WORKMAN 3200 AND 4200 - Toro

To understand this product, and for safety and opti-mum performance, read this manual before startingthe engine. Pay special attention to SAFETYINSTRUCTIONS highlighted by this symbol.

It means CAUTION, WARNING or DANGER—personal safety instruction. Failure to comply withthe instruction may result in personal injury.

OPERATORMANUAL

FORM NO. 3318-342 GB Rev A

MODEL NO. 07200—60001 AND UPMODEL NO. 07202—60001 AND UPMODEL NO. 07216—60001 AND UP

WORKMAN 3200 AND 4200 UTILITY VEHICLES

®

© The TORO Company, 1996

The TORO WORKMAN® was developed to providean efficient, versatile, trouble free and economicalwork vehicle. The latest concepts of engineering,design and safety have been incorporated into thismachine, along with the highest quality parts andworkmanship. Excellent service will be derived ifproper operation and maintenance practices are fol-lowed. This vehicle is not designed or manufacturedfor use on roads, streets or highways. It is not appro-priate for such use.

You know, since you have purchased the industryleader in maintenance excellence, that future perfor-mance and dependability are of prime importance.TORO also is concerned about future use of themachine and of safety to the user. Therefore, thismanual must be read by you and those involved withthe WORKMAN® to make sure that safety, propersetup, operation and maintenance procedures are fol-lowed at all times.

Safety, mechanical and some general information inthis manual are emphasized. DANGER, WARNINGand CAUTION identify safety messages. Wheneverthe triangle safety symbol appears, it is followed bya safety message that must be read and understood.For more details concerning safety, read the safetyinstructions on pages 4 and 5. IMPORTANT identi-fies special mechanical information and NOTE iden-tifies general information worthy of special attention.

If help concerning set up, operation, maintenance orsafety is ever needed, contact your local AuthorizedTORO Distributor. In addition to genuine TOROreplacement parts, the distributor also has optionalequipment for the complete line of TORO turf careequipment. Keep your TORO all TORO. Buy gen-uine TORO parts and accessories.Servicing AirCleaner Filter

2

Table of Contents

Foreword

Page

Safety 3

Specifications 11

Before Operating 13

Controls 17

Operating 20

Maintenance 28

The WORKMAN ® 3200 and 4200 were designedand tested to offer safe service when operated andmaintained properly. Although hazard controland accident prevention partially are dependentupon the design and configuration of the machine,these factors are also dependent upon the aware-ness, concern, and proper training of the person-nel involved in the operation, maintenance andstorage of the machine. Improper use or mainte-nance of the machine can result in injury ordeath.

This is a specialized utility vehicle designed foroff-road use. its ride and handling will have a dif-ferent feel than what drivers experience with pas-senger cars or trucks. So take time to becomefamiliar with your WORKMAN ®. Not all of theattachments that adapt to the WORKMAN® arecovered in this manual. See the specificOperator’s Manual provided with the attachmentfor additional safety instructions. READ THESEMANUALS.

TO REDUCE THE POTENTIAL FOR INJURYOR DEATH, COMPLY WITH THE FOLLOW-ING SAFETY INSTRUCTIONS.

SUPERVISOR’S RESPONSIBILITIES

1. Make sure operators are thoroughly trained andfamiliar with the Operator’s Manual and alllabels on the vehicle.

2. Be sure to establish your own special proceduresand work rules for unusual operating conditions(e.g. slopes too steep for vehicle operation). Usethe 3rd High Lockout switch if high speed couldresult in a safety or vehicle abuse situation.

BEFORE OPERATING

3. Operate the machine only after reading andunderstanding the contents of this manual. Areplacement manual is available by sendingcomplete model and serial number to: The ToroCompany, 8111 Lyndale Avenue South,Minneapolis, Minnesota 55420.

4. Never allow children to operate the vehicle.Never allow adults to operate it without proper

instructions. Only trained and authorized personsshould operate this vehicle. Make sure all opera-tors are physically and mentally capable of oper-ating the vehicle. Anyone who operates the vehi-cle should have a motor vehicle license.

5. This vehicle is designed to carry only you, theoperator, and one passenger in the seat providedby the manufacturer. Never carry any other pas-sengers on the vehicle.

6. Never operate the vehicle when under the influ-ence of drugs or alcohol.

7. Become familiar with the controls and knowhow to stop the engine quickly.

8. Keep all shields, safety devices and decals inplace. If a shield, safety device or decal is mal-functioning, illegible, or damaged, repair orreplace it before operating the machine.

9. Always wear substantial shoes. Do not operatemachine while wearing sandals, tennis shoes orsneakers. Do not wear loose fitting clothing orjewelry which could get caught in moving partsand cause personal injury.

10. Wearing safety glasses, safety shoes, long pantsand a helmet is advisable and required by somelocal safety and insurance regulations.

11. Keep everyone, especially children and pets,away from the areas of operation.

12. Before operating the vehicle, always check allparts of the vehicle and any attachments. Ifsomething is wrong, stop using vehicle. Makesure problem is corrected before vehicle orattachment is operated again.

13. Since gasoline is highly flammable, handle itcarefully.

A. Use an approved gasoline container.

B. Do not remove cap from fuel tank whenengine is hot or running.

3

Safety

Safety

C. Do not smoke while handling gasoline.

D. Fill fuel tank outdoors and to about one inchbelow top of tank (bottom of filler neck). Donot 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 interlockswitches in the safety system, whether they areworking properly or not.

WHILE OPERATING

WARNING: Engine exhaust contains carbonmonoxide which is an odorless, deadly poison.Carbon monoxide is also known to the Stateof California to cause birth defects. Do notrun engine indoors or in an enclosed area.

15. Operator and passenger should remain seatedwhenever the vehicle is in motion. Operatorshould keep both hands on steering wheel, when-ever possible and passenger should use the handholds provided. Keep arms and legs within thevehicle body at all times. Never carry passengersin box or on attachments. Remember your pas-senger may not be expecting you to brake or turnand may not be ready.

16. Never overload your vehicle. Name plate (locat-ed under dash on passenger side) shows loadlimits for vehicle. Never overfill attachments orexceed the vehicle maximum GVW.

17. When starting the engine:

A. Sit on operator’s seat and engage the parkingbrake.

B. Disengage PTO (if so equipped) and returnthe hand throttle lever to OFF position (if soequipped).

C. Move shift lever to NEUTRAL and depressclutch pedal.

D. Keep foot off the accelerator pedal.

E. Turn ignition key to START.

18. Using the machine demands attention. Failure tooperate vehicle safely may result in a accident,tip over of vehicle and serious injury or death.Drive carefully. To prevent tipping or loss ofcontrol:

A. Use extreme caution, reduce speed andmaintain a safe distance around sand traps,ditches, creeks, ramps, any unfamiliar areasor other hazards.

B. Watch for holes or other hidden hazards.

C. Use caution when operating vehicle on asteep slope. Normally travel straight up anddown slopes. Reduce speed when makingsharp turns or when turning on hillsides.Avoid turning on hillsides whenever possi-ble.

D. Use extra caution when operating vehicle onwet surfaces, at higher speeds or with a fullload. Stopping time will increase with a fullload. Shift into a lower gear before startingup or down a hill.

E. When loading bed, distribute load evenly.Use extra caution if the load exceeds thedimensions of the vehicle/bed. Operate vehi-cle with extra caution when handling off-center loads that cannot be centered. Keeploads balanced and secure to prevent themfrom shifting.

F. Avoid sudden stops and starts. Do not gofrom reverse to forward or forward toreverse without first coming to a completestop.

G. Do not attempt sharp turns or abrupt maneu-vers or other unsafe driving actions that maycause a loss of vehicle control.

H. When dumping, do not let anyone standbehind vehicle and do not dump load on anyone’s feet. Release tailgate latches from sideof box, not from behind.

4

I. Before backing up, look to the rear andassure no one is behind. Back up slowly.

J. Watch out for traffic when near or crossingroads. Always yield the right of way topedestrians and other vehicles. This vehicleis not designed for use on streets or high-ways. Always signal your turns or stop earlyenough so other persons know what you planto do. Obey all traffic rules and regulations.

K. Never operate vehicle in or near an areawhere there is dust or fumes in the air whichare explosive. The electrical and exhaust sys-tems of the vehicle can produce sparks capa-ble of igniting explosive materials.

