Toro 7220 User manual

FORM NO. 3325-605
The TORO Company - 2001
MODEL NO. 07220 - 210000001 & Up OPERATOR'S
MANUAL
WORKMAN3210
Liquid Cooled Gas Heavy Industry Vehicle
To ensure maximum safety, optimum performance,
and to gain knowledge of the product, it is essential
that you or any other operator of the machine read
and understand the contents of this manual before
the engine is ever started. Pay particular attention
to the SAFETY INSTRUCTIONS highlighted by this
symbol-
The safety alert symbol means CAUTION,
WARNING or DANGER  personal safety
instruction. Failure to comply with the instruction
may result in personal injury or death.

2
FOREWORD
The TORO WORKMANwas developed to provide an efficient, versatile, trouble free and economical work vehicle.
The latest concepts of engineering, design and safety have been incorporated into this machine, along with the
highest quality parts and workmanship. Excellent service will be derived if proper operation and maintenance
practices are followed.
WARNING
The WORKMANis an off-highway
vehicle only, and is not designed,
equipped, or manufactured for use on
public streets, roads or highways.
You know, since you have purchased the industry leader in maintenance excellence, that future performance and
dependability are of prime importance. TORO also is concerned about future use of the machine and of safety to the
user. Therefore, this manual must be read by you and those involved with the WORKMANto make sure that safety,
proper setup, operation and maintenance procedures are followed at all times. The major sections of the manual
are:
1. Safety Instructions
2. SetUp Instructions
3. Before Operating
4. Operating Instructions
5. Maintenance
Safety, mechanical and some general information in this manual are emphasized. DANGER, WARNING and
CAUTION identify safety messages. Whenever the triangle safety symbol appears, it is followed by a safety
message that must be read and understood. For more details concerning safety, read the safety instructions on
pages 5-7. IMPORTANT identifies special mechanical information and NOTE identifies general information worthy
of special attention.
The engine exhaust from this product
contains chemicals known to the State of
California to cause cancer, birth defects,
or other reproductive harm.

3
FOREWORD
The TORO WORKMAN meets the requirements of ANSI B56.8a-1994 and SAE J2258.
Supervisors, operators and service persons should be familiar with the following standards and publications:
(The material may be obtained from the address shown).
Flammable and Combustible Liquids Code:
ANSI/NFPA 30
National Fire Protection Association:
ANSI/NFPA #505; Powered Industrial Trucks
ADDRESS:
National Fire Prevention Association
Barrymarch Park
Quincy, Massachusetts 02269 U.S.A
ANSI/ASME B56.8 Personal Burden Carriers
ADDRESS:
American National Standards Institute, Inc.
1430 Broadway
New York, New York 10018 U.S.A.
ANSI/UL 558; Internal Combustion Engine Powered Industrial Trucks
ADDRESS:
American National Standards Institute, Inc.
1430 Broadway
New York, New York 10018 U.S.A.
OR
Underwriters Laboratories
333 Pfingsten Road
Northbrook, Illinois 60062 U.S.A.
OPTIONAL SPARK ARRESTER
In some places a spark arrester muffler must be used because of local, state or federal regulations. The spark
arrester, available from your local Toro Distributor is approved by the United States Department of Agriculture and
the United States Forest Service.
When the machine is used or operated on any California forest, brush or grass covered land, a properly
operating spark arrester must be attached to the muffler. The operator is violating state law, Section 442
Public Resources Code if a spark arrester is not used.
If help concerning set up, operation, maintenance or safety is ever needed, contact your local Authorized TORO
Distributor. In addition to genuine TORO replacement parts, the distributor also has optional equipment for the
complete line of TORO turf care equipment. Keep your TORO all TORO. Buy genuine TORO parts and accessories.

