Toro Workman 3000 Series

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Printed in the USA

 1993, 2003, 2004 by The Toro Company

8111 Lyndale Avenue South

Bloomington, MN 55420-1196

Automatic Tailgate Release Kit

Workman 3000 Series

Part No. 92–1220

Form No. 3315–461 Rev B

Installation Instructions

Note: Before installing automatic tailgate release kit, install

bed, bed sides and tailgate.

Note: Left, right, front and rear of machine is determined

while seated in operator’s position.

1. If bed is raised to ease installation, be sure to use safety

support.

2. To use bed safety support:

A. Raise bed until cylinders are fully extended.

B. Remove bed support from storage location.

C. Push bed support onto cylinder rod, making sure

support end tabs rest on end of cylinder barrel and

on cylinder rod end.

D. To store bed support, remove bed support from

cylinder and return it to it’s storage position.

E. Always install or remove bed support from outside

of bed.

F. Do not try to lower bed with bed safety support on

cylinder.

WARNING

Always have someone assist you when lifting

bed or use a hoist.

Always install safety support from outside of

vehicle, never from under bed.

Never work under raised bed without position-

ing safety support on a fully installed cylinder

rod.

3. Remove capscrews and washers mounting tailgate

pivot brackets. Pivot brackets upward into storage

position and re–secure with front capscrews. Reinstall

rear capscrews securing corners of bed sides to bed

(Fig. 1).

Note: To use tailgate in standard operating position,

reinstall tailgate pivot brackets.

Figure 1

1. Pivot bracket

4. Slide a tailgate pivot shaft under each side of bed and

over bed frame channels until they meet at rear, center

of bed (Fig. 2). Pivot shaft with welded bracket to be

used on left side. Both shafts to be positioned rear of

bed pivot brackets.

Figure 2

1. Tailgate pivot shaft

2. Bed pivot bracket

3. Bed mounting brackets

4. Pivot shaft keeper

5. Pivot lever

6. Bent bracket

5. Secure ends of pivot shafts together with (2) 5/16–18 x

1–1/4” lg. capscrews and locknuts (Fig. 2). Check to

assure shafts are aligned. Loosen screws and realign if

necessary. Tighten capscrews securely.

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Summary

Installation Instructions

Bed Safety and Lifting Procedures

Procedures for safely lifting the bed and using the bed safety support system.

Mounting Tailgate Pivot Brackets and Shafts

Installing the tailgate pivot brackets and tailgate pivot shafts onto the bed.

Connecting Dump Linkage

Mounting Pivot Lever and Rod Assembly

Attaching the pivot lever and pivot link rod assembly to the bed.

Securing Rear Dump Link

Connecting the rear dump link to the pivot lever.

Installing and Adjusting Dump Links

Connecting front and rear dump links and adjusting their length.

Summary

Installation Instructions

Bed Safety and Lifting Procedures

Procedures for safely lifting the bed and using the bed safety support system.

Mounting Tailgate Pivot Brackets and Shafts

Installing the tailgate pivot brackets and tailgate pivot shafts onto the bed.

Connecting Dump Linkage

Mounting Pivot Lever and Rod Assembly

Attaching the pivot lever and pivot link rod assembly to the bed.

Securing Rear Dump Link

Connecting the rear dump link to the pivot lever.

Installing and Adjusting Dump Links

Connecting front and rear dump links and adjusting their length.

The Toro Workman 3000 Series Automatic Tailgate Release Kit, Part No. 92-1220, is an accessory designed to enhance the functionality of the Workman 3000 Series utility vehicle by automating the tailgate release mechanism. This kit allows for convenient and efficient unloading of materials from the bed, improving productivity and ease of operation.

Function Description

The primary function of this kit is to enable the automatic release of the tailgate. This is achieved through a series of interconnected mechanical components that link the bed's dumping action to the tailgate's latching mechanism. When the bed is raised to dump its contents, the linkage system is designed to automatically unlatch the tailgate, allowing materials to exit freely. Conversely, when the bed is lowered, the system is designed to re-latch the tailgate securely.

