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Workman 3200 & 4200

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Workman 3200 & 4200 Form No. 3355–925 Rev C ) Workman 3200 & 4200 Liquid Cooled Gas Utility Vehicle Model No. 07360—Serial No. 260000001 and Up Model No. 07361—Serial No. 260000001 and Up Model No. 07361TC—Serial No. 260000001 and Up Model No. 07365—Serial No. 260000001 and Up Operator’s Manual English (EN, GB) Page Warning Check Front Differential Oil. 22 Check Torque Of Wheel Nuts. 23 CALIFORNIA Check Tire Pressure. 23 Proposition 65 Warning Check Brake Fluid. 23 The engine exhaust from this product contains Check Fan Belt Tension. 23 chemicals known to the State of California to cause Operation. 24 cancer, birth defects, or other reproductive harm. Controls. 24 Pre–starting Checks. 27 Important The engine in this product is not equipped Starting Engine. 27 with a spark arrester muffler. It is a violation of California Driving Vehicle. 27 Public Resource Code Section 4442 to use or operate this Stopping Vehicle. 28 engine on any forest-covered, brush-covered, or Stopping Engine. 28 grass-covered land as defined in CPRC 4126. Other states or federal areas may have similar laws. New Vehicle Break–in. 28 Check Interlock System. 28 This spark ignition system complies with Canadian Operating Characteristics. 29 ICES-002. Passengers. 29 Ce système d’allumage par étincelle de véhicule est Speed. 30 conforme à la norme NMB-002 du Canada. Turning. 30 Braking. 30 Tipovers. 30 Contents Hills. 31 Page Loading And Dumping. 31 Introduction. 3 Using The Differential Lock. 32 Safety. 3 Four Wheel Drive. 32 Safe Operating Practices. 3 Transporting Vehicle. 32 Supervisor’s Responsibilities. 4 Towing Vehicle. 32 Before Operating. 4 Trailer Towing. 33 While Operating. 4 Hydraulic Control. 33 Maintenance. 5 Maintenance. 35 Sound Pressure Level. 6 Service Interval Chart. 35 Vibration Level. 6 Greasing Bearings And Bushings. 35 Safety and Instruction Decals. 7 Maintenance. 37 Specifications. 13 Recommended Maintenance Schedule. 37 General Specifications. 13 Daily Maintenance Checklist. 38 Dimensions. 14 Heavy Duty Operation. 39 Setup. 15 Using Bed Safety Support. 39 Install Rear Fenders. 16 Jacking Vehicle. 40 Install Wheels. 16 General Air Cleaner Maintenance Practices. 40 Install Steering Wheel. 16 Servicing Air Cleaner. 40 Install Front Fenders. 17 Changing Engine Oil And Filter. 41 Install ROPS. 17 Fuel System. 41 Activate and Charge Battery. 17 Removing Debris From Engine Cooling System. 42 Full Bed Removal. 18 Changing Engine Coolant. 42 Re–Install Full Bed. 19 Adjusting Belts. 43 Before Operating. 20 Adjusting Accelerator Pedal. 44 Check Crankcase Oil. 20 Changing Transaxle / Hydraulic Fluid. 44 Fill Fuel Tank. 21 Replacing Hydraulic Filter. 45 Check Cooling System. 21 Cleaning Hydraulic Strainer. 45 Check Transaxle / Hydraulic Fluid. 22 Change Front Differential Oil. 45 W 2006 by The Toro Company 8111 Lyndale Avenue South All Rights Reserved Bloomington, MN 55420-1196 2 Printed in the USA Page Warning signals a hazard that may cause serious injury or Replacing Spark Plugs. 46 death if you do not follow the recommended precautions. Adjusting Brake Pedal. 46 Caution signals a hazard that may cause minor or moderate Adjusting Clutch Pedal. 47 injury if you do not follow the recommended precautions. Adjusting Parking Brake. 48 This manual uses two other words to highlight information. Adjusting Shift Cables. 48 Important calls attention to special mechanical Adjusting High–low Cable. 49 information and Note: emphasizes general information Adjusting Differential Lock Cable. 49 worthy of special attention. Inspect Brakes. 49 Inspect Tires. 49 Front Wheel Toe. 49 Safety Inspect Constant Velocity Boot. 50 The TORO WORKMAN meets the requirements of Emergency Box Raising. 50 SAE J2258. Fuses. 51 Supervisors, operators and service persons should be Jump Starting Procedure. 51 familiar with the following standards and publications: Battery Storage. 52 (The material may be obtained from the address shown). Battery Care. 52 • Flammable and Combustible Liquids Code: Hydraulic Schematic. 53 ANSI/NFPA 30 Electrical Schematic. 54 • The Toro General Commercial Products Warranty. 56 National Fire Protection Association: ANSI/NFPA #505; Powered Industrial Trucks ADDRESS: National Fire Prevention Association Introduction Barrymarch Park Quincy, Massachusetts 02269 U.S.A Read this manual carefully to learn how to operate and maintain your product properly. The information in this • ANSI/ASME B56.8 Personal Burden Carriers manual can help you and others avoid injury and product ADDRESS: damage. Although Toro designs and produces safe American National Standards Institute, Inc. products, you are responsible for operating the product 1430 Broadway properly and safely. New York, New York 10018 U.S.A. Whenever you need service, genuine Toro parts, or • ANSI/UL 558; Internal Combustion Engine Powered additional information, contact an