Radiator Kit

Workman® HDX Utility Vehicle

Model No. 147-8199-Serial No. and Up

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 fingers, hands and clothing clear of rotating fan and drive belt.

  • Shut off the engine and remove the key before performing maintenance.

Installation

Preparing the Machine

  1. Park the machine on a level surface.

  2. Engage the parking brake.

  3. Shut off the engine and remove the key.

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Figure 1

Draining the Engine Coolant

Warning

If the engine has been running, the pressurized, hot coolant can escape and cause burns.

  • Do not open or add coolant to the radiator; doing so introduces air into the system and results in engine damage. Add only engine coolant to the reservoir.

  • 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.

  1. Raise the bed and position the safety support on the extended lift cylinder to secure the bed.

  2. Remove the radiator cap.

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    Figure 2

    1. Radiator cap

  3. Remove the reserve-tank cap.

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    Figure 3

    1. Reserve-tank cap
    2. Reserve tank

  4. Disconnect the lower radiator hose and allow the coolant to flow into a drain pan.

Installing the Radiator Kit

Parts needed for this procedure:

Spring latch2
Hex-head bolt (5/16 x 5/8 inch)4
Upper mount plate1
Flange bushing4
Square nut4
Upper radiator mount1
Screw5
Radiator-mount assembly1
Jumper wire harness1
Lower mount plate1
Radiator assembly1

  1. Remove the existing radiator and associated hardware.

  2. Remove the existing radiator-mount assembly and associated hardware.

  3. Install the new radiator-mount assembly.

  4. Install the radiator and the cooling fan and harness.

  5. Install the upper radiator mount and associated hardware.

  6. Install the lower mount plate and associated hardware.

  7. Install the upper mount plate and associated hardware.

  8. Cut the existing hose from the radiator to the reserve tank to 66 cm (26 inches) and route the hose as shown below.

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Figure 4

  1. Latch spring
  2. Hex-head bolt (5/16 x 5/8 inch)
  3. Upper mounting plate
  4. Flange bushing
  5. Square nut
  6. Radiator assembly
  7. Upper radiator mount
  8. Screw
  9. Radiator mounting assembly
  10. Jumper wire harness
  11. Lower mounting plate

Filling the Cooling System

Cooling System Specifications:

  • Cooling system capacity: 3.7 L (4 US qt)

  • Coolant type: a 50/50 solution of water and permanent ethylene-glycol antifreeze

Note: Your vacuum-fill tool may look different than the one shown below. Toro does not sell the vacuum-fill tool but you can purchase one from a tool vendor.

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Figure 5

  1. With the cooling system empty, install the vacuum-fill tool onto the coolant-reserve tank.

  2. Put the cooling system into a vacuum at -12 PSIG.

  3. Place the vacuum-fill tool suction hose into the premixed coolant.

  4. Fill the cooling system completely with the coolant and top off the coolant-reserve tank to the appropriate level.

    Cooling system capacity: 3.7 L (4 US qt)

  5. Install the reserve-tank cap.

  6. Start and run the engine to the normal operating temperature and verify that the cooling system is filled and purged of any air in the system.

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Figure 6

  1. Hose to shop air
  2. Reserve tank
  3. Vacuum-fill tool
  4. Hose to the premixed coolant
  5. Premixed coolant jug