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Installing the Rollover
Protection System (ROPS)

For Crew (4-Person) Models

Parts needed for this procedure:

Left, front roll bar assembly

Right, front roll bar assembly

Left, rear roll bar assembly

Right, rear roll bar assembly

Left, middle roll bar assembly

Right, middle roll bar assembly

Roll bar connector assembly

Rear seat handle assembly

Front crosslink

Middle crosslink

Rear crosslink

Seat panel

Shoulder restraint

Hex-head bolt (3/8 x 1-1/4 inches)

Carriage bolt (5/16 x 3/4 inch)

Hex-washer head bolt (5/16 x 3/4 inch)

Hex-washer head bolt (1/4 x 3/4 inch)

Hex-washer head bolt (1/4 x 1 inch)

Button-head bolt (5/16 x 1-1/2 inches)

Flange-head bolt (3/8 x 2-1/4 inches)

Flange-head bolt (3/8 x 1 inch)

Locknut (5/16 inch)

Locknut (3/8 inch)

Locknut (1/4 inch)

Locknut (7/16 inch)

Clip (1/4 inch)

Procedure

Raise the cargo bed (

Figure 30

g364836

Figure 30

Содержание 08102

Страница 1: ...Workman UTX Diesel Utility Vehicle Model No 08102 Serial No 400000000 and Up Model No 08102TC Serial No 400000000 and Up Model No 08103 Serial No 400000000 and Up Register at www Toro com Original In...

Страница 2: ...cancer and reproductive harm Wash hands after handling Introduction This utility vehicle is intended to be primarily used off highway to transport people and material loads Using this product for purp...

Страница 3: ...ter from mph to km h 10 5 Checking the Fluid Levels and Tire Pressure 11 6 Installing the Rollover Protection System ROPS 12 7 Installing the Rollover Protection System ROPS 30 8 Burnishing the Brakes...

Страница 4: ...designed in accordance with the requirements of EN 16990 and SAE J2258 General Safety This product is capable of causing personal injury Always follow all safety instructions to avoid serious personal...

Страница 5: ...5 1 Engine coolant under pressure 3 Warning do not touch the hot surface 2 Explosion hazard read the Operator s Manual 4 Warning read the Operator s Manual decal145 2205 145 2205 1 Do not exceed a ton...

Страница 6: ...the key before leaving the machine 5 Warning do not allow people under the age of 16 to operate the machine decal145 2225 145 2225 Note Gasoline machines only 1 Front differential lock and 4 wheel dri...

Страница 7: ...gers 2 Attention read the Operator s Manual maximum weight 567 kg 1 250 lb For Crew 4 Person Models decal144 2293 144 2293 1 Runover backover hazard do not carry passengers 2 Attention read the Operat...

Страница 8: ...it from the hub of the steering wheel 2 Remove the locknut 1 2 inch from the steering shaft 3 Ensure that the front wheels are centered 4 Slide the steering wheel onto the steering shaft 5 Secure the...

Страница 9: ...e connecting the negative black cable 1 Connect the positive battery cable red to the positive terminal of the battery and secure the cable using the bolt and nuts Figure 4 2 Slide the insulator boot...

Страница 10: ...te Use a cable tie to secure the loose connection g400894 Figure 5 1 Default US jumper connection 4 Converting the Speedometer from mph to km h No Parts Required Procedure 1 Shift the transmission lev...

Страница 11: ...ansaxle Fluid Level page 91 3 Check the front differential oil level before you first start the engine refer to Checking the Front Differential Oil Level page 92 4 Check the engine coolant level befor...

Страница 12: ...1 Rear crosslink 1 Seat panel 2 Shoulder restraint 8 Hex head bolt 3 8 x 1 1 4 inches 12 Carriage bolt 5 16 x 3 4 inch 4 Hex washer head bolt 5 16 x 3 4 inch 10 Hex washer head bolt 1 4 x 3 4 inch 2...