L. Always watch out for and avoid low overhangs such as tree limbs, door jambs, overhead walkways, etc. Make sure there isenough room over head to easily clear thevehicle and your head.

M. If ever unsure about safe operation, STOPWORK and ask your supervisor.

19. Do not touch engine, transaxle, radiator, muffleror muffler shield while engine is running or soonafter it has stopped because these areas may behot enough to cause burns.

20. If the machine ever vibrates abnormally, stopimmediately, turn engine off, wait for all motionto stop and inspect for damage. Repair all dam-age 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 tostop.

D. Set the parking brake.

E. Remove key from ignition.

F. Block wheels if machine is on an incline.

MAINTENANCE

22. Before servicing or making adjustments to themachine, stop engine, set the parking brake andremove key from ignition to prevent accidentalstarting of the engine.

23. Never work under a raised bed without placingbed safety support on fully extended cylinderrod.

24. Make sure all hydraulic line connectors are tight,and all hydraulic hoses and lines are in goodcondition before applying pressure to the system.

25. Keep body and hands away from pin hole leaksor nozzles that eject hydraulic fluid under highpressure. Use paper or cardboard, not hands, tosearch for leaks. Hydraulic fluid escaping underpressure can have sufficient force to penetrateskin and do serious damage. If fluid is injectedinto the skin it must be surgically removed with-in a few hours by a doctor familiar with thisform of injury or gangrene may result.

26. Before disconnecting or performing any work onthe hydraulic system, all pressure in system mustbe relieved by stopping engine, cycling dumpvalve from raise to lower and/or lowering boxand attachments. Place the remote hydraulicslever in the float position. If box must be inraised position, secure with safety support.

27. To make sure entire machine is in good condi-tion, keep all nuts, bolts and screws properlytightened.

28. To reduce potential fire hazard, keep the enginearea free of excessive grease, grass, leaves andaccumulation 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 engineand any moving parts. Keep everyone away.

30. Do not overspeed engine by changing governorsettings. Maximum engine speed is 3650 rpm. Toassure safety and accuracy, have an AuthorizedTORO Distributor check maximum engine speed

5

Safety

with a tachometer.

31. If major repairs are ever needed or assistance isrequired, contact an Authorized TORODistributor.

32. To be sure of optimum performance and safety,always purchase genuine

TORO replacement parts and accessories.Replacement parts and accessories made byother manufacturers could be dangerous.Altering this vehicle in any manner may affectthe vehicle’s operation, performance, durabilityor its use may result in injury or death. Such usecould void the product warranty of The TOROCompany.

33. This vehicle should not be modified without theTORO Company’s authorization. Direct anyinquiries to:

Sound & Vibration Levels

Sound Levels

This unit has an equivalent continuous A-weightedsound pressure at the operator ear of: 78 dB(A)based on measurements of identical machines per84/538/EEC.

Vibration Levels

This unit has a vibration level of 2.5 m/s2 at the pos-terior, based on measurements of identical machinesper ISO 2631 procedures.

This unit does not exceed a vibration level of 0.5m/s2 at the posterior based on measurements of iden-tical machines per ISO 2631 procedures.

Safety

6

7

Symbol Glossary

SAFETY ALERT SYMBOL GENERAL HAZARD SAFETY ALERT 

CRUSHING OF WHOLE BODY, APPLIED FROM ABOVE

CRUSHING OF FINGERS OR HAND, FORCE APPLIED FROM SIDE

CUTTING OF FINGERS OR HAND CUTTING OF FOOT

WHOLE BODY ENTANGLEMENT, IMPLEMENT INPUT DRIVE  LINE

THROWN OR FLYING OBJECTS, WHOLE BODY EXPOSURE

READ OPERATOR’S MANUAL LOCK UNLOCK MANUALCAUSTIC LIQUIDS, CHEMICAL BURNS TO FINGERS OR HAND

KEEP CHILDREN A SAFE DISTANCE FROM BATTERY

EXPLOSION FIRE OR OPEN FLAME FIRE, OPEN LIGHT & SMOKING PROHIBITED

EYE PROTECTION MUST BE WORN

CAUTION, TOXIC RISK FIRST AID FLUSH WITH WATER

BATTERY CHARGING CONDITION

DO NOT DISPOSE IN THE GARBAGE

STAY A SAFE DISTANCE FROM MACHINE

CRUSHING OF TOES OR FOOT, FORCE APPLIED FROM ABOVE

FUEL TANK FILL LINE

25mm

ON/START OFF/STOP HEADLIGHTS

STAY A SAFE DISTANCE FROM DRAINING TANK

STAY A SAFE DISTANCE FROM MACHINE STAY A SAFE DISTANCE FROM HYDRAULIC OIL VALVE

SECURE LIFTING CYLINDER WITH LOCKING DEVICE BEFORE GETTING IN HAZARDOUS AREA

DO NOT OPEN OR REMOVE SAFETY SHIELDS WHILE ENGINE IS RUNNING

HAND & ARM ENTANGLEMENT, BELT DRIVE

CRUSHING OF TORSO, FORCE APPLIED FROM THE SIDE

CRUSHING OF FINGERS OR HAND, FORCE APPLIED FROM ABOVE

HIGH PRESSURE SPRAY, EROSION OF FLESH

ENGINE START ENGINE STOP ENGINE LUBRI- CATING OIL

GLOW PLUG ENGINE INTAKE, COMBUSTION AIR

ATTACHMENT RAISE

ATTACHMENT LOWER

ATTACHMENT FLOAT LIMITED RECTI- LINEAR MOTION

BRAKE SYSTEMENGAGE DISENGAGE FAST SLOW CONTINUOUS VARIABLE, LINEAR PARKING BRAKE DIFFERENTIAL LOCK CLUTCH LIFT POINT

HOPPER CLOSED HOPPER OPEN CLOCKWISE ROTATION COUNTER CLOCKWISE ROTATION

PROHIBITED ACTION OR HAZARDOUS LOCATION

VEHICLE BED LOWER VEHICLE BED RAISE

133 bar

PTO HYDRAULIC PRESSURE HYDRAULIC OIL PRESSURE INTAKE AIR

3HTRANSMISSION, 3RD HIGH GEAR

HORN

LTRANSMISSION, LOWTRANSMISSION OIL

< 250 kg

WEIGHT

HTRANSMISSION, HIGH HOUR METER, ELAPSED

OPERATING HOURS

DO NOT WELD DO NOT DRILL

8

Symbols Glossary

THROWN OR FLYING OBJECTS, FACE EXPOSURE

SEVERING OF FINGERS OR HAND, ENGINE FAN

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

MACHINE TIPPING USE CAUTION ON STEEP HILLS MACHINE TIPPING MACHINE TIPPING

DO NOT JUMP FROM TIPPING MACHINE

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

STAY CLEAR OF ARTICULATION AREA WHILE ENGINE IS RUNNING

RUNOVER/BACKOVER, VEHICLE REAR POWER TAKE OFF

(9)GREASE LUBRICATION POINT GREASE LUBRICATION POINT

2. 4.3.1.

< 680 kg< 90 kg

< 1179 kg

635 kg

< 1814 kg

635 kg

MACHINE DIRECTION OF MOVEMENT BEFORE LEAVING OPERATOR POSITION, TURN OFF IGNITION, LOCK PARKING BRAKE, DISENGAGE PTO, REMOVE KEY FROM IGNITION. 

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

LOAD RATING, HOPPER LOAD RATING, TRAILER AND HITCH

LOAD RATING

< 1179 kg

726 kg

< 1905 kgLOAD RATING

< 318 kg

LOAD RATING, HOPPER

FULL BED REMOVAL (Model07202 only)

1. Start the engine. Engage the hydraulic lift leverand lower the bed until the cylinders are loose inthe slots. Release the lift lever and turn off theengine.

2. Remove the Iynch pins from the outer ends ofthe cylinder rod clevis pins (Fig. 1).

Figure 11. Bed mounting plate 4. Lynch pin2. 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 rodends to the bed mounting plates by pushing thepins toward the inside (Fig. 2).

4. Remove the Iynch pins and clevis pins securingthe pivot brackets to the frame channels (Fig. 2).

5. Lift the bed off the vehicle.

CAUTION: The full bed weighs approximately210 pounds, so do not try to install or remove itby yourself. Get the help of two or three otherpeople.

6. Store the cylinders in the storage clips. Engagethe hydraulic lift lock lever on the vehicle to pre-vent accidental extension of the lift cylinders.

