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25

Stopping Engine

To stop engine, rotate ignition key to OFF and engage

parking brake. Remove key from switch to prevent

accidental starting.

New Vehicle Break–in

Your Workman is ready for work. To provide proper

performance and long vehicle life, follow these guidelines

for the first 100 operating hours.

Check the fluid and engine oil levels regularly and be

alert for indications of overheating in any component of

the vehicle.

After starting a cold engine, let it warm up at idle speed

for about 15 seconds before shifting into gear.

Avoid racing the engine.

To assure optimum performance of the brake system,

burnish (break–in) the brakes before use. To burnish

brakes: Operate the vehicle at full speed for 3 minutes,

apply the brakes for 30 seconds while driving in 1st

gear. Repeat these steps 20 to 30 times. To verify the

brakes are completely burnished remove a rear tire and

inspect the brake drum for residue. The residue color

should be light grey to almost white color.

Vary vehicle speeds during operation. Avoid excessive

idling. Avoid fast starts and quick stops.

A break–in oil for the engine is not required. Original

engine oil is the same type specified for regular oil

changes.

Refer to Maintenance section of Operator’s Manual for

any special low hour checks.

Check Interlock System

The purpose of the interlock system is to prevent the engine

from cranking or starting unless the clutch pedal is

depressed.

To verify clutch interlock switch operation:

1.

Sit on operator’s seat and engage parking brake. Move

shift lever to NEUTRAL position.

2.

Without depressing clutch pedal, rotate key clockwise

to start position.

3.

If engine cranks or starts, there is a malfunction in the

interlock system that must be repaired before operating

vehicle.

If safety interlock switches are disconnected or
damaged the machine could operate unexpectedly
causing personal injury.

Do not tamper with the interlock switches.

Check the operation of the interlock switches

daily and replace any damaged switches before

operating the machine.

Replace switches every two years or 1500 hours,

whichever occurs first, regardless of whether

they are operating properly or not.

Caution

Refer to Attachment Operator’s Manual for procedure

on checking attachment interlock system.

Operating Characteristics

The vehicle is designed with safety in mind. It has four

wheels for added stability. It uses familiar automotive style

controls, including the steering wheel, brake pedal, clutch

pedal, accelerator pedal, and gear shift. It is important to

remember, however, that this vehicle is not a passenger car.

It is a work vehicle and is designed for off road use only.

The WORKMAN is an off–highway vehicle
only, and is not designed, equipped, or

manufactured for use on public streets, roads
or highways.

Warning

The vehicle has special tires, low gear ratios, a locking

differential, and other features that give it extra traction.

These features add to the versatility of the vehicle but, they

can also get you into dangerous situations. You must keep

in mind that the vehicle is not a recreation vehicle. It is not

an all terrain vehicle. And, it is definitely not meant for

“stunt driving” or “horsing around”. It is a work vehicle,

not a play vehicle. Children should not be allowed to

operate the vehicle. Anyone who operates the vehicle

should have a motor vehicle license and be trained how to

operate vehicle.

Driver and passenger should always use the seat belts.

If you are not experienced at driving the vehicle, practice

driving it in a safe area away from other people. Be sure

you are familiar with all the vehicle’s controls, particularly

those used for braking, steering and transmission shifting.

Learn how your vehicle handles on different surfaces. Your

operating skills will improve with experience, but as in

operating any vehicle, take it easy as you begin. Be sure

you know how to stop quickly in an emergency. If you need

help, ask your supervisor for assistance.

Summary of Contents for 7363

Page 1: ...Operator s Manual English EN Form No 3352 442 Rev C Workman 3100 Air Cooled Gas Utility Vehicle Model No 07363 Serial No 250000001 and Up...

Page 2: ...21 Controls 21 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 Passe...

Page 3: ...precautions Warning signals a hazard that may cause serious injury or death if you do not follow the recommended precautions Caution signals a hazard that may cause minor or moderate injury if you do...

Page 4: ...te 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 operat...

Page 5: ...never possible 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...

Page 6: ...ngine area free of excessive grease grass leaves and accumulation of dirt If the engine must be running to perform a maintenance adjustment keep hands feet clothing and any parts of the body away from...

Page 7: ...ual 2 Crushing hazard install the cylinder lock 93 9442 1 Maximum tongue weight is 90 kg maximum trailer weight is 680 kg 2 For information on transmission fluid read the Operator s Manual 93 6687 1 D...

