Toro 08120 User manual

Form No. 3465-437 Rev A
Heater Kit
W orkman
®
UTX Utility V ehicle
Model No. 08120
Installation Instructions
Safety
Cooling System Safety
•Swallowing engine coolant can cause poisoning;
keep out of reach from children and pets.
•Discharge of hot, pressurized coolant or touching
a hot radiator and surrounding parts can cause
severe burns.
– Always allow the engine to cool at least 15
minutes before removing the radiator cap.
– Use a rag when opening the radiator cap, and
open the cap slowly to allow steam to escape.
•Do not operate the machine without the covers
in place.
•Keep your ngers, hands and clothing clear of
rotating fan and drive belt.
•Shut of f the engine and remove the key before
performing maintenance.
Safety and Instructional Decals
Safety decals and instructions are easily visible to the operator and are located near any area
of potential danger . Replace any decal that is damaged or missing.
decal145-2229
145-2229
1. Fan—of f
3. Heat—low
2. Fan—on full
4. Heat—high
© 2023—The T oro® Company
81 1 1 L yndale A venue South
Bloomington, MN 55420
Register at www .T oro.com.
Original Instructions (EN)
Printed in the USA
All Rights Reserved
*3465-437*

Installation
Loose Parts
Use the chart below to verify that all parts have been shipped.
Procedure Description
Qty .
Use
1
No parts required
–
Prepare the machine.
Heater control panel 1
Rotary switch 1
Rotary linear switch 1
Switch nut (7/16 inch)
2
Knob 2
Button-head bolt (5/8 inch)
4
Locknut (#10-24)
4
Control cable
1
2
Wire harness 1
Install the heater control panel.
3
No parts required
–
Cut the holes for the vents.
Heater box assembly 1
Heater mount bracket 1
Carriage bolt (1/4 x 3/4 inch)
6
Locknut (1/4 inch)
6
Coolant hose (5/8 x 13 inches)
1
Coolant hose (5/8 x 26 inches)
1
V ent hose (2 x 18 inches)
8
Y -adapter 2
Band clamp 2
Cable tie
16
4
V ent 6
Assemble the heater box assembly .
Hex bolt (5/16 x 3/4 inch)
2
Carriage bolt (1/4 x 3/4 inch)
25
Locknut (1/4 inch)
2
Install the heater box assembly .
Cable tie
6
Band clamp 2
W ater valve 16
Hose 3
Route the hoses.
7
Pan-head bolt (#10-24 x 3/8 inch)
1 Install the wire harness.
8
No parts required
–
Connect the battery .
9
No parts required
–
Burp the cooling system.
2

1
Preparing the Machine
No Parts Required
Procedure
1. Park the machine on a level surface.
2. Shift the transmission lever to the P (P ARK )
position.
3. Shut of f the engine and remove the key .
4. W ait for the engine to cool completely .
g364252
Figure 1
5. Disconnect the negative (-) battery cable from
the battery post.
g365494
Figure 2
1. Negative (-) battery cable
2. Battery post
6. Raise the hood; refer to the machine Operator ’ s
Manual .
7. Drain approximately 2 L (1/2 US gallon) of
engine coolant (or until coolant stops owing out
of the rubber hoses) from the cooling system;
refer to the Operator ’ s Manual .
Note: Retain coolant for reuse after installation
of the kit.
3

2
Installing the Heater Control
Panel
Parts needed for this procedure:
1 Heater control panel
1 Rotary switch
1 Rotary linear switch
2
Switch nut (7/16 inch)
2 Knob
4
Button-head bolt (5/8 inch)
4
Locknut (#10-24)
1
Control cable
1 Wire harness
Procedure
1. On the dashboard, remove the 4 switch plugs
and cut out the material between the switch
cutouts ( Figure 3 ).
g398819
Figure 3
2. Locate the 2 drill pilot dimples ( Figure 4 ) and
drill 2 pilot holes (3/16 inch) directly over the
pilot dimples.
g398820
Figure 4
1. Drill pilot dimples
W ARNING
Using a drill without wearing eye
protection may allow debris to enter the
eye, causing personal injury .
When drilling, always wear eye
protection.
3. Using the heater control panel as a template,
drill the other 2 holes located on the right side.
4. Install the 2 switches onto the control panel with
2 switch nuts (7/16 inch) as shown in A of Figure
5.
5. Install a knob over each switch (B of Figure 5 ).
g430408
Figure 5
4