Authorized Toro Industrial Trucks Distributor or Toro Customer Service and have the model ADDRESS: and serial numbers of your product ready. These numbers American National Standards Institute, Inc. are stamped into a plate located on the right frame member 1430 Broadway under dash. New York, New York 10018 U.S.A. OR Write the product model and serial numbers in the space Underwriters Laboratories below: 333 Pfingsten Road Northbrook, Illinois 60062 U.S.A. Model No: Safe Operating Practices Serial No. Warning This manual identifies potential hazards and has special safety messages that help you and others avoid personal The WORKMAN is an off–highway vehicle injury and even death. Danger, Warning, and Caution are only, and is not designed, equipped, or signal words used to identify the level of hazard. However, manufactured for use on public streets, roads regardless of the hazard, be extremely careful. or highways. Danger signals an extreme hazard that will cause serious injury or death if you do not follow the recommended The WORKMAN was designed and tested to offer precautions. safe service when operated and maintained properly. Although hazard control and accident prevention 3 partially are dependent upon the design and • Become familiar with the controls and know how to configuration of the machine, these factors are also stop the engine quickly. dependent upon the awareness, concern, and proper • training of the personnel involved in the operation, Keep all shields, safety devices and decals in place. If a maintenance and storage of the machine. Improper use shield, safety device or decal is malfunctioning, or maintenance of the machine can result in injury or illegible, or damaged, repair or replace it before death. operating the machine. • This is a specialized utility vehicle designed for off–road Always wear substantial shoes. Do not operate machine use only. its ride and handling will have a different feel while wearing sandals, tennis shoes or sneakers. Do not than what drivers experience with passenger cars or wear loose fitting clothing or jewelry which could get trucks. So take time to become familiar with your caught in moving parts and cause personal injury. WORKMAN. • Wearing safety glasses, safety shoes, long pants and a Not all of the attachments that adapt to the helmet is advisable and required by some local safety WORKMAN are covered in this manual. See the and insurance regulations. specific Operator’s Manual provided with attachment • Keep everyone, especially children and pets, away from for additional safety instructions. READ THESE the areas of operation. MANUALS. • Before operating the vehicle, always check all parts of TO REDUCE THE POTENTIAL FOR INJURY OR the vehicle and any attachments. If something is wrong, DEATH, COMPLY WITH THE FOLLOWING stop using vehicle. Make sure problem is corrected SAFETY INSTRUCTIONS. before vehicle or attachment is operated again. • Since gasoline is highly flammable, handle it carefully. Supervisor’s Responsibilities – Use an approved gasoline container. • Make sure operators are thoroughly trained and familiar – Do not remove cap from fuel tank when engine is with the Operator’s Manual and all labels on the hot or running. vehicle. – Do not smoke while handling gasoline. • Be sure to establish your own special procedures and work rules for unusual operating conditions (e.g. slopes – Fill fuel tank outdoors and to about one inch below too steep for vehicle operation). Use the 3rd High top of tank (bottom of filler neck). Do not overfill. Lockout switch if high speed could result in a safety or vehicle abuse situation. – Wipe up any spilled gasoline. • Use only an approved non–metal, portable fuel container. Static electric discharge can ignite gasoline Before Operating vapors in a ungrounded fuel container. Remove the fuel • Operate the machine only after reading and container from the bed of the vehicle and place on the understanding the contents of this manual. A ground away from the vehicle before filling. Keep replacement manual is available by sending complete nozzle in contact with container while filling. Remove model and serial number to: The Toro Company, 8111 equipment from vehicle bed before filling Lyndale Avenue South, Minneapolis, Minnesota 55420. • Check the safety interlock system daily for proper • Never allow children to operate the vehicle. Never operation. If a switch should malfunction, replace the allow adults to operate it without proper instructions. switch before operating machine. After every two years, Only trained and authorized persons should operate this replace the interlock switches in the safety system, vehicle. Make sure all operators are physically and whether they are working properly or not. mentally capable of operating the vehicle. Anyone who operates the vehicle should have a motor vehicle license. While Operating • • This vehicle is designed to carry only you, the operator,.
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