Page 8: ...ry 100 hours 3 Add grease 9 grease points 93 8071 1 Hot surface burn hazard stay a safe distance from the hot surface 106 2353 1 Electrical power 106 2355 1 Slow to fast 2 Transmission third high no f...

Page 9: ...Manual 2 Fire hazard stop the engine before fueling 3 Tipping hazard do not drive the vehicle across or up a slope greater than 12 degrees slow down and turn gradually do not exceed 16 mph 26 kmh and...

Page 10: ...draulic lock 5 Engage 6 Power take off PTO 7 Disengage 8 Warning read the Operator s Manual 9 Entanglement hazard shaft keep bystanders a safe distance from the vehicle 10 Retract hydraulics 11 Extend...

Page 11: ...e 25 mm between the fuel and the top of the tank read the Operator s Manual Battery Symbols Some or all of these symbols are on your battery 1 Explosion hazard 2 No fire open flames or smoking 3 Caust...

Page 12: ...ead Rear tires 24 x 12 12 6 ply rating turf tread Brakes 4 wheel hydraulic dual safety circuit self adjusting drum 8 diameter front and rear Hand actuated parking brake actuates rear brake shoes ROPS...

Page 13: ...ss Vehicle Weight 4 000 lbs Tow Capacity Tongue weight 200 lbs Maximum trailer weight 1 500 lbs Ground Clearance 7 w no load Wheel Base 70 Wheel Tread center line to center line Front 46 Rear 47 7 Dim...

Page 14: ...tery If battery is not filled with electrolyte or activated it must be removed from vehicle filled with electrolyte and charged Bulk electrolyte with 1 260 specific gravity can be purchased from a loc...

Page 15: ...ell until level is up to fill ring Install filler caps Important Do not overfill battery Electrolyte will overflow onto other parts of the vehicle and severe corrosion and deterioration will result 7...

Page 16: ...hoist or get the help of two or three other people Caution 6 Store cylinders in storage clips Engage hydraulic lift lock lever on vehicle to prevent accidental extension of lift cylinders Re Install F...

Page 17: ...ylinders for alignment with holes Keep fingers out Note Unused slot can be plugged with a capscrew and nut to prevent assembly errors 4 Start engine and engage hydraulic lift lever to raise bed Releas...

Page 18: ...en adding oil remove dipstick to allow proper venting pour oil slowly and check the level often during this process DO NOT OVERFILL Important When adding engine oil or filling oil there must be cleara...

Page 19: ...very 8 hours or daily thereafter Capacity of system is 7 5 qt 1 Position the vehicle on a level surface 2 Clean area around dipstick 3 Unscrew dipstick from top of transaxle and wipe it with a clean r...

Page 20: ...2 1 Figure 11 1 Cup holder 2 Knob 3 Fluid level should be up to FULL line on reservoir 1 Figure 12 1 Brake fluid reservoir 4 If fluid level is low clean area around cap remove reservoir cap and fill t...

Page 21: ...ervice brakes to stop or slow vehicle Worn or misadjusted brakes may result in personal injury If brake pedal travels to within 1 1 2 of the vehicle floor board the brakes must be adjusted or repaired...

Page 22: ...nal speeds for precise speed control Fig 14 Vehicle must be completely stopped before shifting between High and Low range Shift only on level ground Depress clutch pedal fully Move lever fully forward...

Page 23: ...e is a malfunction in the system which must be repaired Note If engine was just turned off it may take 1 to 2 minutes for light to come on Fuel Gauge Shows amount of fuel in tank Operates only when ig...

Page 24: ...pedal and hold it to the floor until the engine starts Never pump the accelerator pedal 5 Insert key into ignition switch and rotate it clockwise to start the engine Release key when engine starts Im...

Page 25: ...njury Do not tamper with the interlock switches Check the operation of the interlock switches daily and replace any damaged switches before operating the machine Replace switches every two years or 15...

Page 26: ...your passenger does not know what you are going to do next and may not be prepared for turning stopping accelerating and bumps You and your passenger should remain seated at all times keeping arms and...

Page 27: ...area in which vehicle is being operated The best way for operators to prevent serious injury or death to themselves or others is to familiarize themselves with the proper operation of the utility vehi...

Page 28: ...duce steering traction With the load all the way to the back the front wheels can even come off of the ground when going over bumps or up a hill This will result in a loss of steering and may lead to...

