Form No. 3352–442 Rev C Workman) 3100 Air Cooled Gas Utility Vehicle Model No. 07363—Serial No.
Warning Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tipovers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hills . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Loading And Dumping . . . . . . . . . . . . . . . . . . . . . Using The Differential Lock . . . . . . . . . . . . . . . .
Introduction Safety Read this manual carefully to learn how to operate and maintain your product properly. The information in this manual can help you and others avoid injury and product damage. Although Toro designs and produces safe products, you are responsible for operating the product properly and safely. The TORO WORKMAN) meets the requirements of SAE J2258.
Safe Operating Practices • 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. Warning The WORKMAN is an off–highway vehicle only, and is not designed, equipped, or manufactured for use on public streets, roads or highways.
• Check the safety interlock system daily for proper 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. – 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. – When loading bed, distribute load evenly.
• If major repairs are ever needed or assistance is required, contact an Authorized TORO Distributor. – Stop movement of the machine. – Lower bed. • 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.
Safety and Instruction Decals Safety decals and instructions are easily visible to the operator and are located near any area of potential danger. Replace any decal that is damaged or lost. 93-9852 1. Warning—read the Operator’s Manual. 2. Crushing hazard—install the cylinder lock. 93-9442 1. Maximum tongue weight is 90 kg; maximum trailer weight is 680 kg. 93-9850 2. For information on transmission fluid, read the Operator’s Manual. 1. Do not repair or revise—read the Operator’s Manual. 93-6687 1.
93-9879 1. Stored energy hazard—read the Operator’s Manual. 106-2353 1. Electrical power 66-6840 106-2355 80-8040 1. Slow to fast 2. Transmission—third high; no fast speed 106-7897 1. The maximum load is 1019 kg, the vehicle weight is 795 kg, and the maximum gross vehicle weight is 1814 kg. 93-9449 1. Read the Operator’s Manual. 2. Grease every 100 hours. 3. Add grease (9 grease points). 93-8071 1. Hot surface/burn hazard—stay a safe distance from the hot surface.
106-2352 1. Warning—do not operate the vehicle on public streets, roads, or highways. 2. Preheat–glow plug (Diesel only) 3. Headlights 4. Engine—low oil pressure 5. Engine—preheat indicator (Diesel only) 6. Horn 7. Battery –low charge (Liquid cooled only) 8. Temperature level (Liquid cooled only) 9. Hour meter 10. Off 11. On 106-2383 1. Warning—read the Operator’s Manual. 2. Fire hazard—stop the engine before fueling. 3.
6-2384 106-2377 1. 2. 3. 4. 5. Locked Differential lock Unlocked Hydraulic lock Engage 6. Power take-off (PTO) 7. Disengage 8. Warning—read the Operator’s Manual. 9. Entanglement hazard, shaft—keep bystanders a safe distance from the vehicle. 10. Retract hydraulics 10 11. Extend hydraulics 12. Transmission—high speed 13.
106-7894 1. Engine—start 2. Ignition 3. Headlights 4. Power point 106-7767 1. Warning—read the Operator’s Manual. 2. Avoid tipping the machine. 3. Wear the seat belt. 4. Lean away from the direction the machine is tipping. 93-9448 1. Warning—when adding fuel to the tank, leave 25 mm between the fuel and the top of the tank; read the Operator’s Manual. Battery Symbols Some or all of these symbols are on your battery. 1. Explosion hazard 2. No fire, open flames, or smoking. 3.
Specifications Note: Specifications and design subject to change without notice. General Specifications Type 4 wheel step through, out front operator style, two person vehicle. Certified to meet SAE J2258. 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 525 cold cranking Amps @ 0 degrees F. Fuel System Gasoline tank capacity is 7 gallons.
Base Weight (Dry w/o flatbed) 1470 lbs. Rated Capacity 2,530 lbs. (includes 200 lb. operator, 200 lb. passenger and loaded attachment). Maximum. Gross Vehicle Weight Tow Capacity Ground Clearance Wheel Base Wheel Tread (center line to center line) 4,000 lbs. Tongue weight 200 lbs. Maximum trailer weight 1,500 lbs. 7” w/ no load 70” Front 46” Rear 47.7” Dimensions Overall Width Overall Length 63” 128.25” w/o bed 130.38” w/full bed 136.
