Toro 110-2626 User manual

FormNo.3393-926RevA

RemoteHydraulicsManifoldKit

Heavy-DutyWorkman®Vehicles

ModelNo.110-2626

InstallationInstructions

WARNING

CALIFORNIA

Proposition65Warning

ThisproductcontainsachemicalorchemicalsknowntotheStateofCaliforniato

causecancer,birthdefects,orreproductiveharm.

8111LyndaleAvenueSouth

Bloomington,MN55420

Registeratwww.Toro.com.OriginalInstructions(EN)

PrintedintheUSA.

AllRightsReserved*3393-926*A

Safety

SafetyandInstructionalDecals

Safetydecalsandinstructionsareeasilyvisibletotheoperatorandarelocatednearanyareaofpotential

danger.Replaceanydecalthatisdamagedorlost.

110-2627

1.Warning3.Flowdirection—whenthe

liftleverisintheBposition

2.Hydraulicoil

pressure—124bar

4.Flowdirection—whenthe

liftleverisintheAposition

110-2628

1.Hydraulicmanifoldfuseblock—10Afuse

110-2629

1.Remotehydraulics2.Bedtilt

Installation

LooseParts

Usethechartbelowtoverifythatallpartshavebeenshipped.

ProcedureDescriptionQty.Use

1Nopartsrequired–Preparetoinstallthekit

2Nopartsrequired–Removethehood.

3Nopartsrequired–Removetheseats.

4Nopartsrequired–Removingthecoolanttank,ROPS

shield,andseatshroud.

5Nopartsrequired–Removethehydraulicliftlines.

6Nopartsrequired–Removethequickdisconnecthose

ttingsandthequickdisconnectbracket.

Hydrauliccontrolmanifold1

Straighthydraulictting(11/16x9/16x

3/8inch)1

45°hydraulictting1

90°hydraulictting3

Straighthydraulicttings(9/16x9/16x

3/8inch)2

Preparethehydrauliccontrolmanifold.

Flatmanifoldbracket1

Flangedmanifoldbracket(HDX-Auto

Workmanmodels)1

Bolt(5/16x3/4inch)2

Lockwasher(5/16inch)2

Installthemanifoldbracketand

Hydrauliccontrolmanifold.

Hose(3/8x95inch)2

3-positionswitch1

9CabletiesAR

Installthehydrauliclifthoses.

10Nopartsrequired–Connecttheliftcylinderhosestothe

manifold.

WiringHarness1

3-positionswitch1

11CabletiesAR

Installthewiringharness.

Fuseblock1

Fuse(12amp)1

Decal(fuseblock)1

Bolt(5/16x3/4inch)1

Locknut(5/16inch)1

Installthefuseblock.

3-positionswitch1

13CabletiesARInstallthemanifoldcontrolswitch.

Neutralswitch1

Locknut(10-24inch)1

Carriagebolt(10-24x5/8inch)1

14Switchplate1

Installthehydraulicliftleverneutral

switch.

ProcedureDescriptionQty.Use

15Nopartsrequired–Installtheseatshroud,ROPshield,and

coolanttank.

16Nopartsrequired–Installtheseatsandcenterconsole.

17Nopartsrequired–Installthehood.

18Nopartsrequired–Installthebed.

PreparingtoInstalltheKit

NoPartsRequired

Procedure

Note:Ifyouareinstallingtheremotehydraulicsmanifold

kitonaWorkmanmodelwithaserialnumberintherangeof

240000000through249999999,youmustreplacetheswitch

inthiskit.Purchasethenewswitch(ToroPartNo.105-0023)

fromyourToroDistributorandinstalltheswitch.

1.Movethemachinetoacleanandlevelsurface.

2.Shutofftheengine,settheparkingbrake,andremove

thekeyfromthekeyswitch.

3.Removethebedfromthemachine;refertothe

Operator’sManualforyourWorkmanmodelforthebed

removalprocedure.

4.Disconnectthebatteryasfollows:

A.Squeezethebatterycovertoreleasethetabsfrom

batterybase(Figure1).

Figure1

B.Removethebatterycoverfromthebatterybase

(Figure1).

C.Removetheterminalofthepositivebatterycable

fromthebatterypost(Figure2).

Note:Ensurethattheterminalpositivebattery

cabledoesnottouchthebatterypost.

G022071

1 2 3 4

Figure2

1.Terminalcover3.Batterypost

2.Positiveterminal4.Battery

5.Bleedthehydraulicpressurefromthemachinebyfully

movingtheliftcontrolforthecargoboxforwardand

backwardseveraltimes(Figure3).

