Toro Workman 3100 Manuals

Manuals and User Guides for Toro Workman 3100. We have 6 Toro Workman 3100 manuals available for free PDF download: Service Manual, Operator's Manual

Toro Workman 3100 Service Manual (438 pages)

Brand: Toro | Category: Utility Vehicle | Size: 10.25 MB

Chapter 5 - Kohler Command Series

3
- Table of Contents
  3
Before Operating

7
- Chapter 1 - Safety
  
  7
  - Safety Instructions
    7
    
    Before Operating
    7
    
    While Operating
    8
  - Maintenance and Service
    9
  - Jacking the Vehicle
    10
  - Using Bed Safety Support
    11
- Chapter 2 - Product Records and Maintenance
  
  13
  - Product Records
    13
  - Equivalents and Conversions
    14
  - Torque Specifications
    15
  - Lubrication
    19
  - Operation and Service History Report
    23
Table of Contents

39
- Chapter 3 - Liquid Cooled Mitsubishi Gas Engine
  
  40
  - General Information
    40
  - Specifications
    41
  - General
    41
  - Engine
    42
  - Lubrication System
    46
  - Fuel System
    46
  - Cooling System
    46
  - Electrical System
    47
  - Special Tools
    50
  - Inspection and Adjustments
    55
  - Valve Clearance
    55
  - Timing Belt Tension
    57
  - Idle Speed
    58
  - Ignition Timing
    58
  - CO Concentration (Mixture Adjustment)
    59
  - Governor / Accelerator Pedal
    60
  - Carburetor Acceleration Pump
    62
  - Choke Valve
    63
  - Full-Auto-Choke
    63
  - Choke Breaker Opening
    64
  - Fast Idle
    65
  - Troubleshooting
    66
  - Testing
    68
  - Compression Pressure
    71
  - Intake Manifold Vacuum
    71
  - Centrifugal Timing Control Device
    72
  - Vacuum Timing Control Device
    73
  - Crankcase Emission Control System
    74
  - Exhaust Emission Control System
    75
  - Thermo Valve
    77
  - Ignition Coil
    78
  - Starter Pinion Gap
    79
  - Starter No-Load Test
    80
  - Magnetic Switch Pull-In Test
    81
  - Magnetic Switch Hold-In Test
    81
  - Magnetic Switch Return Test
    81
  - Alternator Regulated Voltage
    82
  - Preparation for Engine Repair
    84
  - Cylinder and Cylinder Block Overhaul
    84
  - External Engine Component Repairs
    85
  - External Engine Component Repair
    85
    
