Toro Workman UTX User manual

FormNo.3445-604RevA
Workman®UTXDieselUtility
Vehicle
ModelNo.08102—SerialNo.400000000andUp
ModelNo.08102TC—SerialNo.400000000andUp
ModelNo.08103—SerialNo.400000000andUp
Registeratwww.Toro.com.
OriginalInstructions(EN)*3445-604*

ThisproductcomplieswithallrelevantEuropean
directives;fordetails,pleaseseetheseparateproduct
specicDeclarationofConformity(DOC)sheet.
ItisaviolationofCaliforniaPublicResourceCode
Section4442or4443touseoroperatetheengineon
anyforest-covered,brush-covered,orgrass-covered
landunlesstheengineisequippedwithaspark
arrester,asdenedinSection4442,maintainedin
effectiveworkingorderortheengineisconstructed,
equipped,andmaintainedforthepreventionofre.
Theenclosedengineowner'smanualissupplied
forinformationregardingtheUSEnvironmental
ProtectionAgency(EPA)andtheCaliforniaEmission
ControlRegulationofemissionsystems,maintenance,
andwarranty.Replacementsmaybeorderedthrough
theenginemanufacturer.
WARNING
CALIFORNIA
Proposition65Warning
Dieselengineexhaustandsomeofits
constituentsareknowntotheStateof
Californiatocausecancer,birthdefects,
andotherreproductiveharm.
Batteryposts,terminals,andrelated
accessoriescontainleadandlead
compounds,chemicalsknownto
theStateofCaliforniatocause
cancerandreproductiveharm.Wash
handsafterhandling.
Introduction
Thisutilityvehicleisintendedtobeprimarilyused
off-highwaytotransportpeopleandmaterialloads.
Usingthisproductforpurposesotherthanitsintended
usecouldprovedangeroustoyouandbystanders.
Readthisinformationcarefullytolearnhowtooperate
andmaintainyourproductproperlyandtoavoid
injuryandproductdamage.Youareresponsiblefor
operatingtheproductproperlyandsafely.
Visitwww.Toro.comforproductsafetyandoperation
trainingmaterials,accessoryinformation,helpnding
adealer,ortoregisteryourproduct.
Wheneveryouneedservice,genuineT oroparts,
oradditionalinformation,contactanAuthorized
ServiceDistributororToroCustomerServiceand
havethemodelandserialnumbersofyourproduct
ready.Figure1identiesthelocationofthemodeland
serialnumbersontheproduct.Writethenumbersin
thespaceprovided.
Important:Withyourmobiledevice,youcan
scantheQRcodeontheserialnumberdecal(if
equipped)toaccesswarranty,parts,andother
productinformation.
g388484
Figure1
1.Modelandserialnumberlocation
ModelNo.
SerialNo.
©2022—TheToro®Company
8111LyndaleAvenueSouth
Bloomington,MN554202
Contactusatwww.Toro.com.
PrintedintheUSA
AllRightsReserved