Page 29: ...icle When towing either standard tongue or 5th wheel trailers having a Gross Trailer Weight GTW in excess of 1500 lbs use either a chassis mounted draw bar hitch rated for 3500 lb GTW or 5th wheel kit...

Page 30: ...position Important Check hydraulic oil level after installation of attachment Check operation of attachment by cycling attachment several times to purge air from system then recheck hydraulic oil leve...

Page 31: ...essure Power steering hard Hydraulic oil level low Hydraulic oil hot Pump not operating Hydraulic leaks Fittings loose Fitting missing o ring Attachment does not function Quick couplers not fully enga...

Page 32: ...on is required if used for heavy duty vehicle operations The grease fitting locations and quantities are Steering pitman arm 1 and Steering ball joint ends 2 Fig 24 Tie rod ends 4 Fig 25 Front ball jo...

Page 33: ...33 Figure 25 Figure 26 Figure 27 Figure 28...

Page 34: ...ds and clean fins Every 200 hours Check cable adjustments Check pump drive belt tension Replace air cleaner filter Check engine RPM idle and full throttle Torque wheel lug nuts Every 400 hours Check f...

Page 35: ...evel Check the transaxle oil level Check the brake fluid level Check the air filter prefilter Inspect engine cooling fins Check for any unusual engine noises Check for any unusual operating noises Che...

Page 36: ...r inspect the vehicle Avoid fire hazards and have fire protection equipment present in the work area Do not use an open flame to check level or leakage of fuel battery electrolyte or coolant Do not us...

Page 37: ...any one beneath it 3 The jacking point at the front of the vehicle is under the front center frame support and at the rear it is under the axle tube 4 When jacking up front of vehicle always place a 2...

Page 38: ...2 Remove drain plug and let oil flow into drain pan When oil stops install drain plug 3 Remove oil filter Apply a light coat of clean oil to the new filter seal before screwing it on Screw filter on...

Page 39: ...p until desired belt tension is attained Tighten nuts Adjusting Choke 1 Raise bed and place safety support on extended lift cylinder to hold up bed Stop engine and engage parking brake 2 Loosen cable...

Page 40: ...o obtain 3600 50 rpm when throttle lever contacts stop 5 Stop engine 6 Adjust ball joint on accelerator cable and or cable jam nuts while throttle lever is against high idle stop to allow 100 250 of c...

Page 41: ...Hydraulic Strainer Clean hydraulic strainer every 800 hours 1 Position the vehicle on a level surface stop engine engage the parking brake and remove key from ignition switch 2 Remove drain plug Fig...

Page 42: ...st jam nuts or ball joint until bottom rear edge of clutch pedal is 3 75 12 from top of floor plate diamond pattern when an 4 lb force is applied to pedal Note Force is applied so release bearing ligh...

Page 43: ...ew after adjustment has been attained 5 Install rubber grip onto parking brake lever Adjusting Shift Cables Check adjustment every 200 hours 1 Move shift lever to Neutral position 2 Remove clevis pins...

Page 44: ...ition after an accident Front Wheel Toe After every 400 operating hours or annually check front wheel toe out 1 Measure center to center distance at axle height at front and rear of steering tires The...

Page 45: ...coupler hoses from the hoses secured to the coupler bracket Fig 54 1 Figure 54 1 Quick coupler hoses On the disabled vehicle connect the two jumper hoses to the hoses that were disconnected Fig 55 Ca...

Page 46: ...ing Observe all battery warnings while jump starting your vehicle Be sure your vehicle is not touching the jump start vehicle Connecting cables to the wrong post could result in personal injury and or...

Page 47: ...ly maintained and the top of the battery kept clean lf the machine is stored in a location where temperatures are extremely high the battery will run down more rapidly than if the machine is stored in...

Page 48: ...48 Hydraulic Schematic...

Page 49: ...KE SW P102 B BN W BK CLUTCH SWITCH ENGINE BU P101 F BK P102 A OIL PRES W BK 86 TAIL BRAKE LIGHTS STARTER FACTORY SHUNT VIA MATING CONN TEMPERATURE SENDER TEMP I G S FUEL S G I GN GREEN OR ORANGE BK R...

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Page 52: ...limited to weather storage practices contamination use of unapproved coolants lubricants additives or chemicals etc Normal wear and tear items Normal wear and tear includes but is not limited to dama...

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