Form No. 3326-233 Workman 3100 Air Cooled Gas Utility Vehicle Model No. 07214—Serial No.
FOREWORD The TORO WORKMAN 3100 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.
FOREWORD The TORO WORKMAN 3100 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.
TABLE OF CONTENTS SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . 5-7 SAFETY AND INSTRUCTION DECALS . . . . . . . 7-9 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 LOOSE PARTS CHART . . . . . . . . . . . . . . . . . . . . . . . 11 SET-UP INSTRUCTIONS . . . . . . . . . . . . . . . . 12-13 Install Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install Steering Wheel . . . . . . . . . . . . . . . . . . . . . 12 Install Front Fenders . . . . . . . . . . . .
SAFETY INSTRUCTIONS The WORKMAN 3100 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 INSTRUCTIONS 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 GVW. 17. When starting the engine: A. Sit on operator's seat and engage parking brake. B. Disengage PTO's (if so equipped) and return hand throttle lever to OFF position (if so equipped). C. Move shift lever to NEUTRAL and depress clutch pedal. D. Pull up choke knob when engine is cold. E.
SAFETY INSTRUCTIONS 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. 32.
SAFETY AND INSTRUCTION DECALS ON LEFT FRAME RAIL AND NEAR ENGINE MANIFOLD (Part No. 93-8071) ' ON SKIRT (Part No. 87-5920) UNDER DASH NEXT TO FUSE BLOCK (Part No. 87-6670) ON SPRING CRADLE (Part No. 93-9879) ON CONSOLE (Part No. 87-6000) UNDER RIGHT SIDE OF DASH (Part No. 87-9510) ON LIFT CYLINDERS & BED SUPPORT (Part No. 93-9852) ON DASH (Part No. 87-5910) ON DASH (Part No.
SAFETY AND INSTRUCTION DECALS ON CONSOLE (Part No. 87-6020) ON CONSOLE (Part No. 87-5960) ON AXLE TUBE (Part No. 93-9442) ON SKIRT (Part No. 87-5930) ON BATTERY COVER (Part No. 93-6687) ON DASH (Part No. 94-5272) ON CONSOLE (Part No. 87-6010) ON ROPS (Part No. 105-4214) ON FAN SUPPORT (Part No. 93-7814) ON ROPS (Part No.
SPECIFICATIONS Type: 4 wheel step through, out front operator style, two person vehicle. Certified Specifications B56.8a-1994. to meet ANSI Engine: Kohler, 4 cycle, air cooled, 23 hp @ 3600 rpm, 41.1 cu. in. (674 cc) displacement. Mechanical fuel pump, 2 qt. oil capacity. Large capacity dual element air cleaner. Battery: 12 volt with 370 cold cranking Amps @ 0 degrees F. Fuel System: Gasoline tank capacity is 7 gallons. Transmission: Rear transaxle configuration, twin axle drive.
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 Wheel Nut Wheel-Front Wheel Nut Wheel-Rear 10 2 10 2 Steering wheel Foam Seal Washer Nut Cap 1 1 1 1 1 Fenders-Front Phillips Screw 10-24 Washer Locknut 10-24 2 14 14 14 ROPS Capscrew 1/2-13 x 3" lg.
SET-UP INSTRUCTIONS INSTALL WHEELS (Fig. 1) INSTALL FRONT FENDERS (Fig. 3) 1. Remove and discard fasteners securing wheels. 1. Mount a fender to each side of skirt with (7) 10-24 Phillips screws, flat washers and locknuts. 2. Mount wheels and torque nuts to 45 55 ft lb. 1 Figure 3 1. Fender 2 1 INSTALL ROPS (Fig. 4) 1. Insert each side of ROPS into mounting bracket on each side of vehicle frame, positioning ROPS as shown in figure 4. Figure 1 1. Wheel 2. Wheel Nut INSTALL STEERING WHEEL (Fig.
SET-UP INSTRUCTIONS ACTIVATE AND CHARGE BATTERY (Fig. 5 & 6) If 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. 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.
BEFORE OPERATING CAUTION 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 safety support on extended lift cylinder, to hold up bed, before working under raised bed. Note: When adding oil, remove dipstick to allow proper venting, pour oil slowly and check the level often during this process. DO NOT OVERFILL.