Thismanualuses2wordstohighlightinformation.
Importantcallsattentiontospecialmechanical
informationandNoteemphasizesgeneralinformation
worthyofspecialattention.
Thesafety-alertsymbol(Figure2)appearsbothin
thismanualandonthemachinetoidentifyimportant
safetymessagesthatyoumustfollowtoavoid
accidents.Thissymbolwillappearwiththeword
Danger,Warning,orCaution.
•Dangerindicatesanimminentlyhazardous
situationwhich,ifnotavoided,willresultindeath
orseriousinjury.
•Warningindicatesapotentiallyhazardous
situationwhich,ifnotavoided,couldresultin
deathorseriousinjury.
•Cautionindicatesapotentiallyhazardoussituation
which,ifnotavoided,mayresultinminoror
moderateinjury.
g000502
Figure2
Safety-alertsymbol
Contents
Safety.......................................................................4
GeneralSafety...................................................4
SafetyandInstructionalDecals..........................5
Setup........................................................................8
1InstallingtheSteeringWheel............................8
2ConnectingtheBattery....................................9
3ChangingtheBlinkerModefromUnited
States(US)toEuropean(EU).......................10
4ConvertingtheSpeedometerfrommphto
km/h..............................................................10
5CheckingtheFluidLevelsandTire
Pressure........................................................11
6InstallingtheRolloverProtectionSystem
(ROPS).........................................................12
7InstallingtheRolloverProtectionSystem
(ROPS).........................................................30
8BurnishingtheBrakes....................................49
ProductOverview...................................................50
Controls...........................................................50
Specications..................................................56
Attachments/Accessories.................................56
BeforeOperation.................................................57
BeforeOperationSafety...................................57
PerformingDailyMaintenance..........................57
CheckingtheTirePressure...............................58
AddingFuel......................................................58
BreakinginaNewMachine..............................59
DuringOperation.................................................59
DuringOperationSafety...................................59
OperatingtheCargoBed..................................61
StartingtheEngine...........................................63
DrivingtheMachine..........................................63
UsingtheCruiseControl...................................64
AdjustingtheGroundSpeedGovernor.............64
StoppingtheMachine.......................................64
ShuttingOfftheEngine.....................................64
Usingthe4-WheelDrive/Differential
Lock(s)..........................................................65
ControllingtheEngineThrottleWhileinthe
P(PARK)Position..........................................66
LoadingtheCargoBed.....................................67
AfterOperation....................................................68
AfterOperationSafety......................................68
HaulingtheMachine.........................................68
TowingtheMachine..........................................69
TowingaTrailer................................................69
Maintenance...........................................................70
MaintenanceSafety..........................................70
RecommendedMaintenanceSchedule(s)...........71
DailyMaintenanceChecklist.............................73
MaintainingtheMachineunderSpecial
OperatingConditions....................................73
Pre-MaintenanceProcedures..............................74
PreparingtheMachineforMaintenance............74
RaisingtheMachine.........................................74
AccessingtheHood..........................................75
3

Lubrication..........................................................76
GreasingtheMachine.......................................76
EngineMaintenance...........................................78
EngineSafety...................................................78
ServicingtheAirCleaner..................................78
ServicingtheEngineOil....................................79
CheckingandAdjustingtheAlternator
Belt................................................................81
CalibratingtheThrottleActuator.......................82
FuelSystemMaintenance...................................83
ChangingtheFuelFilter/WaterSeparator
......................................................................83
CheckingtheFuelLinesand
Connections..................................................83
ElectricalSystemMaintenance...........................84
ElectricalSystemSafety...................................84
ServicingtheBattery.........................................84
ServicingtheFuses..........................................87
DriveSystemMaintenance..................................88
MaintainingtheTires........................................88
CheckingtheSteeringandSuspension
Components.................................................88
Checking/AdjustingtheFrontWheel
Alignment......................................................89
AdjustingtheFrontRideHeight........................90
CheckingtheTransaxle-FluidLevel..................91
ChangingtheTransaxleFluid...........................91
CheckingtheFrontDifferentialOil
Level.............................................................92
ChangingtheFrontDifferentialOil....................92
CoolingSystemMaintenance..............................93
CoolingSystemSafety.....................................93
CheckingtheEngine-CoolantLevel..................93
RemovingDebrisfromtheCooling
System..........................................................94
CheckingtheCoolantHoses............................95
ChangingtheEngineCoolant...........................95
BrakeMaintenance.............................................96
CheckingtheBrakes.........................................96
CheckingtheBrake-FluidLevel........................96
ChangingtheBrakeFluid.................................96
BeltMaintenance................................................97
ServicingtheDriveBelt.....................................97
Cleaning..............................................................98
WashingtheMachine.......................................98
Storage...................................................................99
StorageSafety..................................................99
StoringtheMachine..........................................99
Troubleshooting....................................................100
Safety
Thismachinehasbeendesignedinaccordancewith
therequirementsofEN16990andSAEJ2258.
GeneralSafety
Thisproductiscapableofcausingpersonalinjury.
Alwaysfollowallsafetyinstructionstoavoidserious
personalinjury.
•Readandunderstandthecontentsofthis
Operator’sManualbeforeyoustartthemachine.
Ensurethateveryoneusingthisproductknows
howtouseitandunderstandsthewarnings.
•Carryingaheavyloadwithand/oradding
attachmentstothevehiclemayaffectitsstability,
dependingontheamountanddistributionofthe
weight.
•Useyourfullattentionwhileoperatingthe
machine.Donotengageinanyactivitythat
causesdistractions;otherwise,injuryorproperty
damagemayoccur.
•Donotputyourhandsorfeetnearmoving
componentsofthemachine.
•Donotoperatethemachinewithoutallguards
andothersafetyprotectivedevicesinplaceand
workingonthemachine.
•Keepbystandersandchildrenoutoftheoperating
area.Neverallowchildrenunder16tooperatethe
machineunlesstheyhaveobtainedastate-issued
motorvehicledriver’slicense.
•Stopandshutoffthemachineandremovethekey
beforeservicingorfueling.
Improperlyusingormaintainingthismachinecan
resultininjury.Toreducethepotentialforinjury,
complywiththesesafetyinstructionsandalways
payattentiontothesafety-alertsymbol,which
meansCaution,Warning,orDanger—personalsafety
instruction.Failuretocomplywiththeseinstructions
mayresultinpersonalinjuryordeath.
4