Страница 13: ...e 8 3 Remove the hex washer head bolts 1 4 x 3 4 inch from the right and left seat base panels Figure 9 Remove the fuel tank cap from the left seat base panel Figure 10 Note Do not pull the cap out un...

Страница 14: ...g361802 Figure 9 14...

Страница 15: ...t and left rear frame tubes Figure 11 g361803 Figure 11 1 Locknut 3 8 inch 2 Latch pin 5 Loosely secure the right rear roll bar assembly to the right rear frame tube using 1 flange head bolt 3 8 x 2 1...

Страница 16: ...roll bar mount bracket using 2 hex head bolts 3 8 x 1 1 4 inches and 2 locknuts 3 8 inch as shown in Figure 13 g361799 Figure 13 8 Loosely secure the right front roll bar assembly to the right rear r...

Страница 17: ...1 inch and 1 locknut 1 4 inch as shown in Figure 15 g361801 Figure 15 10 Repeat steps 7 through 9 for the left front roll bar assembly 11 Secure the front crosslink to the front roll bar assemblies us...

Страница 18: ...mblies using 4 carriage bolts 5 16 x 3 4 inch and 4 locknuts 5 16 inch as shown in Figure 17 Ensure that you position the crosslink as shown in Figure 17 g361808 Figure 17 1 Ensure that the notch is o...

Страница 19: ...13 Secure the seat panel to the rear roll bar assemblies using 4 carriage bolts 5 16 x 3 4 inch and 4 locknuts 5 16 inch as shown in Figure 18 g362076 Figure 18 19...

Страница 20: ...14 Secure the seat panel to the rear frame crosslink channel using 4 hex washer head bolts 1 4 x 3 4 inch as shown in Figure 19 g361809 Figure 19 1 Hex washer head bolts 1 4 x 3 4 inch 20...

Страница 21: ...15 Torque the fasteners to the specifications shown in Figure 20 g362077 Figure 20 21...

Страница 22: ...roll bar assemblies using 4 hex washer head bolts 5 16 x 3 4 inch 2 button head bolts 5 16 x 1 1 2 inches and 2 locknuts 5 16 inch as shown in Figure 21 Torque the locknuts 5 16 inch to 22 6 N m 200 i...

Страница 23: ...re 22 B Insert seat belt into the roll bar seat belt bracket and secure the seat belt using a locknut 7 16 inch as shown in Figure 22 Torque the locknut 7 16 inch to 48 8 N m 432 in lb as shown in Fig...

Страница 24: ...cks to the seat panel using 6 hex washer head bolts 1 4 x 3 4 inch as shown in Figure 23 g361805 Figure 23 19 Torque the 6 hex washer head bolts 1 4 x 3 4 inch to 5 4 N m 48 in lb as shown in Figure 2...

Страница 25: ...20 Install the previously removed locknuts 3 8 inch and latch pins to the right and left rear frame tubes Figure 25 g361795 Figure 25 25...

Страница 26: ...21 Adjust the alignment nut for the cargo bed latch until you close the gap and the cargo bed latches securely Figure 26 g361794 Figure 26 26...

Страница 27: ...ocknut 3 8 inch to 40 7 N m 360 in lb as shown in Figure 27 g361813 Figure 27 23 Secure the right and left seat base panels using the previously removed hex washer head bolts 1 4 x 3 4 inch as shown i...

Страница 28: ...g361811 Figure 28 28...

Страница 29: ...24 Install the fuel tank cap to the left seat base panel Figure 29 g364835 Figure 29 29...

Страница 30: ...sembly 1 Front crosslink 1 Middle crosslink 1 Rear crosslink 2 Seat panel 4 Shoulder restraint 20 Hex head bolt 3 8 x 1 1 4 inches 16 Carriage bolt 5 16 x 3 4 inch 8 Hex washer head bolt 5 16 x 3 4 in...