RE-INSTALLING THE FULL BED(Model 07202 only)

Note: If bed sides will be installed on the flatbed, it is easier to install them beforeinstalling the bed on the vehicle.

Note: Assure the rear pivot plates are bolted tothe bed frame/channel so that the lowerend angles to the rear (Fig. 2).

Figure 21. Left rear corner of bed2. Vehicle frame channel3. Pivot plate4. Clevis pin5. Lynch pin

Note: Make sure spacer brackets and wearblocks (Fig. 3) are installed or the radia-tor cover may be damaged.

9

Figure 31. Spacer bracket2. Wear block

1. Assure lift cylinders are fully retracted.

CAUTION: The full bed weighs approximately210 pounds, so do not try to install or remove itby yourself. Get the help of two or three otherpeople.

2. Carefully set bed onto vehicle frame aligningrear bed pivot plate holes with holes in rearframe channel and install (2) clevis pins andIynch pins (Fig. 3).

3. With bed lowered, secure each cylinder rod end,to appropriate slots in bed mounting plates withclevis pin and Iynch pin. Insert clevis pin fromoutside of bed with Iynch pin toward outside(Fig. 1). Rear slots are for full bed installationand front slots are for 2/3 bed installation.

Note: Engine may need to be started to extendor retract cylinders for alignment withholes. Keep fingers out!

Note: Unused slot can be plugged with a cap-screw and nut to prevent assemblyerrors.

4. Start engine and engage hydraulic lift lever toraise bed. Release lift lever and turn off engine.Secure raised bed with a hoist or block it to pre-vent it from accidentally falling.

5. Install Iynch pins to inside ends of clevis pins.

Note: If automatic tail gate release has beeninstalled on bed, make sure front dumplink rod has been placed on inside of leftside clevis pin before Iynch pin isinstalled.

6. Once cylinder installation has been completed,the bed safety support can be used to preventaccidental lowering of the bed. Refer to UsingThe Bed Safety Support.

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Type: 4-wheel step-through, out-front operator style,two-person vehicle. Certified to meet ANSISpecifications 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 rpmby a mechanical governor.657 cc (40 cu. in.) dis-placement. Forced lubrication by gear pump. 40-ampalternator with I/C regulator. Spin-on oil filter.

Air Cleaner: Heavy-duty, 2-stage, remote mountedair cleaner.

Battery: 12 volt with 370 cold-cranking Amps @–18° C (0 degrees F.)

Cooling System:Mid-mounted radiator with remov-able screen and lower clean out access. Cooling sys-tem capacity is approximately 3.8 l (4 qts.) of 50/50mixture of ethylene glycol anti-freeze.

Fuel System: Fuel tank capacity is 26.5 l (7 gal-lons). 12-volt, electric fuel pump.

Transmission: Rear transaxle configuration, twinaxle drive. 3-speed synchromesh, H-shift patternwith high-low range providing 6 forward and 2reverse speeds. Manual engage differential lock. 4-Wheel 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 1ratio.

Center Differential: (4-Wheel drive only) Bi-direc-tional overrunning clutch.

Frame: Welded, high-strength steel channels andtubes.

Front Suspension:Independent “A” frame controlarm, dual coil springs and dual shock absorbers withanti-sway bar.

Rear Suspension:DeDion axle (weight carryingaxle is independent of transaxle), leaf spring anddual shock absorbers.

Steering System:Power assist, 3-position tilt steer-ing wheel, 3-3/4 turns lock-to-lock. 17.5 to 1 ratio,35.5 cm (14 inch) diameter steering wheel.

Tires:

Front tires: 50.8 x 25.4 cm (20” x 10”)-10, 4-ply rat-ing, 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 self-adjusting drum: 17.8 (7”) diameter front, 20.3 (8”)diameter rear. Hand-actuated parking brake actuatesrear brake shoes.

Roll Over Protection System: 2-post roll over pro-tection structure with shoulder restraint.

Hydraulics: 4 gpm pressure balanced gear pumpprovides hydraulic flow for power steering, lift andoptional remote hydraulics. Lift control valve anddual cylinders for lifting dump box. Transaxle isused for reservoir for hydraulic system. 7.6 l (8quart) total capacity. Spin-on 25-micron hydraulic oilfilter. 100 mesh strainer in transaxle.

Seat: Twin molded cushions and backrests, withshoulder and hip restraints.

Controls: Foot-operated accelerator, clutch andbrake pedals. Hand-operated shifter, differential lock,parking brake, high–low range shifter, hydraulic liftand 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 tempera-ture gauge. Warning light cluster includes engine lowoil pressure, charge indicator and on diesel modelsonly, a glow plug indicator. Tachometer optional.

Lights: Twin halogen headlights and single taillight.Rear stop light.

Interlocks: Clutch pedal must be depressed to startengine. PTO must be disengaged (if so equipped) tostart 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 (4,000lbs.) 2-wheel drive

1,568 kg (4,200 lbs.) 4 wheel drive

Tow CapacityTongue 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 OverProtection 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 with-out notice.

Specifications

12

CHECK THE CRANKCASE OIL

The engine is shipped with oil in the crankcase; how-ever, the level of oil must be checked before andafter the engine is first started.

1. Position the machine on a level surface.

2. Remove the dipstick and wipe it with a cleancloth Insert the dipstick into the tube and makesure it is seated fully. Remove the dipstick andcheck the level of oil . If the oil level is low,remove the filler cap and add enough oil to raisethe level to the FULL mark on the dipstick.

3. Gasoline engines use any high-quality detergentoil having the American Petroleum Institute—API—“service classification” SG or SG/CD.Seethe viscosity chart for recommended weightto use.

4. Pour oil into the fill opening until the oil level isup to the “FULL” mark on the dipstick. Add theoil slowly and check the level often during this

process. DO NOT OVERFILL.

IMPORTANT: Check the level of oil every 8operating hours or daily. Change the oil andfilter initially after the first 50 hours of opera-tion, thereafter, change the oil and filter every100 hours. However, change the oil more fre-quently when the engine is operated inextremely dusty or dirty conditions.

5. Install the dipstick firmly in place.

FILL THE FUEL TANK

Fuel tank capacity is approximately 32 l.

THE TORO COMPANY STRONGLY RECOM-MENDS THE USE OF FRESH, CLEAN,UNLEADED REGULAR GRADE GASOLINE INTORO GASOLINE POWERED PRODUCTS.UNLEADED GASOLINE BURNS CLEANER,EXTENDS ENGINE LIFE, AND PROMOTESGOOD STARTING BY REDUCING THE BUILD-UP OF COMBUSTION CHAMBER DEPOSITS.LEADED GASOLINE CAN BE USED IFUNLEADED IS NOT AVAILABLE. MINIMUMOCTANE RATING OF 87.

NOTE: NEVER USE METHANOL, GASOLINECONTAINING METHANOL, GASOLINECONTAINING MORE THAN 10%ETHANOL, GASOLINE ADDITIVES, ORWHITE GAS BECAUSE ENGINE FUEL

13

Figure 41. Dipstick 2. Filler cap

➁

➀

Before servicing or making adjustments to themachine, stop the engine, set the parking brake andthe remove key from the switch. Any load materialmust be removed from the bed or other attachmentbefore working under the raised bed. Always rotatethe safety support to the down position before work-ing under the raised bed.

CAUTION

Before Operating

Anticipated atmospherictemperature range

SAE viscosity No.

* SAE 5W-20 Not recommended for sustained high-speed vehi-cle operation.

C° F°

49

38

27

16

0

–12

–23

–29

120

100

80

60

32

10

–10

–20

20w2020w4020w50

10w5010w4010w30

*5w205w305w40

SYSTEM DAMAGE COULD RESULT.

1. Clean the area around the fuel tank cap.

Figure 51. Fuel tank cap

2. Remove the fuel tank cap.

3. Fill the tank to about one inch below top of thetank, (bottom of the filler neck). DO NOTOVERFILL. Then install the cap.

4. Wipe up any fuel that may have spilled to pre-vent a fire hazard.

CHECK THE COOLING SYSTEM

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

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

1. Park the machine on a level surface.

2. Check coolant level. Coolant should be up to theCOLD line on the reserve tank when the engineis cold.

Figure 61. Reserve tank2. Cold line3. Hot line

3. If coolant is low, remove the reserve tank capand add a 50/50 mixture of water and permanentethylene glycol anti-freeze. DO NOT OVER-FILL.