BEFORE OPERATING 1. Clean area around fuel tank cap. CHECK TRANSAXLE / HYDRAULIC FLUID (Fig. 10) The transaxle reservoir is filled with Dexron IIl ATF. Check level before engine is first started and every 8 hours or daily, thereafter. Capacity of system is 7.5 qt. 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 rag. 1 Figure 9 1. Fuel tank cap 4. Screw dipstick into transaxle and make sure it is seated fully.
BEFORE OPERATING 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. Figure 11 1. Brake fluid reservoir 2. Full line CHECK TORQUE OF WHEEL NUTS WARNING Failure to maintain proper torque could result in failure or loss of wheel and may result in per sonal injury.
CONTROLS Accelerator Pedal (Fig. 12) - 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. 1 2 3 Figure 12 IMPORTANT: Do not shift the transaxle to the reverse or forward gear unless the vehicle is standing still. Damage to transaxle may occur.
CONTROLS Parking Brake (Fig. 13) -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.
CONTROLS 3 2 5 2 4 1. Light switch 2. Hour meter 3. Fuel gauge 1 Figure 15 4. 3rd High lockout switch 5. Steering wheel Steering Wheel (Fig. 15) - Turns vehicle. If engine stalls or power assist fails due to a malfunction, vehicle steering will require greater effort. Passenger Hand Hold (Fig. 16) -On dashboard. 1 Figure 16 1. Passenger hand hold 2. Tachometer (Option al) Tachometer-Optional (Fig. 16) - Indicates engine RPM. Gear selection graphics indicates speed.
OPERATING INSTRUCTIONS 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.
OPERATING INSTRUCTIONS 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.
OPERATING INSTRUCTIONS 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. TIPOVERS The TORO WORKMAN is equipped with a roll bar, hip restraints, shoulder restraints and hand hold.
OPERATING INSTRUCTIONS 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 3100 has excellent hill climbing ability. The differential lock will increase this ability. Hill climbing traction can also be increased by adding weight to the rear of the vehicle in one of the following ways: LEAN AWAY HILLS Adding weight to inside of box, making sure it is secured. Mounting wheel weights to rear wheels.
OPERATING INSTRUCTIONS 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 55 inches wide by 65 inches long and can hold up to 2000 pounds of evenly distributed cargo.
OPERATING INSTRUCTIONS 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. When equipped with a tow hitch bolted onto rear axle tube, your Workman can tow trailers or attachments with a Gross Trailer Weight (GTW) up to 1500 lbs.
MAINTENANCE CHART AND CHECKLIST Daily Maintenance: (duplicate this page for routine use) Check proper section of Operator's Manual for fluid specifications Daily Maintenance Check For Week Of _________________ Maintenance MON TUES WED THURS FRI SAT SUN Check Item Safety Interlock Operation Service & Park Brake Operation Clutch & Shifter Operation Fuel Level Engine Oil Level Transaxle Oil Level Brake Fluid Level Air Filter Prefilter Inspect Engine Cooling Fins Unusual Eng
SERVICE INTERVAL CHART LUBRICATION CAUTION 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 safety support on extended lift cylinder, to hold up bed, before working under raised bed. IMPORTANT: When greasing drive shaft universal shaft bearing crosses, pump grease until it comes out of all 4 cups at each cross. 1.
LUBRICATION Figure 20 Figure 22 Figure 23 Figure 21 IMPORTANT Heavy Duty Operation If vehicle is subjected to conditions listed below, maintenance should be performed twice as frequently.
MAINTENANCE CAUTION 1 Only qualified and authorized personnel shall be permitted to maintain, repair, adjust or in spect 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. Many of the subjects covered in this maintenance section require raising and lowering the bed.
MAINTENANCE 4. When jacking up front of vehicle, always place a 2x4 block (or similar material) between jack and vehicle frame. 1 2 3 1 4 Figure 26 1. Front jacking point 5 6 7 1 1 Figure 27 1. Rear jacking points SERVICING AIR CLEANER (Fig. 28) The foam pre-cleaner must be cleaned and re-oiled after every 25 hours engine operation if engine is operated in clean air conditions. However, air cleaner must be cleaned every few hours if operating conditions are extremely dusty or sandy. 1.