SafetyandInstructionalDecals
Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyarea
ofpotentialdanger.Replaceanydecalthatisdamagedormissing.
decal106-6755
106-6755
1.Enginecoolantunder
pressure.
3.Warning—donottouchthe
hotsurface.
2.Explosionhazard—read
theOperator'sManual.
4.Warning—readthe
Operator'sManual.
decal145-2205
145-2205
1.Donotexceedatongueweightof90.7kg(200lb);donot
exceedatransportloadof907kg(2,000lb).
decal145-2215
145-2215
1.Warning—Readthe
Operator'sManual,weara
seatbelt,avoidtippingthe
machine.
2.Warning—donotdrillor
weld.
5

decal144-1143
144-1143
1.Warning—readtheOperator’sManual.6.Warning—donotoperatethemachineundertheinuenceof
drugsoralcohol.
2.Warning—alloperatorsshouldbetrainedbeforeoperating
themachine.
7.Fallinghazard—donotcarrypassengersinthebed;donot
carryextrapassengersinbetweentheseats.
3.Warning—wearhearingprotection.8.Firehazard—shutofftheenginewhenaddingfueltothe
machine.
4.Collisionhazard—donotoperatethemachineonpublic
streets,roads,orhighways.
9.Warning—shiftthetransmissionlevertotheP(PARK)position,
turnthekeytotheoffposition,andremovethekeybefore
leavingthemachine.
5.Warning—donotallowpeopleundertheageof16tooperate
themachine.
decal145-2225
145-2225
Note:*Gasolinemachinesonly
1.Frontdifferentiallockand4-wheeldrivedisengagerelay12.Frontandreardifferentials
2.Frontdifferentiallockand4-wheeldriveengagerelay13.Coolingfan
3.Frontdifferentiallockdisengagerelay14.Positionlightsandturn-signallights
4.Frontdifferentiallockengagerelay15.Powersteering
5.Reardifferentiallockengagerelay16.Displayandthrottle
6.Fuelrelay17.Fuelrelay
7.Starterrelay18.Saltspreader
8.ReadtheOperator’sManualforfuseinformation.19.Bedlift
9.Enginepower(gasolinemachinesonly)20.Headlightsandhazardlights
10.USB/telematics21.Horn
11.Alternator,powersteering,andspeedsensorenable
6