Before Operating

14

Because fuel is flammable, caution must be usedwhen storing or handling it. Do not fill the fueltank while the engine is running, hot or when themachine is in an enclosed area. Vapors maybuild up and be ignited by a spark or flamesource many feet away. DO NOT SMOKE whilefilling the fuel tank to prevent the possibility ofan explosion. Always fill the fuel tank outsideand wipe up any spilled fuel before starting theengine. Use a funnel or spout to prevent spilling,and fill the tank no higher than 2.5 cm (one inch)below top of the tank, (bottom of the filler neck).DO NOT OVER FILL.

Store fuel in a clean safety approved containerand keep the cap on the container. Keep fuel in acool, well-ventilated place; never in an enclosedarea such as a hot storage shed. To assurevolatility, do not buy more than a 30-day supplyof gasoline, or a 6-month supply of diesel fuel.

Since many children like the smell of gasoline,keep it out of their reach because the fumes areexplosive and dangerous to inhale.

DANGER

If the engine has been running, pressurized hotcoolant can escape if radiator cap is removed andcause burns. Allow the engine to cool at least 15minutes or until the radiator cap is cool enough totouch without burning hand.

CAUTION

➀

➁

➂

➀

4. Install the reserve tank cap.

CHECK THE TRANSAXLE /HYDRAULIC FLUID

The transaxle reservoir is filled with Dexron II ATF.Check the level before the engine is first started andevery 8 hours or daily, thereafter. Capacity of thesystem is 7.1 l (7.5 qt).

1. Position the vehicle on a level surface.

2. Clean the area around the dipstick.

3. Unscrew the dipstick from the top of thetransaxle and wipe it with a clean cloth.

Figure 71. Dipstick

4. Screw the dipstick into the transaxle and makesure it is seated fully. Unscrew the dipstick andcheck fluid level. Fluid should be up to the top offlat portion of the dipstick. If the level is low,add enough fluid to achieve the proper level.

CHECK FRONT DIFFERENTIALOIL

Four-Wheel Drive Model Only

The differential is filled with 10W30 oil. Check thelevel of oil every 100 hours or monthly. Capacity ofthe system is 0.95 l.

Figure 81. Front differential2. Fill plug3. Drain plug

1. Position the vehicle on a level surface.

2. Clean the area around the fill plug on the side ofthe differential

3. Remove the fill plug and check the level of oil.Oil should be up to the hole. If it is low, add10W30 oil.

4. Install the fill plug.

CHECK WHEEL NUT TORQUE

CHECK BRAKE FLUID

The brake fluid reservoir is shipped from the factoryfilled with brake fluid. Check the level before theengine is first started and every 8 hours or daily,thereafter.

1. Park the machine on a level surface.

2. Fluid level should be up to the FULL line onreservoir.

15

Before Operating

➀

Failure to maintain proper torque could result infailure or loss of wheel and may result in personalinjury. Torque front and rear wheel nuts to 61–88Nm after 1–4 hours of operation and again after 10hours of operation and every 200 hours thereafter.

WARNING

3. If the fluid level is low, clean the area aroundcap, remove the reservoir cap and fill to properlevel. DO NOT OVERFILL.

Figure 91. Brake fluid reservoir2. Full line

CHECK TIRE PRESSURE

Check tire pressure every 8 hours or daily.

Maximum air pressure in the front tires is 1,4 kg/cm2

and 1,3 kg/cm3 in the rear (24”) tires tires. Optionalrear (23”) tire pressure is 2,3 kg/cm2 maximum.

1. The air pressure needed is determined by thepayload carried.

2. The lower the air pressure, the less the com-paction and tire marks are minimized. Lowerpressure should not be used for heavy payloadsat high speeds. Tire damage may result.

3. Higher pressures should be used for heavier pay-loads at higher speeds.

Do not exceed the maximum pressure. Use the fol-lowing charts to determine correct tire pressures fortire size and payload of vehicle.

Before Operating

16

373

411

448

485

523

560

597

373411448485523560635672709784821858896933970

635

672

709

784

821

858

896

933

970

635

6955 9783 110 124 138152

6955 9783 110 124 138

165179193207 221

6955 9783 110 124 138 152

Tire pressure (Nm)

20” FRONT TIRES

Max

imum

Tot

al F

ront

Axl

e W

eigh

t (kg

)M

axim

um T

otal

Rea

r A

xle

Wei

ght (

kg)

Max

imum

Tot

al R

ear

Axl

e W

eigh

t (kg

) 24” EXTRA WIDE REAR TIRES

23” REAR TIRES

TIRE PRESSURE (Nm)

TIRE PRESSURE (Nm)

Accelerator Pedal(Fig. 10)—Used to vary engineand ground speed when the transmission is in gear.Depressing the pedal increases engine RPM andground speed. Releasing it will decrease engineRPM and ground speed.

Figure 101. Accelerator pedal2. Clutch pedal3. Brake pedal

Clutch Pedal (Fig. 10)—The clutch pedal must befully depressed to disengage the clutch when startingthe engine or shifting transmission gears. Releasethe pedal smoothly when the transmission is in gearto prevent unnecessary wear on the transmission andother related parts.

IMPORTANT: Do not ride the clutch pedal dur-ing operation. The clutch pedal must be fully outor the clutch will slip causing friction and wear.Never hold the vehicle stopped on a hill using theclutch pedal. Damage to the clutch may occur.

Brake Pedal(Fig. 10)—The brake pedal is used toapply service brakes to stop or slow vehicle.

Gear Shift Lever (Fig. 11)—Fully depress theclutch pedal and move shift lever into desired gearselection. A diagram of the shift pattern is indicatedbelow.

Shift Pattern

IMPOR-TANT: Do

not shift the transaxle to the reverse or forwardgear unless the vehicle is standing still. Damageto the transaxle may occur.

Differential Lock (Fig. 11)—Allows rear axle to belocked for increased traction. Differential lock maybe engaged with vehicle in motion. Move the leverforward and to the right to engage the lock.

Note: Vehicle motion plus a slight turn is requiredto engage or disengage the differential lock.

17

Controls

Down shifting from too high a speed can cause therear wheels to skid and can result in loss of vehiclecontrol. Shift smoothly to avoid grinding gears..

CAUTION

Turning with the differential lock on can result inloss of vehicle control. Do not operate with differ-ential lock on when making sharp turns or at highspeeds.

WARNING

Worn or misadjusted brakes may result in personalinjury. If the brake pedal travels to within 2.5 cm ofthe vehicle floor board, the brakes must be adjustedor repaired.

CAUTION

➀

➁ ➂

R 2

31

Controls

18

Figure 111. Gear shift lever2. Differential lock3. Parking brake4. High-low range shifter5. Hydraulic lift6. Hydraulic lift lock7. Passenger hand hold8. PTO lever (optional)

Parking Brake (Fig. 11)—Whenever the engine isshut off, the parking brake must be engaged to pre-vent accidental movement of the vehicle. To engagethe parking brake, pull back on the lever. To disen-gage, push lever forward. Make sure the parkingbrake is released before moving the vehicle. If thevehicle is parked on a steep grade, make sure theparking brake is applied. Also, shift the transmis-sion into 1st gear on an uphill grade or into reverseon a down hill grade. Place chocks at the down hillside of wheels.

Hydraulic Lift (Fig. 11)—Raises and lowers bed.Move rearward to raise, forward to lower.

IMPORTANT: When lowering the bed, hold thelever in the forward position for 1 or 2 secondsafter the bed contacts the frame to secure it in thelowered position. Do not hold the hydraulic liftin either the raise or lower position for more than5 seconds after the cylinders have reached theend of their travel. The hydraulic pump mayoverheat, resulting in pump damage.

Hydraulic Lift Lock (Fig. 11)—Locks the lift leverso the hydraulic cylinders do not operate when vehi-cle is not equipped with a bed.

Passenger Hand Hold(Fig. 11)—On the left side ofthe passenger seat.

High-Low Range Shifter (Fig. 11)—Adds three

additional speeds for precise speed control.

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.

D. Move the lever fully forward for High and fullyrearward for Low.

HIGH is for higher speed driving on level, dry sur-faces with light loads. LOW is for low-speed dri-ving. Use this range when greater than normalpower or control is required. For example, steepgrades, difficult terrain, heavy loads, slow speed buthigh engine speed (spraying).