6. Move the control knobs to the middle position
as shown in Figure 6 .
g430155
Figure 6
1. Move the knobs to the middle position.
7. Ensure that the heater switch is in the middle
position and connect one end of the control
cable to the back of the heater switch ( Figure 7 ).
g430382
Figure 7
8. Ensure that the water valve is in the middle
position and connect it onto the other end of the
control cable ( Figure 8 ).
9. Ensure that the heater switch can sweep from
low heat to high heat and that the water valve
fully opens and closes. Adjust the cable if
necessary .
g460374
Figure 8
5

10. Plug the 5-terminal connector on the kit wire
harness into the back of the airow switch
(Figure 9 ).
g430409
Figure 9
1 1. Route the control cable, water valve, and wire
harness through the dashboard and secure the
control panel assembly onto the dashboard with
4 button-head bolts (5/8 inch) and 4 locknuts
(#10-24); refer to Figure 10 . T orque the bolts to
3 N∙m (30 in-lb).
g430435
Figure 10
6

3
Cutting the Holes for the
V ents
No Parts Required
Procedure
1. Locate the 4 drill pilot dimples on the top of the
dashboard ( Figure 1 1 ) and drill 4 holes (76 mm
or 3 inches) directly over the pilot dimples.
Note: Use a 76 mm (3 inch) hole saw to drill
the vent holes.
g398901
Figure 1 1
1. Drill pilot dimples
2. Locate the 2 drill pilot dimples on the oorboard
(Figure 12 ) and drill 2 holes (76 mm or 3 inches)
directly over the pilot dimples.
Note: It is recommended to use a 76 mm (3
inch) hole saw to drill the vent holes.
3. Remove the burrs from the holes.
g398912
Figure 12
1. Drill pilot dimples
7

4
Assembling the Heater Box
Assembly
Parts needed for this procedure:
1 Heater box assembly
1 Heater mount bracket
6
Carriage bolt (1/4 x 3/4 inch)
6
Locknut (1/4 inch)
1
Coolant hose (5/8 x 13 inches)
1
Coolant hose (5/8 x 26 inches)
8
V ent hose (2 x 18 inches)
2 Y -adapter
2 Band clamp
16
Cable tie
6 V ent
Procedure
Important: Do not interfere with the shifter
linkage or steering column when installing the
hoses.
1. Connect 6 vent hoses to the adjustable vents
using 6 large cable ties ( Figure 13 ).
Note: Ensure that the vents are orientated to
blow air toward the operator on the operator ’ s
side of the machine and toward the passenger
on the passenger ’ s side.
2. Route the hoses and install the 4 adjustable
vents into the 4 top holes ( Figure 13 ).
3. Route the hoses and install the 2 adjustable
vents into the lower 2 holes ( Figure 13 ).
4. Connect the 2 outer vent hoses to the 2 lower
hoses using the 2 Y -adapters and 4 cable ties
(Figure 13 and Figure 14 ).
Connect 2 additional vent hoses to the
assembled outer vent hoses and secure them
using 2 cable ties ( Figure 13 and Figure 14 ).
5. Connect the 4 vent hoses to the heater box
using 4 cable ties ( Figure 13 and Figure 14 ).
g460891
Figure 13
1. V ent
3. Cable tie
2. Y -adapters
g460561
Figure 14
1. Outer hose assemblies
8

6. Attach the heater box assembly to the heater
mount bracket with 6 carriage bolts (1/4 x 3/4
inch) and 6 locknuts (1/4 inch); refer to Figure
15 . T orque the bolts to 1 1 N∙m (100 in-lb).
g460444
Figure 15
1. Heater box assembly 3. Heater mount bracket
2. Locknut (1/4 inch) 4. Carriage bolt (1/4 x 3/4
inch)
7. Connect the 2 coolant hoses onto the front of
the heater box with 2 band clamps as shown in
Figure 16 .
g460443
Figure 16
9

5
Installing the Heater Box
Assembly
Parts needed for this procedure:
2
Hex bolt (5/16 x 3/4 inch)
2
Carriage bolt (1/4 x 3/4 inch)
2
Locknut (1/4 inch)
Procedure
Note: If the machine has the glass windshield and
wiper kit installed, remove the washer bottle from the
frame of the machine. Install it onto the side of the
heater box assembly after the heater box is installed
on the machine (see step 3).
1. Attach the front of the heater box assembly to
the frame of the machine with 2 hex bolts (5/16
x 3/4 inch).
g399053
Figure 17
1. Hex bolt (5/16 x 3/4 inch)
3. Heater box assembly
2. Machine frame
2. Attach the back of the heater box assembly
to the dash brackets on the machine with 2
carriage bolts (1/4 x 3/4 inch) and 2 locknuts
(1/4 inch); refer to Figure 18 .
g460678
Figure 18
1. Locknuts (1/4 inch) 2. Carriage bolts (1/4 x 3/4
inch)
3. If the machine has the glass windshield and
wiper kit installed, install the washer bottle onto
the side of the heater box assembly as shown
in Figure 19 .
g429465
Figure 19
10