Setup Note: Determine the left and right side of the machine from the normal operating position. Description Qty. ROPS frame 1 Capscrew 1/2–13 x 3” lg. 4 Locknuts 1/2–13 4 Operator’s Manual (vehicle) 2 Parts Catalog 1 Use Mount ROPS (Rollover Protection System) Read before operating the machine. Install ROPS Activate and Charge Battery 1. Insert each side of ROPS into mounting bracket on each side of vehicle frame, positioning ROPS as shown in figure 1.
1. Loosen knobs securing battery cover to battery base and slide cover off. 2 1 2 2 1 Figure 3 3 1. Positive (+) cable Figure 2 1. Battery cover 2. Knob 2. Hold down 6. Remove filler caps. Slowly add electrolyte to each cell until level is up to fill ring. Install filler caps. 3. Battery base Important Do not overfill battery. Electrolyte will overflow onto other parts of the vehicle and severe corrosion and deterioration will result. 2.
Full Bed Removal 3 1 1. Start engine. Engage hydraulic lift lever and lower bed until cylinders are loose in slots. Release lift lever and turn off engine. 2. Remove lynch pins from outer ends of cylinder rod clevis pins (Fig. 4). 5 4 1 6 2 5 Figure 5 1. Left rear corner of bed 2. Vehicle frame channel 3. Pivot plate 4 2 3 4. Clevis pin 5. Lynch pin Note: Carriage bolt heads are to be positioned inside the machine. Figure 4 1. Bed mounting plate 2. Cylinder rod end 3. Clevis pin 4.
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 lynch pins (Fig. 5). 3. With bed lowered, secure each cylinder rod end, to appropriate slots in bed mounting plates with clevis pin and lynch pin. Insert clevis pin from outside of bed with lynch pin toward outside (Fig. 5). Rear slots are for full bed installation and front slots are for 2/3 bed installation.
Before Operating 4. Pour oil into fill opening until the oil level is up to the “FULL” mark on the dipstick. Note: When adding oil, remove dipstick to allow proper venting, pour oil slowly and check the level often during this process. DO NOT OVERFILL. 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.
3. Unscrew dipstick from top of transaxle and wipe it with a clean rag. 2. Remove fuel tank cap. Danger Under certain conditions, diesel fuel and fuel vapors are highly flammable and explosive. A fire or explosion from fuel can burn you and others and can cause property damage. 1 • Use a funnel and fill the fuel tank outdoors, in an open area, when the engine is off and is cold. Wipe up any fuel that spills. • Do not fill the fuel tank completely full.
3. Fluid level should be up to FULL line on reservoir. Important When replacing tires, on the 4wd vehicle, only use replacements approved for the Workman. Use of tires not approved may cause turf damage or accelerated drive train damage. 1 Check Brake Fluid 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.
Operation Caution Note: Determine the left and right side of the machine from the normal operating position. Worn or misadjusted brakes may result in personal injury. If brake pedal travels to within 1–1/2” of the vehicle floor board, the brakes must be adjusted or repaired. Controls Accelerator Pedal Gear Shift Lever The accelerator pedal (Fig. 13) gives the operator the ability to vary engine and ground speed of the vehicle, when the transmission is in gear.
2 • Depress clutch pedal fully. 4 • Move lever fully forward for High and fully rearward for Low. HIGH is for higher speed driving on level, dry surfaces with light loads. 5 3 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). 6 1 Figure 14 1. Gear shift lever 2. Parking brake 3.
third gear when in High range. Key is installed with teeth pointing downward. Push key in to turn. Key is removable in either position. Tachometer (Optional) Light Switch Horn Button Toggle switch (Fig. 16) to activate headlights. Push to turn lights “ON”. Pressing button activates horn (Fig. 16). Indicates engine RPM (Fig. 16). Choke Oil Pressure Warning Light To start a cold engine, close the carburetor choke by pulling the choke control (Fig. 16) out to the ON position.