NOTE: There is a location between HIGH andLOW in which the transaxle is in neither range. Thisshould not be used as a neutral position because thevehicle could move unexpectedly if the HIGH-LOWshifter is bumped and the gear shift lever is in gear.

Tilt Steering Lever (Fig. 12)—Lever on right sideof the console lets you adjust the steering wheel foryour comfort.

Figure 121. Tilt steering lever2. Ignition switch3. Horn button 4. Coolant temp. gauge5. Engine low oil pressure light6. Charge indicator

Horn Button (Fig. 12)—Pressing this button acti-vates the horn.

➀

➃

➄

➅

➁➂

16

5

3

8

7

2

4

19

Controls

Coolant Temperature Gauge(Fig. 12)—Registerscoolant temperature in the engine. Operates onlywhen the ignition switch is in the On position.

Engine Low Oil Pressure Light(Fig. 12)—Thislight glows if engine oil pressure drops below a safelevel while the engine is running. If the light flickersor remains ON, stop the vehicle, turn off the engineand check the oil level. If the oil level was low, butadding oil does not cause light to go out when theengine is restarted, turn the engine off immediatelyand contact your local TORO distributor for assis-tance.

IMPORTANT: Do not operate the vehicle untilrepair is complete. Failure to observe this precau-tion may result in damage to the engine.

Ignition Switch (Fig. 12)—The ignition switch, usedto start and stop the engine, has three positions: OFF,RUN and START. Turn the key clockwise—STARTposition—to engage the starter motor. Release thekey when the engine starts. The key will move auto-matically to the ON position. To shut the engine off,turn the key counterclockwise to OFF.

Charge Indicator (Fig. 12)—Illuminates when thebattery is being discharged. If light illuminates dur-ing operation, stop the vehicle, turn Off the engineand check for possible causes, such as the alternatorbelt.

IMPORTANT: If the alternator belt is loose orbroken, do not operate the vehicle until adjust-ment or repair is complete. Failure to observe thisprecaution may result in damage to the engine.

To check warning light operation:

1. Apply the parking brake.

2. Turn the ignition key to “ON”, but do not startthe engine. The charge indicator and oil pressurelights should glow. If any light does not func-tion, either a bulb is burned out or there is a mal-function in the system which must be repaired.

Note: For gasoline models, two functions ofthe warning light cluster are not used:glow plug and high water temperature.

Hour Meter (Fig. 13)—Indicates the total hours ofmachine operation. The hour meter starts to functionwhenever the key switch is turned to the “ON” posi-tion.

Light Switch (Fig. 13)—Toggle this switch to acti-vate the headlights. Push to turn lights “ON”.

Fuel Gauge(Fig. 13)—Shows the amount of fuel inthe tank. Operates only when the ignition switch isin the “ON” position.

3rd High Lockout Switch (Fig. 13)—Moving thisswitch to the slow position and removing the keywill prevent use of third gear when in the Highrange. The engine will shut off if the shift lever ismoved to third gear when in the High range. Installthe key with its teeth pointing downward. Push thekey in to turn it. The key is removable in either posi-tion.

Figure 131. Light switch2. Hour meter3. Fuel gauge4. 3rd High lockout switch 5. Steering wheel

Steering Wheel(Fig. 13)—Turns the vehicle. If theengine stalls or the power assist fails, vehicle steer-ing will require greater effort.

Tachometer (optional-not shown)—Indicates engineRPM. Gear selection graphics indicate speed.

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

➀➃

➄

➁ ➂

PRE-STARTING CHECKS

Safe operation begins before taking the vehicle outfor a day’s work. You should check these items eachtime:

1. Check tire pressure.

Note: These tires are different than car tires,they require less pressure to minimizeturf compaction and damage.

2. Check all fluid levels and add the appropriateamount of Toro-specified fluids, if any are foundto be low.

3. Check brake pedal operation.

4. Check to see that the lights and horn are work-ing.

5. Turn the steering wheel to the left and right tocheck steering response.

6. Check for oil leaks, loose parts and any othernoticeable malfunctions. Make sure engine is offand all moving parts have stopped before check-ing for oil leaks, loose parts and other malfunc-tions.

If any of the above items are not correct, notify yourmechanic or check with your supervisor before tak-ing the vehicle out for the day. Your supervisor maywant you to check other items on a daily basis, soask what your responsibilities are.

STARTING THE ENGINE

1. Sit on the seat and engage the parking brake.

2. Disengage the PTO Power Take Off (if soequipped) and return the hand throttle lever tothe OFF position (if so equipped).

3. Move the shift lever to NEUTRAL and depressthe clutch pedal.

4. Keep your foot off the accelerator pedal.

A. In extremely cold weather (below 18° C)—fully depress and release the acceleratorpedal several times before trying to start theengine.

B. If the engine is hot—depress and hold theaccelerator pedal about half way down whilecranking the engine.

C. If the engine is flooded—fully depress theaccelerator pedal and hold it to the floor untilthe engine starts. Never pump the accelera-tor pedal.

5. Insert the key into the ignition switch and turn itclockwise to start the engine. Release the keywhen the engine starts.

IMPORTANT: To prevent overheating thestarter motor, do not engage the starter longerthan 15 seconds. After 15 seconds of continu-ous cranking, wait 60 seconds before engagingthe starter motor again.

DRIVING THE VEHICLE

1. Release the parking brake.

2. Fully depress the clutch pedal.

3. Move the gear shift lever to 1st gear.

4. Release the clutch pedal smoothly while depress-ing the accelerator pedal.

5. When the vehicle gains enough speed, removeyour foot from the accelerator pedal, fullydepress the clutch pedal, move gear shift lever tothe next gear and release the clutch pedal whiledepressing the accelerator pedal. Repeat thisprocedure until desired speed is attained. Stopthe vehicle before shifting to reverse and for-ward.

Note: Avoid long periods of engine idling.

Note: Leaving the ignition switch in the “ON”position for long periods of time withoutrunning the engine will discharge the

20

Operating

21

Operating

battery.

IMPORTANT: Do not keep the front wheelsturned against the right or left stops forlonger than 5 seconds. The hydraulic pumpmay over heat, resulting in pump or steeringgear damage.

6. Do not push or tow the vehicle to get it started.Damage to the drive train could result.

STOPPING THE VEHICLE

To stop the machine, remove your foot from theaccelerator pedal, depress the clutch pedal, thendepress the brake pedal.

STOPPING THE ENGINE

To stop the engine, turn the ignition key to OFF andengage the parking brake. Remove the key from theswitch to prevent accidental starting.

NEW VEHICLE BREAK-IN

Your Workman® is ready for work. To provide topperformance and long vehicle life, follow theseguidelines for the first 100 operating hours.

• Check the fluid and engine oil levels regularlyand be alert for indications of overheating in anypart of the vehicle.

• After starting a cold engine, let it warm up forabout 15 seconds before shifting into gear.

• Avoid racing the engine.

• Avoid situations requiring hard stops, especiallywhen hauling heavy loads or pulling a trailer. Itis necessary to fully break-in a new set of brakelinings to achieve full braking performance.Follow this guideline whenever new linings areinstalled.

• Vary vehicle speeds during operation. Avoidexcessive idling. Avoid fast starts and quickstops.

• A break-in oil for the engine is not required. Theoriginal engine oil is the same type specified forregular oil changes.

• Refer to Maintenance section for any special lowhour checks.

CHECKING THE INTERLOCKSYSTEM

The interlock system prevents the engine fromcranking or starting unless the clutch pedal isdepressed or PTO (if so equipped) is disengaged.

To verify the clutch interlock switch operation:

1. Sit on the seat and engage the parking brake.Move the shift lever to the NEUTRAL position.Disengage the PTO (if so equipped).

2. Without depressing the clutch pedal, turn the keyclockwise to the START position.

3. If the engine cranks or starts, there is a malfunc-tion in the interlock system that must be repairedbefore operating the vehicle.

The interlock switches are for the operator’sprotection, so do not bypass them. Check oper-ation of the switches daily to assure the systemis operating. If a switch is malfunctioningreplace it before operating. Regardless ofwhether switches are operating properly,replace them every two years to assure maxi-mum safety. Also, do not rely entirely on safe-ty switches—use common sense!

CAUTION

OPERATING CHARACTERISTICS

The vehicle is designed with safety in mind. It hasfour wheels for added stability. It uses familiar auto-motive style controls, including the steering wheel,brake pedal, clutch pedal, accelerator pedal, and gearshifter. It is important to remember, however, thatthis vehicle is not a passenger car. It is a work vehi-cle and not designed for use on roadways.