Страница 31: ...3 Remove the hex washer head bolts 1 4 x 3 4 inch from the 2 right and 2 left seat base panels Figure 32 Remove the fuel tank cap from the left rear seat base panel Figure 33 Note Do not pull the cap...

Страница 32: ...g364843 Figure 32 32...

Страница 33: ...ad bolts 5 16 x 1 inch securing the foot well and remove the foot well Figure 34 g364842 Figure 34 5 Remove the locknut 3 8 inch and latch pin from the right and left rear frame tubes Figure 35 g36484...

Страница 34: ...1 locknut 3 8 inch as shown in Figure 36 g364845 Figure 36 7 Repeat step 6 on the left side 8 Loosely secure the right roll bar connector assembly to the right rear roll bar assembly using 2 hex head...

Страница 35: ...t using 2 hex head bolts 3 8 x 1 1 4 inches and 2 locknuts 3 8 inch as shown in Figure 38 g364838 Figure 38 11 Loosely secure the right front roll bar assembly to the dash panel using 1 hex washer hea...

Страница 36: ...olts 3 8 x 1 1 4 inches and 4 locknuts 3 8 inch as shown in Figure 40 g364867 Figure 40 13 Loosely secure the bottom of the right middle roll bar assembly to the seat base assembly using 2 flange head...

Страница 37: ...carriage bolts 5 16 x 3 4 inch and 4 locknuts 5 16 inch as shown in Figure 42 g364850 Figure 42 16 Secure the middle crosslink to the middle roll bar assemblies using 4 hex head bolts 3 8 x 1 1 4 inc...

Страница 38: ...mblies using 4 carriage bolts 5 16 x 3 4 inch and 4 locknuts 5 16 inch as shown in Figure 44 Ensure that you position the crosslink as shown in Figure 44 g364852 Figure 44 1 Ensure that the notch is o...

Страница 39: ...4 inch and 4 locknuts 5 16 inch as shown in Figure 45 A B g364854 Figure 45 19 Secure a seat panel to the rear frame crosslink channel using 4 hex washer head bolts 1 4 x 3 4 inch as shown in Figure 4...

Страница 40: ...nd 2 locknuts 5 16 inch as shown in Figure 47 g364841 Figure 47 21 Loosely secure the rear seat handle assembly to the middle seat panel using 2 carriage bolts 5 16 x 3 4 inch and 2 locknuts 5 16 inch...

Страница 41: ...r head bolts 1 4 x 3 4 inch as shown in Figure 50 Torque the 4 hex washer head bolts 1 4 x 3 4 inch to 11 3 N m 100 in lb g364849 Figure 50 24 Secure the bottom of the foot well using the previously r...

Страница 42: ...25 Torque the fasteners to the specifications shown in Figure 52 g364859 Figure 52 42...

Страница 43: ...lies and middle roll bar assemblies using 8 hex washer head bolts 5 16 x 3 4 inch 4 button head bolts 5 16 x 1 1 2 inches and 4 locknuts 5 16 inch as shown in Figure 53 Torque the locknuts 5 16 inch t...

Страница 44: ...re 54 B Insert seat belt into the roll bar seat belt bracket and secure the seat belt using a locknut 7 16 inch as shown in Figure 54 Torque the locknut 7 16 inch to 48 8 N m 432 in lb as shown in Fig...

Страница 45: ...bolts 1 4 x 3 4 inch as shown in Figure 55 Torque the 12 hex washer head bolts 1 4 x 3 4 inch to 5 4 N m 48 in lb g364846 Figure 55 29 Install the previously removed locknuts 3 8 inch and latch pins...

Страница 46: ...30 Adjust the alignment nut for the cargo bed latch until you close the gap and the cargo bed latches securely Figure 57 g364830 Figure 57 46...

Страница 47: ...knut 3 8 inch to 40 7 N m 360 in lb as shown in Figure 58 g364858 Figure 58 32 Secure the 2 right and 2 left seat base panels using the previously removed hex washer head bolts 1 4 x 3 4 inch as shown...