Pre–starting Checks Driving Vehicle Safe operation begins before taking the vehicle out for a day’s work. You should check these items each time: 1. Release parking brake. 2. Fully depress clutch pedal. • Check tire pressure. 3. Move gear shift lever to 1st gear. Note: These tires are different than car tires, they require less pressure to minimize turf compaction and damage. 4. Release clutch pedal smoothly while depressing accelerator pedal.
Stopping Engine Caution To stop engine, rotate ignition key to OFF and engage parking brake. Remove key from switch to prevent accidental starting. If safety interlock switches are disconnected or damaged the machine could operate unexpectedly causing personal injury. New Vehicle Break–in • Do not tamper with the interlock switches. • Check the operation of the interlock switches daily and replace any damaged switches before operating the machine.
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. 1 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.
accident. In the event of a tip over, the risk of serious injury or death will be reduced if the operator is using the ROPS system and follows the instructions provided. 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.
Loading And Dumping 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. 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. As a general rule, position the weight of the load evenly from front to rear and evenly from side to side.
Transporting Vehicle Several types of tow hitches are available for the Workman, depending on your application. Contact your Authorized TORO Distributor for details. For moving the vehicle long distances, a trailer should be used. Make sure the vehicle is secured to the trailer. Refer to Figures 21 and 22 for location of tie down points. 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.
Lower (Quick Coupler “B” Position) Important 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. This position will lower the bed, rear hitch attachment or apply pressure to quick coupler ”B”.
Hydraulic Control Trouble Shooting: • Difficulty in connecting or disconnecting quick couplers. • Pressure not relieved (Quick coupler under pressure). • Power steering hard. • Hydraulic oil level low. • Hydraulic oil hot. • Pump not operating. • Hydraulic leaks. • Fittings loose. • Fitting missing o–ring. • Attachment does not function. • Quick couplers not fully engaged. • Quick couplers are interchanged. • Squealing noise.
Maintenance Note: Determine the left and right side of the machine from the normal operating position. Service Interval Chart Lubrication 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.
Figure 27 Figure 25 Figure 28 Figure 26 33
Recommended Maintenance Schedule Maintenance Service Interval Maintenance Procedure After first 5 hours • Replace the engine oil and filter. After first 10 hours • • • • Check cable adjustments Check pump drive belt tension Torque wheel lug nuts Replace transaxle filter Every 50 hours • • • • Check the battery fluid level. Check the battery cable connections.
Daily Maintenance Checklist Duplicate this page for routine use. For the week of: Maintenance Check Item Mon. Tues. Check the safety interlock operation. Check service and park brake operation. Check the fuel level. Check the accelerator operation Check the clutch and shifter operation Check the engine oil level. Check the transaxle oil level. Check the brake fluid level Check the air filter/prefilter Inspect engine cooling fins Check for any unusual engine noises. Check for any unusual operating noises.
Caution If you leave the key in the ignition switch, someone could accidently start the engine and seriously injure you or other bystanders. Remove the key from the ignition before you do any maintenance. Heavy Duty Operation Warning Important If the vehicle is subjected to any of the conditions listed below, maintenance should be performed twice as frequently: Before servicing or making adjustments to the machine, stop engine, set parking brake and remove key from ignition switch.
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. 3. Push bed support onto cylinder rod, making sure support end tabs rest on end of cylinder barrel and on cylinder rod end (Fig. 30). 4. When jacking up front of vehicle, always place a 2x4 block (or similar material) between jack and vehicle frame. 1 1 3 Figure 31 1. Front jacking point 2 Figure 30 1. Bed support 2. Cylinder barrel 3. Bed 1 4.
1 2 3 4 1 2 5 Figure 34 6 1. Engine oil drain plug 7 2. Engine oil filter 4. Add oil to crankcase, refer to Check Engine Oil. Fuel System Fuel Lines and Connections Check lines and connections every 400 hours or yearly, whichever comes first. Inspect for deterioration, damage, or loose connections. Figure 33 1. 2. 3. 4. Knob & O–ring Air cleaner cover Wing nut Inner cover 5. Breather seal 6. Foam pre–cleaner 7.