4
TABLE OF CONTENTS
SAFETY INSTRUCTIONS 5-7. . . . . . . . . . . . . . . . . . .
SAFETY AND INSTRUCTION DECALS 8-10. . . . .
SPECIFICATIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
LOOSE PARTS CHART 12. . . . . . . . . . . . . . . . . . . . . . .
SET-UP INSTRUCTIONS 13-15. . . . . . . . . . . . . . . .
Install Wheels 13. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install Steering Wheel 13. . . . . . . . . . . . . . . . . . . . .
Install Front Fenders 14. . . . . . . . . . . . . . . . . . . . . .
Install Seat Frame 14. . . . . . . . . . . . . . . . . . . . . . . .
Install Seat Back Cushions, Manual Tube and
Bed Support 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Install ROPS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Activate and Charge Battery 14. . . . . . . . . . . . . . .
BEFORE OPERATING 16-21. . . . . . . . . . . . . . . . . . .
Check Crankcase Oil 16. . . . . . . . . . . . . . . . . . . . . .
Fill Fuel Tank 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Cooling System 17. . . . . . . . . . . . . . . . . . . .
Check Transaxle / Hydraulic Fluid 17. . . . . . . . . . .
Check Torque Of Wheel Nuts 18. . . . . . . . . . . . . .
Check Brake Fluid 18. . . . . . . . . . . . . . . . . . . . . . . .
CONTROLS 19-20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING INSTRUCTIONS 21-31. . . . . . . . . . . . .
Pre-starting Checks 21. . . . . . . . . . . . . . . . . . . . . .
Starting Engine 21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Driving Vehicle 21. . . . . . . . . . . . . . . . . . . . . . . . . . .
Stopping Vehicle 21. . . . . . . . . . . . . . . . . . . . . . . . .
Stopping Engine 21. . . . . . . . . . . . . . . . . . . . . . . . .
New Vehicle Break-in 21. . . . . . . . . . . . . . . . . . . .
Check Interlock System 22. . . . . . . . . . . . . . . . . . .
Operating Characteristics 22. . . . . . . . . . . . . . . . . .
Passengers 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Speed 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Turning 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Braking 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tipovers 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Hills 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading And Dumping 24. . . . . . . . . . . . . . . . . . . .
Transporting Vehicle 25. . . . . . . . . . . . . . . . . . . . . .
Towing Vehicle 25. . . . . . . . . . . . . . . . . . . . . . . . . . .
Trailer Towing 26. . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE CHART & CHECKLIST 27. . . . . . . .
LUBRICATION 28-29. . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE 30-42. . . . . . . . . . . . . . . . . . . . . . . . .
Jacking Vehicle 30. . . . . . . . . . . . . . . . . . . . . . . . . . .
General Air Cleaner Maintenance 30. . . . . . . . . . .
Servicing Air Cleaner 31. . . . . . . . . . . . . . . . . . . . . .
Changing Engine Oil And Filter 31. . . . . . . . . . . . .
Fuel System 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Debris From Cooling System 32. . . . .
Changing Engine Coolant 32. . . . . . . . . . . . . . . . .
Adjusting Belts 32. . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Oil Level In Governor 33. . . . . . . . . . . . .
Adjusting Accelerator Pedal 33. . . . . . . . . . . . . . . .
Changing Transaxle / Hydraulic Fluid 34. . . . . . .
Replacing Hydraulic Filter 34. . . . . . . . . . . . . . . . .
Cleaning Hydraulic Strainer 34. . . . . . . . . . . . . . . .
Replacing Spark Plugs 34. . . . . . . . . . . . . . . . . . . .
Adjusting Brake Pedal 35. . . . . . . . . . . . . . . . . . . . .
Adjusting Clutch Pedal 35. . . . . . . . . . . . . . . . . . . .
Adjusting Parking Brake 36. . . . . . . . . . . . . . . . . . .
Adjusting Shift Cables 36. . . . . . . . . . . . . . . . . . . .
Inspect Brakes 36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspect Tires 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Wheel Toe-in 36. . . . . . . . . . . . . . . . . . . . . . .
Fuses 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Jump Starting Procedure 37. . . . . . . . . . . . . . . . . .
Battery Storage 37. . . . . . . . . . . . . . . . . . . . . . . . . .
Battery Care 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE SCHEDULE 38. . . . . . . . . . . . . . . . . .
HYDRAULIC SCHEMATIC 39. . . . . . . . . . . . . . . . . . . .
ELECTRICAL SCHEMATIC 40. . . . . . . . . . . . . . . . . . .
IDENTIFICATION AND ORDERING 43. . . . . . . . . . . .
Model And Serial Numbers 43. . . . . . . . . . . . . . . .
WARRANTY BACK COVER. . . . . . . . . . . . . . . . . . . . . .