    Belt Replacement and Adjustment
    85
    
    Timing Belt Replacement
    86
    
    Water Pump, Hose, Pipe and Thermostat Removal and Installation
    93
    
    Governor Removal and Installation
    95
    
    Electrical System Repairs
    96
    
    Spark Plug Replacement
    96
    
    Alternator Removal and Installation
    97
    
    Alternator Service
    98
    
    Starter Removal and Installation
    102
    
    Starter Service
    103
    
    Distributor Removal and Installation
    107
    
    Distributor Service
    108
    
    Carburetor Removal and Installation
    110
    
    Fuel System Repairs
    110
    
    Carburetor Service
    111
    
    Removing and Installing the Engine
    117
    
    Removing the Engine
    117
    
    Installing the Engine
    118
    
    Cylinder Head Overhaul
    119
    
    Intake and Exhaust Manifolds
    119
    
    Rocker Arm, Rocker Shaft and Camshaft
    120
    
    Rocker Arm and Rocker Shaft
    123
    
    Cylinder Head and Valves
    124
    
    Cylinder Block Overhaul
    129
    
    Front Case, Counterbalance Shaft and Oil Pan
    129
    
    Piston and Connecting Rod
    134
    
    Oil Pump
    139
    
    Crankshaft and Flywheel
    142
    
    Cylinder Block
    147
    
    Lubrication System Repair
    149
    
    Oil Screen, Dipstick and Oil Filter
    149
Liquid Cooled Diesel Engine

151
- Chapter 4 - Mitsubishi Diesel Engine
  
  152
  - General Information
    152
  - Specifications
    153
  - General
    154
  - Engine
    155
  - Lubrication System
    157
  - Cooling System
    158
  - Fuel System
    158
  - Electrical System
    159
  - Tightening Torque
    160
  - Special Tools
    161
  - Adjustments
    163
  - Valve Clearance
    163
  - Engine Speed Adjustments
    164
  - Accelerator Pedal Adjustment
    165
  - Troubleshooting
    165
  - Glow Plug Test
    168
  - Testing
    168
  - Compression Test
    169
  - Nozzle Tests
    170
  - Injection Pump Test
    172
  - Injection Timing Test
    173
  - Fuel Pump Test
    174
  - Thermostat Test
    174
  - Fuel Stop (ETR) Solenoid
    175
  - Engine Oil Pressure Switch
    176
  - Temperature Gauge Sender
    177
  - Checking Starter Pinion Gap
    178
  - Starter No-Load Test
    178
  - Magnetic Switch (Solenoid) Attraction Test
    179
  - Magnetic Switch (Solenoid) Holding Test
    179
  - Magnetic Switch (Solenoid) Return Test
    179
  - Alternator Output Test
    180
  - Alternator Regulated Voltage Test
    180
  - Cylinder and Cylinder Block Overhaul
    181
  - Preparation for Engine Repair
    181
  - Belt Replacement and Adjustment
    182
  - External Engine Component Repair
    182
  - Thermostat Removal and Installation
    183
  - Water Pump Service
    183
  - Alternator Removal and Installation
    184
  - Electrical System Repairs
    184
  - Starter Removal and Installation
    184
  - Glow Plug Replacement
    186
  - Oil Pressure Switch Replacement
    186
  - Starter Service
    187
  - Alternator Service
    191
  - Governor Operation
    195
  - Governor System Repairs
    195
  - Governor Inspection
    196
  - Governor Service
    197
  - Installation of Torque Spring Set
    198
  - Assembly of Torque Spring Set
    199
  - Bleeding the Fuel System
    200
  - Fuel System Repairs
    200
  - Bleeding Air from the Injectors
    201
  - Fuel Pump Service
    201
  - Injection Pump Service
    202
  - Nozzle Service
    205
  - Removing and Installing the Engine
    207
  - Removing the Engine
    207
  - Installing the Engine
    208
  - Cylinder Head Overhaul
    209
  - Cylinder Head Removal
    209
  - Cylinder Head Service
    210
  - Valve Guides
    211
  - Valve Seats
    212
  - Valves
    212
  - Rocker Arm and Rocker Shaft
    213
  - Valve Springs
    213
  - Cylinder Head Reassembly and Installation
    214
  - Cylinder Block Overhaul
    216
  - Gear Case and Oil Pump
    216
  - Timing Gears and Camshafts
    219
  - Piston and Connecting Rod
    222
  - Crankshaft
    226
  - Cylinder Block
    229
Air Cooled Gas Engine

231
- Chapter 5 - Kohler Command Series
  
  231
  - Kohler Engine Service Manual
    231
  - Specifications
    232
  - General Information
    233
    
    Removing Debris from the Engine
    233
    
    Spark Plug Replacement
    233
  - Adjustments
    234
    
    Belt Adjustment
    234
  - Carburetor Adjustment
    234
  - Accelerator Adjustment
    235
  - Engine Removal and Installation
    236
  - Repairs
    236
- Chapter 6 - Drive Train
  