MAINTENANCE REMOVING DEBRIS FROM ENGINE To ensure proper cooling, make sure the grass screen, cooling fins and other external surfaces of the engine are kept clean at all times. Every 100 hours of operation (more often under extremely dusty, dirty conditions) remove the blower housing and other cooling shrouds and clean the cooling fins and external surfaces as necessary. Make sure cooling shrouds are reinstalled. 1 2 Figure 29 1. Engine oil drain plug 2. Engine oil filter 3. Remove oil filter.
MAINTENANCE ADJUSTING CHOKE ADJUSTING ACCELERATOR (Fig. 33) 1. Raise bed (if so equipped) and place safety support on extended lift cylinder to hold up bed. Stop engine and engage parking brake. 2. Loosen cable clamp screw securing cable to engine. 3. Push choke knob down to OFF position. 4. Push choke cable firmly toward operators side of vehicle and tighten cable clamp screw. REPLACING SPARK PLUGS (Fig. 32) Check adjustment every 200 hours. 1.
MAINTENANCE CHANGING TRANSAXLE / HYDRAULIC FLUID (Fig. 34) Change Transaxle hydraulic fluid, filter and clean strainer every 600 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. 1 2 Figure 35 1. Hydraulic Filter 2. Gasket 1 CLEANING HYDRAULIC STRAINER (Fig. 36) 1.
7. Reinstall and tighten drain plug. MAINTENANCE 8. Fill reservoir with approximately 7.5 qt. of Dexron II ATF. Refer to Checking Hydraulic Fluid. ADJUSTING BRAKE PEDAL (Fig. 37-38) 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 .020-.080". Note: Force is applied so release bearing lightly contacts pressure plate fingers. 4. Reconnect return spring to clutch lever. 5. Verify that rear edge of clutch pedal is 5.5" + .
MAINTENANCE 2. Rotate knob until a force of 45 lbs. is required to actuate lever. 3. Tighten set screw after adjustment has been attained. 3 ADJUSTING HIGH-LOW CABLE (Fig. 42) 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. ADJUSTING DIFFERENTIAL LOCK CABLE 1 2 (Fig.
MAINTENANCE INSPECT BRAKES Visually inspect brakes for worn brake shoes after every 400 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. If engine will not crank, the load and box (attachment) must be removed to service engine or transaxle. FUSES (Fig. 46) There are 3 fuses in the machine's electrical system.
MAINTENANCE 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. 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..
MAINTENANCE SCHEDULE Minimum Recommended Maintenance Intervals Maintenance Procedure Check Battery Fluid Level Check Battery Cable Connections Lubricate Engine Prefilter Change Engine Oil and Filter Maintenance Interval & Service Every 50hrs Every 100hrs Every 200hrs Every 400hrs Every 800hrs Lubricate All Grease Fittings Remove Engine Shrouds, Clean Fins Inspect Condition and Wear of Tires Check Cable Adjustments Check Pump Drive Belt Tension Replace Air Filter Check Engine RPM (idle and full throt
HYDRAULIC SCHEMATIC (Base Vehicle)
YELLOW BLACK BROWN R/BK R/W BROWN BLACK BLACK BLACK TAIL/BRAKE LIGHT RED R/W BLACK BROWN BLACK WHT/BK BLACK R/W BLACK BLACK HEADLIGHTS R/BK R/W WHT/BK WHT/BK B A X RUN START BLACK BLUE/WHT WHT/BK WHT/BK GRAY RED ORANGE ELEC. CLUTCH KIT IGNITION DASH LTS/HORN RED BLACK GRAY 7.
IDENTIFICATION AND ORDERING MODEL AND SERIAL NUMBERS The WORKMAN 3100 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.
The Toro General Commercial Products Warranty A Two-Year Limited Warranty Conditions and Products Covered The Toro Company and its affiliate, Toro Warranty Company, pursuant to an agreement between them, jointly warrant your 1996 or newer Toro Commercial Product (“Product”) purchased after January 1, 1997, to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