Страница 48: ...g364831 Figure 59 48...

Страница 49: ...Parts Required Procedure To ensure optimum performance of the brake system burnish the brakes before use 1 Bring the machine up to full speed apply the brakes to rapidly stop the machine without lock...

Страница 50: ...o the OFF position The key switch has 3 positions OFF RUN and START Rotate the key switch clockwise to the START position to engage the starter motor Release the key switch when the engine starts The...

Страница 51: ...switch Figure 61 to toggle between 2 wheel drive and 4 wheel drive refer to Using the 4 Wheel Drive Differential Lock s page 65 Horn Switch Press the horn switch Figure 61 to sound the horn USB Power...

Страница 52: ...cator 4 Right turn signal indicator 12 Fuel gauge 5 Glow plug indicator diesel machines only 13 Charge indicator 6 Headlights indicator 14 Oil pressure warning light 7 Display button ground speed gove...

Страница 53: ...Drive 4 Wheel Drive Switch Position Differential Lock Switch Position Result 2 5 No indicator 2 4 2 3 blinking inactive configuration 1 5 1 4 1 3 Cruise Control Speed Limited Indicator If the cruise c...

Страница 54: ...the engine and operates only when the key switch is in the ON position Figure 62 The 8 coolant bars blink and a fault code appears if the engine overheats Charge Indicator The charge indicator illumin...

Страница 55: ...d speed Releasing the pedal decreases the engine speed and ground speed g356337 Figure 64 1 Brake pedal 2 Accelerator pedal Brake Pedal Use the brake pedal to stop or slow the machine Figure 64 CAUTIO...

Страница 56: ...Model 08102TC 203 cm 80 inches Wheel base Model 08103 295 cm 116 inches Height 201 cm 79 inches to top of ROPS Inside 113 cm 44 1 2 inches Cargo bed length Outside 127 cm 50 inches Inside 142 cm 56 i...

Страница 57: ...n s lap Ensure that all passengers understand and follow the instructions and warnings in the Operator s Manual Check that all safety devices and decals are in place Repair or replace all safety devic...

Страница 58: ...engine runs on clean fresh diesel fuel with a minimum cetane rating of 40 Purchase fuel in quantities that you can use within 30 days to ensure fuel freshness Use summer grade diesel fuel No 2 D at te...

Страница 59: ...hing or loose jewelry Wear an approved helmet whenever you operate the machine on rough or uneven terrain or at high speeds Use your full attention while operating the machine Do not engage in any act...

Страница 60: ...transmission muffler or exhaust manifold while the engine is running or soon after you shut off the engine because these areas may be hot enough to cause burns Do not leave a running machine unattende...

Страница 61: ...afety Do not exceed the gross vehicle weight GVW of the machine when operating it with a load in the cargo bed and or towing a trailer Distribute the load in the cargo bed evenly to improve the stabil...

Страница 62: ...way when lowering the bed Slowly push down the cargo bed until it latches securely Opening the Tailgate 1 Ensure that the cargo bed is down and latched 2 Using both hands raise the tailgate using the...

Страница 63: ...t the machine is in the P PARK position 2 Rotate the key switch to the ON position Note When the glow plug indicator light turns off approximately 5 to 10 seconds the engine is ready to start 3 With y...

Страница 64: ...gage cruise control press the switch to the down OFF position Figure 71 Note When you press the brake pedal the cruise control disengages g391453 Figure 71 1 Set cruise control increase cruise speed 3...

Страница 65: ...If the 4 wheel drive differential lock s are on when making a sharp turn at a higher speed and the inside rear wheel lifts off the ground there may be a loss of control which could cause the machine t...

Страница 66: ...gage the differential lock s by pressing the differential lock switch to the down position Figure 73 Note The differential lock s icon will not be illuminated on the display when the switch is disenga...