  237
Chapter 6 Drive Train

239
- General Information
  240
- Specifications
  241
- Special Tools
  242
- Adjustments
  244
  - Clutch Pedal
    244
  - High-Low Cable
    245
  - Differential Lock Cable
    246
  - PTO Cable
    246
- Troubleshooting
  247
- Repairs
  250
  - Stub Axle and Drive Shaft Service
    251
  - Drive Shaft Universal Joint Service
    253
  - P.T.O. Removal and Installation
    254
  - Transaxle Removal and Installation
    255
  - Clutch Service
    258
  - Transaxle Service
    260
Chapter 7 Steering, Brakes and Suspension

303
- Specifications
  304
- Special Tools
  305
- Adjustments
  306
  - Brake Pedal Adjustment
    306
  - Parking Brake Adjustment
    307
  - Front Wheel Toe-In
    307
- Troubleshooting
  308
- Repairs
  312
  - Wheel Installation
    312
  - Front Wheel Bearing Service
    313
  - Rear Wheel Bearing Service
    313
  - Brake Service
    314
- Bleeding the Brakes
  317
- Master Brake Cylinder Service
  318
- Parking Brake Cable Replacement
  319
- Steering Linkage Service
  320
- Steering Wheel Installation
  320
- Rear Shock Absorber Replacement
  322
- Rear Leaf Spring Replacement
  326
- Steering Gear Service
  328
Electrical System

335
- Chapter 8 - Electrical System
  
  336
  - Wiring Schematics
    336
    
    Workman 3100 (Model 07210 and 07214)
    336
    
    Workman 3200/4200
    337
    
    Workman 3200/4200
    338
    
    Workman 3300-D/4300-D (Models 07205, 07206, 07215, 07205TC, 07206TC, 07215TC)
    339
    
    Workman 3300-D/4300-D (Models 07213, 07217, 07213TC, and 07217TC)
    340
    
    Workman 3210
    341
    
    Workman 3310-D
    342
    
    Workman 3120 (Industrial Model 07232)
    343
    
    Workman 3220 (Industrial Model 07231)
    344
    
    Workman 3320-D (Industrial Model 07230)
    345
    
    Workman 3420-LP (Industrial Model 07233)
    346
  - Special Tools
    347
  - Troubleshooting
    348
    
    Verify Interlock System Operation
    350
  - Testing
    351
    
    Ignition Key Switch
    351
    
    Brake Switch
    352
    
    Clutch Switch
    352
  - Rear PTO Switch
    352
    
    2-3 and High-Low Lockout Switches
    353
  - 3Rd-High Lockout Key Switch
    353
    
    Relays
    353
    
    Battery
    354
    
    Indicator Lights and Gauges
    354
    
    Fuel Gauge Sender
    355
  - Service and Repairs
    356
    
    Battery Service
    356
    
    Fuses
    359
    
    Headlamp Replacement
    359
    
    Tail Lamp Replacement
    360
Chapter 9 Hydraulic System

361
- Specifications
  362
- General Information
  363
  - Hydraulic Hoses
    363
  - Hydraulic Fitting Installation
    363
- Hydraulic Schematics
  365
  - Base Vehicle
    365
  - Vehicle with Optional Remote Hydraulic Kit
    366
- Special Tools
  368
  - Hydraulic Pressure Test Kit
    368
  - Hydraulic Tester (Pressure and Flow)
    368
- Troubleshooting
  370
- Testing
  372
  - Test No. 1: Pump Flow and Relief Pressure
    373
- Test No. 2: Remote Hydraulics Relief Pressure
  374
- Test No. 3: Power Steering Relief Pressure
  375
- Removing Hydraulic System Components
  377
  - Pump Drive Shaft Service
    378
  - Pump Removal and Installation
    380
- Service and Repairs
  377
- Pump Repair
  381
- Lift Valve Repair
  384
- Lift Cylinder Repair
  385
Front Wheel Drive - 4Wd

387
- Specifications
  388
- General
  389
  - Check Front Differential Oil
    389
- Repairs
  390
  - Front Wheel Assembly
    390
  - Front Wheel Bearing
    391
  - Front Brake
    394
- Chapter 10 Constant Velocity (CV) Joint
  