The system utilizes pivot shafts, pivot levers, and dump links to translate the movement of the bed into the opening and closing of the tailgate. The pivot shafts are mounted to the underside of the bed and connect to the tailgate pivot brackets. These shafts are equipped with curved latches that engage with the tailgate to hold it closed. A pivot lever, also mounted to the underside of the bed, connects to a pivot link rod assembly. This rod assembly, in turn, connects to a tailgate shaft bracket. The rear dump link connects the pivot lever to the bed's dumping mechanism.

The kit includes two front dump links: a short one for when the bed is mounted in the forward (full bed) position and a long one for when the bed is mounted in the rearward (2/3 bed) position. This adaptability ensures proper operation regardless of the bed's configuration. The length of the dump link assembly is adjustable, which is crucial for fine-tuning the tailgate latching and unlatching action. Proper adjustment ensures that the tailgate latches securely when the bed is down and releases smoothly when the bed is raised.

Important Technical Specifications

Part Number: 92-1220
Compatibility: Toro Workman 3000 Series
Components:
- Tailgate pivot shafts (one with a welded bracket for the left side)
- Pivot shaft keepers
- Pivot levers
- Bent brackets
- Pivot link rod assembly (spring-tensioned)
- Rear dump link
- Front dump links (short and long options)
- Various capscrews, locknuts, washers, and cotter pins
Fasteners:
- Pivot shaft keepers: (2) 1/4–20 x 1/2" lg. capscrews, lockwashers, flat washers
- Pivot lever to bent bracket: 5/16–18 x 1-1/4" lg. capscrew, flat washer, locknut
- Pivot link rod assembly to pivot lever: washer, cotter pin
- Rod fitting to tailgate shaft bracket: flat washer, cotter pin
- Rear dump link to pivot lever: washer, cotter pin
- Pivot shafts together: (2) 5/16–18 x 1-1/4" lg. capscrews, locknuts
Adjustment Range: The dump link assembly length is adjustable to achieve a 1/8" gap between the front of the cylinder pin and the front of the cylinder rod slot when the bed is fully retracted and the tailgate is securely closed.

Usage Features

Automated Tailgate Release: Eliminates the need for manual unlatching of the tailgate, streamlining the dumping process.
Enhanced Efficiency: Speeds up material unloading, increasing productivity for tasks involving frequent dumping.
Configurable for Bed Position: Includes different front dump links to accommodate both forward (full bed) and rearward (2/3 bed) bed mounting positions, ensuring versatility.
Adjustable Linkage: Allows for precise adjustment of the dump link assembly to ensure proper tailgate latching and unlatching, preventing rattling or linkage bending.
Safety Considerations: The manual emphasizes the importance of using a safety support when the bed is raised for installation or maintenance, and warns against working under a raised bed without proper support. It also advises against trying to lower the bed with the safety support engaged.
Installation Sequence: The instructions detail a step-by-step installation process, starting with the removal of existing tailgate pivot brackets and progressing through the assembly and adjustment of the new components.
Pre-installation Requirement: Requires the bed, bed sides, and tailgate to be installed on the vehicle before the kit can be fitted.

Maintenance Features

Adjustable Linkage for Longevity: The ability to adjust the dump link assembly helps in maintaining optimal performance over time. If the tailgate rattles, the dump link can be lengthened. If the linkage bends when the bed is lowered, it indicates the dump link is too long and needs to be shortened. This adjustment capability contributes to the longevity of the system by preventing undue stress on components.
Spring-Tensioned Pivot Link Rod: The pivot link rod assembly is factory-tensioned. While disassembly is possible, caution is advised when removing the nut due to the spring tension. This design suggests a robust mechanism intended for consistent operation.
Secure Fastening: The use of various capscrews, locknuts, and cotter pins ensures that all components are securely fastened, reducing the likelihood of loosening during operation and minimizing maintenance needs. Regular checks of these fasteners are implied for continued safe and effective operation.
Alignment Checks: The instructions emphasize checking for shaft alignment after securing the pivot shafts together, and realigning if necessary. This attention to detail in installation contributes to the overall reliability and reduces future maintenance.
Component Replacement: The modular design of the kit, with individual components like pivot shafts, levers, and links, suggests that specific parts could be replaced if damaged, rather than requiring a complete system overhaul.