6
Routing the Hoses
Parts needed for this procedure:
6
Cable tie
2 Band clamp
1 W ater valve
3 Hose
Procedure
1. Disconnect the existing coolant hose from the
side of the coolant tank ( Figure 20 ) and shorten
the hose by 23 cm (9 inches).
Retain the band clamp for reuse.
g409844
Figure 20
1. Coolant tank
2. Existing coolant hose
1 1

2. Connect the 2 coolant hoses that were
previously installed to the heater box to their
appropriate ports on the water valve with 2 band
clamps ( Figure 21 ).
Note: If a BOSS snowplow is installed on the
machine, route the heater core lower hose
(Figure 21 ) around the plow solenoid.
3. Connect the previously shortened thermostat
bypass hose to the water valve with a band
clamp ( Figure 21 and Figure 22 ).
4. Connect the remaining hose to the water valve
with a band clamp, then connect the other end of
the hose to the large port on the upper reservoir
with a band clamp ( Figure 21 and Figure 22 ).
g460521
Figure 21
1. T o the heater core lower
hose
3. T o the upper reservoir
large port
2. From the thermostat
bypass hose
4. T o the heater core upper
hose
g460460
Figure 22
1. Coolant tank
3. W ater valve
2. Coolant hoses (3)
4. Existing coolant hose
(previously removed
from coolant tank and
shortened)
12

7
Installing the W ire Harness
Parts needed for this procedure:
1
Pan-head bolt (#10-24 x 3/8 inch)
Procedure
1. Install the fuse cover (supplied with kit wire harness) onto the left side of the heater box with the pan-head
bolt (#10-24 x 3/8 inch) as shown in Figure 23 .
2. Route the kit wire harness as shown in Figure 23 .
g460700
Figure 23
1. T o airow switch (previously installed)
4. T o machine wire harness
2. Fuse cover—connected to the heater box with a pan-head
bolt (#10-24 x 3/8 inch)
5. T o heater box
3. T o fuse cover
13

8
Connecting the Battery
No Parts Required
Procedure
Connect the negative (-) battery cable to the battery
post.
g365493
Figure 24
1. Negative (-) battery cable
2. Battery post
9
Burping the Cooling
System
No Parts Required
Procedure
W ARNING
If the engine has been running, the
pressurized, hot coolant can escape and
cause burns.
• Do not open the radiator cap when the
engine is running.
• Use a rag when opening the radiator cap,
and open the cap slowly to allow steam to
escape.
Coolant type: 50% ethylene-glycol with organic
additive technology (OA T) 50% distiller water
1. Remove the cap from the cooling system
reservoir .
2. Fill the cooling system reservoir until coolant
reaches the lower line within the reservoir .
3. Rotate the temperature-control knob to full heat.
4. Start and run the engine until the cooling fan
cycles.
When the machine is at operating temperature,
the coolant level within the reservoir should be
at the upper line.
5. Add coolant as necessary to replace air that has
been purged from the cooling system.
6. Install the cooling system reservoir cap.
14

Operation
Operating the Fan
The fan has 4 speeds ( O FF , L OW , M EDIUM , and H IGH ).
Rotate the fan-control knob to regulate the speed of
the fan.
Rotate the temperature-control knob to regulate the
air temperature in the cab.
Maintenance
Servicing the Heater Air
Filter
Service Interval : Every 250 hours —Change the
heater air lter (more frequently in
dusty or dirty conditions).
Note: The heater air lter is designed to keep the
cabin air clean.
1. Remove the lter access cover from the heater
box assembly ( Figure 25 ).
g41 1877
Figure 25
1. Filter access cover
2. Gently remove the lter from the heater box
assembly .
Note: Do not attempt to clean the lter .
3. Inspect the new lter for damage by looking
into the lter while shining a bright light on the
outside of the lter .
Note: Holes in the lter appear as bright
spots. Inspect the element for tears, an oily
lm, or damage to the rubber seal. If the lter is
damaged, do not use it.
Note: Use care when handling the lter to avoid
damaging or deforming it.
4. Carefully install the lter .
5. Install the lter access cover on the heater box
assembly with the corresponding hardware.
Cleaning the Heater
Important: Do not get the heater box or heater
components wet.
15