  398
  - Change Front Differential Oil
    401
  - Front Suspension Control Arm Assembly
    402
  - Front Differential
    403
  - Ring to Pinion Gear Engagement
    416
  - Differential Drive Shaft
    419
  - Bidirectional Clutch
    420
  - Lubrication
    424
Liquid Propane Gas Conversion Kit

425
- Specifications
  426
- General Information
  427
  - Gas Fuel Systems
    427
  - Refueling
    428
  - Starting Engine
    428
- Special Tools
  429
- Functional Operation
  430
- Chapter 11 Testing LP Gas Fuel System
  
  433
  - Adjustments
    434
    
    Adjust LP Fuel System
    434
  - Service and Repairs
    435
    
    Check Spark Plug Gap
    435
    
    Fuel Tank Assembly
    436
    
    Conversion Kit Assembly
    437

Toro Workman 3100 Operator's Manual (52 pages)

Air Cooled Gas Utility Vehicle

Brand: Toro | Category: Utility Vehicle | Size: 2.11 MB

Introduction
2
Table of Contents
3
Safety
4
- Safe Operating Practices
  4
- Supervisor's Responsibilities
  4
- Before Operating
  4
- While Operating
  5
- Maintenance
  6
- Sound Pressure Level
  7
- Vibration Level
  7
- Safety and Instructional Decals
  8
1 Install ROPS

13
2 Remove Full Bed

13
- Setup
  13
3 Re-Install the Full Bed

14
- Product Overview
  15
  - Controls
    15
  - Specifications
    19
  - Attachments/Accessories
    19
- Operation
  19
  - Check Crankcase Oil
    19
  - Fill Fuel Tank
    20
  - Check Transaxle / Hydraulic Fluid
    21
  - Check Torque of Wheel Nuts
    21
  - Check Tire Pressure
    21
  - Check Brake Fluid
    22
  - Check Pump Belt Tension
    22
  - Pre-Starting Checks
    22
  - Starting Engine
    23
  - Driving Vehicle
    23
  - Stopping Vehicle
    23
  - Stopping Engine
    23
  - New Vehicle Break-In
    23
  - Check Interlock System
    24
  - Operating Characteristics
    24
  - Passengers
    25
  - Speed
    25
  - Turning
    25
  - Braking
    26
  - Tipovers
    26
  - Hills
    26
  - Loading and Dumping
    27
  - Using the Differential Lock
    27
  - Transporting Vehicle
    28
  - Towing Vehicle
    28
  - Trailer Towing
    28
  - Hydraulic Control
    29
- Maintenance
  31
  - Recommended Maintenance Schedule(S)
    31
    
    Service Interval Chart
    32
    
    Heavy Duty Operation
    32
  - Premaintenance Procedures
    33
    
    Using Bed Safety Support
    33
    
    Jacking Vehicle
    34
  - Lubrication
    34
    
    Greasing Bearings and Bushings
    34
  - Engine Maintenance
    36
    
    Servicing Air Cleaner
    36
    
    Changing Engine Oil and Filter
    36
    
    Replacing Spark Plugs
    36
  - Fuel System Maintenance
    37
    
    Fuel System
    37
  - Electrical System Maintenance
    38
    
    Fuses
    38
    
    Jump Starting Vehicle
    38
    
    Battery Care
    39
  - Drive System Maintenance
    40
    
    Adjusting Shift Cables
    40
    
    Adjusting High-Low Cable
    40
    
    Adjusting Differential Lock Cable
    40
    
    Inspect Tires
    40
    
    Front Wheel Toe
    40
  - Cooling System Maintenance
    42
    
    Removing Debris from Engine Cooling System
    42
  - Brake Maintenance
    42
    
    Inspect Brakes
    42
    
    Adjusting Parking Brake
    42
    
    Adjusting Brake Pedal
    43
  - Belt Maintenance
    43
    
    Adjusting Belt
    43
  - Controls System Maintenance
    44
    
    Adjusting Accelerator
    44
    
    Adjusting Clutch Pedal
    44
    
    Adjusting Choke
    45
  - Hydraulic System Maintenance
    46
    
    Changing Transaxle / Hydraulic Fluid
    46
    
    Replacing Hydraulic Filter
    46
    
    Cleaning Hydraulic Strainer
    46
    
    Emergency Box Raising
    47
- Storage
  49
- Schematics
  50

Toro Workman 3100 Operator's Manual (52 pages)

