Toro 07200 Operator's Manual

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Service manual (248 pages)

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Page 1 FORM NO. 3318-342 GB Rev A MODEL NO. 07200—60001 AND UP OPERATOR MODEL NO. 07202—60001 AND UP MANUAL MODEL NO. 07216—60001 AND UP ® WORKMAN 3200 AND 4200 UTILITY VEHICLES To understand this product, and for safety and opti- It means CAUTION, WARNING or DANGER—...
Page 2: Table Of Contents
TORO also is concerned about future use of the equipment for the complete line of TORO turf care machine and of safety to the user. Therefore, this equipment.
Page 3: Safety
A 13. Since gasoline is highly flammable, handle it replacement manual is available by sending carefully. complete model and serial number to: The Toro Company, 8111 Lyndale Avenue South, A. Use an approved gasoline container. Minneapolis, Minnesota 55420.
Page 4: While Operating
Safety C. Do not smoke while handling gasoline. D. Keep foot off the accelerator pedal. D. Fill fuel tank outdoors and to about one inch E. Turn ignition key to START. below top of tank (bottom of filler neck). Do not overfill.
Page 5 E. Remove key from ignition. 30. Do not overspeed engine by changing governor settings. Maximum engine speed is 3650 rpm. To F. Block wheels if machine is on an incline. assure safety and accuracy, have an Authorized TORO Distributor check maximum engine speed...
Page 6 Such use This unit does not exceed a vibration level of 0.5 could void the product warranty of The TORO at the posterior based on measurements of iden- Company.
Page 7 Symbol Glossary SAFETY ALERT SYMBOL GENERAL HAZARD SAFETY CRUSHING OF WHOLE BODY, CRUSHING OF TOES OR FOOT, CRUSHING OF FINGERS OR HAND, CUTTING OF FINGERS OR HAND CUTTING OF FOOT ALERT APPLIED FROM ABOVE FORCE APPLIED FROM ABOVE FORCE APPLIED FROM SIDE BATTERY CHARGING STAY A SAFE DISTANCE FROM MACHINE STAY A SAFE DISTANCE FROM DRAINING...
Page 8 Symbols Glossary THROWN OR FLYING OBJECTS, SEVERING OF FINGERS OR RIDING ON THIS MACHINE IS SHUT OFF ENGINE & REMOVE FACE EXPOSURE HAND, ENGINE FAN ALLOWED ONLY ON A PASS- KEY BEFORE PERFORMING ENGER SEAT & ONLY IF THE MAINTENANCE OR REPAIR WORK DRIVER'S VIEW IS NOT HINDERED MACHINE TIPPING USE CAUTION ON STEEP HILLS MACHINE TIPPING...
Page 9 FULL BED REMOVAL (Model RE-INSTALLING THE FULL BED 07202 only) (Model 07202 only) Note: If bed sides will be installed on the flat 1. Start the engine. Engage the hydraulic lift lever bed, it is easier to install them before and lower the bed until the cylinders are loose in installing the bed on the vehicle.
Page 10 Note: If automatic tail gate release has been installed on bed, make sure front dump link rod has been placed on inside of left side clevis pin before Iynch pin is installed. 6. Once cylinder installation has been completed, the bed safety support can be used to prevent accidental lowering of the bed.
Page 11: Specifications
Specifications Type: 4-wheel step-through, out-front operator style, Tires: two-person vehicle. Certified to meet ANSI Specifications B56.8-1988. Front tires: 50.8 x 25.4 cm (20” x 10”)-10, 4-ply rat- ing, rib tread. Engine: Mitsubishi three-cylinder, liquid-cooled, counterbalanced, gasoline engine. Rated at 20 kW Rear tires: 61 x 38 cm (24"...
Page 12 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).
Page 13: Before Operating
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 IN TORO GASOLINE POWERED PRODUCTS.
Page 14 Before Operating SYSTEM DAMAGE COULD RESULT. 4. Wipe up any fuel that may have spilled to pre- vent a fire hazard. 1. Clean the area around the fuel tank cap. CHECK THE COOLING SYSTEM CAUTION If the engine has been running, pressurized hot coolant can escape if radiator cap is removed and cause burns.
Page 15 Before Operating 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 and every 8 hours or daily, thereafter. Capacity of the system is 7.1 l (7.5 qt).
Page 16: Check Tire Pressure
Before Operating 3. If the fluid level is low, clean the area around cap, remove the reservoir cap and fill to proper 20” FRONT TIRES level. DO NOT OVERFILL. 138 152 Tire pressure (Nm) Figure 9 23” REAR TIRES 1. Brake fluid reservoir 2.
Page 17: Controls
Controls Accelerator Pedal (Fig. 10)—Used to vary engine Shift Pattern and ground speed when the transmission is in gear. Depressing the pedal increases engine RPM and ground speed. Releasing it will decrease engine RPM and ground speed. IMPOR- TANT: Do not shift the transaxle to the reverse or forward gear unless the vehicle is standing still.
Page 18 Controls 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 fully rearward for Low.
Page 19 “ON” position. engine is restarted, turn the engine off immediately and contact your local TORO distributor for assis- 3rd High Lockout Switch (Fig. 13)—Moving this tance. switch to the slow position and removing the key...
Page 20: Operating
Never pump the accelera- tor pedal. 2. Check all fluid levels and add the appropriate amount of Toro-specified fluids, if any are found 5. Insert the key into the ignition switch and turn it to be low.
Page 21: Stopping The Vehicle
Operating battery. • A break-in oil for the engine is not required. The original engine oil is the same type specified for IMPORTANT: Do not keep the front wheels regular oil changes. turned against the right or left stops for longer than 5 seconds.