5
SAFETY INSTRUCTIONS
The WORKMANwas designed and tested to offer
safe service when operated and maintained
properly. Although hazard control and accident
prevention partially are dependent upon the design
and configuration of the machine, these factors are
also dependent upon the awareness, concern, and
proper training of the personnel involved in the
operation, maintenance and storage of the
machine. Improper use or maintenance of the
machine can result in injury or death.
This is a specialized utility vehicle designed for
off-road use only. Its ride and handling will have a
different feel than what drivers experience with
passenger cars or trucks. So take time to become
familiar with your WORKMAN.
Not all of the attachments that adapt to the
WORKMANare covered in this manual. See the
specific Operator's Manual provided with
attachment for additional safety instructions. READ
THESE MANUALS.
TO REDUCE THE POTENTIAL FOR INJURY OR
DEATH, COMPLY WITH THE FOLLOWING SAFETY
INSTRUCTIONS.
SUPERVISOR'S RESPONSIBILITIES
1. Make sure operators are thoroughly trained and
familiar with the Operator's Manual and all labels on the
vehicle.
2. Be sure to establish your own special procedures
and work rules for unusual operating conditions (e.g.
slopes too steep for vehicle operation).
BEFORE OPERATING
3. Operate the machine only after reading and
understanding the contents of this manual. A
replacement manual is available by sending complete
model and serial number to:
The Toro Company
8111 Lyndale Avenue South
Bloomington, Minnesota 55420-1196.
4. Never allow children to operate the vehicle. Never
allow adults to operate it without proper instructions.
Only trained and authorized persons should operate
this vehicle. Make sure all operators are physically and
mentally capable of operating the vehicle. Anyone who
operates the vehicle should have a motor vehicle
license.
5. This vehicle is designed to carry only you, the
operator, and one passenger in the seat provided by
the manufacturer. Never carry any other passengers
on the vehicle.
6. Never operate the vehicle when under the
influence of drugs or alcohol.
7. Become familiar with the controls and know how to
stop the engine quickly.
8. Keep all shields, safety devices and decals in
place. If a shield, safety device or decal is
malfunctioning, illegible, or damaged, repair or replace
it before operating the machine.
9. Always wear substantial shoes. Do not operate
machine while wearing sandals, tennis shoes or
sneakers. Do not wear loose fitting clothing or jewelry
which could get caught in moving parts and cause
personal injury.
10. Wearing safety glasses, safety shoes, long pants
and a helmet is advisable and required by some local
safety and insurance regulations.
11. Keep everyone, especially children and pets, away
from the areas of operation.
12. Before operating the vehicle, always check all
parts of the vehicle and any attachments. If something
is wrong, stop using vehicle. Make sure problem is
corrected before vehicle or attachment is operated
again.
13. Since gasoline is highly flammable, handle it
carefully.
A. Use an approved gasoline container.
B. Do not remove cap from fuel tank when engine
is hot or running.
C. Do not smoke while handling gasoline.
D. Fill fuel tank outdoors and to about one inch
below top of tank (bottom of filler neck). Do not
overfill.
E. Wipe up any spilled fuel.
14. Check the safety interlock system daily for proper
operation; refer to page 25. If a switch should
malfunction, replace the switch before operating
machine. After every two years, replace the interlock
switches in the safety system, whether they are
working properly or not.
WHILE OPERATING
15. Operator and passenger should remain seated
whenever the vehicle is in motion. Operator should
keep both hands on steering wheel, whenever
possible and passenger should use hand holds
provided. Keep arms and legs within the vehicle body
at all times. Never carry passengers in box or on
attachments. Remember your passenger may not be
expecting you to brake or turn and may not be ready.
16. Never overload your vehicle. Name plate (located
under dash on passenger side) shows load limits for
vehicle. Never overfill attachments or exceed the
vehicle maximum GVW.