Adjusting Choke 4. Remove clamps securing fuel filter to fuel lines. 5. Install new fuel filter to fuel lines with clamps previously removed. Filter to be mounted so arrow points toward carburetor. 1. Raise bed 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. Removing Debris From Engine 3. Push choke knob in to OFF position.
Adjusting Accelerator pedal arm and top of diamond tread floor plate, when a 25 lb. force is applied to center of pedal. Tighten locknut. Check adjustment every 200 hours. 1. Position vehicle on level surface, stop engine and engage the parking brake. 2. With return spring installed, hold engine governor arm toward operator’s side of vehicle and adjust low idle stop to obtain a .01” – .05” gap between O.D. of hole in throttle lever and inside of governor spring hook. .100–.
4. Remove strainer and clean by back flushing with a clean degreaser. Allow to air dry before reinstalling. Important Use only hydraulic fluids specified. Other fluids could cause system damage. Replacing Transaxle Filter 1 Initially, replace the hydraulic filter after 10 operating hours, thereafter, replace filter every 800 hours. Use the Toro replacement filter (Part No. 54–0110). Important Use of any other filter may void the warranty on some components. 1.
3. Adjust jam nuts/or ball joint until bottom rear edge of clutch pedal is 3.75” + .12” from top of floor plate diamond pattern, when an 4 lb. force is applied to pedal. 3. Loosen jam nuts securing yoke to master cylinder shaft (Fig. 43). 4. Adjust yoke until its holes align with hole in brake pedal pivot. Secure yoke to pedal pivot with clevis pin and cotter pin. Note: Force is applied so release bearing lightly contacts pressure plate fingers. 4. Reconnect return spring to clutch lever. 5.
3. Lift up on clutch pedal (Fig. 44) until it contacts frame. 4. Tighten set screw after adjustment has been attained. 4. Adjust clutch cable until ball joint end is aligned with hole in clutch pedal pivot. Insert rod end into pivot hole. 5. Install rubber grip onto parking brake lever. 5. While holding clutch pedal against frame, tighten jam nuts securing cable to frame bracket. Adjusting Shift Cables Check adjustment every 200 hours. 6. Secure rod end to pedal pivot with nut previously removed. 1.
Adjusting Differential Lock Cable Front Wheel Toe After every 400 operating hours or annually, check front wheel toe–out. Check adjustment every 200 hours. 1. Measure center–to–center distance (at axle height) at front and rear of steering tires. The measurement must be .25 $ .12“ greater at the front of the tire than at the rear. 1. Move differential lock lever to Off position. 2. Loosen jam nuts securing differential lock cable to bracket on transaxle. Front of Vehicle .25 $ .
• If engine will not crank, the load and box (attachment) must be removed to service engine or transaxle. Jumping Hydraulic System 1 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. Never work under a raised bed without positioning safety support on a fully installed cylinder rod.
Fuses Jump Starting Procedure The fuses for the machine’s electrical system are located under the center of the dash panel. Warning 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 damage the electrical system. • Never attempt to jump start a discharged battery that is frozen. It could rupture or explode during jump starting.
Battery Care negative post of the discharged battery. Connect it to the engine. Do not connect the jumper cable to the fuel system. 5. Remove the negative jumper cable first from your engine, then the battery in the other vehicle. 1. Battery electrolyte level must be properly maintained and the top of the battery kept clean.
Hydraulic Schematic 48
15 A 15 A F3 F4 PK OR R PK BK P100–A POWER POINT BK R (–) R = RED Y = YELLOW W = WHITE T = TAN FRAME GROUNDS LOW OR GY R/BK BK = BLACK BR = BROWN BU = BLUE OR = ORANGE PK = PINK VIO = VIOLET MAGNETO GN = GREEN GY = GRAY VOLTAGE REGULATOR BK BK GROUND CONNECTION TO FRONT HARNESS IS VIA THE REAR HARNESS (SEE P100–A) ENGINE GROUND NEGATIVE BATTERY CABLE BK BK B+ POSITIVE BATTERY CABLE TIE POINT ON STARTER BATTERY (+) Y S A START RUN I FUSIBLE LINK INSIDE HARNESS AT FUSE
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 Toro Commercial Product (“Product”) to be free from defects in materials or workmanship for two years or 1500 operational hours*, whichever occurs first.