Страница 67: ...eight in the cargo bed from front to back Important Loss of steering control or the machine may tip over if you position the load behind the rear axle and the traction on the front tires is reduced Us...

Страница 68: ...ater or other appliance Keep all parts of the machine in good working condition and all hardware tightened Maintain and clean the seat belt s as necessary Replace all worn damaged or missing decals Ha...

Страница 69: ...ve the gear selector to the N NEUTRAL position Towing a Trailer The machine is capable of pulling trailers and attachments Contact your authorized Toro distributor for the available tow hitches Your m...

Страница 70: ...machine is running Keep away from moving parts If you must run the machine to perform a maintenance adjustment keep your hands feet clothing and any parts of the body away from any moving parts Keep...

Страница 71: ...components Check the front wheel alignment Check the brakes Every 250 hours Grease the machine lubricate more frequently in heavy duty applications Change the air cleaner filter more frequently in dus...

Страница 72: ...orking order as indicated in these instructions CAUTION Only qualified and authorized personnel should maintain repair adjust or inspect the machine Avoid fire hazards and have fire protection equipme...

Страница 73: ...accelerator operation Wash the machine Touch up any damaged paint Maintaining the Machine under Special Operating Conditions Important If the machine is subjected to any of the conditions listed belo...

Страница 74: ...o not start the machine while the machine is on a jack as the engine vibration or wheel movement could cause the machine to slip off the jack Always remove the key from the key switch before getting o...

Страница 75: ...the handle of the rubber latches on each side of the hood 2 Raise the hood g398991 Figure 78 Closing the Hood 1 Gently lower the hood 2 Secure the hood by aligning the rubber latches onto the latch a...

Страница 76: ...gun apply grease into the grease fittings on the machine 3 Wipe any excess grease off the machine The grease fitting locations and quantities are as follows Front control arm pivots 2 refer to Figure...

Страница 77: ...Rear knuckle pivots 4 refer to Figure 82 g390952 Figure 82 Right side shown 1 Rear knuckle pivots grease fittings Drive shaft 2 refer to Figure 83 g357005 Figure 83 1 Drive shaft grease fittings 77...

Страница 78: ...aner body Figure 84 g002401 Figure 84 1 Air cleaner cover 2 Filter 2 Squeeze the dust cap sides to open it and knock the dust out 3 Gently slide the filter out of the air cleaner body Figure 84 Note A...

Страница 79: ...meets or exceeds the following specifications API service category CJ 4 or higher ACEA service category E6 JASO service category DH 2 Important Using engine oil other than API classification CJ 4 or...

Страница 80: ...Park the machine on a level surface 2 Shift the transmission lever to the P PARK position 3 Shut off the engine and remove the key 4 Raise the cargo bed 5 Change the engine oil as shown in Figure 86...

Страница 81: ...2 inch 2 7 to 10 mm 1 4 to 3 8 inch 2 If needed adjust the belt tension as follows 3 Loosen the adjusting bolts and nuts then move the alternation using a wrench to tighten the belt to the correct ten...

Страница 82: ...simultaneously let go of both The throttle actuator angle will start to increase 1 degree every 2 seconds When the calibration process is complete a new offset is created and the angle on the display...

Страница 83: ...r more often in dirty and dusty conditions g031412 Figure 92 Checking the Fuel Lines and Connections Service Interval Every 500 hours Yearly whichever comes first Check the fuel lines fittings and cla...

Страница 84: ...ith skin eyes or clothing Wear eye protection and rubber gloves Fill the battery wherever clean water is available for flushing the skin Charge the battery in a well ventilated place so that the gasse...

Страница 85: ...connecting the negative black cable 1 Disconnect the battery cables Figure 94 g357128 Figure 94 1 Negative battery cable black 4 Bolt 2 Positive battery cable red 5 Nuts 3 Insulator boot positive batt...