decal144-2255
144-2255
Note:*Replacemorefrequentlyindustyordirtyconditions
**1,000hoursor5years;whichevercomessooner
1.Fronttirepressure4.Engineoilandlter7.Drivebelt10.Brakeuid
2.Reartirepressure(varies
dependingoncargoload)
5.Engine-airlter8.Fuellter/waterseparator11.Enginecoolant
3.ReadtheOperator’s
Manualbeforeperforming
maintenance.
6.Transaxleuid9.Frontdifferentialuid12.Hours
ForStandard(2-Person)Models
decal144-1144
144-1144
1.Runover/backover
hazard—donotcarry
passengers.
2.Attention—readthe
Operator’sManual;
maximumweight567
kg(1,250lb).
ForCrew(4-Person)Models
decal144-2293
144-2293
1.Runover/backover
hazard—donotcarry
passengers.
2.Attention—readthe
Operator’sManual;
maximumweight453
kg(1,000lb).
decalbatterysymbols
BatterySymbols
Someorallofthesesymbolsareonyourbattery.
1.Explosionhazard6.Keepbystandersaway
fromthebattery.
2.Nore,opename,or
smoking
7.Weareyeprotection;
explosivegasescan
causeblindnessandother
injuries.
3.Causticliquid/chemical
burnhazard
8.Batteryacidcancause
blindnessorsevereburns.
4.Weareyeprotection.9.Flusheyesimmediately
withwaterandgetmedical
helpfast.
5.ReadtheOperator's
Manual.
10.Containslead;donot
discard
7

Setup
Note:Determinetheleftandrightsideofthemachinefromthenormaloperatingposition.
1
InstallingtheSteering
Wheel
TCModelsOnly
Partsneededforthisprocedure:
1Steeringwheel
1Cover
Procedure
1.Ifthecoverisinstalled,removeitfromthehub
ofthesteeringwheel.
2.Removethelocknut(1/2inch)fromthesteering
shaft.
3.Ensurethatthefrontwheelsarecentered.
4.Slidethesteeringwheelontothesteeringshaft.
5.Securethesteeringwheeltotheshaftusing
thepreviouslyremovedlocknut(1/2inch)and
tightenitto24to30N∙m(18to22ft-lb).
6.Installthecoverontothesteeringwheel.
g357124
Figure3
1.Cover3.Steeringwheel
2.Locknut(1/2inch)4.Steeringshaft
8

2
ConnectingtheBattery
TCModelsOnly
NoPartsRequired
Procedure
WARNING
Incorrectbatterycableroutingcoulddamage
themachineandcables,causingsparks.
Sparkscancausethebatterygasesto
explode,resultinginpersonalinjury.
•Alwaysdisconnectthenegative(black)
batterycablebeforedisconnectingthe
positive(red)cable.
•Alwaysconnectthepositive(red)battery
cablebeforeconnectingthenegative
(black)cable.
1.Connectthepositivebatterycable(red)tothe
positive(+)terminalofthebatteryandsecure
thecableusingtheboltandnuts(Figure4).
2.Slidetheinsulatorbootoverthepositiveterminal
(Figure4).
Note:Theinsulatorbootpreventsapossible
short-to-groundfromoccurring.
3.Connectthenegativebatterycable(black)tothe
negative(–)terminalofthebatteryandsecure
thecableusingtheboltandnuts(Figure4).
g357128
Figure4
1.Negativebatterycable
(black)
4.Bolt
2.Positivebatterycable(red)5.Nuts
3.Insulatorboot(positive
batterycable)
9

3
ChangingtheBlinkerMode
fromUnitedStates(US)to
European(EU)
InternationalModelsOnly
NoPartsRequired
Procedure
DisconnectthedefaultUSjumperconnectionlocated
underneaththehood(Figure5).
Note:Useacabletietosecurethelooseconnection.
g400894
Figure5
1.DefaultUSjumperconnection
4
Convertingthe
Speedometerfrommph
tokm/h
NoPartsRequired
Procedure
1.ShiftthetransmissionlevertotheP(PARK)
position.
2.RotatethekeyswitchtotheONposition.
3.Pressandholdthedisplaybuttonbetween3to
10secondstoconvertthespeedometerfrom
mphtokm/h.
g367226
Figure6
1.Button
10