Air Cooled Gas Utility Vehicle

Brand: Toro | Category: Utility Vehicle | Size: 4.95 MB

Table of Contents
2
Introduction
3
Safety
3
- While Operating
  5
- Safety and Instruction Decals
  7
Specifications
12
Setup
14
- Install ROPS
  14
- Activate and Charge Battery
  14
- Full Bed Removal
  16
- Re-Install Full Bed
  16
Before Operating
18
- Check Crankcase Oil
  18
- Fill Fuel Tank
  18
- Check Transaxle / Hydraulic Fluid
  19
- Check Torque of Wheel Nuts
  19
- Check Tire Pressure
  19
- Check Brake Fluid
  20
Operation
21
- Controls
  21
  - Ignition Switch
    22
  - Parking Brake
    22
  - Hour Meter
    22
  - Horn Button
    23
  - Light Switch
    23
  - Oil Pressure Warning Light
    23
  - Fuel Gauge
    23
- Pre-Starting Checks
  24
- Starting Engine
  24
- Driving Vehicle
  24
- Stopping Vehicle
  24
- Stopping Engine
  25
- New Vehicle Break-In
  25
- Check Interlock System
  25
- Operating Characteristics
  25
- Passengers
  26
- Speed
  26
- Turning
  26
- Braking
  27
- Tipovers
  27
- Hills
  27
- Loading and Dumping
  28
- Using the Differential Lock
  28
- Transporting Vehicle
  29
- Towing Vehicle
  29
- Trailer Towing
  29
- Hydraulic Control
  29
Maintenance
32
- Service Interval Chart
  32
- Lubrication
  32
- Recommended Maintenance Schedule
  34
- Daily Maintenance Checklist
  35
- Heavy Duty Operation
  36
- Using Bed Safety Support
  36
- Jacking Vehicle
  37
- Servicing Air Cleaner
  37
- Changing Engine Oil and Filter
  38
- Fuel System
  38
- Removing Debris from Engine
  39
- Adjusting Belt
  39
- Adjusting Choke
  39
- Replacing Spark Plugs
  39
- Adjusting Accelerator
  40
- Changing Transaxle / Hydraulic Fluid
  40
- Replacing Transaxle Filter
  41
- Cleaning Hydraulic Strainer
  41
- Adjusting Brake Pedal
  41
- Adjusting Clutch Pedal
  42
- Adjusting Parking Brake
  43
- Adjusting Shift Cables
  43
- Adjusting High-Low Cable
  43
- Adjusting Differential Lock Cable
  44
- Inspect Brakes
  44
- Inspect Tires
  44
- Front Wheel Toe
  44
- Emergency Box Raising
  44
- Fuses
  46
- Jump Starting Procedure
  46
- Battery Storage
  47
- Battery Care
  47
- Hydraulic Schematic
  48
- Electrical Schematic
  49
The Toro General Commercial Products Warranty
52

Toro Workman 3100 Operator's Manual (48 pages)