6
SAFETY INSTRUCTIONS
17. When starting the engine:
A. Sit on operator's seat and engage parking
brake.
B. Disengage any attachments and return hand
throttle lever to OFF position (if so equipped).
C. Move shift lever to NEUTRAL and depress
clutch pedal.
D. Keep foot off accelerator pedal.
E. Turn ignition key to ON, then to START.
18. Using the machine demands attention. Failure to
operate vehicle safely may result in a accident, tip over
of vehicle and serious injury or death. Drive carefully. To
prevent tipping or loss of control:
A. Use extreme caution, reduce speed and
maintain a safe distance around indoor obstacles,
ditches, creeks, ramps, any unfamiliar areas or
other hazards.
B. Watch for holes or other hidden hazards.
C. Use caution when operating vehicle on a steep
slope. Normally travel straight up and down
slopes. Reduce speed when making sharp turns
or when turning on hillsides. Avoid turning on
hillsides whenever possible.
D. Use extra caution when operating vehicle on
wet surfaces, at higher speeds or with a full load.
Stopping time will increase with a full load. Shift
into a lower gear before starting up or down a hill.
E. When loading bed, distribute load evenly. Use
extra caution if the load exceeds the dimensions of
the vehicle/bed. Operate vehicle with extra caution
when handling off-center loads that cannot be
centered. Keep loads balanced and secure to
prevent them from shifting.
F. Avoid sudden stops and starts. Do not go from
reverse to forward or forward to reverse without
first coming to a complete stop.
G. Do not attempt sharp turns or abrupt
maneuvers or other unsafe driving actions that
may cause a loss of vehicle control.
H. When dumping, do not let anyone stand
behind vehicle and do not dump load on any one's
feet. Release tailgate latches from side of box, not
from behind.
I. Before backing up, look to the rear and assure
no one is behind. Back up slowly.
J. Watch out for traffic when near or crossing
roads. Always yield the right of way to pedestrians
and other vehicles. This vehicle is not designed for
use on streets or highways. Always signal your
turns or stop early enough so other persons know
what you plan to do. Obey all traffic rules and
regulations.
K. Never operate vehicle in or near an area where
there is dust or fumes in the air which are explosive.
The electrical and exhaust systems of the vehicle
can produce sparks capable of igniting explosive
materials.
L. Always watch out for and avoid low over hangs
such as tree limbs, door jambs, over head
walkways, etc. Make sure there is enough room
over head to easily clear the vehicle and your head.
M. If ever unsure about safe operation, STOP
WORK and ask your supervisor.
19. Do not touch engine, transaxle, radiator, muffler or
muffler shield while engine is running or soon after it
has stopped because these areas may be hot enough
to cause burns.
20. If the machine ever vibrates abnormally, stop
immediately, turn engine off, wait for all motion to stop
and inspect for damage. Repair all damage before
commencing operation.
21. Before getting off the seat:
A. Stop movement of the machine.
B. Shut engine off and wait for all movement to
stop.
C. Set parking brake.
D. Remove key from ignition.
E. Block wheels if machine is on an incline.
MAINTENANCE
22. Before servicing or making adjustments to the
machine, stop engine, set parking brake and remove
key from ignition to prevent accidental starting of the
engine.
23. Never work under a raised bed without placing a
bed safety support under bed to keep bed in raised
position.
24. Make sure all hydraulic line connectors are tight,
and all hydraulic hoses and lines are in good condition
before applying pressure to the system.
25. Keep body and hands away from pin hole leaks or
nozzles that eject hydraulic fluid under high pressure.
Use paper or cardboard, not hands, to search for
leaks. Hydraulic fluid escaping under pressure can
have sufficient force to penetrate skin and do serious
damage. If fluid is injected into the skin it must be
surgically removed within a few hours by a doctor
familiar with this form of injury or gangrene may result.