The vehicle has special tires, low-gear ratios, a lock-ing differential, and other features that give it extratraction. These features add to the versatility of thevehicle but they can also get you into dangerous situ-ations. You must remember that the vehicle is not arecreation vehicle or an all-terrain vehicle. And it isdefinitely not meant for “stunt driving”. It is a workvehicle, not a play vehicle. Do not allow childrenshould to operate the vehicle. Anyone who operatesthe 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 otherpeople. Be sure you are familiar with all the vehicle’scontrols, particularly those used for braking, steeringand transmission shifting. Learn how your vehiclehandles on different surfaces. Your operating skillswill improve with experience, but as in operating anyvehicle, take it easy as you begin. Be sure you knowhow to stop quickly in an emergency. If you needhelp, ask your supervisor for assistance.

Many factors contribute to accidents. You have con-trol over several of the most important. Your actions,such as driving too fast for conditions, braking toofast, turning too sharp, and combinations of these,are frequent causes of accidents.

One of the major causes of accidents is fatigue. Besure to take occasional breaks. It is important thatyou stay alert at all times.

Never operate the vehicle, or any equipment, if youare under the influence of alcohol or other drugs.Even prescription drugs and cold medicines cancause drowsiness. Read the label on the medicine orcheck with your doctor or pharmacist if you areunsure about a certain medication.

One of the most important rules to follow is to goslower in unfamiliar areas. It is surprising how muchdamage and injury common things can cause. Treebranches, fences, wires, other vehicles, tree stumps,ditches, sand traps, streams, and other things foundin most parks and golf courses can be hazardous tothe operator and passenger.

Avoid driving when it is dark, especially in unfamil-iar areas. If you must drive when it is dark, be sureto drive cautiously, use the head lights, and even con-sider adding additional lights.

PASSENGERS

Whenever you have a passenger riding in the vehiclemake sure he or she is holding on securely. Driveslower and turn less sharply because your passengerdoes not know what you intend to do next and maynot be prepared for turning, stopping, accelerating,and bumps.

You and your passenger should remain seated at alltimes, keeping arms and legs inside the vehicle. Theoperator should keep both hands on steering wheel,whenever possible and passenger should use thehand holds provided.

There should never be passengers in the dump box oron any attachments. The vehicle is meant to have onedriver and only one passenger-no more.

SPEED

Speed is one of the most important variables leadingto accidents. Driving too fast for the conditions cancause 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 causeinjury and damage, but, driving into a tree at highspeed can destroy the vehicle and kill you and yourpassenger.

Never drive too fast for the conditions. If there isany doubt about how fast to drive, slow down.

When using heavy attachments (more than 500 kg),

22

Operating

23

Operating

such as sprayers, top dressers, or spreaders, etc.,operating speeds should be restricted by moving 3rdhigh lockout switch to slow position.

TURNING

Turning is another important variable leading to acci-dents. Turning too sharply for the conditions cancause the vehicle to lose traction and skid, or eventip over.

Wet, sandy and slippery surfaces make turning moredifficult and risky. The faster you are going, theworse this situation becomes so, slow down beforeturning.

During a sharp turn at higher speeds, the inside rearwheel may lift off of the ground. This is not a flawin the design, it happens with most four wheel vehi-cles including passenger cars. If this happens, youare turning too sharply for the speed at which you aretraveling. Slow down!

BRAKING

It is good practice to slow down before you get nearan obstacle. This gives you extra time to stop or turnaway. Hitting an obstacle can damage the vehicleand its contents. More important, it can injure youand your passenger.

Gross vehicle weight has a major impact on yourability to stop and/or turn. Heavier loads and heavierattachments 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 bedor attachment on the vehicle. Fast stops may causethe rear wheels to lock up before the front wheelslock up, which may affect the control of the vehicle.It is a good idea to decrease vehicle speed with nobed or attachment.

Turf and pavement are much slipperier when they arewet. It can take 2 to 4 times as long to stop on wetsurfaces as on dry surfaces.

If you drive through standing water deep enough to

get the brakes wet, they will not work well until theyare dry. After driving through water, you should testthe brakes to make sure they work properly. If theydo not, drive slowly in first gear while putting lightpressure on the brake pedal. This will dry thebrakes.

Do not downshift for braking on icy or slippery sur-faces (wet grass) or while going down a hill becauseengine braking may cause skidding and loss of con-trol. Shift to a lower gear before starting down a hill.

TIPOVERS

The TORO WORKMAN® is equipped with a rollbar, hip restraints, shoulder restraints and hand hold.The Roll Over Protection System used on the vehiclewill reduce the risk of serious or fatal injury in theunlikely event of a tipover, although the system can-not protect the operator from all possible injuries.

Replace a damaged Roll Over Protection System; donot repair or revise. Any alteration of Roll OverProtection System must be approved by manufactur-er.

The best way to prevent accidents involving utilityvehicles is through continuous supervision and train-ing of operators and paying constant attention to thearea in which vehicle is being operated.

The best way for operators to prevent serious injuryor death to themselves or others, is to familiarizethemselves with the proper operation of the utilityvehicle, to stay alert and to avoid actions or condi-tions which could result in a accident. In the event ofa tip over, the risk of serious injury or death will bereduced if the operator is using the Roll-OverProtection System and follows the instructions pro-vided.

HILLS

Use extra care when on hills. Never go on hills thatare extremely steep. Stopping while going down ahill will take longer than on level ground. Turningwhile going up or down a hill is more dangerousthan turning on the level. Turns while going downhill, especially with the brakes on, and, turning uphill while traversing a hill are particularly dangerous.Even at a slow speed and without a load, tip oversare more likely if you turn on a hill.

Slow down and shift into a lower gear before startingup or down a hill. If you have to turn while on a hill,do it as slowly and cautiously as possible. Never

24

Operating

Tipping or rolling the vehicle on a hill will causeserious personal injury.

• If the engine stalls or you lose headway on ahill, never attempt to turn the vehicle around.

• Always back straight down a hill in reversegear.

• Never back down in neutral or with the clutchdepressed, using only the brakes.

• Never drive across a steep hill, always drivestraight 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

In case of tipover

Don’t jump

Lean away

Operator: Hold tight and brace feet.

Passenger: Hold hip restraint andhand hold, brace feet

Tipover can occur if the truck is improp-erly operated. Injury or death couldresult.

make sharp or fast turns on a hill.

If you stall or begin to lose headway while climbinga 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 con-trolling the vehicle on the hill and help you backdown the hill more safely.

Reduce the weight of the load if it is a steep hill or ifthe load has high center of gravity. Remember, loadscan shift. Secure them.

Note: The Workmen have excellent hill climbingability. The differential lock will increasethis ability. Hill climbing traction can alsobe increased by adding weight to the rear ofthe vehicle in one of the following ways:

• Adding weight to inside of box, makingsure it is secured.

• Mounting wheel weights to rear wheels.

• Adding liquid ballast (calcium chloride)to rear tires.

• Traction will increase with no passengerin front seat.

LOADING AND DUMPING

The weight and position of the cargo and passengercan change the vehicle center of gravity and vehiclehandling. To avoid loss of control resulting in per-sonal injury, follow these guidelines.

Do not carry loads which exceed the load limitsdescribed on the vehicle weight label.

The vehicle has several combinations of boxes, plat-forms, and attachments available. These can be usedin various combinations that allow for maximumcapacity and versatility. The full-sized box is 1.4mwide by 1.64 m long and can hold up to 900 kg ofevenly distributed cargo.

Loads vary in how they are distributed. Sandspreads out evenly and quite low. Other items, suchas bricks, fertilizer or landscape timbers, stack higherin the box.

The height and weight of the load has a significantinfluence on tip overs. The higher a load is stacked,the more likely the vehicle is to tip over. You mayfind that 900 kg stacks too high for safe operation.Reducing the total weight is one way to reduce therisk of a tip over. Distributing the load as low aspossible is another way to reduce the risk of a tipover.

If the load is positioned toward one of the sides, itwill make the vehicle much more likely to tip overon that side. This is especially true when turning ifthe load is on the outside of the turn.

Never position heavy loads behind the rear axle. Ifthe load is positioned so far to the rear that it isbehind the rear axle, it will reduce the weight on thefront wheels and this will reduce steering traction.With the load all the way to the back, the frontwheels can even come off of the ground when goingover bumps or up a hill. This will result in a loss ofsteering and may lead to the vehicle tipping over.