Air Cooled Gas Utility Vehicle

Brand: Toro | Category: Utility Vehicle | Size: 1.87 MB

Table of Contents
2
Introduction
3
Safety
3
Safety and Instruction Decals
7
Specifications
12
Setup
14
Install Wheels
15
Install Steering Wheel
15
Install Front Fenders
15
Install ROPS
15
Activate and Charge Battery
16
Full Bed Removal
17
Re-Install Full Bed
17
Before Operating
19
Check Crankcase Oil
19
Fill Fuel Tank
19
Check Transaxle / Hydraulic Fluid
20
Check Brake Fluid
20
Check Torque of Wheel Nuts
21
Check Tire Pressure
21
Operation
22
Controls
22
Pre-Starting Checks
25
Starting Engine
25
Driving Vehicle
25
Stopping Vehicle
25
Stopping Engine
25
New Vehicle Break-In
25
Check Interlock System
26
Operating Characteristics
26
Passengers
27
Speed
27
Turning
27
Braking
27
Tipovers
27
Hills
28
Loading and Dumping
29
Using the Differential Lock
29
Transporting Vehicle
30
Towing Vehicle
30
Trailer Towing
30
Maintenance
31
Service Interval Chart
31
Lubrication
32
Recommended Maintenance Schedule
33
Daily Maintenance Checklist
34
Heavy Duty Operation
35
Using Bed Safety Support
35
Jacking Vehicle
36
Servicing Air Cleaner
36
Changing Engine Oil and Filter
37
Fuel System
37
Removing Debris from Engine
38
Adjusting Belt
38
Adjusting Choke
38
Replacing Spark Plugs
38
Adjusting Accelerator
39
Changing Transaxle / Hydraulic Fluid
39
Replacing Transaxle / Hydraulic Filter
40
Cleaning Hydraulic Strainer
40
Adjusting Brake Pedal
40
Adjusting Clutch Pedal
41
Adjusting Parking Brake
41
Adjusting Shift Cables
41
Adjusting High-Low Cable
42
Adjusting Differential Lock Cable
42
Inspect Brakes
42
Inspect Tires
42
Front Wheel Toe-In
42
Emergency Box Raising
43
Fuses
43
Jump Starting Procedure
43
Battery Storage
44
Battery Care
44
Hydraulic Schematic
45
Electrical Schematic
46
The Toro General Commercial Products Warranty
48

Toro Workman 3100 Operator's Manual (36 pages)

Brand: Toro | Category: Utility Vehicle | Size: 1.05 MB

Table of Contents
2
Safety
3
While Operating
4
Specifications
9
Before Operating
11
Check Tire Pressure
13
Controls
15
- Starting the Engine
  17
- Stopping the Vehicle
  18
- Stopping the Engine
  18
Operating
19
- Transporting the Vehicle
  23
- Daily Maintenance Procedures
  25
Maintenance
26
- Maintenance Schedule
  27
- Jacking the Vehicle
  30
- Jump Starting Procedure
  33

Toro Workman 3100 Operator's Manual (44 pages)

Air Cooled Gasoline Utility Vehicle

Brand: Toro | Category: Utility Vehicle | Size: 1.67 MB

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Toro Workman 3100 Manuals

Toro Workman 3100 Service Manual (438 pages)

Table of Contents

Chapter 5 - Kohler Command Series

Before Operating

Chapter 1 - Safety

Chapter 2 - Product Records and Maintenance

Table of Contents

Chapter 3 - Liquid Cooled Mitsubishi Gas Engine

Liquid Cooled Diesel Engine

Chapter 4 - Mitsubishi Diesel Engine

Air Cooled Gas Engine

Chapter 5 - Kohler Command Series

Chapter 6 - Drive Train

Chapter 6 Drive Train

Chapter 7 Steering, Brakes and Suspension

Electrical System

Chapter 8 - Electrical System

Chapter 9 Hydraulic System

Front Wheel Drive - 4Wd

Chapter 10 Constant Velocity (CV) Joint

Liquid Propane Gas Conversion Kit

Chapter 11 Testing LP Gas Fuel System

Toro Workman 3100 Operator's Manual (52 pages)

Table of Contents

1 Install ROPS

2 Remove Full Bed

3 Re-Install the Full Bed

Toro Workman 3100 Operator's Manual (52 pages)

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