7
SAFETY INSTRUCTIONS
26. Before disconnecting or performing any work on
the hydraulic system, all pressure in system must be
relieved by stopping engine.
27. To make sure entire machine is in good condition,
keep all nuts, bolts and screws properly tightened.
28. To reduce potential fire hazard, keep the engine
area free of excessive grease, grass, leaves and
accumulation of dirt.
29. If the engine must be running to perform a
maintenance adjustment, keep hands, feet, clothing,
and any parts of the body away from the engine and
any moving parts. Keep everyone away.
30. Do not overspeed engine by changing governor
settings. Maximum engine speed is 3650 rpm. To
assure safety and accuracy, have an Authorized TORO
Distributor check maximum engine speed with a
tachometer.
31. If major repairs are ever needed or assistance is
required, contact an Authorized TORO Distributor.
32. To be sure of optimum performance and safety,
always purchase genuine TORO replacement parts
and accessories. Replacement parts and accessories
made by other manufacturers could be dangerous.
Altering this vehicle in any manner may affect the
vehicle's operation, performance, durability or its use
may result in injury or death. Such use could void the
product warranty of The TORO Company.
33. This vehicle should not be modified without the
TORO Company's authorization. Direct any inquiries
to:
The TORO Company
Commercial Division
Vehicle Engineering Dept.
300 West 82nd St.
Bloomington, Minnesota 55420-1196 USA
SOUND PRESSURE LEVEL
This unit, when operating at 3600 RPM, has an
equivalent continuous Aweighted sound pressure at
the operator ear of 78 dB(A), based on measurements
of identical machines per Directive 84/538/EEC and
amendments.
VIBRATION LEVEL
HandArm
This unit does not exceed a vibration level of 2.5 m/s,
at the hands based on measurements of identical
machines per ISO 5349 procedures.
WHOLE BODY
This unit does not exceed a vibration level of 0.5 m/s
at the posterior based on measurements of identical
machines per ISO 2631 procedures.

8
SAFETY AND INSTRUCTION DECALS
The following safety and instruction decals are installed on the machine. If any become damaged or illegible,
replace them. Decal part numbers are listed below and in the parts catalog. Order replacements from your
Authorized TORO Distributor.
ON REAR SKIRT
(Part No. 99-1125)
ON REAR AXLE TUBE
(Part No. 87-9080)
ON FAN SHROUD
(Part No. 76-8750)
ON DASH
(Part No. 87-8520

9
SAFETY AND INSTRUCTION DECALS
UNDER DASH NEXT
TO FUSE BLOCK
(Part No. 87-6670) ON SKIRT
(Part No. 87-5920)
ON LEFT FRAME RAIL
(Part No. 66-6840)
ON SPRING CRADLE
(Part No. 44-0760)
THIS ARM IS SPRING LOADED!
SEE OPERATORS MANUAL FOR DISASSEMBLY PROCEDURE
WARNING
UNDER RIGHT SIDE OF DASH
(Part No. 87-9500)
'
ON BATTERY COVER
(Part No. 36-3400)
DO NOT STEP
ON FAN SUPPORT
(Part No. 80-8040)
ON DASH
(Part No. 94-5272)

10
SAFETY AND INSTRUCTION DECALS
ON ROPS
(Part No. 87-5980)
ON AXLE TUBE
(Part No. 87-6060)
HITCH RATING:
MAXIMUM TONGUE
WEIGHT 200 LBS.
MAXIMUM
TRAILER WEIGHT;
1500 LBS.
TRANSMISSION
FLUID
USE DEXRON IIl
AUTOMATIC
TRANSMISSION
FLUID OR
EQUIVALENT
ON ROPS
(Part No. 87-5940)
ON SKIRT
(Part No. 87-5930)
ON CONSOLE
(Part No. 87-6020)
IN FRONT OF RADIATOR
(Part No. 87-9420)