As a general rule, position the weight of the loadevenly from front to rear and evenly from side toside.

If a load is not secured, or you are transporting a liq-uid in a large container such as a sprayer, it can shift.

25

Operating

When lowering the box it is possible for you orothers to get their hands or other body parts in thewrong spot and have them crushed. Take extra carethat no one will get hurt. Also, do not dump onanyone’s feet. It may seem funny but, it can bedangerous.

WARNING

The bed will lower whenever the dump lever ispushed down, even when the engine is off. Turningoff the engine will NOT prevent the box from low-ering. Always place the safety support on extendedlift cylinder to hold box up if you are not going tolower it right away.

WARNING

This shifting happens most often while turning,going up or down hills, suddenly changing speeds orwhile driving over rough surfaces. Shifting loadscan lead to tip overs. Always secure loads so thatthey do not shift. Never dump the load while thevehicle is sideways on the hill.

Heavy loads increase stopping distance and reduceyour ability to turn quickly without tipping over.

The rear cargo space is intended for load carryingpurposes only, not for passengers.

USING THE DIFFERENTIALLOCK

The differential lock increases the vehicle’s tractionby locking the rear wheels so one wheel will not spinout. This can help when you have heavy loads tohaul on wet turf or slippery areas, going up hills andon sandy surfaces.

It is important to remember however, that this extratraction is only for temporary limited use. Its usedoes not replace the safe operation, already discussedconcerning steep hills and heavy loads.

The differential lock causes the rear wheels to spin atthe same speed. When using differential lock your

ability to make sharp turns is somewhat restrictedand may scuff the turf. Use the differential lock onlywhen needed, at slower speeds and only in first orsecond gear.

FOUR-WHEEL DRIVE

Four Wheel Drive Model Only

The “Automatic On Demand” four-wheel drive fea-ture on this vehicle does not require operator activa-tion. The front-wheel drive is not engaged (nopower delivered to the front wheels) until the rearwheels begin to lose traction. When the clutch sens-es the rear wheels slipping, it delivers power to thefront wheels until the rear wheels have enough trac-tion to move the vehicle without slipping. Once thisoccurs, the system reverts to 2-wheel drive. Thisoccurs in both forward and reverse. However, whenturning, the rear wheels will slip slightly more beforepower is delivered to the front wheels.

TRANSPORTING THE VEHICLE

For moving the vehicle long distances, a trailershould be used. Make sure the vehicle is secured tothe trailer.

TOWING THE VEHICLE

In case of emergency, the vehicle can be towed for ashort distance. However, Toro does not recommendthis as a standard procedure.

Towing the vehicle is a two-person job. Affix a towline to the holes in the front frame member. Movethe shifter to Neutral and release the parking brake.If the machine must be moved a considerable dis-tance, transport it on a truck or trailer.

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

26

Towing at excessive speeds could cause the vehicleto lose steering control. Never tow the vehiclefaster than 8 km/h.

WARNING

Operating

Tipping or rolling the vehicle on a hill will causeserious injury.

• The extra traction available with the differen-tial lock can be enough to get you into danger-ous situations such as climbing slopes that aretoo steep to turn around. Be extra careful whenoperating with the differential lock on, espe-cially on steeper slopes.

• If the differential lock is on when making asharp turn at a higher speed and inside rearwheel lifts off the ground, there may be a lossof control which could cause the vehicle toskid (Refer to Differential Lock Operation).Use the differential lock only at slower speeds.

WARNING

Figure 141. Eye holes in frame

Figure 151. Axle tube2. Hitch plate location (optional)

TRAILER TOWING

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

Several types of tow hitches are available for theWorkman, depending on your application. Contactyour Authorized TORO Distributor for details.

When equipped with a tow hitch bolted onto rearaxle tube, your Workman can tow trailers or attach-ments with a Gross Trailer Weight (GTW) up to 680kg. Always load a trailer with 60% of the cargoweight in the front of the trailer. This places approx-imately 10% (90 kg max.) of the Gross TrailerWeight (GTW) on the tow hitch of the vehicle.

When towing either standard tongue or 5th wheeltrailers having a Gross Trailer Weight (GTW) inexcess of 900 kg, use either a chassis mounted drawbar hitch (rated for 1590 kg. GTW) or the 5th wheelkit with the brakes. Trailer brakes are requiredwhenever a trailer over 900 kg. GTW is towedbehind a Workman vehicle.

When hauling cargo or towing a trailer (attachment),do not overload your vehicle or trailer. Overloadingcan cause poor performance or damage to the brakes,axle, engine, transaxle, steering, suspension, bodystructure or tires.

Important: To reduce potential for drive linedamage, use low range.

When towing 5th wheel attachments, like a fairwayaerator, always install the bar included with the 5thwheel kit to prevent the front wheels from lifting offthe ground if the towed attachments movement issuddenly impaired.

27

Operating

➀

➀➁

Daily Maintenance Procedures

Check the following items daily

• 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 (dust cup & baffle)

• Unusual engine noises

• Tire pressure

• Radiator screen/cleanout door

• Hydraulic hoses for damage

• Fluid leaks

• Instrument operation

• Lubricate all grease fittings (also immediately after every washing

• Touch-up damaged paint

28

Maintenance

29

Maintenance

Maintenance Procedure Maintenance Interval& Service

✝ Initial break in at 10 hours‡ Initial break in at 50 hours

✝Replace the transaxle filterChange the transaxle oilClean the transaxle strainerPack front wheel bearings (2-wheel drive)Change the front differential oil (4-wheel drive)Adjust valvesReplace spark plugs and check timing

Maintenance Schedule

Replace all interlock switchesFlush the cooling the cooling system and replace fluidChange the brake fluidRep;lace the timing belt

Check front wheel alignmentInspect service and parking brakesInspect fuel linesReplace fuel filter

✝Check cable adjustments✝Check alternator and fan beltsService the air filterCheck front axle boot joint (4-wheel drive)Check engine RPM (idle and full throttle)✝Torque the wheel lug nuts

Lubricate all grease fittingsInspect the condition and wear of the tiresCheck front differential oil level (4-wheel drive)‡Change engine oil and filterInspect cooling system hosesCheck governor oil level

Check battery fluid level/ cable connections

Every 400

hours

Every 800

hours

Every 200

hours

Every100

hours

Every 50hours

Minimum Recommended Maintenance Intervals

Annual RecommendationsItems are recommended every 1200 hours

or 2 years, whichever occurs first.Replace the engine timing belt every 2,000

hours or 2 years, whichever comes first.

30

Check/Service

1. Engine oil level 8.1 Radiator screen cleanout door2. Engine oil drain 9. Air filter3. Transaxle/Hydraulic oil level (dipstick) 10. Fuel filter4. Belts (Governor, water pump 11. Battery

hydraulic pump)5. Coolant level fill 12. Tire pressure—maximum 1,4 kg/cm2

front 2,3kg/cm2 rear (23" tire) oder 1,3 kg/cm2 rear (24" tire)

6. Fuel(Unleaded gas only) 13. Fuses (Lights 10 A, ignition 7,5 A, dash accessories 7,5 A)

7. Grease points (34) 100 hours 14. Hydraulic strainer8. Radiator screen 15. Hydraulic oil filter

16. Brake fluid

Fluid Type Capacity Change IntervalsFluid Filter Filter Part No.

Engine Oil 10°C to 40°C SAE 10W 30 CD 3.2 l 100 hours 100 hours 67-4330

Transmission/Hydraulic Oil Dextron II ATF 7.1 l 800 hour 800 hours 54-0110

Air Cleaner Clean Every 50 hours 200 hours 33-1300

Fuel/Filter Unleaded 26.5 400 hours 18-1520

Coolant 50/50 Ethylene GlycolWater — 3.3 1200 hours 400 hours

Strainer — Clean 800 hours 87-3990Clean 800 Hours

FLUID SPECIFICATIONS/CHANGE INTERVALS

FOR HEAVY DUTY OPERATION, MAINTENANCE SHOULD BE PERFORMED TWICE AS FREQUENTLY

Maintenance

GREASING BEARINGS ANDBUSHINGS

The vehicle has grease fittings that must be lubricat-ed regularly with No. 2 General Purpose LithiumBase Grease. If the machine is operated under nor-mal conditions, lubricate all bearings and bushingsafter every 100 hours of operation. More frequentlubrication is required if used for heavy duty vehicleoperations.