Note:Youmustbleedthehydraulicpressurefromthe

machinewiththeengineshutoff.

Figure3

1.Forward3.Liftcontrol

2.Backward

RemovingtheHood

NoPartsRequired

Procedure

1.Whilegraspingthehoodintheheadlightopenings,lift

uponthehoodtoreleasethelowermountingtabs

fromtheslotsinthebumper(Figure4).

Figure4

1.Hood

2.Pivotthebottomofthehoodupwarduntilthetop

mountingtabscanbepulledfromtheframeslots

(Figure4).

3.Pivotthetopofhoodforwardandunplugthewire

connectorsfromtheheadlights(Figure4).

4.Removethehood.

RemovingtheSeats(HDand

HDXseriesmodels)

NoPartsRequired

RemovingtheCenter-ConsoleCovers

1.Ensurethattheparkingbrakeisset.

2.Removethecenterconsolecoversasfollows:

•ForWorkmanmodelswithanmanual

transmission—

A.shiftthedifferentiallocktotheLockposition

(Figure5).

B.removetheshifterhandleandjamnutfrom

thetransmission-shiftrod(Figure5).

Figure5

1.Transmission-shiftrod5.Controlknobs

2.Jamnut6.Differentiallockrod

3.Shifterhandle7.High—lowrangerod

4.Hydraulicbed-liftrod

•ForWorkmanmodelswithanautomatic

transmission—

A.movethetransmissionlevertotheL(low

forward)position(Figure6).

B.removethetransmissionleverknob(Figure

6).

C.movethespeed-rangelevertotheA(high

range)position(Figure6).

Figure6

1.Brakelever5.Transmissionlever(L

position)

2.Knob(hydraulic-liftlever)6.Hydraulic-liftlock(locked

position—left)

3.Knob(speed-rangelever)7.Speed-rangelever(A

position)

4.Knob(transmissionlever)

3.Movethehydraulic-liftlevertotheraisethebed

position,andsetthehydraulic-liftlock(Figure5and

Figure6).

4.Removetheremainingknobsfromconsoleleversby

rotatingtheknobscounterclockwise(Figure6).

5.ForWorkmanmodelswithanautomatictransmission

removetheshiftindicatorasfollow:

A.Removethe4hex-headscrewsthatsecurethe

shift-indicatorcovertotheseatshroud(Figure7).

Figure7

WorkmanmodelswithanAutomaticTransmission

1.Indicatorconnector4.Controlcover

2.Shift-indicatorcover5.Machine-harness

connector

3.Hex-headscrews

B.Liftshiftindicatorassemblyup,disconnect

electricalconnectorsofthemachineharnessand

indicator,andremovetheindicatorfromthe

machine.(Figure7).

6.Removethe6hex-headscrewsthatsecurethecontrol

covertotheseatshroud,andremovethecontrolcover

(Figure7andFigure8).

Figure8

WorkmanmodelswithaManualTransmission

1.Screw2.Coverplate

RemovingtheSeats

1.Removethe8socket-headboltsthatsecuretheseat

railsoftheseattothechassisandremovetheseats

(Figure9).

Figure9

1.Socket-headbolts3.Seat

2.Seatrail

2.Repeatstep1fortheotherseat(Figure9).

RemovingtheCoolantTank

(non-HDmodels),ROPS

Shield,andSeatShroud(HD

andHDXseriesmodels)

NoPartsRequired

RemovingtheCVTCoolingDuctand

CoolantTank

1.ForHDX-AutoWorkmanmodels,removetheCVT

coolingductasfollows:

A.RemovethehoseclampthatsecurestheCVT

coolingducttotheangeoftheCVTintakeat

thebackoftheROPSpanelonthepassengerside

(Figure10).

Figure10

1.CVTintake3.CVTcoolingduct

2.Hoseclamp

B.RemovetheCVTcoolingductfromtheangeof

theCVTintake(Figure10).

2.Fornon-HDmodels,liftthecoolanttankupandout

ofthesupportbracketonthebackoftheROPSshield

(Figure11).

Figure11

1.Coolanttank3.Supportbracket

2.Coolant-tankbracket

3.Setthecoolanttankuprightontotheengine/chassis.

RemovingtheROPSPanelandSeat

Shroud

1.Removethe6carriageboltsand6nutsthatsecurethe

ROPSpaneltothemountingbracketsontheROPS

bar(Figure12).