5
CheckingtheFluidLevels
andTirePressure
NoPartsRequired
Procedure
1.Checktheengine-oillevelbeforeyourststart
theengine;refertoCheckingtheEngine-Oil
Level(page79).
2.Checkthetransaxle-uidlevelbeforeyou
rststarttheengine;refertoCheckingthe
Transaxle-FluidLevel(page91).
3.Checkthefrontdifferentialoillevelbeforeyou
rststarttheengine;refertoCheckingtheFront
DifferentialOilLevel(page92).
4.Checktheengine-coolantlevelbeforeyou
rststarttheengine;refertoCheckingthe
Engine-CoolantLevel(page93).
5.Checkthebrake-uidlevelbeforeyourststart
theengine;refertoCheckingtheBrake-Fluid
Level(page96).
6.Checktheairpressureinthetires;referto
CheckingtheTirePressure(page58).
11

6
InstallingtheRollover
ProtectionSystem(ROPS)
ForStandard(2-Person)Models
Partsneededforthisprocedure:
1Left,frontrollbarassembly
1Right,frontrollbarassembly
1Left,rearrollbarassembly
1Right,rearrollbarassembly
1Frontcrosslink
1Rearcrosslink
1Seatpanel
2Shoulderrestraint
8Hex-headbolt(3/8x1-1/4inches)
12Carriagebolt(5/16x3/4inch)
4Hex-washerheadbolt(5/16x3/4inch)
10Hex-washerheadbolt(1/4x3/4inch)
2Hex-washerheadbolt(1/4x1inch)
2Button-headbolt(5/16x1-1/2inches)
2Flange-headbolt(3/8x2-1/4inches)
14Locknut(5/16inch)
10Locknut(3/8inch)
2Locknut(1/4inch)
2Locknut(7/16inch)
Procedure
1.Raisethecargobed(Figure7).
g361797
Figure7
12

2.Raisethehood(Figure8).
g361798
Figure8
3.Removethehex-washerheadbolts(1/4x3/4
inch)fromtherightandleftseat-basepanels
(Figure9).
Removethefuel-tankcapfromtheleftseat-base
panel(Figure10).
Note:Donotpullthecapoutuntilyoureach
theendofthetether.
13

g361802
Figure9
14

g364231
Figure10
4.Removethelocknut(3/8inch)andlatchpinfrom
therightandleft,rearframetubes(Figure11).
g361803
Figure11
1.Locknut(3/8inch)2.Latchpin
5.Looselysecuretheright,rearrollbarassembly
totheright,rearframetubeusing1ange-head
bolt(3/8x2-1/4inches)and1locknut(3/8inch)
asshowninFigure12.
g361804
Figure12
15

6.Repeatsteps3through5fortheleft,rearroll
barassembly.
7.Looselysecuretheright,frontrollbarassembly
totherightrollbarmountbracketusing2
hex-headbolts(3/8x1-1/4inches)and2
locknuts(3/8inch)asshowninFigure13.
g361799
Figure13
8.Looselysecuretheright,frontrollbarassembly
totheright,rearrollbarassemblyusing2
hex-headbolts(3/8x1-1/4inches)and2
locknuts(3/8inch)asshowninFigure14.
g361800
Figure14
16

9.Looselysecuretheright,frontrollbarassembly
tothedashpanelusing1hex-washerheadbolt
(1/4x1inch)and1locknut(1/4inch)asshown
inFigure15.
g361801
Figure15
10.Repeatsteps7through9fortheleft,frontroll
barassembly.
11.Securethefrontcrosslinktothefrontrollbar
assembliesusing4carriagebolts(5/16x3/4
inch)and4locknuts(5/16inch)asshownin
Figure16.
g361807
Figure16
17

12.Securetherearcrosslinktotherearrollbar
assembliesusing4carriagebolts(5/16x3/4
inch)and4locknuts(5/16inch)asshownin
Figure17.
Ensurethatyoupositionthecrosslinkasshown
inFigure17.
g361808
Figure17
1.Ensurethatthenotchis
onthetop.
2.Ensurethattheholesare
onthebottom.
18

13.Securetheseatpaneltotherearrollbar
assembliesusing4carriagebolts(5/16x3/4
inch)and4locknuts(5/16inch)asshownin
Figure18.
g362076
Figure18
19

14.Securetheseatpaneltotherearframecrosslink
channelusing4hex-washerheadbolts(1/4x
3/4inch)asshowninFigure19.
g361809
Figure19
1.Hex-washerheadbolts(1/4x3/4inch)
20