Page 22 Operating OPERATING One of the most important rules to follow is to go slower in unfamiliar areas. It is surprising how much CHARACTERISTICS damage and injury common things can cause. Tree branches, fences, wires, other vehicles, tree stumps, The vehicle is designed with safety in mind. It has ditches, sand traps, streams, and other things found four wheels for added stability.
Page 23 TIPOVERS difficult and risky. The faster you are going, the worse this situation becomes so, slow down before turning. The TORO WORKMAN ® is equipped with a roll bar, hip restraints, shoulder restraints and hand hold. During a sharp turn at higher speeds, the inside rear The Roll Over Protection System used on the vehicle wheel may lift off of the ground.
Page 24 Operating In case of tipover Don’t jump Tipover can occur if the truck is improp- erly operated. Injury or death could result. HILLS WARNING Tipping or rolling the vehicle on a hill will cause serious personal injury. Operator: Hold tight and brace feet. •...
Page 25 Operating make sharp or fast turns on a hill. The weight and position of the cargo and passenger can change the vehicle center of gravity and vehicle If you stall or begin to lose headway while climbing handling. To avoid loss of control resulting in per- a steep hill, quickly apply the brakes, shift to neutral, sonal injury, follow these guidelines.
Page 26: Transporting The Vehicle
In case of emergency, the vehicle can be towed for a out. This can help when you have heavy loads to short distance. However, Toro does not recommend haul on wet turf or slippery areas, going up hills and this as a standard procedure.
Page 27 Several types of tow hitches are available for the Workman, depending on your application. Contact your Authorized TORO Distributor for details. When equipped with a tow hitch bolted onto rear axle tube, your Workman can tow trailers or attach- ments with a Gross Trailer Weight (GTW) up to 680 kg.
Page 28: Maintenance
Maintenance 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 •...
Page 29: Maintenance Schedule
Maintenance Maintenance Schedule Minimum Recommended Maintenance Intervals Maintenance Procedure Maintenance Interval& Service Check battery fluid level/ Every Every Every Every Every 50 cable connections hours hours hours hours hours Lubricate all grease fittings Inspect the condition and wear of the tires Check front differential oil level (4-wheel drive) ‡Change engine oil and filter Inspect cooling system hoses...
Page 30 Maintenance Check/Service 1. Engine oil level Radiator screen cleanout door 2. Engine oil drain Air filter 3. Transaxle/Hydraulic oil level (dipstick) Fuel filter 4. Belts (Governor, water pump Battery hydraulic pump) 5. Coolant level fill Tire pressure—maximum 1,4 kg/cm front 2,3kg/cm rear (23"...
Page 31 Maintenance GREASING BEARINGS AND BUSHINGS WARNING Before servicing or making adjustments to the machine, stop the engine, set the parking brake and remove key from the ignition switch. Any load material must be removed from bed or other attach- ment before working under raised bed. Never work under a raised bed without positioning safety sup- port on a fully installed cylinder rod.
Page 32 Maintenance Figure 19 Figure 21 Figure 20 Figure 22 IMPORTANT • Construction work • After extended operation in mud, sand, water or Heavy Duty Operation similar dirty conditions, have your brakes inspected and cleaned and drive axle joints If the vehicle is subjected to conditions listed below, greased as soon as possible.
Page 33: Jacking The Vehicle
Maintenance 5. Always install or remove bed support from out- CAUTION side of bed. Only qualified and authorized personnel shall be 6. Do not try to lower bed with bed safety support permitted to maintain, repair, adjust or inspect the on cylinder.
Page 34 Maintenance rear it is under the axle tube. Locations For Selected Maintenance Procedures 4. When jacking up front of the vehicle, always place a 50 x 100mm block (or similar material) between the jack and vehicle frame. Figure 25 1. Front jacking point Figure 27 1.
Page 35 Maintenance Figure 33 Figure 30 1. Governor belt 3. Idler pulley 1. Fuel Filter 2. Alternator belt Figure 31 1. Radiator screen cover 2. Clean out door Figure 34 1. Fan belt 2. Idler pulley CHECKING THE OIL LEVEL IN THE GOVERNOR Check the oil level in the governor after every 600 hours of operation.
Page 36 Maintenance When the oil is at point of overflowing from the check plug hole, install the check plug and fill plug. Figure 37 1. Hydraulic Filter 2. Gasket Figure 35 1. Governor 2. Check plug 3. Fill plug 4. Governor output lever 5.
Page 37: Jump Starting Procedure
Maintenance 3. Rotate tie rod to move front of tire inward or outward. 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 cranking Figure 40 starter and holding lift lever.
Page 38 Connecting cables to the wrong post could result in personal injury and/or damage to the To order replacement parts from an authorized TORO Distributor, supply the following information: electrical system. 1. Model and serial numbers. 2. Part number, description, and quantity of parts desired.

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07202 07216 Workman 4200 3200

Toro 07200 Operator's Manual

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