Figure12

1.Nuts3.ROPSpanel

2.Mountingbracket(ROPS

bar)

4.Carriagebolts

2.RemovetheROPSpanelfromthemachine(Figure12)

3.Lifttheseatshroudupandremoveitfromthemachine

(Figure13).

Figure13

1.Seatshroud

RemovingtheHydraulicLift

Lines

NoPartsRequired

DisconnectingtheHydraulicLiftHoses

(3000and4000seriesWorkman)

Disconnecttheextendandretracthosesfromthestraight

ttingsthatareconnectedtothemaleandfemalequick

couplersatthequickdisconnectbracketfortheliftcylinders.

RemovingtheHydraulicLiftTubes(HD,

HDX,andHDXAutoseriesWorkman)

1.Disconnectthetubenutsfortheextendandretract

tubesfromthestraightttingsthatareconnected

tothemaleandfemalequickcouplersatthequick

disconnectbracketfortheliftcylinders(Figure14).

Note:Allowthehydraulicuidtodrainfromthe

tubesintoadrainpan.

Figure14

1.Backofthemachine3.Tube(liftcylinder—retract

circuit)

2.Tube(liftcylinder—extend

circuit)

4.Quickdisconnectbracket

2.Removethe5/16x1-1/2inchboltandclampthat

securestheextendandretracttubestothetubesupport

bracket.

3.Disconnecttheextendandretracttubesatthelift

cylindercontrolvalve(Figure15).

Figure15

1.Frontofthemachine3.Tube(liftcylinder—retract

circuit)

2.Liftcylindercontrolvalve4.Tube(liftcylinder—extend

circuit)

4.Removethetubesfromthemachine.

Note:Discardthetubes.

RemovingtheQuick

DisconnectHoseFittings

andtheQuickDisconnect

Bracket

NoPartsRequired

RemovingtheQuickDisconnectHose

Fittings

1.Aligndrainpanunderthettingsatthequick

disconnectbracketattherightrearofthemachine

(Figure16).

Figure16

1.Quickdisconnectbracket3.Quickdisconnecttting

(female—extendcircuit)

2.Quickdisconnecttting

(male—retractcircuit)

2.Removethe2liftcylinderhosesfromthequick

disconnectbracket(Figure16).

3.Removethe90°ttingsandthequickdisconnect

ttingsfromtheendofthe2liftcylinderhoses(Figure

16).

Note:Temporarilyinstallaplugintotheendofeach

hose.

RemovingtheQuickDisconnect

Bracket

1.Removethe2angedheadboltsand2angedlocknuts

thatsecurethequickdisconnectbrackettotheange

ofthetransmissionsupportofthemachine(Figure17)

Note:Retaintheangedheadboltandanged

locknutforinstallationofthemanifoldbracketin8

InstallingtheManifoldBracketandHydraulicControl

Manifold(page12).

Figure17

1.Flangedheadbolt3.Flangedheadnut

2.Quickdisconnectbracket

2.Removethebracketfromthemachine(Figure17).

3.Removethestraightttingsandthequickdisconnect

couplingfromthequickdisconnectbracket.

Note:Retainthemaleandfemalequickdisconnect

couplingsandstraightttings;discardthebracket.

PreparingtheHydraulic

ControlManifold

Partsneededforthisprocedure:

1Hydrauliccontrolmanifold

1Straighthydraulictting(11/16x9/16x3/8inch)

145°hydraulictting

390°hydraulictting

2Straighthydraulicttings(9/16x9/16x3/8inch)

PreparingtheHydraulicControl

Manifold(non-HDX-AutoWorkman

models)

Note:EnsurethattheO-ringsareinstalledonthettings

andlubricatedwithhydraulicuidfromthemachinebefore

installingthettingsintothemanifold.

1.InstalltheAandBportttingsintothemanifoldas

follows:

•For2000and3000seriesWorkman

Installthe2straighthydraulicttingthatyou

removedinstep3ofRemovingtheQuick

DisconnectBracket(page10)intoportsAandB

ofthemaniod(Figure18).

Figure18

1.PortB(hydrauliccontrol

manifold)

3.PortA(hydrauliccontrol

manifold)

2.Straighthydraulictting

•ForHD,HDX,andHDX-DWorkman

A.Install1ofthestraighthydraulicttingsthat

youremovedinstep3ofRemovingtheQuick

DisconnectBracket(page10)intoportBof

thehydrauliccontrolmanifold(Figure19).

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