The grease fitting locations and quantities are: Tierod ends (4) Fig. 16; front ball joints (4) Fig. 16; reardrive shafts (6) Fig. 172; Mid-drive shaft—4 wheel -drive only (3) Fig. 18; pedal pivots (4) Fig. 19; steer-ing shaft (1) Fig. 20; front pivot bushings (2) Fig. 21and governor Lever (1) Fig. 22.

IMPORTANT: When greasing drive shaft univer-sal shaft bearing crosses, pump grease until itcomes out of all 4 cups at each cross.

1. Wipe the grease fitting clean so foreign mattercannot be forced into the bearing or bushing.

2. Pump grease into the bearing or bushing.

3. Wipe off excess grease.

Figure 16

Figure 17

Figure 18

31

Maintenance

Before servicing or making adjustments to themachine, stop the engine, set the parking brake andremove key from the ignition switch. Any loadmaterial must be removed from bed or other attach-ment before working under raised bed. Never workunder a raised bed without positioning safety sup-port on a fully installed cylinder rod. Always rotatethe safety support to the down position beforeworking under the raised bed.

WARNING

32

IMPORTANT

Heavy Duty Operation

If the vehicle is subjected to conditions listed below,maintenance should be performed twice as frequent-ly.

• Desert operation

• Cold climate operation (below 32° F)

• Trailer or 5th wheel towing

• Frequent operation on dusty roads

• Frequent operation under maximum vehiclegross weight

• Construction work

• After extended operation in mud, sand, water orsimilar dirty conditions, have your brakesinspected and cleaned and drive axle jointsgreased as soon as possible. This will preventany abrasive material from causing excessivewear.

• Under frequent heavy duty operating conditions,lubricate all grease fittings and inspect air cleanerdaily to prevent excessive wear.

Maintenance

Figure 21Figure 19

Figure 20 Figure 22

Many maintenance procedures require raising andlowering the bed. The following precautions mustbe taken or serious injury or death could result.

After maintenance is completed, remove the safetysupport, slide it onto storage stud and lower the bed.

USING THE BED SAFETY SUPPORT

1. Raise the bed until the lift cylinders are fullyextended.

2. Remove the bed support from storage stud ontop of the back rest support channel on theWorkman (Fig. 23).

3. Push the bed support onto the cylinder rod, mak-ing sure support end tabs rest on the end of thecylinder barrel and on cylinder rod end (Fig. 24).

4. To store the bed support, remove bed supportfrom cylinder and insert on stud on top of backrest support channel.

5. Always install or remove bed support from out-side of bed.

6. Do not try to lower bed with bed safety supporton cylinder.

Figure 231. Bed support 2. Storage stud

Figure 241. Bed support 3. Bed2. Cylinder barrel

JACKING THE VEHICLE

1. Do not start the engine while the vehicle is onjack, because engine vibration or wheel move-ment could cause the vehicle to slip off the jack.

2. Do not work under the vehicle without jackstands supporting it. The vehicle could slip offjack, injuring any one beneath it.

3. The jacking point at the front of the vehicle isunder the front center frame support and at the

33

Maintenance

Before servicing or making adjustments to themachine, stop the engine, set the parking brake andremove key from the ignition switch. Any loadmaterial must be removed from bed or otherattachment before working under raised bed.Always rotate safety support to the down positionbefore working under raised bed.

WARNING

Only qualified and authorized personnel shall bepermitted to maintain, repair, adjust or inspect thevehicle.

Avoid fire hazards and have fire protection equip-ment present in the work area. Do not use an openflame to check the level or leakage of fuel, batteryelectrolyte or coolant. Do not use open pans offuel or flammable cleaning fluids for cleaningparts.

CAUTION

rear it is under the axle tube.

4. When jacking up front of the vehicle, alwaysplace a 50 x 100mm block (or similar material)between the jack and vehicle frame.

Figure 251. Front jacking point

Figure 261. Rear jacking points

Locations For SelectedMaintenance Procedures

Figure 271. Dust Cup & Baffle2. Filter Element 3. Air Cleaner Body

Figure 281. Engine Oil Drain Plug

Figure 291. Engine Oil Filter

34

Maintenance

➀

➀ ➀ ➀

➀

Figure 301. Fuel Filter

Figure 31 1. Radiator screen cover 2. Clean out door

Figure 321. Radiator cap 2. Reserve tank cap

Figure 331. Governor belt 3. Idler pulley2. Alternator belt

Figure 34 1. Fan belt 2. Idler pulley

CHECKING THE OIL LEVEL INTHE GOVERNOR

Check the oil level in the governor after every 600hours of operation.

1. Position the vehicle on level surface, stop theengine and engage the parking brake.

2. Raise box (if so equipped) and place safety sup-port on extended lift cylinder to hold up box.

3. Clean the area around the check plug on the gov-ernor.

4. Remove the check plug from the governor. Theoil level must be up to the bottom of hole. If theoil level is low, remove the oil fill plug and addthe same oil that is being used in the engine.

35

Maintenance

➀

➀

➁

➀

➁

➀

➁

➂

➀

➁

When the oil is at point of overflowing from thecheck plug hole, install the check plug and fillplug.

Figure 35 1. Governor2. Check plug3. Fill plug4. Governor output lever5. Surge screw6. Locknut

CHANGING THE TRANSAXLE/HYDRAULIC FLUID

Change the transaxle hydraulic fluid, filter and cleanthe strainer every 800 hours.

Figure 361. Hydraulic Reservoir2. Drain plug

Figure 371. Hydraulic Filter2. Gasket

Figure 381. Front differential2. Fill plug3. Drain plug

Figure 391. Hydraulic strainer

36

Maintenance

➀

➃

➄

➅

➁

➂

➀

➁

➀➁

Figure 40

FRONT WHEEL TOE-IN

After every 600 operating hours or annually, checkfront wheel toe-in.

1. Measure center-to-center distance (at axleheight) at front and rear of steering tires. Frontmeasurement must be equal to the rear measure-ment 3mm.

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

Figure 421. Tie rod

3. Rotate tie rod to move front of tire inward oroutward.

4. Tighten tie rod jam nuts when adjustment is cor-rect.

EMERGENCY BOX RAISING(without starting the engine)

The box can be raised in an emergency by crankingstarter and holding lift lever. Run starter for 15 sec-onds then wait 60 seconds before engaging starteragain.

If the engine will not crank, the load and box (attach-ment) must be removed to service the engine ortransaxle.

FUSES

There are three fuses in the machine’s electrical sys-tem. They are located under right side of dash panel.

FUSESOPEN —LIGHTS & HORN 10AIGNITION7.5ADASH7.5A

Figure 431. Fuse block

JUMP STARTING PROCEDURE

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

2. Connect a jumper cable between the positiveposts of the two batteries. The positive post may

37

Maintenance

Figure 41

Center-to-Center Distance

➀

be identified by a “+” sign on top of batterycover.

Figure 441. Positive (+) cable

3. Connect one end of the other jumper cable to thenegative terminal of the battery in the other vehi-cle. The negative terminal has “NEG” on the bat-tery cover. Do not connect the other end of thejumper cable to the negative post of the dis-charged battery. Connect it to the engine. Do notconnect the jumper cable to the fuel system.

4. Start the engine in the vehicle providing thejump start. Let it run a few minutes, then start

your engine.

5. Remove the negative jumper cable first fromyour engine, then the battery in the other vehicle.

6. Reinstall battery cover to battery base and tight-en knobs.

IDENTIFICATION AND ORDERING

MODEL AND SERIAL NUMBERS

The WORKMAN® has two identification numbers: amodel number and a serial number. These numbersare stamped into a plate located on the right framemember under dash. In any correspondence concern-ing the unit, supply the model and serial numbers toensure correct information and replacement parts areobtained.

To order replacement parts from an authorizedTORO Distributor, supply the following information:

1. Model and serial numbers.

2. Part number, description, and quantity of partsdesired.

38

Maintenance

➀

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

• Never jump start with a voltage sources greaterthan 15 volts D.C. This will damage the elec-trical system.

• Never attempt to jump start a discharged bat-tery that is frozen. It could rupture or explodeduring jump starting.

• Observe all battery warnings while jump start-ing your vehicle.

• Be sure your vehicle is not touching the jumpstart vehicle.

• Connecting cables to the wrong post couldresult in personal injury and/or damage to theelectrical system.

WARNING