Страница 86: ...ttery from the machine refer to Removing the Battery page 85 2 Connect a 3 to 4 A battery charger to the battery posts Charge the battery at a rate of 3 to 4 A for 4 to 8 hours 12 V Note Do not overch...

Страница 87: ...rential lock and 4 wheel drive engage relay 8 Read the Operator s Manual for fuse information 14 Position lights and turn signal lights 20 Headlights and hazard lights 3 Front differential lock diseng...

Страница 88: ...nts Service Interval Every 100 hours Check the steering and suspension for loose or damaged components With the steering wheel at the centered position Figure 99 turn the steering wheel to the left or...

Страница 89: ...he front tires at the axle height at both the front and rear of the front tires Figure 101 g009235 Figure 101 1 Tire center line back 3 Axle center line 2 Tire center line front 6 If the measurement i...

Страница 90: ...heck the tire pressure to ensure that the front tires are inflated properly refer to Checking the Tire Pressure page 58 The ground clearance should be 23 cm 9 inches for standard wheels and tires or 2...

Страница 91: ...14 to 30 N m 10 to 22 ft lb g362542 Figure 104 1 Drain plug 2 Fill plug Changing the Transaxle Fluid Service Interval Every 500 hours Fluid Type Toro Premium Synthetic Transaxle Fluid Toro Part 145 20...

Страница 92: ...ce Interval Every 1 000 hours Change the front differential oil Fluid Type 80W 90 Gear Oil Fluid Capacity 0 3 L 0 32 US qt 1 Park the machine on a level surface 2 Shift the transmission lever to the P...

Страница 93: ...the coolant Coolant type 50 ethylene glycol with organic additive technology OAT 50 distiller water WARNING If the engine has been running the pressurized hot coolant can escape and cause burns Do no...

Страница 94: ...n lever to the P PARK position 3 Shut off the engine and remove the key 4 Clean the engine area thoroughly of all debris 5 Remove the 7 screws securing the grill and remove the grill Figure 107 g36521...

Страница 95: ...r cracks swelling or deterioration Replace the hoses if there are cracks swelling or deterioration g401265 Figure 108 Changing the Engine Coolant Service Interval Every 1 000 hours Every 5 years which...

Страница 96: ...ne on a level surface 2 Shift the transmission lever to the P PARK position 3 Shut off the engine and remove the key 4 Raise the hood to access to the master brake cylinder and reservoir Figure 109 g3...

Страница 97: ...t 7 Using compressed air clean the clutches thoroughly of all debris Figure 112 8 Install the belt cover Figure 111 9 Lower the cargo bed Replacing the Drive Belt Service Interval Every 500 hours Repl...

Страница 98: ...e Important Do not use power washing equipment to wash the machine Power washing equipment may damage the electrical system loosen important decals or wash away necessary grease at friction points Avo...

Страница 99: ...use an alcohol based stabilizer ethanol or methanol Important Do not store fuel containing stabilizer conditioner longer than the duration recommended by the fuel stabilizer manufacturer B Run the en...

Страница 100: ...ged 3 Contact your authorized Toro distributor 1 There is a blown fuse in the electrical system 1 Inspect and replace the fuse 2 The feature was disabled during software setup 2 Contact your authorize...

Страница 101: ...ad 3 Contact your authorized Toro distributor The engine does not reach maximum rpm while driving 1 The cable is stretched and or the assembly in the system has settled 1 Perform the throttle calibrat...

Страница 102: ...to restaurants grocery stores hotels schools and hospitals and on a wide variety of products Additionally some online and mail order retailers provide Prop 65 warnings on their websites or in catalogs...

Страница 103: ...for marketing purposes Retention of your Personal Information Toro will keep your personal information as long as it is relevant for the above purposes and in accordance with legal requirements For mo...

Страница 104: ...roduct warranty and become the property of Toro Toro will make the final decision whether to repair any existing part or assembly or replace it Toro may use remanufactured parts for warranty repairs D...

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