always place the safety support on extended lift cylinder to hold box up if you are not going to lower it right away.
Operating out. This can help when you have heavy loads to haul on wet turf or slippery areas, going up hills and on sandy surfaces. In case of emergency, the vehicle can be towed for a short distance. However, Toro does not recommend this as a standard procedure. 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. Towing the vehicle is a two-person job.
Operating kg. Always load a trailer with 60% of the cargo weight in the front of the trailer. This places approximately 10% (90 kg max.) of the Gross Trailer Weight (GTW) on the tow hitch of the vehicle. When towing either standard tongue or 5th wheel trailers having a Gross Trailer Weight (GTW) in excess of 900 kg, use either a chassis mounted draw bar hitch (rated for 1590 kg. GTW) or the 5th wheel kit with the brakes. Trailer brakes are required whenever a trailer over 900 kg.
Maintenance Daily Maintenance Procedures Check the following items daily • Safety interlock operation • Service & park brake operation • Clutch and shifter operation • Fuel level • Engine oil level • Transaxle oil level • Brake fluid level • Air filter prefilter • Inspect engine cooling fins • Unusual engine noises • Tire pressure • Hydraulic hoses for damage • Fluid leaks • Instrument operation • Lubricate all grease fittings (also immediately after every washing) • Touch-up
Maintenance WORKMAN 3100 QUICK REFERENCE AID Check/Service Engine Oil 10°C-40°C Transmission/Hydraulic Oil 1. Engine oil level 2. Engine oil drain 3. Transaxle/Hydraulic oil level (dipstick) 10. 4. 5. 6. 7. 8. 9. 12. 13. 14. Belt (Hydraulic pump) Fuel (unleaded fuel only) Grease points (33) 100 hours Air filter Fuel filter Battery Strainer Change Intervals Fluid Filter Fluid Type Capacity SAE 10W 30 CD 1.9 l 50 hours 50 hours 1205001 Dextron II ATF 7.
Maintenance Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Check battery fluid level Every 50 Check battery cable connections hours Lubricate engine prefilter ✝Change engine oil and filter Maintenance Interval& Service Every 100 hours Every 200 hours Every 400 hours Every 800 hours Lubricate all grease fittings Remove engine shrouds, clean fins Inspect the condition and wear of tires Inspect cooling system hoses ‡Check cable adjustments ‡Check pump drive belt te
Maintenance GREASING BEARINGS AND BUSHINGS The vehicle has (33) grease fittings that must be lubricated regularly with No. 2 General Purpose Lithium Base Grease. If the machine is operated under normal conditions, lubricate all bearings and bushings after every 100 hours of operation. More frequent lubrication is required if used for heavy duty vehicle operations. Figure 12 The grease fitting locations and quantities are: Tie rod ends (4) (Fig. 11), Front ball joints (4) (Fig.
Maintenance IMPORTANT Heavy Duty Operation If the vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently.
Maintenance 5. Always install or remove bed support from outside of bed. 6. Do not try to lower bed with bed safety support on cylinder. rear it is under the axle tube. 4. When jacking up front of the vehicle, always place a 50 x 100mm block (or similar material) between the jack and vehicle frame. ➀ Figure 18 1. Front jacking point Figure 16 1. Bed support 2. Storage stud ➀ ➀ Figure 19 1. Rear jacking points Locations For Selected Maintenance Procedures Figure 17 1. Bed support 2.
Maintenance Figure 21 1. Pre-cleaner 2. Paper element Figure 24 1. Pump belt Figure 25 Figure 22 1. Engine oil drain plug 2. Engine oil filter CHANGING THE TRANSAXLE/ HYDRAULIC FLUID Change the transaxle hydraulic fluid, filter and clean the strainer every 600 hours. ➀ ➀ ➁ Figure 23 1. Fuel filter Figure 26 1. Hydraulic reservoir 2.
Maintenance Center-to-Center Distance ➀ Figure 29 ➁ Figure 27 1. Hydraulic filter 2. Gasket 2. To adjust, loosen jam nuts at both ends of tie rod. ➀ Figure 30 1. Tie rod Figure 28 1. Hydraulic strainer FRONT WHEEL TOE-IN 3. Rotate tie rod to move front of tire inward or outward. 4. Tighten tie rod jam nuts when adjustment is correct. After every 600 operating hours or annually, check front wheel toe-in. EMERGENCY BOX RAISING (without starting the engine) 1.
Maintenance tem. They are located under right side of dash panel. FUSES OPEN LIGHTS & HORN 10A IGNITION 7.5A DASH 7.5A — 2. Connect a jumper cable between the positive posts of the two batteries. The positive post may be identified by a “+” sign on top of battery cover. ➀ ➀ Figure 32 Figure 31 1. Positive (+) cable 1. Fuse block JUMP STARTING PROCEDURE WARNING Jump starting can be dangerous.
Maintenance IDENTIFICATION AND ORDERING MODEL AND SERIAL NUMBERS The WORKMAN® has two identification numbers: a model number and a serial number. These numbers are stamped into a plate located on the right frame member under dash. In any correspondence concerning the unit, supply the model and serial numbers to ensure correct information and replacement parts are obtained. To order replacement parts from an authorized TORO Distributor, supply the following information: 1. Model and serial numbers. 2.
